Energy Savers
Wide Bay Burnett

Moore Sugar Cane Farm

Proposed
25
Energy Savings
84.1
Savings
38,829
Industry
Cane
Irrigation
Travelling Gun, Flood
Pumps
Centrifugal
Technology
Pump upgrade, Tariffs
Capital Cost
40,800

Summary

A recent energy audit showed how improving the current pumping system conformed by five pumps can lead to energy and cost savings. Energy savings of 23% and carbon reductions of 84.1 t CO2-e per year have been estimated, with a total capital cost of $40,800. The recommendations explored in the audit included the installation of VFD to pumps one, two, three and five, as well as conversion to Tariff 33 at pumps two, three, and five.

A sugarcane farming enterprise located in Moore Park Beach could benefit from a recent Energy Savers Audit. Farming requires constant decision making to maximise production and profit. Often irrigation systems are out of date and are in need of replacement to incorporate new technologies and updated knowledge.

The total area of cropping lands consists of 244 ha and is divided into three sectors that are serviced by five pumps. Although there are five operational pumps, only four analysis’ are reported as Pump four was unable to be obtained due to the drought experienced during the audit.

Pump one services 55 ha and has been experiencing operational difficulties noted as severe pump cavitation, slow system fill on start-up, evidence of iron oxide issues and some pipe fitting irregularities. This pump provides water to a high-pressure gun and low-pressure flood irrigation. Pumps two, three and four are interconnected by an underground mainline which supplies water to 139 ha. Pumping distances and efficiency issues associated with friction means that the best operational procedure in sector two is to irrigate the area closest to each pump. Pump five draws its water supply from the Bundaberg surface water supply scheme and has a system design that manages distribution pressure via a manual check valve. Unfortunately, this is a highly expensive way to achieve this outcome. Pump four is located on a gully dam within grazing land attached to the sugarcane operation. The pumping unit is relatively new and is fitted with VFD and connected to Tariff 33.

Energy consumption from the site showed that a total of 426,071 kWh at a cost of $91,008 was used during the 2018-2019 period. A recent energy audit showed how improving the current systems can lead to energy and cost savings. The recommendations explored in the audit included:

  • The installation of VFD to pumps one, two, three and five.
  • Conversion to Tariff 33 at pumps two, three, and five.

Table 1. Energy savings from audit recommendations

Recommendations Annual Energy Savings (kWh) Annual Cost Savings ($) Emission Savings (tCO2-e)  Capital Cost ($) Payback Period (years)
Install VFD in 4 pumps 105,174 27,768 84.1 33,300 1.4
Change 3 pumps to tariff 33 11,016 7,500 0.8
Total 105,174 38,829 84.1 40,800 1.1

 

The addressing of the operational issues related to iron sludge restrictions and replacement of suction pipe fittings at pump one will improve the functionality of the pumping system and improve performance. Repairs and maintenance or replacement of the Southern Cross pump will further enhance the functionality and performance of the pumping system. Energy demand and consumption will decline with the introduction of VFD technology which will manage the system operating head (m) to meet the specific target demand. Conversion to Tariff 33 is recommended to maintain lower energy cost over the longer term.

The combined effect of all the recommendations will reduce the annual enterprise energy demand by an estimated 98,031 kWh saving $37,471 to yield approximately 18,000 tonnes annually.

By installing the recommendations in the audit, the business could reduce energy consumption for pumping by 25% and costs by 43%, with carbon emission savings of 84.1 tCO2e per year, which will enhance the profitability and productivity of the farm.

Table 2. Pre and post audit energy consumption, costs, and energy productivity savings

Metric  Pre-Audit  Post-Audit  Reduction (%)
Energy Consumption (kWh) 426,071 320,897 25
Cost ($)  91,008 52,179 43
Energy Productivity (kWh/ha) 1,746 1,315 25


An energy audit is a good investment
 

An energy audit is a great first step in moving a business towards a more efficient future by reducing energy use, costs and carbon emissions onsite.  

An energy auditor will review your past energy bills, your equipment and the way your business operates. They’ll show you where you’re using excess energy and explain what you can do about it. Find out about what’s involved in an energy audit HERE. 

See our range of agricultural energy efficiency case studies HERE and Subscribe to our bi-monthly energy e-news HERE  

If you have any energy efficiency related questions for the team get in touch at energysavers@qff.org.au.  

The Energy Savers Plus Extension Program is delivered by the Queensland Farmers Federation with support and funding from the Queensland Department of Energy and Public Works. 

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