Energy savings on mining compressed air networks through dedicated process plant compressors

Most large gold mines in South Africa have centralised compressor houses which supply compressed air for a pipe network system. The various operational pneumatic equipment found on these sites usuallyrequiresdifferent air flows and pressures. These multiple and varied requirements must be considered when an energy savings project is to be implemented. Very often a mine compressed air system is operating at a higher pressure than required for several reasons. One of these is the limitations set by the process plants connected to the compressed air network. The pneumatic equipment of these plants requires high pressure and low air flow. To supply this high pressure to the process plant the entire compressed air ring must supply air at a higher pressure. The solution to this problem would be operating a dedicated compressor for the individual components requiring high pressure air. This will allow the plant to be isolated from the compressed air network. The network pressure can then be reduced while the process plant is supplied with the high pressure it requires. The result of this method is a reduction in the energy consumption of the network's compressors due to the reduced system pressure. A further advantage is that the process plant is supplied from a dedicated high pressure supply and will not be subjected to the random fluctuations of a communal compressed air network. Another benefit is that any moisture in the air from the small dedicated air compressor can be easily removed. Excess moisture in the compressed air system can condensate in the pneumatic equipment and cause damage and/or failure. Energy savings on the compressed air network as well as operational benefits to process plants are shown to be viable and sustainable options when separating high pressure from low operational pressure systems.