The paper describes types of limestone crusher properties and comparison between different types of crushers with respect to reduction ratio and feeding material. The type which we deal with in this paper is hammer impact crusher with apron feeder speed control system. The old conventional speed control system, which was depending on relay logic and timers, has been recently replaced by a new advanced system using PLC
and SCADA system. The main advantages of the new control system are: increasing production rate, saving time in fault detection, monitoring and data logging. The ability of Proportional Integral Derivative (PID) controllers to regulate many practical industrial processes has led to their wide acceptance in industrial applications. This paper presents the application of the Ziegler-Nichols tuning method to design and testing a PI
controller for an apron feeder speed control system of a practical limestone crusher in a cement factory. After tuning the speed PI-Controller of the apron feeder of the limestone crusher, it has been noted that the crusher production rate has increased from 879 ton/hour to 964 ton/ hour, i.e. the production rate increased by 85 ton/hour. The crusher is running 12 hour per day and 300 days per year, thus the annual crusher
production will increase by 306,000 ton/year