Using the information gathered in Chapter 2, a design strategy was developed in Chapter 3. The new strategy was implemented to reconfigure the compressed air networks of two South African gold mines. The first case study was a reconfiguration that entailed the relocation of a compressor from an abandoned shaft to the main production shaft. The second case study focused on interconnecting two shafts with a pipeline to export compressed air from one section to another section. The following sections discuss the inner details of the reconfiguration strategy implementation. 4.2 Energy efficiency by repositioning a compressor System background 4.2.1 According to the nameplates of the compressors, at the time of the study Mine C was approximately forty years old. Mine C comprised three shafts and one gold plant. The shafts will further be referred to as three shaft (3#), four shaft (4#) and five shaft (5#). The gold plant will further be referred to as GP. The only operational shaft was 5#, mining the Basal and B Reefs [48]. The expansion on mining levels was part of near future plans for 5# [48]. Mine C used 4# for ventilation, pumping and as a second outlet for mined ore from 5# [48]. The expected remaining lifespans of 5# and 4# were approximately fifteen years at the beginning of 2012. Mine C's 3# had been decommissioned and only hosted a baseload compressor for mining activities at the other two shafts. An ESCO implemented an EE strategy on 5#'s underground compressed air network during 2011/2012. Control valves were installed on all the mining levels. The control valves were used to reduce the compressed air demand on underground levels during mining off-peak periods. In turn, a reduction in the power consumption of the compressors was achieved.
Electricity cost risks such as carbon tax, ECS and unavoidable tariff increases threaten the financial wellbeing of South African gold mines. Some of these proposed cost risks are however not enforced as yet. However, once approved, they could result in thousands of jobs being lost.The Eskom Integrated Demand Management (IDM) funding program for industrial projects has also been put on hold. With more than 97 large (367 MW total) projects already implemented on South African gold mines, these savings or projects were regarded as easier and with the largest savings. Therefore, new projects could be difficult to motivate due to longer payback periods of IDM funding being stopped.The aim of this study is therefore to investigate the total electricity cost risk reduction potential of one of the largest gold mining companies in South Africa. The electricity reduction potential will then be quantified in relation to the largest electricity consuming services and optimal production ratio.Benchmarking was used to provide the optimal point of production related to energy intensity. These results also provide electricity reduction targets for other South African gold mines.1.
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