Costs saving measures are important for South African gold producers due to increasing energy costs and decreasing production volumes. Demand Side Management (DSM) is an effective strategy to reduce electricity consumption and costs. DSM projects have been implemented widely on South African mining systems such as pumping, refrigeration, rock transport and compressed air. Implementations have, however, been limited on gold processing plants despite the significant amounts of energy that this section consumes. The main objective of gold processing plants is production orientated and energy management is not a primary focus. This rationale is re-evaluated owing to high electricity price inflation and availability of DSM incentives. This study investigated the cost saving potential of DSM interventions on gold plants. Electrical load management was identified as a key opportunity that can deliver substantial cost savings. These savings were shown to be feasible in respect of the required capital expenditure, effort of implementation and maintenance of operational targets. Investigation procedures were compiled to identify feasible load management opportunities. The most potential for electricity cost savings was identified on comminution equipment. Consequently, a methodology was developed to implement electrical load management on the identified sections. The methodology proposed simulation techniques that enabled load management and subsequent electricity cost optimisation through production planning. Two electrical load management case studies were successfully implemented on comminution equipment at two gold processing plants. Peak period load shift of 3.6 MW and 0.6 MW, respectively, was achieved on average for a period of three months. The annual cost savings of these applications could amount to R1.4-million and R 660 000. This results in specific electricity cost reductions of 3% and 7% for the two respective case studies. Results from the two case studies are an indication of potential for electrical load management on South African gold processing plants. If an average electricity cost saving of 5% is extrapolated across the South African gold processing industry, the potential cost savings amount to R 25-million per annum. Although the costs saving opportunities are feasible, it is influenced by the reliability of the equipment and the dynamics of ore supply. This insight plays a decisive role in determining the feasibility of DSM on gold processing plants. / MIng (Mechanical Engineering), North-West University, Potchefstroom Campus, 2015

Costs saving measures are important for South African gold producers due to increasing energy costs and decreasing production volumes. Demand Side Management (DSM) is an effective strategy to reduce electricity consumption and costs. DSM projects have been implemented widely on South African mining systems such as pumping, refrigeration, rock transport and compressed air. Implementations have, however, been limited on gold processing plants despite the significant amounts of energy that this section consumes. The main objective of gold processing plants is production orientated and energy management is not a primary focus. This rationale is re-evaluated owing to high electricity price inflation and availability of DSM incentives. This study investigated the cost saving potential of DSM interventions on gold plants. Electrical load management was identified as a key opportunity that can deliver substantial cost savings. These savings were shown to be feasible in respect of the required capital expenditure, effort of implementation and maintenance of operational targets. Investigation procedures were compiled to identify feasible load management opportunities. The most potential for electricity cost savings was identified on comminution equipment. Consequently, a methodology was developed to implement electrical load management on the identified sections. The methodology proposed simulation techniques that enabled load management and subsequent electricity cost optimisation through production planning. Two electrical load management case studies were successfully implemented on comminution equipment at two gold processing plants. Peak period load shift of 3.6 MW and 0.6 MW, respectively, was achieved on average for a period of three months. The annual cost savings of these applications could amount to R1.4-million and R 660 000. This results in specific electricity cost reductions of 3% and 7% for the two respective case studies. Results from the two case studies are an indication of potential for electrical load management on South African gold processing plants. If an average electricity cost saving of 5% is extrapolated across the South African gold processing industry, the potential cost savings amount to R 25-million per annum. Although the costs saving opportunities are feasible, it is influenced by the reliability of the equipment and the dynamics of ore supply. This insight plays a decisive role in determining the feasibility of DSM on gold processing plants. / MIng (Mechanical Engineering), North-West University, Potchefstroom Campus, 2015

Carbon tax, increased reactive power charges, tariff increases and the Energy Conservation Scheme (ECS) are some of the worrying electricity cost risks faced by large South African industries. Some of these proposed cost risks are not enforced as yet, but once approved could threaten company financial viability and thousands of jobs. Managing multiple cost risks associated with electricity consumption at several mines can be laborious and complex. This is largely due to circumstantial rules related to each potential electricity cost risk and unique mine characteristic. To limit the electricity cost risks for a mining company, clear strategies and focus areas need to be identified. No literature was found that provides a simplified integrated electricity cost risk and mitigation strategy for the South African gold mining industry. Previous studies only focused on a single mine or mining subsystem. Literature pertaining to potential risks is available, however the exact impact and mitigation on the gold mining industry has yet to be determined. The aim of this study is to accurately predict the impact of electricity cost risks and identify strategies that could alleviate their cost implications. Electricity consumption and installed capacities were used to benchmark mines and categorise them according to investigated risks. The benchmarked results provided an accurate starting point to identify best practices and develop electricity cost saving strategies. This study will highlight the additional benefits that can be obtained by managing electricity usage for a group of mines or mining company. Newly developed models are used to quantify savings on pumping, compressed air and cooling systems. To manage and report on the potential risks and mitigation, an ISO 50001 based energy management system was developed and implemented. The applied and developed models can also be adjusted to review and manage the potential cost risks on other types of mines. Derived risk and mitigation models were further used to quantify the impact on one of the largest gold mining companies in South Africa. These models indicate a potential annual price increase of 12%, while mitigation strategies could reduce the electricity consumption by more than 7%. Mitigation savings resulted from proposed projects as well as behavioural change-induced savings due to improved management. Over a five-year period the projects identified could result in electricity costs savings of between R675-million and R819-million. / PhD (Electrical Engineering), North-West University, Potchefstroom Campus, 2014

Carbon tax, increased reactive power charges, tariff increases and the Energy Conservation Scheme (ECS) are some of the worrying electricity cost risks faced by large South African industries. Some of these proposed cost risks are not enforced as yet, but once approved could threaten company financial viability and thousands of jobs. Managing multiple cost risks associated with electricity consumption at several mines can be laborious and complex. This is largely due to circumstantial rules related to each potential electricity cost risk and unique mine characteristic. To limit the electricity cost risks for a mining company, clear strategies and focus areas need to be identified. No literature was found that provides a simplified integrated electricity cost risk and mitigation strategy for the South African gold mining industry. Previous studies only focused on a single mine or mining subsystem. Literature pertaining to potential risks is available, however the exact impact and mitigation on the gold mining industry has yet to be determined. The aim of this study is to accurately predict the impact of electricity cost risks and identify strategies that could alleviate their cost implications. Electricity consumption and installed capacities were used to benchmark mines and categorise them according to investigated risks. The benchmarked results provided an accurate starting point to identify best practices and develop electricity cost saving strategies. This study will highlight the additional benefits that can be obtained by managing electricity usage for a group of mines or mining company. Newly developed models are used to quantify savings on pumping, compressed air and cooling systems. To manage and report on the potential risks and mitigation, an ISO 50001 based energy management system was developed and implemented. The applied and developed models can also be adjusted to review and manage the potential cost risks on other types of mines. Derived risk and mitigation models were further used to quantify the impact on one of the largest gold mining companies in South Africa. These models indicate a potential annual price increase of 12%, while mitigation strategies could reduce the electricity consumption by more than 7%. Mitigation savings resulted from proposed projects as well as behavioural change-induced savings due to improved management. Over a five-year period the projects identified could result in electricity costs savings of between R675-million and R819-million. / PhD (Electrical Engineering), North-West University, Potchefstroom Campus, 2014