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Scalable automation solution optimises process at new Kaolin plant

WA Kaolin is using Rockwell Automation technology to enhance operational efficiency as it ramps up production. A new kaolin mining operation in Wickepin, Western Australia, is utilising an integrated automation solution to reduce overall costs, improve scheduling, and deliver ongoing benefits to operations. Kaolin, which is becoming increasingly valuable, is a soft white clay that has been surging in demand, with uses in applications including paper and plasterboard, ceramics, fiberglass, paints and coatings, plastics, rubber, pharmaceuticals and medicine, cosmetics, concrete construction materials and agriculture. WA Kaolin – an ASX-listed mineral exploration, extraction, and processing company – has developed a proprietary dry processing method known as K99, which turns raw material into market-suitable feedstock for global customers. Combined with the high quality of the ore reserve, the K99 process delivers high-quality ultra-bright kaolin at a lower cost than conventional chemical bleaching and magnetic separation processing. WA Kaolin has constructed a Stage 1 commercial processing plant on a three-hectare site in Wickepin, about 200 kilometres southeast of Perth, Western Australia. The site has been identified as having a mineral resource estimate of more than 600 million tonnes of extremely high grade, easy access kaolin across its mining and retention tenements, one of the largest known remaining premium primary resources of kaolin in the world. There is a strategic plan in place to expand production capacity to exceed 400,000 tons per annum (tpa) after 36 months, so WA Kaolin selected engineering and planning consultancy, Willyung Electrical & Controls Engineering (WECE) to manage the process of steadily scaling up. WECE analysed the requirements, and selected Rockwell Automation’s PlantPAx® Distributed Control System (DCS) to provide a single, plant-wide control system, with the flexibility to make better and faster business decisions and a scalable solution for future expansion. In late 2022, WA Kaolin successfully commenced […]

What is steel scrap and how can it help us reach net zero?

Recycled steel scrap is a low-emitting source of the metal – here’s how we can improve its collection and production to help decarbonise the industry. From bridges to cars to paper clips, steel is ubiquitous in our material world. It is one of the enabling materials that has led to unprecedented living standard rises and progress for humanity. Yet, as with all other emitting economic sectors and material groups, the steel industry needs to decarbonise to meet the climate challenge. Its success as a material means global crude steel production is over 1.9 gigatonnes, but it accounts for an estimated 3 gigatonnes of CO2 emissions annually (albeit this is lower-emitting than most other materials potentially used for the same applications). Steel is made from either primary sources: that is, extracting iron ore from nature and transforming it into pure iron; or from secondary sources, that is, remelting steel scrap into new steel, or a combination of both. This secondary-source steel scrap is the discarded steel that becomes available from manufacturing waste generation and from recovered steel in buildings, infrastructure, equipment, vehicles and products discarded at their end of life. The amount of steel scrap available globally is finite, constrained by the rate of disposal by society. In contrast, the availability of iron ore-based steel is expandable, as mine activity can be increased to meet growing steel demand. There are two principal methods of producing steel. Image: ArcelorMittal Innate circularity Steel has excellent circularity properties. Whereas other materials are often downcycled at their end of life, for many applications, steel scrap can be turned back repeatedly into new steel, retaining its original properties. The magnetic properties of steel make it easy to segregate steel scrap from mixed waste streams. Global emissions from steel are primarily generated while producing steel from primary source iron […]

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Sensing the future of energy

Michael Jary – Managing Director, APAC and EMEA, Sense Energy retailer business models have faced extraordinary pressures for over a decade. Even before the war in Ukraine prompted a global crisis in energy markets, retailers were facing a very difficult environment. An inexorable rise in energy costs, together with regulatory intervention and increased customer churn, have eroded retail margins and prompted several exits. Attempts at diversification to adjacent businesses such as home services have often failed because the necessary competencies can be starkly different. At the same time, grid edge intelligence and real-time, appliance-level load disaggregation are generating huge interest in the energy sector. Advances in technology and AI mean that this long heralded technology is now a compelling proposition. Testament to its potential, Sense has recently closed the biggest funding round yet in the sector – a $127m Series C. With millions of next generation smart meters due to roll out with Sense capability in North America, decision makers worldwide are now giving the technology serious consideration for future rollouts. As more than three million Sense-enabled meters begin to roll out in the US, this technology is now coming to Australia, where it can integrate with local smart meters. This is particularly timely, with the Australian Energy Market Commission (AEMC) proposing 100% uptake of smart meters by 2030. Intelligent decisions made today will build an efficient and effective energy monitoring and management system for the future. The benefits to consumers and the energy transition are clear. Sense intelligence represents a powerful tool for reducing both their energy bills and their carbon footprint. It also reduces the overall cost of managing, maintaining, and balancing the energy system. However, the potential to transform retailer business models is what’s seizing the imagination of the industry. So how does Sense intelligence work? Intelligent […]

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New process extracts silicon from solar panels to build better batteries

Researchers have developed a sustainable and highly lucrative way to address two big issues in the clean energy transition, reclaiming one of the most valuable elements from end-of-life solar panels and reconfiguring it to build better batteries. More than 100,000 tonnes of end-of-life solar panels are estimated to enter Australia’s waste stream by 2035. Scientists from Deakin University’s Institute for Frontier Materials (IFM) have successfully tested a new process that can safely and effectively extract silicon from old solar panels, then convert it into a nano material worth more than $45,000 per kilo. This nano-silicon is then mixed with graphite to develop a new type of battery anode shown to increase lithium-ion battery capacity by a factor of 10, a critical breakthrough in energy storage technology. Lead researcher Dr Md Mokhlesur Rahman said that for Australia (and the world) to address the enormous issue of solar panel waste and develop a successful recycling program to divert it away from landfill, scientists must find a way to harvest and repurpose the panels’ most valuable components. “Solar panel cells are fabricated using high-value silicon, but this material cannot be re-used without purification, as it becomes highly contaminated over the 25 to 30 years of the panel’s life,” Dr Rahman said. “We have developed a process that returns silicon collected from used cells to greater than 99 per cent purity, within a day and without the need for dangerous chemicals. This thermal and chemical process is far greener, cheaper, and more efficient than any other technique currently on the market.” But it’s the next step that’s the real game-changer. The Deakin process then takes this regular-sized purified silicon and reduces its size to nanoscale using a special ball-milling process. Again, without the need for toxic chemicals. “We are using that nano-silicon to develop […]

Reducing plastic waste at Christmas

A world-first open platform to help reduce plastic waste and encourage sustainable solutions is being launched in time for the biggest waste dump of the year – Christmas. With approximately 30 per cent more waste produced at this time of year, now is the perfect time to start. I’M PLASTIC FREE www.implasticfree.com is a free platform to find eco services and products for consumers and businesses and provides up-to-date independent research – no greenwashing – and information for living more sustainably and ethically. Its values are simple: all materials and products are treated with value, and the circular economy is an integral part of our everyday life. ‘If every person made one or two easy changes using eco-friendly materials instead of single-use plastics, the impact would be enormous,’ says founder, Simona Paganetto. ‘Reuse and repurpose are first so there’s no waste, but when it’s time to replace your item, we provide a platform that makes finding and choosing an alternative easy.’ At Christmas this can really add up. Australians use an average of eight metres of paper for Christmas gifts. That might not sound like much, but it adds up to around 150,000 kilometres of wrapping paper. Enough to circumnavigate the globe four times. ‘We’re talking about something that is just ripped away and discarded, and if it’s got any type of foil or shine on it, it can’t be recycled,’ says Simona. ‘Don’t forget the ribbon and tinsel too, which are made from plastic.’ A different approach can make a huge difference. ‘Firstly, reusing paper, ribbon and tinsel is great,’ she says, ‘but if you don’t have any to reuse, there are many alternatives.’ I’M PLASTIC FREE has a handy Christmas checklist to help. ‘If every Australian family wrapped just a quarter of their presents in reused or alternative-paper […]

Four easy ways to make your office greener

As more businesses choose to go green and be environmentally responsible, the process can seem a little overwhelming given the plethora of greening solutions. Below are four easy ways to go green in the office, and save money and achieve efficiencies in the process. 1.Eliminate the printing of forms We are all too familiar with filling in office forms. Typically, these are often supplied in a paper format, and completed and signed manually before being returned to their point of origin. The process is both time and resource intensive. According to the National Waste Report 2020, prepared for Australia’s Department of Agriculture, Water and the Environment by Blue Environment Pty Ltd, 5.9 Megatonnes of paper and cardboard waste was generated between 2018-2019 in Australia.1 Paper manufacturing leads to deforestation, increased carbon emissions and climate change. The use of paper can also be operationally expensive for firms. Apart from the cost of the paper itself, once the completed paper forms have been processed, they are usually assigned to the inevitable – filing cabinets and storage facilities – which add to operational costs. Software solutions however, can eliminate the need for paper forms and help your office go green. Common software programs such as Microsoft’s Word allow you to quickly and easily create digital forms. Better still, software solutions such as Kofax Power PDF, let you convert the form into a PDF for greater flexibility and collaboration. Power PDF even converts images into fillable PDF forms. Colleagues can then easily access the PDF form to quickly complete details, highlight data, or leave comments. And the software’s inbuilt digital signature capability lets businesses capture signatures electronically. What’s more, the forms can then be filed electronically and also integrated directly into document management systems. This negates the need for filing cabinets and physical storage […]

Victorian opposition recognises gas for cleaner energy future

Australia’s oil and gas industry has noted the return of a balanced discussion about Victorian energy policy, with recognition from the State Opposition that natural gas is central to the cleaner energy future. The Australian Petroleum Production & Exploration Association (APPEA) today said Opposition Leader Matthew Guy’s pledge to end natural gas bans and use the energy source to replace coal and partner with renewables on the road to net zero was a sensible position backed by experts. APPEA Chief Executive Samantha McCulloch said: “This position understands the fundamental energy system changes occurring globally – with natural gas widely acknowledged to have a central, and even wider, role in the future energy mix than it does today. “Natural gas will replace higher emitting coal and firm renewable power generation, support manufacturing, help make everyday products as well as act as a feedstock for hydrogen. “As the Federal Government’s special adviser on low emissions technology, former chief scientist Dr Alan Finkel, said recently, gas can even speed up the journey to a cleaner energy future.” Ms McCulloch said Mr Guy had called out the untenable position of Victoria relying heavily on coal-powered electricity while having minimal onshore gas production because of a decade of development bans, which have deprived Victorians of the cheapest gas available to them. “Victorians currently pay $2 extra for every gigajoule of gas to be transported from Queensland under this policy, which ignores the fundamental rule that the cheapest gas is the gas produced closest to the customer,” she said. “The industry has announced over $20 billion of new supply investments over the past two years. But little of that has been in Victoria because of a decade of uncertainty, moratoriums and bans. We need certainty and the investment policy settings to be right. “As well as […]

Crucial role for gas for decades

Gas will play a crucial role for decades as a stabliser for the electricity grid in a cleaner energy future, according to a new 30-year roadmap by the national energy market regulator. The Australian Petroleum Production & Exploration Association (APPEA) today said the Australian Energy Market Operator (AEMO) had confirmed the long and enduring value of natural gas partnering with renewables with the release of its 2022 Integrated System Plan (ISP). APPEA Acting Chief Executive Damian Dwyer said the Plan showed the key role of gas as the world decarbonises by citing the mid-2040s as a time when gas would back up electricity largely powered by renewable generation after the retirement of coal-fired power. “As a sector strongly committed to economy-wide net zero by 2050, the oil and gas industry recognises the growth of renewables and the importance of multiple energy sources working together to ensure the power generation sector can continue to decarbonise,” Mr Dwyer said. “The plan confirms the central role of gas in that future as a reliable and flexible stabliser for renewable power generation when the wind doesn’t blow and the sun doesn’t shine. “Coal won’t get you to the goal and this plan details how gas will step up and take over from coal and also be a cleaner source of energy in the grid.” Mr Dwyer said this firming role was exemplified in the Plan’s modelling showing how gas would be needed during low and high outputs of renewables during peak demand periods. “Even at a period of high renewable output, AEMO says gas will be required to firm renewables during high demand just after sunset and through the night to cover wind variability,” he said. Mr Dwyer said the need for rapid gas during recent energy system pressures – when coal outages combined […]

Henkel Australia powers adhesive sites with 100% renewable energy

Henkel Australia has begun using electricity generated fully from renewable energy sources at its adhesive plants in Seven Hills, New South Wales, and Kilsyth, Victoria. The adhesive plants serve a wide range of industries, such as flexible packaging, engineered wood, food and beverage, steel, paper, mining, and maintenance, repair and overhaul. Thanks to more than 2,000 solar panels on their rooftops and renewable energy contracts, the sites are expected to realise more than 50 percent savings in carbon emissions in 2022, compared to last year. “Globally, Henkel is accelerating its climate actions. In line with this, we have successfully switched to using 100 percent renewable electricity to power our adhesive plants in Australia. In tandem, we are exploring more ways to improve energy efficiency and decarbonise our operations as we progress towards becoming a climate positive company,” said Daniel Rudolph, President of Henkel Australia and New Zealand. To optimise energy consumption and drive energy savings, new boilers, air compressors and scrubbers that come with variable speed drive (VSD) smart controllers are being used. Passive infrared (PIR) motion sensors are also being installed. Henkel is pursuing ambitious goals to make its production processes climate positive by 2030. By 2025, the company aims to reduce the carbon footprint at its sites worldwide by 65 percent compared to the base year 2010. Furthermore, the electricity used is to be generated 100 percent from renewable sources by 2030.

Study to research opportunity of carbon capture and storage in WA

A new study investigating opportunities in Western Australia for carbon capture, utilisation and storage (CCUS) and carbon capture and storage (CCS) is a positive step in finding pathways to decarbonise the economy, according to Australia’s oil and gas industry. The Australian Petroleum Production & Exploration Association (APPEA) today backed the study commissioned by the Western Australian LNG Jobs Taskforce, supported by APPEA members bp, Chevron, Eni, Santos, Shell, and Woodside. APPEA WA Director Claire Wilkinson said the research would provide critical intelligence on how best to deploy CCUS and CCS to decarbonise not just the state’s gas industry but many other sectors as well. “The oil and gas industry is committed to achieving net zero greenhouse gas emissions by 2050, with several companies targeting even earlier timeframes,” Ms Wilkinson said. “Decarbonising our existing and future operations means there is a need to invest in renewable energy and lower emission technologies and this study will help inform the investment opportunities in this space. “CCUS and CCS have key roles in lowering the carbon intensity of gas production and in supporting the development of a blue hydrogen industry here in WA, a key enabler to a viable hydrogen industry. “The study will help us chart a way forward with natural gas set to be a key part of a cleaner energy mix.” The study will be conducted by the CSIRO and the Global Carbon Capture & Storage Institute and is expected be completed in the second half of this year. The Western Australian LNG Jobs Taskforce aims to maximise local jobs and establish WA as a global LNG hub. Originally established by the WA Premier in 2018, it comprises of the Minister for State Development, Jobs and Trade; heads of Woodside, Chevron, Shell, Santos, and INPEX, and representatives from APPEA and UnionsWA.

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