16 Aug 2011 Wynand Oosthuysen KDC Energy Conservation AMRE-SACEA JOINT MEETING
16 Aug 2011
Wynand Oosthuysen
KDC Energy Conservation
AMRE-SACEA JOINT MEETING
• Impact of Electricity on KDC
•Escalation on Electricity Cost
•Make-up of the Bill
•Counter measures taken
Content
2
Impact of Electricity on KDC
3
240
250
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340Ju
n-06
Aug
-06
Oct
-06
Dec
-06
Feb-
07A
pr-0
7Ju
n-07
Aug
-07
Oct
-07
Dec
-07
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08A
pr-0
8Ju
n-08
Aug
-08
Oct
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09A
pr-0
9Ju
n-09
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10A
pr-1
0Ju
n-10
Aug
-10
Oct
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11A
pr-1
1Ju
n-11
kWh
Milli
ons
KDC Energy Consumption
Reduction of and average of 44 MW
Impact of Electricity on KDC
4
Electricity cost increase year on year even though theenergy consumption is decreasing.
R 0
R 20
R 40
R 60
R 80
R 100
R 120
R 140
R 160
R 180
R 200
Jul-0
6Se
p-06
Nov
-06
Jan-
07M
ar-0
7M
ay-0
7Ju
l-07
Sep-
07N
ov-0
7Ja
n-08
Mar
-08
May
-08
Jul-0
8Se
p-08
Nov
-08
Jan-
09M
ar-0
9M
ay-0
9Ju
l-09
Sep-
09N
ov-0
9Ja
n-10
Mar
-10
May
-10
Jul-1
0Se
p-10
Nov
-10
Jan-
11M
ar-1
1M
ay-1
1Ju
l-11
kWh
Milli
ons
KDC Energy Cost
Escalation on Electricity Cost
5
0
50
100
150
200
250
300
350F0
2
F03
F04
F05
F06
F07
F08
F09
F10
F11
F12
F13
F14
c/kW
h
Low Season Tariff
Peak Standard Off Peak
Expect increase of 28.5%
Escalation on Electricity Cost
6
0
50
100
150
200
250
300
350F0
2
F03
F04
F05
F06
F07
F08
F09
F10
F11
F12
F13
F14
c/kW
hHigh Season Tariff
Peak Standard Off Peak
Expect increase of 28.5%
Make-up of the Bill
7
25.7%
15.0%
27.6%
9.3%
5.4%0.0%
8.0%
8.6% 0.3% Consumption: Off Peak
Peak
Standard
Electrification and Rural SubsidyRetail Enviromental Levy ChargeReactive Energy Charge
NAC and TX NAC
Network Demand Charge
Admin / Serv / Fix
Make-up of the Bill
8
83.0%
8.0% 8.6%
0.3%
Total Energy Dependant Charges
NAC and TX NAC
Completed Initiatives:• Pump scheduling.• Geyser Load switches in low density residential
areas.• In line heater at high density residential areas.• Energy efficient lighting.• Guide vane control on main ventilation fans.• Re-evaluate power factor correction installations.• Compressed air load control.• KDC East 1# Water System Optimization• Energy recovery turbines K3 & D5 - ±6.5 MW• Introduction / extension on closed loop cooling.• Extensive installation of ventilation seals.
Counter measures taken
9
Pump Scheduling at 5 Shaft KDC WestCompleted Initiatives
10
Intelligent Pump Scheduling and ControlOpportunities • East 5#
Scheduling out of Eskom evening peak time i.e. 6pm to 8pm4 Stages to surface with 6 pumps per stage/level into dams on 52L, 42L, 23L and IPC with current dam capacity
Max Demand Load Shift 8.22 MW
Pump Scheduling at 5 Shaft KDC WestCompleted Initiatives
11
12.547 MW Shifted
Geyser Load switches in low density residential areas-Completed Initiatives
12
Village Geyser Control
Opportunities • East Village (~976)• PhomolongVillage (~215)• LetsasingVillage (~354)•West Village (~160)• Single Quarters (~16)• Other (~9)
TOTAL ~ 1,730Households
Max Demand Load Shift between 18h00-20h00
1.06 MW
Geyser Load switches in low density residential areas-Completed Initiatives
13
1.095 MW Shifted
In line heater at high density residential areas.Completed Initiatives
14
In line heater at high density residential areas.Completed Initiatives
15
0.943 MW Shifted
Energy efficient lighting.Completed Initiatives
16
Original installed lighting capacity on KDC West
Post implementation installed lighting capacity on KDC West
Reduction in installed capacity was 5961.6kWAt a load factor of 33.33% (8 hours/day) resulted in an average savings of 1.987MW
Guide vane control on main ventilation fansCompleted Initiatives
17
Guide vane control on main ventilation fansCompleted Initiatives
18
9.0
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MW
KDC West Main Ventilation Fan Demand
Demand clipping during evening peak of ± 5MWAverage demand saving of 1.88 MW per month
Completed Initiatives
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0
5
10
15
20
25
30
35
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45N
ov-0
2Ja
n-03
Mar
-03
May
-03
Jul-0
3S
ep-0
3N
ov-0
3Ja
n-04
Mar
-04
May
-04
Jul-0
4S
ep-0
4N
ov-0
4Ja
n-05
Mar
-05
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-05
Jul-0
5S
ep-0
5N
ov-0
5Ja
n-06
Mar
-06
May
-06
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6S
ep-0
6N
ov-0
6Ja
n-07
Mar
-07
May
-07
Jul-0
7S
ep-0
7N
ov-0
7Ja
n-08
Mar
-08
May
-08
Jul-0
8S
ep-0
8N
ov-0
8Ja
n-09
Mar
-09
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-09
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ep-0
9N
ov-0
9Ja
n-10
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ov-1
0Ja
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Jul-1
1
kVar
hM
illio
ns
KDC West - Reactive Energy - Total Mine
Excess Reactive Energy (kVARh) Off Peak Standard Peak
Re-evaluate power factor correction installations
16.6 Mvarh to 12.9 MVarh to 7.7 MVarh
Compressed air load control.
• 50 Valve installation done on various shafts.
• Compressor guide vane control upgraded.
• Individual compressor load sharing and between compressor houses
Completed Initiatives
20
Compressed air load control.Completed Initiatives
21
KDC East 1# Water System OptimizationCompleted Initiatives
22
3.219 MW Average Weekday saving
New Initiatives:.• More Energy recovery turbines at K4 21 lev. – 0.5 MW.• Reverse flow pumps at KDC West 4 shaft 2 MW• Refrigeration plant load shifting K4 & D5 – 9 MW.• Introduction of an Ice Plant at K3 - 7.65 MW• DSM Air project at K7 - 1.5 MW• Heat pumps at industrial change houses – 1.5 MW• Additional Geyser Load switches in low density residential
areas – 1.26 MW• Compressor intake filter refurbishment – 2.2 MW.• Concentrated Solar Power (CSP) for Gold Plant• Compressed air leak detection and fixing at KDC West.• KDC fans Impeller efficiency – axial flow fans.• Heat recovery from compressors.• 3CPS.
Counter measures taken
23
New InitiativesHeat recovery from Compressors
24
Pump 1
Existing Cooling Tower
Existing Aftercooler
Existing Aftercooler
Existing Aftercooler
Compressed Air To
Underground Users
New Heat Exchanger
New Heat Exchanger
New Heat Exchanger
Compressor with Intercoolers
Compressor with Intercoolers
Compressor with Intercoolers
Pump 2
Pump 3
Hot Water (60°C) to Storage Tank
Cold Water Return
Thermal Storage Tank (typically >400m3)(to absorb variations in
supply and demand of hot water)
Pump 4
Cold Water from RWB
ILH ILH
Showers Showers
Change House
Calorifier
Hot Water Return
Hot Water Supply A B A B
Valve opens when flow to
showers is zero, and vice
versa
Valve A normally open and Valve B closed.
When no hot water in Storage tank or when no discharge pressure on Pump 4, then Valve A closed and Valve B open.
HOSTEL AREA
COMPRESSOR HOUSEExisting In-Line Heaters (ILH) are only on standby. Their electrical energy consumption are replaced by the thermal energy from the compressor heat recovery system.
•KDC West 5 Shaft - 4.337 MW
•KDC West 1 Shaft – 5.843 MW
•KDC East 4 Shaft – 3 MW
3CPSNew Initiatives
25
New Initiatives
26
New Initiatives3CPS.
27
FRIDGE SURFACE
PRVPRVPRVPRVPRV
50,5L
42L44L46L48L50L
23L
21L
IPC3.8 MW Turbine
3CPS
|c
c
42 L
23L
42L
LP filling pump
1.0Ml Balance dam
FRIDGE SURFACE
PRVPRVPRVPRVPRV
50,5L
42L44L46L48L50L
23L
21L
IPC
3CPS
|c
c
|c
c
42 L
23L
42L
LP filling pump
21L Booster pump
Bypass dissipator
KDC West 5# 42L--De-watering reticulation after 3CPS
Questions ?
28