Energy-efficient control of pneumatic conveying systems in mining enterprises
Энергоэффективное управление пневмотранспортной установкой горнодобывающего предприятия
Tataeva Z.K. Babazade I.S. Begimbayev E.B.
2025North Caucasian Institute of Mining and Metallurgy, State Technological University
Sustainable Development of Mountain Territories
2025#17Issue 2965 - 977 pp.
Introduction. Ensuring reliable and energy-efficient ventilation in underground mining remains a critical challenge due to high dust levels, fluctuating loads, and harsh operating conditions. Traditional solutions such as throttling devices or fixed-speed drives often lead to excessive energy losses, unstable pressure dynamics, and accelerated equipment wear. This study addresses these limitations by developing and modeling an automated control system for a pneumatic conveying unit based on a frequency-controlled asynchronous electric drive and a screw compressor, with the aim of improving stability, energy efficiency, and operational reliability. Methods. A combined theoretical–experimental approach was applied. A mathematical model of the asynchronous motor with vector control was developed using d–q coordinate equations and integrated with compressor performance equations. Simulation experiments were performed in MATLAB/Simulink to analyze transient processes under varying load conditions, including soft-start operation and anti-surge control. A laboratory-scale installation with a 200 kW motor, frequency converter, and pressure sensors was assembled to validate the model. Key parameters–torque, outlet pressure, air flow rate, current, and energy consumption–were recorded and compared with simulation outcomes. Results. The proposed control system reduced peak electromagnetic torque from 18,000 to 13,500 N·m and shortened acceleration time by 32% (from 70 to 48 s). Stable outlet pressure of 4.35–4.40 MPa was maintained with deviations not exceeding ±0.05 MPa under disturbances. Peak currents were reduced by 18%, improving thermal stability, while energy consumption decreased by 15–17% compared to fixed-speed operation. Compressor efficiency increased to 88–89%, and anti-surge regulation expanded the safety margin of gas flow by 12–14%. Experimental data closely matched simulation results, confirming model adequacy with an error below 4%. Conclusions. Integrating a frequency-controlled asynchronous drive with an automatic control system for pneumatic conveying units significantly enhances the performance of mine ventilation equipment. The system ensures smoother transients, reduces dynamic loads, extends equipment service life by up to 2.5 times, and lowers operating costs. The methodology is applicable to both modernization of existing installations and the design of new systems. Future development should focus on incorporating digital twins and adaptive algorithms to further improve efficiency and sustainability in mining operations.
asynchronous electric drive , mine ventilation , operational reliability , pneumatic conveying system , screw compressor , variable frequency drive
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“Digital Engineering of Machinery and Equipment”, Institute of Power Engineering and Mechanical Engineering, K.I. Satbayev Kazakh National Research Technical University, 22, Satpayeva str., Almaty, 050000, Kazakhstan
Department of Electric Power Engineering, Research Institute of Geotechnological Problems of Oil, Gas and Chemistry, Azerbaijan State Oil Industry University, 36, Azadlig ave., Baku, 370010, Azerbaijan
K.I. Satbayev Kazakh National Research Technical Uniersity, 22, Satpayeva str., Almaty, 050000, Kazakhstan
“Digital Engineering of Machinery and Equipment”
Department of Electric Power Engineering
K.I. Satbayev Kazakh National Research Technical Uniersity
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