Project
Challenges
The 2MWt Product Dryer fired with CO gas operates 24/7 to dry wet Titanium Ore which enters the dryer at 35% moisture content, (currently entering at 60% moisture content) and exits at 15% moisture content. The Product Dryer has a 350kW supply air fan and a 500kW induction extraction fan. The annual cost to operate the product dryer is US$1M p.a.
Goals & Objectives
The primary objective was to design and implement a productivity improvement of the product dryer by targeting a 50% moisture content reduction and reduction in electricity use through tracking excess oxygen in the exhaust stack.
Solutions
Service provided
Design of Efficient Product Dryer operation
Process Optimisation of the Titanium Ore separation
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
40% IRR
Capital Investment $3M
Annual Gross Savings $1.8M
2.5% COGS
Technologies applied
VSD Fan and Pump Operation
Equipment Optimisation
Meter Technology
Online Electricity Dashboard
ESG Impact
5,000 tons CO2 savings
Project Location
Richards bay Minerals, Nzalabantu, South Africa