Sibanye-Stillwater (via Energy Drive)

Sibanye-Stillwater, one of the world's largest platinum group metals and gold producers, faces energy costs that represent a significant portion of total operating expenditure across its deep-level mining operations. Mining equipment — hoists, conveyors, ventilation fans, and pumps — runs continuously at fixed speeds regardless of actual load demand, consuming power inefficiently around the clock. In an industry where margins are directly tied to commodity prices outside management's control, unmanaged energy draw across multiple shaft systems creates both a cost burden and a sustainability liability that compounds with scale.

Working through Energy Drive, Sibanye-Stillwater deployed Rockwell Automation's energy-efficient variable frequency drives (VFDs) across key mining equipment applications. VFDs regulate motor speed in proportion to actual process demand rather than running at fixed full speed, eliminating the excess energy consumption inherent in traditional fixed-speed motor control. The implementation targeted high-consumption assets — most likely ventilation, pumping, and conveyor systems — where load variation is greatest and savings potential is highest. Rockwell Automation's Allen-Bradley drive platform was selected for its reliability in harsh underground environments and its compatibility with existing control infrastructure, allowing integration without wholesale system replacement. Energy Drive served as the implementation partner, managing site-level engineering and commissioning.

The deployment delivered significant energy savings across Sibanye-Stillwater's targeted operations, reducing consumption on affected equipment by matching motor output precisely to load requirements. While specific kilowatt-hour or rand-value figures are not disclosed in available source material, VFD retrofits on mining-scale motors (typically 100kW–several MW per unit) routinely yield energy reductions of 20–50% on variable-load applications. Qualitative outcomes include:

• Reduced peak demand charges alongside consumption savings
• Extended motor and mechanical equipment lifespan due to softer starts and reduced thermal stress
• Improved operational visibility into energy usage per asset
• Progress toward Sibanye-Stillwater's broader sustainability and carbon reduction commitments

• Target variable-load assets first — ventilation fans, pumps, and conveyors with fluctuating demand deliver the fastest VFD payback in mining environments.
• Harsh-environment compatibility is non-negotiable — drive selection must account for dust, humidity, and vibration conditions typical of underground and surface mining sites.
• Integration with existing control systems reduces deployment risk — choosing drives compatible with installed infrastructure avoids costly control system overhauls.
• Energy savings compound at scale — for multi-shaft operations like Sibanye-Stillwater's, even modest per-site reductions aggregate into material cost impact across a portfolio.
• Sustainability framing unlocks capital approval — positioning VFD projects under ESG and emissions reduction goals alongside OpEx savings strengthens the internal business case.