ADF Saves LKAB 4% Energy and Increases Output by 8.5%

Uptime and cost efficiency are important profit drivers in process applications such as the mining industry. LKAB managed to increase production capacity by 8.5% and at the same time save 4% energy in a concentrating application by installing ADF. An additional profitable benefit is the reduced occurrences of production disturbances.

 

lkab_case1 "The performance of ADF allows us to reduce our energy costs and simultaneously increase process output"

- Anders Lundkvist,
Energy & Environment Manager

Background

LKAB is one of the world's leading suppliers of refined iron ore products and industrial minerals to the steel industry. LKAB continuously strives to make the energy intensive mining and refining process as cost efficient as possible. Saving energy is also an important part of LKAB's environmental policy. Accordingly, new technologies and products are evaluated with respect to their energy performance.

Challenge

In its concentrating plant in Kiruna in northern Sweden, LKAB processes ore by grinding it in rotating mills. This process features several large motor drives and other loads which cause severe harmonics and reactive power. Suppressing these to reduce the number of production stops and power consumption were the object of interest.

The milling process gives rise to a fine metal powder that can cause flashovers if it enters the energy optimizing equipment. This harsh air condition disqualifies air cooling and brings about the need for an alternative cooling method.

Solution

To compensate for unnecessary electrical losses in the rotating mill process, a 500kVA ADF system from Comsys was installed. The system was commissioned to manage reactive power and eliminate damaging harmonics. Other distinguishing characteristics that were important for LKAB when choosing ADF include:

  • Water cooling allows Comsys ADF to operate in harsh conditions
  • Lower maintenance costs
  • Prolonged equipment lifetime
  • More robust transmission network

Result

The installation of Comsys ADF reduced system energy consumption by 4% and allowed LKAB to increase production output by 8.5%. Yet another important benefit is the reduced number of production disturbances from power quality issues. This increased uptime is important to LKAB, as it is to anyone in a process-based industry.

After realizing the success of their first Comsys ADF installation, LKAB is examining how this technology can be applied to increase production capacity, save energy and increase uptime in other areas of their operations.

 

Key benefits | AC drive:

  • Energy savings: 4%
  • Production capacity increase: 8.5%
  • Reduction in production interruptions; increased uptime

LKAB_case1_graph