Adrian Abbott &Jody Asquith

Benchmarking Energy Consumption in Coal Mining

“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?”

The Answer…

Energy Benchmarking

Benchmark energy performanceSite(s) performance relative to like operationsTypical ranges of performance

equipment levelprocess level

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

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.

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

ACME Colliery

• Open cut mine using truck and shovel

• CHPP

• 7.5 million ROM tonnes/4 million tonnes product

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

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ME 7 8 10 12 30 5 14 26 6 3 18 21 28 9 19 17 32 31

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Site Identifier

Benchmarking Energy KPI - all mine types

Similar sites

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20 22 29 ACME 7 8 12 30 14 18 28 19 17 32 31

Open Cut

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Site Identifier

Benchmarking Energy KPI against all other Open Cut using Truck and Shovel

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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Monthly Production, Thousand Tonne

Energy Cost per Saleable Tonne vs Production - Monthly

All Sites ACME Colliery

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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All Sites Max Range Min Range ACME

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Energy Performance Range

Max

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Average

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

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MJ/tonne Saleable Coal

Energy Use per Tonne Saleable Coal - Conveyors

ACME

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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Electrical Energy Intensity by Equipment Type

ACME Colliery All Sites

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?

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