Project
Challenges
The Three (3) 30 ton Boilers supported by a coal supply of 20,000 tons per annum. Two (2) of the boilers operate 24/7, to supply steam to the copper refinery and only are shutdown apart from short periods when the refinery in not operational. The annual coal cost to operate the boilers is US$3M p.a.
Goals & Objectives
The primary objective was to develop a process redesign of the control of the boiler coal feed conveyor to improve energy efficiency by 25% by monitoring excess oxygen on the exhaust stack.
Solutions
Service provided
Design of 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
45% IRR
Capital Investment $1.25M
Annual Gross Savings $0.6M
2.5% COGS
Technologies applied
Excess Oxygen Control
Equipment Optimisation
Meter Technology
Online Electricity Dashboard
ESG Impact
850 ton CO2 savings
Project Location
Phalaborwa, South Africa