Future mine compressed air planning using digital twin simulations

Abstract

Most deep-level gold mines use compressed air services for various applications that directly influence gold production. Amongst others, these applications include drilling, agitation and loading boxes. However, similar to other supporting mining systems, compressed air planning is often overlooked. A lack of compressed air planning can lead to unforeseen problems and unscheduled maintenance. In turn, this can lead to significant downtime, during which valuable production is lost. Therefore, a need exists for a proactive compressed air planning strategy for preventing these problems and solving production challenges. This will help ensure that compressed air services meet the requirements for planned mining. A literature study was completed on compressed air services planning and how digital twin simulations can be used to advance this field. Simulations can effectively identify and develop solutions to compressed air inefficiencies, but no research has been conducted on applying these methods to the planning of mine compressed air services. This study used digital twin simulations to identify and solve future problems and inefficiencies in mine compressed air systems. A proactive compressed air planning methodology was developed based on a detailed literature study. The developed methodology included digital twin modelling, full data analysis, proactive solution development and, lastly, implementing the developed solution to validate the study. The developed methodology was applied to Mine A. The method identified a problem on the compressed air services system of the main production level. This system would have been unable to meet the required compressed air pressure for mining in the stoping ends. Implementing the solution, produced by the proactive planning strategy, increased the compressed air pressure by 32%. The developed proactive planning methodology was successful in identifying problems and inefficiencies that the compressed air services system would have faced in the future. The methodology successfully developed proactive solutions to these identified problems. In the case of Mine A's compressed air services system, it ensured that the required compressed air pressure was available for all planned mining activities and avoided unnecessary production loss.