Asarco’s Hayden and Ray facilities (each at 35 MW) are actively involved in developing ways to produce energy-intensive copper at a reduced rate. The Hayden facility operates using a concentrator and copper smelter, an oxygen flash furnace, anode casting, oxygen plant, acid plant, and support facilities. The Ray facility operates using an open-pit mine that includes a concentrator, solvent extraction electro-wining operation, and associated support facilities.
To achieve a significant amount of reduction in the energy budget, Lincus was brought on board to analyze the sites’ energy-consumption and identify cost savings opportunities that could be achieved at both the ASARCO Hayden and Ray Mine facilities.
Lincus’ team of skilled engineers set the bar high to design an integrated online tool that would provide beneficial reductions in three specific areas for electric, gas, water, and demand-response audit customers:1) Reduce auditing time from three weeks to a single day. 2) Reduce processing time from 10 weeks to two weeks. 3) Reduce costs up to 75%! A uniform software solution was created called the Commercial Energy Audit Tool (CEAT) that addressed all three areas and significantly improved the overall quality control involved in the auditing process. This paperless new system allowed for real time data gathering, targeted calculations, and accessible photos via use of hand-held devices. Reports could now be accessed on-site or through the Web, with the ability to collect multiple EEMs into a single, editable final audit report for complete review simplification.
Through use of this Web-based application that fully supports utility DSM programs through secure software for sensitive Utility and customer data, San Diego Gas and Electric was able to accurately perform and track valuable information and calculations, significantly eliminating errors in data transfer and lost files. The cost savings is anticipated to be $1 million per year (based on an average savings of $5,000 per audit spread over 200 small-to-medium commercial energy audits scheduled to be performed this year). The improved reporting template and standard calculation method offered through the CEAT allows for a reduction in time for quality control through easy automation and validation, as well as a huge reduction in the time needed to deliver the final, comprehensive report with analyses and costs that are based on the generally-accepted engineering principals, ASHRAE audit standards with interactive effects, eQuest, and DEER database. Additional benefits provided through use of the CEAT include: