Energy Efficiency Case StudiesKENNECOTT BINGHAM CANYON MINE REFINERY AND SMELTERSalt Lake City
Although constructed in the mid-1990s as a state-of-the-art facility, the smelter and refinery are very energy-intensive metal production facilities. Accordingly, Kennecott collaborated with the U.S. Department of Energy’s (DOE) Industrial Technologies Program to complete a plant energy assessment aimed at identifying projects to conserve energy and improve production processes. Experts from DOE’s national laboratories conducted a series of assessments of the plant, focused on identifying the large energy consumers at the refinery and smelter, and also looking for preventative maintenance, cost-reduction, and performance-improvement opportunities. The assessments identified energy-savings opportunities in process heating, steam systems, pumping systems, compressed air, and insulation, and also discovered potential improvements in operating practices and maintenance. Three projects were selected for detailed analysis and implementation based on the results of the assessments. Replacing the heated matte launders (a trough used to transport molten copper) with water-cooled launders has the potential to generate $365,000 in annual fuel savings, and $600,000 in total annual savings due to reduced materials and repair costs. By optimizing the natural gas-fired concentrate dryer (used to dry 4,000 tons of wet copper concentrate per day), a 30% reduction of the smelter’s total fuel consumption can be achieved, saving $80,000 per year in fuel costs. Finally, by using the methane gas generated at an adjacent municipal landfill to fire two steam boilers at the refinery, nearly $250,000 per year in fuel costs can be saved. Potential annual cost savings of $930,000 and potential annual fuel savings of 452,000 MMBtu of natural gas were identified through the assessments. In addition, opportunities were discovered to reduce maintenance, repair costs, waste, and emissions, while improving industrial hygiene and safety. |
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The Bingham Canyon Mine is one of the world’s largest open pit copper mines.
A copper smelter and copper refinery are included amongst the processing
facilities at the mine. Employing over 1,600 people, the mine yields 300,000
tons of refined copper per year, and has been in operation for over 100 years.