Mobile in-pit diesel power plant: Design and operation experience

Power supply of electric excavators and other machines in open pit mines uses fixed or movable lines. As the mining front changes, the machines are moved to the in-pit distribution points using special cable connections. When there are no power lines at the relocation sites of excavators, the self-sustained mobile diesel power plants can be employed. This article describes the design, analysis and commercial operation of high-voltage (6 kV) plants to ferry excavators and drill rigs having different-type dc and ac motors in open pit mines. The plants contain a diesel motor, a generator, a high-voltage distribution facility, a guidance and a control and safety system placed on a KAMAZ dump truck. The plant is connected to an excavator using a standard cable. When connected, partial operation of all main motion drives is possible. An operator controls the plant performance from the truck driver’s cabin. All systems of the excavator, including safety, control and information diagnostics function. The plant meets the safety standards and the effective regulations set for electric equipment in mines. In case of the single line-to-body fault, the microcontroller safety of the plant ensures shut-off for 70 ms. The power plant capacities are calculated for ferrying different excavators. The high-voltage ferrying plants operate successfully at Apatit, Lebedinsky GOK and Elgacoal. The experimental research of power processes in ferrying of excavators is described.

Malafeev S. I., Serebrennikov N. A. Mobile in-pit diesel power plant: Design and operation experience. MIAB. Mining Inf. Anal. Bull. 2023;(8):152-164. [In Russ]. DOI: 10. 25018/0236_1493_2023_8_0_152.

S.I. Malafeev¹, Dr. Sci. (Eng.), Professor, Alexander and Nikolay Stoletovs Vladimir State University, 600000, Vladimir, Russia; Chief Researcher, e-mail: simalafeev@gmail.com; sim@jpc.ru,
N.A. Serebrennikov¹, General Director, e-mail: serebrennikov@jpc.ru,
¹ Joint Power Co., Ltd., 111672, Moscow, Russia.

S.I. Malafeev, e-mail: simalafeev@gmail.com.

1. Hustrulid W., Kuchta M., Martin R. Open pit mine planning & design. Vol. 1. Fundamentals. CRC Press. London–New-York–Leiden. 2013, 1306 p.

2. Czaplicki J. M. Mining equipment and systems. Theory and practice of exploitation and reliability. CRC Press, Balkema. London–New-York–Leiden. 2010, 285 p.

3. Ivanov S. L., Ivanova P. V., Kuvshinkin S. Yu. Evaluation of mining excavators of a promising model range in real operating conditions. Journal of Mining Institute. 2020, vol. 242, pp. 228—233. [In Russ]. DOI: 10.31897/PMI.2020.2.228.

4. Babokin G. I. Influence of technical parameters, work conditions and operating mode on energy efficiency of single-bucket exactor. MIAB. Mining Inf. Anal. Bull. 2019, no. 11, pp. 199—207. [In Russ]. DOI: 10.25018/0236-1493-2019-11-0-199-207.

5. Manikandana P., Maitya T. Performance analysis of a digitally retrofitted ward— leonard control dragline—a case study in coal mine. Journal of Mining Science. 2020, vol. 56, no. 1, pp. 59—65. DOI: 10.1134/S106273912001648X.

6. Lajunen A., Sainio P., Laurila L., Pippuri-Mäkeläinen J., Tammi K. Overview of powertrain electrification and future scenarios for non-road mobile machinery. Energies. 2018, vol. 11, no. 5, article 1184. DOI: 10.3390/en11051184.

7. Khakulov V. A., Shapovalov V. A., Ignatov M. V., Islamova O. V. Improvement of technology design and management of mining operations on the functioning basis intellectual complexes drilling machine — excavator — dump truck. MIAB. Mining Inf. Anal. Bull. 2019, no. S37, pp. 271—281. [In Russ]. DOI: 10.25018/0236-1493-2019-11-37-271-281.

8. Ge L., Quan L., Zhang X., Dong Z., Yang J. Power matching and energy efficiency improvement of hydraulic excavator driven with speed and displacement variable power source. Chinese Journal of Mechanical Engineering. 2019, vol. 32, no. 1, pp. 1—12. DOI: 10.1186/ s10033-019-0415-x.

9. Ertugrul N., Kani A. P., Davies M., Sbarbaro D., Morán L. Status of mine electrification and future potentials. 2020 International Conference on Smart Grids and Energy Systems (SGES), Perth, Australia. 2020, pp. 1—6. DOI: 10.1109/SGES51519.2020.00034.

10. Bise C. J. Modern American coal mining: Methods and applications. Society for Mining, Metallurgy and Exploration, Inc. Englewood. 2013, 576 p.

11. Zhang T., Fu T., Yunhao Cui Y., Song X. Toward autonomous mining: design and development of an unmanned electric shovel via point cloud-based optimal trajectory planning. Frontiers of Mechanical Engineering. 2022, vol. 17, no. 3, article 30. DOI: 10.1007/s11465-022-0686-2.

12. Chulkov N. N. Elektrifikatsiya kar'erov [Quarry electrification], Moscow, Nedra, 1974, 344 p.

13. Malafeev S. I., Malafeev S. S. Analysis of a quarry mobile diesel generator station during the moving of an excavator. Proceedings of the 6th International Conference on Industrial Engineering (ICIE 2020), Lecture Notes in Mechanical Engineering. 2021, vol. II, pp. 803—810. DOI: 10.1007/978-3-030-54817-9_93.

14. Peters E. R. Osnovy teorii odnokovshovykh ekskavatorov [Fundamentals of the theory of single–bucket excavators], Moscow, 1955, 260 p.

15. Malafeev S. I., Malafeev S. S. Investigation of electric power processes during the operation of a mining excavator. 2019 International Conference on Industrial Engineering, Applications and Manufacturing (ICIEAM). 2019, pp. 1—6. DOI: 10.1109/ICIEAM.2019.8743002.

16. Stefanovskiy B. S., Dokolin Yu. M., Sorokin V. P., Vasil'ev E. A., Korsi E. K., Skobtsov E. A. Ispytaniya dvigateley vnutrennego sgoraniya [Testing of internal combustion engines], Moscow, Mashinostroenie, 1972, 368 p.

17. Pavlenko S. V., Maklakov V. E., KHomyakov S. F., Goncharov E. D. Patent RU 2330958, MPK E01S 47/00. 10.08.2008. [In Russ].

18. Mouni E., Moser S., Betge P., Morisseau V. Patent US 2016/0329847 A1. Int. Cl.: H02P 9/00; H02P 9/08. 11.10.2016.

19. Toader D., Vintan M., Solea C., Vesa D., Greconici M. Analysis of the possibilities of selective detection of a single line-to-ground fault in a medium voltage network with isolated neutral. Energies. 2021, vol. 14, no. 21, article 7019. DOI: 10.3390/en14217019.

20. Lyakhomskiy A. V., Gerasimov A. I., Perfil’eva E. N. Modeling phase-to-ground faults in 6kW grids in open pit mining MIAB. Mining Inf. Anal. Bull. 2021, no. 2, pp. 164—178. [In Russ]. DOI: 10.25018/0236-1493-2021-2-0-164-178.

21. Malafeev S. I., Mikryukov V. I., Malafeeva A. A. High-voltage mobile station in open pit mine: Electrosafety analysis. MIAB. Mining Inf. Anal. Bull. 2022, no. 3, pp. 143—153. [In Russ]. DOI: 10.25018/0236_1493_2022_3_0_143.

22. Naidenov A. I., Dmitriev E. A. Parameters of grounding devices for personnel and equipment protection. Proceedings of Irkutsk State Technical University. 2011, no. 11(58), pp. 109—112. [In Russ].