Energy efficiency assessment of electric shovel operating in opencast mine

Highlights: • An analytical model is developed to optimize energy consumption of electric shovel. • The model is based on real time data of operating time and power consumption. • A case study of P & H shovel operating in large opencast mine of India is presented. • The results shows an energy savings potential of 13.45% in electric shovel. • The model can be applied for benchmarking and setting target in operating mines. Electric shovels are used for loading in opencast mines. Energy efficiency assessment of electric shovel is important to minimise its electrical energy usage. Specific power consumption (SPC) has been used as performance indicator to assess energy efficiency of shovel. A modelling framework is developed for estimating SPC of electric shovel from operating time and power measured for each process. The model is illustrated with a case study of 42 cu. m. P & H shovel operating in a large opencast mine of India. The SPC of shovel is optimized for actual operating cycle time components (idle time and digging time). Results of field measurements show that digging operation consumes maximum power in comparison to other operations of electric shovel in a cycle. The model has been used to assess the energy saving potential of electric shovel by using the real time operational data. The minimum SPC of electric shovel is 0.12 kWh/cum for zero idle time and the energy saving potential is 13.45%. The optimization of SPC has also been done for different digging conditions. The model developed can help to set a target for energy consumption of electric shovel operating in a mine.