Samarco advances energy recovery in conveyor belts and boosts operational efficiency

Pilot project at the Germano Complex validates technology that harnesses the weight of the ore in downhill sections to reduce electricity consumption and increase operational efficiency

Samarco has completed a pilot project that demonstrates the potential for energy recovery in mobile conveyor belts installed in downhill sections of the Germano Complex, in Mariana (MG). Developed by the unit's Mine Electrical and Utilities teams, the project evaluated the regenerative behavior of the equipment and paves the way for new applications in the operation.

Estimates indicate that a conveyor equipped with two 400 hp drives, operating 80% of the time and with 60% of the load, can recover approximately 166,000 kWh per month. This volume is equivalent to the annual consumption of about 69 households, considering an average of 200 kWh per month per family unit.

The principle of energy regeneration is already used in different industrial and mining applications around the world, but its application in mobile conveyor belts installed along downhill sections still offers opportunities for expansion in the industry.

“When a conveyor operates downhill, the weight of the transported ore helps move the system. Under this condition, the motor stops acting solely as an energy consumer and starts functioning as a generator”, states Alex Augusto Cândido Teixeira, Maintenance supervisor at Samarco. “With the use of regenerative drives, this energy is fed back into the electrical system in a controlled manner and used by other plant loads, reducing the unit's total power demand”, he adds.

In applications with similar characteristics, international studies indicate that regenerative systems installed in conveyor belts operating in downhill sections can recover between 30% and 45% of the energy consumed by conventional systems.

In addition to energy gains, the initiative can contribute to reducing operational costs and making better use of energy resources already available in the operation, reinforcing the competitiveness of the production process.

The initiative is part of Samarco's efforts to increase the energy efficiency of its operations and support the company's goal to reduce greenhouse gas emissions by 30% by 2032. With the results obtained in the pilot project, new opportunities for technology application are already being evaluated at the Germano Complex, reinforcing the company's commitment to innovation, competitiveness, and sustainability.