Integrated Energy-Specific Method for Calculating Fuel Consumption of Mining Haul Trucks Considering Transport Cycle Structure
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Abstract
The accuracy of calculating diesel fuel consumption by mining haul trucks is limited by the fact that the power unit operates predominantly in transient modes, whereas most engineering methods rely on steady-state data. The article proposes an express method in which the per-trip fuel consumption is determined through the equivalent engine operating time at rated power, formed by summing the phases of the transport cycle (loading, loaded travel, dumping, empty return, maneuvering) weighted by the rated-power utilization factors. Unlike lumped tractive calculations that account only for the mechanical work of haulage, the method is based on the energy balance of the diesel engine (the first law of thermodynamics and analysis of the Diesel cycle) and covers the energy expenditure of all trip processes, including non-productive phases and auxiliary systems; the influence of transient modes is captured through calibration of the coefficients against actual operational data. The rated-power utilization factors are justified theoretically from tractive-dynamic relations and compared with the ranges of the national school of mining road transport. The method is verified against the consolidated indicators of the haul-transport balance of the Kalmakyr open pit of Almalyk MMC JSC for 12 months of 2024 for two truck types - BelAZ-75307 (220 t) and BelAZ-75131 (130 t). For the BelAZ-75131 the model parameters were computed independently, without tuning to the reference value, and the calculated consumption matched the actual one (over a sample of 82 thousand loaded trips per year) with a relative error of 1.9 %, which confirms the universality of the coefficient set and is not the result of a single calculation case. The specific fuel consumption is reported in the units traditional for mining, g/(t·km), with the equivalent in l/(t·km). The applicability domain of the express method and its error are substantiated in comparison with simplified (5-10 %) and simulation (2-5 %) methods; the low computational cost of the method allows its embedding into digital systems for operational planning and dispatching of mining road transport.
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