Energy Crises!

Scaw SA empowers itself with 66 000 kWH per day saving

“I don’t regard the problems of energy supply here as a disaster. And South Africa is not alone: there are pressures on supply regarding our expansion projects in Chile and Brazil,” said Ms Carrol at a Mining Indaba earlier this year.

“Sure, the problems here are serious; overcoming them will require ingenuity, especially in energy efficiency and energy saving, as well as the development of alternative power supplies. But if all of us can forge strong partnerships to tackle the situation, we will all come through – I hope relatively unscathed. This is not a time for finger pointing, but for working together in finding solutions.”

Finding solutions is exactly what Scaw South Africa has been doing. Johan Claassen, Union Junction’s maintenance engineer, explains, “Eskom sent out a communiqué stating that in order to avoid being load shedded, a 10% savings on our 2007 load profile was required. Scaw decided to drive this 10% saving aggressively and, if achieved, hold Eskom to its promise. The second objective was to make this saving without affecting production output.

“Initially it was seen as almost impossible to make such a big saving without investing millions. However, we went ahead and requested personnel to switch off air conditioning units and, instead, open windows, blinds and curtains to allow natural light and warmth into their offices; to switch off their monitors and other electrical appliances and chargers when not in use; and switch off geysers where shower facilities were not required. Plant equipment that normally operates 24 hours a day but is not always required was switched off, for example dust, fume extraction, cooling and pumping systems.”

SAVINGS MADE

Scaw Union Junction made a 66 000 kWH/day saving as a result of this drive. This was a massive saving but only 30% of what was required. Consequently, Scaw reviewed the arc furnace power programmes and charge make up, and this has brought about excellent results.
Not only has Scaw gained a better understanding of its energy balance but it has been able to improve production output while using less energy. This was all achieved through better efficiencies and energy utilisation.

IN BETTER SHAPE: HEALTHIER STATISTICS FOR THE GROUP AHEAD

At the end of June, Union Junction was at almost 8% and confident of achieving Eskom’s required 10%. The operation has reduced it total energy consumption (all energy sources) by 4% from 6.42 to 6.16 GJ/ton
Electrical energy has dropped by 69 kWH/ton, 3.6 million kWH or  R615 000/month saved. 
The same initiatives were launched at all the other South African sites as well. Standard Foundry has achieved its 10%. No metering has been installed at the Steel Wire Rope operation but indications are that it has also done well.