Improving the energy efficiency of pumping units in mining enterprises: analysis, diagnostics, and optimization paths

This article addresses the critical issue of improving the energy efficiency of pumping units, which are among the primary consumers of electricity, in the mining industry. The paper presents a comprehensive analysis of the causes of low efficiency, including a detailed examination of hydraulic, volumetric, and mechanical losses in pumps. Particular attention is paid to the impact of the technical condition and operating modes of the equipment on its overall efficiency. Using a real-world example of an electrolytic shop pumping fleet, an approach to selecting electric motors is demonstrated, taking into account actual operating conditions, such as increased hydraulic resistance due to salt deposits. The study focuses on the results of an energy audit, which revealed serious power quality issues: current asymmetry in phases (up to 7% difference, neutral current 2.04 A) and a significant level of higher harmonic distortion (up to 7% for the 11th and 13th harmonics), which leads to additional losses and a reduced equipment service life. Based on the analysis, a set of technical and organizational measures was proposed to optimize energy consumption. Key measures include the implementation of variable-frequency drives for variable-load pumps, reactive power compensation, cascade control of pump groups, and the reduction of hydraulic losses in pipeline networks and leak control. Implementation of these measures significantly reduces operating costs and improves the reliability of critical mining equipment. Pumping units at mining facilities have significant potential for improved energy efficiency, as confirmed by an analysis of all types of losses and the results of energy audits.

Klyuev R. V. Improving the energy efficiency of pumping units in mining enterprises: analysis, diagnostics, and optimization paths. MIAB. Mining Inf. Anal. Bull. 2026;(1):156–167. DOI: 10.25018/0236_1493_2026_1_0_156.

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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