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Date submitted2023-05-17
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Date accepted2023-08-17
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Date published2023-10-27
Scientific and technical substantiation of the possibility for the organization of needle coke production in Russia
Russia is one of the world's leading steel producers, while about 33 % of production comes from the scrap remelted in arc steelmaking furnaces. The graphitized electrodes of SHP and UHP grades, mainly consisting of needle coke, are used for high current loads and temperatures in furnaces. USA, Japan, Korea, and China are focused on needle coke production, where coal (tar and pitch) and petroleum (decantoil), by-products of metallurgical factories and oil refineries, are used as raw materials. Russia's annual demand for needle coke is approximately 100 thousand tons, but all of it is covered by imports. Russia's raw material potential, established by the authors of the article, is more than 5 million tons per year and includes decantoil, coal tar and pitch, and heavy pyrolysis tar. The results of obtaining needle coke from decantoil and heavy pyrolysis tar are given below. The prototypes of needle coke were produced on specially designed delayed coking laboratory units (loading up to 0.25 and 80 kg). Raw materials were modified according to the original technology of Saint Petersburg Mining University, the convergence of target properties of which is confirmed by the results of quality analysis of the obtained needle coke, including after 100-fold scaling. The electrodes were molded from the obtained coke. After standardized stages of firing, mechanical processing and graphitization at 2,800-3,000 °C, the coefficient of linear thermal expansion was less than 1 × 10–6 К–1, and the value of specific electrical resistance was 7.1-7.4 μOhm, which proves that the obtained carbon material corresponds in quality to Japanese analogues and Super Premium needle coke.
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Date submitted2023-03-10
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Date accepted2023-06-20
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Date published2023-07-19
Enhancement of energy efficiency of the vacuum oil distillation unit using pinch analysis
- Authors:
- Еkaterina А. Yushkova
- Vladimir A. Lebedev
The actual task of the state is to increase the energy efficiency of the oil refinery. The object of research is a vacuum distillation unit, including a preheating unit for raw materials and a furnace for heating fuel oil before the column. Pinch analysis allows to analyze and optimize a large number of heat flows. In this study the analysis and enhancement of efficiency of the research object is carried out by enthalpy pinch analysis. In order to reduce the heat load of the furnaces, the additional flows were introduced into the heat exchange system of the oil heating unit. Parametric optimization of the new heat exchange system was carried out. The minimum needs of the heat exchange system in external energy carriers are determined. An enthalpy cascade of the heat exchange system has been constructed, which clearly shows the distribution of heat between each heat flow of the system. In the analysis of the energy efficiency of a furnace, an important point is the determination of the optimal heat capacity of the combustion products. In this work, we have determined the optimal flow heat capacity, at which the heat loss with the exhaust gases is minimal. As a result of the studies carried out, the efficiency of the fuel oil preheating unit has been increased by maximizing heat recovery, and the cost of external energy carriers has been minimized. By reducing heat loss with flue gases, it was possible to increase the efficiency of the furnace.
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Date submitted2023-03-14
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Date accepted2023-06-20
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Date published2023-07-19
Evaluation of the energy efficiency of functioning and increase in the operating time of hydraulic drives of sucker-rod pump units in difficult operating conditions
The necessity of improving the drives of the sucker-rod hydraulic pump units (SRHP), operated in conditions of marginal and complicated wells, is substantiated. For complicated oil production conditions, it is promising to use the SRHP drive, which makes it possible to select and set rational operating modes for downhole equipment. The results of comparative tests of conventional mechanical and hydraulic actuators SRHP with pneumatic and electrodynamic balancing types are presented. A generalized indicator for evaluating the effectiveness of the advanced SRHP drives functioning, the energy efficiency coefficient, is proposed. It has been experimentally proven that the use of the SRHP drive with pneumatic balancing is characterized by low energy efficiency of the well fluid production process. The use of the tested SRHP hydraulic drive made it possible to successfully eliminate asphalt, resin, and paraffin deposits and minimize the well downtime. The results of the tests of the traditional SRHP mechanical drive and the hydraulic drive with electrodynamic balancing showed a satisfactory energy efficiency of the latter. The advantage of the SRHP drive with electrodynamic balancing is the simplicity of the design of the hydraulic part. The process of energy regeneration during the drive control system operation causes an increase in the reactive power component in the oil field network and the appearance of harmonic interference that adversely affects the consumers operation. Technical solutions aimed at improving the operation energy efficiency and increasing the operating time of SRHP drives in the conditions of marginal and complicated wells are proposed. The methodological bases for assessing the economic efficiency of the introduction of the advanced SRHP drives are given.
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Date submitted2023-03-12
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Date accepted2023-06-20
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Date published2023-07-19
Increasing the energy efficiency of an autonomous power supply system of a drilling rig in case of voltage dips
The article discusses the emergency modes of operation of an autonomous electrical complex of a drilling rig. The concept of voltage failure and its influence on the technological process of industrial enterprises is revealed. A description of the methods used in the power supply of industrial enterprises to overcome voltage dips and load surges in autonomous power systems is presented, from which it is possible to single out the accelerated lifting of critical equipment to prevent emergency conditions, as well as the use of backup storage, usually batteries. An algorithm has been developed for the interaction of the battery and the diesel generator set as backup power sources during various modes of operation of the electric motor, taking into account load surges, which allows successfully overcoming voltage dips in the system both in transient and in steady state. It is proposed to use a combined method to eliminate the voltage dip, a feature of which is the use of a combined structure of backup power sources as part of a diesel generator set and a battery, acting on the base of the proposed interaction algorithm in autonomous electrical complexes. The method makes it possible to overcome sudden load surges and voltage dips caused by a shortage of reserve power in the electrical system. The use of a rechargeable battery as a transitional element makes it possible to switch between the main and backup power sources without stopping the technological one and to expand the overload threshold of an autonomous electrical complex up to 60 %. The use of the combined method increases the energy efficiency of the autonomous complex due to a reduction in the number of emergency shutdowns of equipment, process interruptions and additional power consumption.
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Date submitted2022-01-21
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Date accepted2022-11-14
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Date published2023-08-28
Strategy of mine ventilation control in optimal mode using fuzzy logic controllers
- Authors:
- Aleksei V. Kashnikov
- Yuri V. Kruglov
The issues related to improving the efficiency of automatic ventilation control systems of mines that regulate the air supply to the mine in accordance with the need are considered. During the tests of such a system in the 3RU mine of OAO Belaruskali, the shortcomings of its existing, implementation, associated with the incorrect choice of the most difficult-to-ventilate direction, were revealed. The possibilities of implementing a control strategy, in which the system automatically determines the optimal configuration of the operating modes of fans and regulators, are demonstrated. As an alternative to the implemented algorithms, it is proposed to use a fuzzy control device to account for the nonlinearity of the dependence of the input and output parameters of ventilation equipment and to set the conditions for the optimal operating mode of the system in a declarative form. To assess the effectiveness of the proposed approach, the data of simulation modeling of the current ventilation mode and the transition from one ventilation mode to another are analyzed with comparison with the actual data of the system operation. The simulation results show that the use of an upgraded control scheme for the main ventilation fan based on fuzzy logic in the implementation of automatic ventilation control systems makes it possible to eliminate the possibility of a shortage of fresh air in the regulated directions of its movement, as well as excessive power consumption of the main ventilation fan.
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Date submitted2020-12-24
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Date accepted2021-10-18
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Date published2021-12-16
Natural gas methane number and its influence on the gas engine working process efficiency
The natural gas usage as a vehicle fuel in the mining industry is one of the priority tasks of the state. The article pays special attention to the component composition of natural gas from the point of view of its thermal efficiency during combustion in the combustion chamber of a power plant on a heavy-duty vehicle in difficult quarry conditions. For this, domestic and foreign methods for determining the main indicator characterizing the knock resistance of fuel in the combustion process – the methane number – are considered. Improvement of technical and economic indicators will be carried out by changing the composition of the gas mixture based on methane to fit the design features of the gas power plant, the methane number will be the determining indicator. A theoretical analysis of the influence of the methane number on such engine parameters as the compression ratio and the maximum speed of the flame front propagation in the second phase of combustion in the engine cylinder, expressed through the angle of rotation of the crankshaft, is presented. Based on the results of theoretical and experimental studies, the dependences of the influence of the methane number on the efficiency of the working process of the engine and its external speed characteristic were obtained.
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Date submitted2020-06-02
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Date accepted2020-12-15
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Date published2020-12-29
Method for calculating dynamic loads and energy consumption of a sucker rod installation with an automatic balancing system
The efficiency of sucker rod pump installations, which have become widespread in mechanized lift practice, is largely determined by the balance of the drive. During the operation of sucker rod installations, the balance of loads acting on the rod string and the drive can change significantly due to changes in the dynamic fluid level, which leads to a decrease in balance and an increase in loads on the pumping equipment units. The increase and decrease in the dynamic level in accordance with the pumping and accumulation cycle occurs in wells operating in the periodic pumping mode. It is shown that during the operation of equipment in a periodic mode, fluctuations in the dynamic level and, accordingly, in the loads acting on the nodes occur. This leads to the need for dynamic adjustment of the balancing weights to ensure the balance of the pumping unit. A system for automatic balancing of the rod drive has been developed, including a balancing counterweight, an electric motor that moves the load along the balance beam, a propeller and a computing unit. To study the effectiveness of the proposed device, a complex mathematical model of the joint operation of the reservoir - well - sucker rod pump - rod string – pumping unit has been developed. It is shown that due to the dynamic adjustment of the balance counterweight position, the automatic balancing system makes it possible to significantly reduce the amplitude value of the torque on the crank shaft (in comparison with the traditional rod installation) and provide a more uniform load of the electric motor. Equalization of torque and motor load reduces the power consumption of the unit.
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Date submitted2020-05-21
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Date accepted2020-10-05
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Date published2020-11-24
Method of calculating pneumatic compensators for plunger pumps with submersible drive
- Authors:
- Eduard O. Timashev
One of the most promising ways to improve the efficiency of mechanized oil production is a plunger pump with a submersible drive, which allows obtaining harmonic reciprocating movement of the plunger. In the pumping process of well products by plunger pumps, oscillations in the velocity and pressure of the liquid in the lifting pipes occur, which lead to an increase in cyclic variable loads on the plunger, a decrease in the drive life period and the efficiency of the pumping unit. To eliminate the pulsation characteristics of the plunger pump and increase the reliability indicators of the pumping unit (in particular, the overhaul period), pneumatic compensators can be used. A method for calculating the optimal technological parameters of a system of deep pneumatic compensators for plunger pumping units with a submersible drive, based on mathematical modeling of hydrodynamic processes in pipes, has been developed. Calculations of the forming flow velocity and pressure in the lifting pipes of submersible plunger units equipped with pneumatic compensators (PC) have been carried out. Influence of the PC technological parameters on the efficiency of smoothing the oscillations of velocity and pressure in the pipes has been analyzed. Non-linear influence of the charging pressure and PC total volume on the efficiency of their work has been established. Optimal pressure of PC charging, corresponding to the minimum pressure in the tubing during the pumping cycle for the considered section of the tubing, is substantiated. Two ultimate options of PC system placement along the lifting pipes are considered. In the first option, PC are placed sequentially directly at the outlet of the plunger pump, in the second - evenly along the lift. It is shown that the first option provides the minimum amplitude of pressure oscillations at the lower end of the tubing and, accordingly, variable loads on the pump plunger. Nature of the pressure and flow velocity oscillations in the tubing at the wellhead for both options of PC placement has similar values .
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Date submitted2019-07-07
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Date accepted2019-09-13
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Date published2019-12-24
Installation for experimental research of multiphase electromechanical systems
- Authors:
- V. M. Tereshkin
- D. A. Grishin
- I. A. Makulov
The subject of this study is an installation for experimental research designed to study the characteristics and control algorithms of multiphase motors with the number of working phases from 3 to 8, connected by a star, a triangle, or in another way, allowing phase currents to flow, creating a rotating electromagnetic field. The installation consists of two separate independent units: a controller, or a human-machine control interface, and a power inverter module (converter). The controller is connected to the converter by a two-wire half-duplex interface (RS485) via the Modbus RTU communication protocol. The installation also includes synchronous motors with the number of phases 3, 5, 7. Using the developed installation for experimental research, it is possible to carry out experimental studies of multiphase motors when implementing various control algorithms for a converter that implements pulse-width vector modulation. The time required to implement control algorithms is minimal. According to the results of the experiments, it is possible to carry out a comparative analysis of multiphase motors in terms of energy efficiency, in terms of vibration of electromagnetic origin, in dynamic parameters. An experimental assessment of the load of the converter keys is possible. The created installation is an effective tool for checking the reliability of the results of theoretical studies of electromechanical systems based on multiphase motors.
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Date submitted2019-05-07
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Date accepted2019-07-11
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Date published2019-10-23
Operation of a Single-phase Autonomous Inverter as a Part of a Low-power Wind Complex
- Authors:
- A. A. Belsky
- V. S. Dobush
- Shaiban Fuad Haikal
The article discusses the experience of operating a wind power complex with a low-power wind power installa- tion (5 kW), the use of which is promising for powering remote oil production facilities, exploration and other types of mining operations. The structure of the studied complex and its characteristics, technical problems that have arisen during operation for 6 years are given. The elements of the wind energy complex – the battery charge regulator and the inverter-converter are considered. The consequences of the mechanical regulator failure of battery charge are con- sidered and recommendations for its replacement are presented. The issues of diagnostics and repair of one of the main elements of the complex – the inverter-converter, its component – DC link are highlighted in detail. Oscil- lograms of the output voltage of the inverter-converter are presented for different capacities of the DC link and the images of the repaired inverter-converter are given. Recommendations are given on choosing an inverter-converter and setting up the operating modes of the wind energycomplex.
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Date submitted2018-01-12
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Date accepted2018-03-08
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Date published2018-06-22
A method for controlling siltation of water catchments of district drainage systems of kimberlite mines
- Authors:
- N. P. Ovchinnikov
High contamination of mine water leads to intensive siltation of water catchments of district water drainage installations of kimberlite mines in Russia, because of which their pumping equipment periodically works in non-stationary regimes. At present, a number of known methods are used to limit the operation of pumping equipment in non-stationary modes: equipping the pump with a hand hoist to regulate the depth of lowering its suction pipeline into the sinkhole; preliminary dismantling of one of the two screen filters, mounted in the suction pipeline of the pump, which has smaller cells. Experience in the operation of water-drainage farms of kimberlite mines shows that these two methods allow to prevent the operation of pumping equipment in non-stationary modes only for a short period of time. A mine drainage installation is proposed, the technical result of which is the effective struggle against the silting of the water catchments of the district drainage systems of the kimberlite mines of the country.
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Date submitted2017-09-20
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Date accepted2017-11-09
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Date published2018-02-22
Development of the system for air gap adjustment and skip protection of electromagnetic lifting unit
- Authors:
- B. A. Zhautikov
- A. A. Aikeeva
The efficiency of the electromagnetic lifting system is ensured by the well-coordinated work of all its parts and elements, namely those providing the strictly vertical movement of the skip. The deviation of the skip movement from the vertical axis can lead to a stop and damage of both the skip and the unit. Therefore, the air gap adjustment and skip protection system of the electromagnetic lifting system, which includes determining the size of the air gap between the electromagnet of the skip and the electromagnet of the aligning device, and the development of a stabilization system to ensure a constant air gap and regulate the current in the electromagnet winding, provide both a strictly vertical movement skip, and its protection. The article is devoted to the theoretical determination of the air gap between the electromagnets of the aligning device and the skip using the Biot – Savar – Laplace law.
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Date submitted2010-07-13
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Date accepted2010-09-13
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Date published2011-03-21
Actual ways of increasing the effectiveness of facilities for hydrotransport mountain companies
- Authors:
- A. A. Velnikovskiy
Shown the necessity of improving hydrotransport installations. Built a functional model of the hydrotransport system. As a result of its analysis identified the most relevant ways to improve efficiency of hydrotransport on mining enterprises.
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Date submitted2010-07-01
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Date accepted2010-09-23
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Date published2011-03-21
Improving the efficiency of system of deleting waste on Udachny GOK
- Authors:
- V. P. Dokukin
- A. A. Velnikovskiy
Examined ways to improve the efficiency of hydrotransport systems. A method for determining the most advantageous modes of GTP. The calculation of basic characteristics of the flow of pulp when the grain size, density and quantity released to the enrichment of solid material to installation hydrotransport concentrator.
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Date submitted2009-09-22
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Date accepted2009-11-08
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Date published2010-06-25
Auger machine for year-round peat production
- Authors:
- P. G. Talalai
- E. Yu. Stepuk
Russian Federation can solve problems of local power and ecology, increasing of soil quality, rising of peat export by the developing of peat industry. To change over the peat plants to the year-round production cycle the auger machine is proposed.
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Date submitted2009-08-05
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Date accepted2009-10-07
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Date published2010-02-01
Electrical supply of power installations of oil extracting from independent power stations
- Authors:
- A. V. Turysheva
In article the imitating model of the closed system of an independent electrical supply with the energy carrier in the form of passing oil gas, with which help probably is presented: to establish parities of capacities of microturbine installation and погружного the electric motor for system work in a nominal mode; to eliminate the higher harmonious components of a current and pressure for maintenance with the electric power of the remote areas of the oil extracting satisfying with GOST 13109-97.