INTRODUCTION TO THE HAC DEMONSTRATOR PROJECT - 29 January, 2015 Dean Millar MIRARCO Research Chair of Energy in Mining, Bharti School of ...
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INTRODUCTION TO THE HAC DEMONSTRATOR PROJECT 29th January, 2015 Dean Millar MIRARCO Research Chair of Energy in Mining, Bharti School of Engineering, Laurentian University, Sudbury, Ontario www.mirarco.org
UDMN HAC Project Team
Al Ackerman Tom Clifford Dr Caterina Noula
CEMI / UDMN Alex Hutchison Valeria Pavese
Riventa Canada Inc.
Theme 3 Leader Roto-dynamic MIRARCO Dr Dean Millar Maxine Myre Electrale Politecnico di
Gas mixing MIRARCO / LU MIRARCO Innovation Ltd.
Torino, Italy,
efficiency /separation Project Leader Communications Analytical Chemist HAC Efficiency
Javier Rico-Paez Sujit Sengupta David Vitone Steve Young
Admira DHES Ltd CEMI / UDMN
UQAT MIRARCO
Jet Pump Cooling Cryogenics / Project Manager Hydrodynamics
Electrical
www.mirarco.orgProject Objectives – to be “1st to be 19th”
• Lab scale HAC & Demonstrator scale HAC – Year 1
– Cheap compressed air for mining operations
– Obtain OPA certification as energy efficient
– Prove applicability for deep mine cooling
– M&V activities at demonstration scale
– Establish / prove supply chain
• Marketing and Commercialization – Year 2, onwards
– Pneumatic power for mines
– Air separation systems
– Advanced products
• Innovation program – Year 2 & 3
– Compressed air yield enhancement
– Carbon capture
– Refrigerant compression
– Tower block air conditioning
– Autoclave mineral processing
www.mirarco.orgDemonstrator Project Location www.mirarco.org
Q3 - 2014 Q4 - 2014 Q1 - 2015 Q2 - 2015 Q3 - 2015 Q4
Schedule Lab scale prototype - "Baby HAC" design
J A S O N D J F M A M J J A S O N
& Budget Baby HAC assembled
Conceptual design
Detailed engineering design "DE HAC"
Procurement of instrumentation & control equipment
Mass spectrometer
SCADA
Pumps
VFD
Inverters
Motors
Flow meters / controllers
PLC
Valves
Air power instruments
Thermodynamic instruments
Pump torque instruments
Electrical power instruments
Level sensors
Starter panels
$850k Permitting - Building / Commitment / Certification
DE HAC Component fabrication
Piping fabrication
Sub-structure fab / assembly
Super-structure fab / assembly
Taylor air-water mixing head
Cyclone separator
DE HAC installation
Mobilization
Electrical
Foundation slab
Sub-structure installation
Super-structure erection
Connection to water / drainage
Building envelope
Demobilization
Commissioning
Mechnical / electrical systems
Instrumentation installation
Commissioning trials
www.mirarco.orgWhy are you here? • Project procurement ‘flurry’ between May & Oct 2015 • Not particularly specialist parts • Project brief to stimulate business activity • Need to establish and prove HAC supply chain • Preference to procure locally • We undertake to ensure that general contractor will inform you of procurement processes, for items on which you have expressed interest in supplying • Ultimately, procurement decisions will have to be based on lowest cost meeting specification www.mirarco.org
HYDRAULIC AIR COMPRESSOR FUNCTIONAL DESCRIPTION Dean Millar MIRARCO Research Chair of Energy in Mining, Bharti School of Engineering, Laurentian University, Sudbury, Ontario www.mirarco.org
The Ragged Chutes HAC installed at Cobalt, ON was designed by
Charles Havelock Taylor
Schulze, L.E., 1954. Hydraulic air compressors. Source: virtualmuseum.ca-
Bureau of Mines Information Circular 7683. The Cobalt Adventure
Pittsberg, Pa, US Dept of Interior
www.mirarco.orgRagged Chutes, the largest ever HAC, produced 40,000 cfm @ 120 psi(g) (22.7 kg/s @ 8.3 bar(g)) but is now derelict www.mirarco.org
The Atlas Copco GT153 installed in a Chinese steel mill produces
322,500 Sm3/h air at 6 bar(a) (190,000 cfm @ 87 psi(a) )
Compressed air price ($/tonne) if built in Sudbury
Cost of capital Electricity price (2013 CAD/MWh)
(%) 55 65 70 80
2 3.984 4.596 4.902 5.514
5 4.108 4.726 5.035 5.653
10 4.331 4.958 5.271 5.898
15 4.574 5.210 5.527 6.162
20 4.839 5.482 5.803 6.445
Source: http://www.atlascopco-gap.com/fileadmin/download/magazine/109.pdf
www.mirarco.orgIn the Clausthal mine
HAC was installed in an
existing shaft system
Source: Schulze, L.E., 1954.
www.mirarco.orgThe HAC installed within Peterborough
Lift Lock is the template for DE HAC Source:
Schulze, L.E., 1954.
www.mirarco.orgThere are 4 main components of a HAC:
water-air intake, down-comer shaft, separation device, riser shaft
Mixing process
Compression
Potential energy
recovery
Separation
www.mirarco.orgA modern day description of how Taylor’s 20th century intake head works may defy the best that 21st century CFD has to offer www.mirarco.org Source: Schulze, L.E., 1954.
www.mirarco.org
THEORETICAL CHALLENGES:
Control regime
Jet pump analysis
Mixing of air &
water phases
Two-phase flow
Differential pressure
Solubility of gases
Gas-liquid
www.mirarco.org separationFor more information:
Dean Millar
dmillar@mirarco.org
Millar, D.L., 2014. A review of the
case for modern-day adoption of
hydraulic air compressors. Applied
Thermal Engineering, Vol. 69,
pp 55-77
www.mirarco.orgQuestions? www.mirarco.org
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