report on equipment efficiency - EE

REPORT ON EQUIPMENT EFFICIENCY
Author: Michalis Painesis
Contributor: S&B Industrial Minerals
Project acronym: EE-QUARRY Project.
Grant Agreement No:
Issue Date:
Deliverable Number:
WP Number:
Status :
August
D 2.4
WP 2
Finished
DISEMINATION LEVEL
PU = Public
X
PP = Restricted to other programme participants (including the JU)
RE = Restricted to a group specified by the consortium (including the JU)
CO = Confidential, only for members of the consortium (including the JU)
Report on equipment efficiency
Version
1st
2nd
3rd
Date
20/07/11
28/07/11
15/08/11
Author
Michalis P.
Michalis P.
Michalis P
EEQ-S&B-WP2-2.4
Document History
Description
1st Draft
2nd Draft
Final Version
Disclaimer
The information proposed in this document is provided as a generical explanation on the
proposed topic. No guarantee or warranty is given that the information fits for any particular
purpose. The user thereof must assume the sole risk and liability of this report practical
implementation.
The document reflects only the author’s views and the whole work is not liable for any empirical
use of the information contained therein.
(August – 2011)
Page 2 of 40
Report on equipment efficiency
EEQ-S&B-WP2-2.4
SUMMARY
This document is the deliverable D2.4 of the WP 2 of the EE-QUARRY Project “Develop of a
new and highly effective modeling and monitoring Energy Management System technique in
order to improve Energy Efficiency and move to a low CO2 emission in the energy intensive nonmetallic mineral industry.
The scope of the D2.4 is to identify the potential improvement points regarding energy efficiency
throughout the whole production chain in the quarry, by comparing the actual consumptions of the
equipment and machineries with the nominal consumptions as are given by the manufacturers.
We have to point out that in some cases the manufacturers don’t provide data regarding energy
consumption or when the machinery is quiet old there is lack of such data.
(August – 2011)
Page 3 of 40
Report on equipment efficiency
EEQ-S&B-WP2-2.4
CONTENTS
SUMMARY .................................................................................................................................... 3
ABBREVIATIONS AND GLOSSARY ........................................................................................... 5
1
INTRODUCTION ................................................................................................................... 9
2. ENERGY CONSUMPTION AND EQUIPMENT EFFICIENCY IN AN OPEN PIT MINE. .......... 11
2 ................................................................................................................................................... 12
2.1
DISCONTINUOUS SYSTEMS ..................................................................................... 12
2.2
DISCONTINUOUS SYSTEMS COMBINED WITH SEMI-MOBILE CRUSHING PLANTS
AND CONTINUOUS BELT CONVEYOR SYSTEMS............................................................... 12
2.3
CONTINUOUS SYSTEMS, OPEN PIT MINING OF SOFT ROCK............................... 12
2.4
CONTINUOUS SYSTEMS, OPEN PIT MINING OF SOLID ROCK ............................. 13
3. CASE STUDY: MONTE SPARAU ( ITALY) PERLITE QUARRY ........................................... 14
3.1 LOCATION AND GEOLOGY ........................................................................................... 15
3 ................................................................................................................................................... 17
3.1 ........................................................................................................................................... 17
3.2
MONTE SPARAU PRODUCTION PROCESS OVERVIEW......................................... 17
3.2.1 Extraction ................................................................................................................. 17
3.2.2 Loading – transportation. ......................................................................................... 21
3.2.3 Processing ............................................................................................................... 23
3.2.4 Acciona Ivonne Quarry in Barcelona ........................................................................ 34
3.2.5 Acciona Cazebo Gordo ............................................................................................ 35
3.2.6 Outbound logistics ................................................................................................... 36
4. CONCLUSION ......................................................................................................................... 37
5. REFERENCES ........................................................................................................................ 38
A. DELIVERABLE REVIEW REPORT ................................................................................. 39
B. TECHNICAL RESULT OF THE DELIVERABLE .............................................................. 39
C. LENGTH, STRUCTURE AND PRESENTATION OF THE DELIVERABLE...................... 40
D. RATING FOR THE DELIVERABLE ................................................................................. 40
(August – 2011)
Page 4 of 40
Report on equipment efficiency
EEQ-S&B-WP2-2.4
ABBREVIATIONS AND GLOSSARY
EE-QUARRY
Develop of a new and highly effective modeling and monitoring Energy Management System
technique in order to improve Energy Efficiency and move to a low CO2 emission in the energy
intensive non-metallic mineral industry.
WP
Work Package
S/T
Scientific and Technical
Btu
British Thermal Unit
EMDS
Electric Motor Driven Systems
(August – 2011)
Page 5 of 40
Report on equipment efficiency
EEQ-S&B-WP2-2.4
LIST OF TABLES
Table 1.
Average age of mobile equipment ........................................................................ 33
Table 2.
Bentonite - Installed crusher capacity ................................................................. 33
Table 3.
Perlite - Installed crusher capacity ....................................................................... 34
Table 4.
Electric power consumption ................................................................................. 34
Table 5.
Machinery in the Ivonne quarry ............................................................................ 34
Table 6.
Machinery in the Ivonne quarry ............................................................................ 35
(August – 2011)
Page 6 of 40
Report on equipment efficiency
EEQ-S&B-WP2-2.4
LIST OF FIGURES
Figure 1. Quarry Production Flow Chart ................................................................................... 9
Figure 2.Monte Sparau mine Sardinia Italy ............................................................................. 14
Figure
3. Geological Map of Cenozoic Volcanic Rocks of Sardinia
(Source: Industrial mineral occurrences associated with Cenozoic volcanic rocks of
Sardinia (Italy). N. Palomba, G. Padalino, N. Marchi (February 2004)) .................................. 16
Figure 4. CAT D9R and CAT 330 C with hydraulic hammer .................................................. 18
Figure 5. Counter of working hours installed in the VOLVO L180F loader. .......................... 23
Figure 6. Ground plan of Rhyolite processing plant. ............................................................. 23
Figure 7. Flow sheet of perlite processing plant. The total installed power at the perlite
processing plant is 1150 Kw with 56 electrical motors .......................................................... 24
Figure 8. Shedder...................................................................................................................... 26
Figure 9. Air Sun drying ........................................................................................................... 27
Figure 10. Industrial Drying...................................................................................................... 27
Figure 11 Perlite Processing .................................................................................................... 28
Figure 12 Storage area ............................................................................................................. 28
Figure 13 Voudia ....................................................................................................................... 29
Figure 14 Kanava ...................................................................................................................... 29
Figure 15 Ampourdektakia ....................................................................................................... 29
Figure 16 Real Vs Theoretical consumptions front end loader ............................................ 30
Figure 17 Real Vs Theoretical consumptions of Bulldozer .................................................... 30
Figure 18 Real Vs Theoretical consumption rigid truck ........................................................ 31
Figure 19 fuel consumption per ton material front end loader .............................................. 31
Figure 20 Fuel consumption per ton of material by a Bulldozer ............................................ 32
Figure 21 Fuel consumption per Ton of material moved by rigid road trucks .................... 32
Figure 22 Fuel consumption per Ton of material moved by mobile equipment category ... 33
(August – 2011)
Page 7 of 40
Report on equipment efficiency
EEQ-S&B-WP2-2.4
LIST OF GRAPHICS
Graphic 1. The distribution of unit CO2-e values per MT aggregate for different type of
rock . (Source: Atac BASCETIN, Deniz ADIGUZEL (Istanbul University, Faculty of
Engineering, Department of Mining Engineering)................................................................... 10
Graphic 2. . Energy consumption by Equipment Category in Mineral Mining Industry
(Source: “Mining Industry Energy Bandwidth study”. US Dpt of Energy. Industrial
Technologies Program. June 2007).......................................................................................... 12
Graphic 3 .Monte Sparau – raw material production for the years 2008-2009- 2010 ............ 17
Graphic 4. Hourly fuel consumption of D9R dozzer- Monte Sparau mine. ........................... 19
Graphic 5. (D9R dozer) Real consumption vs. theoretical consumption given by F.C.C. ... 20
Graphic 6. CAT 330 C excavator, real consumption vs. theoretical consumption given by
F.C.C. .......................................................................................................................................... 21
Graphic 7. Diesel consumption of VOLVO L180F front loader comparing to the F.C.F given
in the deliverable D2.3 ............................................................................................................... 22
Graphic 8. Diesel consumption of VOLVO L150 front loader comparing to the F.C.F given
in the deliverable D2.3. .............................................................................................................. 22
Graphic 9. Bentonite and Perlite operations on Milos Island................................................. 25
(August – 2011)
Page 8 of 40
Report on equipment efficiency
EEQ-S&B-WP2-2.4
1
INTRODUCTION
In the D2.3 “Report of product embedded energy”, it was presented extensively the whole
production process of an aggregate quarry and the energy that is consumed in every step.
A typical flow chart of a quarry is the following (Figure 1):
Figure 1. Quarry Production Flow Chart
A major challenge in analyzing the mining industry’s energy consumption is the variability in
mining operations. Even within a single mineral group, processes will differ according to the
depth at which the material is mined and the degree of refining required. Moreover, every
commodity that is mined has different mechanical and physical properties. These properties can
vary over an order of magnitude between deposits and can vary significantly even within
individual mines. For example, the work indices (a measure of energy required to grind rock) of
mined commodities vary from 1.43 kWh/ton for calcined clay to 134.5 kWh/ton for mica. This
results in large variations in grinding equipment energy requirements. Therefore, different mines
will have drastically different energy requirements for a given process. A mine could be designed
for maximum efficiency, yet consume more energy than an inefficient mine with the same output.
Cost wise the electricity represents 33% of the total energy cost, the fuel 57% and the use of
explosives the 10%.
(August – 2011)
Page 9 of 40
Report on equipment efficiency
EEQ-S&B-WP2-2.4
If we consider the CO2-e the contribution of each of the three energy elements (explosives-fuelelectricity) is significantly different, as recent research of the University of Istanbul has shown:
Graphic 1. The distribution of unit CO2-e values per MT aggregate for different type of rock .
(Source: Atac BASCETIN, Deniz ADIGUZEL (Istanbul University, Faculty of Engineering, Department of
Mining Engineering)
The question that arises every day in the mind of a quarry manager is how efficient, regarding the
energy consumption, the equipment that are taking part in the production process are. In this
report we shall examine the equipment’s efficiency using as a real example the Monte Sparau
Quarry in Sardinia Italy ownership of S&B Industrial Minerals, taking under consideration the
data provided in the D2.3 report and use some of the Key Performance Indicators from the D 2.5
report in order to evaluate the process.
Finally in a chapter apart we will briefly examine the energy embedded in the outbound logistics
especially for the aggregates market. By “outbound logistics” we mean the transportation of the
final product from the quarry to the customer/consumer.
(August – 2011)
Page 10 of 40
Report on equipment efficiency
EEQ-S&B-WP2-2.4
2. ENERGY CONSUMPTION AND EQUIPMENT EFFICIENCY IN AN OPEN
PIT MINE.
In 2007 the U.S. Department of Energy’s (DOE) Office of Energy Efficiency and Renewable
Energy (EERE) through its Industrial Technologies Program (ITP) conducted a study and
generated a bandwidth analysis report to identify energy-saving opportunities in coal, metals, and
mineral mining.
The bandwidth analysis relies on estimating the following quantities:
•
•
•
•
Current Energy Consumption – The average energy consumption for performing a given
process
Best Practice Energy Consumption – The energy consumed by mine sites with aboveaverage energy efficiency
Practical Minimum Energy Consumption – The energy that would be required after R&D
achieves substantial improvements in the energy efficiency of mining processes
Theoretical Minimum Energy Consumption – The energy required to complete a given
process, assuming it could be accomplished without any energy losses.
The difference between current energy consumption and best practice consumption
corresponds to energy-saving opportunities from investments made in state-of -the-art
technologies or opportunity existing today which has not been fully implemented in mine
operations. The difference between best practice and practical minimum energy consumption
quantifies opportunities for research and development or near-term opportunity with few
barriers to achieving it. Finally, the difference between the practical and theoretical minimum
energy consumption refers to the energy recovery opportunity which is considered impractical
to achieve because it is a long-term opportunity with major barriers or is infeasible.
The study has shown extensive potential for energy savings between current consumption
and practical minimum consumption:
(August – 2011)
Page 11 of 40
Report on equipment efficiency
EEQ-S&B-WP2-2.4
Energy requirement (trillion Btu /yr
Energy consumption by Equipment Category in
Mineral Mining Industry (Trillion Btu/yr)
160
140
120
100
80
60
40
20
0
Drilling
Ancillary Operations
Diesel Equipment
Digging
Dewatering
Separations
Grinding
Electric Equipment
Blasting
Graphic 2. . Energy consumption by Equipment Category in Mineral Mining Industry
(Source: “Mining Industry Energy Bandwidth study”. US Dpt of Energy. Industrial Technologies Program.
June 2007)
A very important factor that influences the energy consumption in an open pit mine is the
extraction technology. The choice of system effects the selection of machinery and thus energy
consumption. We can distinguish four different types of mining systems. The most commonly
used methods in the quarries are the No1 and No 2.
2.1 Discontinuous Systems
These are mostly hydraulic and rope shovel excavators for extracting and loading the raw
materials with or without previous blasting of the rock (depending of its consistency and
hardness). Transportation is carried out by large trucks with payloads of up to 400 t, which
sometimes cover the entire transport distance from the extraction site in an open-pit mine to an
outside dump for overburden material – located kilometers away – or to processing and
preparation plants for the valuable mineral. In strip mine operations – as usual in big coal mines
in the USA – overburden removal will be done by use of draglines.
Discontinuous Systems Combined with Semi-mobile Crushing Plants and
Continuous Belt Conveyor Systems
Here, the loosening and loading of the material is also handled by hydraulic and rope shovel
excavators. Further transportation within the open pit is also carried out by trucks, but only to a
semi-mobile crushing plant located in the immediate vicinity. This breaks up the material into
coarse pieces, thus preparing it for further transportation via a belt conveyor system. The
discontinuous use of trucks is thus considerably reduced and only takes place in the so-called
shuttle operation.
2.2
2.3 Continuous Systems, Open Pit Mining of Soft Rock
Here, a bucket wheel excavator carries out the tasks of loosening and loading directly in-situ,
because the extraction does not require blasting and the material’s compressive strength is low.
(August – 2011)
Page 12 of 40
Report on equipment efficiency
EEQ-S&B-WP2-2.4
Further transportation of the material follows – partly by means of intermediate mobile belt
conveyor modules – via belt conveyor systems and in the case of overburden systems directly to
the dumping point using spreaders.
2.4 Continuous Systems, Open Pit Mining of Solid Rock
The material is mostly broken loose from the rock formation by means of preliminary blasting
operations. Hydraulic or rope shovel excavators then handle the task of loading the blasted
broken rock directly into the feeding hopper of a fully mobile crushing plant. This breaks up the
very coarse material in the first crushing stage directly at the point of extraction, thus preparing it
for subsequent belt conveyor transportation and for further downstream processing.
The major differences with respect to energy efficiency and CO2 relevance of the abovementioned Open pit mining technologies are in the energy requirement and the energy supply.
Continuous open pit mining equipment is almost exclusively electrically powered, while most
discontinuous open-pit mining equipment is powered by diesel engines. The deposit
characteristics of open pit mines in unconsolidated and solid rock also have a substantial impact
on transport distances for the extracted raw material or the overburden and are thus also a major
factor determining energy use, operating costs and resulting CO2 emissions. Flat deposits in
unconsolidated rock usually require transport routes over long distances but with little difference
in elevation. Ore deposits, in contrast, extend to greater depths, and their extraction therefore
requires extreme elevation differences. In this case, the energy required for transportation by
truck increases substantially. Today, application of innovative techniques, such as the use of fully
mobile crushing plants, makes it possible to carry out loading and crushing directly at the point of
extraction. This can be considered a way to save resources by utilizing belt conveyor systems for
further transportation.
(August – 2011)
Page 13 of 40
Report on equipment efficiency
EEQ-S&B-WP2-2.4
3. CASE STUDY: MONTE SPARAU ( ITALY) PERLITE QUARRY
In order to examine the energy efficiency of the equipment, we decided to use as a real example
the perlite mine of Monte Sparau in Sardinia Italy which belongs to S&B Industrial Minerals
Group.
Figure 2.Monte Sparau mine Sardinia Italy
Generally there is a difficulty to collect energy consumption data; especially from the electrical
equipment (motors of crushers, screens and conveyors) since very rarely KWh counters are
installed in each of the main units. On the other hand the diesel consumption, as we will discover
below, is more controllable and of course more easy to be registered and monitored.
(August – 2011)
Page 14 of 40
Report on equipment efficiency
EEQ-S&B-WP2-2.4
3.1 Location and Geology
Monte Sparau mine is located in the west side of Sardinia Italy and the perlite –rhyolite formation
is a part of the Monte Arci volcanic complex. The Monte Arci volcanic complex is associated with
the PPC ( Pliocene – Pleistocene – Cenozoic ) and hosts the only known perlite deposit in
Sardinia.
Perlite is a generic term for naturally occurring siliceous rock. It is a form of natural glass which in
aqueous suspensions results in neutral pH. The main constituent of perlite is amorphous silica
(70-76% SiO2), while it contains lower quantities of aluminum, potassium, sodium, calcium, iron
and magnesium (Table-1). Part of the total alkalis (Na2O+K2O = 6-10%) is present in the
amorphous matrix forming a solid solution.
SiO2
Al2O3
TiO2
Fe2O3
MgO
CaO
Na2O
K2 O
LOI
Greek
74,5
12,5
0,1
0,8
0,2
1,0
3,7
4,4
2,9
Turkish
72,4
13,0
0,1
0,9
0,1
0,9
2,6
5,0
4,7
USA
73,9
12,4
0,1
0,4
0,0
0,5
5,1
4,5
3,2
Italian
71,1
13,8
0,4
1,5
0,4
1,0
3,2
5,6
2,9
Chinese
73,2
12,3
0,1
0,5
0,0
0,7
3,4
5,0
4,8
Table 1. Indicative chemical composition (%) of perlites of various origins.
The distinguishing feature which sets ground perlite apart from other volcanic glasses is that
when heated rapidly to a suitable point in its softening range, it expands from four to twenty times
its original apparent volume.
The complex of Monte Arci (about 150 km2 in surface outcrop) is composed of a subalkaline
sequence evolving from subalkaline basalt to rhyolite. A minor amount of transitional basalts also
occurs, related to silica-oversaturated alkaline trachyte; alkaline basalt is also sporadically
present.
The perlite mineralization is hosted in obsidian-rich rhyolite lava faces, and is proximal to the rock
cooling joints. It shows macroscopic features characterized by a typical classical perlite textures
on the micro- to macro-scale.
(August – 2011)
Page 15 of 40
Report on equipment efficiency
EEQ-S&B-WP2-2.4
Monte
Sparau
mine
Monte Arci volcanic complex
Figure 3. Geological Map of Cenozoic Volcanic Rocks of Sardinia
(Source: Industrial mineral occurrences associated with Cenozoic volcanic rocks of Sardinia (Italy). N.
Palomba, G. Padalino, N. Marchi (February 2004))
(August – 2011)
Page 16 of 40
Report on equipment efficiency
EEQ-S&B-WP2-2.4
Monte Sparau Production Process overview.
3.2
Monte Sparau mine is producing three different products: perlite, pozzolana and rhyolite. All three
products have the same geological origins , are all acidic lavas, and the factor that differentiates
one from the other is the level of crystallization and the percentage of the combine water.
• Rhyolite is much harder than perlite and pozzolana and it is used as an aggregate for
road construction.
• Pozzolana is used for the production of Pozzolanic cements substituting a significant part
of clinker which varying from 10% to 25%.
• Perlite , in its expanded granular form is widely used: 1) as main component in ThermalAcoustical insulation Ceiling Tiles, 2) as a Light-weight, Thermal & Heat insulating agent
in gypsum Plasters and cement Mortars, 3) as a Light-weight aggregate in concrete,
enhancing self-leveling ability and fire resistance, 4) for Loose-Fill insulation in masonry
construction. Also It is used with success in greenhouse growing, plant propagation
(“soil-less mixes”) and landscape gardening.
• Perlite contrary to Rhyolite and pozzolana requires a more complex process which
includes crushing, drying, grinding and classifying.
Extraction
3.2.1
Each year more than 200,000 tons of all three products are extracted.
350000
Raw Material Production (Metric Tons)
300000
Metric Tons
250000
Rhyolite
200000
Pozzalana
150000
Perlite
100000
50000
0
Year 2008
Year 2009
Year 2010
Graphic 3 .Monte Sparau – raw material production for the years 2008-2009- 2010
(August – 2011)
Page 17 of 40
Report on equipment efficiency
EEQ-S&B-WP2-2.4
For the extraction of raw material a dozer CAT D9 R is used both with an excavator CAT 330C.
Figure 4. CAT D9R and CAT 330 C with hydraulic hammer
A) CATERPILLAR D9R
The technical specification of the CAT D9R dozer, are depicted in the following table:
Engine
Make
Model
Gross Power
Power Measured @
Displacement
Number of Cylinders
Operational
Operating Weight
Fuel Capacity
Engine Oil Capacity
Hydraulic Fluid Capacity
Powertrain Fluid Capacity
Final Drives Fluid Capacity
Operating Voltage
(August – 2011)
Caterpillar
3408ETA
410 hp
1900 rpm
1098.4 cu in
8
109276.5 lb
216 gal
12 gal
19 gal
44 gal
5 gal
24 V
305.7 kw
18 L
49567 kg
817.6 L
45.4 L
71.9 L
166.6 L
18.9 L
Page 18 of 40
Report on equipment efficiency
EEQ-S&B-WP2-2.4
Transmission
Type
Number of Forward Gears
Number of Reverse Gears
Max Speed - Forward
Max Speed - Reverse
Undercarriage
Ground Pressure
Ground Contact Area
Standard Shoe Size
Number of Track Rollers per Side
Track Gauge
Standard Blade
Width
Height
Capacity
Cutting Depth
Dimensions
Length w/o Blade
Length w/ Blade
Width Over Tracks
Height to Top of Cab
Length of Track on Ground
Ground Clearance
Powershift
3
3
7.4 mph
9.1 mph
11.9 km/h
14.6 km/h
16.1 psi
6569 in2
24 in
8
7.4 ft in
110.9 kPa
4.2 m2
610 mm
15.3 ft in
76.1 in
21.4 yd3
23.9 in
4650 mm
1934 mm
16.4 m3
606 mm
17 ft in
23.6 ft in
9.6 ft in
12.5 ft in
11.4 ft in
1.9 ft in
5180 mm
7180 mm
2930 mm
3820 mm
3470 mm
591 mm
2250 mm
Table 2. Specifications of CAT D9R.
Taking the monthly data for 2010 the average diesel consumption was 43,1 lt/h.
CAT D9R fuel consumption (lt/h data 2010)
Consumption (lt/h)
60,0
50,0
40,0
30,0
20,0
10,0
0,0
Graphic 4. Hourly fuel consumption of D9R dozzer- Monte Sparau mine.
(August – 2011)
Page 19 of 40
Report on equipment efficiency
EEQ-S&B-WP2-2.4
In the deliverable D2.3 (Report of Product embedded energy per processes) ,prepared by the
Group CAMT, we saw that the fuel consumption is directly linked with the engine power for
different working conditions. Furthermore in D2.3 a table was providing us a Fuel Consumption
Factor (lt/kw of engine power) per type of equipment and type of working conditions (Light,
medium and heavy).
Taking under consideration the fuel consumption factor for the given power of the engine (305,7
kw), we can create a chart which will show if our equipment’s consumption falls into the generally
accepted range:
Fuel Consumption factor vs. real
consumption CAT D9R
80,0
70,0
60,0
lt/h
50,0
40,0
lt/h Light working
conditions
30,0
lt/h Medium working
conditions
20,0
10,0
lt/h Heavy working
conditions
0,0
Graphic 5. (D9R dozer) Real consumption vs. theoretical consumption given by F.C.C.
The conclusion is that the real consumption is very close to the theoretical hour consumption for
light working conditions.
B) CAT 330 C excavator.
The other main equipment used for extraction and loading is the Caterpillar 330C
excavator. In the following table are shown the technical specifications of the CAT 330C.
Engine Model CAT C9
Flywheel Power
ISO 9249
SAE J1349
EEC 80/1269
Bore
Stroke
Displacement
(August – 2011)
184 kW
184 kW
182 kW
184 kW
112 mm
149 mm
8.8 L
247 hp
247 hp
244 hp
247 hp
4.41 in
5.87 in
537 in3
Page 20 of 40
Report on equipment efficiency
EEQ-S&B-WP2-2.4
Following the same approach as we did with the D9 dozer, we will try to figure out how close the
real consumption is to the theoretical one.
50,00
45,00
40,00
35,00
30,00
25,00
20,00
15,00
10,00
5,00
0,00
Consumption (lt/h)
lt/h Light working
conditions
18/07/11
16/07/11
14/07/11
12/07/11
10/07/11
08/07/11
06/07/11
04/07/11
02/07/11
30/06/11
28/06/11
26/06/11
lt/h Medium working
conditions
24/06/11
Consumption lt/h
CAT 330C.
Real fuel consumptio vs. theoretical
consumption
lt/h Heavy working
conditions
Graphic 6. CAT 330 C excavator, real consumption vs. theoretical consumption given by F.C.C.
Here the image is totally different from the one we encountered examining the consumption of
D9R. The excavator’s consumption reaches and sometimes surpasses the theoretical
consumption.
3.2.2
Loading – transportation.
The raw material is loaded on 3-axis and 4-axis trucks by using 2 VOLVO wheel loaders.
The models are the L180F (235 KW) and L150G (220 KW). Both of them are brand new and very
technologically advanced. They have some features which render them very efficient regarding
the energy consumption.
The daily consumption is closely monitored though a system, certified by the fiscal authorities,
which counts the hours and the liter of diesel that are supplied to the loaders.
Using the table with Fuel Consumption Factor, we prepared the following two charts for each
model of wheel loader.
(August – 2011)
Page 21 of 40
Report on equipment efficiency
EEQ-S&B-WP2-2.4
VOLVO L180F
Fuel consumption vs theoretical
consumption
Consumption lt/h
60,0
50,0
Consumption (lt/h)
40,0
30,0
lt/h Light working
conditions
20,0
lt/h Medium working
conditions
10,0
26/07/11
19/07/11
12/07/11
05/07/11
28/06/11
21/06/11
14/06/11
07/06/11
31/05/11
24/05/11
17/05/11
10/05/11
03/05/11
0,0
lt/h Heavy working
conditions
Graphic 7. Diesel consumption of VOLVO L180F front loader comparing to the F.C.F given in the
deliverable D2.3
VOLVO L150G
Fuel consumption vs. theoretical
consumption
Fuel consumptio lt/h
60
50
Consumption (lt/h)
40
30
lt/h Light working
conditions
20
lt/h Medium working
conditions
10
29/07/11
27/07/11
25/07/11
23/07/11
21/07/11
19/07/11
17/07/11
15/07/11
13/07/11
11/07/11
09/07/11
07/07/11
05/07/11
03/07/11
01/07/11
0
lt/h Heavy working
conditions
Graphic 8. Diesel consumption of VOLVO L150 front loader comparing to the F.C.F given in the
deliverable D2.3.
(August – 2011)
Page 22 of 40
Report on equipment efficiency
EEQ-S&B-WP2-2.4
Figure 5. Counter of working hours installed in the VOLVO L180F loader.
As a conclusion we could say that both loaders are consuming fewer diesels that the theoretical
value for the light working conditions. This fact pinpoints the importance of the technological
advanced systems incorporated in the newly built equipment which allow us to achieve significant
energy savings.
3.2.3
•
Processing
For the Rhyolite processing raw materials we are using a series of screens, jaw crushers,
hammer mills and conveyor belts. All the machineries are electrically operated. In the
perlite processing plant we are using a series of screens, conveyor belts, jaw crushers,
hammer mills, vertical impact crusher and bag house filters.
Hopper & feeder
Jaw Crusher CR900
Screen 5000
Screen 3000
Hammer Mill
Jaw crusher CR750
Figure 6. Ground plan of Rhyolite processing plant.
(August – 2011)
Page 23 of 40
Report on equipment efficiency
•
EEQ-S&B-WP2-2.4
The total installed power of the Rhyolite processing plant is 346,5 Kw with 21 electrical
motors and in Perlite processing plant is 1150 KW, with 56 electrical operated motors.
BUNKER
0 - 500 mm
STO RAGE HOPPER
0 - 8 mm
PRIMARY CRUSHING
AND STORAGE
0 - 70
Jaw crusher 750 mm
0 - 8,0
FILTERS
Con. Belt
STO RAGE BIN
0 - 70 mm
0 - 0,4
Con. Belt
FT2
FT3
0 - 70
0 - 0,6
FT1
Con. Belt pos.6
SECONDARY
CRUSHING
0,7 - 4,0
DVEM POS. 5,1;2;3
MOG.
MOG.
P. 23,6
P. 23,5
MOG.
MOG.
MOG.
MOG.
P.23,4
P. 23,3
P. 23,2
P. 23,1
4,0 - 8,0
DVEM pos. 8,1 - 8,2
0,7 - 2,5
MOG.1
MOG.2
Mogensen pos. 9,1 - 9,2
Y
L
E
P
C
PLANS.
be
lt
C
PLANS.
PLANS.
P. 26,2
P. 26,1
0,15 - 0,6
Con. Belt
0 - 8,0
PLANS.
P. 26,3
on
.
E
C
R
O
S.
21
2,0 - 4,0
P. 26,4
POS. 13
FILLER
CYCLONES
HMS1
HMS2
FMC1
FILTERS
DVK 11
SILO 7
FMC2
RECYCLE
SILO 1
STORAGE FILLER
SILO 2
SILO 3
SILO 4
SILO 5
SILO 6
Con. belt POS. 19
DVEM POS 15,1
Pos. 17,1
Ham. Mill
DVEM P. 15,2
DRYERS
Pos. 17,2
MT. S PARAU PLANT
Figure 7. Flow sheet of perlite processing plant. The total installed power at the perlite processing
plant is 1150 Kw with 56 electrical motors
As we said before the driving force of the processing plants is the electricity. The electricity sector
has a particular importance in the EU, with electricity generation accounting for about 35 % of
total primary energy use and about 30 % of man- made CO2 emissions.
Electric motors convert electrical power into mechanical power within a motor‐driven system.
The vast majority of the electricity used by an EMSD is consumed by the electric motor itself.
Only a very small amount is used to power control functions or other ancillary circuits.
Electric motors and the systems they drive are the single largest electrical end‐use, consuming
more than twice as much as lighting, the next largest end‐use. It is estimated that EMDS
accountfor between 43% and 46% of all global electricity consumption, giving rise to about 6 040
Mt of CO2 emissions. By 2030, without comprehensive and effective energy‐efficiency policy
measures, energy consumption from electric motors is expected to rise to 13 360 TWh per year
and CO2 emissions to 8 570 Mt per year. End‐users now spend USD 565 billion per year on
electricity used in EDMS; by 2030, that could rise to almost USD 900 billion
(August – 2011)
Page 24 of 40
Report on equipment efficiency
EEQ-S&B-WP2-2.4
Sector
Electricity
consumption
% of all
electricity
EMDS %
of
electricity
Industrial
4 488 TWh/year
64%
69%
Commercial
1 412 TWh/year
20%
38%
Residential
948 TWh/year
13%
22%
Transport
agriculture
and 260 TWh/year
3%
39%
sector
Table 3. EDMS (Electric Motor Driven Systems) electricity consumption by sector
(Source: IEA statistics, 2006 (national electricity demand); A+B International, 2009 (motors calcula
tions).
Using the best available motors will typically save about 4% to 5% of all electric motor energy
consumption. Linking these motors with electromechanical solutions that are cost‐optimised for
the end‐user will typically save another 15% to 25%. The potential exists to cost‐effectively
improve energy efficiency of motor systems by roughly 20% to 30%,which would reduce total
global electricity demand by about 10%.
The three major routes to achieving these savings are:
• Use of properly sized and energy‐efficient motors.
• Use of adjustable‐speed drives (ASDs)2, where appropriate, to match motor speed and
torque to the system mechanical load requirements. This makes it possible to replace
inefficient throttling devices and, in some cases with “direct‐drive”, to avoid wasteful
mechanical transmissions and gears.
• Optimization of the complete system, including correctly sized motor, pipes and ducts
efficient gears and transmissions, and efficient end‐use equipment (fans, pumps,
compressors, traction, and industrial handling and processing systems) to deliver the
required energy service with minimal energy losses.ç
Graphic 9. Bentonite and Perlite operations on Milos Island
(August – 2011)
Page 25 of 40
Report on equipment efficiency
3.2.3.1
EEQ-S&B-WP2-2.4
Milos’s island geology
Milos Island belongs to the Attica - Cycladic mass and is part of the Aegean volcanic arc. The
crystallic base of the island consists of folded and heavily eroded metamorphic rocks. Sediments
are between Miocene and Pliocene and have been deposited asyphonous above the base rocks,
followed by the products of the volcanic activity between Pliocene and Quaternary. The
lithological column closes with recently discordantly deposited alluvial formations.
Bentonite
The Bentonite mining area is dominated by the green Lachar formation, as well ashydrothermally
altered lava and tuffs bentonitization, kaolinitization, zeolithization or silification . Bentonite has
been formed from the alteration of acidic volcanic rocks.
Bentonite is plastic clay with strong colloidal properties that increases its volume several times
when coming into contact with water. The Main Markets Served by S&B’s products are shown in
the table below:
Foundry
binder for green sand foundry molds for metal casting
Construction projects
thixotropic additive for foundation engineering, diaphragm wall
construction, grouting and tunneling, landfill sealants
Iron ore
binder for the production of iron ore pellets
Absorbents
pet litter
Paper Industry
additive in paper for retention improvement, adsorption and fixation of
impurities in paper stock
Oil drilling
thixotropic additive for the production of drilling mud
Other special
applications
additive in chemical industry, ceramics, waste water treatment
Table 4. The Main Markets Served by S&B’s products are shown
Bentonite Processing
The stages of bentonite process are:
1. SHREDDER: at this stage the size is reduced at less than 80 cm and activation is by soda
ash addition.
Figure 8. Shedder
(August – 2011)
Page 26 of 40
Report on equipment efficiency
EEQ-S&B-WP2-2.4
2. AIR-SUN DRYING: the moisture reduces from ~30% to ~22% and due to scraping further
size reduction and initial blending.
Figure 9. Air Sun drying
3. INDUSTRIAL DRYING: at this stage, the moisture reduces from ~23% to customers
specs (~13-16%), size reduces to the customers specs (usually below 25 mm) and final
blending.
Figure 10. Industrial Drying
Perlite
Perlite is Natural volcanic glassy material which has been created by rapid pulling of lava onto the
surface. Its volume increases 10-20 times and its bulk density decrease accordingly, leading to
excellent thermal and acoustic insulation properties. The Main Markets Served by S&B’s products
are:
Main Markets Served:
Formed building products acoustical ceiling tiles, roofing tiles, boards and panels
Bulk building materials
plasters, mortars, lightweight aggregates
Horticulture
growing medium for greenhouse cultivation and soil mixes, substrates
Filtration
Industrial applications
Cryogenic industries
(August – 2011)
filter aids for the production of juices, beverages, edible oils, chemical,
pharmaceutical and petroleum products
cryogenic insulation, pipeline insulation, heat-resistant applications in
foundries
raw material for the pozzolanic cement, silica source
Table 5 . Main Markets Served by S&B’s products
Page 27 of 40
Report on equipment efficiency
EEQ-S&B-WP2-2.4
Figure 11 Perlite Processing
The stages of perlite process are:
1. PRE-CRUSHING: at this stage the size is reduced at 0.5 m >-15 cm.
2. SECONDARY CRUSHING: size is reduced at 15cm >-5 mm.
3. INDUSTRIAL DRYING: Moisture is reduced at 7% to 0.5%.
4. SCREENING: Sizing.
5. STORAGING
Figure 12 Storage area
3.2.3.2
Loading.
The following 3 ports service S&B needs on the Island:
LOCATION
1) VOUDIA
2) KANAVA
3) AMPOURDEKTAKI
(August – 2011)
CAPACITY
800 tns/hr
750 tns/hr
450 tns/hr
Page 28 of 40
Report on equipment efficiency
EEQ-S&B-WP2-2.4
Figure 13 Voudia
Figure 14 Kanava
Figure 15 Ampourdektakia
3.2.3.3
Key Figures for 2010
Bentonite
There are 6 active mines on Milos. The Stripping volume year is 866.724 m3 and the Stripping
ratio 0,7 m3/ton. The ROM (Run On Mine) Bentonite is 1.284.299 tons and the Final product is
1.021.133 tons. Therefore Yield is 80%.
Perlite
There are 2 active mines on Milos. The Stripping volume year is 54.301 m3 and the Stripping
ratio 0,1 m3/ton. The ROM Perlite is 596.491 tons and the Final product is 445.619 ton. Therefore
Yield is 75%.
(August – 2011)
Page 29 of 40
Report on equipment efficiency
EEQ-S&B-WP2-2.4
.
Figure 16 Real Vs Theoretical consumptions front end loader
Figure 17 Real Vs Theoretical consumptions of Bulldozer
(August – 2011)
Page 30 of 40
Report on equipment efficiency
EEQ-S&B-WP2-2.4
Figure 18 Real Vs Theoretical consumption rigid truck
Figure 19 fuel consumption per ton material front end loader
(August – 2011)
Page 31 of 40
Report on equipment efficiency
EEQ-S&B-WP2-2.4
Figure 20 Fuel consumption per ton of material by a Bulldozer
Figure 21 Fuel consumption per Ton of material moved by rigid road trucks
(August – 2011)
Page 32 of 40
Report on equipment efficiency
EEQ-S&B-WP2-2.4
Figure 22 Fuel consumption per Ton of material moved by mobile equipment category
(August – 2011)
Table 1.
Average age of mobile equipment
Table 2.
Bentonite - Installed crusher capacity
Page 33 of 40
Report on equipment efficiency
EEQ-S&B-WP2-2.4
Table 3.
Table 4.
3.2.4
Perlite - Installed crusher capacity
Electric power consumption
Acciona Ivonne Quarry in Barcelona
The rock type is Granodiorite. The Stripping ratio is 2m3 per 100 MT Granodiorite and the
Production yield is 100%.
The Production phases are:
o Blasting with packaged emulsion explosives (96 gr/MT)
o Loading
o Transportation to crusher
o Crushing
o Hauling to silos
The equipment used is:
Table 5.
(August – 2011)
Machinery in the Ivonne quarry
Page 34 of 40
Report on equipment efficiency
EEQ-S&B-WP2-2.4
3.2.5 Acciona Cazebo Gordo
The rock type is Granodiorite and the stripping ratio is 2m3 per 100 MT Granodiorite. The
production yield is100%.
The production phases are:
o Drilling (12m depth)
o Blasting
o Loading
o Transportation to crusher
o Primary crushing
o Main crushing and separation
o Milling
o Hauling to silos
The equipment is described at the following tables:
Table 6.
(August – 2011)
Machinery in the Ivonne quarry
Page 35 of 40
Report on equipment efficiency
3.2.6
EEQ-S&B-WP2-2.4
Outbound logistics
Outbound logistics is the movement of material associated with storing, transporting and
distributing goods to the customers. In an aggregate quarry that means the whole logistics chain
in order to the material to arrive to the site of its end use, like construction sites , ready mix plant
etc. Usually outbound logistics is a disregarded factor of energy consumption and consequently
of CO2 emissions. The quarries must be strategically located near the end user sites in order to
minimize the impact of the outbound logistics.
The Italian Ministry of Infrastructure for trucks more than 26 Mt of gross weight calculates an
average consumption of 2, 8 km per lt. That means for an articulated truck of 30 Mt net weights
(which the most common truck in use) we have a specific consumption of 0,012 lt. of diesel per
km and MT. For a mine like Monte Sparau with an annual output of 250,000 MT and a median
distance to the final customer of 30 km, we have a theoretical diesel consumption of 90,000 lt.
(August – 2011)
Page 36 of 40
Report on equipment efficiency
EEQ-S&B-WP2-2.4
4. CONCLUSION
In the previous chapters we looked into the energy efficiency of a real production site such is the
Monte Sparau quarry ownership of S&B Industrial Minerals.
For mobile equipment like excavators, bulldozers and wheel loaders, the main factor that
influences their efficiency, is how modern the diesel engines are. Engines that incorporate new
technologies could guarantee very low consumption and gas emissions. In our case study, the
newly acquired wheel loader with engines that fulfill the most recent European and US standards
(EU Directive 97/68/EC, stage 3A and US EPA Tier 3 and California Tier 3), displayed very low
fuel consumption (much lower from the theoretical associated to the engine power).
As for the electrical motors Improvement of their efficiency can be obtained with the following
methods:
- Reduction of size (replacement of the motor), when the motor operates in an area of partial load
- Increasing the size (replacement of the motor), when the motor is operating with a higher partial
load
- Voltage reduction, when the motor is permanently operating with partial load.
To sum up, there are a lot of challenges in analyzing the Mining Industry’s Energy Efficiency. The
main factors affecting the results are:
• Major variations in size and extension of orebodies
• Fast changing mine layout in small operations
• Different mechanical and physical properties of every deposit and its host rock
• Missing measuring mechanisms for data collection
• Companies not providing data for reasons of competition
• Intransparent production procedure due to outsourcing of activities (mining, processing,
transportation)
The energy efficiency of mobile equipment is affected by:
• Good maintenance, allows an efficient operation of older equipment
• New equipment is the solution if extensive maintenance fails improving efficiency
For the electric Motor Driven Systems, main challenges are:
• the use of properly sized and energy efficient motors
• the optimization of the complete system, including correctly sized motor, pipes and ducts
efficient gears and transmissions, and efficient end‐use equipment (fans, pumps,
compressors, traction, and industrial handling and processing systems) to deliver the
required energy service with minimal energy losses.
(August – 2011)
Page 37 of 40
Report on equipment efficiency
EEQ-S&B-WP2-2.4
5. REFERENCES
1. Energy- efficiency policy opportunities for Electric Motor- driven systems.
International Energy Agency. Paul Waide and Conrad U. Brunner 2011
2. Energy efficient electric motors. Paul Hanitsch . University of Technology BERLIN.
Rio world climate/ energy event January 2002.
3. Mining Industry Energy Bandwidth study. US Dpt of Energy. Industrial Technologies
program June 2007.
4. Comparison of energy efficiency and CO2 emissions for truckshaulage vs. in-pit crushing
and conveying of materials: Calculation methods and case studies
Victor Raaz and Ulrich Mentges . ThyssenKrupp Foredertechnik GmbH
(August – 2011)
Page 38 of 40
Report on equipment efficiency
EEQ-S&B-WP2-2.4
ATTACHMENTS
a. Deliverable review report
Date
Reviewer
Company
Venue
b. Technical result of the deliverable
Deliverable covers the topic specified in the title
Yes
Partly
No
Technical contents are relevant to EE-QUARRY and to the WPs
Yes
Partly
No
Presented results in the deliverable are of high value
Yes
Good
Partly
No
Technical sound of the deliverable
Regular
Bad
Described work in the deliverable follows a clear methodology
Good
Regular
Bad
Please add your comments on the content and the technical results of the deliverable. Please
comment the problems, if any.
Comments
:
(August – 2011)
Page 39 of 40
Report on equipment efficiency
EEQ-S&B-WP2-2.4
c. Length, structure and presentation of the deliverable
Good
Adequate length of the deliverable
Regular
Bad
Good
Deliverable organization is appropriate
Regular
Bad
Good
Presentation of the deliverable clear and concise
Regular
Bad
Please add your comments on the length, the structure and the presentation.
Comments
:
d. Rating for the deliverable
Please provide a rating for this deliverable from 5 (excellent) to 1 (very poor): ____
Deliverable is
Accepted
Accepted
with
revisions
Rejected
unless
modified
as
suggested
Rejected
Comments
:
(August – 2011)
Page 40 of 40