Project
Challenges
The Concentrate Product Dryer supported by an 350kW forced draft fan. It operates 24/7, apart from short periods when the smelter in undergoing maintenance. The annual electricity cost is US$0.25M p.a.
Goals & Objectives
The primary objective was to develop a process redesign of the Concentrate Product Dryer forced draft fan operation with a Variable Speed Drive to minimise its electricity use of both the dryer and the motor, by tracking the dryness of the concentrate on the output of the dryer, the motor forced draft fan speed will be matched to be optimise product feed and motor fan speed use to increase product throughput by 25%, maintain the dried concentrate at 15% moisture content with an electricity reduction of 25%.
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
40% IRR
Capital Investment $0.15M
Annual Gross Savings $0.1M
2.5% COGS
Technologies applied
Forced Draft Fan
Equipment Optimisation
Meter Technology
Online Electricity Dashboard
ESG Impact
1,450 ton CO2 savings
Project Location
Rustenburg, South Africa