Intelligence in Aggregates

User Scenarios

Looking to dig deeper to find energy efficiencies?

Need to cut energy usage and running costs and find cost-effective ways to drive sustainability within your operations?

Wasted and inefficient use of energy has a significant impact on profitability and environmental performance. A structured approach to energy management helps you maximum uptime, achieve peak efficiency, and improve competitiveness.

Implementing energy saving and monitoring solutions will enable you to boost the efficiency and reliability of your assets and operations, which improves productivity and reduces energy costs.

The process of collecting, analysing, and presenting energy data plays a crucial role in evaluating energy performance and identifying areas for improvement.

By harnessing the power of your data, you can measure energy consumption and monitor costs but also pinpoint opportunities to increase efficiency, resulting in reduced consumption, cost savings, and a more sustainable operation.

Let’s explore how implementing the right energy saving solutions can help you to unlock efficiency and operational improvements:

Challenge

The aggregates and quarrying industry is an energy hungry process. Crushers, pumps and bulk handling conveyors come with large motors which are heavy energy consumers, if no remedial action is taken.

There is a growing need to reduce emissions from energy consumption, both from legislation and the community, highlighting the need for a dynamic and performance-based approach to energy monitoring.

Accurately tracking energy consumption and emissions will drive down costs and reduce your carbon footprint. This happens in both mining and aggregates processing plants.

Traditional energy audits may not always provide a comprehensive understanding of energy usage due to the diversity of machines and technologies used. That's where specialised energy monitoring solutions can help.

The real impact of energy consumption in aggregates processing: take a closer look with this example of a 55kW Lagoon Pump:

Operates for 9 hours daily, 5 days a week, for 50 weeks annually
Consumes 132,353 kWh of energy at £0.23 per kWh
Produces 93 tonnes of CO2 equivalents
Average energy cost: £30,449.19

Are you aware fully aware of your energy consumption?

Solution

Mitsubishi Electric’s energy saving solutions will increase your profitability whilst reducing your carbon footprint as they are designed to optimise power consumption and provide you with total visibility of your energy hot spots. Energy saving strategies are deployed throughout your plant.

Solutions range from equipping the motors that drive your bulk conveyors and pumps, with energy efficient variable speed drives (VSDs), to total smart energy monitoring and analytical solutions. By implementing these solutions at device and enterprise levels you can quickly optimise your plant’s energy efficiency, saving costs.

These solutions can be deployed in stages, perhaps solving the worst hot spots in phase one and moving towards your ultimate energy model as and when budget is available or as you see return on investment (ROI) for each phase.

Let’s consider the impact of fitting an energy efficient VSD to the lagoon pump in our previous example;

The difference a Mitsubishi Electric VSD from the FR-800 series can make by decreasing the pump speed by 10% is significant. With this technology, it is possible to achieve the following benefits:

Save 32,884 kWh of energy
Reduce carbon footprint by 23 tonnes of CO2 equivalents
Increase pumping equipment lifespan
Improve motor control
Receive full payback in less than one year

Implementing data-driven solutions designed to optimise your overall energy consumption can increase profitability whilst decreasing emissions. At the same time, these can help to improve the sustainability and competitiveness of your operation.

The adoption of Mitsubishi Electric's energy-saving and monitoring solutions, combined with advanced data-driven automation technologies, helps you to optimise energy usage and reduce your environmental footprint.

Advanced energy savings and monitoring of plant assets can provide:

Enhanced energy efficiency and cost savings
Real-time monitoring and tracking of key assets
Intuitive data visualisation for rapid decision-making
Improved compliance with industry regulations
Increased profitability
Reduced carbon footprint

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