Justification of equipment parameters for mobile crushing-reloading-conveyor complexes in open-pit mining

The article addresses pressing issues of enhancing the efficiency of open-pit mining operations through the implementation of cyclic-flow technology using mobile crushing–reloading–conveyor complexes (MCRCC). The main focus is on the selection and substantiation of equipment parameters for mobile complexes, considering geological, mining, and organizational factors that determine system performance. A structural diagram has been developed, illustrating the interconnection of all components of the complex, including the excavator, crusher, reloader, and conveyor transport. A methodology for selecting and calculating technological parameters is proposed, taking into account the excavator’s productivity and operating modes. Special attention is given to maintaining a balanced performance among all subsystems of the complex to ensure its stable and efficient operation. Furthermore, the article establishes a functional dependence of the excavator’s productivity on the cut width when loading the mobile crushing unit, which allows for a justified optimization of technological process parameters. The obtained results and proposed approaches can serve as a methodological basis for the design of modern open-pit mines and for improving the efficiency of mineral extraction

Annakulov T. J., Temirov K. M., Otajonov B. O., Yunusov J. F., Norimonov Sh. N. Justification of equipment parameters for mobile crushing-reloading-conveyor complexes in open-pit mining. MIAB. Mining Inf. Anal. Bull. 2025;(12-3):5—22. [In Russ]. DOI: 10.25018/0236_1493_2025_123_0_5.

Annakulov T. J., Cand. Sci. (Eng.), Associate Professor, Head of the Department of Mining Electromechanics, TSTU, 2 Universitet Street, Almazar District, Tashkent, 100095, Uzbekistan, e-mail: a.tulkin1275@yandex.ru, ORCID ID: 0000-0003-3106-144X;
Temirov K. M., Senior Lecturer, Department of Mining and Electromechanics, TSTU, e-mail: kmtemirov@gmail.com, ORCID ID: 0009-0005-2259-7834;
Otajonov B. O., Senior Lecturer, Department of Mining and Electromechanics, TSTU, e-mail: bahrom9097@yandex.com, ORCID ID: 0000-0001-8871-7724;
Yunusov Jasurbek Farhod ugli, Assistant Lecturer, Department of Mining and Electromechanics, TSTU, e-mail: jasurbekyunusov@tdtu.uz, ORCID ID: 0009-0002-5126-0059;
Norimonov S. N., master student, Department of Mining and Electromechanics, TSTU, e-mail: shamsiddintmjgorniy@gmail.com, ORCID ID: 0009-0001-7785-3082.

T. J. Annakulov, e-mail: a.tulkin1275@yandex.ru.

1. Abbaspour, H., Drebenstedt, C. (2023). Truck–Shovel vs. In-Pit Crushing and Conveying Systems in Open Pit Mines: A Technical Evaluation for Selecting the Most Effective Transportation System by System Dynamics Modeling. Logistics, 7(4), 92. https://doi.org/10.3390/logistics7040092

2. Hay, E., Nehring, M., Knights, P., Kizil, M. S. (2020). Ultimate Pit Limit Determination for Semi-Mobile In-Pit Crushing and Conveying System: A Case Study. International Journal of Mining, Reclamation and Environment, 34(6), 410–427. https://doi.org/10.1080/17480930.2019.1639006

3. Liu, D., Pourrahimian, Y. (2021). A Framework for Open-Pit Mine Production Scheduling under Semi-Mobile In-Pit Crushing and Conveying Systems with the High-Angle Conveyor. Mining, 1(1), 5. https://doi.org/10.3390/mining1010005

4. Osanloo, M., Paricheh, M. (2020). In-Pit Crushing and Conveying Technology in Open-Pit Mining Operations: A Literature Review and Research Agenda. International Journal of Mining, Reclamation and Environment, 34(3), 165–187. https://doi.org/10.1080/17480930.2019.1565054

5. Zhukovsky, Yu.L., Suslikov, P. K. (2024). Assessment of the potential effect of applying demand management technology at mining enterprises; Sustainable Development of Mountain Territories, 16(3), 895−908. https://doi.org/10.21177/1998-4502-2024-16−3-895−908 

6. Annakulov T. J. Development of technological schemes for open-pit mining of deposits using mobile crushing-reloading-conveyor complexes. E3S Web of Conferences, 2020, 201, 01010. https://doi.org/10.1051/e3sconf/202020101010 

7. Shibanov D., Agaguena A., Annakulov T. Extraction of Inclined Exit Ledges in Coal Mines in Presence of Mobile Crushing and Conveyor Complexes. (2024) International Journal of Engineering, Transactions B: Applications, 37 (8), pp. 1658 1666, https://doi.org/10.5829/ije.2024.37.08b.17 

8. Glebov A. V. Methodological principles for selecting the main equipment for the structures of cyclic-flow technology mechanization. MIAB. Mining Inf. Anal. Bull. 2021, No. 5–2, pp. 296–308 [In Russ]. https://doi.org/10.25018/0236_1493_2021_52_0_296

9. Chaplygin, V. V., Sadykov, A. A., & Matveev, A. V. On the issue of optimizing technological parameters for the development of semi-rock overburden by mechanical shovels at the Kuzbass open-pit mines. MIAB. Mining Inf. Anal. Bull. 2023, No. 9, pp. 84–98 [In Russ]. https://doi.org/10.25018/0236_1493_2023_9_0_84.

10. Zhuravlev, A. G., Kardashin, E. D. Modeling of cargo flows during the operation of an in-pit crushing and conveying complex.. Subsoil Use Problems, No. 4, 2024, pp. 6–15 [In Russ]. https://doi.org/10.25635/2313−1586.2024.04.006 

11. Khamidov, O. U., Shibanov, D. A., Shishkin, P. V., Kolpakov, V. O. Efficiency of excavator application at open-pit mines in Uzbekistan. Mining Industry, 2024, No. 5, pp. 135–142 [In Russ]. https://doi.org/10.30686/1609-9192-2024-5-135−142 

12. Yudin A. V., Shestakov V. S. Systematic approach, principles of formation, and evaluation criteria for flexible overloading systems. Izvestia of Ural State Mining University, 2019, Issue 4(56), pp. 118–126 [In Russ]. https://doi.org/10.21440/2307-2091-2019-4-118−126 

13. Aliyeva L., Zhukov I. A. Improving the efficiency of impact-rotary drilling of high-strength rocks by optimizing the structure of the blade-less rock-breaking tool. Sustainable Development of Mining Territories, 2024, Vol. 16, No. 4, pp. 1681–1694 [In Russ]. https://doi.org/10.21177/1998-4502-2024-16−4-1681−1694 

14. Teplyakova A. V., Azimov A. M., Aliyeva, L., Zhukov I. A. Review and analysis of technical solutions for improving the durability and technological performance of the impact nodes of drilling machines. MIAB. Mining Inf. Anal. Bull. 2022, No. 9, pp. 120–132 [In Russ]. https://doi.org/10.25018/0236_1493_2022_9_0_120 

15. Efimov D. A., Gospodarikov, A. P. Prospects for the use of Relo-profile rolls in crushers and high-pressure grinding rolls. Mining Equipment and Electromechanics, 2022, No. 4(162), pp. 36–43 [In Russ]. https://doi.org/10.26730/1816-4528-2022-4-36−43

16. Moradi I., Irannajad M. Fractal dimension of crushing products: effects of feed size distribution and feed rate. Particulate Science and Technology. 2021. Т. 39. №. 7. Р. 877−886. https://doi.org/10.1080/02726351.2020.1856248 

17. Bulatov, G., Annakulov, T. Investigation of the width of the entry of an excavator when loading a mobile crushing plant in the conditions of the Angren coal mine of Uzbekistan. IOP Conference Series: Earth and Environmental Science, 2021, 937(4), 042088. https://doi.org/10.1088/1755−1315/937/4/042088

18. Sheshukova E. I., Shibanov D. A., Ivanov S. L., Shishkin P. V. Evaluation of Loads on the Drives of Mining Excavator Working Equipment (Part 2). Mining Industry. 2024;(4):108–114. DOI: 10.30686/1609-9192-2024-4-108−114. 

19. Salimov A. E., Shibanov D. A., Ivanov S. L. Failure risks of mine excavator associated with its maintenance and repair. Russian Mining Industry. 2024;(2):97–102. [In Russ]. https://doi.org/10.30686/1609-9192-2024-2-97−102 

20. Korolev N. A., Zhukovsky, Yu. L., Buldysko, A. D., Baranov, G. D., Chen, P. Assessment of energy resources based on the diagnostics of the technical condition of electromechanical equipment in the mineral resource complex. MIAB. Mining Inf. Anal. Bull. 2024, No. 5, pp. 158–181 [In Russ]. https://doi.org/10.25018/0236_1493_2024_5_0_158