In the conditions of rapid growth in global demand for energy resources and the constant rise in their cost, the issue of transition to environmentally friendly, energy-efficient and renewable energy sources is becoming increasingly relevant.

Currently, the role of energy efficiency in production, which consists in optimizing energy costs and reducing the harmful impact on the environment, is incredibly high. The transition to alternative energy sources, including solar energy, allows us to reduce dependence on traditional sources and reduce greenhouse gas emissions. Reducing energy intensity and increasing the energy efficiency of equipment using modern technologies allows us to reduce energy consumption. Automation of the technological process and the introduction of artificial intelligence in process management optimize energy consumption by regulating the operation of equipment depending on the needs of production and the current load.

All this generally increases the competitiveness of the enterprise. Companies that implement energy-saving measures can offer more competitive prices, improved product quality and a higher level of service.

This is well understood by the specialists of the zinc plant of Almalyk Mining and Metallurgical Combine, who are constantly introducing the latest technologies into the production processes of the workshops, which allow the plant to make global changes in this direction.

This year, a Roadmap for saving fuel and energy resources of the zinc plant was drawn up. First of all, the company's specialists critically studied the key indicators. Thus, according to the data for 2022-2024, it was found that electricity costs in the cost of production of finished products amount to 27.2% of the total cost. The most energy-intensive process section of the plant is the electrolytic shop - 75-80% of the total electricity consumption, and the Waelz shop is the main consumer of natural gas. Based on this, a set of measures was drawn up to reduce energy costs. The priority at the first stage of drawing up the Roadmap was that in order to achieve the parameters for reducing fuel and energy consumption, it is necessary to use cost-free and low-cost measures. In the future, gradually, at the expense of the saved funds, move on to high-cost ones.

Modernization of the electrolytic and roasting shops, leaching and Waelz shops (installation of bag filters, aspiration systems) made it possible to improve the working conditions of our workers, reduce dust emission and gas pollution in the workplace.

Thanks to the modernization of the filter and drying equipment of the Waelz shop, which includes the replacement of 6 drying drums, operating disk vacuum filters with modern press filters, not only electricity costs have been reduced, but also the consumption of natural gas has been significantly reduced – more than 674 thousand cubic meters have been saved in just four months of 2025!

In recent years, interest in solar energy, which is considered a technically accessible and absolutely safe for the environment energy source, has been growing especially rapidly. And we all understand perfectly well that in order to improve the environmental situation in our region, it is necessary not only to introduce technologies for cleaning air, water, wastewater, etc., but it is also simply necessary to use "green" energy in everyday life and in production.

Speaking about the introduction of renewable energy sources, I will note that at present, 3 photovoltaic stations with a capacity of 125, 200 and 160 kW per hour have been installed on the territory of the zinc plant, which have generated 203,657 kW of "green" energy in four months. And now we do not use natural gas to generate electricity, but consume it from the sun. In this way, we reduce carbon dioxide emissions into the atmosphere, avoid the greenhouse effect, improve the environmental situation in the region and save energy resources.

I would like to note that the human factor is of great importance in saving energy. It is important to systematically conduct explanatory campaigning aimed at increasing the literacy of employees in this area, as well as educating a careful attitude to energy resources. Visual campaigning for saving fuel and energy resources plays a major role at our enterprise: posters on saving water resources, electricity, and natural gas are hung in all workshops.

The management of the zinc plant, the heads of the workshops constantly say that electricity should be saved not only in production, but also in everyday life. For those families who consume more than 350-400 kW per month, it would be more expedient to install solar panels. Recently, we were visited by representatives of one company, who held a presentation of their products, and some of our workers were interested in them.

Thus, an integrated approach to solving the problems of the program for improving the energy efficiency of production allows the zinc plant team not only to save fuel and energy resources, but also to contribute to improving the environmental situation in the region and, what is equally important, to significantly facilitate the working conditions of their employees.

Georgiy EMANUILOV,

Chief Power Engineer of the Zink Plant