CRUSHING

START-UP &
SHUTDOWN
PROCESS TRAINING SEQUENCES
 PRESENTATION PLAN

1. Start-up sequence
2. Shutdown sequence
3. Emergency shutdown procedure
4. PFD, P&ID, GA
5. Quiz
6. Answers
 1. START-UP SEQUENCE

• First, verify the general condition of the

workplace and the equipment.
• Then, start the crushing circuit according to
the following start-up sequence (steps 1 to
23).
 1. START-UP SEQUENCE

1. Make sure that one of the two main air

compressors located near the concentrator is
up and running. If not, have one started by
the concentrator control room operator.
2. Make sure that the 34 000 m3/h dust collector
cleaning mechanism is operating and start
the fan.
 1. START-UP SEQUENCE

3. Make sure that the cleaning mechanism of

the bin vent located on top of the 50 tonne
surge bin is operating and start the fan.
4. Make sure that the cleaning mechanism of
the bin vent located on top of the 1200 tonne
fine ore bin is operating and start the fan.
 1. START-UP SEQUENCE

5. Give permission to the mine haulage trucks

to dump the run-of-mine ore into the hopper
using the red/green light system.
6. Start the secondary cone crusher lubrication
and cooling unit according to the supplier’s
procedure.
 1. START-UP SEQUENCE

7. Start the secondary cone crusher’s hydraulic

setting power pack according to the
supplier’s procedures.
8. Start the tertiary cone crusher’s lubrication
and cooling unit according to the supplier’s
procedures.
 START-UP SEQUENCE

• Start the tertiary cone crusher hydraulic setting

power pack according to the supplier’s
procedures.
• Activate the electromagnet located on top of
the 50 tonne surge bin.
• Activate the metal detector located on the
transfer belt conveyor.
 1. START-UP SEQUENCE

12. Before proceeding further, make sure that all

the grease, lubrication, cooling units and
hydraulic power packs are running smoothly
according to the supplier’s specification.
 1. START-UP SEQUENCE

13. Start the fine ore belt conveyor.

14. Start the 34 000 m3/h dust collector screw
conveyor and the rotary valve consecutively.
15. Start the crusher discharge belt conveyor.
16. Start the secondary cone crusher.
 1. START-UP SEQUENCE

17. Start the tertiary cone crusher.

18. Start the triple deck screen.
19. Start the transfer belt conveyor.
20. Start the jaw crusher.
 1. START-UP SEQUENCE

21. Make sure there is sufficient ore in the truck

discharge hopper.
22. Start the vibrating grizzly feeder.
23. Once there is sufficient ore in the 50 tonne
surge bin (about half full), start the vibrating
feeder.
This concludes the start-up sequence of the
crushing circuit.
 2. SHUTDOWN SEQUENCE

• The shutdown sequence must be followed in

order to be able to restart the circuit without
difficulties and to facilitate access to the
equipment for maintenance.
• Shutdown the crushing circuit according to the
following sequence (steps 1 to 21).
 2. SHUTDOWN SEQUENCE

1. Inform the mine authorities that the crushing

circuit will be shut down and that the mine
haulage trucks will not be authorized to dump
into the crushing plant hopper.
2. Withdraw permission to the mine haulage
trucks to dump run-of-mine ore into the
hopper using the red/green light system.
 2. SHUTDOWN SEQUENCE

3. Empty the hopper and stop the vibrating

grizzly feeder.
4. Stop the jaw crusher once it is empty of ore.
5. Keep the rest of the crushing circuit operating
until the surge bin is nearly empty, or
completely empty if maintenance activities
are planned on the vibrating feeder.
 2. SHUTDOWN SEQUENCE

6. Once the surge bin is nearly empty or

completely empty, stop the vibrating feeder.
7. Once it is empty of material, stop the transfer
belt conveyor.
8. Once it is empty of material, stop the triple
deck screen.
 2. SHUTDOWN SEQUENCE

9. Once they are empty of material, stop the

secondary and tertiary cone crushers.
10. Once it is empty of material, stop the crusher
discharge belt conveyor.
11. Stop the 34 000 m3/h dust collector rotary
valve and the screw conveyor.
 2. SHUTDOWN SEQUENCE

12. Once it is empty of material, stop the fine ore

belt conveyor.
13. De-activate the metal detector located on the
transfer belt conveyor.
14. De-activate the electromagnet located on top
of the 50 tonne surge bin.
 2. SHUTDOWN SEQUENCE

15. Stop the tertiary cone crusher hydraulic

setting power pack according to the
supplier’s procedures.
16. Stop the tertiary cone crusher lubrication and
cooling unit according to the supplier’s
procedures.
 2. SHUTDOWN SEQUENCE

17. Stop the secondary cone crusher hydraulic

setting power pack according to the
supplier’s procedures.
18. Stop the secondary cone crusher lubrication
and cooling unit according to the supplier’s
procedures.
 2. SHUTDOWN SEQUENCE

19. Stop the bin vent fan located on top of the

1200 tonne fine ore bin.
20. Stop the bin vent fan located on top of the 50
tonne surge bin.
21. Stop the 34 000 m3/h dust collector fan.
This concludes the shutdown sequence of
the crushing circuit.
 3. EMERGENCY SHUTDOWN

• In case of fire or major event, the entire

crushing circuit can be shutdown by
shutting down the dust collector fan.
• The shutdown of the dust collector fan will
trigger the shutdown of the three belt
conveyors.
• The shutdown of the belt conveyors will stop
all the other equipment by interlock effect.
 3. EMERGENCY SHUTDOWN

• In case of a power failure, no equipment

needs to be maintained in operation by the
emergency generator.
• There are no special considerations to restart
the crushing circuit since every piece of
equipment is capable of restarting under full
load.
4. PFD #1000-49D1-0002
4. PFD #1000-49D1-0003
4. P&ID #1100-48D1-0001
4. P&ID #1100-48D1-0004
4. P&ID #1100-48D1-0005
4. GA #1000-45D2-0003
4. GA #1000-45D2-0004
 5. QUIZ

• Question 2.6 – Multiple choices

– In what order must the crushers be started?
a) Jaw crusher, secondary crusher, tertiary crusher
b) Tertiary crusher, secondary crusher, jaw crusher
c) Secondary crusher, tertiary crusher, jaw crusher
d) Secondary crusher, jaw crusher, tertiary crusher
• Question 2.7 – True or false?
– The surge bin should only be about half full for the
vibrating feeder to be started.
 5. QUIZ

• Question 2.8
– Why does the shutdown sequence have to be
followed (2 reasons)?
• Question 2.9 – True or false?
– The first step of the shutdown sequence is to inform
the mine authorities that the crushing circuit will be
shutdown.
• Question 2.10
– Which equipment should be stopped in case an
emergency shutdown is required?
 6. ANSWERS

• Question 2.6 – Multiple choices

– In what order must the crushers be started?
a) Jaw crusher, secondary crusher, tertiary crusher
b) Tertiary crusher, secondary crusher, jaw crusher
c) Secondary crusher, tertiary crusher, jaw crusher
d) Secondary crusher, jaw crusher, tertiary crusher
• Question 2.7 – True or false?
– The surge bin should only be about half full for the
vibrating feeder to be started.
 6. ANSWERS

• Question 2.8
– Why does the shutdown sequence have to be
followed (2 reasons)?
The shutdown sequence must be followed in
order to be able to restart the circuit without
difficulties and to facilitate access to the
equipments for maintenance.
 6. ANSWERS

• Question 2.9 – True or false?

– The first step of the shutdown sequence is to inform
the mine authorities that the crushing circuit will be
shutdown.
• Question 2.10
– Which equipment should be stopped in case an
emergency shutdown is required?
The dust collector fan