IMPROVING COOLING SYSTEM EFFICIENCY WITH PRE-COOLING AJ Schutte 15 August 2012
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IMPROVING COOLING SYSTEM EFFICIENCY WITH PRE-COOLING
AJ Schutte
15 August 2012
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Introduction National power network under strain
Electricity price increases
Mining is electricity intensive
Cost effective mining
Inefficient mine cooling and ventilation system
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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
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Surface refrigeration system layout
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Mine cooling Surface refrigeration
Cooling load Mine production water
Bulk air coolers (BAC)
Cooling components Pre-cooling towers
Refrigeration machines
BAC thermal load contribution
Production thermal load contribution
Pre-cool tower thermal energy
Resultant refrigeration machine thermal energy
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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
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Pre-cool towers Layout
Fan
Mist eliminators
Spray nozzles
Fill
Production water cools
Crystals + solid particles
Electric motor
Mist eliminator
Fill
Ambient air
Water to pre-cool
dam
Water from chill dam
Spray nozzles
Gear box
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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
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Replaced pre-cool towers Original design
exceed requirement
New fill specified
Direct drive fans
New fill vibrates
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Results - Temperatures Inlet temperature of 30oC
Flow 340l/s
Old tower outlet temperature 23oC
New tower outlet temperature 19oC
Improvement of 4oCPre-cool tower electrical energy
Electrical energy saving
Refrigeration machine electrical energy
Pre-cool tower thermal energy
Pre-cool towers thermal energy gained
Resultant refrigeration machine thermal energy
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Results - Electricity
1 MW saving through out the day
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Mine refrigeration system power profile
Baseline Actual profile
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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
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The End
Questions?
Thank you