Running a compressor-management system has saved Cloud Peak Energy more than 25% fuel on one of its rigs and significantly cut its carbon-dioxide emissions.

One of the problems with drill rig compressors is that most set-ups are usually running whether the machine is drilling or not.

To address this, Sandvik developed its Compressor Management System, which isolates the compressor and eliminates the need to maintain pressure when the machine is not drilling.

This reduces load on the engine, saving a significant amount of fuel and reducing wear and tear.

Cloud Peak had the Sandvik CMS retrofitted to a 14-year-old rotary drill at its Cordero Rojo coal mine in Gillette, Wyoming.

Once the system was installed and calibrated, Sandvik engineers used the machine’s Engine Control Module data as a reference point.

Before the installation, the drill was using 22.9 gallons of fuel an hour.

After running the Sandvik CMS for five week,s the rig was using just 16.9 gallons per hour, a reduction of 26.2%.

Assuming 4500 hours of operation and a price of $4 per gallon, this cut translated to significant savings of about 24,000 gallons of fuel and $108,000.

This also meant savings of more than 300 tonnes of carbon emissions annually on fuel alone.

Additional savings are expected from increasing engine life.

Cloud Peak bought two Sandvik rigs in 2013 with Sandvik CMS installed.

Sandvik Mining vice-president for rotary and high-pressure down-the-hole drilling Ken Stapylton said Sandvik had wanted to prove the CMS could consistently make significant savings for customers.