Strategic placement of compressors for future
mine developments
HG Brand
August 2012
Introduction
 Rustenburg Platinum Mine (RPM) consists of eight
shafts supplied with air from six compressor
houses
 Mandate of the simulation:
1. Determine the best position of the compressors
replacing the West 10 compressors
2. Reduce the system’s reliance on the VK-125
compressor
3. Determine whether Khusuleka 1 (Townlands) and
Khusuleka 2 (Boschfontein) can be isolated
Surface layout
Simulation 1: Description
 Aim: Verify accuracy at high flow rates
 The average flow profile for the air network is
determined
 The simulation is run to replicate the pressures
at the shafts
 These pressures are compared to the actual
pressures at the shafts
Simulation 1: Results
Simulation 2: Description
 Aim: To alleviate the system’s reliance on the
VK-125
 West 10 compressor house is decommissioned
 The high risk pipe section from Siphumelele 3
(Bleskop), via West 10 to Khomanani 1 (Frank
1) is removed
 Two BB Sulzer compressors are simulated at
Khomanani 1 (Frank 1)
 A GHH compressor is moved from West 10 to
Siphumelele 1 (Turffontein) to replace the
VK-125
Simulation 2: Results
Simulation 2: Summary
 Average required flow at Siphumelele 1
(Turffontein) is 107 Х 10³ m³/h
 Peak flow can be 30 Х 10³ m³/h above average
profile and the required flow can be as high as
137 Х 10³ m³/h
 Available flow from two GHHs is 66 Х 10³ m³/h
 The available flow is too low and the VK-125
cannot be stopped
Simulation 3: Description
 Both GHHs and the VK-125 are started at
Siphumelele 1 (Turffontein)
 Aim: Determine maximum pressure at
Siphumelele 1 (Turffontein)
Simulation 3: Results
Simulation 3: Summary
 The pressure at Siphumelele 1 (Turffontein)
increases to 622 kPa at the compressor house
while the pressure at the shaft is 605 kPa
 The pressure rating of the pipes are 800 kPa
Simulation 4-6: Description
 With the VK-125 running - Determined how
many additional BB Sulzers are required and
where to position them
 A BB Sulzer was placed at Thembalani 1
(Paardekraal), Khomanani 1 (Frank 1) and
Khomanani 2 (Frank 2)
 One GHH and the VK-125 was running at
Siphumelele 1 (Turffontein)
Simulation 4-6: Results
Simulation 4-6: Summary
 Best position to place the BB Sulzer is at
Khomanani 2 (Frank 2), followed by
Khomanani 1 (Frank 1) and then Thembelani 1
(Paardekraal)
 Flow spikes occur at Khusuleka 1 (Townlands)
and Khomanani 2 (Frank 2)
 To accommodate flow spikes it is suggested
that the second BB Sulzer compressor be
positioned at Khomanani 1 (Frank 1)
Simulation 7-8: Description
 Aim - Determine whether to place the two BB
Sulzers in one or two compressor houses
 Three simulations are run
 In all the simulations one GHH and the VK-125
is running at Siphumelele 1 (Turffontein)
Simulation 7-8: Description
 Solution 1 - One compressor is placed at
Khomanani 1 (Frank 1) and one at Khomanani 2
(Frank 2)
 Solution 2 - Both compressors are placed at
Khomanani 1 (Frank)
 Solution 3 – Both GHH compressors at
Siphumelele are running together with the VK125
 Compare to the existing system pressures
Simulation 7-8: Results
Simulation 7-8: Summary
 Solution 3 is not viable
 Solution 1 offers the best option, followed by
solution 2.
 Solution 2 will be the preferred option
 In both solution 1 and 2 the flow to Khusuleka 1
(Townlands) is in excess of 10 000 m³/h
 This confirms that these shafts cannot be isolated
Conclusion
 The simulations indicated that the system
relies too heavily on the VK-125 compressor
 The best compressor placement was at
Khomanani 1 (Frank 1)
 Khusuleka 1 (Townlands) and Khusuleka 2
(Boschfontein) cannot be isolated from the
rest of the air network.