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PowerSaver provides $257K in Estimated Annual Savings at Iron Ore Mine

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The Challenge

Our client in the Pilbara Region WA is among the largest producers of iron ore in the world. With the downturn in commodity prices, there has been significant pressure on operations to lower costs. Power consumption is a major cost consideration with conveyor systems typically consuming the most power on a mine site.

Key Benefits

  • 9.8% Average Energy Saving
  • 19% Average Energy Saving at Stacker Limit
  • $257K Estimated Annual Savings^

The Solution

  • Fenner Conveyors identified that reducing pulley cover resistance offered the best prospect for achieving the10% energy reduction target.
  • Fenner Conveyors had developed PowerSaver™, a low rolling resistance (LRR) compound to be applied to the bottomcover of the belt.
  • PowerSaver™ was designed to minimise cover indentation on the pulley cover, assist with easy flow over the idlers and reduce energy consumption.
  • Fenner Conveyors’ R&D team designed, developed and factory tested the optimum LRR belt for the client’s application utilising the PowerSaver™ compound.
  • The client nominated a trial conveyor due to configuration and timing of change out.
  • Trial conducted on stacker conveyor, 8500tph using ST2000 1800mm wide belt and 1km in length– head pulley to tail pulley.
  • The client benchmarked historical performance data and a straight changeover with previous belt was performed.

The Results

  • The client conducted ongoing monitoring and data collection, then presented the results after an initial 12 month trial.
  • *Average energy saving of 9.85% (all data analysed with a flow rate of ≥ 7000tph).
  • At or near stacker limit average energy saving of ~15%.
  • **Seasonal comparisons showed that the warmer months yielded even better results with average energy saving at 12.6% and average saving when stacking at or near stacker limit of ~19%.
  • Client identified better performance when the compound is worked harder.
  • Results confirm reduced motor load on the trial conveyor.
  • There was no evidence of pulley cover wear.
  • Zero quality, belt tracking or splicing issues.
  • Fenner Conveyors estimate client utility bill savings of $257k annually on trial conveyor^
  • Even greater energy saving % expected on fixed length (non-stacker) conveyors and >1 km in length

^Based on 30.9 Cents/ KW / hour - WA Department of Finance - Large Business Tariff (Tariff M2–High Voltage) & conveyor parameters of - 8500tph, 1800mm wide belt, 1km fixed length. Electricity rates current as of 12/07/16: https://www.finance.wa.gov.au/cms/Public_Utilities_Office/Businesses_and_Government/Electricity/Electricity_prices.aspx