RECENT TRENDS IN MINE VENTILATION

A SEMINAR REPORT SUBMITTED IN PARTIAL FULFILLMENT OF THE

REQUIREMENTS FOR THE DEGREE OF
BACHELOR OF ENGINEERING
IN
MINING ENGINEERING
BY
HIMANSHU KHATIK
ROLL NUMBER: 15BMI70017

DEPARTMENT OF MINING ENGINEERING

FACULTY OF ENGINEERING AND ARCHITECTURE
JODHPUR-342001
January 2016

A SEMINAR
ON
RECENT TRENDS IN MINE VENTILATION

BY

HIMANSHU KHATIK

UNDER THE GUIDENCE OF

Dr. D. M. SURANA
FORMER PROFESSOR & HEAD

DEPARTMENT OF MINING ENGINEERING

FACULTY OF ENGINEERING AND ARCHITECTURE
JODHPUR-342001
January 2016
i

ABSTRACT
The practice of ventilation is continually evolving with new technological advances
developed in the mining industry. In recent years the advances in diesel engine
technologies, ventilation modeling software, and ventilation management capacities have
redefined the historical methods used to evaluate systems. The advances re-evaluate
previous methods used to calculate the airflow requirements for the dilution of diesel
exhaust fumes. Modeling software has become an integral part of planning and
developing ventilation systems in partnership with graphical mine design software
packages to generate realistic representations of the mine. Significant advances in
ventilation control strategies through remote sensors and monitoring capabilities have
been developed to results in cost savings. Though there has been much advancement in
mine ventilation technology, the practices and basic ventilation principles enacted
through the ventilation engineer cannot be placated with technological advances only.
With the increase of mine depth, the ventilation is facing great challenges. This report
primarily elaborates the research and status quo of controlled circulating ventilation at
home and aboard, and then analyzes its operational principles and introduces application
development of the technology in Hongtoushan copper mine. The report suggests that
this technology can effectively tackle the problem of ventilation in deep mining and
improve the working condition of deep mining by saving energy and reducing
consumption.

ii

ACKNOWLEDGEMENT
I would like to express my gratitude and indebtedness to Dr. D. M. Surana, former
Professor & Head of Department, for his kindness in allowing me to do work on this
topic and for his inspiring guidance, constructive criticism and valuable suggestions
throughout this seminar work.
I would also like to thank Dr. A.S. Sheoran, Head of Department, for his valuable
guidance throughout the seminar work.

DATE : 16 FEB 2016

NAME: HIMANSHU KHATIK

ROLL NO. 15BMI70017

iii

CERTIFICATE
This is to certify that Mr. HIMANSHU KHATIK, student of Final Year B.E. (Mining
Engineering) has submitted the seminar report entitled RECENT TRENDS IN MINE
VENTILATION, which is record of his own work carried out under my guidance.

Dated
Dr. D.M SURANA
FORMER PROF. & HEAD
Department of Mining Engineering
M.B.M Engineering College, JODHPUR

iv

CONTENTS

ABSTRACT

ii

ACKNOWLEDGEMENT

iii

CERTIFICATE

iv

CONTENTS

LIST OF FIGURES& TABLES

vi

1.0

2.0

INTRODUTION
CURRENT TREND IN MINE VENTILATION

2.1 Ventilation on Demand

2.2 Ventilation Monitoring System

2.3 Software for Ventilation Planning

3.0 RESEARCH AND APPLICATION OF CONTROLLED CIRCULATING

VENTILATION
3.1 Application of Controlled Ventilation
3.1.1 The Technology Principle

7
7

3.1.2 The Technical Route Of Controlled Circulating Ventilation

3.1.3The Construction Of Controlled Circulating Ventilation

10

3.1.4 The operational Effect of Controlled Circulating Ventilation

11

4.0 STRATEGIES FOR ENERGY EFFICIENT VENTILATION

12

4.1 Ventilation as Required

12

4.2 Control of Primary Air-Flow

15

4.3 Modification of Main Fan to Improve Efficiency

16

4.4 Controlled Recirculation

17

5.0 CONCLUSIONS

17

REFERENCES

19
v

LIST OF FIGURES & TABLES

Number
Fig. 3.1

Title
Schematic diagram of the circulating

Page Number
7

ventilation(Wang et al., 2014)

Fig. 3.2

The technical route of controlled circulating

ventilation(Wang et al., 2014)

Fig. 3.3

The controlled circulating ventilation of

10

Hongtoushan Copper Mining(Wang et al., 2014)

Fig. 3.4

The spray device(Wang et al., 2014)

11

Fig. 3.5

Air quality monitor(Wang et al., 2014)

11

Fig. 3.6

The electric choke(Wang et al., 2014)

11

Fig. 4.1

Example of VOD to vary flow in workings based

14

on presence of equipment ( Karsten and Mackay

2012)
Table 4.1 Targeted & Achieved Power Saving ( Karsten and

15

Mackay 2012)

vi

1. INTRODUCTION
The practice of ventilation is continually evolving with new technological advances
developed in the mining industry. In recent years the advances in diesel engine technologies,
ventilation modeling software, and ventilation management capacities have redefined the
historical methods used to evaluate systems. The advances re-evaluate previous methods
used to calculate the airflow requirements for the dilution of diesel exhaust fumes. Modeling
software has become an integral part of planning and developing ventilation systems in
partnership with graphical mine design software packages to generate realistic
representations of the mine. Significant advances in ventilation control strategies through
remote sensors and monitoring capabilities have been developed to results in cost savings.
Though there has been much advancement in mine ventilation technology, the practices and
basic ventilation principle enacted through the ventilation engineer cannot be placated with
technological advances only.
With the use of reliability-engineering and ergonomics theory, the various factors which can
impact the reliability of a mine ventilation system should be approached in report. It
indicates that the main factors which will impact the reliability of the mine ventilation
network are the mine ventilation system, the harmful diagonal structure of the network and
changes in ventilation network. The main factors which will impact the normal operation of
the fan are the types of the fan, its inherent quality, installation, use and maintenance
management, the placement environment of equipment, equipment operators, and the
method of operation of the main fan. The effectiveness of mine ventilation control
equipment changes the resistance in the network branch roadway, which will have a major
impact on the systems reliability; the main mining process underground will cause a serious
disturbance of air-flow to the mine ventilation system. In addition, ventilation management
has also a significant effect on the reliability of a mine ventilation system.(Keith et al., 2015)
The challenges unique to deep mining are well known. There are countless examples of
underground mines that have gradually progressed downwards and been forced to reassess
their engineering design as they did so. It is, however, less common to see two mines
simultaneously mining the same orebody at different depths, especially when both are
operated by the same company and, to some extent, share technical staff and resources.
1

2.0 CURRENT TREND IN MINE VENTILATION

In metal mines there is a trend for larger diesel equipments, increased production pressures
resulting in a larger number of operating faces, the use of series ventilation to minimize
airflow, increased regulations to lower respirable particulate dust (silica), increased
refrigeration requirements as mines go deeper, use of haulage ramp air as an intake or
exhaust from sublevels, and an increase in electrical power costs that can drive designs to a
minimal ventilation system. In coal mines the trends include, improved real time
communication and tracking systems for effective escape and/or refuge planning, applying
inert gas injection to sealed gob areas to reduce explosive atmospheres, improved rock
dusting application to minimize explosive dust, increased legislative requirements to control
silica and coal dust exposers, and use of underground booster fans to enhance ventilation to
working areas. Some of the current state of the art work in ventilation addresses the trends
presented above. Advances include:
-Ventilation on demand (VOD).
-Mine ventilation monitoring systems.
-Software for ventilation planning.
-Software to predict the impact of an underground fire.
-Advances in diesel engine technology to minimize DPM.
-Remote monitoring of long wall gob particularly when inert gas is injected.
-Energy savings regarding ventilation and air cooling systems.
-Real time monitoring of the underground environment including devices to measure dust
and DPM. (Keith et al., 2015)

2.1. Ventilation on Demand

The concept of ventilation on demand (VOD) is to apply airflow to only the working areas
of the mine while minimizing airflow to remaining areas. This concept is typically applied to
metal/non-metal mines and not coal mines. The system can be as simple as one that turns on
ventilation to a zone regardless of the work activity or a relatively complicated one that
controls the flow based on air quality sensors. The latter system usually requires fan motors
on variable speed drives or variable frequency drives (VFD), air gas sensors (e.g. carbon
monoxide, oxygen, nitrogen oxides, etc.), airflow sensors, regulator and fan control systems,
2

and equipment and personnel tagging systems. The concept is to provide airflow as needed
during the mining cycle. For example, an LHD entering a stope would require a specific
airflow rate. This airflow rate would be predetermined for the LHD. A regulator or fan
would be opened to provide this airflow. The tagging system would identify the location of
the LHD to ensure the flow is constant during its operation in the area. Air quality sensors
monitor the air condition during the mining cycle. When the LHD leaves the area, these
sensors will maintain the airflow rate until such a time as the air quality is acceptable and the
regulator or fan can be turned down or off. This logic would apply to any operating
equipment in the mine and for personnel. In addition, the primary fans would also have VFD
control. The cost of installing such monitoring systems and the maintenance to keep the
system operational is high. Therefore, mines considering such a system usually take a
phased approach. This approach is typically:Stage 1 A VOD system that is remotely controlled. It requires less design up front than an
automated system, but requires more moment to moment manual adjustments for
optimization. This includes the installation of automation and instrumentation to remotely
operate ventilation infrastructure such as fans, regulators, doors, and personnel tracking
systems.
Stage 2 This represents a VOD system that is controlled by a list of predesigned modes or
set points of operation. These modes or set points would be triggered by certain events such
as a shift change, or mining activities such as pre/post blasting. These modes could be
manually triggered, but would better be initiated by an automated system responding to
appropriate initiation signals. (Brian et al., 2015)
Stage 3 This represents a fully dynamic control system where airflow is continually
controlled and balanced based on knowledge of equipment location and mining activities.
This would be the most highly optimized stage resulting in an optimized reduction in wasted
air.
Some calculations have shown that a fully automated VOD system can have an electrical
power savings of up to 50 percent over a conventional mine ventilation system. The use of
VOD for coal mines is far more challenging since many governments legislate minimum
airflow quantities at strategic locations. Varying the flow could have serious consequences if
the sensors or control systems are not operating correctly. (Brian et al., 2015)
3

2.2 Ventilation Monitoring Systems

In some countries monitoring of certain fan operating conditions and/or air quality is
mandatory. Continuous fan static pressure measurements are required at U.S. coal mines. In
addition, monitoring of explosive gases in sealed gob and in entries is required. Other
parameters measured can include carbon monoxide, carbon dioxide, oxygen, and methane.
For metal mines, the gases measured are similar to above but may include sulfide gases and
nitrates of oxide. Additionally, on conveyors smoke sensors are often included in the
monitoring program. Other parameters monitored are airflows at strategic underground
locations and through fan systems, door and regulator positions, and air temperatures. Other
parameters can include DPM and dust continuous monitors. Subsystems can include water
flow and temperature for heat exchangers (water sprays) and fan data such as on/off and
operating position if the motor is equipped with a VFD. These systems allow for real time
evaluation of the underground environment and can be used in a VOD system to provide
ventilation flow control to minimize fan power costs. (Brian et al., 2015)

2.3 Software for Ventilation Planning

In the past 5 years significant improvements have been made in software for ventilation
planning purposes. As PC computers have become more powerful, users have become
accustomed to better graphical interfaces and more tools to support ventilation planning.
Mine ventilation networks are now developed with on screen graphic construction and/or
importing of mine networks from mine design software and/or computer aided design
(CAD) packages. The software results exactly resemble the mine layout in all three
dimensions. Network simulation requires training and practice, as well as a thorough
understanding of the inputs that are required. As software becomes easier to use, it becomes
more challenging for the user to be cognizant of its output. The old adage garbage in
equals garbage out needs to be well understood. It is very easy for the engineer to accept
the software default values as meaningful and allow the software to make basic engineering
decisions as to the model parameters. This can be a dangerous practice. There is no problem
using default values provided the user has set these up based on either measured information
or basic engineering principles. The user must be aware of the model inputs and the limits to
4

the modeling if the model is to be accurate. For existing mines, the network simulation
needs to represent the actual mine system. To this end, the model needs to be verified
against actual measured data. Validating a model is essential if the model is to be used for
future projections. This validation can be achieved through a detailed ventilation survey or,
as a minimum, through spot verification and friction factor calculations.
The purpose of network simulation is to predict the mine ventilation system at some future
time. It is intended to provide mine management with the information needed to procure and
install primary and booster fans, size of raises and shafts, to determine the number of
parallel airways needed for intake and/or return systems, and to evaluate the location of
ventilation infrastructure, such as doors, regulators, and bulkheads or stoppings. In other
words, the results of the modeling work will be used to determine the cost of implementing a
ventilation system and the mining schedule to implement the system. Simulation packages
also have routines to support calculations related to mine gas distribution, radon decay
products, and mine environmental conditions (e.g. wet and dry bulb temperatures and
worker heat predictions). Some can assist in sizing and locating heat exchangers and chilled
water piping. (Brian et al., 2015)
In addition to network simulations, more mining companies are using CFD simulation
programs to solve complicated airflow problems in three dimensions. CFD analysis has been
used to evaluate ventilation and contaminate concentrations around continuous miners, dust
extractor systems, gas levels during an inrush of gas, assess shock losses of ventilation
infrastructure (raises in metal mines and air crossing in coal mines), impact of in-gob gas
movements based on bleeder road configurations, fan duct inlets and exhausts, hoisting skip
effects on shaft airflows, air plenum designs, and fan inlet guide vanes. This is an example
list of the powerful application of CFD studies in mine ventilation. In the future it is
expected that computer power will continue to grow resulting in additional software
capabilities. Real time communication will increase along with Wi-Fi and Bluetooth
technologies. This will result in real time airflow, air quality, personnel and equipment
location, door and regulator settings, and other ventilation related information being
available on virtually any device. PC-based tools are currently becoming mobile based tools
with applications developed for tablet, smart phone, and smart watch applications. This
information will integrate seamlessly with spatial data basis (cloud based) and will be
5

available to mine planning and design teams. However, the experience and knowledge of the
ventilation practitioner will always be required to issue commands and input data. (Brian et
al., 2015)

3.0 RESEARCH AND APPLICATION OF CONTROLLED VENTILATION

Because it was assumed that there were serious potential safety hazards, the underground
circulating wind had not been recognized. But since British Ceyhan Mining successfully
applied circulating wind in 1971, people have different visions for it. The Royal Mining
Administration has approved another 5 trials of circulating ventilation in mining since 1971,
among which the dust concentration of the work surface for Sutton Mining reduced from
8mg/3 to 2mg/ 3 . Wearmouth Coal Mining has been saving 300 thousand pounds of
electrical cost each year by using this technology. In 1982, Loraine Gold Mining in South
Africa conducted a test for controlled circulating ventilation, which made the productivity of
mining areas rise from 6000 t to 15000 t per month. University of Queensland, Australia had
carried out contrast experiments between the traditional ventilation methods with the
controlled circulating ventilation method. Results of the experiments had indicated that the
underground operation environment would be better improved and energy saving and
consumption reducing would be better achieved when the circulating wind was properly
utilized underground (Peng et al., 2014).
Some papers had begun to introduce the underground circulating ventilation in China in
1979, which drew much attention from many scholars. But the Xikuangshan Bureau of
Mines had successfully applied the technology of the controlled circulating ventilation and
thus improved the ventilation of the work surface until the early 1990s. Later on, by using
this technology, Qingchengzi Dressing Plant had succeeded in cutting down the
contradiction between anti-dust and anti-cold in winter, and Taochong Iron Ore had reduced
the dust concentration of the work surface. Whats more, some coal mine factories are
experimenting on the controlled circulating ventilation in China at present. A large number
of high schools and research units have been conducting theoretical research on the
controlled circulating ventilation in China, among which Northeastern University believes
that this technology can better iron out the problems of dispelling blasting fume, reduce the
6

dust concentration and improve the working condition in driving roadway. In a word, the
theoretical analysis of many experts and production practices both prove that the technology
can effectively prevent gases from gathering in roadway; reduce the dust concentration;
improve the underground environment of work surface; and conserve the resources.

3.1 The Applications of The Controlled Circulating Ventilation

The Hongtoushan Mining has experienced more than 50 years of mining with an
exploitation depth of over 1300 m, which is the largest deep mine of nonferrous metals in
China. The deep mining has been continuously extending the ventilating circuit, which has
been greatly increasing the consumption of energy and leading to the environment
deterioration of the underground work. Since the 1980s, the researches and applications of
the controlled circulating ventilation technology have mostly concentrated on the surface or
roadway heading, while on the contrary, the regional and entire applications are relatively
small. The Hongtoushan Copper Mining has successfully converted the existing ventilation
into the entire ore controlled circulating ventilation for its own ventilation difficulties.

3.1.1 The Technology Principle: In the Fig. 1, Qi is the wind volume, m3/s; Qr is the wind
circulation indoor, m3/s; Ci is the inlet wind pollutant concentration, %; Cr is the return
wind pollutant concentration, %; Cm is the mixed inlet wind pollutant concentration, %;
while q is the output of pollutant, m3/s. (Peng et al., 2014).

Fig. 3.1 Schematic diagram of the circulating ventilation (Wang et al., 2014)
7

In Fig. 3.1(a), return wind pollutant concentration Cr is elicited from formula (1):

= +

(1)

In Fig. 3.1(b), pollutant volumes Q in point 2 is elicited from formula (2):

= + +

(2)

= ( + )

(3)

Combining (2) with (3), we get:

= +

(4)

Mixed wind pollutant concentration Cm in point1 is elicited from the following formula:
=

+
+

(5)

Supposing the component coefficients of the circulating ventilation is R, that is

= +

(6)

Combining (5) with (6), we get:

= +

(7)

Comparing (1) and (4), we can figure out that the intensity generated by the return wind
pollutant concentration and the pollutant of the work surface is related to the wind volume of
the work surface instead of the wind circulation indoor. While comparing (7) and (8), we
know that the pollutant concentration of mixed inlet wind is relevant to the wind circulation
indoor, that is to say, it increases with the circulating wind and it is bigger than that of
without circulation wind Rq/Qi. Therefore, as long as a certain fresh wind inlet volume, the
controlled circulating ventilation would not only keep away the pollutants, but it also would
improve the utilization rate of the wind flow (Peng et al., 2014).

3.1.2 The Technical Route of Controlled Circulating Ventilation: The essence of

controlled circulating ventilation technology is to purify the contaminated wind discharged
from the work surface layer upon layer by using the existence of abandoned roadway
engineering and gob at the shallows, and reuse the supply of underground operation when
the air quality meets the health standards. The technical route of controlled circulating
8

ventilation is shown in Fig. 3.2, Firstly, choose appropriately abandoned roadway

engineering for the wind and pressure relief in the mine ventilation, to make the original
ventilation form a controlled recirculation loop. The contaminated wind discharged from the
mining level will firstly go through the gob, and start the first layer of purification. And then
the artificial purification measures will be used to conduct the second layer of purification
for the contaminated wind in the abandoned roadway.
In order to further improve the air quality. Because the roadway excavation and the stoping
blasting operation in the mine will produce high concentrations of contaminated wind that is
not suitable for use as recirculation wind, the opening of the controlled circulating
ventilation shall avoid the concentrated period of blasting operations. In addition, in order to
improve the reliability, the whole monitoring of air quality shall be implemented and the
electric choke remote control shall be installed to achieve the automatic control in the path
of the whole circulation ventilation (Peng et al., 2014).

Fig. 3.2 The technical route of controlled circulating ventilation (Wang et al., 2014)

3.1.3 The Construction Of Controlled Circulating Ventilation: According to the

technical route above mentioned, the Hongtoushan Copper Mining has built safe and reliable
controlled circulating ventilation.as shown in fig. 3.3.
By the field monitoring, the contaminated wind enters into the gob from the middle segment
of -467 primarily and conduct the preliminary purification, and then it enters the middle
segment of -287 m and begins to carry out the multiple and artificial purification, and it
passes into the wind shaft to implement the controlled circulating ventilation when the air
quality reaches the standard.
(1) The circulation ventilation loop is identified in the middle segment of -287 m.
(2) In middle segment of -287 m, centrally mount the spray device and combine other
cleaning measures to multiply purify the contaminated wind of the circulation by using the
abandoned roadways as shown in fig. 3.4.
(3) In the middle segment of -287 m, install five sets of "air quality monitor" to carry out the
whole monitoring of harmful substances, see fig. 3.5.(Peng et al., 2014)

(4) In the middle segment of -287 m , set an electric choke that can be remote controlled,,
see fig. 3.6.

Fig. 3.3 The controlled circulating ventilation of Hongtoushan Copper Mining (Peng et al.,
2014)
10

Fig. 3.4 The spray device (Peng et al., 2014)

Fig. 3.5 Air quality monitor (Peng et al.,

2014)

(a) Closed state

(b) On-state
Fig. 3.6 The electric choke.(Peng et al., 2014).

3.1.4 The Operation Effect of Controlled Circulating Ventilation: The controlled

circulating ventilation works stably, and this technology makes the wind volume of the
original ventilation system increase from 55 m3/s to 79 m3/s, 43.6% of growing rate.
Furthermore, this technology reduces the resistance of the original ventilation system, which
is equivalent to an increase of 712 kW installed power. And the electricity can be saved
11

about $500000 a year. In addition, the technology has an obvious cooling effect, which
makes the deep mining environment temperature decrease from 30C to 26C or below,
greatly improving the climate environment of underground work (Peng et al., 2014).

4.0 STRATEGIES FOR ENERGY EFFICIENT VENTILATION ANDCOOLING

SYSTEMS

4.1 Ventilation On Demand

An energy-efficient primary distribution system delivers air to areas that need it - rather than
ventilating for the worst case of all of the mine being ventilated all of the time, the minimum
quantity of air should be directed to each area depending on the activity. Ensuring that
leakages and short circuits are minimized is also important. This will require controls
(regulators or fans), but the cost of these would be offset by the energy saved.
As mining moves from one area or level to the next, ventilation resources need to be
reallocated and non-working areas sealed off. For example, in a mechanized mine, where
equipment moves freely throughout the mine, the air distribution must be modified to ensure
that there is always sufficient air to dilute fumes and heat wherever the equipment is
working or travelling. This is the principle of ventilation on demand (VOD).
Under normal circumstances a loading zone will be provided with the minimum air quantity
to dilute the fumes of the LHD and the truck being loaded, but when the full truck leaves,
the area could be over-ventilated. The controls would ensure that the air delivered to the
loading area is reduced but the air delivered to the truck route is increased. Equipment
would be fitted with sensors so that it could automatically switch fans on/off as it moves
through areas. An example of an end ventilated by fan fitted with a variable speed drive
(VSD), see Fig. 4.1. The minimum flow for gas dilution will be provided when no
equipment is present, but when an LHD alone or an LHD and a truck are present then the
minimum flow that is provided depends on the rating of the equipment present ( Karsten and
Mackay 2012).
VOD systems can be applied in conventional as well as mechanized mines, with mechanized
mines generally requiring more rapid variations in localized flow delivery because of the
12

transitory nature of equipment usage. Care must be taken when making changes to the
ventilation distribution that minimum quantities are still being delivered to areas where
equipment is no longer working and that fans and regulators in the circuit are operating
within their envelopes. Software such as VUMA-live can be used to predict the effect of
alterations to the circuit. In this system a mine ventilation network model is set up and
initially calibrated to ensure that predictions and measured values agree. The ventilation
network model is linked with a mine monitoring system and the predicted values are
compared with monitored data at a few (maximum 5 or 6) strategic locations. The monitored
values are used as reference points in the network and will enable predictions for areas
downstream of the monitored locations to be accepted with confidence. During the ongoing
monitoring process, differences between predicted and monitored values can be used to
identify potential problems in the circuit, for example, excessive change in temperature
required will indicate that a cooler is not operating; similarly, excessive changes required in
fan pressure or airway resistance indicate that a primary airway could be blocked. The
system is used as follows:
If primary ventilation and cooling is to be reduced during periods of low activity, the
prediction can check that minimum quantities are available in all areas for flammable gas
dilution (this would set the level to which flow is reduced) and temperatures can be checked
prior to arrival of personnel to ensure that acceptable conditions are achieved in all areas
(this would set the time when cooling must be re-started and level of initial cooling required)
If the mine is mechanized, the effect of reallocating air to different locations as the
equipment moves around the mine can be simulated and the effect on distribution of primary
air to all locations checked (Karsten and Mackay 2012).
The system would identify whether sufficient air is being supplied to working places.
Acentral control station could be alerted whenever conditions do not satisfy minimum
requirements. If the program is linked to a central vehicle dispatch system, it would ensure
that sufficient air follows equipment as it moves through the mine. VUMA-live could

13

Fig.4.1 Example of VOD to vary flow in workings based on presence of equipment (Karsten
and Mackay 2012).
instruct the SCADA system to manipulate fans/regulators and indicate whether equipment is
allowed to move to certain locations. The system has successfully been implemented in a
number of projects on gold mines, with good correlation being obtained between measured
and predicted values.

14

4.2 Control of Primary Air Flow

Mine fans are major energy consumers, with the equipment generally operating 24 hours per
day, seven days per week. A number of projects have been undertaken to identify energy
saving opportunities at surface fans. Initially, three different technologies to reduce main fan
absorbed power during strategic periods of the day and week were examined, namely, fan
outlet dampers, variable-speed drives, and fan pre-rotational inlet guide vanes [IGV]. Pooe
et al.9 showed that energy savings of between 27 per cent and 29 per cent were achieved in
three projects where main fan flow was reduced by 10 per cent during the peak energy
demand period of 18:00 to 20:00 using IGV control (Table 4.1).

Table 4.1 Targeted & Achieved Power Saving ( Karsten and Mackay 2012).

In Refrigeration plant surplus cooling capacity because of Eskoms time-of-use tariff

structure, considerable power cost savings can be achieved by utilizing refrigeration plant
surplus cooling capacity and chilled water storage capacity to shift load from the higher
tariff periods to the lower tariff periods.
Surplus cooling capacity is the difference between the maximum cooling capacity and the
normal operational required cooling capacity (operational cooling capacity). The required
operational cooling capacity for surface refrigeration plants is highly dependent on the
ambient air conditions. Surplus capacity during the winter season (low wet-bulb
temperature) can be twice as much as during the summer (high wet-bulb temperature). The
underground water demand is fed from the surface chilled water storage dams. The ideal
15

scenario during peak Eskom tariff periods will be to stop all refrigeration equipment and
supply the mine with the required water from the chilled dams. The surplus cooling capacity
must then be utilized during low tariff periods to prepare dam levels for the next peak tariff
period. The calculation of the maximum load shift potential of a refrigeration plant requires
complex mathematical modelling and simulation. Each piece of equipment within the
mines water handling and water transfer system needs to be characterized and modelled.
All these models are then linked within a larger simulation model to simulate the mines
complete water handling process. The decision engine is then integrated with the simulation
model to calculate the optimized running schedule for each piece of equipment in order to
minimize power cost while adhering to all mine constraints (Karsten and Mackay 2012).

4.3 Modification of Main Fans To Improve Efficiency

An investigation of the operation of main fan efficiency on gold and platinum mines
revealed that a large number of fans operate at aerodynamic efficiencies below 65 per cent
(Fourie et al.,2014). Typically the fan impellers were designed for higher pressures at the
design operating point, but the fans generally operate at lower efficiencies because of
changes over many years in the planned mine development. As a result of the lower
operating pressures, significant losses occur due to flow separation as the impeller blades are
designed for a larger supply head. Fan shaft power is proportional to fan air power and
inversely proportional to the aerodynamic efficiency of the fan impeller. Therefore a
considerable energy reduction could be achieved by improving the aerodynamic efficiency
of the fan impeller. On mines where fans do not operate at the design or best efficiency
point, drop-in impeller replacements are feasible (Fourie et al., 2014)
The purpose of a drop-in impeller is to replace the existing impeller with a new, more
efficient impeller. The design uses the actual operating point as the best efficiency point for
the new impeller design. An important feature of the drop-in concept is that the changeover
requires minimum changes to the existing structural design of the fan. This is done to reduce
the costs of implementation and, more importantly, to reduce the effect on production time
during the installation of the new drop-in impeller. Typically the hardware replacement of a
drop-in impeller design will be the new impeller, a new shrink-wrapped shaft, and minor

16

modifications to the existing casing. The new impeller design is more aerodynamically
efficient and reduces the shaft load on the motor.
As a result the electrical load is reduced, therefore reducing the electrical running costs at all
times of the day. Belle12 carried out a desktop study to examine the benefits of impeller
replacement. The study showed that the combined effect of both the electricity savings and
carbon credits is significant, even at low expected increases in main fan efficiencies. A 10
per cent increase in fan efficiency with 10 per cent reduction in electricity consumption
resulted in an electricity saving of about 11 MW per annum. The present value of this
benefit amounted to some US$16 million over 10 years. With the inclusion of carbon credits
at US$26 per ton, this benefit rose to US$42 million in total. The study showed that up to 81
000 t of C2 equivalent (C2e) could be saved.
4.4 Controlled Recirculation
In the 1990s there was significant interest in the recirculation of air underground; see, for
example, Rose and Bluhm. In a recirculation system, a portion of the return air used to
ventilate a mining section is cooled and reintroduced into the area. The main benefits of
recirculation are the increased volume circulating through the area and hence the reduction
in volume required to be delivered from surface. Because the recirculated air does not travel
from surface it does not undergo the effects of auto compression and the associated increase
in temperature, and the additional fan pressure to deliver the air from surface and back is not
required. One of the concerns relating to recirculation was the potential increase in
contaminants, particularly radiation. However, recent work has shown that it is possible to
design and build scrubber systems to reduce contaminants to acceptable levels in
recirculation systems. (Karsten and Mackay 2012)

5.0 CONCLUSION
As new ventilation technology emerges we must not lose focus on the basic principles. The
use of ventilation modeling software represents a significant time saving tool and can greatly
assist the ventilation engineer in developing complete and thorough designs, allowing for the
rapid development of numerous permeations and design options. However, the ventilation
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engineer should never lose sight of first principles. The tools available to the ventilation
engineer are only as good as the project inputs developed by the engineer. Technological
advances in monitoring and control systems have made the implementation of VOD systems
a reality. However, they must be properly designed such that safety is not sacrificed in the
search of increasing efficiency and decreasing power and infrastructure costs. Developing
and installing monitoring systems has increased the level of safety by allowing continuous
monitoring of gasses and temperatures throughout the mining areas. This allows the mine to
evacuate or receive notification when adverse or dangerous conditions are encountered. The
continued advances in ventilation technology will help to elevate the health and safety of the
miners, as long as the ventilation engineers do not lose perspective of the founding
principles of ventilation.
With great economic and social benefits, the controlled circulating ventilation technology
can optimize ventilation system of deep mining, benefit a dilution to the pollutant
concentration, significantly improve the climatic environment of the deep mining operation,
as well as conserve the resource.

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REFERENCES
Peng, W., Kunlei, Z., Yu, Z., Jingxian, L. and Changyan, S. 2014.Research and application
of controlled circulating ventilation in deep mining. Procedia Engineering vol. 84, pp 758763.
Keith, W., Brian, P. and Daniel, J. S., 2015,The practice of mine ventilation
engineering.International Journal of Mining Science and Technology, vol. 25, pp 165169.
Karsten, M., and Mackay. L., 2012, Underground environmental challenges in deep
platinum mining and some suggested solutions.The Southern African Institute of Mining
and Metallurgy Platinum.
Shuiping, Z., Juan, Q., and Gang.C., 2011, Heat transfer analysis on double-skin air tube in
ventilation of deep mine heading face. Procedia Engineering vol. 26, pp 1626-1632.
Liu, Z.,Wang, X., Cheng, Z., Sun, R., and Zhang, A., 2014, Simulation of construction
ventilation in deep diversion tunnelsusingeulerlagrange method. Computers and Fluids,
vol. 105, pp 28-38.

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