Doing the right thing in quarries

Drives and monitoring software support sustainable practices...

“Efficiency is doing things right,” said the American businessman Peter Drucker, “effectiveness is doing the right things.” However, UK Government figures suggest the quarrying industry still has some way to go until it is doing the right thing by the environment. The country’s mining and quarrying industry produced 17.2 million metric tonnes of greenhouse gas (GHG) emissions in 2022. Here, David Strain from Technidrive, an expert in integrated automation systems, explains how quarries can achieve both energy efficiency and operational effectiveness by integrating variable speed drives (VSDs) and advanced monitoring software.

For quarry operators, prioritising energy-efficient practices not only supports environmental goals but also enhances operational sustainability amid growing regulation and pressuring statistics, such as those published by the UK Government. However, achieving energy efficiency in quarrying is easier said than done, as the industry is characterised by harsh environments and specific operational demands.

Let’s look at sand pumps as an example. Sand pumps are specialised equipment used in quarry applications for handling sand and similar materials. The pumps are crucial for various operations within quarries, including transporting sand from extraction points to processing areas, such as wash plants or separators. Their effective management is key to minimising operational costs, enhancing sustainability, and ensuring continuous production in quarry environments.

Sand pumps

Traditionally, sand pumps operate at full speed using methods like Direct Online (DOL) starting. DOL connects the motor directly to full voltage at startup, causing a high inrush current and potential voltage dips.

It is a straightforward and economical method but places significant stress on equipment such as couplings, belts, motor bearings and windings due to the abrupt demands during start-up and the continuous operation at full speed. Once operational, these pumps are often regulated using valves to control flow rates — but doing this manually can lead to inefficiencies in energy consumption.

Solutions such as variable speed drives (VSDs), are increasingly adopted to optimise the performance of sand pumps in quarries. VSDs control the speed of electric motors by adjusting the frequency and voltage of alternating current (AC) power supplied to the motor.

Technidrive recommends integrating VSDs into the pump system to optimise energy usage. VSDs allow pumps to operate at variable speeds, adjusting dynamically to the required flow rates. This not only enhances energy efficiency but also reduces wear and tear on mechanical components, thereby improving overall reliability and extending equipment lifespan.

Need for speed

Traditionally, these pumps operate at full speed, leading to increased wear and energy inefficiencies. These issues were experienced by one Technidrive customer, a large quarry operator, which was experiencing significant energy consumption challenges with its sand pumps. The pumps were operated at maximum speed, controlled manually through valve adjustments, leading to high energy waste and wear on equipment.

Equipped with VSDs, the speed of the pumps is adjusted based on demand, resulting in substantial energy savings. The VSDs also provide smoother operation, reducing strain on mechanical components and extending equipment lifespan.

VSDs also combine with significant advancements in motor technology, including high-efficiency motors meeting IE3 and IE4 standards, underscoring Technidrive's commitment to sustainability. These motors minimise energy losses and comply with stringent ecodesign regulations, contributing to reduced CO2 emissions and improved overall equipment effectiveness.

Advanced monitoring

Additionally, the large quarry operator uses WEG's Pump Genius software, which enhanced operational efficiency further. The software's advanced features allowed for intelligent monitoring and control of the pumps, automatically adjusting parameters based on real-time conditions. This integration not only improved energy efficiency but also streamlined maintenance efforts, minimising downtime and enhancing overall productivity.

By leveraging innovative technologies like VSDs and advanced monitoring software, Technidrive not only addresses immediate energy challenges but supports sustainable practices and operational excellence in quarry operations.

Going forward, Technidrive continues to innovate and expand its impact across the quarrying sector. It collaborates closely with industry partners and regulatory bodies to shape sustainable mining practices.

By advocating for the adoption of high-efficiency motor standards and supporting initiatives that promote energy conservation and emissions reduction, Technidrive contributes to a greener future for the quarrying industry — to help ensure that “efficiency is doing things right.”