Key performance indicators

EEQ-S&B-WP2-2.5

KEY PERFORMANCE INDICATORS

Author: Michalis Painesis

Contributor: S&B Industrial Minerals
Project acronym: EE-QUARRY Project.
Grant Agreement No:
Issue Date:
Deliverable Number:
WP Number:
Status :

August
D 2.5
WP 2
Finished

DISEMINATION LEVEL
PU = Public
X
PP = Restricted to other programme participants (including the JU)
RE = Restricted to a group specified by the consortium (including the JU)
CO = Confidential, only for members of the consortium (including the JU)

(August 2011)

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Key performance indicators

Version
1st
2nd
3rd

Date
20/07/11
28/07/11
15/08/11

Author
Michalis P.
Michalis P.
Michalis P

EEQ-S&B-WP2-2.5

Document History

Description
1st Draft
2nd Draft
Final Version

Disclaimer
The information proposed in this document is provided as a generical explanation on the
proposed topic. No guarantee or warranty is given that the information fits for any particular
purpose. The user thereof must assume the sole risk and liability of this report practical
implementation.
The document reflects only the authors views and the whole work is not liable for any empirical
use of the information contained therein.

(August 2011)

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Key performance indicators

EEQ-S&B-WP2-2.5

SUMMARY
This document is the deliverable D2.5 of the WP 2 of the EE-QUARRY Project Develop of a new
and highly effective modeling and monitoring Energy Management System technique in order to
improve Energy Efficiency and move to a low CO2 emission in the energy intensive non-metallic
Mineral industry.
The scope of this document is to identify the Key Performance Indicators, mainly from
bibliographical sources, that could be used to examine the efficiency of the production process.
Our focus will be mainly on the Key Performance Indicators related with energy consumption
efficiency.

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CONTENTS
SUMMARY .................................................................................................................................... 3
CONTENTS ................................................................................................................................... 4
ABBREVIATIONS ......................................................................................................................... 5
INTRODUCTION ........................................................................................................................... 7
1

KEY PERFORMANCE INDICATORS ................................................................................... 8

1.1

PRODUCTION RATE .................................................................................................... 8

1.2

YIELD ............................................................................................................................ 8

1.3

OPERATIONAL AVAILABILITY ..................................................................................... 8

1.4

EQUIPMENT UTILIZATION ........................................................................................... 9

1.5

STRIPPING RATIO........................................................................................................ 9

1.6

SPECIFIC CO2 (KG CO2 PER MT OF PRODUCT) ...................................................... 9

1.7

ENERGY USE (MJ PER MT OF PRODUCT) .............................................................. 13

1.8

SPECIFIC EXPLOSIVES CONSUMPTION ................................................................. 13

1.9

THE KPI FOR PERLITE AND BENTONITE FOR THE YEAR 2010 ............................ 14

CONCLUSIONS .......................................................................................................................... 15
REFERENCES ........................................................................................................................... 16
ATTACHMENTS.......................................................................................................................... 17

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ABBREVIATIONS

EE-QUARRY
Develop of a new and highly effective modeling and monitoring Energy Management System
technique in order to improve Energy Efficiency and move to a low CO2 emission in the energy
intensive non-metallic mineral industry.

WP

CO2-e

Work Package

Carbon dioxide emissions

S/T

GHG

Scientific and Technical

Green House Gases

KPI
Key Performance Indicator

MT
Metric Ton

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LIST OF TABLES
Table 1. Industrial Processes emission factors for explosive use Source: AGO 2006a. ...... 9
Table 2 Emission Factors for Calculating CO2 Emissions Generalized Approach .......... 12
Table 3 National and European emission factors for consumed electricity .......................... 12
Table 4 Conversion factor energy units to MJ ........................................................................ 13
Table 5 KIPs perlite and bentonite for 2010 ............................................................................ 14

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INTRODUCTION
Key Performance Indicators are a set of quantifiable measures, agreed to beforehand, that a
company or industry uses to gauge or compare performance in terms of meeting their strategic
and operational goals. KPIs vary between companies and industries, depending on their priorities
or performance criteria. Also they are referred as "key success indicators (KSI)".
In our case that we are talking about quarries the KPIs are related to productivity, energy
consumption and cost efficiency. Companies face numerous challenges, both in selecting
appropriate KPIs at the company level and in implementing the selected KPIs at the operational
level.

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Key performance indicators

1
1.1

EEQ-S&B-WP2-2.5

KEY PERFORMANCE INDICATORS

Production Rate

Production rate is the number of goods that can be produced during a given period of time.
Alternatively, the amount of time it takes to produce one unit of a good.
In mining, most commonly, the production rate is expressed in MT/h or m3/hour.
1.2 Yield
Yield is the quotient of the saleable or useful product expressed in MT to the quantity of extracted
material. For example if from 100 MT of extracted material, the saleable grade is 75 MT, the yield
is 75%. Sometimes yield is also called Non-product output and it is expressed in MT of Waste
per MT of product.

1.3 Operational availability

Operational availability is a measure of the average availability over a period of time and it
includes all experienced sources of downtime, such as administrative downtime, logistic
downtime, etc. It is the probability that an item will operate satisfactorily at a given point in time
when used in an actual or realistic operating and support environment. It includes logistics time,
ready time, and waiting or administrative downtime, and both preventive and corrective
maintenance downtime. It is essentially the a posteriori availability based on actual events that
happened to the system.
Operational availability is the ratio of the system uptime and total time. Mathematically, it is given
by:

Where the operating cycle is the overall time period of operation being investigated and uptime is
the total time the system was functioning during the operating cycle. Operational availability is
required to isolate the effectiveness and efficiency of maintenance operations. It is the actual
level of availability realized in the day-to-day operation of the facility. It reflects plant maintenance
resource levels and organizational effectiveness. Operational availability is required to isolate the
effectiveness and efficiency of maintenance operations.

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1.4 Equipment Utilization

Equipment Utilization is defined as the percentage of PLANT OPERATING TIME (C) during
which equipment is in production, that is, production is not prevented by equipment malfunction,
operating delays, or scheduled downtimes.

1.5 Stripping ratio

The main characteristic employed in economic evaluation of open pit mining is the Stripping ratio
(SR) Stripping ratio is the volume of removed waste- overburden per unit of mineral. Usually it is
expressed in m3 of overburden per MT or m3 of ore. It is obvious that a large stripping ratio is
less economical than a small one, because more rock must be moved for a certain amount of
revenue generating ore.
1.6

Specific CO2 (kg CO2 per MT of product)

One of the most commonly used indicators in order to monitor energy efficiency is the Specific
CO2 which is the kg of CO2 emitted for the production of 1 MT of product.
Data from Aggregate industries in UK indicate comparable specific CO2 at between 4,0-5,0
kg/MT. In a quarry operation we can distinguish 3 groups by means of CO2 emissions:
a) CO2-e occurring during blasting
The use of explosives in mining leads to the release of greenhouse gases. The activity
level is the mass of explosive used (MT). Emissions are calculated using the EFs from
Emission factor
Explosive type
ANFO

MT CO2/ MT explosive
0.17

Heavy ANFO
Emulsion

0.18

0.17

Table 1. Industrial Processes emission factors for explosive use

Source: AGO 2006a.

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b) CO2-e occurring by the combustion in diesel fuel operating vehicles or/and

generators. That called also Direct emissions from Combustion sources
CO2 production from combustion is a fairly straightforward process, at least in theory. A
reaction between carbon in any fuel and oxygen in the air proceeds stoichiometrically. For
every 12 kg of carbon burned, there is combustion (a chemical reaction) which results in 44
kg of CO2, or a net mass multiplier of 3.67. There are two basic approaches for estimating
direct CO2 emissions:
Direct measurement and calculation based method.
Direct measurement of CO2-e is performed through the use of a Continuous Emissions
Monitoring System (CEMS). Calculation based method is a mass balance approach where the
carbon content and carbon oxidation factors are applied to the fuel input levels to determine
emissions. Most commonly it is used the calculation based method and especially the
generalized approach.
The generalized emission factors are reported in terms of mass of CO2 per unit of fuel energy or
per unit of mass or volume. Table 2 lists emission factors for different fuel types.

Emission Factors for Calculating CO2 Emissions Generalized Approach

Fuel Type

CO2 Emission Factor

CO2 Emission Factor

Fossil Fuel Combustion

Coal and Coke
Anthracite Coal
Bituminous Coal
Sub-bituminous Coal
Lignite
Unspecified (residential/commercial)
Unspecified (industrial coking)
Unspecified (other industrial)
Unspecified (electric utility)
Coke
Natural Gas (by Higher Heating Value)
975 - 1,000 Btu/scf
1,000 - 1,025 Btu/scf
1,025 - 1,050 Btu/scf
1,050 - 1,075 Btu/scf
1,075 - 1,100 Btu/scf
> 1,100 Btu/scf
U.S. Weighted Average (1,029 Btu/scf)
Petroleum Products
Asphalt and Road Oil
Aviation Gasoline
Distillate Fuel Oil (#1, 2, and 4)
Jet Fuel
Kerosene
(August 2011)

kg CO2/MMBtu
103.62
93.46
97.09
96.43
95.33
93.72
93.98
94.45
113.67
kg CO2/MMBtu
52.56
52.91
53.06
53.46
53.72
54.71
53.06
kg CO2/MMBtu
75.61
69.19
73.15
70.88
72.31

kg CO2/ton
2,599.83
2,330.04
1,674.86
1,370.32
2,012.29
2,462.12
2,072.19
1,884.53
2,818.93
kg CO2/scf
Varies
Varies
Varies
Varies
Varies
Varies
0.0546
kg CO2/gallon
11.95
8.32
10.15
9.57
9.76
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LPG (average for fuel use)

Propane
Ethane
Isobutene
n-Butane
Lubricants
Motor Gasoline
Residual Fuel Oil (#5 and 6)
Crude Oil
Naphtha (<401 oF)
Natural Gasoline
Other Oil (>401 oF)
Pentanes Plus
Petrochemical Feedstocks
Petroleum Coke
Still Gas
Special Naphtha
Unfinished Oils
Waxes
Waste Tires
Waste Tires

63.16
63.07
59.58
65.08
64.97
74.21
70.88
78.80
74.54
66.51
66.88
73.15
66.88
71.02
102.12
64.20
72.82
74.54
72.64
kg CO2/MMBtu
112.84

5.79
5.74
4.14
6.45
6.70
10.72
8.81
11.80
10.29
8.31
7.36
10.15
7.36
9.18
14.65
9.17
9.10
10.34
9.58
kg CO2/ton
3,159.49

Non-Fossil Fuel Combustion

Non-Fossil Fuels (solids)
Wood and Wood Waste (12% moisture)
Kraft Black Liquor (North American
Kraft Black Liquor (North American
f
d) Fuels (Gas)
Non-Fossil
Landfill Gas (50% CH4/50% CO2) - 502.50

kg CO2/MMBtu
93.87
94.41

kg CO2/ton
1,443.67
1,130.76

95.13

1,164.02

kg CO2/MMBtu
52.07

kg CO2/scf
0.0262

Wastewater Treatment Biogas

52.07
Varies
Source: The Climate Registry (TCR) General Reporting Protocol, Version 1.0, March 2008, Table 12.1
(http://www.theclimateregistry.org/downloads/GRP.pdf); USEPA Climate Leaders GHG Inventory Protocol
Di

tE i i

St ti

b ti

2007 T bl B 3 th

hB5

Alternative Fuels1
kg CO2/MMBtu
kg CO2/gal
Animal Fat2
74
9.2
Waste Oil
74
Plastics
75
Solvents
74
Impregnated Saw Dust
75
Other Fossil based wastes
80
Dried Sewage Sludge
110
Mixed Industrial waste
83
Municipal Solid Waste
90.652
1. Source of data for Alternative Fuels is primarily the EPA Proposed Greenhouse Gas Reporting
Rule, Table C-2, of Subpart C. These values are subject to change when EPAs final rule is in
effect. http://www.epa.gov/climatechange/emissions/downloads/GHG_Rule/RulePart98A-P.pdf
Note the units of the Emission factor in Table C-2 are in kg CO2/MMBtu.
2.

DAQ is assuming Animal Fat can be treated as waste oil. Input-based emission factor calculated as
kg
CO2/gal
based
on
heating
value
of
124,586
Bt/gal.
Source:
htt //d
t t
/
it /
it
i
/ ll
t
02112008 df
T bl 2
d

(August 2011)

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Table 2 Emission Factors for Calculating CO2 Emissions Generalized Approach

c) Indirect CO2 emissions, equivalent for every Kwh of electricity consumed.

Indirect CO2 emissions are emissions that are consequences of the activities of the company
(quarry) but occur at sources owned or controlled by another company.
Each European country uses a different mix of fuels to produce electricity, or exploits renewable
energy sources in different level and therefore each country has a different conversion factor in
order to calculate the CO2 e that correspond to every Kwh. At the following table 3, are
presented the European and National emission factors for electricity consumption.
Country

Austria
Belgium
Germany
Denmark
Spain
Finland
France
United Kingdom
Greece
Ireland
Italy
Netherlands
Portugal
Sweden
Bulgaria
Cyprus
Czech Republic
Estonia
Hungary
Lithuania
Latvia
Poland
Romania
Slovenia
Slovakia
EU-27

Standard emission factor

(MT CO2/MWhe)
0.209
0.285
0.624
0.461
0.440
0.216
0.056
0.543
1.149
0.732
0.483
0.435
0.369
0.023
0.819
0.874
0.950
0.908
0.566
0.153
0.109
1.191
0.701
0.557
0.252
0.460

LCA* emission factor

(MT CO2-eq/MWhe)
0.310
0.402
0.706
0.760
0.639
0.418
0.146
0.658
1.167
0.870
0.708
0.716
0.750
0.079
0.906
1.019
0.802
1.593
0.678
0.174
0.563
1.185
1.084
0.602
0.353
0.578

Table 3 National and European emission factors for consumed electricity

(A life cycle assessment (LCA, also known as life cycle analysis, ecobalance, Cradle to grave analysis) is a
technique to assess environmental impacts associated with all the stages of a product's life from-cradle-to-grave (i.e.,
from raw material extraction through materials processing, manufacture, distribution, use, repair and maintenance,
and disposal or recycling). LCAs can help to avoid a narrow outlook on environmental concerns)

(August 2011)

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1.7 Energy Use (MJ per MT of product)

This indicator is very important to evaluate the energy efficiency of our process.
Gross calorific (high heat value) of fuels shall be used to convert energy units to MJ (see table 4).
In case of use of other fuels, the calorific value used for the calculation should be indicated. The
use of explosives should be included in the figure for total energy consumption. Electricity means
net imported electricity coming from the National grid and internal electricity generation measured
as electric power.

Fuel

Quantity

Units

Conversion
factor

Natural gas

kg

54.1

Natural gas

Nm3

38.8

Propane

kg

50.0

Butane

kg

49.3

Kerosene

kg

46.5

Gasoline

kg

52.7

Diesel

kg

44.6

Gas oil

kg

45.2

Heavy fuel oil

kg

Dry steam coal

kg

30.6

Anthracite

kg

29.7

Charcoal

kg

33.7

Industrial coke

kg

27.9

Electricity

kWh

Energy (MJ)

42.7

3.6

Table 4 Conversion factor energy units to MJ

1.8 Specific Explosives consumption

Specific explosives consumption is the kg of explosive used to extract 1 MT or m3 of material
(ore, overburden etc). The specific explosives consumption depends heavily on type or rock and
the type of the explosive itself.

(August 2011)

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1.9

EEQ-S&B-WP2-2.5

The KPI for Perlite and Bentonite for the year 2010

Table 5 KIPs perlite and bentonite for 2010

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CONCLUSIONS
Choosing the right KPIs is reliant upon having a good understanding of what is important to the
organization. During last years for the mining business sustainability and energy efficiency
became an increasingly important factor. Next to the traditional KPIs were introduced new
indicators and energy information systems. However all the management systems based on KPIs
can become unusable without careful consideration of what data to collect, how often to collect it
and how to present and decode the data collected.

(August 2011)

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REFERENCES

Mining Engineering Handbook Howard Hartman The Climate Registry (TCR) General
Reporting Protocol, Version 1.0, March 2008.-

The Control of energy consumption and the investigation of CO2 emissions in the
production of aggregates (Basketin, Adiguzel, Tuylu, Istanbul University , Faculty of
engineering , Dpt of Mining engineering 2010).

A management System of energy (Georgia Tech).

European Environment Agency .

(August 2011)

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ATTACHMENTS
a. Deliverable review report
Date
Reviewer
Company

Venue

b. Technical result of the deliverable

Deliverable covers the topic specified in the title
Yes

Partly

No

Technical contents are relevant to EE-QUARRY and to the WPs

Yes

Partly

No

Presented results in the deliverable are of high value

Yes

Good

Partly

No

Technical sound of the deliverable

Regular
Bad

Described work in the deliverable follows a clear methodology

Good
Regular
Bad
Please add your comments on the content and the technical results of the deliverable. Please
comment the problems, if any.
Comments
:

(August 2011)

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c. Length, structure and presentation of the deliverable

Good

Adequate length of the deliverable

Regular
Bad

Good

Deliverable organization is appropriate

Regular
Bad

Good

Presentation of the deliverable clear and concise

Regular
Bad

Please add your comments on the length, the structure and the presentation.
Comments
:

d. Rating for the deliverable

Please provide a rating for this deliverable from 5 (excellent) to 1 (very poor): ____
Deliverable is
Accepted

Accepted
with
revisions

Rejected
unless
modified
as
suggested

Rejected

Comments
:

(August 2011)

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