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Below is a series of case studies that detail some of the processes used, and opportunities being identified and implemented by corporations undertaking Energy Efficiency Opportunities (EEO) program assessments. When planning for assessments, program participants should ensure they refer directly to the key requirements of the Assessment Framework which are published in the EEO Industry Guidelines. Businesses should not rely solely on the information contained in the examples.
Industry Case Study: Analysis of Diesel Use for Mine Haul and Transport Operations [PDF, 696KB]
This Case Study aims to provide mining companies with examples of comprehensive analyses of diesel use in mining operations used by Fortescue Metals Group Ltd, Downer EDI Mining Pty Ltd and Leighton Contractors Pty Limited.
Industry Case Study: Iluka Resources Limited [PDF, 696KB]
This case study presents Iluka Resources Limited's successful adoption of the EMB as the core method of energy analysis in its Synthetic Rutile facility in Iluka's South West Operations, Western Australia.
Industry Case Study: Alcoa [PDF, 696KB]
The Alcoa case study outlines the systems and approaches that Alcoa has developed over the last 20 years to improve energy efficiency. It demonstrates how these systems operate at Alcoa's Pinjarra refinery and the outcomes and benefits delivered to date.
Industry Case Study: Bunker Freight Lines [PDF, 612KB]
Bunker Freight Lines' involvement in the EEO program has helped the company take energy management to a new level. This case study in the transport sector explores how an energy efficiency assessment resulted in the identification of 32 energy efficiency opportunities with potential to reduce fuel consumption by at least 12% and greenhouse gas emissions by at least 13%.
Bunker Freight Lines, the largest sub-contract trucking company in Australia, conducted a trial assessment of its prime movers as part of a trial of the EEO program in 2006. This case study demonstrates that companies with excellent systems in place can still find opportunities to further improve their energy use and efficiency due to the rigorous nature of the EEO assessment framework. It also highlights the value of using external expertise to challenge the status quo and encourage organisational change.
Industry Case Study: Incitec Pivot [PDF, 666KB]
The Incitec Pivot plant at Gibson Island in Queensland uses about 13 PJs of energy annually in the manufacture of nitrogen-based fertilisers. This case study looks at the assessment approach adopted by a company which regarded the EEO program requirements as an opportunity to go beyond a compliance-level approach, and fully resource the assessment to deliver productivity benefits over and above energy savings. This case study outlines the merits of accurate data collection and the benefits of undertaking an Energy Mass Balance to quantify energy consumption by individual process. It also describes three projects estimated to save 150,000 GJs of energy annually.
Industry Case Study: Midland Brick [PDF, 471KB]
Industry Case Study: Midland Brick update[PDF, 666KB]
For Midland Brick in Perth, energy represents some 40% of total production costs. The company has a clear incentive to reduce energy consumption wherever possible. Midland Brick participated in an EEO Trial Assessment in 2006 and learned that a fresh approach using EEO guidelines could deliver further energy savings even in areas that had previously been identified and considered. The Case Study outlines the Trial Assessment and the update looks at some of the lessons learned particularly related to accurate data collection and adequate resourcing.
Industry Case Study: Nyrstar [PDF, 666KB]
The Nyrstar Port Pirie smelter is more than 100 years old. Its smelting and ore refinery operations are energy intensive and complex. Due to the age of the site, there was very limited measurement and monitoring of energy use. Nyrstar recognised that real benefits would accrue from its EEO assessment only if the company tackled inherent complexity; and challenged old assumptions and practices. Nyrstar undertook a series of Energy Mass Balances across the plant and used Sankey diagrams to illustrate energy inputs, outputs and potential savings. Financial savings related to opportunity implementation are estimated to be in the order of $5.5 million annually.
Industry Case Study: OneSteel [PDF, 445KB]
This case study examines how OneSteel is embedding energy efficiency into its core business processes. It describes OneSteel's approach to energy efficiency and the new systems and tools that were developed for the Sydney Steel Mills group and are now being rolled out across OneSteel. As a result, Onesteel are expected to achieve an annual energy saving of over 6% of total energy use through adopted savings opportunities identified by its assessments for the EEO program.
Industry Case Study: Orica [PDF, 406KB]
Orica conducted a successful trial assessment for the EEO program at its Mining Services site in Newcastle, NSW, allowing it to meet State and Australian Government requirements and maximise business benefits at one time. Orica has a history of setting and achieving challenging energy efficiency targets. With this background, and as a large user of energy, Orica saw that conducting a trial assessment for the Energy Efficiency Opportunities program would allow it to meet State and Australian Government requirements and maximise business benefits at the one time.
This case study follows the assessment and shows how the company identified over 70 potential energy efficiency opportunities. The direct financial savings of just 13 of these projects is likely to be well in excess of $1,000,000 per year.<
Industry Case Study: Thiess' Australian Mining Business Unit [PDF, 666KB]]
Thiess' Australian Mining Business Unit provides contracted earth moving equipment and services to some of Australia's largest mining operations. The company developed a representative assessment approach for specific classes of machinery and discovered four areas for significant energy savings. As a contractor, Thiess has few opportunities to cut costs. Energy (fuel) savings are therefore one area central to maintaining a competitive edge. The case study describes how the EEO program has assisted Thiess to find fuel savings worth approximately $3.7 million.
Industry Case Study: Xstrata Coal [PDF, 452KB]
Xstrata Coal New South Wales maximised the business benefits of its EEO assessment by going well beyond a compliance approach, and achieved improvements in energy efficiency by promoting cultural change in the way energy was managed.
Xstrata Coal New South Wales maximised the business benefits of its assessment for the EEO program by going well beyond a compliance approach, and achieved improvements in energy efficiency by promoting cultural change in the way energy was managed. As a result, the company designed a flexible energy assessment process that would meet Federal and State legislative requirements and optimise business outcomes.
Xstrata Coal conducted assessments at eight mines in NSW over a 12 month period. This case study describes how the company conducted the assessments and identified 47 cost-effective projects to reduce energy use.
Industry Case Study: Xstrata Copper [PDF, 383KB]
Xstrata Copper's refinery in Townsville conducted a trial assessment over a period of six months for the EEO program. Savings captured far outweighed the cost of the trial, and additional savings will be achieved over time. This case study highlights the importance of developing an energy mass balance so that energy flows through processes can be understood and optimised. It also demonstrates the value of using expertise from outside the site to apply 'fresh eyes' to the search for energy efficiency.
Industry Case Examples from trial corporations [PDF, 571KB]
These industry case examples illustrate how some of the trial corporations are meeting the intent and key requirements of the EEO Assessment Framework.
The examples aim to demonstrate:
- what a key requirement or intent looks like in practice
- that different approaches to assessments can be undertaken
- that existing systems and processes can be utilised and built upon
- some of the early benefits coming out of energy efficiency opportunities assessments.
It is important to remember when reading these examples that most companies are in the early stages of the assessment and identification process.
If you are having trouble viewing links or finding information on the Energy Efficiency Opportunities program, phone the EEO Hotline on 1300 799 186.