Benchmarks & Client Cases
Efficiency in Process Industry
The Challenge
Impact measurement by utility
Problem
• Average water consumption of 19.4 m³ per ton produced
• Average electricity consumption of 518 kWh per ton produced
• Average of 1,6 non-quality incidents per day
Root Causes
• Excessive water use in certain circuits and lack of monitoring mechanisms
• Gradual increase of NaOH cost by 23%
• Lack of knowledge about the application of sub-products within internal processes
• Stoppages caused by incorrect sensor readings that leads to overconsumption upon restarting
The Solution
System for monitoring process data
Visual data for deviation analysis
• Optimization of the use of recovered water and reduction of clogging
• Creation of a control chart with real-time data for process monitoring
• Planned shutdowns for preventative maintenance, with a focus on emission control and energy consumption
• Modification of maintenance stock management system and storage conditions
• Implementation of a tool to control processed solids, steam management and concentrator washing
The Results
The project generated Annual Savings of $7 million.
Electricity Consumption
Electricity consumption reduced by 8%.
Non-quality incidents
Non-quality incidents eliminated.
Water consumption
Water consumption reduced by 19%.
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