Global energy consumption due to friction and wear in the mining industry

Holmberg, Kenneth; Kivikytö-Reponen, Päivi; Härkisaari, Pirita; Valtonen, Kati; Erdemir, Ali

doi:10.1016/j.triboint.2017.05.010

Cited by 351 publications

(174 citation statements)

References 94 publications

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“…Figure 1 shows the International Energy Agency (IEA) estimation of key technologies for reduction of CO 2 emissions in order to limit the global warming to 2 °C above pre-industrial levels by 2050 [13]. The largest impact (38%) is expected to come from end-use energy efficiency and in this area, tribology could contribute considerably with new technical solutions such as new materials and coatings, surface engineering (including surface treatments, modifications, and texturing), new lubricants and additives (including nanomaterials and solid lubricants); new component design with microsensors; new methodologies like biomimetics, nanotechnology and integrated computational material design [12,14,15]. These are all related to the concept of "green tribology" which has recently been introduced and defined as the tribological aspects of ecological balance and of environmental and biological impacts [16].…”

Section: Introductionmentioning

confidence: 99%

Influence of tribology on global energy consumption, costs and emissions

2017

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Abstract:Calculations of the impact of friction and wear on energy consumption, economic expenditure, and CO 2 emissions are presented on a global scale. This impact study covers the four main energy consuming sectors: transportation, manufacturing, power generation, and residential. Previously published four case studies on passenger cars, trucks and buses, paper machines and the mining industry were included in our detailed calculations as reference data in our current analyses. The following can be concluded:-In total, ~23% (119 EJ) of the world's total energy consumption originates from tribological contacts. Of that 20% (103 EJ) is used to overcome friction and 3% (16 EJ) is used to remanufacture worn parts and spare equipment due to wear and wear-related failures.-By taking advantage of the new surface, materials, and lubrication technologies for friction reduction and wear protection in vehicles, machinery and other equipment worldwide, energy losses due to friction and wear could potentially be reduced by 40% in the long term (15 years)and by 18% in the short term (8 years). On global scale, these savings would amount to 1.4% of the GDP annually and 8.7% of the total energy consumption in the long term.-The largest short term energy savings are envisioned in transportation (25%) and in the power generation (20%) while the potential savings in the manufacturing and residential sectors are estimated to be ~10%. In the longer terms, the savings would be 55%, 40%, 25%, and 20%, respectively.-Implementing advanced tribological technologies can also reduce the CO 2 emissions globally by as much as 1,460 MtCO 2 and result in 450,000 million Euros cost savings in the short term. In the longer term, the reduction can be 3,140 MtCO 2 and the cost savings 970,000 million Euros.Fifty years ago, wear and wear-related failures were a major concern for UK industry and their mitigation was considered to be the major contributor to potential economic savings by as much as 95% in ten years by the development and deployment of new tribological solutions. The corresponding estimated savings are today still of the same orders but the calculated contribution to cost reduction is about 74% by friction reduction and to 26% from better wear protection. Overall, wear appears to be more critical than friction as it may result in catastrophic failures and operational breakdowns that can adversely impact productivity and hence cost.

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Section: Introductionmentioning

confidence: 99%

Influence of tribology on global energy consumption, costs and emissions

2017

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“…E 1 may be obtained by the product of force F and displacement s [17]. Therefore, a characteristic equation of energy consumption model can be expressed as equation (1).…”

Section: Energy Consumption Analysismentioning

confidence: 99%

“…To estimate the energy requirement in size reduction according to Equation (1), pressure p is needed to calculate the force on the liner. Pressure is related to material properties, operating parameters, and structural parameters of the cone crusher.…”

Section: Energy Consumption Analysismentioning

confidence: 99%

“…With the development of the modern social economy, the amount of material needed to be crushed has gradually increased along with a proportional rise in energy consumption. However, cone crushers typically have very low efficiency, which directly relates to their economic benefit [1,2]. Therefore, further studies on energy consumption related to the crushing process are necessary.…”

Section: Introductionmentioning

confidence: 99%

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Influence of Operating Conditions and Crushing Chamber on Energy Consumption of Cone Crusher

Liu

Shi

et al. 2018

Energies

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Abstract:This paper provides an energy consumption model and explains how the operating conditions and structural parameters of a crushing chamber affect energy consumption. Energy consumption is closely related to compressive pressure and displacement. The relationship between pressure, displacement and structural parameters is discussed. The influence of operating parameters on pressure and displacement based on the law of motion of material is examined. Energy consumption can be obtained by the product of pressure and displacement. In consideration of the pressure on the liner surface, which varies according to both height and circumference, an infinitesimal method was used to solve the issue of energy consumption. We validated the predicted energy consumption during breakage with experimental data from a PYGB1821 cone crusher which was consistent with the measured results. Finally, we provide an explanation of the influence of operating parameters and structural parameters on compressive pressure and displacement as well as energy consumption.

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“…New concepts might lead to a reduction of those losses by 30% in the next 20 years, which would significantly contribute to reduced CO 2 emissions, fuel savings and sustainability. In this context, a large range of possible approaches can be named, such as new material concepts with improved strength and hardness properties, more efficient surface treatments, newly designed lubricants, as well as advanced coatings [5].…”

Section: Introductionmentioning

confidence: 99%

Low Friction and High Solid-Solid Contact Ratio—A Contradiction for Laser-Patterned Surfaces?

2017

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Abstract:Recording of Stribeck-like curves is a common way to study the effect of laser-patterned surfaces on the frictional efficiency. However, solely relying on the coefficient of friction when identifying the lubrication regime and the underlying working principles can be misleading. Consequently, a ball-on-disc tribometer was combined with an electrical resistivity circuit to simultaneously measure Stribeck-like curves and solid-solid contact ratios for polished and laser-patterned samples. Line-like surface patterns with different periodicities were produced by direct laser interference patterning on steel substrates (AISI304). The reference shows a Stribeck-like behavior well correlating with the contact ratios. The behavior deviates for high sliding velocities (high contact ratios) due to a loss of lubricant induced by centrifugal forces pulling the lubricant out of the contact zone. In contrast, the solid-solid contact ratio of the laser-patterned samples is around 80% for all sliding velocities. Those values can be explained by higher contact pressures and the structural depth induced by the surface topography which make a full separation of the surfaces unlikely. Despite those high values for the contact ratio, laser-patterning significantly reduces friction, which can be traced back to a reduced real contact area and the ability to store oil in the contact zone.

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Global energy consumption due to friction and wear in the mining industry

Cited by 351 publications

References 94 publications

Influence of tribology on global energy consumption, costs and emissions

Influence of tribology on global energy consumption, costs and emissions

Influence of Operating Conditions and Crushing Chamber on Energy Consumption of Cone Crusher

Low Friction and High Solid-Solid Contact Ratio—A Contradiction for Laser-Patterned Surfaces?

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