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Energy Efficiency Analysis of Copper Ore Ball Mill Drive Systems

Author

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  • Piotr Bortnowski

    (Department of Mining and Geodesy, Faculty of Geoengineering, Mining and Geology, Wroclaw University of Science and Technology, 50-421 Wroclaw, Poland)

  • Lech Gładysiewicz

    (Department of Mining and Geodesy, Faculty of Geoengineering, Mining and Geology, Wroclaw University of Science and Technology, 50-421 Wroclaw, Poland)

  • Robert Król

    (Department of Mining and Geodesy, Faculty of Geoengineering, Mining and Geology, Wroclaw University of Science and Technology, 50-421 Wroclaw, Poland)

  • Maksymilian Ozdoba

    (Department of Mining and Geodesy, Faculty of Geoengineering, Mining and Geology, Wroclaw University of Science and Technology, 50-421 Wroclaw, Poland)

Abstract

Milling is among the most energy-consuming technological stages of copper ore processing. It is performed in mills, which are machines of high rotational masses. The start of a mill filled to capacity requires appropriate solutions that mitigate the overloading. One method for increasing the energy efficiency of ball mills is to optimize their drive systems. This article looks at two variants of drive systems with efficiencies higher than the already existing solutions. The first variant is a low-speed synchronous motor with permanent magnets without a gearbox, and the second variant is an asynchronous high-efficiency motor with a gearbox and a fluid coupling. The energy performance analysis of the three solutions was based on the average energy consumption indicator per mass unit of the milled material and on the energy consumption per hour. The investigations required models of the drive systems and analyses with the use of the Monte Carlo methods. The highest energy efficiency is observed in the case of the solution based on the permanent magnet motor. However, the drive system with the high-speed motor offers a gentle start-up possibility owing to the fluid coupling.

Suggested Citation

  • Piotr Bortnowski & Lech Gładysiewicz & Robert Król & Maksymilian Ozdoba, 2021. "Energy Efficiency Analysis of Copper Ore Ball Mill Drive Systems," Energies, MDPI, vol. 14(6), pages 1-14, March.
    • Handle: RePEc:gam:jeners:v:14:y:2021:i:6:p:1786-:d:522858
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    References listed on IDEAS

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    1. Malinauskaite, J. & Jouhara, H. & Ahmad, L. & Milani, M. & Montorsi, L. & Venturelli, M., 2019. "Energy efficiency in industry: EU and national policies in Italy and the UK," Energy, Elsevier, vol. 172(C), pages 255-269.
    2. Tesema, Gudise & Worrell, Ernst, 2015. "Energy efficiency improvement potentials for the cement industry in Ethiopia," Energy, Elsevier, vol. 93(P2), pages 2042-2052.
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    Cited by:

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    3. Paweł Strzałkowski, 2021. "Characteristics of Waste Generated in Dimension Stone Processing," Energies, MDPI, vol. 14(21), pages 1-16, November.
    4. Adam Wróblewski & Pavlo Krot & Radosław Zimroz & Timo Mayer & Jyri Peltola, 2023. "Review of Linear Electric Motor Hammers—An Energy-Saving and Eco-Friendly Solution in Industry," Energies, MDPI, vol. 16(2), pages 1-28, January.
    5. Dawid Szurgacz & Beata Borska & Ryszard Diederichs & Sergey Zhironkin, 2022. "Development of a Hydraulic System for the Automatic Expansion of Powered Roof Support," Energies, MDPI, vol. 15(3), pages 1-15, January.
    6. Dawid Szurgacz & Sergey Zhironkin & Stefan Vöth & Jiří Pokorný & A.J.S. (Sam) Spearing & Michal Cehlár & Marta Stempniak & Leszek Sobik, 2021. "Thermal Imaging Study to Determine the Operational Condition of a Conveyor Belt Drive System Structure," Energies, MDPI, vol. 14(11), pages 1-18, June.
    7. Ryszard Błażej & Leszek Jurdziak & Agata Kirjanów-Błażej & Mirosław Bajda & Dominika Olchówka & Aleksandra Rzeszowska, 2022. "Profitability of Conveyor Belt Refurbishment and Diagnostics in the Light of the Circular Economy and the Full and Effective Use of Resources," Energies, MDPI, vol. 15(20), pages 1-15, October.
    8. Dawid Szurgacz & Beata Borska & Sergey Zhironkin & Ryszard Diederichs & Anthony J. S. Spearing, 2022. "Optimization of the Load Capacity System of Powered Roof Support: A Review," Energies, MDPI, vol. 15(16), pages 1-15, August.
    9. Zare Banadkouki, Mohammad Reza, 2023. "Selection of strategies to improve energy efficiency in industry: A hybrid approach using entropy weight method and fuzzy TOPSIS," Energy, Elsevier, vol. 279(C).
    10. Dawid Szurgacz & Beata Borska & Ryszard Diederichs & Anthony J. S. Spearing & Sergey Zhironkin, 2023. "Minimizing Internal Leaks of a Powered Roof Support’s Hydraulic Prop Based on Double Block with Charging," Energies, MDPI, vol. 16(3), pages 1-14, January.

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