Operational Environment Effects on Energy Consumption and Reliability in Mine Truck Haulage

Przemysław Bodziony, Zbigniew Krysa and Michał Patyk ()
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Przemysław Bodziony: Department of Mining Engineering and Work Safety, Faculty of Civil Engineering and Resource Management, AGH University of Kraków, Al. Mickiewicza 30, 30-059 Cracow, Poland
Zbigniew Krysa: Faculty of Geoengineering, Mining and Geology, Wroclaw University of Technology, Wybrzeże Wyspiańskego 27, 50-370 Wrocław, Poland
Michał Patyk: Department of Mining Engineering and Work Safety, Faculty of Civil Engineering and Resource Management, AGH University of Kraków, Al. Mickiewicza 30, 30-059 Cracow, Poland

Energies, 2025, vol. 18, issue 12, 1-20

Abstract: This study investigates the factors influencing the energy consumption and reliability of haul trucks in open-pit mines and quarries, where fuel costs and the environmental impact are significant. Traditional analysis of haulage systems often overlooks crucial aspects such as energy efficiency in the specific mining environment and the effect of road configurations on truck performance. As sustainability becomes increasingly important, reducing fuel consumption not only reduces costs but also reduces greenhouse gas emissions. A key focus of the study is the link between haul truck reliability and overall efficiency. Frequent breakdowns increase maintenance costs, lead to unplanned downtime, and increase fuel consumption, all of which have an impact on the environment. Reliable transport systems, on the other hand, improve efficiency, reduce costs, and support sustainability goals. The authors analyze the energy consumption of trucks in relation to vehicle performance parameters and transport route characteristics. Discrete modeling of the transport system showed the impact of the operating environment on the variability of energy consumption and vehicle reliability. The study highlights the importance of understanding specific energy consumption in order to optimize the choice of transport system, as transport costs are a major cost of resource extraction. By analyzing the effect of road quality on vehicle performance, the authors suggest that improvements to the road surface can more easily improve vehicle reliability and energy intensity than changes to other road design elements. The study presents a quantitative analysis of the impact of haul road conditions on the operational efficiency of haul trucks in mining environments. Through discrete simulation models, two scenarios were analyzed. Total operational time decreased by 11.2% when road quality improved, demonstrating the critical role of surface maintenance. Additionally, breakdown times were reduced by 44%, maintenance by 15%, and empty travel by 9% in the optimized scenario. These findings underscore the necessity of maintaining optimal road conditions to prevent substantial efficiency losses and increased maintenance costs.

Keywords: mining haulage; energy consumption; reliability parameters (search for similar items in EconPapers)
JEL-codes: Q Q0 Q4 Q40 Q41 Q42 Q43 Q47 Q48 Q49 (search for similar items in EconPapers)
Date: 2025
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