Energy efficiency and optimum performance of mining and processing plants and equipment

This study analyzes energy efficiency of the Urup Mining and Processing Plant—a large copper pyrite ore producer in the North Caucasus. The relevance of the study is due to the required optimization of energy consumption at the higher ecological standards and improved energy efficiency. Spotlight is on the key indicators: specific energy consumption, 30 min wattage and supply line loss. The subject of research are the production processes in the mine and at the processing factory. The aim of the study is to develop an energy consumption prediction and calculation procedure to enhance production efficiency. The study used the statistical and probabilistic methods, including the correlation and regression analyses of data for a few years. The main results are: a great disagreement between the actual and calculated indexes of equipment utilization (coefficients kW=0.2–0.52 at the standard of 0.5–0.8); the energy consumption procedure using statistical samplings; prediction of 30 min wattage using various methods (least squares, growth rates, Holt’s method). The results are reflective of the 4–5-fold idle capacity of equipment. The further research should be connected with the introduction of a monitoring system for energy consumption and process variables in real time, and with the digital model of process flows toward more accurate prediction. The research findings demonstrate a high optimization potential of energy consumption. The implementation of the proposed measures can both help reduce electricity expenses and enhance overall efficiency of production.

Klyuev R. V. Energy efficiency and optimum performance of mining and processing plants and equipment. MIAB. Mining Inf. Anal. Bull. 2025;(7):157-169. [In Russ]. DOI: 10.25018/0236_1493_2025_7_0_157.

R.V. Klyuev, Dr. Sci. (Eng.), Assistant Professor, Professor, Moscow Polytechnic University, 107023, Moscow, Russia, e-mail: kluev-roman@rambler.ru, ORCID ID: 0000-0003-3777-7203.

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