Compressed air makes up an important part of South African precious metal mining processes. Rising operational costs in the struggling mining sector increased the interest of the power utility, Eskom, and mine management in achievable electrical energy savings. Demand side management initiatives, funded by Eskom, realised a significant improvement in electrical energy efficiency of compressed air networks. Supply side interventions further aided optimisation by lowering operational costs. Previous research identified the need for integrating compressed air supply and demand side initiatives. Automated compressor control systems were needed in industry to realise missed opportunities due to human error on manual control systems. Automatic systems were found to be implemented in the industry, but missed savings opportunities were still encountered. This was due to the static nature of these control systems, requiring human intervention from skilled artisans. A comprehensive system is required that can adjust dynamically to the ever-changing demand and other system changes. Commercially available simulation software packages have been used by various mine groups to determine an optimal control philosophy. Satisfactory results were obtained, but the simulations were still based on static control inputs. No simulation system was found that could solve and optimise a system based on real-time instrumentation feedback. By combining simulation capabilities with dynamic control in real time, advanced optimisation could be achieved. Development was done on the theoretical design of the system, where mathematical calculations and the accuracy of the system were evaluated. This study proved that the new controller was viable and, as a result, the development of a fully dynamic control Automation of compressor networks through a dynamic control system iii system incorporating the verified mathematical models followed. All of this was done following a theoretical approach. Intricate control requirements on the supply side were evaluated to determine the impact of new intelligent compressor control strategies. It was found that improved compressor control realised an additional 6.2% electrical energy saving on top of existing savings initiatives. Practical limitations and human perception issues were also addressed. Financial cost-benefit analyses were used to evaluate the viability of using automated compressor control. Ample maintenance data obtained from two leading mining companies was used to evaluate the impact of increased stopping and starting of compressors. Financial cost savings from electrical energy efficiency control strategies were found to considerably outweigh the minimal increase in compressor maintenance. Savings potential on deep-level mines proved to be in the order of 5% of the baseline consumption. When these results are extrapolated to the remaining 22 South African deep-level gold and platinum mines already subjected to demand side management initiatives, potential savings of 12.67 MW can be realised. Based on the Eskom 2014/2015 Megaflex tariff structure, the financial cost saving from 12.67 MW is R61 million. / PhD (Electrical Engineering), North-West University, Potchefstroom Campus, 2015

Compressed air makes up an important part of South African precious metal mining processes. Rising operational costs in the struggling mining sector increased the interest of the power utility, Eskom, and mine management in achievable electrical energy savings. Demand side management initiatives, funded by Eskom, realised a significant improvement in electrical energy efficiency of compressed air networks. Supply side interventions further aided optimisation by lowering operational costs. Previous research identified the need for integrating compressed air supply and demand side initiatives. Automated compressor control systems were needed in industry to realise missed opportunities due to human error on manual control systems. Automatic systems were found to be implemented in the industry, but missed savings opportunities were still encountered. This was due to the static nature of these control systems, requiring human intervention from skilled artisans. A comprehensive system is required that can adjust dynamically to the ever-changing demand and other system changes. Commercially available simulation software packages have been used by various mine groups to determine an optimal control philosophy. Satisfactory results were obtained, but the simulations were still based on static control inputs. No simulation system was found that could solve and optimise a system based on real-time instrumentation feedback. By combining simulation capabilities with dynamic control in real time, advanced optimisation could be achieved. Development was done on the theoretical design of the system, where mathematical calculations and the accuracy of the system were evaluated. This study proved that the new controller was viable and, as a result, the development of a fully dynamic control Automation of compressor networks through a dynamic control system iii system incorporating the verified mathematical models followed. All of this was done following a theoretical approach. Intricate control requirements on the supply side were evaluated to determine the impact of new intelligent compressor control strategies. It was found that improved compressor control realised an additional 6.2% electrical energy saving on top of existing savings initiatives. Practical limitations and human perception issues were also addressed. Financial cost-benefit analyses were used to evaluate the viability of using automated compressor control. Ample maintenance data obtained from two leading mining companies was used to evaluate the impact of increased stopping and starting of compressors. Financial cost savings from electrical energy efficiency control strategies were found to considerably outweigh the minimal increase in compressor maintenance. Savings potential on deep-level mines proved to be in the order of 5% of the baseline consumption. When these results are extrapolated to the remaining 22 South African deep-level gold and platinum mines already subjected to demand side management initiatives, potential savings of 12.67 MW can be realised. Based on the Eskom 2014/2015 Megaflex tariff structure, the financial cost saving from 12.67 MW is R61 million. / PhD (Electrical Engineering), North-West University, Potchefstroom Campus, 2015

Mines in general, make use of compressed air systems for daily operational activities. Compressed air on mines is traditionally distributed in two typical fashions. Firstly, direct pipe feed systems for single shafts or compressed air ring networks where multiple shafts are supplied with compressed air from an integral system. These compressed air networks make use of number compressors feeding the ring from various locations in the network. While mines have sophisticated control systems to control these compressors they are not dynamic. Compressors are selected on static priorities for a chosen time period of the day. While this is acceptable for some days it is not always the ideal solution. The compressed air demand of the ring is dynamic and it is difficult to estimate the future need of the system. The Dynamic Compressor Selector (DCS) is described as a solution to this problem. DCS is a computer based control system featuring a Graphical User Interface (GUI). The aim of DCS is to dynamically calculate a control pressure set-point, given the demand for compressed air as well as choose the optimal compressors to supply the given compressed air. This will reduce the power requirement of the compressed air ring as well as reduce compressor cycling. DCS was implemented and tested on a single mine compressed air system. Achieved results were 1.8 MW in electricity savings as well as the added benefit of reduced cycling. This saving results in a cost saving of R3.7 million per annum. The problems and shortfalls of the system are also discussed as well as possible future directions for moving forward. / MIng (Computer and Electronic Engineering), North-West University, Potchefstroom Campus, 2014

The generation of compressed air comprises 20% of the total electricity usage in the mining industry, although compressed air is often seen as a free source of energy. There are however significant costs associated with generating compressed air and maintaining a compressed air system. There are several methods to optimise the electricity used to generate compressed air. The focus of this study is on one of these methods – the implementation of a dynamic air compressor selector. A Dynamic Compressor Selector (DCS) system was developed to fulfil this purpose. DCS is a system that combines demand- and supply-side management of a compressed air network. DCS calculates a pressure set point for compressors and schedules the compressors according to the demand from the end-users. End-users include shafts, plants, workshops and smelters. DCS takes all of the compressors and end-users into consideration while doing the calculations. This dissertation focuses on the DCS implementation process and on the problems encountered by previous authors while implementing the DCS technology. Additional problems were encountered while the DCS technology was implemented. DCS was however still successfully implemented. This study will expand the implementation procedure to ensure that the technology can be implemented successfully in the future. DCS was implemented at a platinum mine in South Africa where it was able to calculate pressure set points for the compressors. DCS was able to accurately match the supply of, and demand for compressed air closely, resulting in lower overall compressed air usage. DCS improved compressor scheduling and control, limiting compressor cycling. Improved compressor scheduling and control resulted in significant decreases in the electricity used to generate compressed air at the mine. A target average evening peak clip of 2.197 MW was simulated, set and achieved. Evening peak clip power savings in excess of an average of 3 MW were achieved. / MIng (Mechanical Engineering), North-West University, Potchefstroom Campus, 2015

Mines in general, make use of compressed air systems for daily operational activities. Compressed air on mines is traditionally distributed in two typical fashions. Firstly, direct pipe feed systems for single shafts or compressed air ring networks where multiple shafts are supplied with compressed air from an integral system. These compressed air networks make use of number compressors feeding the ring from various locations in the network. While mines have sophisticated control systems to control these compressors they are not dynamic. Compressors are selected on static priorities for a chosen time period of the day. While this is acceptable for some days it is not always the ideal solution. The compressed air demand of the ring is dynamic and it is difficult to estimate the future need of the system. The Dynamic Compressor Selector (DCS) is described as a solution to this problem. DCS is a computer based control system featuring a Graphical User Interface (GUI). The aim of DCS is to dynamically calculate a control pressure set-point, given the demand for compressed air as well as choose the optimal compressors to supply the given compressed air. This will reduce the power requirement of the compressed air ring as well as reduce compressor cycling. DCS was implemented and tested on a single mine compressed air system. Achieved results were 1.8 MW in electricity savings as well as the added benefit of reduced cycling. This saving results in a cost saving of R3.7 million per annum. The problems and shortfalls of the system are also discussed as well as possible future directions for moving forward. / MIng (Computer and Electronic Engineering), North-West University, Potchefstroom Campus, 2014

The generation of compressed air comprises 20% of the total electricity usage in the mining industry, although compressed air is often seen as a free source of energy. There are however significant costs associated with generating compressed air and maintaining a compressed air system. There are several methods to optimise the electricity used to generate compressed air. The focus of this study is on one of these methods – the implementation of a dynamic air compressor selector. A Dynamic Compressor Selector (DCS) system was developed to fulfil this purpose. DCS is a system that combines demand- and supply-side management of a compressed air network. DCS calculates a pressure set point for compressors and schedules the compressors according to the demand from the end-users. End-users include shafts, plants, workshops and smelters. DCS takes all of the compressors and end-users into consideration while doing the calculations. This dissertation focuses on the DCS implementation process and on the problems encountered by previous authors while implementing the DCS technology. Additional problems were encountered while the DCS technology was implemented. DCS was however still successfully implemented. This study will expand the implementation procedure to ensure that the technology can be implemented successfully in the future. DCS was implemented at a platinum mine in South Africa where it was able to calculate pressure set points for the compressors. DCS was able to accurately match the supply of, and demand for compressed air closely, resulting in lower overall compressed air usage. DCS improved compressor scheduling and control, limiting compressor cycling. Improved compressor scheduling and control resulted in significant decreases in the electricity used to generate compressed air at the mine. A target average evening peak clip of 2.197 MW was simulated, set and achieved. Evening peak clip power savings in excess of an average of 3 MW were achieved. / MIng (Mechanical Engineering), North-West University, Potchefstroom Campus, 2015

Eskom is under increasing pressure to provide reliable and sustainable electricity. Demand Side Management (DSM), offers a short– to medium–term solution to this problem. During 2009, the mining sector consumed approximately 16% of the domestic electricity supplied by Eskom. This made the mining sector one of the major targets for Eskom–initiated DSM programmes. The mining industry uses compressed air for a wide variety of applications and production purposes. This creates many opportunities to reduce electricity consumption and operating costs. Reducing the airsystem demand may however not result in significant electrical energy savings, unless the compressed–air supply is accurately managed to meet the reduced demand. Until recently, compressor control in the mining sector generally consisted of operating the compressors continuously, regardless of the actual demand for compressed air. Excessive compressed air is blown off into the atmosphere resulting in energy loss. This usually occurs when the compressors are operated manually. A computer–controlled compressor management solution, which optimises the efficiency potential of the compressed–air supply, is required to obtain significant electrical energy savings. The need for such a solution was addressed by the development of an energy management solution for mine compressor systems. This solution is referred to as Energy Management System (EMS) and is capable of starting, stopping, loading and unloading compressors. In addition to this, compressor output can be controlled to maintain a desired pressure set–point. In this study, the development and implementation of EMS on ten different mine compressor systems is presented. Automatic compressor capacity control was implemented, while an operator manually initiated compressor starting; stopping; loading and unloading, according to EMS control schedules. Centralised compressor control is one of the main advantages offered by EMS, especially for compressed–air systems with multiple compressor systems at different geographic locations. EMS facilitated effective and sustainable electrical energy reductions for all these compressed–air systems. / Thesis (M. Ing. (Computer and Electronical Engineering))--North-West University, Potchefstroom Campus, 2011.

Eskom is under increasing pressure to provide reliable and sustainable electricity. Demand Side Management (DSM), offers a short– to medium–term solution to this problem. During 2009, the mining sector consumed approximately 16% of the domestic electricity supplied by Eskom. This made the mining sector one of the major targets for Eskom–initiated DSM programmes. The mining industry uses compressed air for a wide variety of applications and production purposes. This creates many opportunities to reduce electricity consumption and operating costs. Reducing the airsystem demand may however not result in significant electrical energy savings, unless the compressed–air supply is accurately managed to meet the reduced demand. Until recently, compressor control in the mining sector generally consisted of operating the compressors continuously, regardless of the actual demand for compressed air. Excessive compressed air is blown off into the atmosphere resulting in energy loss. This usually occurs when the compressors are operated manually. A computer–controlled compressor management solution, which optimises the efficiency potential of the compressed–air supply, is required to obtain significant electrical energy savings. The need for such a solution was addressed by the development of an energy management solution for mine compressor systems. This solution is referred to as Energy Management System (EMS) and is capable of starting, stopping, loading and unloading compressors. In addition to this, compressor output can be controlled to maintain a desired pressure set–point. In this study, the development and implementation of EMS on ten different mine compressor systems is presented. Automatic compressor capacity control was implemented, while an operator manually initiated compressor starting; stopping; loading and unloading, according to EMS control schedules. Centralised compressor control is one of the main advantages offered by EMS, especially for compressed–air systems with multiple compressor systems at different geographic locations. EMS facilitated effective and sustainable electrical energy reductions for all these compressed–air systems. / Thesis (M. Ing. (Computer and Electronical Engineering))--North-West University, Potchefstroom Campus, 2011.