Molycop Strives for Greater Sustainability
- Case Studies
- May 13, 2025
- Northmore Gordon
About Molycop
Molycop is the largest and most experienced manufacturer and supplier of grinding media to mining operations worldwide. Molycop is striving for greater sustainability through superior resource efficiency and defining a new standard of environmental performance.
How we helped
Since 2006, the Northmore Gordon Newcastle team has helped Molycop achieve annual energy cost savings and maximise their return on investment in energy projects through:
- Energy management strategy
- Energy audits
- Project development support
- Grants and funding options
- Energy and carbon reporting
- Energy and carbon certificates
The Challenge
Molycop is the largest and most experienced manufacturer and supplier of grinding media to mining operations worldwide. Whilst energy has always been important, and compliance with regulation critical, the Waratah site has since expanded its focus to form a long-term goal of decarbonisation through an end-toend energy strategy.
With over 20 years of experience and extensive knowledge in the steel sector, Northmore Gordon was selected to help Molycop develop their comprehensive portfolio of energy projects. Northmore Gordon consultants worked closely with the client’s energy and operations teams to investigate their processes and identify opportunities for improving efficiency. More recently, Northmore Gordon’s Energy and Carbon experts have been assisting Molycop to plan towards a low carbon emissions steel-making process.
The Process
Northmore Gordon adopted a systematic approach to identifying and prioritising energy and carbon management opportunities. This included investigating capital projects, low cost process improvements, government funding and revenue from energy and carbon certificates.
Our Energy and Carbon Consultants helped Molycop access over one million dollars worth of revenue through the NSW government’s Energy Saving Scheme and capital grants. Northmore Gordon also assisted Molycop in their purchasing of renewable energy through a corporate Power Purchase Agreement.
Some projects that have been implemented include:
- Installing Variable Speed Drives on large fans and pumps, including high voltage motors
- Modifying controls on fume extraction and cooling systems
- Improving yield
- Improving furnace controls
- Reducing pilot flame gas consumption
- Upgrade bag house
- Improving furnace heat recovery system
- Installing heat recovery on ladle preheating equipment
- Cooling tower upgrades
Outcome
Through Northmore Gordon’s multi-disciplinary approach, Molycop’s energy savingsElectricity or gas savings or both. has grown to over $1.5M per annum. The consequential reduction in Greenhouse gas emissions has resulted in 15K tonnes of corresponding carbon emissions abatement each year. This has resulted in over $12M in energy costs and certificate revenue over the course of the project.
Do you need help developing a decarbonisation strategy? Contact: c.morgan@northmoregordon.com
A global leader in grinding media, mining chemicals, and rail consumables, supporting the mining and resources sector with innovative, sustainable solutions.Industry
Manufacturing
Location
Australia
Angela Clarke
Principal Engineer
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Get in touch
Australia
1300 854 561 (Advisory)
1300 878 500 (Certificates)
Melbourne
Suite 1, Level 4
607 Bourke Street
Melbourne
VIC 3000
Singapore
Singapore
1 Keong Saik Road,
Singapore 089109
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Services
- Energy Audit Services
- M&V Services
- EEO Assessments
- Corporate Energy and Carbon Management
- Grants and Program
- Strategic Energy Sourcing
- Virtual Energy Manager
- Climate Active Certification
Sectors
- Animal Processing
- Chemical Processing
- Commercial Buildings
- Food & Beverage
- Manufacturing
- Mining
- Oil & Gas
- Pharmaceutical & Health Products
- Public Sector
- Waste & Wastewater
- Wood, Paper & Cardboard Processing
Upgrades
- Boiler Upgrades
- Commercial Lighting
- Hot Water Systems
- Mid Scale Solar
- NABERS
- Public Lighting
- Refrigerated Display Cabinets
- Solar PV Small Scale
- UPS
Certificates
- Live Certificate Prices
- International Renewable Energy Certificates
- Tradable Instrument for Global Renewables
- Australian Carbon Credit Units
- Energy Savings Certificates
- Large-scale Generation Certificates
- Small-scale Technology Certificates
- Victorian Energy Efficiency Certificates
Government Schemes
Helpful Links
What does Molycop do?
Molycop is the largest and most experienced manufacturer and supplier of grinding media to mining operations worldwide. It is described as a global leader in grinding media, mining chemicals, and rail consumables, supporting the mining and resources sector with innovative, sustainable solutions.
What sustainability goal is Molycop pursuing?
Molycop is striving for greater sustainability through superior resource efficiency and defining a new standard of environmental performance, with its Waratah site pursuing a long-term goal of decarbonisation through an end-to-end energy strategy.
How long has Northmore Gordon worked with Molycop, and what services have they provided?
The Northmore Gordon Newcastle team has helped Molycop since 2006 achieve annual energy cost savings and maximise return on investment in energy projects through energy management strategy, energy audits, project development support, grants and funding options, energy and carbon reporting, and energy and carbon certificates.
Why was Northmore Gordon selected to help Molycop?
Northmore Gordon was selected due to its over 20 years of experience and extensive knowledge in the steel sector, helping Molycop develop a comprehensive portfolio of energy projects, with consultants working closely with Molycop's energy and operations teams to identify efficiency opportunities.
What approach did Northmore Gordon take in the process of helping Molycop?
Northmore Gordon adopted a systematic approach to identifying and prioritising energy and carbon management opportunities, investigating capital projects, low-cost process improvements, government funding, and revenue from energy and carbon certificates.
How much funding did Northmore Gordon help Molycop access, and through what schemes?
Northmore Gordon's Energy and Carbon Consultants helped Molycop access over one million dollars worth of revenue through the NSW government's Energy Saving Scheme and capital grants, and also assisted Molycop in purchasing renewable energy through a corporate Power Purchase Agreement.
What kinds of energy efficiency projects have been implemented at Molycop?
Projects implemented include installing Variable Speed Drives on large fans and pumps (including high voltage motors), modifying controls on fume extraction and cooling systems, improving yield, improving furnace controls, reducing pilot flame gas consumption, upgrading the bag house, improving furnace heat recovery systems, installing heat recovery on ladle preheating equipment, and cooling tower upgrades.
What were the outcomes of Northmore Gordon's work with Molycop?
Through Northmore Gordon's multi-disciplinary approach, Molycop's energy savings have grown to over $1.5M per annum, resulting in 15,000 tonnes of corresponding carbon emissions abatement each year, and over $12M in energy costs and certificate revenue over the course of the project.
Who is the key contact for Molycop's decarbonisation strategy work, and how can they be reached?
Angela Clarke, Principal Engineer, is listed as the contact associated with the Molycop case study; those needing help developing a decarbonisation strategy are directed to contact c.morgan@northmoregordon.com.
In what industry and location does Molycop operate according to the case study?
According to the case study, Molycop operates in the Manufacturing industry and is located in Australia.
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