ENERGY SAVINGS ON MINE VENTILATION FANS USING QUICKWIN TECHNOLOGY A PERSPECTIVE

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ENERGY SAVINGS ON MINE VENTILATION FANS
USINGQUICK-WIN TECHNOLOGYA PERSPECTIVE
Dr. B. K. Belle bbelle_at_angloamerican.co.za
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Outline

• Introduction
• Energy Economy
• Carbon Market and Mine Ventilation Engineering
• Quick-Win Innovative Ventilation Solutions
• Implementation
• Conclusions and Recommendations

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ENERGY ECONOMY
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Energy Worldwide

• Large increase in energy demand forecast
• Resources becoming scarcer

• Geo-Political and Asian growth dominating
  headlines

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Energy Scenario

• In 2004, the global energy business-US2 trillion
  per year.
• The World Energy Council-1990 and 2020, global
  investment in energy --US16 trillion.
• Due to its strategic value, the energy sector is
  being driven by various forces such as
• Risks associated with security and reliability of
  energy supply
• Worldwide trend of energy sector de-regulation
• Birth of environmentally conscious societies
• State -of-the-art energy efficient technologies

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Energy Scenario-Southern Africa

• January 2008 ESKOM acknowledged the energy
  crisis until 2016
• Introduced concept of power conservation

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CARBON ERA1992 to
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Kyoto Country Status
Carbon News
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Kyoto Country Status

• Rio Earth Summit 1992-UNFCCC United Nations
  Framework Convention on Climate Change
• Adopted on May 9, 1992 and ratified by
  governments worldwide
• Under UNFCCC-the KYOTO Protocol was adopted in
  1997.
• The first major international agreement
  -Industrialized countries to reduce emissions of
  six greenhouse gases CO2, CH4, N2O, HFCs, CFCs,
  SF6 to 5-8 below 1990 levels between 2008 -
  2012.
• Kyoto Protocol- JI, CDM, IET Mechanisms

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Carbon Market

• Carbon Credits
• The reduction of Greenhouse gas emission levels
• Carbon credits are a potential new source of
  revenue in addition to revenue from energy
  savings.
• Carbon Market
• An entity where the carbon credits are validated
  and exchanged for monetary value by operations in
  developed and developing countries
• Energy Savings
• The reduction of energy consumption by increasing
  efficiency

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Energy Efficiency Accord

• Signatory-May 5 2005
• It is against this background that the National
  Business Initiative (NBI), with the active
  support of Business Unity South Africa,
  facilitated the process for a voluntary Energy
  Efficiency Accord-Signed by the mining industry
• National Energy Efficiency Accord
• Industry and Mining - 15 reduction in energy
  demand by 2015

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Carbon Stock Exchange

• Kyoto Protocol
• Carbon Economy

29 May 2008EUA DEC 2008  26.45 0.25 US
36.945
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MINE VENTILATIONENGINEERING
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Ventilation Design Parameters
27.5 C
308EC mg/m3
CH4 1.4 CO 25ppm
5 mg/m3
27.5 C
Regulatory Compliance Limits
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Gold Mine Example
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Underground Mining Ventilation
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Underground Mining Ventilation
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Underground Mining Ventilation
EFFICIENT
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Underground Mining Ventilation
INEFFICIENT
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Main Fan Operating Expenditure
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Comparative Power Consumption

• Ventilation fans consume a large quantity of power

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Mine Ventilation

• Mine ventilation is a significant cost component
  of mining.
• The main cost component of mine ventilation is
  the operation of main fans-US 50 Million-Opex.

• Some ventilation fans operating at low
  efficiencies (40 to 50 ).
• Modern technology 80-86

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INNOVATIVE SOLUTIONS
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Opportunities for Savings

• 1. Ventilation (Main Fan) Retrofit Opportunities
• Hermit crab technique
• Composite materials
• Variable speed drive
• Replacing over sized motors
• Ventilation on demand systems

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Hermit Crab Schematic
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Application-Cost Analysis

• 10 years forward application of existing energy
  reduction at Korean Steel Mill
• Application of Hermit Crab
• Efficiency gain of 12.3
• Cost US161,607
• NPV10 Electricity saving US565,000
• Reduction of 2,829 tonnes of CO2e
• NPV10 US 656,000 at US5.00 t/CO2e
• NPV10 US 1.85m at US26.39 t/CO2e

Spain
Korea
Philippines

• Average efficiency improvement 11.2
• Average power reduction 230kW pa (10)
• Average Return on Investment lt1 year

Source Flakt Woods
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Typical SA Scenario

• Large main fan
• Original design duty 250 m3/s _at_ 5.5 kPa (1 375 kW
  air power)
• Design Efficiency 73 (1883 kW input power)
• Current operating point 270 m3/s _at_ 3.6 kPa (972
  kW air power)
• Current efficiency 57 (1705 kW input power)
• Fit new impeller suited to current duty
• 270 m3/s _at_ 3.6 kPa at 81 efficiency
• 1200 kW input power
• Simple savings 505 kW at R1400 p.a. R707 000
  p.a
• Estimated capital cost of new impeller R1 000
  000
• Simple payback of 1.4 years

Spain
Korea
Philippines

• Average efficiency improvement 11.2
• Average power reduction 230kW pa (10)
• Average Return on Investment lt1 year

Source Flakt Woods
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110 MW Application

• 10 reduction in Main Fan energy usage across
  Group-A over 10 years
• Cost US 4.6m
• NPV10 Electricity saving US 16.1m
• Reduction of 80,745 tonnes of CO2e
• NPV10 US 18.6m at US5.00 t/CO2e
• NPV10 US 29.4m at US26.39 t/CO2e

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Composite Blades-Early Days
Table 5.0 Test Results of FRP Fans Vs.
Conventional Metallic Fans
Tested on the Test Rig as per ANSI/AMCA
210-85 Tested on Site
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Motivators
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Motivators
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Conclusions

• Quick Win Energy Saving Ventilation Technology
• Imperative to Create and Maintain Mine
  Ventilation Engineering Database on Energy
  Intensive Units
• Close Interaction between Mining/Planning and
  Mine Ventilation Engineering
• Large Opportunities--Energy Savings in the Carbon
  Market Era for Mine Ventilation Engineering

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Food for Thought!!!

• Late Prof. Lambrechts (1974, SA) recommended to
  mine management, the ventilation engineer should
  be given every opportunity to become an active
  member of the planning team, fully in the picture
  at all times and not simply left with the
  impossible task of ventilating a poorly planned
  mine