introduction to the hac demonstrator project · demonstrator project location . schedule &...
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INTRODUCTION TO THE HAC
DEMONSTRATOR PROJECT
29th January, 2015
www.mirarco.org
29 January, 2015
Dean Millar
MIRARCO Research Chair of Energy in Mining,
Bharti School of Engineering,
Laurentian University, Sudbury, Ontario
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UDMN HAC Project Team
Tom CliffordRiventa Canada Inc.Roto-dynamic efficiency
Alex HutchisonMIRARCOGas mixing /separation
Dr Dean MillarMIRARCO / LUProject Leader
Valeria PavesePolitecnico di Torino, Italy, HAC Efficiency
Dr Caterina NoulaElectrale Innovation Ltd.Analytical Chemist
Al AckermanCEMI / UDMNTheme 3 Leader
Maxine MyreMIRARCOCommunications
www.mirarco.org
Steve YoungMIRARCOHydrodynamics
David VitoneCEMI / UDMNProject Manager
Sujit SenguptaAdmira DHES LtdCryogenics /Electrical
Javier Rico-PaezUQATJet Pump Cooling
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Project 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
www.mirarco.org
– 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
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Demonstrator Project Location
www.mirarco.org
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Schedule
& Budget
Q3 - 2014 Q4 - 2014 Q1 - 2015 Q2 - 2015 Q3 - 2015 Q4
J A S O N D J F M A M J J A S O N
Lab scale prototype - "Baby HAC" design
Baby HAC assembled
Conceptual designDetailed engineering design "DE HAC"
Procurement of instrumentation & control equipment
Mass spectrometer
SCADA
PumpsVFD
Inverters
Motors
Flow meters / controllers
PLC Valves
Air power instruments
Thermodynamic instruments
Pump torque instruments
Electrical power instrumentsLevel sensors
Starter panels
Permitting - Building / Commitment / Certification$850k
www.mirarco.org
Permitting - Building / Commitment / Certification
DE HAC Component fabrication
Piping fabricationSub-structure fab / assembly
Super-structure fab / assembly
Taylor air-water mixing head
Cyclone separator
DE HAC installationMobilization
Electrical
Foundation slab
Sub-structure installation
Super-structure erectionConnection to water / drainage
Building envelope
Demobilization
Commissioning
Mechnical / electrical systemsInstrumentation installation
Commissioning trials
$850k
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Why are you here?
• Project procurement ‘flurry’ between May & Oct 2015
• Not particularly specialist parts
• Project brief to stimulate business activity
• Need to establish and prove HAC supply chain
• Preference to procure locally
www.mirarco.org
• Preference to procure locally
• We undertake to ensure that general contractor will inform you of procurement processes, for items on which you have expressed interest in supplying
• Ultimately, procurement decisions will have to be based on lowest cost meeting specification
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HYDRAULIC AIR COMPRESSOR
FUNCTIONAL DESCRIPTION
www.mirarco.org
Dean Millar
MIRARCO Research Chair of Energy in Mining,
Bharti School of Engineering,
Laurentian University, Sudbury, Ontario
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The Ragged Chutes HAC installed at Cobalt, ON was designed by
Charles Havelock Taylor
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Source: virtualmuseum.ca-The Cobalt Adventure
Schulze, L.E., 1954. Hydraulic air compressors. Bureau of Mines Information Circular 7683. Pittsberg, Pa, US Dept of Interior
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Ragged Chutes, the largest ever HAC, produced 40,000 cfm @
120 psi(g) (22.7 kg/s @ 8.3 bar(g)) but is now derelict
www.mirarco.org
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The Atlas Copco GT153 installed in a Chinese steel mill produces
322,500 Sm3/h air at 6 bar(a) (190,000 cfm @ 87 psi(a) )
www.mirarco.org
Source: http://www.atlascopco-gap.com/fileadmin/download/magazine/109.pdf
Cost of capital Electricity price (2013 CAD/MWh)
(%) 55 65 70 80
2 3.984 4.596 4.902 5.514
5 4.108 4.726 5.035 5.653
10 4.331 4.958 5.271 5.89815 4.574 5.210 5.527 6.162
20 4.839 5.482 5.803 6.445
Compressed air price ($/tonne) if built in Sudbury
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In the Clausthal mine
HAC was installed in an
existing shaft system
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Source: Schulze, L.E., 1954.
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The HAC installed within Peterborough
Lift Lock is the template for DE HAC Source: Schulze, L.E., 1954.
www.mirarco.org
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There are 4 main components of a HAC:
water-air intake, down-comer shaft, separation device, riser shaft
Mixing process
www.mirarco.org
Compression
Separation
Potential energy
recovery
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A 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.
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www.mirarco.org
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Jet pump analysis
Two-phase flow
Mixing of air & water phases
Control regime
THEORETICAL CHALLENGES:
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Two-phase flow
Differential pressureSolubility of gases
Gas-liquidseparation
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For more information:
Dean Millar
www.mirarco.org
Millar, D.L., 2014. A review of thecase for modern-day adoption ofhydraulic air compressors. AppliedThermal Engineering, Vol. 69, pp 55-77
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Questions?
www.mirarco.org