Fuel consumption and engine load factors of equipment in quarrying of crushed stone

Abstract

Load factors, defined as portion of utilized engine power, are used in estimation of the diesel mining equipment fuel consumption. Every type of equipment is involved in the specific work operation, common in quarrying of crushed stone. Furthermore, load factors are specific for the equipment type and their application/operating conditions. Based on the mining company’s empirical data on fuel consumption, load factors of the main equipment in quarrying of crushed stone are determined in this paper. This includes bulldozer, backhoe excavators, wheel loaders, trucks, blasthole drill, mobile crushing and screening plants, and mobile belt conveyor. With an assumption of similar operating conditions, those factors can be considered as characteristic for small quarries of crushed stone, but also for mining on other surface pits, depending on the specific equipment application. The obtained load factors are compared to the available data from other sources in order to verify the results and establish the appropriate procedure for assessment ofunknown load factors in different operating conditions.

Full text

M. Klanfar i dr. Potrošnja goriva i koeficijenti opterećenja pogonskih motora mehanizacije pri eksploataciji tehničko-građevnog kamena
Tehnički vjesnik 23, 1(2016), 163-169 163
ISSN 1330-3651 (Print), ISSN 1848-6339 (Online)
DOI: 10.17559/TV-20141027115647
FUEL CONSUMPTION AND ENGINE LOAD FACTORS OF EQUIPMENT IN QUARRYING OF
CRUSHED STONE
Mario Klanfar, Tomislav Korman, Trpimir Kujundžić
Original scientific paper
Load factors, defined as portion of utilized engine power, are used in estimation of the diesel mining equipment fuel consumption. Every type of
equipment is involved in the specific work operation, common in quarrying of crushed stone. Furthermore, load factors are specific for the equipment type
and their application/operating conditions. Based on the mining company’s empirical data on fuel consumption, load factors of the main equipment in
quarrying of crushed stone are determined in this paper. This includes bulldozer, backhoe excavators, wheel loaders, trucks, blasthole drill, mobile
crushing and screening plants, and mobile belt conveyor. With an assumption of similar operating conditions, those factors can be considered as
characteristic for small quarries of crushed stone, but also for mining on other surface pits, depending on the specific equipment application. The obtained
load factors are compared to the available data from other sources in order to verify the results and establish the appropriate procedure for assessment of
unknown load factors in different operating conditions.
Keywords: crushed stone; diesel drive; fuel consumption; load factor; mining equipment; quarrying
Potrošnja goriva i koeficijenti opterećenja pogonskih motora mehanizacije pri eksploataciji tehničko-građevnog kamena
Izvorni znanstveni članak
Koeficijenti opterećenja, definirani kao udio nazivne snage pogonskog motora angažirane pri radu, koriste se pri procjeni potrošnje goriva rudarske
mehanizacije. Svaka vrsta mehanizacije koristi se u specifičnom radnom procesu pri eksploataciji tehničko-građevnog kamena. Koeficijenti opterećenja
karakteristični su za vrstu stroja i radni proces/uvjete rada. Prema empirijskim podacima potrošnje goriva koncesionara, u ovome radu su određeni
koeficijenti opterećenja pogonskih motora glavnih strojeva pri eksploataciji tehničko-građevnog kamena. Ovo uključuje dozer, bagere, utovarivače,
kamione, bušaću garnituru, pokretna postrojenja za sitnjenje i klasiranje, te pokretni tračni transporter. S pretpostavkom sličnih radnih uvjeta, dobiveni
koeficijenti opterećenja mogu se smatrati karakterističnima za male kopove tehničko-građevnog kamena, ali i ostale površinske kopove, zavisno o
primjeni mehanizacije. Dobiveni koeficijenti opterećenja uspoređeni su s drugim izvorima radi verifikacije rezultata i određivanja pogodne procedure
procjene nepoznatih koeficijenata opterećenja u nepoznatim radnim uvjetima.
Ključne riječi: dizel pogon; koeficijent opterećenja; potrošnja goriva; rudarstvo; tehničko-građevni kamen
1 Introduction
In the lack of empirical data on fuel consumption, a
common practice is to estimate the latter based on the
specific fuel consumption, engine load factor and rated
engine power.
Specific fuel consumption is a mass of fuel spent per
unit of time and unit of power, with an engine operating at
full rated power. It is usually expressed in kg/(kW∙h) and
mainly depends on an engine type and efficiency. For
diesel engines it ranges from 0,21 to 0,26 kg/(kW∙h),
where the lower values correspond to modern and low-
aged engines, while the higher values correspond to old,
technologically less efficient and worn out engines [1]. It
also varies with engine size and power, since larger diesel
engines have higher fuel efficiency [2]. The authors of the
previous paper presented fuel consumption of several
engines with the rated power between 1864 kW and 2722
kW, operating at 100 % load. The obtained data is herein
converted into specific fuel consumption based on the
usual diesel fuel density of 0,85 kg/l. In Fig. 1 it can be
observed how it ranges between 0,2 and 0,208 kg/(kW∙h),
for given engine powers. Also, there is a decrease of
9×10−6 kg/(kW∙h) per 1 kW.
Engine load factor is defined as a portion of the rated
engine power that is utilized during work process. It is
very specific to the equipment type and
application/operating conditions, but independent on the
equipment size and the rated engine power [3]. For cyclic
equipment it can range from below 0,1 during idle
operation to 1,0 during full power operation. The
continuous equipment usually has a relatively constant
load factor, since there is little variation in power demand
during operation, as opposed to the cyclic equipment.
Figure 1 Specific fuel consumption related to engine power
Calculation of fuel consumption requires an average
load factor across a cycle, or a longer period of operation.
One can be estimated from a cycle character or calculated
from the empirical data, obtained by measuring and
monitoring the actual fuel consumption. Those calculated
from empirical data can then be applied to the equipment
of the same type and the application/operating conditions,
but of different sizes and engine power.
The basic approach in estimating fuel consumption is
to assume the specific fuel consumption according to the
engine condition and type, then apply the rated engine
power known from equipment specifications, and
eventually define the load factor specifically for the
equipment type and the application/operating conditions.

Fuel consumption and engine load factors of equipment in quarrying of crushed stone M. Klanfar et al.
164 Technical Gazette 23, 1(2016), 163-169
Knowing these values, consumption can be calculated
using the following equation [4]:
dod skPq ⋅⋅=
, (1)
where: P – rated engine power (kW), ko – engine load
factor, sd – specific fuel consumption (kg/(kW∙h)).
2 Research goals and method
The main goal in this research is to obtain load
factors for equipment used in quarrying of crushed stone.
Factors were determined for equipment and operating
conditions common in small quarries. They are based on
five-year data on fuel consumption and can be considered
characteristic for specific operating conditions, which are
related to mentioned quarry type.
The other goal is to provide estimation of load factors
in different operating conditions. Determined empirical
factors were compared to the other sources, some of
which contain description of operating conditions as main
aspect that load factor depend upon. It considers that
sources with highest correspondence to empirical data are
the most convenient for estimation.
Fuel consumption data was collected from a mining
company and averaged by the equipment type and model.
The results were calculated back to load factors using
transformation of Eq. (1). Knowing the quarrying process
and application of equipment in company's quarries,
factors are classified to matching operating conditions and
compared to the other sources. Details on equipment
usage, calculation of factors and data comparison are
provided in the subsequent chapters.
3 Fuel consumption and load factors overview
Typical engine load factors are based on equipment
type and application/operating conditions. They can be
found in some literature on mining and construction
equipment, but generally represent a rare topic and cover
only a narrow span of equipment types. On the other
hand, equipment manufacturers offer fuel consumption
data related to a broad range of the specific equipment
models [5, 6]. This is useful but less versatile when
dealing with sizing and selection of the equipment. Some
other sources provide load-specific fuel consumption,
which represents hourly consumption at operating load,
reduced to engine power and expressed in l/(kW∙h). The
latter can be considered as the equivalent to the load
factor, since it expresses consumption at operating load. It
does not, however, provide means to account for
differences in fuel density and engine efficiency during
estimation of consumption. Mentioned data on load
factors are available for the commonly used equipment
like trucks, excavators, scrapers and dozers, but it is
hardly found for hydraulic hammers, blasthole drills or
mobile crushing plants, screening plants and belt
conveyors. Therefore, it is useful to provide some insight
into those factors and their span for this latter group of
equipment, even if they are suitable for specific quarry
type.
Several sources are used in this research in order to
compare them with empirical data, and mutually. Tab. 1
and Tab. 2 show typical load factors for trucks and dozers
after Kennedy [1]. They are classified into three groups of
operating conditions: light, average and heavy, where
single value is assigned for every group. Description of
operating conditions is available, as a guideline for factor
assessment. Tab. 3 and Tab. 4 show the general factors
according to Day [7] and Chitkara [8]. In contrast to the
first source, these only provide values simply classified
into three groups, but without any detailed description.
The equipment handbooks by Caterpillar and
Komatsu offer fuel consumption of specific equipment
models, classified into three ranges of load conditions.
Conditions are similarly described in both manuals and
those applicable to quarries of crushed stone are
summarized in Tab. 5. To present large amount of the
data from this sources, fuel consumption ranges of every
equipment model were divided by engine power in order
to obtain load-specific consumption. An average value of
the latter, for the same equipment type, is then assigned to
the corresponding load condition range. The same
procedure was done using the data from construction
equipment catalogue by Đukan et al. [9], since it contains
consumption and engine power for many models.
Difference from other sources is that it provides single
value as the average consumption across all load
conditions (Tab. 6). Gransberg et al. [10] provides the
explicitly specified load-specific consumptions, and thus
no conversion is done in this case (Tab. 7). Both of the
latter sources provide no details on operating conditions.
Table 1 Typical truck load factors according to Kennedy [1]
Truck type
Load factor*
Light
Average
Heavy
Conventional rear dump
0,25
0,35
0,50
Tractor-trailer
0,35
0,50
0,65
Integral bottom dump
0,25
0,35
0,50
*Light: Considerable idle, loaded hauls on favourable grades and good
haulage roads
*Average: Normal idle, loaded hauls on adverse grades and good
haulage roads
*Heavy: Minimum idle, loaded hauls on steep adverse grades
Table 2 Typical bulldozer load factors according to Kennedy [1]
Dozer type
Load factor*
Light
Average
Heavy
Crawler
0,45
0,60
0,75
Wheel
0,45
0,60
0,80
*Light: Considerable idle or travel with no load
*Average: Normal idle, normal production dozing, back track push
loading scrapers, steady shovel cleanup
*Heavy: Minimum idle and reverse travel, heavy production dozing,
chain and shuttle push loading scrapers, steady ripping
Table 3 Typical load factors for various equipment according to Day [7]
Type of equipment
Operating conditions
Excellent
Average
Severe
Wheel-type, paved road
0,25
0,30
0,40
Wheel-type, off highway
0,50
0,55
0,60
Crawler-track type
0,50
0,63
0,75
Power excavators
0,50
0,55
0,60
Table 4 Load factors in different operating conditions according to
Chitkara [8]
Operating conditions
Favourable
Average
Unfavourable
Bulldozer
0,60
0,70
0,80
Wheel loader
0,35
0,45
0,55
Truck
0,25
0,35
0,45

M. Klanfar i dr. Potrošnja goriva i koeficijenti opterećenja pogonskih motora mehanizacije pri eksploataciji tehničko-građevnog kamena
Tehnički vjesnik 23, 1(2016), 163-169 165
Table 5 Operating conditions and load-specific fuel consumption according to Caterpillar [6] and Komatsu [5]
Low
Medium
High
Bulldozers
Stockpile operation1
Intermittent full throttle operation1
Considerable idling or travel with no load
Spreading work2
Considerable idling or travel with no
load
2
Dozing in clays, sands, gravels1
Land claring1
Some idling and some travel with no load1
Digging, dozing, ripping of soft rock, clay, most
material2
Digging, dozing, ripping of hard rock2
Object materials, blasted rock2
Continuous use with engine at full throttle2 Little or
no idling or travel in reverse1
0,10 ÷ 0,14 l/(kW∙h)1
0,07 ÷ 0,11 l/(kW∙h)
2
0,14 ÷ 0,18 l/(kW∙h)1
0,11 ÷ 0,16 l/(kW∙h)
2
0,18 ÷ 0,23 l/(kW∙h)1
0,16 ÷ 0,20 l/(kW∙h)
2
Excavators
Sandy loam, free flowing, low density
material.1
Little travelling and little or no impact1
Slope finishing, light material digging,
and other light-duty operation2
Excavation and trenching in natural bed clay
soils1
Some travelling and steady, full throttle
operation1
Mainly excavating and loading2
Breaker operation
2
Continuous trenching or truck loading in rock or shot
rock soils1
Constant high load factor and high impact1
Using hammer, working in quarries1
Excavation of hard bank2
0,05 ÷ 0,10 (l/kWh)1
0,06 ÷ 0,09 (l/kWh)
2
0,10 ÷ 0,15 l/(kW∙h)1
0,09 ÷ 0,12 l/(kW∙h)
2
0,15 ÷ 0,20 l/(kW∙h)1
0,12 ÷ 0,20 l/(kW∙h)
2
Trucks
Continuous operation at an average gross
weight less than recommended1
No overloading, low load factor1
High ratio of loading time to cycle time2
Good haul road conditions2
Continuous operation at an average gross weight
approaching recommended1
Minimal overloading. good haul roads1
Medium ratio of travelling time to cycle time2
Medium haul road conditions and grade2
Total resistance; Over 2 % through 10 %2
medium load factor of truck2
Continuous operation at or above maximum
recommended gross weight1
Overloading1
Poor haul roads1
High ratio of travelling time to cycle time2
Severe haul road conditions and grade2
Total resistance; 10 % and above2
Tough load factor of truck
2
0,05 ÷ 0,07 l/(kW∙h)1
0,05 ÷ 0,07 l/(kW∙h)
2
0,07 ÷ 0,10 l/(kW∙h)1
0,07 ÷ 0,10 l/(kW∙h)
2
0,10 ÷ 0,12 l/(kW∙h)1
0,10 ÷ 0,13 l/(kW∙h)
2
Wheel loaders
Intermittent aggregate truck loading from
stockpile1
Free flowing. low density materials1
Smooth surfaces for short distances with
minimal grades1
Operation with substantial truck waiting
time2
Considerable amount of idling2
Continuous truck loading from stockpile1
Low to medium density materials in properly
sized bucket1
Normal surfaces with low to medium rolling
resistance and slight adverse grades1
Non-stop operation over a long distance2
Operation according to a basic loader cycle with
frequent idling2
Loading shot rock from a face1
Steady loading from very tight banks1
High density materials with counterweighted
machine1
Longer travel distances on poor surfaces with
adverse grades1
Bank excavation and loading2
Loading of blasted rock2
Non-stop operation according to a basic loader cycle
2
0,04 ÷ 0,08 l/(kW∙h)1
0,07 ÷ 0,10 l/(kW∙h)
2
0,08 ÷ 0,11 l/(kW∙h)1
0,10 ÷ 0,13 l/(kW∙h)
2
0,11 ÷ 0,14 l/(kW∙h)1
0,13 ÷ 0,17 l/(kW∙h)
2
1 – adopted from Caterpillar [6]; 2 – adopted from Komatsu [5]
Table 6 Load -specific fuel consumption after Đukan et al. [9]
Load-specific fuel consumption l/(kW∙h)
Excavators
0,28
Wheel loaders
0,19
Bulldozers
0,25
Trucks
0,22
Table 7 Load-specific fuel consumption after Gransberg et al. [10]
Load-specific fuel consumption
at operating conditions l/(kW∙h)
Favourable
Average
Unfavourable
Wheel loader
0,10 ÷ 0,12
0,14 ÷ 0,18
0,16 ÷ 0,24
Bulldozer
0,14 ÷ 0,17
0,19 ÷ 0,20
0,23 ÷ 0,24
Truck
0,09 ÷ 0,15
0,12 ÷ 0,19
0,15 ÷ 0,23
A recent research within EPA's NONROAD model
for calculation of emissions includes a number of direct
measurements of fuel consumption and determination of
load factors for various equipment and engine types [11,
12]. The individual test results found in these sources, for
the equipment of interest here, show that factors can vary
significantly - from 0,34 to 0,7 for excavators, from 0,16
to 0,48 for wheel loaders and from 0,46 to 0,58 for
bulldozers. In a larger scale the data on load factors for all
equipment are averaged and put into three categories,
'high', 'low', and 'steady-state'. Within this categorization,
excavators, bulldozers, off-highway trucks, and wheel
loaders fall into 'high' category with the average factor of
0,59. Drill rigs and crushing/processing plants are put into
'steady-state' category with the average value of 0,43.
4 Quarrying process and operating conditions
Typical operations in quarrying of crushed stone first
include overburden removal, if necessary. The excavation
technique depends on deposit materials characteristics.
Overburden commonly appears as the top layer of soil
and humus or friable rock. Weak mechanical properties of
these materials allow for usage of bulldozers and
excavators for removal. Secondly, an underlying mineral
raw material is excavated by drilling and blasting
operations.
The following operation is transport of excavated
rock material. Since most quarries are hillside type,
gravitational transport, i.e. throwing from upper to lower
benches, is used as the most economical method. This
operation takes place until raw material reaches the first
haulage way or pit bottom, where succeeding operations
are continued.
The order of further operations depends on a specific
quarrying system, but regularly includes the secondary
reduction of oversized material, a transportation system
and processing.
The secondary reduction is usually done using a
hydraulic hammer, and rarely by blasting. Mainly because
of safety, noise and discontinued production issues related
to explosives. Load and haulage systems in small quarries
of crushed stone are regularly composed of excavators or
wheel loaders and rear dump trucks. Many quarries still
process mineral raw material on fixed, i.e. stationary

Fuel consumption and engine load factors of equipment in quarrying of crushed stone M. Klanfar et al.
166 Technical Gazette 23, 1(2016), 163-169
plants, but mobile crushing and screening is increasingly
used in addition to stationary one, or even as the only
processing equipment. Mobile equipment provides greater
flexibility and savings in haulage expenses.
The specific mining company that provided the data
on fuel consumption uses all the mentioned equipment,
for quarrying of diabase and dolomite. Quarries are
typical for crushed stone and so are the operating
conditions described in the following text.
The bulldozer is almost exclusively used for
gravitational transport of excavated overburden and
mineral raw material. It mostly operates with loose
material on horizontal benches and without any ripping.
Its cycle composes of forming the drag prism during the
larger part of trajectory, discharging full blade load over
the bench crest and backwards return. This could be
defined as light to average operating conditions.
Backhoe excavators are mostly utilized on excavation
of top soil and friable rock sections, and loading of
blasted rock material into mobile processing plants and
trucks. This represents the average operating conditions
for excavators, with transition to heavy if excavation of
rock occurs. One excavator is an exception that frequently
operates with hydraulic hammer, on secondary breaking
of oversized material.
Wheel loaders and trucks perform typical operations
for this type of equipment. Loaders are used for loading
and short transport of loose and finer-granulated material,
such as processed crushed rock. Both, loaders and trucks,
operate on relatively stiff and well maintained surfaces
with slight or no grades. This includes pit bottom and
haulage roads. Operating conditions for this equipment
can be considered as light.
The blasthole drill operates in diabase and dolomite
on benches that are mostly 20 m in height and with the
usual drill pattern of 2,7 × 3 m. It is equipped with DTH
hammer and 90 mm drill bits.
Mobile crushing and screening plants are used for
processing of multiple rock types and production of
various aggregate fractions depending on market
demands.
The mobile belt conveyor is used in addition to
processing plants for deposition of outlet rock materials in
order to achieve larger heaps.
5 Load factors analysis
Load factors were derived from the continuous, five-
year period, data on fuel consumption of the main
equipment used in quarrying process.
Averaged hourly fuel consumption, expressed in
litres per hour, is converted into fuel mass using the usual
fuel density of 0,85 kg/l [13].
All the equipment is up to six years old and equipped
with modern diesel engines. Thus, for specific fuel
consumption of diesel engines, the value of 0,22
kg/(kW∙h) is selected. To confirm this value, the relation
from Fig. 1 was used. As rated engine power of
equipment subjected to this research ranges from 28,8 to
370 kW, selected value of 0,22 kg/(kW∙h) is suitable.
Finally, empirical load factors for equipment were
obtained by dividing hourly fuel consumption by rated
engine power and selected specific fuel consumption.
Tab. 8 presents input data and calculated results.
The average load factor for excavators amounts to
0,561 with a slight deviation between models. According
to different sources this value belongs within the average
operating conditions, which is also the case in these
quarries. The exception is the light wheel excavator
R200W-7 with the factor of 0,301. This unit is very
frequently used with the hydraulic hammer for reduction
of the oversized rock material. It is possible that the
hammer engages a lower portion of engine power
compared to the excavation and loading operations.
However, due to the fact that it is the only unit in this
research, the general conclusion cannot be derived.
Wheel loaders have an average load factor of 0,273
and for trucks it amounts to 0,236. Deviation between
models is negligible, especially for trucks. This
equipment can be considered as the least engine-power
demanding in the quarrying process. The reason for low
load factors can be partially found in working cycles of
this equipment, where half of the cycle is done without
load (cargo). Good operating conditions in quarries, with
well-maintained haulage roads and without steep grades,
are favourable for low power demand. Same conditions
belong into the light range according to other sources.
The only bulldozer used in this analysis has a load
factor of 0,485, which corresponds to light to average
operating conditions according to other sources.
Conditions in these specific quarries can be described as
such, considering that the bulldozer is used in
gravitational transport that includes moving of loose rock
material on the horizontal benches, in one direction.
The mining company has one blasthole drill for
which the calculated load factor amounts to 0,616. As this
is the only unit, it is difficult to say that the results are
typical representative for this type of equipment. Besides,
calculated factor represents an average value for drilling
in two rock types, diabase and dolomite. Thus, it is not
known if the factor differs when drilling is performed in
different rock types.
Load factors for two jaw crushers deviate very
slightly, and average to 0,467. Cone crusher shows
somewhat lower factor of 0,387 and that is why it is set
aside from the crusher’s average. The difference between
jaw and cone crusher could be attributed to the crusher
type, and probably also to different rock types that are
processed.
Mobile screening plants show the largest deviation of
load factors among the models, from 0,22 to 0,783, with
an average of 0,491. The lowest factor is for the roller
screen, while vibrating screens show generally higher
factors, but with the significant deviation between the
models. It can be assumed that the screen working
principle affects the load factor, but is also influenced by
constructional features like the number of screen decks,
engine power and the number of belt conveyors.
Mobile belt conveyor has the load factor of 0,52.
Constructional features could have an important influence
on it, similarly to screening plants. It is the only unit of
that type used in the research, thus no span of the factor
can be derived.

M. Klanfar i dr. Potrošnja goriva i koeficijenti opterećenja pogonskih motora mehanizacije pri eksploataciji tehničko-građevnog kamena
Tehnički vjesnik 23, 1(2016), 163-169 167
Table 8 Data on fuel consumption and calculated load factors
Manufacturer and model Rated power
(kW)
Fuel consumption
(l/h)
Load-specific fuel
consumption
l/(kW∙h)
Calculated
load factor
Average
load
factor
Excavators
Hyundai R 200W - 7 (hammer)
114
8,87
0,078
0,301
0,30
Liebher R 944 C HD-S Litronic
190
32,52
0,171
0,661
0,56
Liebher R 944 B HD-S Litronic
180
23,96
0,133
0,514
Liebher R 934 C HD-S Litronic
150
21,96
0,146
0,566
Liebher R 934 B HD-S Litronic
145
17,62
0,122
0,469
Liebher R 914 B Litronic
112
17,29
0,154
0,596
Wheel loaders
Caterpillar 966 H
213
15,07
0,071
0,273
0,27
Caterpillar 966 H
213
14,59
0,068
0,265
Liebherr L 576
205
16,43
0,080
0,310
Liebherr L 576
205
14,50
0,071
0,273
Liebherr L 576
205
13,96
0,068
0,263
Liebherr 574
195
12,76
0,065
0,253
Trucks
Bell B40D
308
18,67
0,061
0,234
0,23
Bell B40D
308
18,78
0,061
0,236
Terex TR45
370
22,74
0,061
0,237
Bulldozer
Komatsu D155 AX - 6
264
33,16
0,126
0,485
0,48
Blasthole drill
Bohler BPI 155
125
19,96
0,160
0,616
0,61
Mobile crushing plants
Locotrack LT 105 S (jaw)
224
27,98
0,125
0,483
0,46
Locotrack LT 110S (jaw)
310
36,26
0,117
0,452
Locotrack LT 200 HP (cone)
310
31,04
0,100
0,387
0,38
Mobile screening plants
Finly 393 (vibrating)
69
6,00
0,087
0,336
0,49
Chieftain 2100 (vibrating)
74
15,00
0,203
0,783
Posch FLEX RO – RO (roller)
149
8,49
0,057
0,220
Warrior 1800 (vibrating)
74
12,00
0,162
0,627
Mobile belt conveyor
TELESTACK TC 421
28,8
3,90
0,135
0,523
0,52
6 Data comparison
The above mentioned sources provide the data which
can be classified into three types: hourly fuel consumption
expressed in l/h, load-specific fuel consumption expressed
in l/(kW∙h), and engine load factor. In order to compare
these different types of data to the empirical ones, all
values were converted to load factors. Afore stated values
for fuel density of 0,85 kg/l and the specific fuel
consumption of 0,22 kg/(kW∙h) were used. Different data
types were converted as presented in the following table:
Table 9 Conversions to load factor
Input data
Conversion
Result
Hourly fuel
consumption
850
220 ,
,powerengine
X⋅
⋅
Load
factor
Load-specific fuel
consumption
850
220 ,
,
X⋅
Load
factor
Load factor no conversion
Load
factor
The results are presented within diagram in Fig. 2,
where load factors from different sources are grouped by
the equipment type and classified by operating conditions.
Diagram contains empirical data points compared to
other sources. Depending on the source, factors are
presented either as single point that represent one
operating condition, or as lines that represent ranges of
the same (low, medium and high, or their equivalents).
Factors are marked as unclassified in case those
conditions are not specified, or there is no basis to define
them.
The data for the common equipment i.e. bulldozers,
excavators, wheel loaders and trucks are specified in most
sources. The comparison shows that the mean empirical
load factors fall within the same range for trucks and
wheel loaders, where the description of operating
conditions [1, 5, 6] corresponds to the operations in the
specific quarries subjected to this research. For excavators
and the bulldozer they fall into the same range or are
slightly shifted into the adjacent range. The sources
without details on operating conditions generally show
either higher values of load factor, compared to empirical
data, or an inadequate span of values across operating
conditions. With the exception of favourable conditions
for trucks according to Chitkara [8] and for bulldozers
according to Day [7].
The hydraulic breaker represents the operating
condition of an excavator, but it is separated for clarity.
According to the equipment manuals [5, 6] an excavator
using a breaker can fall into the medium or high range of
conditions. Still, the empirical data point falls below these
values.

Fuel consumption and engine load factors of equipment in quarrying of crushed stone M. Klanfar et al.
168 Technical Gazette 23, 1(2016), 163-169
Figure 2 Comparison of load factors
7 Conclusions
Engine load factors of main equipment used in
quarrying of crushed stone are calculated based on the
five-year data on fuel consumption. The obtained
empirical values can be used in estimation of fuel
consumption if similar operating conditions exist in
quarries and other surface pits. This applies especially to
trucks with the mean value of 0,24 and wheel loaders with
the value of 0,27, due to the low deviation from mean
values and a good correlation to the most other sources.
The empirical load factors for excavators and mobile
processing plants are more scattered around the mean
value, but their span in quarrying of crushed stone is
evident. They range from 0,47 to 0,66 for excavators and
from 0,39 to 0,48 for mobile processing plants.
Load factors for other equipment can be used as
approximate, since there are not enough data to achieve a
greater level of certainty. The data for only one bulldozer,
blasthole drill, hydraulic breaker and belt conveyor unit
are used in this research. The bulldozer, with factor value
of 0,48 is an exception, because it shows a good
correlation to several other sources.
The excavator using a hydraulic breaker has a load
factor of 0,3, which is much lower than the values stated
in literature [5, 6]. The specific excavator is a wheel type.
Therefore, it is possible that the low load factor is caused
by using the breaker. Lower rolling resistance, compared
to the crawler type, could also have some influence.
Mobile screening plants tend to have a very wide
span of load factors, from 0,22 to 0,78. This could be
caused by a number of factors, including constructional
features of the plant and mineral raw material properties.
For this reason it is difficult to define common operating
conditions for this type of equipment.

M. Klanfar i dr. Potrošnja goriva i koeficijenti opterećenja pogonskih motora mehanizacije pri eksploataciji tehničko-građevnog kamena
Tehnički vjesnik 23, 1(2016), 163-169 169
The belt conveyor and blasthole drill also lack the
definition of operating conditions. Due to the insufficient
data it is not possible to conclude how much would the
load factor differ with the operation in other mineral raw
materials, or with different constructional features of
equipment?
In the absence of empirical data on fuel consumption,
both load factors and load-specific fuel consumption for
the known operating conditions and equipment type can
be used for estimation. The use of load factors is more
versatile because they remain constant and it is possible to
account for changes in engine efficiency and fuel density.
The presented load factors and consumptions based
on Komatsu and Caterpillar manuals correlate most
closely with the empirical data for the majority of
quarrying equipment. It can be assumed that they provide
the most accurate estimation in case of different operating
conditions.
Acknowledgments
The authors wish to thank the mining company IGM
Radlovac for the provided data on fuel consumption.
8 References
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Authors’ addresses
Mario Klanfar, assistant
University of Zagreb
Faculty of Mining, Geology and Petroleum Engineering
Pierottijeva 6, 10000 Zagreb, Croatia
E-mail: mario.klanfar@rgn.hr
Tomislav Korman, assistant
University of Zagreb
Faculty of Mining, Geology and Petroleum Engineering
Pierottijeva 6, 10000 Zagreb, Croatia
E-mail: tomislav.korman@rgn.hr
Trpim ir Kujundžić, assoc. prof.
University of Zagreb
Faculty of Mining, Geology and Petroleum Engineering
Pierottijeva 6, 10000 Zagreb, Croatia
E-mail: trpimir.kujundzic@rgn.hr