Application of Resistance Energy Model T
Application of Resistance Energy Model T
Application of Resistance Energy Model T
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].
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.
Int J Elec & Comp Eng, Vol. 10, No. 3, June 2020 : 2861 - 2873
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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].
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
L
FH
Mass (m)
H
Conveyor Belt
μ
δ
LH
Application of resistance energy model to optimising electric power … (Awingot Richard Akapribo)
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𝐹𝐻 = μ.m.g (2)
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:
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)
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).
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).
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:
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.
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
𝑐(𝑥) ≤ 0
ceq(𝑥) = 0
min𝑓(𝑥) such that 𝐴 • 𝑥 ≤ 𝑏
𝑥
Aeq • 𝑥 = beq
{lb ≤ 𝑥 ≤ ub
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
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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)
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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)
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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
Int J Elec & Comp Eng, Vol. 10, No. 3, June 2020 : 2861 - 2873
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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.
Application of resistance energy model to optimising electric power … (Awingot Richard Akapribo)
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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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Application of resistance energy model to optimising electric power … (Awingot Richard Akapribo)