Dynamic Coal Flow-Based Energy Consumption Optimization of Scraper Conveyor
Fully mechanized mining involves high energy consumption, particularly during cutting and transportation. Scraper conveyors, crucial for coal transport, face energy efficiency challenges due to the lack of accurate dynamic coal flow models, which restricts precise energy estimation and optimization....
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MDPI AG
2025-06-01
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| Series: | Applied Sciences |
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| Online Access: | https://www.mdpi.com/2076-3417/15/13/7366 |
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| author | Qi Lu Yonghao Chen Xiangang Cao Tao Xie Qinghua Mao Jiewu Leng |
| author_facet | Qi Lu Yonghao Chen Xiangang Cao Tao Xie Qinghua Mao Jiewu Leng |
| author_sort | Qi Lu |
| collection | DOAJ |
| description | Fully mechanized mining involves high energy consumption, particularly during cutting and transportation. Scraper conveyors, crucial for coal transport, face energy efficiency challenges due to the lack of accurate dynamic coal flow models, which restricts precise energy estimation and optimization. This study constructs dynamic coal flow and scraper conveyor energy efficiency models to analyze the impact of multiple variables on energy consumption and lump coal rate. A dynamic coal flow model is developed through theoretical derivation and EDEM simulations, validated for parameter settings, boundary conditions, and numerical methods. The multi-objective optimization model for energy consumption is solved using the NSGA-II-ARSBX algorithm, yielding a 33.7% reduction in energy consumption, while the lump coal area is reduced by 27.7%, indicating a trade-off between energy efficiency and coal fragmentation. The analysis shows that increasing traction speed while decreasing scraper chain and drum speeds effectively lowers energy consumption. Conversely, simultaneously increasing both chain and drum speeds helps to maintain lump coal size. The final optimization scheme demonstrates this balance—achieving improved energy efficiency at the cost of increased coal fragmentation. Additional results reveal that decreasing traction speed while increasing chain and drum speeds results in higher energy consumption, while increasing traction speed and reducing chain/drum speeds minimizes energy use but may negatively affect lump coal integrity. |
| format | Article |
| id | doaj-art-1fb6ce4a463e4453aceb177f23bb1e4e |
| institution | OA Journals |
| issn | 2076-3417 |
| language | English |
| publishDate | 2025-06-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Applied Sciences |
| spelling | doaj-art-1fb6ce4a463e4453aceb177f23bb1e4e2025-08-20T02:35:42ZengMDPI AGApplied Sciences2076-34172025-06-011513736610.3390/app15137366Dynamic Coal Flow-Based Energy Consumption Optimization of Scraper ConveyorQi Lu0Yonghao Chen1Xiangang Cao2Tao Xie3Qinghua Mao4Jiewu Leng5School of Mechanical Engineering, Xi’an University of Science and Technology, Xi’an 710054, ChinaSchool of Mechanical Engineering, Xi’an University of Science and Technology, Xi’an 710054, ChinaSchool of Mechanical Engineering, Xi’an University of Science and Technology, Xi’an 710054, ChinaYuandatan Coal Mine, Yulin 719000, ChinaSchool of Mechanical Engineering, Xi’an University of Science and Technology, Xi’an 710054, ChinaGuangdong Provincial Key Laboratory of Computer Integrated Manufacturing System, Guangdong University of Technology, Guangzhou 510006, ChinaFully mechanized mining involves high energy consumption, particularly during cutting and transportation. Scraper conveyors, crucial for coal transport, face energy efficiency challenges due to the lack of accurate dynamic coal flow models, which restricts precise energy estimation and optimization. This study constructs dynamic coal flow and scraper conveyor energy efficiency models to analyze the impact of multiple variables on energy consumption and lump coal rate. A dynamic coal flow model is developed through theoretical derivation and EDEM simulations, validated for parameter settings, boundary conditions, and numerical methods. The multi-objective optimization model for energy consumption is solved using the NSGA-II-ARSBX algorithm, yielding a 33.7% reduction in energy consumption, while the lump coal area is reduced by 27.7%, indicating a trade-off between energy efficiency and coal fragmentation. The analysis shows that increasing traction speed while decreasing scraper chain and drum speeds effectively lowers energy consumption. Conversely, simultaneously increasing both chain and drum speeds helps to maintain lump coal size. The final optimization scheme demonstrates this balance—achieving improved energy efficiency at the cost of increased coal fragmentation. Additional results reveal that decreasing traction speed while increasing chain and drum speeds results in higher energy consumption, while increasing traction speed and reducing chain/drum speeds minimizes energy use but may negatively affect lump coal integrity.https://www.mdpi.com/2076-3417/15/13/7366scraper conveyordynamic coal flowmechanical modelenergy consumptionmulti-objective optimization |
| spellingShingle | Qi Lu Yonghao Chen Xiangang Cao Tao Xie Qinghua Mao Jiewu Leng Dynamic Coal Flow-Based Energy Consumption Optimization of Scraper Conveyor Applied Sciences scraper conveyor dynamic coal flow mechanical model energy consumption multi-objective optimization |
| title | Dynamic Coal Flow-Based Energy Consumption Optimization of Scraper Conveyor |
| title_full | Dynamic Coal Flow-Based Energy Consumption Optimization of Scraper Conveyor |
| title_fullStr | Dynamic Coal Flow-Based Energy Consumption Optimization of Scraper Conveyor |
| title_full_unstemmed | Dynamic Coal Flow-Based Energy Consumption Optimization of Scraper Conveyor |
| title_short | Dynamic Coal Flow-Based Energy Consumption Optimization of Scraper Conveyor |
| title_sort | dynamic coal flow based energy consumption optimization of scraper conveyor |
| topic | scraper conveyor dynamic coal flow mechanical model energy consumption multi-objective optimization |
| url | https://www.mdpi.com/2076-3417/15/13/7366 |
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