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International Journal of Electrical and Computer Engineering (IJECE)

Vol. 10, No. 3, June 2020, pp. 2861~2873


ISSN: 2088-8708, DOI: 10.11591/ijece.v10i3.pp2861-2873  2861

Application of resistance energy model to optimising electric


power consumption of a belt conveyor system

Awingot Richard Akparibo1, Erwin Normanyo2


1Department of Electrical and Electronic Engineering, Ashesi University, Ghana
2Department of Electrical and Electronic Engineering, University of Mines and Technology, Ghana

Article Info ABSTRACT


Article history: Driven by constantly increasing energy demands, prices, environmental
impact caused by carbon dioxide emissions and global warming, efficient use
Received Jul 9, 2019 of energy is gaining grounds in both public and private enterprises.
Revised Dec 6, 2019 The energy consumption of belt conveyors can be lowered using energy
Accepted Dec 13, 2019 modelling techniques. In this research, a resistance-based mathematical
energy model was utilised in the electrical energy efficiency optimisation of
Keywords: the troughed, inclined belt conveyor system taking into account indentation
rolling resistance, bulk solid flexure resistance and secondary resistance as
Belt conveyor system they together contribute 89% resistance to motion. An optimisation problem
Energy model was formulated to optimise the electrical energy efficiency of the belt
Modelling conveyor system and subsequently solved using the “fmincon” solver and
Optimising energy efficiency interior point algorithm of the MATLAB optimisation toolbox. Analysis of
Simulation simulation results showed that for the same given operating capacities,
an average energy saving of about 7.42% and an annual total cost savings of
Gh¢ 5, 852, 669.00 (USD 1, 083, 827.59) for a 2592-hour operation can be
achieved when the used model and optimisation technique are employed over
the constant speed operation.
Copyright © 2020 Institute of Advanced Engineering and Science.
All rights reserved.

Corresponding Author:
Awingot Richard Akapribo,
Department of Electrical and Electronic Engineering,
Ashesi University,
1st University Avenue, Brekusu, PMB CT3, Cantonments, Accra, Ghana.
Email: [email protected]

1. INTRODUCTION
The rising cost of doing business has necessitated companies to search for better ways of
minimising expenses that affect competitiveness and the bottom line. Automating certain functions in
manufacturing and material handling does improve productivity and efficiency creating some cost
savings [1]. A growing area of concern is the increasing energy cost. Cost of energy forms a large part of
the operational cost of belt conveyor systems and according to [2], this constitutes 40% of the operational
cost. Conveyor equipment, aside of gravity conveyors, require motors and other equipment that use
electricity for power [1]. Saving energy of belt conveyor systems offers a lot of benefits aside of the cost
savings. It increases the energy reserves and curbs emissions of carbon dioxide [3].
A belt conveyor is a piece of equipment used to transport materials or products from one place to
another. It converts electrical energy into mechanical motion [4, 5]. Belt conveyors are widely used for
handling bulk material over short to medium conveying distances because of their high efficiency of
transportation as compared to other methods of transportation [5, 6]. They are largely used in the mining
industry, in manufacturing, at bulk terminals, in cement plants, power plants and chemical production
industries for the transportation of goods and services [7]. A typical conveyor system consists of the tail
pulley, idler, belt, take-up and drive pulley [6-8].

Journal homepage: http://ijece.iaescore.com/index.php/IJECE


2862  ISSN: 2088-8708

Material handling is one of the important phenomena in industry. Belt conveyors are being preferred
in most parts of material handling systems because of their high efficiency of transportation. However, they
come with their own problems of electrical energy consumption. According to [1], conveying equipment
consume up to 50% of a facility’s energy usage and account for nearly 70% of electrical load in an industrial
facility [1]. This presents both a challenge and an opportunity for energy savings. Driven by constantly
increasing energy demands, prices, environmental impact caused by carbon dioxide emissions and global
warming, efficient use of energy is gaining grounds in both public and private enterprises [9]. The material
handling industry and for that matter, a belt conveyor system is no exception. The electrical energy
consumption of a belt conveyor is dependent on the drive’s speed and the resistances to motion.
The resistances to motion include indentation rolling resistance, bulk solid flexure resistance, secondary
resistance, idler roll rotating resistance and belt flexure resistance [10, 11]. Figure 1 gives a diagram of a belt
conveyor system with corresponding values of motion resistances [11-16]. This research paper gives focus to
utilisation of resistance energy model taking into account indentation rolling resistance, bulk solid flexure
resistance and secondary resistance as they together contribute 89% resistance to motion. Field studies and
model development approach for the drive system are given consideration.

Figure 1. A belt conveyor system with critical values of motion resistances

2. FIELD STUDIES AND DATA COLLECTION


A number of belt conveyors at the operations of a mining company located in the Tarkwa-Nsuaem
municipality of the Western region of Ghana were studied. During the studies, the electric power consumed,
belt speed, and feed rate of the 12-conveyor system of the mine were recorded at different time intervals with
the aid of the field instruments. The electric power consumed was measured against the belt speed when
the feed rate was held constant at T = 65.4 t/h. Also, the electric power consumed was measured against
the feed rate when the speed was held constant at 𝜈 = 3.7 m/s.
Data on the belt conveyor system of the mining company were collected and analysed. The various
conveyors studied were grouped into two as overland conveyors and crusher conveyors. The data collected
on each conveyor aided the calculation of model parameters C 1 and C2. Also, instruments such as electrical
energy meter, belt motion monitor and belt weightometer were employed to aid in the determination of
the electric motor output power (PM), belt speed (ν) and belt load carrying capacity (T), respectively

3. RESISTANCE ENERGY MODEL


Our focus is to utilise a resistance-based energy model and also a model for the energy cost of a belt
conveyor system in order to minimise electrical energy consumption and operating cost of the belt conveyor
system. The resistance- based energy model is obtained from mathematical calculations of mechanical
resistances of the belt conveyor. Under stationary operating conditions, the energy consumption of belt
conveyors is mainly determined by the resistances to motion of the belt conveyor. With nominal values of
system settings, resistance of the belt conveyor can be calculated. ISO 5048, DIN 22101 and CEMA [17-22],
distinguish four components that make up the total mechanical resistance.

Int J Elec & Comp Eng, Vol. 10, No. 3, June 2020 : 2861 - 2873
Int J Elec & Comp Eng ISSN: 2088-8708  2863

The primary or main resistance component, FH consists of various resistances including flexing
resistances of the conveyor belt as well as the bulk solid material and the indentation rolling resistance of
the idlers. The secondary resistance, FN is the resistance force that is due mainly to frictional and
acceleration forces in the feeding area. The slope/gradient resistance, FSt is the resistance due to inclination
of the belt conveyor. The special resistance component, FS is the resistance for special designed belt
conveyors, e.g. situations where, special curves are involved. The resistance energy model is given
by (1) [10-17].

F U  F H F N FSt FS (1)

The diagrammatic model of a troughed, inclined belt conveyor system modified after [16], is shown
in Figure 2. It is powered by an electric motor-driven system and supported by a system of pulleys. It carries
the bulk material on top of the troughed surface of the belt. The troughed structure of the belt is maintained
by sets of evenly spaced carrying and return idlers. The appropriate idler spacing is determined during
the design stage as recommended by international standards such as CEMA, JIS, ISO and DIN
22101 [21, 22] to avoid excessive belt sag and potential spillages. This ensures that the cross-sectional area
of the belt is fairly constant. The belt is usually fitted with accessories such as a feed chute at the tail end and
a scraper below the head end. The main focus is to utilise a resistance energy model taking into account
indentation rolling resistance and bulk solid flexure resistance which together largely form the main
resistance, FH and secondary resistance, FN but since the belt conveyor system under study is inclined,
the slope/gradient resistance component must be considered as well. The free body diagram illustrated by
the primary resista- nce of the belt conveyor is given by Figure 3.

Head Pulley
and Drive Belt Bulk Material

L
Feed Chute
Carrying Idler
Scraper End View
FH H
Belt
FN
δ Return Idler

Tail Pulley Lh

Figure 2. Model of the troughed inclined belt conveyor system

L
FH

Mass (m)
H
Conveyor Belt
μ
δ

LH

Figure 3. Illustration of primary resistance

Application of resistance energy model to optimising electric power … (Awingot Richard Akapribo)
2864  ISSN: 2088-8708

The resistance energy model is obtained as follows:

𝐹𝐻 = μ.m.g (2)

𝑚 = L g [𝑄R0 + 𝑄RU + (2Q 𝐵 + 𝑄𝐺 ) Cos δ] (3)

Q RR and QB represent the unit mass of rotating rolls and the unit mass of the belt respectively.
In the belt conveyor world, the friction coefficient μ is replaced by the letter f [23]. Therefore,
the main resistance is given in (4) [20, 22, 23] as:

𝐹𝐻 = f L g [𝑄R0 + 𝑄RU + (2Q 𝐵 + 𝑄𝐺 ) Cos δ] (4)

Let: Q RR = QR0  QRU

then, FH is expressed as in (5).

𝐹𝐻 = f L g [𝑄RR + (2Q 𝐵 + 𝑄𝐺 ) Cos δ] (5)

According to experiments [10, 22, 23], the secondary resistance can be expressed with adequate
correctness for belt conveyors with L ˃ 80 m by (6).

FN  (C - 1) FH (6)

where, C = conveyor length coefficient.


Now, by adding (5) and (6), we obtain (7) as follows:

𝐹𝐻 + 𝐹𝑁 = f L g [𝑄RR + (2Q 𝐵 + 𝑄𝐺 ) Cos δ] + (C-1) F𝐻


= f L g [𝑄RR + (2Q 𝐵 + 𝑄𝐺 ) Cos δ] + (C-1) (f L g [𝑄RR + (2Q 𝐵 + 𝑄𝐺 ) Cos δ] )
= f L g [𝑄RR + (2Q 𝐵 + 𝑄𝐺 ) Cos δ] + C f L g [𝑄RR + (2Q 𝐵 + 𝑄𝐺 ) Cos δ]‒
f L g [𝑄RR + (2Q 𝐵 + 𝑄𝐺 ) Cos δ]
= C f L g [𝑄RR + (2Q 𝐵 + 𝑄𝐺 ) Cos δ] (7)

the coefficient, C in (7) depends on the length of the conveyor and can be found in either graphs or in tables.
Neglecting the special resistance component, F S since it is too small, the total resistance to motion can be
found by adding the slope resistance, FSt to (7) to give (8).

𝐹𝑇 = 𝐹𝐻 + 𝐹𝑁 + 𝐹St = C f L g [𝑄RR + (2Q 𝐵 + 𝑄𝐺 ) Cos δ] + g H Q 𝐺 (8)

The unit mass of transporting material, Q G can also be calculated using (9) [20, 22].

𝑇
𝑄𝐺 = (9)
3.6×𝜈

QG
is obtained from the product of the cross-sectional area (A) of the material conveyed and the material
density ( ρ ). It is therefore right for one to say that the total resistances to motion of the belt conveyor are
dependent on the amount of material that the conveyor belt is carrying, specified as Q G since Q RR and QB
which represent the unit mass of rotating rolls and the unit mass of the belt respectively remain fairly
constant whiles the conveyor system is installed. Therefore, FT can be written as in (10).

𝐹𝑇 = f (𝑄𝐺 ) = C f L g (𝑄RR + 2Q 𝐵 Cos δ ) + (C f L g Cos δ + g H)𝑄𝐺 (10)

The mechanical power of the belt conveyor can be calculated using (11) [20, 22].

𝑃𝑇 = F𝑈 × ν (11)

Int J Elec & Comp Eng, Vol. 10, No. 3, June 2020 : 2861 - 2873
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Now, based on the mechanical power of the conveyor it is possible to calculate the electric power of
the drive motor which sets the belt into motion using (12) [20, 22].
𝑃𝑇
𝑃𝑀 = (12)
𝜂
where, PM = electric power drawn by the drive motor in kW. From (12) the electric power of the drive motor
is given as:

𝑃𝑇 𝐹𝑇 .ν C f L g (𝑄RR +2Q𝐵 Cos δ ).ν (C f L g Cos δ+g H) Q𝐺 .ν


𝑃𝑀 = = = + (13)
𝜂 𝜂 𝜂 𝜂

C f L g (𝑄RR +2Q 𝐵 Cos δ ) (C f L g Cos δ+g H)


Let: 𝐶1 = and𝐶2 =
𝜂 𝜂

then (13) reduces to (14). C1 and C2 are physical parameters that can be calculated for a given belt conveyor
system [14-16].

𝑇 𝑇
𝑃𝑀 = 𝐶𝐼 𝜈 + 𝐶2 ν Q 𝐺 = 𝐶𝐼 ν + 𝐶2 ν 3.6×𝜈 = 𝐶𝐼 ν + 𝐶2 (14)
3.6

Therefore, the belt conveyor’s electric power consumption can be expressed as a function of ν and T as given
in (15).

𝑇
𝑃𝑀 = f (ν ,T) = 𝐶1 ν + 𝐶2 3.6 (15)

Thus, the total electrical energy consumed can be calculated by integrating (15) over a given time interval
t 0 to t 1 . This is given in (16).

𝑡 𝑡 𝐶2 𝑡1
𝐸ec (𝑡0 , t1 ) = ∫𝑡 1 f (ν (𝑡), T (𝑡))dt = 𝐶1 ∫𝑡 1 ν (𝑡)dt + ∫ T (𝑡)dt (16)
0 0 3.6 𝑡0

The total energy cost can therefore, be obtained by multiplying the total electrical energy consumed by
the TOU tariff function, U (t) as given in (17).
𝑡 𝑡 𝐶2 𝑡1
𝐸𝑐 (𝑡0 , t1 ) = ∫𝑡 1 f (ν (𝑡), T (𝑡)) (U (𝑡))dt = 𝐶1 ∫𝑡 1 ν (𝑡) U (𝑡)dt + ∫ T (𝑡) U (𝑡)dt (17)
0 0 3.6 𝑡0

For ease of discrete-time numerical analysis, the energy consumption function of (16) and the cost
function (17) are discretised. Let the sampling time be given as in (18).
𝑡1 −𝑡0
𝑡𝑠 = (18)
𝑁

where, N = number of samples. Now, the discrete form of the total energy consumption and total energy cost
can be obtained as in (19) and (20).

𝐸ec = ∑𝑁
𝑗=1 f (𝜈𝑗 ,T𝑗 )𝑡𝑠 (19)

𝐸𝑐 = ∑𝑁
𝑗=1 f (𝜈𝑗 ,T𝑗 )𝑃𝑗 𝑡𝑠 (20)

𝐸ec and 𝐸𝑐 are performance indicators, which are to be employed as the objective functions for optimisation.

4. OPTIMISATION OF THE ELECTRICAL ENERGY EFFICIENCY OF THE BELT


CONVERYOR SYSTEM
Many a time, belt conveyors work under reduced or minimal feed rates. Sometimes, they even run
on no load due to mismatched feeds. The mismatch between speed and the feed rate exists because in
practice, conveyors tend to operate at slightly below full capacity. They are usually oversized during design
in anticipation of capacity expansions and sometimes to standardise component sizes in an effort to lower
maintenance costs [24]. It could also be due to material blockages. In mining applications, conveyors are at
times loaded by an excavator resulting in an uneven loading of the belt, so that the overall material flow rate
Application of resistance energy model to optimising electric power … (Awingot Richard Akapribo)
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is 50% to 70% of full capacity [25]. In this research therefore, we try to optimise the electrical energy
efficiency of the belt conveyor by matching belt speed to the input material feed rate in order to maximise
the mass of material conveyed per unit length and, consequently, per unit of energy. To achieve this,
the electric power is employed as the objective function for minimisation formulated as follows:

Min = f ( , T)
Subject to Tmin ≤ T ≤ Tmax
≤ ≤
where, f (ν, T) = function of electric power drawn by the drive motor
= minimum belt speed in m/s
= maximum belt speed in m/s
Tmin = minimum belt feed rate in t/h
Tmax = maximum belt feed rate in t/h

4.1. Computer simulations of the belt conveyor system


Simulations of the optimisation problem were carried out in MATLAB environment using
the optimisation toolbox. It provides functions for finding parameters that minimise or maximise objectives
while satisfying constraints. The toolbox includes solvers for linear programming, mixed-integer linear
programming, quadratic programming, nonlinear optimisation, and nonlinear least squares. These solvers can
be used to find optimal solutions to continuous and discrete problems, perform trade-off analyses, and
incorporate optimisation methods into algorithms and applications. The “fmincon” solver finds a minimum of
a constrained multivariable function using the interior point algorithm. It finds the minimum of a problem
specified by:

𝑐(𝑥) ≤ 0
ceq(𝑥) = 0
min𝑓(𝑥) such that 𝐴 • 𝑥 ≤ 𝑏
𝑥
Aeq • 𝑥 = beq
{lb ≤ 𝑥 ≤ ub

where, b and beq = vectors


A and Aeq = matrices
c(x) and ceq(x) = functions that return vectors
f(x) = function that returns a scalar
lb and ub = the lower boundary and upper boundary and can be passed as vectors or matrices.
f(x), c(x), and ceq(x) can be linear or nonlinear functions of x.

5. RESULTS AND DISCUSSIONS


This section presents the results and discussions of the research. The results from field studies and
computer simulations of the belt conveyor system are discussed.

5.1. Field studies results


The results from the field studies are presented in Figure 4 and Figure 5.

Figure 4. Graph of electric power consumption Figure 5. Graph of electric power consumption
against belt speed at constant feed rate of against feed rate at constant belt speed of
T = 65.4 t/h ν = 3.7 m/s
Int J Elec & Comp Eng, Vol. 10, No. 3, June 2020 : 2861 - 2873
Int J Elec & Comp Eng ISSN: 2088-8708  2867

5.2. Results of computer simulation for optimisation


The computer simulations were meant to find the optimal solutions of the system of belt conveyors
for belt speed and feed rate both varying from minimum to maximum values i.e., 𝜈min ≤ 𝜈 ≤ 𝜈max and Tmin ≤
T ≤ Tmax respectively. This was necessary to improve the operation efficiency of the belt conveyors by
matching belt speed to the input material feed rate in order to maximise the mass of material conveyed per
unit length and, consequently, per unit of energy. The optimisation problem was solved repeatedly for each
of the twelve conveyors when the feed rate was varied from 100 t/h to 2000 t/h. Results of the plot of the feed
rate at conveyor base case operating speed of 4.5 m/s which is constant and at the optimised speed,
ν varying from 2 m/s to 6 m/s against electric power consumption on the same graph for the twelve
conveyors are given in Figures 6-17. The minimum and maximum speed values selected here were based on
belt conveyors manufacturer’s manual.

Figure 6. Computer simulation results of optimisation for the crusher conveyor CVR 12

Figure 7. Computer simulation results of optimisation for the crusher conveyor CVR 13

Figure 8. Computer simulation results of optimisation for the crusher conveyor CVR 14
Application of resistance energy model to optimising electric power … (Awingot Richard Akapribo)
2868  ISSN: 2088-8708

Figure 9. Computer simulation results of optimisation for the crusher conveyor CVR 15

Figure 10. Computer simulation results of optimisation for the crusher conveyor CVR 16

Figure 11. Computer simulation results of optimisation for the crusher conveyor CVR 17

Int J Elec & Comp Eng, Vol. 10, No. 3, June 2020 : 2861 - 2873
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Figure 12. Computer simulation results of optimisation for the crusher conveyor CVR 18

Figure 13. Computer simulation results of optimisation for the crusher conveyor CVR 19

Figure 14. Computer simulation results of optimisation for the overland conveyor CVR 5B

Application of resistance energy model to optimising electric power … (Awingot Richard Akapribo)
2870  ISSN: 2088-8708

Figure 15. Computer simulation results of optimisation for the overland conveyor CVR 5C

Figure 16. Computer simulation results of optimisation for the overland conveyor CVR 5D

Figure 17. Computer simulation results of optimisation for the overland conveyor CVR 06

5.3. Electrical energy and cost saving analyses


The power savings for each conveyor for given operating capacities were calculated by summing
the differences in power consumption between the optimised case and the base case at each feed rate point.
The percentage savings were calculated using (17). The results of the calculations for each of the twelve
conveyors are given in Table 1.

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Int J Elec & Comp Eng ISSN: 2088-8708  2871

∑(Base case power−Optimised case power at each feed rate point)


% kW = ∑ Base case power at each feed rate point
× 100 (17)

Table 1. Power Savings for the Twelve Conveyors


SN Conveyors Power Savings (kW) %bPower Savings
1 CVR 12 85.96 7.31
2 CVR 13 286.00 7.79
3 CVR 14 53.60 7.29
4 CVR 15 176.20 8.56
5 CVR 16 159.16 7.73
6 CVR 17 164.68 8.00
7 CVR 18 150.00 7.28
8 CVR 19 150.20 7.29
9 CVR 5B 536.60 7.30
10 CVR 5C 208.50 7.09
11 CVR 5D 136.40 6.18
12 CVR 06 106.40 7.24
Average % Savings 7.42

Given that the belt conveyor is operated 30% of the available time of 360 days per year at 24 hours
per day, the production time per year can be computed using Equation Production time per year,
30
𝑡 = 100 × 360 × 24 hrs = 2592 hrs (18)

The electrical energy savings per year can therefore be calculated using (18). Electrical energy
savings per year = kW x t. Given the current electricity tariff of Gh¢ 1.02 per kWh [26], the cost of electricity
savings of each conveyor can be found by multiplying the electrical energy savings by the tariff. Calculations
of the electrical energy savings and the corresponding cost savings per year of each conveyor are tabulated
in Table 2.

Table 2. Electrical energy and cost savings for the twelve conveyors
SN Conveyors Power Savings (kW) Electrical Energy Savings/Year (kWh) Cost Savings/Year (Gh¢)
1 CVR 12 85.96 222808.30 227264.50
2 CVR 13 286.00 741312.00 756138.20
3 CVR 14 53.60 138931.20 141709.80
4 CVR 15 176.20 456710.40 465844.60
5 CVR 16 159.16 412542.70 420793.60
6 CVR 17 164.68 426850.60 435387.60
7 CVR 18 150.00 388800.00 396576.00
8 CVR 19 150.20 389318.40 397104.80
9 CVR 5B 536.60 1390867.00 14186850
10 CVR 5C 208.50 540432.00 551240.60
11 CVR 5D 136.40 353548.80 360619.8
12 CVR 06 106.40 275788.80 281304.60
Total Savings 31104.00 5737910.00 5 852 669.00

5.4. Discussions
This section of the paper discusses the following: field study results, the results of computer
simulations for optimisation and cost savings.

5.4.1. Discussion of field study results


Field studies results revealed that at a constant feed rate of 65.4 t/h, the belt speed and the electric
power consumption of the conveyor maintain a fairly linear relationship shown by the graph in Figure 6.
Moreover, given a constant speed of 3.7 m/s of the belt conveyor, the electric power consumption and
the feed rate shows a more linear correlation compared to the case of constant feed rate. Running the belt
conveyor at a reduced speed while achieving the same purpose can give significant energy savings.
From these analyses, it is important to note that running the belt conveyor at a fixed speed whiles the feed
rate is varying can waste electric power. It becomes imperative therefore, to match belt speed to the feed rate
in order to save energy.

Application of resistance energy model to optimising electric power … (Awingot Richard Akapribo)
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5.4.2. Discussion of results of computer simulations for optimisation


From Fig. 7 to Fig. 18, it is clear that the belt conveyors consume less power when running at
optimised belt speed from 2 m/s to 6 m/s than when operated at the constant belt speed of 4.5 m/s. It is also
clearly shown that the further the feed rate is reduced; the more energy can be saved through the optimisation
of the belt speed. The graphs look similar though, but analyses of the results show that each of the conveyors
has slightly different power improvement levels. Conveyor CVR 15 for example, appears to have performed
quite better than all the other conveyors with power savings of 8.56%. This is quite obvious due to its high
effective efficiency which is 0.86 coupled with its relatively low friction coefficient value of 0.023.
Conveyors CVR 5C and CVR 5D gave quite low power savings of 7.09% and 6.18% respectively as
compared to the rest. This was attributed to low effective efficiencies which are 0.76 and 0.73 respectively
and high coefficients of friction 0.026 each. For low power requirements, a typical overland conveyor
requires efficiency values ranging from 0.80 to 0.98 and a friction coefficient ranging from 0.022 to
0.025 [10].

5.4.3. Discussion of results of cost savings


The cost savings analysis of each of the twelve conveyors given a total production time of 2592
hours per year and a current electricity tariff of Gh¢ 1.02 per kW for non-residential consumers who fall in
the range of 600 kWh and above have been presented in Table 2. The analysis showed that AGA Iduapriem
Mine will be saving a total electrical energy of 5737910.00 kWh and a corresponding cost of Gh¢ 5 852
669.00 when the twelve conveyors are optimally operated in terms of belt speed matching to feed rate for
2592 hours over a period of one year.

6. CONCLUSION
A mathematical energy model for electrical energy efficiency optimisation of belt conveyor system
was successfully utilised. It was established that to improve the operation efficiency of the belt conveyor, it is
necessary to operationally match belt speed to the feed rate. Furthermore, from the findings the following
conclusions hold valid: Belt conveyors consume a considerable amount of the total electrical energy supply
and can be lowered using energy models and optimisation techniques. For optimal performance of the belt
conveyors with regard to electric power consumption, the belt speed should be varied within the maximum
and minimum limits commensurate with the feed rate. Electric power consumption and operational cost of
belt conveyors highly depend on the belt speed, feed rate, effective efficiency and length of the belt
conveyor. The analytical energy model is more appropriate for short belt conveyor analyses while
the proposed model is desirable for long belt conveyors. A considerable amount of power and cost savings
for all the twelve belt conveyors are achievable when the used model and optimisation technique are
employed over the fixed speed operation.

ACKNOWLEDGEMENTS
We are forever grateful to team members of AngloGold Ashanti, Iduapriem Mine, especially
Mr Joseph Effah, Electrical Manager for their unreserved assistance in obtaining the useful data for
the research. We cannot thank Mr Kisman Eghan of AngloGold Ashanti, Obuasi Mine enough for his
genuine comments.

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Int J Elec & Comp Eng, Vol. 10, No. 3, June 2020 : 2861 - 2873
Int J Elec & Comp Eng ISSN: 2088-8708  2873

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Application of resistance energy model to optimising electric power … (Awingot Richard Akapribo)

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