Balancing Load and Speed: A New Approach to Reducing Energy Use in Coal Conveyor Systems

Leszek Jurdziak () and Mirosław Bajda
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Leszek Jurdziak: Department of Mining, Faculty of Geoengineering, Mining and Geology, Wroclaw University of Science and Technology, 50-370 Wrocław, Poland
Mirosław Bajda: Department of Mining, Faculty of Geoengineering, Mining and Geology, Wroclaw University of Science and Technology, 50-370 Wrocław, Poland

Energies, 2025, vol. 18, issue 17, 1-18

Abstract: Reducing energy consumption in belt conveyor systems is critical to improving the overall energy efficiency of lignite mining operations. This study presents a theoretical and empirical analysis of energy use in overburden and coal conveyors, with a focus on balancing the relationship between belt speed and load. Building on the theory of conveyor motion resistance, the energy consumption index ( WskZE )—previously introduced by the authors—is revisited as a function of two key variables: belt speed (v) and real-time material flow rate ( Q r ). Empirical validation was conducted using operational data from variable-speed conveyors in the Konin lignite mine and compared to similar-length conveyors in the Bełchatów mine. Energy consumption measurements allowed for the analysis of energy consumption for two different scenarios: (i) in the Bełchatów mine the belt speed was constant and the excavator capacity was variable and (ii) in the Konin mine the excavator capacity was kept constant and the conveyor belt speed was varied. The results confirm that WskZE is linearly dependent on belt speed and inversely proportional to throughput, as predicted by theoretical models. However, findings also show that lowering belt speed—while effective in reducing energy use—results in a higher proportion of power being consumed to move the belt and heavy idlers, especially when these components are sized for peak loads. This study suggests a revised conveyor design philosophy (a new paradigm) that emphasizes maximizing the mass ratio of transported material to moving components. Additionally, it recommends integrating real-time monitoring of energy performance indicators into mine control systems to enable energy-aware operational decisions.

Keywords: belt conveyors; energy consumption; lignite mining; variable speed drives; energy efficiency index (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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