Abstract

Artificial cooling remains vital to the deep-level mining industry. This is mainly to ensure a safe underground working environment. Unfortunately, the refrigeration systems of South African gold mines are outdated. Aging infrastructure and increasing distances to active mining areas present this industry with a unique set of cooling challenges. Mines are deeper and more complex than ever, yet their refrigeration systems operate according to original design specifications. The importance of mine refrigeration systems adapting to a dynamic environment becomes evident. One solution to this challenge is to re-evaluate the control of refrigeration systems based on dynamic cooling needs. Control optimisation strategies were implemented on a case study to improve the overall performance of a refrigeration system. The implementation of these strategies resulted in multiple benefits for the mine. The operational performance of the refrigeration system was optimised, resulting in both service delivery improvements and energy efficiency. During summer months the chill dam temperature decreased by 1°C at a lower energy consumption of 38 MWh per day. This accumulates to a financial cost saving of R9 million per annum. This study proves that operational performance increases are possible through dynamic control optimisation of deep-level mine refrigeration systems.

Highlights

  • The South African gold mining sector is an industry synonymous with the term ‘deep-level mining’

  • The cooling provided in the evaporator, as stipulated by Equation 1, is used to determine the chiller’s coefficient of performance (COP), which is a measure of how much cooling is provided for each electrical unit consumed by the chiller compressor motor [12]

  • A case study was identified on a South African deep-level gold mine

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Summary

Nov 2018

Artificial cooling remains vital to the deep-level mining industry. This is mainly to ensure a safe underground working environment. Control optimisation strategies were implemented on a case study to improve the overall performance of a refrigeration system. The implementation of these strategies resulted in multiple benefits for the mine. During summer months the chill dam temperature decreased by 1°C at a lower energy consumption of 38 MWh per day. This study proves that operational performance increases are possible through dynamic control optimisation of deep-level mine refrigeration systems. Een oplossing vir hierdie unieke uitdaging is om die beheer van verkoelingstelsels te herevalueer om aan veranderende verkoelings behoeftes te voorsien. Implementering van hierdie strategieë het verskeie voordele tot gevolg gehad, onder andere verbeterings in dienslewering teenn laer energie verbruik. Hierdie studie bewys dus dat operasionele verbeterings in dienslewering moontlik is deur dinamiese beheer van myn verkoelingstelsels

INTRODUCTION
Preamble
Refrigeration system control
Compressor guide vane control
Evaporator water flow control
Condenser water flow control
Integrated control method
Research relevant to refrigeration system control
DYNAMIC OPTIMISATION OF DEEP-LEVEL MINE REFRIGERATION CONTROL
Identification
Detailed investigation and control characterisation
Control solution development and implementation
Introduction
Summer
Winter
Summary
General impact of results on industry
CONCLUSION
Full Text
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