| Part 1 - Corporation Details |
| Controlling Corporation |
| Sun Metals Corporation Pty Ltd |
From |
1 July 2006 |
To |
30 June 2011 |
| |
| Table 1.1 - Major Changes to Corporate Group Structure or Operations |
| Table 1.1 - Major Changes to Corporate Group Structure or Operations |
|
In September 2010 Sun Metals Zinc Refinery modified the zinc leaching process. This involved significant changes in the Leaching &
Purification area, and changes to the distribution and consumption of steam in the first two stages of the refining process. These modifications were made to improve cost efficiency.
|
|
| |
| Table 1.2 - Aggregate energy assessed covered in this report |
| Total energy use covered by all assessments in this report |
4,716,555 GJ |
| Total energy assessed as percentage of total energy use of the corporate group |
100 % |
|
| |
| Declaration |
| Declaration of accuracy and compliance |
The information included in this report has been reviewed and noted
by the board of directors and is to the best of my knowledge, correct and in accordance with the Energy Efficiency Opportunities Act 2006 and Energy Efficiency
Opportunities Regulations 2006.
|
 |
Young Min Park, CEO |
| Date 29 Dec. 2011 |
|
| |
| |
| Part 2 - Assessment Outcomes |
| Table 2.1 - Assessment Details |
| It is compulsory to complete a separate table for each group member, business unit, or key activity that has been assessed |
|
| Name of group member or business unit or key activity |
Sun Metals Corporation |
|
| |
| Total energy use in the last financial year |
4,716,555 GJ |
| Energy use assessed in this entity as a percentage of total entity energy use |
100 % |
| Energy use assessed in this entity as a percentage of total corporate energy use |
100 % |
| Accuracy of above estimates related to energy use assessed |
¡¾5 % |
|
| |
| Period over which assessment was undertaken |
From |
01/05/2008 |
To |
30/11/2008 |
| Description of the way in which the entity carried out its assessment |
|
Since conducting detailed assessments in 2008 as part of the ¡®Energy Efficiency Opportunities¡¯ program, the process of evaluation of
opportunities, as identified and prioritised, has continued. Energy Efficiency Projects have been implemented where the business case demonstrated a clear and sustainable benefit to the business.
The identification, assessment and of implementation of energy efficiency projects involved staff from all levels within the organisation
and external consultants.
Energy assessment and improvement has become part of Sun Metals¡¯ operation, being included in our HSEQ policy, operational plans
and area budgets. Sun Metals has made available all process area superintendants, process coordinators, and team leaders with assistance from the Technical Services department to conduct EEO surveys and projects.
External consultants have also been brought in to assist with surveys and projects.
Sun Metals has experienced a challenging recent few years due to the global financial crisis. As a result the company undertook a program of cost reductions,
meaning that both capital investment and operating expenditure has been limited to that necessary to sustain the operation. Operating in an energy efficient manner and seeking to implement energy efficiency projects is
viewed as smart business at Sun Metals, especially during a period of economic uncertainty.
|
|
| |
| Table 2.2 - Energy efficiency opportunities identified in the assessment |
| Table 2.2A - New Opportunities assessed to an accuracy of better than (≤) ¡¾30% |
| ≤ ¡¾30% |
Number of opportunities |
Estimated energy savings per annum by payback period (GJ) |
Total estimated energy savings per annum (GJ) |
| Status of opportunities identified |
0 - < 2 years |
2 - ≤ 4 years |
> 4 years |
| No of Opps |
GJ |
No of Opps |
GJ |
No of Opps |
GJ |
| Business Response |
Further Investigation Required |
8 |
3 |
909 |
4 |
87,494 |
1 |
394 |
88,797 |
| To be Implemented |
2 |
0 |
0 |
1 |
204,156 |
1 |
34 |
204,190 |
| Implemented |
12 |
10 |
94,443 |
1 |
1,521 |
1 |
1,070 |
97,034 |
| Not to be Implemented |
7 |
0 |
0 |
0 |
0 |
7 |
3,116 |
3,116 |
| Outcomes of assessment |
Total Identified |
29 |
13 |
95,352 |
6 |
293,171 |
10 |
4,614 |
393,137 |
|
| |
| Table 2.2B - New Opportunities assessed to an accuracy of worse than (>) ¡¾30% |
| > ¡¾30% |
Number of opportunities |
Estimated energy savings per annum by payback period (GJ) |
Total estimated energy savings per annum (GJ) |
| Status of opportunities identified |
0 - < 2 years |
2 - ≤ 4 years |
> 4 years |
| No of Opps |
GJ |
No of Opps |
GJ |
No of Opps |
GJ |
| Business Response |
Further Investigation Required |
39 |
7 |
16,482 |
1 |
3,600 |
1 |
22 |
20,104 |
| To be Implemented |
4 |
4 |
1,699 |
0 |
0 |
0 |
0 |
1,699 |
| Implemented |
8 |
5 |
5,011 |
0 |
0 |
2 |
87 |
5,098 |
| Not to be Implemented |
3 |
0 |
0 |
0 |
0 |
1 |
101 |
101 |
| Outcomes of assessment |
Total Identified |
54 |
16 |
23,192 |
1 |
3,600 |
4 |
210 |
27,002 |
|
| |
| Table 2.3 - Details of significant opportunities identified in the assessment |
| Corporate Groups are required to provide at least 3 examples of significant opportunities for improving the energy efficiency of the group
that have been identified in assessments. |
|
| Description of Opportunity |
Voluntary Information |
|
Excess Steam Utilized for Electricity Generation
In the process of ¡®roasting¡¯ zinc concentrates, steam is generated as a by-product from waste heat boilers that cool the off gas stream,
and cooling coils that run through the bed of the roasters and help to maintain the roaster temperature. This steam is 'clean energy' generated with virtually no greenhouse gas emission.
The steam generated has been used for heating in other areas of the process. However due to some process changes at the end of 2010,
there is now a significant amount of excess steam that can be utilized for electricity generation using a steam turbine. The electricity generated will account for about 7% of Sun Metals Corporations total electricity consumption.
This project has been approved for implementation. Construction commenced in November 2011 and is expected to be complete for commissioning and operation from September 2012.
|
Business Response |
To be implemented |
| Energy saved (GJ) |
204,000 |
| Greenhouse gas abated (CO2-e) |
55,800 tonnes |
| $s saved |
$ 2.8 million per year |
| Payback period |
3.4 years |
|
| |
| Description of Opportunity |
Voluntary Information |
|
Improved Electrolyte Solution Quality
Zinc concentrates contain small amounts of magnesium, typically 0.3%. As there is insufficient natural bleed in the electrolytic process,
accumulation occurs in process liquors. Increased levels of magnesium in electrolyte result in unfavorable energy consumption in the electrolysis process
2 projects have been implemented in 2011 to remove magnesium from the zinc circuit.
One of these projects involves treatment of a portion of the in-process solution.
By treating the solution magnesium can be separated from zinc by precipitation. Once this separation is complete the zinc is then returned to the process circuit.
There are additional benefits with this project, including other solutions that can be treated in the same manner to increase zinc recovery.
|
Business Response |
Implemented |
| Energy saved (GJ) |
35,424 |
| Greenhouse gas abated (CO2-e) |
10,037 tonnes |
| $s saved |
$ 2.6 million per year |
| Payback period |
0.2 years |
|
| |
| Description of Opportunity |
Voluntary Information |
|
Improved Temperature Control of Zinc Casting Moulds
LPG burners are used in the Casting Plant to preheat moulds prior to casting zinc ingots.
It is important to maintain the moulds at a high temperature to avoid thermal shock and ensure safe and controlled conditions for casting of the final zinc ingot product.
However if the burners are not set correctly it can result in unfavourable LPG consumption.
A temperature sensor has been installed to monitor the mould temperature. Currently the burner adjustment is manual.
It is proposed to automate the burner adjustment by interlocking it with the temperature sensor.
This project is currently under investigation.
|
Business Response |
Under Investigation |
|
| |
| |
| DETAIL OF ENERGY ASSESSMENTS CONDUCTED BY AREA |
| |
| Part 3 - Energy Efficiency Opportunities that have been identified and evaluated |
| Part 3A - Update of assessments in previous Public Report |
| |
| ROASTING & SULPHURIC ACID PLANT |
| |
| Table 3.1 - Assessment Details |
|
| Name of group member or business unit or key activity |
Roasting & Sulphuric Acid Plant |
|
| |
| Total energy use in the last financial year |
1,272,672 GJ |
| Energy use assessed in this entity as a percentage of total entity energy use |
27.0 % |
| Energy use assessed in this entity as a percentage of total corporate energy use |
100 % |
|
| |
| Period over which assessment was undertaken |
From |
01/05/2008 |
To |
30/11/2008 |
|
| Description of the way in which the entity carried out its assessment |
|
EEO assessments were conducted site-wide at Sun Metals Zinc refinery in 2008.
The Roasting & Sulphuric Acid Plant is the first process area of the Sun Metals Zinc Refinery.
Detailed energy efficiency assessments were conducted in 2008 in line with assessments being conducted in other process areas of the refinery. (as outlined in table 2.1)
Roasting & sulphuric acid plant process area superintendant, process coordinator,
and team leaders have been involved with reviewing energy use, identifying energy efficiency opportunities and assisting the Technical Services department in conducting EEO surveys and projects.
External consultants have also been brought in to assist with surveys and projects.
The Roasting & Sulphuric Acid Plant will continue to evaluate and implement energy efficiency opportunities that are beneficial to the business.
|
|
| |
| Table 3.1A - Opportunities assessed to an accuracy of better than (<) ¡¾30% |
| ≤ ¡¾30% |
Number of opportunities |
Estimated energy savings per annum by payback period (GJ) |
Total estimated energy savings per annum (GJ) |
| Status of opportunities identified |
0 - < 2 years |
2 - ≤ 4 years |
> 4 years |
| No of Opps |
GJ |
No of Opps |
GJ |
No of Opps |
GJ |
| Business Response |
Further Investigation Required |
3 |
1 |
68 |
1 |
11,983 |
1 |
394 |
12,445 |
| To be Implemented |
1 |
0 |
0 |
1 |
204,156 |
0 |
0 |
204,156 |
| Implemented |
2 |
2 |
12,740 |
0 |
0 |
0 |
0 |
12,740 |
| Not to be Implemented |
4 |
0 |
0 |
0 |
0 |
4 |
2,403 |
2,403 |
| Outcomes of assessment |
Total Identified |
10 |
3 |
12,808 |
2 |
216,139 |
5 |
2,797 |
231,744 |
|
| |
| Table 3.1B - Opportunities assessed to an accuracy of worse than (>) ¡¾30% |
| > ¡¾30% |
Number of opportunities |
Estimated energy savings per annum by payback period (GJ) |
Total estimated energy savings per annum (GJ) |
| Status of opportunities identified |
0 - < 2 years |
2 - ≤ 4 years |
> 4 years |
| No of Opps |
GJ |
No of Opps |
GJ |
No of Opps |
GJ |
| Business Response |
Further Investigation Required |
10 |
3 |
8,119 |
0 |
0 |
1 |
22 |
8,141 |
| To be Implemented |
0 |
0 |
0 |
0 |
0 |
0 |
0 |
0 |
| Implemented |
3 |
2 |
1,384 |
0 |
0 |
1 |
74 |
1,458 |
| Not to be Implemented |
1 |
0 |
0 |
0 |
0 |
0 |
0 |
0 |
| Outcomes of assessment |
Total Identified |
14 |
5 |
9,503 |
0 |
0 |
2 |
96 |
9,599 |
|
| |
| |
| LEACHING AND PURIFICATION PLANT |
| |
| Table 3.2 - Assessment Details |
|
| Name of group member or business unit or key activity |
Leaching & Purification Plant |
|
| |
| Total energy use in the last financial year |
579,337 GJ |
| Energy use assessed in this entity as a percentage of total entity energy use |
12.3 % |
| Energy use assessed in this entity as a percentage of total corporate energy use |
100 % |
|
| |
| Period over which assessment was undertaken |
From |
01/05/2008 |
To |
30/11/2008 |
|
| Description of the way in which the entity carried out its assessment |
|
EEO assessments were conducted site-wide at Sun Metals Zinc refinery in 2008.
The Leaching & Purification Plant is the second process area of the Sun Metals Zinc Refinery.
Detailed energy efficiency assessments were conducted in 2008 in line with assessments being conducted in other process areas of the refinery. (as outlined in table 2.1)
Leaching & Purification plant process area superintendant, process coordinator,
and team leaders have been involved with reviewing energy use, identifying energy efficiency opportunities and assisting the Technical Services department in conducting EEO surveys and projects.
External consultants have also been brought in to assist with surveys and projects.
The Leaching & Purification Plant will continue to evaluate and implement energy efficiency opportunities that are beneficial to the business.
|
|
| |
| Table 3.2A - Opportunities assessed to an accuracy of better than (<) ¡¾30% |
| ≤ ¡¾30% |
Number of opportunities |
Estimated energy savings per annum by payback period (GJ) |
Total estimated energy savings per annum (GJ) |
| Status of opportunities identified |
0 - < 2 years |
2 - ≤ 4 years |
> 4 years |
| No of Opps |
GJ |
No of Opps |
GJ |
No of Opps |
GJ |
| Business Response |
Further Investigation Required |
2 |
0 |
0 |
2 |
3,475 |
0 |
0 |
3,475 |
| To be Implemented |
1 |
0 |
0 |
0 |
0 |
1 |
34 |
34 |
| Implemented |
2 |
2 |
1,958 |
0 |
0 |
0 |
0 |
1,958 |
| Not to be Implemented |
2 |
0 |
0 |
0 |
0 |
2 |
0 |
0 |
| Outcomes of assessment |
Total Identified |
7 |
2 |
1,958 |
2 |
3,475 |
3 |
34 |
5,467 |
|
| |
| Table 3.2B - Opportunities assessed to an accuracy of worse than (>) ¡¾30% |
| > ¡¾30% |
Number of opportunities |
Estimated energy savings per annum by payback period (GJ) |
Total estimated energy savings per annum (GJ) |
| Status of opportunities identified |
0 - < 2 years |
2 - ≤ 4 years |
> 4 years |
| No of Opps |
GJ |
No of Opps |
GJ |
No of Opps |
GJ |
| Business Response |
Further Investigation Required |
10 |
1 |
241 |
0 |
0 |
0 |
0 |
241 |
| To be Implemented |
0 |
0 |
0 |
0 |
0 |
0 |
0 |
0 |
| Implemented |
3 |
2 |
3,563 |
0 |
0 |
1 |
13 |
3,576 |
| Not to be Implemented |
0 |
0 |
0 |
0 |
0 |
0 |
0 |
0 |
| Outcomes of assessment |
Total Identified |
13 |
3 |
3,804 |
0 |
0 |
1 |
13 |
3,817 |
|
| |
| |
| ELECTROLYSIS PLANT |
| |
| Table 3.3 - Assessment Details |
|
| Name of group member or business unit or key activity |
Electrolysis Plant |
|
| |
| Total energy use in the last financial year |
2,664,731 GJ |
| Energy use assessed in this entity as a percentage of total entity energy use |
56.5 % |
| Energy use assessed in this entity as a percentage of total corporate energy use |
100 % |
|
| |
| Period over which assessment was undertaken |
From |
01/05/2008 |
To |
30/11/2008 |
|
| Description of the way in which the entity carried out its assessment |
|
EEO assessments were conducted site-wide at Sun Metals Zinc refinery in 2008.
The Electrolysis Plant is the third process area of the Sun Metals Zinc Refinery.
Detailed energy efficiency assessments were conducted in 2008 in line with assessments being conducted in other process areas of the refinery. (as outlined in table 2.1)
Electrolysis plant process area superintendant, process coordinator,
and team leaders have been involved with reviewing energy use, identifying energy efficiency opportunities and assisting the Technical Services department in conducting EEO surveys and projects.
External consultants have also been brought in to assist with surveys and projects.
The Electrolysis Plant will continue to evaluate and implement energy efficiency opportunities that are beneficial to the business.
|
|
| |
| Table 3.3A - Opportunities assessed to an accuracy of better than (<) ¡¾30% |
| ≤ ¡¾30% |
Number of opportunities1 |
Estimated energy savings per annum by payback period (GJ) |
Total estimated energy savings per annum (GJ)2 |
| Status of opportunities identified |
0 - < 2 years |
2 - ≤ 4 years |
> 4 years |
| No of Opps |
GJ |
No of Opps |
GJ |
No of Opps |
GJ |
| Business Response |
Further Investigation Required |
1 |
0 |
0 |
1 |
72,036 |
0 |
0 |
72,036 |
| To be Implemented |
0 |
0 |
0 |
0 |
0 |
0 |
0 |
0 |
| Implemented |
2 |
2 |
77,465 |
1 |
0 |
0 |
0 |
77,465 |
| Not to be Implemented |
0 |
0 |
0 |
0 |
0 |
0 |
0 |
0 |
| Outcomes of assessment |
Total Identified |
3 |
2 |
77,465 |
1 |
72,036 |
0 |
0 |
149,501 |
|
| |
| Table 3.3B - Opportunities assessed to an accuracy of worse than (>) ¡¾30% |
| > ¡¾30% |
Number of opportunities1 |
Estimated energy savings per annum by payback period (GJ) |
Total estimated energy savings per annum (GJ)2 |
| Status of opportunities identified |
0 - < 2 years |
2 - ≤ 4 years |
> 4 years |
| No of Opps |
GJ |
No of Opps |
GJ |
No of Opps |
GJ |
| Business Response |
Further Investigation Required |
7 |
1 |
3,780 |
1 |
3,600 |
0 |
0 |
7,380 |
| To be Implemented |
0 |
0 |
0 |
0 |
0 |
0 |
0 |
0 |
| Implemented |
0 |
0 |
0 |
0 |
0 |
0 |
0 |
0 |
| Not to be Implemented |
0 |
0 |
0 |
0 |
0 |
0 |
0 |
0 |
| Outcomes of assessment |
Total Identified |
7 |
1 |
3,780 |
1 |
3,600 |
0 |
0 |
7,380 |
|
| |
| |
| CASTING PLANT |
| |
| Table 3.4 - Assessment Details |
|
| Name of group member or business unit or key activity |
Casting Plant |
|
| |
| Total energy use in the last financial year |
184,710 GJ |
| Energy use assessed in this entity as a percentage of total entity energy use |
3.9 % |
| Energy use assessed in this entity as a percentage of total corporate energy use |
100 % |
|
| |
| Period over which assessment was undertaken |
From |
01/05/2008 |
To |
30/11/2008 |
|
| Description of the way in which the entity carried out its assessment |
|
EEO assessments were conducted site-wide at Sun Metals Zinc refinery in 2008.
The Casting Plant is the fouth process area of the Sun Metals Zinc Refinery.
Detailed energy efficiency assessments were conducted in 2008 in line with assessments being conducted in other process areas of the refinery. (as outlined in table 2.1)
Casting plant process area superintendant, process coordinator,
and team leaders have been involved with reviewing energy use, identifying energy efficiency opportunities and assisting the Technical Services department in conducting EEO surveys and projects.
External consultants have also been brought in to assist with surveys and projects.
The Casting Plant will continue to evaluate and implement energy efficiency opportunities that are beneficial to the business.
|
|
| |
| Table 3.4A - Opportunities assessed to an accuracy of better than (<) ¡¾30% |
| ≤ ¡¾30% |
Number of opportunities1 |
Estimated energy savings per annum by payback period (GJ) |
Total estimated energy savings per annum (GJ)2 |
| Status of opportunities identified |
0 - < 2 years |
2 - ≤ 4 years |
> 4 years |
| No of Opps |
GJ |
No of Opps |
GJ |
No of Opps |
GJ |
| Business Response |
Further Investigation Required |
2 |
2 |
841 |
0 |
0 |
0 |
0 |
841 |
| To be Implemented |
0 |
0 |
0 |
0 |
0 |
0 |
0 |
0 |
| Implemented |
3 |
3 |
2,215 |
0 |
0 |
0 |
0 |
2,215 |
| Not to be Implemented |
1 |
0 |
0 |
0 |
0 |
1 |
713 |
713 |
| Outcomes of assessment |
Total Identified |
6 |
5 |
3,056 |
0 |
0 |
1 |
713 |
3,769 |
|
| |
| Table 3.4B - Opportunities assessed to an accuracy of worse than (>) ¡¾30% |
| > ¡¾30% |
Number of opportunities1 |
Estimated energy savings per annum by payback period (GJ) |
Total estimated energy savings per annum (GJ)2 |
| Status of opportunities identified |
0 - < 2 years |
2 - ≤ 4 years |
> 4 years |
| No of Opps |
GJ |
No of Opps |
GJ |
No of Opps |
GJ |
| Business Response |
Further Investigation Required |
10 |
2 |
4,342 |
0 |
0 |
0 |
0 |
4,342 |
| To be Implemented |
3 |
3 |
763 |
0 |
0 |
0 |
0 |
763 |
| Implemented |
2 |
1 |
64 |
0 |
0 |
0 |
0 |
64 |
| Not to be Implemented |
0 |
0 |
0 |
0 |
0 |
0 |
0 |
0 |
| Outcomes of assessment |
Total Identified |
15 |
6 |
5,169 |
0 |
0 |
0 |
0 |
5,169 |
|
| |
| |
| OTHER SERVICES |
| |
| Table 3.5 - Assessment Details |
|
| Name of group member or business unit or key activity |
Other Services |
|
| |
| Total energy use in the last financial year |
15,105 GJ |
| Energy use assessed in this entity as a percentage of total entity energy use |
0.3 % |
| Energy use assessed in this entity as a percentage of total corporate energy use |
100 % |
|
| |
| Period over which assessment was undertaken |
From |
01/05/2008 |
To |
30/11/2008 |
|
| Description of the way in which the entity carried out its assessment |
|
EEO assessments were conducted site-wide at Sun Metals Zinc refinery in 2008.
Other Services at Sun Metals Zinc Refinery, includes process support areas such as Administration and Maintenance.
Detailed energy efficiency assessments were conducted in 2008 in line with assessments being conducted in the process areas of the refinery. (as outlined in table 2.1)
The site electrical engineer, and several mechanical and electrical maintenance personnel have been involved with reviewing energy use,
identifying energy efficiency opportunities and assisting the Technical Services department in conducting EEO surveys and projects.
External consultants have also been brought in to assist with surveys and projects.
There will be a continued focus to evaluate and implement energy efficiency opportunities that are beneficial to the business in 2012.
|
|
| |
| Table 3.5 - Opportunities assessed to an accuracy of better than (<) ¡¾30% |
| ≤ ¡¾30% |
Number of opportunities1 |
Estimated energy savings per annum by payback period (GJ) |
Total estimated energy savings per annum (GJ) |
| Status of opportunities identified |
0 - < 2 years |
2 - ≤ 4 years |
> 4 years |
| No of Opps |
GJ |
No of Opps |
GJ |
No of Opps |
GJ |
| Business Response |
Further Investigation Required |
0 |
0 |
0 |
0 |
0 |
0 |
0 |
0 |
| To be Implemented |
0 |
0 |
0 |
0 |
0 |
0 |
0 |
0 |
| Implemented |
3 |
1 |
65 |
1 |
1,521 |
1 |
1,070 |
2,656 |
| Not to be Implemented |
0 |
0 |
0 |
0 |
0 |
0 |
0 |
0 |
| Outcomes of assessment |
Total Identified |
3 |
1 |
65 |
1 |
1,521 |
1 |
1,070 |
2,656 |
|
| |
| Table 3.5B - Opportunities assessed to an accuracy of worse than (>) ¡¾30% |
| > ¡¾30% |
Number of opportunities1 |
Estimated energy savings per annum by payback period (GJ) |
Total estimated energy savings per annum (GJ)2 |
| Status of opportunities identified |
0 - < 2 years |
2 - ≤ 4 years |
> 4 years |
| No of Opps |
GJ |
No of Opps |
GJ |
No of Opps |
GJ |
| Business Response |
Further Investigation Required |
2 |
0 |
0 |
0 |
0 |
0 |
0 |
0 |
| To be Implemented |
1 |
1 |
936 |
0 |
0 |
0 |
0 |
936 |
| Implemented |
0 |
0 |
0 |
0 |
0 |
0 |
0 |
0 |
| Not to be Implemented |
2 |
0 |
0 |
0 |
0 |
1 |
101 |
101 |
| Outcomes of assessment |
Total Identified |
5 |
1 |
936 |
0 |
0 |
1 |
101 |
1,037 |
|
| |
| |
 |
| |
