Benchmarks & Client Cases

Efficiency in Process Industry

The Challenge

Impact measurement by utility
Impact measurement by utility 


• Average water consumption of 19.4 m³ per tonne produced

• Average electricity consumption of 518 kWh per tonne produced

• Average of 1,6 non-quality incidents per day

Root Causes

• Excessive water use in certain circuits and lack of monitoring mechanisms

• Gradual increase of NaOH cost by 23%

• Lack of knowledge about the application of sub-products in the internal processes

• Stops caused by wrong sensor readings causing overconsumption on restart

The Solution

System for monitoring process data

Visual data for deviation analysis

• Optimisation of use of recovered water and reduction of clogging

• Creation of a control chart with real-time data for process monitoring

• Planned shutdowns for preventive maintenance, with focus on emission control and energy consumption

• Modification of maintenance components control system and storage conditions

• Implementation of tool to control processed solids, steam management and concentrator washing

The Results

The project generated Annual Savings of 7 million €.

Electricity Consumption

Electricity consumption reduced by 8%.

Non-quality Incidents

Non-quality incidents eliminated.

Water Consumption

Water consumption reduced by 19%.

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