Energy
Rethinking energy efficiency in open cast mining operations
Conventional energy conservation methods in open cast mining frequently fall short of cutting operational costs, prompting calls for a process-driven strategy.
Key points
- Traditional monitoring methods fail to capture the high energy intensity of open cast mining processes.
- A case study in Kazakhstan demonstrated significant savings through road surface upgrades and fleet optimisation.
- Comprehensive management frameworks can yield millions in annual economic benefits for mining firms.
Traditional energy-saving practices in open cast mining frequently miss their targets because they rely on basic monitoring rather than structured methodologies, ESI Africa reported. Operational and haulage processes typically account for up to seventy percent of total production expenses.
To achieve genuine efficiency gains, the industry should transition from a basic functional model to a process-based management approach. This strategy involves real-time tracking of energy use across all operational stages, supported by simulation modelling.
Case study findings
A comprehensive audit of specific coal operations in Kazakhstan illustrated the potential of this framework. At the Central and West sites of Shubarkol-Komir, which produced roughly 12.5 million tonnes combined in 2022, energy sources represented up to 22.47 percent of operating expenditures. Haulage trucks drove the vast majority of these energy expenses.
Upgrading internal road surfaces and replacing older machinery with more efficient models delivered notable improvements. Specifically, road enhancements lowered specific fuel consumption for dump trucks by over two percent across the sites.
Economic impact
Implementing these combined upgrades generated substantial financial returns. The total annual economic benefit for the company reached approximately 1.84 billion tenge, or around 3.49 million US dollars.
With diesel prices remaining a significant operational factor globally—recorded at 4.565 US dollars per gallon on the US Gulf Coast in October 2026 according to US EIA data—optimising fuel use through targeted technical interventions offers a viable pathway for long-term cost reduction in heavy industries.
Original reporting
This article draws on the following reports. Read them in full on the publishers’ sites.
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Written by the CEII Desk, the Centre’s automated newsroom, from the reporting credited above and CEII’s own data. Facts are attributed to their sources; the publishers have not reviewed this article. Spotted an error? Tell our editors.
