Energy-efficient BCS for Ordzhonikidze mine

The Kryvyi Rih iron ore basin is the main source of ferruginous magnetite quartzite in Ukraine, and Ordzhonikidze mine is one of the key enterprises in the mining complex of PJSC TsGOK. Today, ore reserves are being developed at the Yuzhnaya Magnetitovaya deposit at a depth of over 500 meters. The mine’s annual production capacity is 1.5 million tons of magnetite ferruginous quartzite ore per year.

Pneumatic systems are widely used for the operation of the enterprise. For example, the main consumers of compressed air at the mine are NKR-100M drilling rigs that drill in medium-strength rocks using a pneumatic hammer. A machine weighing more than 1 ton consumes up to 15,000 cubic meters of compressed air per hour.

The old compressed air production system did not meet modern energy consumption requirements and did not have the ability to regulate productivity (excess air was released into the atmosphere). The large size of the compressors and low energy efficiency limited the ability to install additional equipment.

As part of the modernization project, the specialists of Dalgakiran Compressor Ukraine and Yasno Energy Efficiency were faced with an ambitious task – to create a compact compressor station with flexible capacity control, low power consumption, a modern control system and the ability to provide heat to heating and hot water systems through a recuperation system. After conducting an audit of existing needs, a unique solution was developed in accordance with the customer’s specifications, consisting of:

• The block compressor station BCS – 13512-0.75 U1. It consists of 4 DVK340D direct-drive screw compressors, one Inversys 250 P frequency-controlled screw compressor and RU-0.4 kV switchgear cabinets. This modular design allows for flexible adjustment of the air output, low energy consumption, and increased operational life and fault tolerance.
• A recovery system consisting of a Lowara circulation pumping station, four Ankor HeatTech heat exchangers, two electric boilers for heating the coolant at critical temperatures, two mine heaters and control and measuring devices. The recuperation system provides heating for administrative and amenity buildings, hot water supply and heating of the air supplied to the mine shaft.
• A control system for monitoring and remote control of the BCS and the recovery system.
• ASTOE for metering and data transmission of compressed air, heat and electricity consumption.

According to YASNO Efficiency, the new block compressor station with the recovery system will save up to UAH 10 million annually. Compared to the old system, the total energy savings in production and heating reach 42 percent. In monetary terms, according to YASNO Efficiency experts, the new block compressor station with a recovery system will save up to UAH 10 million annually.

Project manager: Alexander Dyadyushkin