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Date submitted2023-03-14
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Date accepted2023-06-20
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Date published2023-07-19
A reliability study of the traction drive system in haul trucks based on failure analysis of their functional parts
The efficiency of a mining and processing plant depends on the level of complex mechanization of the production process. In mineral extraction, haulage is a major cost category, with haul trucks being the key component of the mining transportation system. To improve production performance, mining operations can increase their haulage turnover and reduce transportation costs, which necessitates making haul trucks more reliable. This can be done by improving their mean time to first failure (MTFF) indicators. This article analyzes the reliability status of the traction drive system inhaul trucks operating in the mineral resources sector. It provides a quantitative assessment of traction drive system failures resulting from part defects and discusses the associated repair costs. By examining failure data from 2018 to 2022 and the results of vibration tests performed on a diesel generator, the study reveals that the most expensive failures are associated with defects in the synchronous generator, which are primarily caused by elevated external vibrations. Based on basic vibration tests and vibration spectra tests at different operating modes, recommendations have been formulated concerning the generator’s robustness to external mechanical forces and the ways to increase the generator’s protection grade to prevent dust intrusion. The study also identifies the frequency range that poses the greatest risk of damage to the windings.
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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 submitted2019-05-30
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Date accepted2019-09-04
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Date published2020-02-25
Prospects for industrial methane production in the mine n.a. V.M.Bazhanov using vertical surface wells
The estimated methane resources in the coal stratum of Donbass are 798.5 billion m 3 , including 119.5 billion m 3 in the Donetsk-Makeevsky area. Such significant potential implies that methane can be used not only for industrial production and energy purposes but also as a commodity for the chemical industry. However, in practice, commercial production of methane from coal seams, as is done in the fields of the USA, Canada, India, and China, is not carried out, and methane, obtained as a by-product, is utilized for ensuring the safety of the main technological processes for coal mining. The main reasons for this are the difficult mining and geological conditions of bedding, low thickness and permeability, which does not allow to separate methane production into an independent type of activity due to its low profitability, especially with the use of new technologies based on hydraulic fracturing of coal seams. The assessment of the possibility of industrial methane production in the mine n.a. V.M.Bazhanov in the Donetsk-Makeevsky area of Donbass, which reserves equal to 23.7 billion m 3 , showed that a significant part of the methane reserves is concentrated in coal seams and interlayers with a gas content of 18.5-20.7 m 3 /m 3 . Moreover, in the host rocks, methane is practically in a liberated state. This circumstance makes possible the commercial production of methane for its utilization from the unloaded rock mass by wells drilled from the surface, without the use of hydraulic fracturing technology. The paper discusses the technology of methane extraction by a degassing well drilled from the surface into a coal-bearing stratum unloaded from rock pressure in a mining field of the 4th eastern face of the m 3 seam of the mine n.a. V.M.Bazhanov and its subsequent use as the fuel of an electric generator. It is shown that over the entire period of operation of the pilot well, the volume of actually produced methane exceeded the design value by 23 %, and the cost of the gas produced amounted to 1535 rubles per 1000 m 3 , which is more than 3 times lower than the market price for natural gas for consumers in the Russian Federation. This made it possible to make a conclusion about the possibility of industrial extraction of mine methane using vertical surface wells for its subsequent utilization in power plants, which does not imply the usage of hydraulic fracturing technology.
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Date submitted2017-09-10
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Date accepted2017-11-01
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Date published2018-02-22
Uninterruptible power supply system for mining industry enterprises
- Authors:
- B. N. Abramovich
Immediate problem of compensating falls and deviations of voltage in the power supply systems of mining enterprises in order to ensure the proper level of power supply reliability for the most important technological consumers is substantiated in the article. The main causes of the voltage falls and deviations occurrence in the power supply systems of mining enterprises have been identified. The degree of different nature voltage falls and deviations influence on the dynamic and static stability of power supply systems is established. The necessity of ensuring an uninterrupted and guaranteed power supply mode for continuous technological processes of mining production is shown. The analysis of the existing regulatory documentation in the field of guaranteed and uninterrupted power supply is carried out. Based on the results of experimental studies and mathematical modeling, a relationship has been revealed between formally independent sources of electricity supply from the viewpoint of existing regulatory documentation. The expression allowing determination of cohesion coefficient of two power supply sources is given. The necessity of taking into account the degree of sources interconnection in the synthesis of uninterruptible power supply systems for mining enterprises is justified. The analysis of existing technical means and solutions for reserving power supply for mining enterprises, including modern uninterruptible online power supply systems, own needs power plants, as well as dynamic voltage distortion compensators, is done. The classification of the consumers categories related to possibility of their complete or partial shutdown in emergency modes in case of voltage falls and interruptions is given. System of uninterruptible power supply for mining enterprises based on the combined use of alternative and renewable energy sources, uninterruptible power supply sources and a multi-step automatic reserve transition system, which allows ensuring uninterrupted mode of energy supply for the most responsible consumers of mining enterprises, was developed.
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Date submitted2015-10-17
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Date accepted2015-12-19
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Date published2016-08-22
Improving the retention of minerals in the course of separating monolith from bedrock with the use of gas generator cartridges
- Authors:
- G. P. Paramonov
- V. N. Kovalevskii
- Peter Mozer
Results are presented on the effect of firing rate on pressure pulse in charge camera and fracture stress during spalling. Results are presented of comparative calculations using the equations of autocatalytic reactions of firing rates and escape of reaction products for the system of sodium chlorate - polythene (propylene) in pipe shape. Dependences are obtained of firing rate on concentration of gas generating mixture, its density, components size distribution and cartridge case size. Experimental and computational data were used to consider the conditions of firing turning into explosion for compositions based on sodium chlorate and hydrocarbons in layered and powdered systems. The relation is retrieved between the technological parameters of mining activities (blast hole to blast hole distance, blast hole diameter, depth of cartridge placement) and specific cartridge consumption along the spalling line with gas generators going off.
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Date submitted2015-10-03
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Date accepted2015-12-10
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Date published2016-08-22
Directions and prospects of using low grade process fuel to produce alumina
- Authors:
- O. A. Dubovikov
- V. N. Brichkin
Power consumption across the globe is constantly increasing for a variety of reasons: growing population, industrialization and fast economic growth. The most widespread gaseous fuel – natural gas – has the low production cost. It is 2-3 times cheaper than liquid fuel production and 6-12 times cheaper than coal production. When natural gas is transported to distances from 1.5 to 2.5 thousand km by the pipeline, its cost with account of transportation is 1.5-2 times less than the cost of coal and the fuel storage facilities are not needed. Plants powered by natural gas have the higher efficiency as compared to the plants operating on other types of fuel. They are easier and cheaper to maintain and are relatively simple in automation, thus enhancing safety and improving the production process flow, do not require complicated fuel feeding or ash handling systems. Gas is combusted with a minimum amount of polluting emissions, which adds to better sanitary conditions and environment protection. But due to depletion of major energy resources many experts see the future of the global energy industry in opportunities associated with the use of solid energy carriers. From the environmental perspective solid fuel gasification is a preferred technology. The use of synthetic gas was first offered and then put to mass scale by English mechanical engineer William Murdoch. He discovered a possibility to use gas for illumination by destructive distillation of bituminous coal. After invention of the gas burner by Robert Bunsen, the illumination gas began to be used as a household fuel. The invention of an industrial gas generator by Siemens brothers made it possible to produce a cheaper generator gas which became a fuel for industrial furnaces. As the calorific value of generator gas produced through gasification is relatively low compared to natural gas, the Mining University studied possibilities to use different types of low grade process fuel at the Russian alumina refineries as an alternative to natural gas, access to which is restricted for some of the regions.