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IMPROVING COOLING SYSTEM EFFICIENCY WITH PRE-COOLING AJ Schutte 15 August 2012

IMPROVING COOLING SYSTEM EFFICIENCY WITH PRE-COOLING AJ Schutte 15 August 2012. Introduction. National power network under strain Electricity price increases Mining is electricity intensive Cost effective mining Inefficient mine cooling and ventilation system. South African mining.

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IMPROVING COOLING SYSTEM EFFICIENCY WITH PRE-COOLING AJ Schutte 15 August 2012

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  1. IMPROVING COOLING SYSTEM EFFICIENCY WITH PRE-COOLING AJ Schutte 15 August 2012

  2. Introduction • National power network under strain • Electricity price increases • Mining is electricity intensive • Cost effective mining • Inefficient mine cooling and ventilation system

  3. South African mining • Reduce operational cost • SA mining depth requires cooling • Surface refrigeration system • System components • Dams and transfer pumps • Heat exchange towers • Refrigeration machines

  4. Surface refrigeration system layout

  5. Mine cooling • Surface refrigeration • Cooling load • Mine production water • Bulk air coolers (BAC) • Cooling components • Pre-cooling towers • Refrigeration machines

  6. Mine water quality • Production cause water temperature increase • Salts dissolve • Evaporation increases solution concentration • Water treatment • Solid particles suspension • Settlers • Mine production surpass settlers and treatment

  7. Pre-cool towers • Layout • Fan • Mist eliminators • Spray nozzles • Fill • Production water cools • Crystals + solid particles

  8. Case study: Replace pre-cool towers • Mine production exceeding infrastructure • Summer refrigeration operate at 100% • Winter period maintenance • High efficiency film fill used • Tower fan maintenance

  9. Replaced pre-cool towers • Original design exceed requirement • New fill specified • Direct drive fans • New fill vibrates

  10. Results - Temperatures • Inlet temperature of 30oC • Flow 340l/s • Old tower outlet temperature 23oC • New tower outlet temperature 19oC • Improvement of 4oC

  11. Results - Electricity • 1 MW saving through out the day

  12. Conclusion • Replacing mine pre-cool towers resulted in a 4oC colder outlet temperature • This resulted in 24hour average electricity saving of 1MW • Fans utilisation increased • Winter period pre-cooling now possible

  13. The End • Questions? • Thank you

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