Simplified High-Level Investigation Methodology for Energy Saving Initiatives on Deep-Level Mine Compressed Air Systems

Rising electricity costs affects the profitability of South African deep level mines. Compressed air systems are some of the largest energy consumers on conventional deep level mines. These installations are not always operated efficiently and provides electricity cost savings opportunities. Energy savings companies (ESCOs) are typically required to carry investigation costs when evaluating savings potential. They are therefore required to take upfront risks without any guarantee of identifying feasible projects. One of the available tools to minimise the risk is by using less resource intensive approaches such as benchmarking. Conventional benchmarking of specific key performance indicators remain time intensive. It was identified that there is a need for a simplified benchmarking method that can highlight electricity cost saving potential on deep level mine compressed air systems. This paper presents an overview of a new benchmarking method that is less resource and time intensive than existing approaches. Power consumption data is typically available for large compressed air systems. The newly developed methodology requires only power consumption as input parameter. This new method reduces the cost and time spent to quantify cost savings potential on deep level mine compressed air networks. It has been shown that the simplified method can provide saving estimates that are up to 95% accurate. The new methodology was used to identify cost saving initiatives worth R60-million per annum.