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Energy Efficiency Opportunities Presentation September 2011

Energy Efficiency Opportunities Presentation September 2011. Bruce Philpott Energy Champion Simcoa Operations Pty Ltd. Presentation Overview. Background on Simcoa Silicon production process Simcoa’s energy profile EEO Opportunities – 2 examples Evaluation of the EEO process.

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Energy Efficiency Opportunities Presentation September 2011

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  1. Energy Efficiency Opportunities PresentationSeptember 2011 Bruce Philpott Energy Champion Simcoa Operations Pty Ltd

  2. Presentation Overview • Background on Simcoa • Silicon production process • Simcoa’s energy profile • EEO Opportunities – 2 examples • Evaluation of the EEO process

  3. Simcoa Operations Pty Ltd

  4. Silicon Production

  5. Simcoa Operations Pty Ltd • Simcoa is a fully integrated silicon smelting operation located in the Kemerton Industrial Park • Australia’s only silicon producer • The site consists of a sawmill, two charcoal retorts, two 27MVA submerged arc furnaces, a filter house , a product handling plant and baghouse as well as site services, laboratory, administration and maintenance areas.

  6. Kemerton Silicon Smelter

  7. The Silicon Industry • Silicon is used in both chemical and metallurgical processes, ultimately producing a range of high-tech products • The majority of the world’s silicon is produced in China, Europe and South America.

  8. The Silicon Industry • Silicon is produced by the reduction of quartz at 3000 - 4000°C using a carbon reductant • SiO2 + C → Si + CO2 • Particularly carbon and energy intensive • International benchmark in process efficiency

  9. Silicon Products • PV Solar Cells • Silicone rubber • Synthetic oil • Optical fibre • High strength aluminum alloys • Silicon chips • Synthetic quartz

  10. Energy Profile • Total energy use at the Kemerton site is approximately 1.5 PJ per year. • The submerged arc furnaces use about 90% of the site’s electrical power with a load of 41 MW • The process is highly endothermic requiring approx 11 MWh/tonne of silicon • The furnaces are currently operating at worlds best practice levels in terms of electrical efficiencies, so opportunities for improvement are limited.

  11. Energy Efficiency Initiatives • Considerable scope for projects that can capture and use waste heat from the smelting process or minimize furnace downtime. • Projects that recover energy (waste heat) are normally only feasible if considered at the design stage.

  12. Energy Savings through EEO • Assessment identified 10 opportunities with a total energy saving of 41,000 GJ • 4 of these opportunities have been implemented, 4 are to be implemented, 1 is under investigation and 1 not to be implemented.

  13. Example Opportunity Replacement of steel contact pads with copper pads Energy saving calculated as ~10,000 GJ.

  14. Example Opportunity Optimize use of ladle pre-heater Natural Gas Historically spare ladles heated under gas fueled pre-heaters so that they could be immediately called into service – with better planning they can be maintained at a lower temperature, which is increased before use Energy saving calculated as ~8,400 GJ.

  15. Examination of the EEO process • Being one of the first participants it was difficult to estimate resources needed – in hindsight probably under-resourced • Identified savings that did not require significant expenditure (for example ladle preheating) • Use of energy bandwidths, while sometimes necessary, can be confusing

  16. Lack of continuity of staff makes reporting difficult • Second cycle will provide an opportunity to apply the knowledge and skills learnt from networking, workshops etc • Short payback period does not make opportunities a sure thing i.e. other variables such as technical risk, cash flow, other strategic priorities etc will influence decision making

  17. For new plant – EEO evaluation at design phase would be helpful – for example new silicon furnace is designed for future energy recovery

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