CORY
POTASH CORPORATION
OF SASKATCHEWAN INC. P.O. BOX 1320, SASKATOON.
PHONE: (306) 382-0525 FAX: (306) 384-9132
SK, CANADA
S7K 3N9
March 4, 1999
Mr. Peter Cooke
Chair, Executive Board
Canadian industry Program for Energy Conservation
75 Jntemational Boulevard
Suite 400
Toronto, Ontario
M9W 6L9
Dear Mr. Cooke:
As part of our corporate undertaking to become an Industrial Energy Innovator, PCS
Potash, Cory Division is submitting its energy conservation Annual Report for 1998 and
Action Plan for 1999. These reports will indicate our energy reduction performance for
1998, and provide a brief description of significant energy conservation projects planned
for 1999.
Yours sincerely,
D. :Matthews
Chief Metallurgist
PCS Potash, Cory Division
C.C.
M. Davyduke
R. Bubnick
M. Woolley, PCS Technical Services
PCS
Potash
POTASH CORPORATION
CANADIAN
Industrial
INDUSTRY
Energy
1998 Annual
CORY
OF SASKATCHEWAN INC. P.O. BOX 1320, SASKATOON,
PHONE: (306) 382-0525 FAX: (306) 384-9132
PROGRAM
Innovators
FOR ENERGY
SK, CANADA
CONSERVATION
S7K 3N9
(CIPEC)
Program
Report
PCS Potash, Cory Division is submitting our 1998 energy use and emissions data as a
continuing step in our formalized energy efficiency target or goal-setting and review
process. The annual energy use and emission data from 199 1 up to the end of 1998 have
been included as well to indicate our division’s past performance. In addition, all projects
pertaining to energy conservation in 1998 are described briefly. Where possible, energy
savings and emissions reductions incurred by these projects are estimated.
LBac;eline Year
The baseline year selected for our division is 1991. Table 1 shows the annual electrical
and natural gas energy use data per tonne of product from the baseline year to the end of
1998. This table also shows the estimated greenhouse gas emissions for our division
during the same years. These emission estimates are based on emission factors for
combustion and process sources provided by Environment Canada. The average
concentration ratio for our process has been included in this table as well (Note:
concentration ratio = tonnes of ore / tonnes of final product).
-
Natural
Gas
m3/t
kg SOJ
product
kg NO$
tonne
product
tonne
223.5
105.1
372.2
412132
199.0
92.1
2.95
457905
188.5
1994
3.04
466242
1995
3.22
1996
Concentration
Ratio
Product
Tonnes
1991
2.95
318020
1992
2.96
1993
Year
Electrical
kWh/t
kg COJ
tonne
VOCI
product
tonne
product
.23 1
2.868
.00455
328.7
.202
2.554
.00399
92.5
321.0
.203
2.419
.00401
184.6
96.8
325.7
.212
2.369
.00419
530196
167.6
98.5
315.3
.216
- 2.151
3.22
625477
160.9
97.8
308.6
.215
2.065
.00423
1997
3.07
625498
157.1
94.5
299.6
.207
2.017
.00410
1998
3.23
676329
151.6
95.6
297.1
.209
1.946
.00414-
-
kg
1998 Enerw
Conservation
iO427
Performance
The overall energy use at PCS Potash, Gory Division in 1998 was 5.5 kWh/t lower for
electrical consumption and 1.1 m3 /t higher for natural gas. This is a 3.50% reduction in
electrical consumption and a 1.16% increase in natural gas use. The net result is a
reduction of 0.8% in greenhouse gas emissions per unit of production.
The actual performance exceeded our target of a 0.5% reduction in energy consumption
for 1998.
1998 Enerw
Conservation
Proiects
In this section, the energy conservation projects that have been undertaken at our division
in 1998 are briefly described. Where possible, estimates of the energy savings and
emissions reductions for each particular project are shown.
Two of the projects that had originally been planned for 1998 had to be delayed due to
higher priority items that came up during the year. The delayed projects were:
1) Refined Circuit Heat Exchanger
2) Slimes Thickener
Replacement
These projects were started in 1998 but will not be completed until 1999.
4
Modify
Crushing
Circuit
The mill feed crushing circuit was modified to eliminate two pumps (200 HP and
300 HP), an impactor (200 HP) and the rod mill (500 HP). This equipment was
replaced with one large crusher (500 HP). This will result in a net savings of 700
HP. In addition, the circuit changes will also improve heat recovery resulting in a
saving of 3 Giga.loules/hour.
The average natural gas savings per tonne of product amounts to 0.4 m3/tonne and
1.8 kWh/tonne. The estimated reduction in annual emissions per tonne of product
amounts to 0.011 kg SOJtonne and 1.0 kg COz/tomre for the five months that the
new circuit was in operation.
B)
Refinery
Lighting
Incandescent lighting in the refinery was replaced with higher efficiency and better
illuminating metal halide light fixtures. In 1998, 200 incandescent fixtures were
removed and replaced with 50 metal halide fixtures. The incandescent light
fixtures removed were 200 Watts and the metal halide fixtures used to replace
them were 175,250, or 400 Watts.
The amount of energy conserved in 1998 is calculated based on 200 incandescent
200 Watt fixtures being replaced with 50 metal halide 275 Watt light fixtures. The
estimated annual energy saved for 1998 per tonne of product is approximately 0.13
kWh/torme. The estimated reduction in annual emissions per tonne of product
amounts to 1.7 x 1Om3
kg SOz/tonne and 0.11 kg COJtonne.
Cl
Install
A New Boiler
A new steam boiler was installed to provide additional heating for increased
production. The new boiler is a more efficient design than the existing boilers and
will increase energy efficiency. The new boiler was just started up at the end of
the year so most of the impact of this project will be noticed in 1999.
D)
Replace 50 Ton Air Conditioning
Unit
-
The mill control room, labs, and motor control centers are cooled by a large air
conditioner. The existing unit was old and in poor condition. A new 50 ton air
conditioner was installed that is of a more efficient design and will reduce energy
consumption.
The average electrical savings per tonne of product amounts to 0.1 kWh/tomre.
The estimated reduction in annual emissions per tonne of product amounts to
0.001 kg S02/tonne and 0.6 kg C02/tomre.
El
Communications
Articles promoting energy conservation, and describing our performance in the
Industrial Energy Innovators program, were included in the newsletters sent out
from the Cory division.
Summary
This report has been submitted as a continuing part of PCS Cory Division’s goal setting
and review process. The baseline year data is used as a reference against which energy
use is measured. Further to this report, an Action Plan for 1999 outlining targets for the
year will be submitted, as well as the long and short term energy conservation measures
proposed.
POTASH CORPORATION
CANADIAN
Action
OF SASKATCHEWAN INC. P.O. BOX 1320, SASKATOON,
PHONE: (306) 382-0525 FAX: (306) 384-9132
INDUSTRY
PROGRAM
FOR ENERGY
SK, CANADA
S7K 3N9
CONSERVATION
Plan for 1999
PCS Inc., Cory Division is submitting our energy conservation Action Plan for 1999.
This report also includes our 12 month energy use reduction goals and estimates of the
energy sayings associated with the various actions that are being proposed.
..
Enerey Reduction
Goals
For the 12 month reporting period of 1999, our goal for reduction in electrical energy use
is 0.5% of 1998 electrical usage in kWh/tonne of product, and our natural gas energy
reduction goal is 0.5% of the natural gas consumption in 1998 in m3/torme of product.
The following table provides a summary of the energy reduction results starting from the
baseline year of 199 1.
kg
SO2
/tonne
kg VOC
/tonne
product product
2.868
0.0046
2.554
0.0040
2.419
0.0040
2.369
0.0042
2.151
0.0043
2.065
0.0042
1997
157.1
70.3%
94.5
89.9%
299.6
0.207
2.017
0.0041
1998
151.6
67.8%
95.6
91.0%
297.1
0.209
1.946
0.004 1
Please note that our natural gas consumption per tonne of product increased in 1994 and
1995 due to changes in product mix. We have significantly increased our production of
Granular products and these products have to be dried a second time after being
compacted which results in an extra 8 m3/tonne of natural gas per tonne of product.
Specific Enerw
Actions
for 1999
The energy conservation projects that are scheduled for this year are listed in this section
of the report. The types of projects for this section may include improved maintenance or
operating practices, energy metering and tracking of energy costs, investment in new
technology, and replacement of inefficient equipment. Specific policy, learning,
communications, or promotion related activities are included in this section as well. The
first two projects listed are carried over from last year as they were not completed before
the end of 1998, but will be completed and operational by April 1999.
4
Refined Circuit
Heat Exchanger
The Refmed leaching circuit is currently heated by the addition of live steam to the
leach tanks. The use of live steam for heating this circuit results in a loss of
condensate from the boilers. Installation of a shell and tube heat exchanger will
return condensate to the boiler room which reduces the requirement for addition of
cold makeup water to the boiler feed and improves boiler efficiency. This project
will reduce the Refmed circuit heat load by 3 GigaJoules/hour resulting in an
overall saving of 0.4 m3 natural gas per tonne of product. (Note: This project was
started in 1998 and will be completed and on-line by April 1999.)
The estimated reduction in annual emissions per tonne of product will be 4 x 10’
kg SOJtonne and 0.7 kg COz/tomre.
B)
Slimes Thickener
Replacement
The existing Slimes thickener will be removed and replaced with a smaller more
efficient unit. The new thickener will have less surface area to minimize radiant
heat loss, and will be better insulated. This project will reduce the Soluble circuit
heat load by 7 GigaJoules/hour, resulting in an overall saving of 1.2 m3 natural gas
per tonne of product. (Note: This project was started in 1998 and will be
completed and on-line by April 1999.)
The estimated reduction in annual emissions per tonne of product will be 1.1 x 1Oq5
kg SOJtonne and 2.2 kg C02/tonne.
Cl
Crystallizer
Particle
Size Enhancement
The growth rate of crystals and crystal size distribution have a direct impact on the
amount of usable production that can be achieved from a crystallizer circuit In
order to increase production and improve recovery the crystallizers are being
modified to produce larger crystals and increase efficiency. These modifications
will result in more product from the same amount of energy input.
The average savings per tonne of product amounts to 0.5 m3/tonne natural gas and
0.7 kWb/tonne electrical. The estimated reduction in annual emissions per tonne
of product amounts to 0.9 x los2 kg S02/tonne and 1.5 kg COz/tonne.
W
Refinery
Lighting
Incandescent lighting in the refinery is being replaced with higher efficiency and
better illuminating metal halide light fixtures. In 1999,200 incandescent fixtures
will be removed and replaced with 50 metal halide fixtures. The incandescent
light fixtures removed are 200 Watts and the metal halide fixtures used to replace
them will be 175,250, or 400 Watts.
The amount of energy conserved in 1999 is calculated based on 200 incandescent
200 Watt fixtures being replaced with 50 metal halide 275 Watt light fixtures. The
estimated annual energy saved for 1999 per tonne of product is approximately 0.13
kWh/tonne. The estimated reduction in annual emissions per tonne of product
amounts to 1.7 x low3kg S02/tonne and 0.11 kg COJtonue.
El
Communications
Articles promoting energy conservation, and describing our performance in the
Industrial Energy Innovators program, will be included in the newsletters sent out
from the Cory division.
-Summary
This Action Plan has been presented as an intermediate step in our goal setting and
review process. As indicated in the Action Plan requirements, we have stated our specific
1999 energy reduction goals, and listed specific energy efficiency actions for the year. At
the end of 1999 we will submit our Annual Report to CIPEC to review our performance,
and present our Action Plan for 2000.