Choosing a Greener Option
Fowler converts its power supply at Rosewarne Quarry from diesel to electricity
As global leaders debated climate change action at the UN Climate Change Conference last November, the world again became focused on global warming and reducing greenhouse gas (GHG) emissions. Recent wildfires and drought conditions in western Canada, coupled with flooding in B.C. and Newfoundland, are close-to-home realities showing how the Canadian climate is changing.
Released in 2020, the federal government’s plan Climate Actions for a Healthy Environment and a Healthy Economy contains an electrification strategy to reduce GHG emissions from energy by replacing fossil fuels with electricity.
The message was taken to heart in Ontario’s aggregate industry. In the case of OSSGA member Fowler Construction, the producer recently took its own steps towards a greener world at its Rosewarne Quarry in Bracebridge. The company’s Rosewarne Power Conversion Project, completed in June 2021, involved converting the diesel generator powering its crusher operations to electricity supplied by the local electric utility, Lakeland Power.
“The large 1.2-megawatt diesel generator powering aggregate operations was nearing the end of its life,” says James Gordon, materials manager for Fowler. “We began looking at replacement options that were greener and more sustainable.”
Fowler contacted Lakeland Power and learned that an electrical option would provide significant operating cost savings in a reasonable timeframe and would dramatically reduce the quarry’s carbon footprint. The plan received senior management approval and the conversion project began in October of 2020. The key steps in the plan included upgrading electrical capacity of the quarry to 27.6 kV, combining the quarry’s electrical needs into one supply line, and running the new electrical line to the asphalt and crusher plants on the property.
“The first step in the process was to prepare a trench that would bury the new power line on the quarry property and run it to the plants,” says Riley Sewell, materials field engineer in training (EIT) and project manager for the conversion. “This approach reduces line strike power outages that could occur with above ground power line poles on-site.” From a health and safety standpoint, a below-grade electrical line reduces the risk of injury to workers.
The trenching was completed in the fall of 2020 and “jump started” the continuing work on the project in the spring of 2021. The next step was bringing the new power line onto the quarry property. This was no easy task. The power source for the 27.6 kV service was on the other side of Highway 11 and at the other end of Rosewarne Drive, where the quarry is located. Completing this step included higher rated power poles, new metering, engineering and commissioning.
To complete the conversion project, a new power line was brought onto the quarry property and higher rated power poles were installed.
Once on the property, the new line was fed through the trench and hooked up to the crusher and asphalt plants. A number of electrical components were needed to complete the conversion, including transformers for each plant, custom circuit breakers, ground fault protection and upgraded capacitor banks at both the aggregate and asphalt operations to reduce peak loads.
GOING LIVE
On June 24, 2021, Fowler Construction president Larry Wilson was finally able to announce the start of operating off the new energy source. As he said at the time, “Fowler went live at their Rosewarne Quarry in Bracebridge with a conversion project that changed our crushing power source from diesel to electricity. The new electrical power is being supplied by Lakeland Power. The end result of this change is a vastly more sustainable and environmentally friendly source of power to help build new roads in Muskoka and surrounding regions. Fowler will be reducing their annual CO2 emissions by 1,100 metric tonnes, which we believe will be great for the community we work and live in.”
The new electrical power supply includes the capability to increase power output if and when it is needed. Another environmental benefit from the conversion is the significant reduction in noise for workers and the community around the quarry that emanated from the diesel generator.
Fowler is also realizing a solid return on investment on the project. Though the capital costs are similar, the operating costs on electricity versus diesel are a significant 17 per cent lower. Operating costs are coming in under budget, and Fowler now is considering similar conversion projects for some of its other sites. “With this project completed, we will be looking at the case for converting more of our quarries and pits,” says Gordon. “The increasing cost of gasoline and diesel is making these conversions more feasible for the company.”
Gordon acknowledges the support of all the partners on the project, including Lakeland Power, Hyline Utility Solutions and Dawson Electric. “I also want to thank Riley and the other members of the Rosewarne Quarry staff who worked on the trenching, electrical team and the design and installation. In the challenging time of COVID when supply of needed materials for the project was difficult, the staff team came through and reduced the timeline for the project.”
Sewell adds: “This new power supply was installed under budget and will now provide Fowler with clear operational savings and environmental benefits going forward as fuel costs continue to climb.”
As a family-owned business providing aggregate and road construction services in central Ontario, Fowler Construction is committed to making an environmental difference in the community it serves. The company’s desire to find sustainable solutions to its operations is something other aggregate suppliers can emulate to reduce the effects of climate change. “If we all look at large or small steps like this,” says Wilson, “we will make a difference in creating a greener future.”