adrian abbott & jody asquith benchmarking energy consumption in coal mining
TRANSCRIPT
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Adrian Abbott &Jody Asquith
Benchmarking Energy Consumption in Coal Mining
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“I understand the value of developing a baseline to know my site’s performance, but how do I know where I stand relative to industry best practice?”
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The Answer…
Energy Benchmarking
Benchmark energy performanceSite(s) performance relative to like operationsTypical ranges of performance
equipment levelprocess level
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Benchmarking Energy Performance
Where are we at?….
• Established an energy baseline• Developed sub process detail
• Identified energy performance metrics• Reporting monthly, quarterly and annually….
…but how do I know where I stand relative to industry best practice?
CHECKCHECK
CHECKCHECK
Benchmark Energy Performance!
• Map ALL of the above to like sites within the organisation, and• Map ALL of the above to industry
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Energetics’ Benchmarking Tool
• Utilises an energy dataset that has been built up and refined over 25 years of working with the industry
• How is your operation performing relative to other, similar operations and against industry best practice?
• How does the variability (range, frequency) of your own energy performance compare with others?
• Identify areas which should be targeted for improvement, even down to process or equipment type.
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Electricity Consumption – O/C
Admin2.01%
Air compressors0.34%
Bath House1.31%
Centrifuge1.06%
Conveyors2.87%
Crushers1.86%
Dragline22.28%
Lighting1.06%
Loadout3.78%
Other38.89%
Pumps10.62%
ROM Handling3.41%
Screens1.07%
Shovels5.37%
Stacker / Reclaimer
2.09%
Vacuum Pump1.70%
Vibrators0.02%
Workshop0.26%
Energy Balance
• “Typical” site
• Focus on areas of highest consumption
• “Other” indicates more metering/ analysis needed
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ACME Colliery
• Open cut mine using truck and shovel
• CHPP
• 7.5 million ROM tonnes/4 million tonnes product
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Average site performance
Energy intensity performance indicators:
• Understand industry average
• “per Saleable Tonne” allows for CHPP
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1 20 24 2 25 27 11 33 22 4 23 29
AC
ME 7 8 10 12 30 5 14 26 6 3 18 21 28 9 19 17 32 31
MJ
per
Sal
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Site Identifier
Benchmarking Energy KPI - all mine types
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Similar sites
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20 22 29 ACME 7 8 12 30 14 18 28 19 17 32 31
Open Cut
MJ
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Site Identifier
Benchmarking Energy KPI against all other Open Cut using Truck and Shovel
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Energy cost performance
Understand range in energy cost per month of saleable coal during varying monthly production.
Understand if your range is ‘above’ or ‘below’ average.
Can be used as a high level ‘Trigger’ for further investigation.
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- 200 400 600 800 1,000 1,200 1,400 1,600
$/ T
on
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Co
al
Monthly Production, Thousand Tonne
Energy Cost per Saleable Tonne vs Production - Monthly
All Sites ACME Colliery
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Understand industry performance ranges and average
Highlights smallest range ‘Min’ & largest range ‘Max’
Energy intensity performance spread – Quality of control!
Here, ACME performs the best in class with a tight range.
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500
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All Sites Max Range Min Range ACME
MJ
/ to
nn
e S
ale
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oa
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Energy Performance Range
Max
Min
Average
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Performance frequency
Does ACME frequently perform within a certain target range?
Why?
Can frequency be improved to the left of chart?
How does ACME compare amongst industry?
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1. - 1.2 - 1.4 - 1.6 - 1.8 - 2. - 2.2 - 2.4 - 2.6 - 2.8 - 3. - 3.2 - 3.4 - 3.6 - 3.8 - 4. - 4.2 - 4.4 - 4.6 - 4.8 - 5. - 5.2 - 5.4 - 5.6 - 5.8 - 6. - 6.2 - 6.4 - 6.6 -
1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8 3 3.2 3.4 3.6 3.8 4 4.2 4.4 4.6 4.8 5 5.2 5.4 5.6 5.8 6 6.2 6.4 6.6 6.8
Fre
qu
en
cy
MJ/tonne Saleable Coal
Energy Use per Tonne Saleable Coal - Conveyors
ACME
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Drilling down…
Identifies major equipment areas
Seek to understand each unit in terms of its level of activity.
Such as:High use by the pumps - is it because the pumps aren’t performing or does the site use too much water?
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MJ
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Electrical Energy Intensity by Equipment Type
ACME Colliery All Sites
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Summary
• Operational benefit
• Improve understanding of site performance (productivity, yield, etc)
• Financial benefits in lower cost of production
• As energy costs escalate, impacts will gain importance
• Energy management is another operational management dimension
• Identify largest stream & analyse/report
• Drill down
• Identify next largest stream…
• Should I accept what I see?
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Next Steps
•“Harvest” the data from what you are already collecting
•Sub-metering and/or analysis to drill down deeper
Energy-mass balance
EEO
•Benchmark your results and identify areas to focus on for potential improvement
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