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Energy efficiencyEnergy efficiency

inin

Mining SectorMining Sector

Presented by

Shri L.K.SAHOO, ScientistCentral Institute of Mining & Fuel Research(CIMFR), CSIR

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Need of energy efficiency improvementNeed of energy efficiency improvementin Mining sectorin Mining sector

z Indian mining industry produces 90 mineralsincluding coal

z Energy cost in mining accounts for 10-11% ofproduction cost in Indian mining industry

z Energy saving potential in mining sector isabout 5-8% based on study by CIMFR .

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Mining ProcessMining Process

BLASTINGEXCAVATION

TRANSPORTATION

OR, HOISTINGSIZING/

FINISHINGSTORAGE

DRILLING

Major Energy Inputs : Diesel , Electricity

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MiningMining --MethodsMethods

Depending upon the depth ofthe deposition & mineconditions. The classification ofmines can be done as follows:

1) Open cast Mines

2) Underground Mines

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Energy saving achieved by major miningEnergy saving achieved by major mining

industriesindustries--CIMFR study on mining sectorCIMFR study on mining sector

Energy Audit Projects

% Energy

saving

Saving in

(Rs.)Energy Audit of Umrer Open

Cast Coal mine, WCL,

Maharashtra 5 22 Lakhs

Energy Audit of 9 Mines of

M/s Manganese Ore (I) Ltd,

Nagpur, Maharashtra 8 182 Lakhs

Energy Audit study of Nimbetiopencast Limestone mine, Shree

cement, Rajasthan 8.4 262 Lakhs

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Shovel

(2.42%)

Sankey diagram of Energy usageSankey diagram of Energy usagein an opencast coal mine(OCM)in an opencast coal mine(OCM)

Dragline(14.57%) Pumping

(17.85%)

Lighting

(3.01%)

Excavators(20.43%)

Dump trucks(32.52%)

Lightvehicle(3.78%)

Coalhandling(5.72%)

Total

energy

(100%)

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Energy efficiency improvement in

Opencast mine(Shree cement Ltd)Shree cement Ltd)

Annual electricity consumption : 54 lakh units

Annual Diesel consumption : 8364 kL/year

Present Specific fuel consumption :0.44 litres/ton

Proposed SFC after implementation : 0.34 litres/ton

Annual Lime stone handling :7,780,000tons/year

Monetary savings :Rs.2.26 cr.(8.4%)

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Energy conservation measures(OCM)Energy conservation measures(OCM)

z Optimization of fuel consumption in dumptrucks and excavators

z Use of High capacity, efficient diesel engine

for dump trucks and excavators

z Improvement of maintenance of HEMMs.

z Introduction of energy efficient motors

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INPUT ENERGY PROFILE OF ANINPUT ENERGY PROFILE OF AN

UNDERGROUND MANGANESE MINEUNDERGROUND MANGANESE MINE

Balaghat U/G Mine,MOILBalaghat U/G Mine,MOILINPUT ENERGY Qty. Eq. energy

in kcal

% of

totalenergy

input

Energy

cost(Lakhs)

% of

Totalenergy

cost

Electricity(kWh) 5173076 4.44 x 10

9

72.19 268.7 87.12

Diesel (Lits)

(kg)

209305

171630

1.71 x 109 27.80 39.7 12.8

6.15 x 109 100 308.4 100

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MAJOR ELECTRICAL ENERGY

CONSUMING AREAS

Air compressors

32%

Pumps & Ventilation Fans

47%

Winders

13%

Mine Lightings

1%Crushing & Screening plant

3%Misc. Load

4%

Thrust areas

AnnualSavings estimated

Compressed Air System : 149520 kWh

Pumping system : 105120 kWh

ventilation Fan : 87600 kWh

Demand Savings : 1284 kVA

Total savings :Rs. 23.81 Lakhs

Savings in energy : 8 %

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Variation of Specific EnergyVariation of Specific Energy

Consumption in U/G minesConsumption in U/G mines

Parameter that affects

Specific energyconsumption:

1.Depth

2.Material handling rate3.Energy efficiency of

Mining equipment

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Energy conservation measures(U/G Mines)Energy conservation measures(U/G Mines)

z Energy efficient motors and Pumpsz Optimization of piping network

z

Power factor and maximum demand control.z Efficient utilization of compressed air for drill

z Energy efficient screw compressors

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ConclusionConclusion

z The Indian mining industry though less energyintensive , implementing various energy saving

measures will improve energy efficiency by 5-8%

z Energy benchmarking and Targeting will help inimproving energy efficiency in mines

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Thank You