South African Energy Efficiency Convention (SAEE 2011)

ANGLOGOLD ASHANTI COMPRESSOR OPTIMIZATION PROJECT THE POTENTIAL OF SYSTEM CFD CODES IN THE MINING INDUSTRY
Jean Greyling
Water and Energy Engineer, AngloGold Ashanti Engineering Field Services, South Africa Region, Vaal River, North West Province, South Africa

ABSTRACT The key discussion for the paper is the usage of System Computational Fluid Dynamic (SCFD) codes to solve the system problem that occurs when trying to give solutions for operational plants on efficiency improvements and their integration into dynamic networks when the system reacts on a time base constraint. The Industrial Energy Efficiency (IEE) Project emphasizes the need to look at system optimization as opposed to components within that system as savings are much more significant. Component saving was in the region of 2-10% where system savings came to 47% in some instances [4]. Of importance is the effect of optimization on all components that make up the system.

Khotsong, adds load to the current energy profile and production staying fairly constant. Currently Mponeng is the deepest mine in the World with these projects looking to exceed 4000m underground. Internal business plan predications show that unless even further savings are achieved the targets are not reachable from high heat and mining loads increases due to Virgin Rock Temperatures (VRT) at these depths. The Multi Year Price Determination MYDP 2 [3] indicates that the percentage price increase for 20011/12 is 25.8% and 2012/13 at 25.9%, this has significant effects on the total company input costs and in order to stay competitive in global markets every opportunity to reduce costs should be looked at. The processes that make up 70% of our monthly energy usage are Main Ventilation fans, Refrigeration, Pumping and Compressed air. Ventilation and Refrigeration are regulatory requirements from the Mine Health and Safety Act and process optimization with system loss reduction are commonly the best method of improving energy requirements and efficiency. Pumping is very integrated with refrigeration requirements, so by improving on one system the other is always affected. The key discussion for the paper is the usage of SCFD codes to solve the system problem that comes from understanding and providing solutions for operational plants with their incorporation in networks, also the efficiency improvements and their integration into dynamic networks that react on a time base constraint.

1.

INTRODUCTION

The mining industry faces the daunting task of serving one of our countrys greatest economic threats when considering the current situations of our electrical supply utility Eskom. Indicators over the past months show increasingly worrisome statistics as seen from the depleting reserve margins during the evening peaks bearing in mind the high escalation in tariff costs. Looking at the Medium Term Risk Mitigation Plan (MTRMP) the shortfall for 2012 and 2013 is still in the region of 9 TWh [1] and feedback from the Energy Intensive User Group (EIUG) shows no significant step changes until Medupi is operational and then we are still not out of the woods. AngloGold Ashanti (AGA) signed the energy accord in 2005 and committed ourselves to achieving the Power Conservation Program (PCP) or Energy Conservation Scheme (ECS) target of 10%. The National Energy Efficiency Strategy [2] calls for an energy demand reduction from industry and mining equal to 15% by 2020. Currently we are exceeding this target by operation at approximately 16% of PCP on a month to month basis. The challenge however is to remain within the target as additional deepening projects at Mponeng and Moab

Figure 1. Breakdown of Energy Usage by Process

South African Energy Efficiency Convention (SAEE 2011)

The Industrial Energy Efficiency (IEE) Project emphasizes the need to look at system optimization as opposed to component in that system savings are much more significant [4]. Component saving was in the region of 2-10% where system savings came to 47% in some instances.

2.

CFD vs. SCFD

A CFD codes solves the differential equations for conservation of mass, momentum and energy on a per unit volume basis with several assumptions on a staggered grid approach. CFD solutions generally involve the solution around a single component and are not always suited for a system with several components [5]. An SCFD code looks at the complete network in a one dimensional system format with nodes and elements. Fluid properties, mass and energy is solved on the nodes and momentum is solved at the elements. If a one dimensional solution is inadequate, 3 dimensional structures can be built up as an assembly of elements for different coordinate directions [5]. Figure 2 illustrates the connection of nodes and elements as used in the SCFD code used for case 1.

Figure 3. Vaal River Compressed Air Ring

3.

COMPRESSOR OPTIMIZATION

The usage of compressed air contributes to approximately 17% of the total monthly bill in AGA South Africa operations and forms the basis for the SCFD discussion. The Vaal River compressed air network consists of several compressors that are connected with piping infrastructure (750mm) over a 32 km length. Some of the compressors that operate on the network range from 30 000 to 100 000 CFM capacity and their general operating function is to accommodate the underground base loads that range between 75 and 106 kg/s. Figure 4 provides an overview of the total compressed air consumption during peak and off peak periods for the last quarter in Vaal River.

Figure 2. Nodes and Elements [6].

The SCFD uses an advanced pipe model that can be used for both compressible and incompressible flow. Pressure drop is calculated using the Darcy-Weisbach model through the element. In the SCFD the compressor and pumps are modelled by interpolating from nondimensional performance maps based on stagnation properties [5].

Figure 4. Average consumption during peak and off peak.

Two main elements, Pipes and Compressors, were used in the SCFD code to simulate the pressure changes and compressor performance within the ring. A non dimensional transformation was done using equation (1) to transform the compressor graphs for usage in the SCFD code as shown in figure 5. During a study to relocate one of the 30 000 CFM machines the SCFD code was used to build the network

South African Energy Efficiency Convention (SAEE 2011)

and evaluate ring pressure conditions. The crucial element that cant be addressed by normal CFD codes is how the pressure set point would react with the reservoir effect of the pipeline, and also the compressor vane control opening and closing and how it affects the ring pressure.

The problem is that if consumption exceeds the supply the ring pressure is fairly constant to a point were the reserve is consumed from the reservoir. The system pressure as an effect starts to drop and the compressor Master controller actions a command for the Moore controllers to open guide vanes. This is not a problem for the system to respond to at off peak load the challenge is during high peak. As the reservoir is then consumed to a point where the pressure starts lowering additional compressors have to be started to not only make up the mass difference but also build up the system mass. Problem with this is that due to the great depth of our shafts the surface ring pressure is lowered to take full advantage of adiabatic auto compression down the main shaft columns. When the surface pressure falls below a certain point the mass is increased in the shaft columns to try and build up pressure at the drill points. The shaft columns only have capacity for a certain flow rate and when exceeded the effect of auto compression is lost. The reservoir acts as a damper between supply and consumption and if the Moore controller cant respond fast enough with vane opening the system pressure is lost. The effect is that additional compressor must be started and so doing increasing the network energy consumption. Important to remember is that not only the energy consumed kWh is billed but the Maximum Demand (MD) charges. Addressing the problem came from increase the speed of vane control to minimize the pressure lost on the system. Problem here is to give the system the ability to understand the imbalance of mass and respond accordingly. Although simple in explanation, when we considering the magnitude of machinery and control that is required to respond from a central point. Also looking at taking into account machine sizing and authorization from efficiency, the problem becomes more complicated. From the SCFD different vane positions were simulated to assess the pressure profile and how the compressors and ring pressure would respond. It was found that the problem is in only looking at pressure at the Moore controller PID. A modification is needed in the return control loop so to consider the difference in supply and consumption for the speed of vane control. So if the supply and consumption differs by 5 kg/s the response is slower on the vane angle opening than if the consumption differs by 10 kg/s. This process was iterative till proper optimization of vane control speed was found. Also during the optimization phase the energy input was minimized to produce the largest amount of air (kg/kWh optimization), it was found that the controlling on some of the peak load machines control philosophy was incorrect.

8# Compressors - Great Noligwa (40 000 CFM - Sulzer) 14 Pressure Ratio (P_o/P_i) 12 10 8 6 4 2 0
0 20000 40000 60000 80000 30' Guide Vane 45' Guide Vane 60' Guide Vane 107' Guide Vane 90' Guide Vane

Flow (m3/hour)

8# Compressors - Great Noligwa (40 000 CFM - Sulzer)

14

Pressure Ratio (P_o/P_i)

12 30' Guide Vane 10 8 6 4 2 0 0 100 200 300 400 500 45' Guide Vane 60' Guide Vane 107' Guide Vane 90' Guide Vane

((m*SqrtT/P) Figure 5. Non Dimensional Transformation

(1)
3

South African Energy Efficiency Convention (SAEE 2011)

Efficiency or most efficient compressors for us is defined by delivering the highest amount of air with the smallest energy input kg/kWh. The SCFD indicated that guide vane control on the machines reduced some of the efficiencies by as much as 37% and increased the total kWh consumption with a lowered air output. A simple illustration is shown in figure 6 when a 40 000 CFM machine is controlled between 14kg/s and 18kg/s. A common mistake in industry is to assume the compressor efficiency over the full range of control as a linear curve with work input (Watts).

Base load optimization to establish a mine specific load profile for the working places. Pipe infrastructure sizing evaluation to have a related pressure drop per meter established. 4. RESULTS

Some of the results form the work thats been done thus far are indicated in the Chart Runner control charts below: Figure 12 shows how the kg/kWh has improved since the start of the project in January 2011. The bandwidth between the upper and lower limits is reduced indicating better control on the overall system. Just to keep in mind this only shows how efficiently air is controlled and not the control of the amount consumed as shown in figure 13 for the same period. Figure 17 is the table of the possible energy savings achievable from running the different vane positions for the kWh optimization. As mentioned this is done by an iterative process in the SCFD of by using the build in optimization tool. In the simulation the designer must understand the system constraints and incorporate it into the simulation for accurate results.

Figure 6. Power Required at Vane Angle for 40 000 CFM Machine.

Currently control principles is re-investigated by using the SCFD to optimize the 24 MW base load and try to reduce it to 21.2 MW on control. For Mponeng we established an individual control matrix in the master controller. By circulating the guide vane control between the machines based on feedback to the master controller a 1 MW saving was made. We achieved this with the Master controller, by instead of reducing the vane opening on all the compressors simultaneously rather cut back on the less efficient machines one at a time till the desired pressure is achieved. This keeps the most efficient machines in production and minimizes the losses in kg/kWh. The SCFD not only allowed the simulation of the complete network with all of its components and how they react to certain boundary conditions but also allowed for the testing of new control philosophies and system upgrades. Some of the new and future control philosophy includes: Controlling pressure profile according to machine high efficiency point. Using compressed air network as reservoir with control on demand and supply from mass flows. Matrix table to allow system and operators to understand combination of machines to operate at certain flow regions.

Figure 7. Kg/kWh Vaal River.

Figure 8. Consumption Profile West Wits

South African Energy Efficiency Convention (SAEE 2011)

Mr Jean Greyling holds a Masters degree in Mechanical Engineering from the North West University, a Government Certificate of Competency (GCC) for Mines and Works and is a registered Certified Energy Manager (CEM). At present he is the Water and Energy Engineer for the South African Region of AngloGold Ashantis operations, a role that he has worked in since October of 2010.

Figure 9. Compressor Energy Saving Table from Optimization.

The total investment on the project is R5m with an annual saving of 24 GWh. 5. REFERENCES

[1] Medium Term Risk Mitigation Plan (MTRM) for electricity in South Africa 2010 - 2016, published by Department of Energy DoE, 17 September 2010,pp 78. [2] The National Energy Efficiency Strategy of South Africa, Published by Department of Energy, DoE, April 2011, pp. 35 43 [3] Revenue Application - Multi Year Price Determination MYPD2, Published by National Energy Regulator of South Africa NERSA, February 2010. [4] Hartzenburg, A., Industrial Energy Efficiency (IEE) Project Energy System Optimization Presentation: Mining and Industrial Energy Optimization Seminar 21 June 2011. [5] Landman, W.A., Greyvenstein G.P. Dynamic System CFD Simulation Code for the Modelling of HTGR Power Plants 22 September 2004, pp 2-11. [6] Flownex Simulation Environment General User Manual, Version 8.0.13 Date Accessed: 01 July 2010. [7] Rousseau, P.G., Van Antwerpen, H.J. , Greyvenstein, G.P., The System CFD approach applied to a Pebble Bed Reactor Core. pp 3-15. [8] Greyvenstein, G.P. The application of System CFD to the design and optimization of high temperature gas cooled Nuclear power plants May 2006. pp 511. 6 AUTHOR