A NEW PERSPECTIVE ON REDUCING ENERGY CONSUMPTION IN GRANITE CUTTING WITH A MULTI-BLADE BLOCK CUTTER: THE CASE OF AN INDUSTRIAL APPLICATION

Abstract

In recent years, the use of natural stone, especially in the construction sector, has increased as a result of rapid economic development. One of the most important cost parameters in natural stone cutting processes is energy costs. Generally, cut granites with block cutters differ from other rocks in terms of both the cutting machines used and the energy consumed. Increases in energy prices and emission reduction requirements require cutting processes to work most efficiently. This article describes the energy consumption process in a stone processing plant, and makes recommendations to decision-makers for the more efficient use of energy. A total of 456 real cutting tests were conducted at three different cutting depths and at three different feed rates using a multi-blade block cutter with 10 saw blades at a plant with a monthly production capacity of over 4000 square meters. Real time energy consumption values were recorded with the help of a power analyzer installed on the control panel of the block cutter. The obtained data were used to calculate specific cutting energy values, and the energy consumed throughout the entire process was analyzed. The energy consumption values as the saw blade moves back and forth were examined in eight different regions, starting with the first phase in which the saw blade approaches the granite block. From the obtained power consumption values and calculated specific cutting energy values, an approach has been introduced in terms of cutting efficiency to the specific cutting energy values and energy consumption characteristics in rock cutting processes using circular saw blade.