Energies

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14 pages, 2606 KiB

Open AccessArticle

The Technical and Economic Aspects of Using DC or AC Motors in the Drive of Hoisting Machines

by Tomasz Siostrzonek, Jacek Pytel and Tomasz Karpiel

Energies 2025, 18(9), 2245; https://doi.org/10.3390/en18092245 - 28 Apr 2025

A hoisting machine is one of the main components of an underground mine process line. The drive systems currently used in these machines are based on direct current, synchronous, or induction (AC) motors. Power electronic converters are used to power and control the [...] Read more.

A hoisting machine is one of the main components of an underground mine process line. The drive systems currently used in these machines are based on direct current, synchronous, or induction (AC) motors. Power electronic converters are used to power and control the speed of the motor, the type and function of which depend on the type of motor. Choosing the right motor is the most important part of the design process. The decision must be based on an evaluation of technical and economic parameters. This article describes the most popular types of hoisting machine drive systems. Four motors that could potentially be used to build a hoisting machine with the assumed parameters were analysed. The selection of the motor was made based on the analyses carried out, and the implementation of the investment and commissioning of the machine with the selected motor confirmed the validity of this choice. The technical–economic analysis of the motor selection for this hoisting machine made it possible to determine how to choose a motor for a specific shaft hoist. The information contained in this article can serve as a guideline during in-depth analyses of motor selection for modernised or constructed hoisting machines due to the possibility of generalising its conclusions. Full article

(This article belongs to the Special Issue Energy Consumption at Production Stages in Mining)

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17 pages, 6208 KiB

Open AccessArticle

Impact of Monthly Load Variability on the Energy Consumption of Twin Belt Conveyors in a Lignite Mine

by Mirosław Bajda, Leszek Jurdziak and Zbigniew Konieczka

Energies 2025, 18(8), 2003; https://doi.org/10.3390/en18082003 - 14 Apr 2025

Viewed by 208

Abstract

This study examines the influence of average monthly load variations on the unit energy consumption indicator (ZE) of belt conveyors, defined as the energy required to transport 1 Mg of bulk material (coal) over a distance of 1 km. The analysis is based [...] Read more.

This study examines the influence of average monthly load variations on the unit energy consumption indicator (ZE) of belt conveyors, defined as the energy required to transport 1 Mg of bulk material (coal) over a distance of 1 km. The analysis is based on energy consumption data from twin belt conveyors operating in a Polish lignite mine over four years. Monthly records included transported mass, conveyor operating time, energy consumed, and atmospheric conditions (temperature and humidity). The results indicate statistically significant differences in ZE between the analyzed conveyors. A relative increase in average load by 35% (from 2000 Mg/h) corresponded to a 26% reduction in ZE, with a specific decrease of 90 Wh/Mg/km. The findings highlight that optimizing conveyor load distribution can significantly reduce energy consumption—by up to 30%. These insights underscore the potential for energy savings through better conveyor load management without requiring significant infrastructural investments. Full article

(This article belongs to the Special Issue Energy Consumption at Production Stages in Mining)

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19 pages, 4720 KiB

Open AccessArticle

Copper as a Critical Resource in the Energy Transition

by Marta Podobińska-Staniec, Anna Wiktor-Sułkowska, Arkadiusz Kustra and Sylwia Lorenc-Szot

Energies 2025, 18(4), 969; https://doi.org/10.3390/en18040969 - 17 Feb 2025

Viewed by 536

Abstract

The energy transition requires significant amounts of critical raw materials, with demand projected to continue increasing. Analyses indicate that the supply of these materials will fall short of the requirements for the energy transition plans based on renewable energy sources. To address this [...] Read more.

The energy transition requires significant amounts of critical raw materials, with demand projected to continue increasing. Analyses indicate that the supply of these materials will fall short of the requirements for the energy transition plans based on renewable energy sources. To address this challenge, it is essential to examine the global value chains of critical raw materials and their intermediates, identifying the risks linked to concentrating downstream processes in countries that may not operate under market-oriented principles. Such countries could become “price makers” on international markets, influencing costs and availability. This article focuses on copper, a key raw material for the energy transition, and explores its global value chains in detail. It highlights the risks associated with copper extraction in regions with the largest identified deposits, such as South America and Africa, as well as challenges related to smelting and refining, which are predominantly carried out in China. Additionally, the article presents an analysis of the operations of KGHM Polska Miedź S.A., one of Europe’s largest copper producers, headquartered in Poland but also active in North and South America. Full article

(This article belongs to the Special Issue Energy Consumption at Production Stages in Mining)

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12 pages, 1618 KiB

Open AccessArticle

Modeling Energetic Effectiveness and Breakage Intensity in Mining and Processing Circuits on Limestone Crushing in HPGR

by Agnieszka Saramak and Daniel Saramak

Energies 2025, 18(1), 122; https://doi.org/10.3390/en18010122 - 31 Dec 2024

Viewed by 544

Abstract

This article refers to the aspects of energy consumption and comminution effectiveness in the mineral processing sector through the evaluation of limestone crushing in a high-pressure grinding roll. The investigative program included a series of crushing tests on limestone samples in a laboratory [...] Read more.

This article refers to the aspects of energy consumption and comminution effectiveness in the mineral processing sector through the evaluation of limestone crushing in a high-pressure grinding roll. The investigative program included a series of crushing tests on limestone samples in a laboratory High Pressure Grinding Rolls (HPGR) press device. The tests were carried out in the scheme of factorial experiment with three levels of pressure (Fsp) and three levels of material moisture (M). The major finding was to determine energetic models referring to consumption of energy and reduction in Bond work index Wi, designed as a function of operational pressure in HPGR and material moisture. The other investigative results encompassed models on fineness effectiveness and throughput. The models appeared statistically significant and showed relationships both with pressure and moisture. The results of the investigations showed that Bond work index Wi decreases when the Fsp increases, but Wi increases as the moisture content decreases. The calculated models also showed an increase in unit energy consumption in the press together with increasing of Fsp and moisture. The models for throughput and finest particle content in HPGR product showed in turn that increasing of Fsp and M results in decreasing of the productivity. Full article

(This article belongs to the Special Issue Energy Consumption at Production Stages in Mining)

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14 pages, 4348 KiB

Open AccessArticle

Impact of Power Quality on the Efficiency of the Mining Process

by Tomasz Siostrzonek, Jakub Wójcik, Mateusz Dutka and Wojciech Siostrzonek

Energies 2024, 17(22), 5675; https://doi.org/10.3390/en17225675 - 13 Nov 2024

Cited by 1 | Viewed by 812

Abstract

There are currently more than 30 underground mines operating in Poland. These are mines extracting hard coal, salt, and metal ores. Each of these plants has its own specifics for operation, but all operate under the same regulations. The basic principle is to [...] Read more.

There are currently more than 30 underground mines operating in Poland. These are mines extracting hard coal, salt, and metal ores. Each of these plants has its own specifics for operation, but all operate under the same regulations. The basic principle is to ensure the safety of the crew and equipment. The progressive mechanization and automation of the mining process results in the installation of power electronic converters in the networks of mining plants, which significantly deteriorate the quality of the power in the plant supply networks. In addition, the constant reconfiguration of these networks related to the progress of the work can affect the safety conditions of the plant. This article describes problems occurring at one underground mining plant that are related to the structure of the power grid. Failures and interruptions in the production process were the result of poor power quality. They directly translated into increased production costs and significantly affected the safety level of the workforce, which could result in further consequences, not only in the financial sphere. The article also addresses the issue of existing legal regulations, the provisions of which may be insufficient in assessing the current state of power quality in mining plants. Full article

(This article belongs to the Special Issue Energy Consumption at Production Stages in Mining)

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28 pages, 5430 KiB

Open AccessArticle

Energy Consumption and Fume Analysis: A Comparative Analysis of the Blasting Technique and Mechanical Excavation in a Polish Gypsum Open-Pit Mine

by Andrzej Biessikirski, Przemysław Bodziony and Michał Dworzak

Energies 2024, 17(22), 5662; https://doi.org/10.3390/en17225662 - 13 Nov 2024

Cited by 2 | Viewed by 842

Abstract

This article presents a comparative assessment of energy consumption and fume emissions such as NOx, CO₂, and CO associated with the excavation of a specified gypsum volume using two mining methods (blasting and mechanical extraction). The analysis was carried out based [...] Read more.

This article presents a comparative assessment of energy consumption and fume emissions such as NOx, CO₂, and CO associated with the excavation of a specified gypsum volume using two mining methods (blasting and mechanical extraction). The analysis was carried out based on a case study gypsum open-pit mine in Poland where both extraction methods are applied. The findings indicate that, for the same output volume, blasting operations require significantly less energy (ranging from 1298.12 MJ to 1462.22 MJ) compared to mechanical excavation (86,654.15 MJ). Furthermore, a substantial portion of the energy in blasting operations is attributed to explosive loading and drilling (970.95 MJ). Conversely, mechanical mining results in higher fume emissions compared to blasting. However, during mechanical extraction, the fumes are dispersed over a prolonged period of 275 h, whereas blasting achieves the same gypsum volume extraction in approximately 7.5 h. The prediction model suggests that, based on the obtained data, overall gypsum extraction will decline unless new operational levels are developed or the mine is expanded. This reduction in gypsum extraction will be accompanied by a corresponding decrease in energy consumption and emission of fumes. Full article

(This article belongs to the Special Issue Energy Consumption at Production Stages in Mining)

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18 pages, 8265 KiB

Open AccessArticle

Potentials of Green Hydrogen Production in P2G Systems Based on FPV Installations Deployed on Pit Lakes in Former Mining Sites by 2050 in Poland

by Mateusz Sikora and Dominik Kochanowski

Energies 2024, 17(18), 4660; https://doi.org/10.3390/en17184660 - 19 Sep 2024

Cited by 1 | Viewed by 1291

Abstract

Green hydrogen production is expected to play a major role in the context of the shift towards sustainable energy stipulated in the Fit for 55 package. Green hydrogen and its derivatives have the capacity to act as effective energy storage vectors, while fuel [...] Read more.

Green hydrogen production is expected to play a major role in the context of the shift towards sustainable energy stipulated in the Fit for 55 package. Green hydrogen and its derivatives have the capacity to act as effective energy storage vectors, while fuel cell-powered vehicles will foster net-zero emission mobility. This study evaluates the potential of green hydrogen production in Power-to-Gas (P2G) systems operated in former mining sites where sand and gravel aggregate has been extracted from lakes and rivers under wet conditions (below the water table). The potential of hydrogen production was assessed for the selected administrative unit in Poland, the West Pomerania province. Attention is given to the legal and organisational aspects of operating mining companies to identify the sites suitable for the installation of floating photovoltaic facilities by 2050. The method relies on the use of GIS tools, which utilise geospatial data to identify potential sites for investments. Basing on the geospatial model and considering technical and organisational constraints, the schedule was developed, showing the potential availability of the site over time. Knowing the surface area of the water reservoir, the installed power of the floating photovoltaic plant, and the production capacity of the power generation facility and electrolysers, the capacity of hydrogen production in the P2G system can be evaluated. It appears that by 2050 it should be feasible to produce green fuel in the P2G system to support a fleet of city buses for two of the largest urban agglomerations in the West Pomerania province. Simulations revealed that with a water coverage ratio increase and the planned growth of green hydrogen generation, it should be feasible to produce fuel for net-zero emission urban mobility systems to power 200 buses by 2030, 550 buses by 2040, and 900 buses by 2050 (for the bus models Maxi (40 seats) and Mega (60 seats)). The results of the research can significantly contribute to the development of projects focused on the production of green hydrogen in a decentralised system. The disclosure of potential and available locations over time can be compared with competitive solutions in terms of spatial planning, environmental and societal impact, and the economics of the undertaking. Full article

(This article belongs to the Special Issue Energy Consumption at Production Stages in Mining)

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19 pages, 24979 KiB

Open AccessArticle

Battery Electric Roof Bolter versus Diesel Roof Bolter—Results of Field Trials at a Polish Copper Mine

by Artur Kozłowski and Łukasz Bołoz

Energies 2024, 17(12), 3033; https://doi.org/10.3390/en17123033 - 20 Jun 2024

Viewed by 970

Abstract

Battery-powered electric machines have been replacing classic combustion vehicles for many years in the automotive and heavy industry. This change has a positive impact on the environment and, in the case of working machines, also on the safety and comfort of operators. In [...] Read more.

Battery-powered electric machines have been replacing classic combustion vehicles for many years in the automotive and heavy industry. This change has a positive impact on the environment and, in the case of working machines, also on the safety and comfort of operators. In underground mining plants, due to limited working space and difficult environmental conditions, the use of battery-powered electric vehicles (BEVs) in place of combustion machines with diesel engines brings even greater benefits in terms of the operator’s work conditions. This article presents the results of comprehensive tests of two roof bolters in a BEV and a vehicle with a combustion engine. The tests were performed in underground conditions, during normal operation of the machines. They covered many aspects of machines’ operation, such as availability; traction properties; battery use; cooling system; efficiency; costs; safety; and ergonomics in terms of gas emissions, noise, vibrations, and generally understood work comfort. The research results showed a significant advantage of the battery-powered machine over the one with a combustion engine. The tests in question are unique due to their scope and the fact that they were carried out in underground conditions, during normal operation, both for the internal combustion machine and its battery-powered equivalent. Full article

(This article belongs to the Special Issue Energy Consumption at Production Stages in Mining)

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