Compressed Air Network
Control of a Chiller Plant
Chilled Water Distribution Network
Air Cooling Units in Deep Mines
Flownex provided M-Tech the first-to-market advantage by providing clients in the mining industry proof of the economical benefit associated with the Air Cooling Units. Flownex provided fast and accurate solutions of the existing Chilling Water Cars and the proposed new Air Cooling Units. The simulation results were used to evaluate the business case of Air Cooling Units when it is implemented at depths in excess of 2km compared to the existing Chilling Water Cars utilized in the mining industry. The business case involved detailed calculations of what the influence of the addition or omission of surface cooling towers and chillers would be on the power consumption of the proposed system incorporating Air Cooling Units.
THEME: Optimizing for Energy Savings
Challenge: This case study ‘Compressor Optimization’, aims to demonstrate the capability of Flownex SE to achieve energy savings through a process of compressor and pipe design optimization studies using the Flownex simulation model to identify where the efficiencies can be achieved.
The case study presents how Flownex SE was successfully employed by AngloGold Ashanti to achieve considerable energy savings on one of their mining compressor and pipe work systems. The entire system was modeled in Flownex, demand load testing scenarios were simulated and system reaction data obtained. New philosophies and possible system modifications were tested in the model, these lead to identifying where the energy and cost savings could be made.
The main benefit of using Flownex SE to optimize the compressed are network performance in the mine was the iterative process which Flownex uses to optimize the system, this means all demand load scenarios and various system configurations could be tested easily and quickly once the representative simulation had been assembled. This allowed for consideration of all possible permutations and delivery of the most ideal configuration for all scenarios.
CASE STUDY: Styldrift Mine Air Reticulation System
Challenge: This case study ‘Styldrift Mine’, aims to demonstrate the capability of Flownex SE to create an accurate simulation model to carry out a design optimization study of a large compressed air network. To determine the ideal design with regard to sizing pipes, accumulators, compressor equipment and future expansion accounting for total equipment consumption and factored losses in the system.
The case study presents how Flownex SE was successfully employed on a large mining installation design project, where it successfully determined the operating conditions of a proposed installation to deliver an optimized final design. The case study describes how using a step by step approach in Flownex through a series of simulations the user can improve operational performance, test every possible demand load scenario. This shows that Flownex is not just a thermo fluids analysis tool, but it can also be used in the mechanical design optimization of thermo fluid systems in the mining industry.
One of the considerable benefits aside from delivering an optimized design on this project was the fact that the detailed mechanical design can be based on the Flownex optimum design recommendations. Thereby reducing the additional project and operational costs usually associated with over or under specification of equipment when an optimized design has not been fully simulated, tested and determined.