Energy Auditing for Ghana Manganese Company’s Carbonate Plant

Abstract

The Ghana Manganese Company’s (GMC’s) carbonate plant faces significant energy inefficiencies and environmental impact concerns, yet its energy consumption practices are largely unmonitored and unregulated. Current energy management strategies at the plant lack systematic approaches, making it difficult to identify and address inefficiencies, resulting in potential environmental harm. This research aims to bridge this critical knowledge gap by conducting a comprehensive energy audit to provide actionable recommendations for improving energy efficiency and reducing the plant's carbon footprint. This was achieved by setting clear specific objectives, defining the study's scope, and developing a detailed audit plan for GMC's carbonate plant. On-site visits were conducted to collect real-time data, which was then analysed using statistical tools to assess energy consumption patterns and identify conservation opportunities. Based on the energy audit, an energy conservation measure was recommended for the company. The energy audit recommended shutting down the plant whenever loader vehicles stop operating to refill, as it was observed that the plant runs inefficiently in their absence. The findings revealed that the highest energy consumption at GMC's carbonate plant occurred in May 2023, reaching 693.770 MWH, with all months from January to July 2023 exceeding 680.00 MWH. After implementing a proposed energy conservation measure, energy usage from August 2023 to February 2024 significantly decreased, consistently falling below 680.00 MWH, thereby reducing energy costs. Additionally, an analysis for an alternative solar power supply indicated that an investment of GH ₵ 6,387,769.44 would be required, offering long-term benefits in energy efficiency and environmental sustainability despite the high initial cost.