Pumps and Pumping Equipment consume close to 25% of all energy associated with motor driven loads, and represent more than 50% of all potential energy savings. In mining, pumps are used in multiple process applications, including raw water supply, leach solutions, dewatering, and mine drainage. This presentation provides an overview of various “Pump System” options that can help mining companies reduce energy consumption of Pumping Systems by up to 30%.

1. How to reduce energy consumption of
your pumping systems by up 30% used
in mining operations
Jack Creamer
Segment Manager – Pumping Equipment
Schneider Electric

2. Topics
●Energy Challenge
●Energy and Pumping
●What is the World Doing?
●Passive and Active Energy Efficiency
●Where are the Savings
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3. Energy Dilemma
The facts
The need
vs
Energy demand by 2050
Electrical energy demand by
CO2 emissions
2030
to avoid dramatic
climate changes
Source: IEA 2008
Source: IPCC 2007, figure (vs. 1990 level)
Energy management is the key
to address the dilemma

4. Energy Demand
Renewable
2008
Non-renewable
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5. Legislation and Influencing Bodies
Support Energy Efficiency
● Legislation texts
● Economic Stabilization Act
● Energy Independence and
Security Act
● European Union Energy Directive
● Kyoto Protocol
● Non-governmental initiatives
● Clinton Climate initiative
● Energy Efficiency accreditation
● Utility Programs
● Alliance to Save Energy
● Other government initiatives
● State Policy and Incentives
● White certificates
●DOE
● Pump Energy Efficiency
Standards under development
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6. Energy Use in Pumping Systems
Pumps represent about
25% of industrial motor
energy use.
Source: DOE Office of Industrial Technology
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7. Pumping –
Energy Savings Potential
GWhr / Year
2,000
1,500
Pump Savings
Motor Upgrades
Air Compressor Savings
1,000
Other Savings
Fan Savings
Downsize Savings
Rewind Savings
500
1000+ HP
501 - 1000 HP
201 - 500 HP
101 - 200 HP
51 - 100 HP
21 - 50 HP
6 - 20 HP
1 - 5 HP
0
Source: U.S. Industrial Motor Systems
Market Opportunities Assessment,
U.S. Department of Energy
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8. Pumping –
Energy Savings Potential
Pumping systems have
the most to gain from
energy savings efforts.
Source: DOE Office of Industrial Technology
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9. Metals Mining Example
Source – Sulzer Pumps
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10. Motor use in mining
● Typical Distribution of Motor Population by HP and Application

11. What is the World Doing?
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12. Lifecycle solutions for Energy Efficiency
Energy Audit
& Measure
Passive Energy Efficiency
Fix the basics
Low consumption devices,
insulation material, power
factor correction
Schneider Electric - Power NA Leadership Forum – January 2010
Active Energy Efficiency
Optimise through
automation &
regulation
Pump control, lighting control,
variable speed drives…
Monitor,
maintain,
improve
Meters installation, monitoring
services, EE analysis software
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13. Passive Energy Savings –
By Design Motor Starting Example
● Energy efficient design provides more features while using less
energy than a standard starter and overload
Contactor + MCP
Starter + Circuit Breaker
Self Protected Motor Starter
SPMS versus IEC based solution -> 50.97% savings
SPMS versus NEMA based solution -> 92.71% savings
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14. Active Energy Savings – VFD Example
● Variable Speed Drives
● On centrifugal loads such as pumps, VFD’s save
energy because of the Affinity Laws
● Provide precise speed control of an AC motor
● Can generate full torque and low motor speed
● Protect a motor and wiring from overload currents
● Have inherent power factor correction increasing efficiency
● Limits inrush current to provide soft-start and soft-stop
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15. Active Energy Savings – By Design
VFD Example
● Affinity Laws of Centrifugal Loads:
● FLOW is proportional to motor speed
● PRESSURE is proportional to the motor speed squared
● POWER is proportional to the motor speed cubed.
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16. Active Energy Savings – VFD Example
A motor running at 90% of full speed requires 70% of the electricity
of a motor running at full speed.
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17. Active Energy Savings – VFD Example
● Situation – Dewatering Application
● A 50hp centrifugal Pump
● Supply air 10 hours/day for 250 days
● Cost at full speed would be:
50 hp x 0.746 kW/hp x 2500hours x $0.08 /kWhr = $7,460
● Assuming the Pump does not have to run at full speed all the time
● 25% of time at 100% speed = 625 hours
● 50% of time at 80% speed = 1250 hours
● 25% of time at 60% speed = 625 hours
● Cost running with an AC Drive:
● 50 x (1.0)3 x 0.746 x 625 x $0.08
● 50 x (0.8)3 x 0.746 x1250 x $0.08
● 50 x (0.6)3 x 0.746 x 625 x $0.08
= $ 1,865
= $ 1,910
= $ 428
Annual savings ($7,460.00 - $4,203.00) = $3,257
Potential Utility Rebate at $50 per HP = $2,500
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18. Maximize the savings
●Efficient devices and installation (saves 10 to 15%)
●Optimized usage via automation (save 5 to 15%)
● Without regulation and control systems (up to 12 % lost)
●Without Monitoring and Maintenance (2 to 8% lost)
Optimized usage
via automation
Energy
Consumption
70%
Efficient devices
and installation
100%
Lack of monitoring,
maintenance programs,
regulation and control
systems
Monitoring & Maintenance
Time
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19. Energy Savings – Through Monitoring
System Level
● Power Monitoring Equipment
● Provides monitoring of facility’s power system
● Capture an record numerous parameters such as:
●Voltage
●Current
●Harmonics
●Power factor
●Transient Voltage
●Energy Consumption
●Peak Consumption
● Monitoring this data allows a facility manager to monitor,
understand, and correct any power issues in order to
maximize the energy usage of the facility
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20. Energy Savings – Through Monitoring
Pump Specifics
● Motor Management System
● Allows control and power monitoring of individual devices
● Allows a user to monitor things such as a motor where it
would be traditionally too expensive for an dedicated power
monitoring device
● Predictive logic can alert a user to potential problems such as an
increase in motor current over a period of time
● Built in communication macros drive integration into System Level
systems allowing a facility to monitor all power aspects from
distribution to device
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21. Conclusions
● Pumps are a primary consumer of energy in mining applications
● Solutions are available that will greatly reduce these costs
● Legislation is driving/incenting energy management
Act NOW!
Source - www.pumpschool.com
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22. Thank you!