With stricter carbon emission laws in many countries, energy efficiency is now a must-have for companies across the board. This is progressively removing any gray areas in the compliance process and forcing companies to more closely monitor and manage their carbon emissions. A substantial portion of any industrial operation relates to its use of fluid flow systems, so it is crucial companies are aware of energy consumption patterns and trends in this aspect of their business.
Cleaner Mining
The mining sector is a major contributor to carbon emissions. Between 4% and 7% of global carbon dioxide (CO2) emissions come from mining.
Regulatory pressures, investor expectations and corporate sustainability goals are now leading mines to commit to net zero carbon and carbon neutral mining targets. Leading players are aiming to reach these goals by as early as 2040 or 2050—with interim targets of 30%-50% reductions to be reached by 2030 or 2035. To get there, companies are adopting low-carbon technologies, electrification, automation and AI-driven process optimization to enhance sustainability while improving operational efficiency.
Pumping systems need to be an area of focus for any efforts in mining to reduce emissions. Estimates differ on how much of a mine’s energy consumption comes from pumps—including dewatering, slurry transportation, ore processing and other fluid handling—but sources like the International Energy Agency (IEA) and the U.S Department of Energy (DOE) agree this accounts for between 25% and 40% of total energy consumed in mining operations.
Decarbonizing Steelmaking
Similarly, in the steel industry, the drive toward decarbonization is ramping up. Steel production accounts for some 8% of global energy use, with blast furnaces and rolling mills being among the largest sources of power demand. As such, the sector is also a leading carbon-emitter, contributing 7%-9% of global CO2 emissions. In many of these operations, traditional hydraulic systems rely on fossil-fuel-powered pumps and inefficient designs, contributing to the high level of CO2 output.
Among the pressures facing steelmakers are global initiatives like the Carbon Border Adjustment Mechanism (CBAM) and Science-Based Targets Initiative (SBTi), which are pushing these producers toward low-carbon technologies. Leading global steelmakers have made ambitious commitments. Most plan to be net zero by 2045 or 2050, with some aiming for an interim target of 50% emission reduction by as early as 2035.
The IEA and DOE have similar estimates of the proportion of energy in steelmaking that can be accounted for by pumping systems—with figures ranging from 5% to 15% of total plant power usage.
Pathways to Net Zero in Mines
Various strategies are proving valuable in moving mines toward their sustainability and zero carbon goals. Key among these is the deployment of high-efficiency motors and variable speed drive (VSD) technology in all fluid transport systems. With the use of IE5 motors (classified as “ultra-premium” in terms of efficiency by the International Electrotechnical Commission) and variable frequency drives (VFDs), mines can reduce their energy use by 30%-40%.
Process optimization and digitalization are also important enablers of energy efficiency. Smart controllers, for instance, analyze real-time data such as flow, pressure and system conditions. These controllers adjust pump operation dynamically—such as modulating speed or switching pumps—to match demand precisely, avoiding overpumping and energy waste. They can predict and respond to changes in system demand, maintaining optimal efficiency at all times. By only running pumps at necessary capacities and by reducing unnecessary cycling, intelligent controls can reduce energy consumption by up to 50% in some applications.
These strategies include harnessing AI in analytics and predictive maintenance to optimize pumping operations. The use of sensors, Internet of Things (IoT)-based telemetry and remote monitoring enhances real-time operational control. This in turn improves integrated system management through industrial control platforms, enabling centralized oversight that simplifies operation and further optimizes energy use.
Mines are also finding that equipment optimization can deliver cost and reliability benefits. In terms of capital expenditure, these energy-efficient solutions reduce their return on investment payback periods to as little as 12 to 18 months, depending on the upgrades. Better reliability of equipment means less unplanned downtime and more streamlined production, which has been quantified to represent cost savings of 20% to 30%.Materials and design also have their part to play in driving efficiency and reducing energy usage and carbon emissions. Wear-resistant metallurgy and coatings enhance durability when pumps are handling high-density and abrasive slurries. Hydraulic designs are becoming more sophisticated and energy-efficient to minimize power consumption and increase throughput.
Efficiency Opportunities in Steel
In the steel sector’s drive to decarbonize, there is scope in operations from high-pressure descaling to forging and cooling. Descaling—which removes oxidation layers from steel surfaces before rolling and finishing—typically requires high-pressure water jets, where conventional systems are often energy intensive and costly. The use of high-efficiency water hydraulic systems reduces energy use and optimizes flow control, saving 20%-30% in energy consumption and delivering a lower carbon footprint.
Forging and press operations require high-powered hydraulic systems that traditionally rely on oil-based hydraulic fluids and fossil-fuel-powered systems, leading to high emissions and operational inefficiencies. Today’s technologies can deliver up to 30% reduction in energy demand per forging cycle, while eliminating fossil-fuel-based hydraulic fluids and reducing environmental risks.
Intelligent fluid management in pumping systems also holds great promise for the steel sector. Traditional pumps and hydraulic systems in steel operations usually run at fixed speeds, consuming excess energy and water. By optimizing these systems with intelligent controls, steelmakers can ensure maximum efficiency with minimal waste.
Another area of progress relates to cooling applications in steel plants. Here, high-efficiency inline vertical pumps with IE5 motors have been shown to deliver reduced energy consumption— further enhanced by VSD technology to optimize flow rates and minimize operational costs.
Recovering waste heat also contributes to energy optimization, where plate heat exchangers and heat recovery solutions help capture and reuse waste heat from furnaces. This has been shown to reduce energy demand by up to 80%. Smart thermal management systems can further lower fuel consumption and emissions.
First Steps
Achieving compliance generally relies on three enabling factors: a starting point to establish energy consumption levels in pumping systems; the application of efficiency-enhancing equipment and solutions; and ongoing monitoring and optimization of pumping systems to enable continuous improvement.
