Project
Challenges
Air Products owns and operates an Air Separation Plant that supplies 99% purity oxygen to the Anglo Converter Process Smelter. The Air Separation Plant for the past 5-years drew 22MW of electricity 24/7, apart from short periods for smelter maintenance. Under a contract that established a target of 12MW for the Air Separation Plant, each 2 MW over the target costs US$1M p.a.
Goals & Objectives
The primary objective was to develop a process redesign of the Air Separation Plant to minimise its electricity use by reducing its power demand to 8MW a reduction of 65%.
Solutions
Service provided
Energy Efficiency
Energy Management Software & IT Energy Modelling
Techno-Economic Modelling to establish the Business Case
Project Management
Measurement and Verification of Energy Saving
Results and Benefits
Financial Results
50% IRR
Capital Investment $6.0M
Annual Gross Savings $3.5M
2.5% COGS
Technologies applied
Air Compressor
Air Blower
Equipment Optimisation
Meter Technology
Online Electricity Dashboard
ESG Impact
98,500 ton CO2 savings
6 jobs created
Project Location
Rustenburg, South Africa