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Underground
Ventilation
EDITED BY Purushotham Tukkaraja
UNDERGROUND VENTILATION
Underground Ventilation contains the proceedings of the 19th North American Mine Ventilation
Symposium held at the South Dakota School of Mines & Technology (South Dakota Mines) in Rapid
City, South Dakota, June 17-22, 2023. South Dakota Mines organized this symposium in collaboration
with the Underground Ventilation Committee (UVC) of the Society for Mining, Metallurgy & Exploration
(SME).
The Mine Ventilation Symposium series has always been a premier forum for ventilation experts,
practitioners, educators, students, regulators, and suppliers from around the world to exchange
knowledge, ideas, and opinions. Underground Ventilation features sixty-seven selected technical
papers in a wide range of ventilation topics including: auxiliary and primary systems, mine fans,
case studies, computational fluid dynamics applications, diesel particulate control, electric machinery,
mine cooling and refrigeration, mine dust monitoring and control, mine fires and explosion prevention,
mine gases, mine heat, mine ventilation and automation, occupational health and safety, renewable/
alternative energy, monitoring and measurement, network analysis and optimization, and planning and
design.
PROCEEDINGS OF THE 19TH NORTH AMERICAN MINE VENTILATION SYMPOSIUM
(NAMVS 2023), 17-22 JUNE 2023, RAPID CITY, SOUTH DAKOTA, USA
Underground Ventilation
Edited by
Purushotham Tukkaraja, Ph.D., QP
Mining Engineering & Management, South Dakota Mines, Rapid City, SD, USA
Front Cover Image: © Zitrón - Ventilation solutions for underground mines
CRC Press/Balkema is an imprint of the Taylor & Francis Group, an informa business
© 2023 selection and editorial matter, Purushotham Tukkaraja; individual chapters, the
contributors
The right of Purushotham Tukkaraja to be identified as the author of the editorial material,
and of the authors for their individual chapters, has been asserted in accordance with sections
77 and 78 of the Copyright, Designs and Patents Act 1988.
All rights reserved. No part of this book may be reprinted or reproduced or utilised in any form
or by any electronic, mechanical, or other means, now known or hereafter invented, including
photocopying and recording, or in any information storage or retrieval system, without
permission in writing from the publishers.
Although all care is taken to ensure integrity and the quality of this publication and the
information herein, no responsibility is assumed by the publishers nor the author for any
damage to the property or persons as a result of operation or use of this publication and/or
the information contained herein.
Table of contents
Preface xi
Organizing committees xiii
Underground Ventilation Committee (UVC) xiii
Review committee xiii
Sponsors and Exhibitors xv
Auxiliary ventilation
An investigation of booster fan placements in a large opening underground stone mine
utilizing CFD 3
N. Gendrue, S. Liu & S. Bhattacharya
Quantifying assemblage losses in auxiliary ventilation systems 15
E. De Souza
v
Diesel particulate control
Comparing diesel and GDiesel® exhaust exposures in an underground mining laboratory 95
R.J. Reed, J.L. Burgess & E.A. Lutz
Improvement of size-selective sampling of diesel aerosols in underground mines 104
A.D. Bugarski, T.L. Barone, J.A. Hummer, T. Lee, S. Vanderslice & S. Friend
Results of diesel exhaust nanoparticle experimental sampling in a cabin of LHD loader
operating in an active ore heading area 115
S. Sabanov, N. Magauiya, A. Zeinulla, A. Abil, A. Qureshi, M. Torkmahalleh,
G. Nurshaiykova & D. Rakhimov
Importance of using real-time and microscopic analysis techniques to characterize DPM in
underground mines 120
A.A. Habibi, K.O. Homan & A.D. Bugarski
Development and evaluation of innovative diesel particulate filter technology 129
J. Stachulak, B. Rubeli, D. Young, K. Watson & B. McLean
DPM reduction through emission assisted maintenance - PT Freeport Indonesia program
update 135
A.A. Habibi, E. Pinto, M. Mardon, K. Wijayanto & C. Rose
vi
Effects of vertical air-blocking ring of drill shroud on dust control for surface mine drilling
operation using CFD 239
Y. Zheng, J.D. Potts & W.R. Reed
Investigation on the effect of water pressure on spray performance for removal of respirable dust 247
H. Jiang, S. Klima, T. Beck & Y. Zheng
Real-time measurements of respirable crystalline silica, kaolinite, coal, and calcite 256
W. Arnott, C. Kocsis, X. Wang, B. Osho, P. Nascimento, S. Taylor, B. Bingham, C. Murphy &
M. Sandink
Comparing respirable dust characteristics from full-scale cutting tests of three rock samples
with conical picks at three stages of wear 264
S. Slouka, E. Sidrow, C. Tsai & J. Brune
Accuracy of low-cost particulate matter sensor in measuring coal mine dust- a wind tunnel
evaluation 274
M.M. Zaid, G. Xu & N.A. Amoah
Parametric studies to maximize the dust protection performance of the two-level manifold
canopy air curtain and computational fluid dynamics modeling 285
N.A. Amoah, G. Xu & A.R. Kumar
Respirable coal mine dust research: Characterization and toxicity analysis based on dust
sources 296
V.P. Salinas, M.C. Das, G. Rubasinghege, P. Roghanchi & K. Zychowski
Comparison of respirable coal and silica dust monitoring systems for underground mining
applications 305
A. Medina, A. Vanegas, E. Madureira, P. Roghanchi, R. Rajapaksha, L. Uecker, T. Rawson &
C. Harb
Evaluation of different surfactants’ performance in varying coal dust concentration through
logistic regression analysis 313
Z. Zhao, A. Ghosh, P. Chang & Y. Liu
Process ventilation solutions for mitigation of combustible and non-combustible dust
hazards at mining operations 322
J. Finn
Development of VR-CFD-based training tool for dust control in gateroad development 330
M. Qiao, T. Ren, J. Roberts, J. Hines, C. Chow & A. Clayton
Mine fans
Stall impact on axial fans and testing of anti-stall rings 341
J. Fernandez
Practical values for the evaluation of fan system efficiencies 353
J. Bowling, G. Schult & J. Van Diest
vii
Evaluation of different suppression techniques for lithium-ion battery fires 384
L. Yuan, W. Tang, R.A. Thomas & J. Soles
Characterization and preliminary assessment of diesel fire prior to setting up large size
battery fire experiment 393
R.I. Pushparaj, G. Xu, A. Iqbal & O.B. Salami
Fire-induced temperature attenuation under the influence of a single ceiling smoke extraction
point in a bifurcated drift 399
O.B. Salami, G. Xu, A.R. Kumar, R.I. Pushparaj & A. Iqbal
Application of pressure balancing techniques at the West Elk coal mine 411
C. Kocsis, F. Calizaya, J. Johnson, T. Dias, N. Nunes, E. Lindgren, G. Atchley & J. Poulos
Mine gases
Underground coal methane gas forecasting using multivariate time series with one and two
auxiliary variables 423
J.C. Diaz, Z. Agioutantis, S. Schafrik & D.T. Hristopulos
Complete degasification of longwall panels in U.S. coal mines 431
P.C. Thakur
Study of in-situ coal seam gas content for Australian coal and gas outburst management:
A field data analysis and laboratory experiment 439
Z.B. Li, T. Ren, M. Qiao, D. Black & J. Juric
Airflow patterns and blast fume dispersion in different mining methods 451
S. Jayaraman Sridharan, A. Adhikari, P. Tukkaraja & J. Connot
The oxiperator for Ventilation Air Methane (VAM) 462
E. Prabhu, M. Prabhu & J.E. Fox
Mine heat
Findings and learnings from thermal parameter studies at four LKAB sites 469
F.K.R. Klose, A.L. Martikainen & T.H. Jones
Scenario-driven evaluation of heat sources in underground production scheduling 484
J.A. Buaba, E. Udofia, A. Newman & A.J. Brickey
viii
Occupational health and safety in mine ventilation
Ventilation research findings for enhanced worker safety when mining near unconventional
gas wells in longwall abutment pillars 529
S.J. Schatzel, K.M. Ajayi, Z. Khademian, R. Kimutis, M.L. Harris, M. Van Dyke, J.D. Addis,
H. Dougherty & E. Watkins
Optimization for fire evacuation applying maximum flow cost algorithm to improve the
time-response in underground coal mines 541
S. Lotero, H. Khaniani, V. Androulakis, M. Hassanalian, S. Shao & P. Roghanchi
Heat mitigation for underground coal mine refuge alternatives 550
D.S. Yantek & L. Yan
Occupancy derating for underground coal mine refuge alternatives 559
D.S. Yantek & L. Yan
ix
Underground Ventilation – Tukkaraja (Ed)
© 2023 The Editor(s), ISBN 978-1-032-55146-3
Preface
This volume contains the proceedings of the 19th North American Mine Ventilation Sympo
sium held at the South Dakota School of Mines & Technology (South Dakota Mines) in
Rapid City, South Dakota, June 17-22, 2023. South Dakota Mines organized this symposium
in collaboration with the Underground Ventilation Committee (UVC) of the Society for
Mining, Metallurgy & Exploration (SME).
The North American Mine Ventilation Symposium series was initiated by the UVC in 1982. The
UVC is a Joint Technical Committee of the Coal and Energy and the Mining and Exploration
Divisions of the SME. The purpose of the UVC is to promote engineering interest and techno
logical progress in the ventilation of mines, tunnels, and other subsurface openings. The UVC
accomplishes its purpose by conducting technical sessions at SME-AIME meetings, sponsoring
the North American Mine Ventilation Symposium with host universities and other organizations,
and soliciting papers for publication in Mining, Metallurgy & Exploration Journal and SME con
ference proceedings. The UVC offers an affiliation home for SME members, and others engaged
in the practice of underground ventilation. In these ways, the UVC seeks to encourage research,
education, publications, and technology transfer in the field of underground ventilation.
The North American Mine Ventilation Symposium, held every two to three years since 1982,
provides a forum for practitioners, educators, and researchers to exchange the latest informa
tion on the ventilation of mines, tunnels, and other underground facilities.
xi
2004 – University of Alaska Fairbanks – Sukumar Bandopadhyay and Rajive Ganguli
With the help of the organizing committee, a solid 3-day program was assembled, with tech
nical papers, panel discussions, and keynote presentations organized in 21 sessions. A total
of 82 abstracts and 67 final papers were received. Session ventilation themes include case
studies, computational fluid dynamics applications, diesel particulate control, electric
machinery, mine cooling and refrigeration, mine dust monitoring and control, primary and
auxiliary systems, mine fans, mine fires and explosion prevention, mine gases, mine heat,
ventilation management, automation, occupational health and safety, renewable/alternative
energy, monitoring and measurement, network analysis and optimization, and planning and
design.
I would like to thank the UVC and Review Committee members for their help with peer-
reviewing papers, chairing technical sessions, and advice to make this symposium a success.
Finally, I would like to thank the Center for Alumni Relations and Advancement (CARA)
and the Office of Marketing and Communications at South Dakota Mines for assisting with
the symposium registration, advertisement, and website services.
xii
Underground Ventilation – Tukkaraja (Ed)
© 2023 The Editor(s), ISBN 978-1-032-55146-3
Organizing committees
Review committee
xiii
Underground Ventilation – Tukkaraja (Ed)
© 2023 The Editor(s), ISBN 978-1-032-55146-3
Sponsors
Platinum
Freeport-McMoRan
G+ Plastics
Hatch
Howden
Minetek
SRK Consulting, Inc.
Gold
Accutron Instruments
Turnstone – ABC VS & JENNMAR
Silver
BBE Consulting
Maestro Digital Mine
Mecanicad
Spendrup Fan Co.
Exhibitors
Accutron Instruments
BBE Consulting
CDC Dust Control & Air Blow Fans
CFT Compact Filter Technic
G+Plastics
Howden
Hyperflo
Maestro Digital Mine
Mecanicad
Minetek
Pinssar
Quick Supply Co
Spendrup Fan Co
SRK Consulting
TLT-Turbo
Turnstone – ABC VS & JENNMAR
Zitron
xv
Auxiliary ventilation
Underground Ventilation – Tukkaraja (Ed)
© 2023 The Author(s), ISBN 978-1-032-55146-3
ABSTRACT: The optimization and planning of the mine ventilation system is a key compo
nent of mine operation given that ventilation related costs can range between 20% and 50% of
the total operating cost of the mine. In large opening mines (LOMs) utilizing perimeter venti
lation schemes minimal guidance is available for determining optimal booster fan (BF) place
ments. A ventilation survey was conducted and published previously by the author which
established a CFD model for a section of an underground room and pillar large opening lime
stone mine. In this work the previously created CFD model was utilized to investigate a total
of 15 BF positions with a focus on recirculation patterns, overall airflow within the BF entry,
and airflow around face area. It was found that the maximum airflow around the face areas
can be achieved with fan positioned on the same side of the entry as face area; with the max
imum airflow through the BF entry being achieved when the fan is placed in the center of the
entry on the upstream side of the pillar line. The recirculation percentages were similar in all
cases reaching a maximum between 35%-40% of the total air movement. However, the highest
recirculation percentages also facilitated, via air entrainment, the highest airflow magnitudes
through the BF entry. The booster fan’s ability to stimulate airflow through adjacent entries
was found to be reduced by approximately 30% for each adjacent entry. Therefore, the recom
mendation was given to position the BF within 3 entries of the face to achieve adequate
airflow.
1 INTRODUCTION
Mine ventilation is an essential part of any underground mining system and accounts for
between 20% and 50% of the total operating cost of the mine (Carter, 2018, Leonida, 2019,
Babu et al., 2015). In large opening mines (LOMs, mines with cross-sections >~1000 ft2), par
ticularly in stone mines utilizing perimeter ventilation schemes, the placement of booster fans
is typically empirically determined by rule of thumb or trial and error until satisfactory condi
tions are achieved. Many LOMs do not utilize typical auxiliary ventilation systems with an
auxiliary fan and bag. Therefore, proper BF placement is imperative considering the lack of
other ventilation controls.
In place of typical auxiliary systems many LOMs utilize large diameter fans that produce
high-volume with low-pressure; and commonly referred to as box fans or propellor fans. Com
pared to jet fans these fans provide the increased airflow needed to maintain regulatory com
pliance; however, the low-pressure tradeoff creates other concerns over the increased role of
natural ventilation plays in the system due to the low system pressure, ventilation efficiency,
recirculation, and short circuiting of mining sections. Specifically for large opening stone
mines there is little quantitative guidance on how to combat these issues. This work will inves
tigate the effect of BF placement within the entry and its influence on recirculation and face
ventilation efficiencies.
DOI: 10.1201/9781003429241-1
3
In Gendrue et al. (Gendrue et al., 2023), a ventilation survey was conducted and used to
create a computational fluid dynamics (CFD) model of a section of a large opening stone
mine. The simulations resulted in a discussion of the mines selected BF placement and its
effectiveness as well as discussions on measurement locations for ventilation surveys. In this
work, the same model will be utilized to simulate different BF placements and discussions on
the BF effectiveness around the face area and airflow directions and quantities will be given.
This work aims to provide a foundation for future CFD BF placement studies on perimeter
ventilation systems and discuss important considerations when selecting a position for a BF.
2 BACKGROUND
Previous mine ventilation studies related to face ventilation focus on auxiliary ventilation of
drifts or dead-end headings with an emphasis on contaminant distributions and removal. Vari
ables typically considered when evaluating face ventilation are fan selection, curtain or auxiliary
tubing placement, airflow penetration depth, entrainment ratios, recirculation, and jet fan
angles being common among the studies listed below. However, large opening stone mine venti
lation schemes are unique and must be evaluated separately. Studies specifically in LOM envir
onments are limited however, the same quantitative variables are used to evaluate the systems.
Dunn et al. (Dunn et al., 1983) studied how BF inclination, fan elevation and ultimately air
flow around open entries and the face area in large and medium sized airways. However, their
results and discussions were derived from field data which inherently limits the analysis due to
the smaller number of sampling locations when compared to numerical simulations. Nonethe
less, their recommendations for optimizing face ventilation were to: (i) utilize a pushing system
rather than a pulling system, however, no pulling systems were investigated, (ii) place fans to
direct flow diagonally across the face, (iii) place fans one pillar inby the general flow to minimize
recirculation. They also noted that larger capacity fans ventilate more effectively and inclination
and elevations of the fans have little effect on face ventilation. Krog and Grau (Krog and Grau,
2006) discussed the use of vane axial or propellor fans in terms of their recirculation, overall
airflow, and entrainment ability for use in LOMs. Ultimately giving recommendations that pro
pellor fans be placed in the fresh air stream and work best for regional ventilation applications
while vane axial fans be placed 1 entry behind the airstream and work best for dead end ventila
tion i.e., headings. They also tested pushing and pulling systems for a new mine utilizing
a textbook example of a split mine ventilation scheme concluding that a BF positioned just
outby a portal is effective for mine airflow. Later, Grau and Krog (Grau III and Krog, 2009)
discussed BF placement and mine design criteria such as long pillars in terms of ventilation effi
ciency for LOMs. Recommendations were given to place the booster fans outby the last open
crosscut. Furthermore, it was noted that fans positioned in the middle of the entry will increase
recirculation and that “not all recirculation is detrimental.”
These three studies, however, do not cover all the common ventilation schemes used today in
LOMs. The study by Krog and Grau (Krog and Grau, 2006) studied only one adjacent entry
when three to five entries are common in perimeter schemes. They also investigated a split mine
ventilation scheme for a new mine. Grau and Krog (Grau and Krog, 2009) utilized a 3-entry
heading which operated under a pseudo split ventilation scheme with fresh air on one side and
return air on the other. The BF as directed perpendicular to the face opposite what is done in
perimeter ventilation where the fan is directed parallel with the face. Furthermore, the study by
Dunn et al. (Dunn et al., 1983) may initially seem like a perimeter ventilation scheme but all the
tested fan positions were at a 90° angle from the general airflow direction which is more analo
gous to a unit ventilation scheme. These studies also utilized smaller fans than are typically seen
today with the largest studies being an 8 ft. in Krog and Grau, 2006. Therefore, these studies are
fundamentally different not only in terms of fan technology but also in terms of their fundamen
tal ventilation system design as defined by Krog et al. (Krog et al., 2004) as split, unit, and per
imeter schemes.
BF placement and ventilation system designs have been noted in many studies as the most
or one of the most important factors in LOM ventilation systems, however, there are minimal
4
studies that discuss optimal BF placement (Thimons et al., 1985, Dunn et al., 1983, Grau and
Krog, 2009, Grau III et al., 2006). Thus, BF placement must be reexamined with current fan
capacities and in a perimeter ventilation context with the fan directing airflow parallel to the
face area rather than at a 90° angle to it.
3 METHOD
Figure 1. Plan view of the partner limestone mine with curtains, stoppings, and booster fans highlighted
in black, with the selected CFD simulation region highlighted in yellow.
5
Table 1. Measured airflow velocities and fan settings observed during the ventilation survey that were
used for the boundary conditions of the CFD simulation, measurement locations and names are shown
in Figure 2B.
6
some level of recirculation. The air flowing South-North (1N-8N) will be referenced as ‘entry’
airflow while the air flowing West-East (1W-12W) will be referenced as ‘crosscut’ airflow. Air
flow that is opposite the BF direction (flowing from north to south) in the entries and from
east to west in the crosscuts is labeled as negative airflow and is used to calculate
a recirculation ratio. The recirculation ratio is defined as the sum of negative airflow across
a pillar line divided by the total airflow across the pillar line.
Figure 2. A) Booster fan placements inside the model geometry, 15 different booster fan locations were
simulated with 9 arranged in a grid pattern between the same pillar marked original fan location, another
3 locations are 2 pillars inby the original location and the final group of 3 locations being 2 pillars outby
the original location B) Location of airflow measurements from the simulation files, entries parallel to the
booster fan direction are labeled 1N-8N while the crosscut entries are labeled 1W-12W with the original
booster fan placement shown as the blue fan symbol.
7
airflows and the traditional entrainment pattern at the first crosscut. Furthermore, the airflow
entering the model through inlets 1-8 in Figure 4A is mainly pulled though entry 8N while the
inlet airflow in Figure 4B is more uniformly distributed throughout all entries. This shows the
importance of BF placement within the context of pillar geometry. The pillar geometry was
created from the mine map, and when pillars are offset, or not perfectly aligned due to blast
ing, then BF airflow and effectiveness can be minimized due to the airstream disruption as
described above. In typical mine ventilation surveys that an operator would perform daily it is
common to measure airflow downstream of the BF and in an adjacent entry when time per
mits. With these minimal measurement locations, the region cannot be fully quantified. In
Figure 4A and 4B the red circled areas on the left upstream side of the region have minimal
airflow of under 0.5 m/s and are insignificantly affected by all fan positions in scenario one.
Figure 3. Airflow through entries 1N-8N for scenario one, fan locations are marked 1 through 9 in
a counterclockwise direction, positive airflow indicates flow in the booster fan direction (downstream)
and negative airflow indicates flow opposite the booster fan direction (upstream).
The right fan positions in the entry (locations 2, 3, and 9) show the lowest total air move
ment across the pillar lines and through entry 6N in Figure 3; these locations also have the
highest downstream positive airflow through entries 7N and 8N which is likely hindering air
entrainment as noted in Krog and Grau (Krog and Grau, 2006) that a more uniform distribu
tion of airflow will not induce entrainment. Since this uniform airflow does not occur when
the BF is on the right side of the entry it is likely due to the fan positioned on the same side of
the entry as the adjacent curtain line. Indicating that a fan positioned on the same side of the
entry as a curtain/stopping line in adjacent entries will minimize BF airflow due to the loss of
the booster fans entrainment abilities.
Table 2 shows the recirculation percentage across the pillar lines 1W-12W as defined in
Figure 2B in section 4.1. Recirculation percentages above 30% are highlighted in orange while
percentages below 10% are highlighted in blue. When no recirculation occurs, the cell is
marked with a dash (-). With the BF positioned in the center of the entry (positions 1, 4,
and 8) there are similar airflow magnitudes in Figure 3 as to when the BF is positioned on the
8
left side of the entry but with less recirculation as seen in Table 2. An increase in airflow and
recirculation can be seen in the first two pillars upstream from the BF when the fan is posi
tioned on the left-side of the entry (positions 5, 6, and 7) which is not seen with the center
positioning (Org 1). The left-side locations (Org 5, 6, and 7) also account for the highest recir
culation percentages in Table 2. With the fan positioned on the left side the cone effect of the
BF is maximized allowing for the airflow to be distributed across the entry without pillar/rib
interaction; however, with these fan positions the recirculation around the left adjacent pillars
are the highest compared to all other positions in Figure 3. Due to the large airflow (velocity)
gradient between the BF entry and the adjacent entries in the left positions it is unsurprising
these locations also have the highest airflow due to recirculation and entrainment properties.
Interestingly, in Figure 3 the position 8 graph is more similar to the left-side graphs in terms
of total airflow, recirculation amounts, and face airflow. Indicating that more total air move
ment can be achieved when the BF is positioned in either position 8, in the middle of the entry
in line with the upstream side of the pillar edge, or in the left positions, on the same side of the
entry as the open/face area.
Figure 5 shows the recirculation percentage through the entries as in Section 4.1. When the
BF is positioned in the center of the entry (positions 1, 4, and 8) there are similar airflow mag
nitudes in Figure 3 as to when the BF is positioned on the left side of the entry but with less
recirculation as seen in Figure 5. An increase in airflow and recirculation can be seen in the
first two pillars upstream from the BF when the fan is positioned on the left-side of the entry
(positions 5, 6, and 7) which is not seen with the center positioning. The left-side locations
also account for the highest recirculation percentages for all pillar lines (1W-12W) in Figure 5.
With the fan positioned on the left side the cone effect of the BF is maximized allowing for the
airflow to be distributed across the entry without pillar/rib interaction; however, with these
fan positions the recirculation around the left adjacent pillars is the highest compared to all
other positions in Figure 3. Due to the large airflow (velocity) gradient between the BF entry
and the adjacent entries in the left positions it is unsurprising these locations also have the
highest airflow due to recirculation and entrainment properties. Interestingly, in Figure 3 the
position 8 graph is more similar to the left-side graphs in terms of total airflow, recirculation
amounts, and face airflow. Indicating that more total air movement can be achieved when the
BF is positioned in either position 8, in the middle of the entry in line with the upstream side
of the pillar edge, or in the left positions, on the same side of the entry as the open/face area.
Figure 5 shows the airflow through the crosscuts labeled1W-12W with each bar representing
a north to south pillar lines labeled as right or left of the BF entry. Again, positive airflow in
Figure 5 represents air moving from west to east in the geometry in Figure 2B. The total bar
height represents the magnitude of airflow through the crosscuts or the exchange between the
9
Figure 4. Velocity contour of positions 6 and 8 of scenario one near the breathing plane (Z=2m), A)
location 6, B) location 8.
entries. The BF location in scenario one is between crosscuts 6W and 8W. Given the large
amounts of air entrainment seen in positions 1, 4, 6, 7, 8, in Figure 3 it is expected that the air
flow in the first and second crosscuts (7W and 8W) are high in magnitude and positive on the left
and negative on the right side of the BF entry indicating air flowing inwards towards the BF
entry i.e., entrainment. Furthermore, the maximum airflow at these locations in Figure 3 is
reached a maximum either one pillar (80 ft.) or two pillars (160 ft.) downstream the BF which is
consistent with the finding of Krog and Grau (Krog and Grau, 2006) as described by Figure 6 in
their work that maximum airflow for propeller fans being reached ~ 52 m (170 ft.) downstream.
Moving to ventilation effectiveness across the face area the ability to dilute contaminates
generated near the face is also related to crosscut flow due to the geometry, the only way to
transport containments out of the mine is towards the general airstream in the BF entry which
must be achieved through crosscut airflow. Therefore, it is important to maximize the crosscut
airflow near the face (5 and 4 pillars to the left of the BF entry). Locations 5, 6, and 8 in
Figure 5 shows similarly high values for airflow 5 entries to the left of the BF entry (between
entries 1N and 2N) compared to all other fan positions. This may be due to the higher overall
airflow generated by the BF across the region however, location 7 also has high absolute air
flow of ~804 m3/s which does not translate to higher face airflow. Interestingly at position 7 in
Figure 5, marked by the red box, the first left adjacent entry (1 left) has the highest positive
and overall airflow through it which does not translate to high face airflow. Thus, leading to
the conclusion that not only is high regional airflow necessary to ventilate further adjacent
entries but some amount of airstream disruption via air diversion from pillar corners is
needed to maximize crosscut exchange between entries.
To quantify the influence of the BF to adjacent entries the percent reduction in airflow
exchange (crosscut airflow) between the BF entry and adjacent entries can be calculated.
When face airflow is higher, as seen in positions 5, 6, and 8 a reduction in crosscut airflow can
be seen starting from 1 pillar to the left of the BF entry until approximately 4 pillars to the left
as shown by the red arrows in position 5 on Figure 5. When averaged across these positions
a total decrease in airflow of 91% on the positive side and 84% on the negative side is seen.
Indicating that crosscut airflow is reduced by approximately 46% to 55% for every consecutive
adjacent entry from the BF entry. Therefore, the BF effectiveness to facilitate airflow past
four adjacent entries is seen to be less than 15% of the BF entry and may not be sufficient to
be relied upon for mine ventilation planning.
4.3 Scenario two: Three pillars inby and outby the original fan location
Six more simulations were conducted three pillars inby and three pillars outby the original BF
location. Booster fan positions 1, 2, and 6 were selected for these inby and outby locations.
The calculated airflow values were obtained in the same way as the previous section.
10
Figure 5. Airflow through the crosscuts (1W-12W) from scenario one, fan locations marked 1 through 9
in a counterclockwise direction, positive airflow indicates flow from west to east in the crosscuts (1W to
12W) while negative airflow values indicate airflow in the opposite direction.
Figure 6 shows the calculated airflow values through entries 1N through 8N with the ori
ginal inby and outby BF locations marked on the y-axis. Inby location 1 shows the highest
airflow through entry 6N with a value of ~ 575 m3/s with inby position 6 showing the lowest
airflow through entry 6N of ~330 m3/s. Inby location 1 showed significant negative airflow
values in entries 3N to 5N throughout the middle portion of the geometry, which facilitates
the high airflow in entry 6N through air entrainment as discussed in Section 4.2. The outby
fan locations in Figure 6 shows minimal airflow through the majority of the geometry due
to the BF being in the outby position. However, similar maximum airflow values are still
reached downstream from the BF. All three of the outby fan positions did not have negative
airflow until 3 pillars upstream from the BF location which allows the majority of the sec
tion to have positive airflow. This leads to all three outby simulations (similar to original
location 2) having positive airflow throughout the face area (entries 1N-3N). However, the
magnitude of the positive airflow seen around the face area was not significantly larger than
any of the other simulations that saw negative airflow. Indicating that if avoiding negative
airflow is a necessity then a more outby BF location would be desired with a preference
towards a fan placement in the middle of the entry or on the same side as the adjacent cur
tain/stopping lines.
The recirculation percentages in Table 3 of the outby and inby fan locations are similar in
magnitude to that of the original locations. The recirculation at the original, and outby loca
tion 6 have the highest magnitude and occurrence while inby location 1 has the highest mag
nitude and occurrence. Recirculation across the BF pillar line can be thought of as the
‘overall sections recirculation’ given that the air is directly recirculating from downstream to
upstream of the BF. Location 6 has the largest magnitude in all positionings, 36% for outby,
30% for original, and 33% for inby positions. This is consistent with the results from Table 2
showing the highest recirculation percentages in original locations 5, 6, and 7 of scen
ario one.
Lastly, the crosscut airflow from the inby, outby, and original locations are shown
in Figure 7. A similar reduction in airflow in adjacent entries can be seen in both the
inby and outby locations. Inby location 6 shows a significantly different pattern than
11
the rest of the locations due the high airflow through entry 4W. Similar to Figure 4A,
the airflow in entry 6N in the inby location 6 simulation caught the corner of a pillar
and split the air stream between entry 6N and crosscut 4W. This air stream continued
towards the face and split resulting in positive airflow downstream and negative air
flow upstream through entry 1N as shown by the red circle in the inby location 6
graph in Figure 6. Even with this extreme example of airflow being directed towards
the face the average reduction in crosscut airflow still remains and is 79% and 74% for
positive and negative airflow respectably in the inby locations. The average reduction
for outby locations is 91% and 77% for positive and negative airflow respectably.
These reductions correspond to a 25-30% reduction per pillar line in all cases, indicat
ing that positioning the BF at an inby or outby locations does not have a significant
effect on crosscut airflow.
Table 3. Recirculation percentage of the inby, original, and outby fan locations,
fan locations 1, 2, and 6.
Figure 6. Airflow through entries 1N-8N for booster fan locations 1, 2, and 6 at the inby, original, and
outby fan locations, positive airflow indicates flow in the booster fan direction (downstream) and nega
tive airflow indicates flow opposite the booster fan direction (upstream).
12
Figure 7. Airflow through the crosscuts (1W-12W) from the inby, original, and outby fan locations, posi
tive airflow indicates flow from entries west to east in the crosscuts (1W to 12W) while negative airflow
values indicate airflow in the opposite direction.
A CFD model was created based on a mine ventilation survey of a typical perimeter ventilation
schemed large opening room and pillar underground mine. 15 BF positions were investigated in
two scenarios: the first scenario consisted of nine fan positions around the original BF placement
selected by the mine operator with the second scenario consisting of three fan positions three pil
lars inby and outby the original location. The airflow around the BF was investigated through
recirculation patterns and overall airflow within the BF entry and the room and pillar region with
a focus around the face velocity. The following conclusions were made based on the simulations:
(1) The highest total airflow in the section may not always be obtained when the BF is posi
tioned at the center of the entry but rather when the BF is positioned on the same side of
the entry as the open room and pillar areas.
(2) As noted in Krog and Grau (Krog and Grau, 2006) and confirmed in these simulations
air entrainment is maximized when high velocity gradients or non-uniform distribution
of airflow is seen through the adjacent BF entries. Furthermore, the maximum airflow
through the BF entry was confirmed through the simulations to be ~ 160 ft downstream
the BF which is consistent with their findings of ~170 ft.
(3) Not only is high regional airflow necessary to ventilate further adjacent entries from the
BF but some amount of airstream disruption via air diversion from pillar corners is
needed to maximize crosscut exchange between entries.
(4) The airflow through the crosscuts observes a 46%-55% reduction per entry indicating
that booster fans in this geometry have minimal effect past 4 adjacent entries. Leading
to a recommendation to keep the BF within 3-4 entries of the face.
(5) In situations where recirculation must be avoided a BF located more outby from the
center of the section is preferable. This outby fan location was shown to create ‘positive’
airflow around the face areas i.e., non-recirculating airflow.
While all mine geometries are unique and BF positioning should be investigated on a case-
by-case basis with the purpose of the BF in mind, these simulations and recommendations can
act as a starting point for LOM operators who utilize a perimeter ventilation scheme.
13
ACKNOWLEDGEMENT
This work was financially supported by The National Institute of Occupational Safety and
Health (NIOSH) under contract No. 75D30119C05743.
REFERENCES
Babu, V.R., Maity, T., Prasad, H., 2015. Energy saving techniques for ventilation fans used in under
ground coal mines—A survey. J. Min. Sci. 51, 1001–1008. https://doi.org/10.1134/S1062739115050198.
Carter, R., 2018. Focusing the Flow. Eng. Min. J. 219, 50–56.
Dunn, M., Kendorski, F., Rahim, M., Mukherjee, A., 1983. Testing Jet Fans in Metal/nonmetal Mines
With Large Cross-sectional Airways.pdf.
Gendrue, N., Liu, S., Bhattacharyya, S., Clister, R., 2023. An investigation of airflow distributions with
booster fan for a large opening mine through field study and CFD modeling. Tunn. Undergr. Sp.
Technol. 132.
Goodman, G., Taylor, C., Thimons, E., 1992. Jet Fan Ventilation in Very Deep Cuts-A Preliminary
Analysis.
Grau III, R.H., Krog, R.B., Robertson, S.B., 2006. Maximizing the ventilation of large-opening mines.
Proc. 11th U.S./North Am. Mine Vent. Symp. - 11th U.S./North Am. Mine Vent. Symp. 2006 53–59.
https://doi.org/10.1201/9781439833391.ch8.
Grau III, H., Krog, R., 2009. Using mine planning and other techniques to improve ventilation in
large-opening mines. Min. Eng. 61, 46–50.
Hargreaves, D.M., Lowndes, I.S., 2007. The computational modeling of the ventilation flows within
a rapid development drivage. Tunn. Undergr. Sp. Technol. 22, 150–160. https://doi.org/10.1016/j.
tust.2006.06.002.
Krog, R.B., Grau III, R.H., Mucho, T.P., Robertson, S.B., 2004. Ventilation planning layouts for large
opening mines. Soc. Mining, Metall. Explor. 1–9.
Krog, R.B., Grau, R.H., 2006. Fan selection for large-opening mines: Vane-axial or propeller fans -
Which to choose? Proc. 11th U.S./North Am. Mine Vent. Symp. - 11th U.S./North Am. Mine Vent.
Symp. 2006 535–542.
Leonida, C., 2019. Changing the Face of Mine Ventilation.
Nguyen, V.D., Heo, W.H., Kubuya, R., Lee, C.W., 2019. Pressurization ventilation technique for con
trolling gas leakage and dispersion at backfilled working faces in large-opening underground mines:
CFD analysis and experimental tests. Sustain. 11. https://doi.org/10.3390/SU11123313.
Parra, M.T., Villafruela, J.M., Castro, F., Méndez, C., 2006. Numerical and experimental analysis of
different ventilation systems in deep mines. Build. Environ. 41, 87–93. https://doi.org/10.1016/j.
buildenv.2005.01.002.
Thimons, E., Kohler, J., 1985. Measurement of air velocity in mines.
14
Underground Ventilation – Tukkaraja (Ed)
© 2023 The Author(s), ISBN 978-1-032-55146-3
E. De Souza
AirFinders Inc., Kingston, Canada
ABSTRACT: While mine ventilation systems may account for 40% to 50% of the energy con
sumption of a mine operation, auxiliary ventilation alone may be accountable for half of this con
sumption. In effect, auxiliary ventilation systems comprise a significant portion of a mine
operation’s base energy demand and is consequently responsible for a large percentage of the total
mine operating costs. This paper presents how engineering design principles can be applied to
design efficient and reliable auxiliary ventilation systems, especially focusing on assemblage losses.
Case studies are presented to demonstrate the effect of design, installation and maintenance prac
tices on system reliability and operating costs. In particular, the effect of assemblage losses is
quantified in terms of operating efficiencies, energy consumption and costs.
1 INTRODUCTION
Increasing costs of electricity have resulted in emphasis on energy-efficient designs and oper
ation for all energy-consuming systems in mining. Since ventilation systems normally account
for 25-40% of the total energy costs and 40-50% of the electrical consumption of a mine oper
ation (De Souza, 2018, 2013), the optimization of ventilation systems is today a ventilation
engineer’s top priority.
While modern duct-fan systems require precise engineering design, meticulous attention to
installation and regular maintenance practices, many installations are often designed based on
outdated rules of thumb and with disregard to best installation practices. In the course of
many years of investigations of duct-fan systems, the author has found them to be, in general,
fairly energy inefficient, with many systems operating at efficiencies below 65% and with air
leakages ranging between 25% and 75% (De Souza, 2004).
Auxiliary ventilation systems comprise a significant portion of a mine operation’s base energy
demand and may be accountable for half of a mine ventilation system energy consumption.
Typical auxiliary ventilation systems are fairly energy inefficient; factors affecting mechanical
and ventilation efficiencies loss include design flaws, installation practices and air leakage.
General solutions and tactics for improving auxiliary ventilation systems as presented in
this paper come from multiple ventilation audits performed by the author. They target sub-
system components which affect shock losses and mechanical and ventilation efficiencies. By
increasing the efficiency of auxiliary ventilation system components and by correcting
inappropriate designs or system degradation caused by poor maintenance, the overall capacity
of the system in delivering air to the required active faces can often be improved.
2 CASE APPLICATION
A case application associated with extensive engineering work conducted by the author is pre
sented in this section to demonstrate how, by conducting detailed ventilation efficiency audits,
simple low-cost solutions can be devised to increase efficiency, reduce power consumption,
and lower operating costs.
DOI: 10.1201/9781003429241-2
15
The case study is based on the auxiliary ventilation system illustrated in Figure 1. A series
of analysis are performed to quantify the contribution of each component of the complete
system to energy consumption and costs: inlet bell, screen, silencers, system friction, couplings,
bends, duct exit. The effect of air leakage and of installation practices is also quantified. The
analysis was based on analytical procedures and scientific guidelines developed by the author
(De Souza & Dirige, 2022) and use of specialized software (AirFinders, 2022).
The auxiliary ventilation system, to be installed in a development drift to supply 18.88 m3/s
air for a diesel production fleet rated at 298.3 kW, has the following design characteristics:
– layflat duct - new, 1.2192 m diameter, provided in 15.24 m long sections, 10 sections of
ducting. Multi clip joints.
– spiral duct, new, 1.2192 m diameter, 1 section 15.24 m for bend. Multi clip joints.
– total column length - 167.64 m.
– fan: 1.219-0.80-1780 (fan diameter-hub diameter-rpm) with a 149.14 kW motor. 600 V.
Motor efficiency 95%. Power factor 0.84.
– inlet bell - 1.651 m diameter, 0.2159 m long.
– screen - wire mesh screen of 95% net free area.
– silencers - two podless flow through silencers.
– bend - right angle normal bend of 1.524 m radius.
– cost of power: $0.08/ kW.hr.
– operation - 24 hours/day, 365 days/year.
– standard density conditions.
Three cases, with operational features presented in Table 1, are considered. Case 1 represents
the system design to meet the flow requirements of at the face of 18.88 m3/s and considers
a design air leakage of 20%. The fan supply flow is 23.6 m3/s. An ‘installation quality factor’ of
10%, representing a ‘good’ installation, is used to adjust the system static resistance pressure.
Case 2 represents the system as installed. Attained flows at the face of 15.56 m3/s do not meet
requirements, and is based on an air leakage of 30%. The fan supply flow is 22.23 m3/s. An
‘installation quality factor’ of 30%, representing a ‘poor’ installation, is used. Case 3 represents
the system with the fan blade setting adjusted to achieve the required face flow of 18.88 m3/s.
Air leakage is not constrained, remaining at 30%. The fan supply flow is 26.97m3/s. The system
installation quality is not improved; an ‘installation quality factor’ of 30% is used.
The contribution of each duct system component to power consumption and operating
costs is presented in the following sections.
16
without an inlet bell. Table 2 presents a summary of results for the 3 cases. For cases 2 and 3,
substantial increases in operating cost of 723% and of 1,370% are noted when an inlet bell is
not used. Table 2 clearly shows that, when an inlet bell is installed, significant energy and cost
savings can be achieved.
Table 2. Head losses, power, and operating costs for inlet bell.
Case Head Loss (Pa) Power (kW) Cost/Year ($/y) % Change in Cost
1 14.73 0.59 412.28 –
2 108.90 4.84 3,393.06 723
3 160.27 8.64 6,058.39 1,370
2.2 Screen
The fan screen prevents debris from entering the fan. Case 1 has a screen of 95% net free area
installed and in Cases 2 and 3 the fan screen is partially blocked by the deposition of debris.
Table 3 presents a summary of results for the 3 cases. For cases 2 and 3, substantial increases
in operating cost of 340% and of 686% are noted when the screen is partly blocked with debris
and not well maintained.
2.3 Silencers
Silencers provide a level of noise reduction to meet specific needs and for compliancy with
regulations. Case 1 has silencers properly connected to the fan and in Cases 2 and 3 the silen
cers have a non-aerodynamic connection to fan. Table 4 presents a summary of results for the
3 cases. For cases 2 and 3, relatively large increases in operating cost of 19.7% and of 45% are
noted when the silencers are not properly installed.
17
Table 4. Head losses, power, and operating costs for silencers.
Case Head Loss (Pa) Power (kW) Cost/Year ($/y) % Change in Cost
1 49.77 1.99 1,392.95 –
2 53.50 2.39 1,666.93 19.67
3 53.50 2.89 2,022.36 45.19
Table 5. Head losses, power, and operating costs for layflat duct friction losses.
Case Head Loss (Pa) Power (kW) Cost/Year ($/y) % Change in Cost
1 604.66 21.60 15,136.12 –
2 469.54 17.47 12,240.01 –19.13
3 691.04 31.19 21,854.54 44.39
Table 6. Head losses, power, and operating costs for spiral duct friction losses.
Case Head Loss (Pa) Power (kW) Cost/Year ($/y) % Change in Cost
1 226.75 9.06 6,346.37 –
2 201.23 8.95 6,269.83 –1.21
3 296.16 15.97 11,195.12 76.40
Table 7. Head losses, power, and operating costs for layflat duct coupling losses.
Case Head Loss (Pa) Power (kW) Cost/Year ($/y) % Change in Cost
1 64.27 2.30 1,608.96 –
2 49.91 1.86 1,301.10 –19.13
3 73.46 3.31 2,323.12 44.39
18
3 cases. Because of the reduced fan flows, case 2 has a reduced operating cost of 1.2% and, for
case 3, because of the increased fan flow, an increase in operating cost of 76.4% is noted.
Table 8. Head losses, power, and operating costs for spiral duct coupling losses.
Case Head Loss (Pa) Power (kW) Cost/Year ($/y) % Change in Cost
1 71.42 2.85 1,998.86 –
2 63.38 2.82 1,974.75 –1.21
3 93.28 5.03 3,526.02 76.40
2.8 Bend
Case 1 has a properly designed bend and, in Cases 2 and 3, the installed bend is ‘kinked’,
resulting in a higher resistance pressure. Table 9 presents a summary of results for the 3 cases.
For cases 2 and 3, relatively large increases in operating cost of 97.6% and of 252.8% are
noted when the bend is not properly installed.
Table 9. Head losses, power, and operating costs for bend losses.
Case Head Loss (Pa) Power (kW) Cost/Year ($/y) % Change in Cost
1 45.40 1.81 1,270.75 –
2 80.59 3.58 2,510.85 97.59
3 118.60 6.40 4,483.27 252.80
Table 10. Head losses, power, and operating costs for exit losses.
Case Head Loss (Pa) Power (kW) Cost/Year ($/y) % Change in Cost
1 157.07 5.02 3,516.58 –
2 337.29 10.50 7,356.40 109.19
3 496.41 18.74 13,134.63 273.51
19
Table 11. Component percent contribution to annual operating costs.
Component Percent $/year change relative to case 1
Case 2 Case 3
Inlet bell 723.0 1,369.5
Screen 340.3 686.1
Silencers 19.7 45.2
Friction layflat –19.1 44.4
Friction spiral –1.2 76.4
Joints layflat –19.1 44.4
Joints spiral –1.2 76.4
Bend 97.6 252.8
Exit 101.2 273.5
Overall 19.1 109.6
the correcting duct outlet. Also, the duct column installation quality should be improved, and
air leakage controlled. These actions will bring the system operation close to the design
specifications.
Figure 2. Fan characteristics and operating points for the three cases.
20
2.12 Operational costs
Table 13 presents annual fan operating costs as a function of the number of duct installations.
Independent on the number of installations, fan operating costs increase by 10% and 93.7%
for cases 2 and 3, relative to case 1. Typical hard rock mines may have well over 40 auxiliary
ventilation systems installed to support development and production activities. For the case
study presented, annual cost savings reaching some $1.65M can be realized when a system is
installed and maintained according to design.
It is noted that the comparative analysis was based on direct costs only. It is recognized that
ventilation training, asset management and preventive maintenance produce significant reduc
tions in ventilation operating costs. While indirect costs are site dependent, the author has
observed that when workers acquire practical ventilation training prior to working under
ground, which normally comes at a very nominal cost, considerable improvements in ventila
tion system performance are readily realized.
Table 13. Annual operating costs for multiple duct system installations.
Number of Duct System Installations
Case 1 5 10 20 30 40
1 43,773 218,865 437,730 875,460 1,313,190 1,750,920
2 48,160 240,800 481,600 963,200 1,444,800 1,926,400
3 84,797 422,983 847,965 1,695,930 2,543,895 3,391,860
3 CONCLUSIONS
This paper has demonstrated how the use of proper engineering design for optimal duct
system installations would dramatically result in reduced energy consumption and in reduced
operating costs. When properly designed, installed, and maintained, an auxiliary ventilation
system can operate efficiently with substantial power and operating cost savings.
In a case study presented, it has been illustrated that savings in fan energy consumption
exceeding 94% can be achieved by correctly commissioning and maintaining a properly
designed auxiliary ventilation system.
REFERENCES
AirFinders, 2022. AirFinders Force Auxiliary Ventilation System Design. Engineering Design software.
De Souza, E. 2004. Auxiliary ventilation operation practices. Proceedings of 10th U.S./ North American
Mine Ventilation Symposium. Anchorage:Balkema. 341–348.
De Souza, E. 2013. Improving the energy efficiency of mine fan assemblages. Proceedings of the 23rd
World Mining Congress, Montreal, QC. pp 9.
De Souza, E. 2018. Cost saving strategies in mine ventilation. CIM Journal. Volume 9. Issue 2.
De Souza, E. & Dirige, P. 2022. Auxiliary mine ventilation manual. Version 2.0. Workplace Safety
North. Pp 261.
21
Case studies of mine ventilation
Underground Ventilation – Tukkaraja (Ed)
© 2023 The Author(s), ISBN 978-1-032-55146-3
A.A. Habibi
Technical Expert, PT Freeport Indonesia
I. Setiawan
Chief Ventilation Engineer, PT Freeport Indonesia
R. Prasojo
Mine Engineer, PT Freeport Indonesia
C. Stewart
Principal Engineer, Minware Consulting
ABSTRACT: A ventilation study was conducted on Kucing Liar (KL) mine. KL is the add
ition to PT Freeport Indonesia (PTFI) panel cave operations and is anticipated to operate in
parallel to Grasberg Block Cave (GBC). The study consisted of model construction, budget
preparation and investigating multiple scenarios to meet the minimum budget requirements.
Utilization of new engine technologies controlled partial air reuse, push-pull and utilization of
Battery Electric Vehicles (BEVs) were considered during this feasibility study. A main intake
and exhaust drift size optimization study was also conducted to determine the number of add
itional main fans and drift sizes required to support the KL mine. The results show the
requirement for two additional 5MW main fans, two intake drifts and two exhaust drifts
(7 m x7 m). The results also show the requirement for eight 6m ventilation raises to support
primary air delivery to KL mine. Proof of concept trials are deemed necessary to determine
the feasibility of applying some of the proposed concepts in underground operations (such as
BEVs). The trial results will be used to complete a detailed ventilation network design.
1 INTRODUCTION
GBC mine development started in 2004 with initial drifting and the first drawbell blast in 2018.
GBC mine is expected to achieve full production rates of 130 kt/d to 160 kt/d of ore by 2025.
Currently, the three active underground mining operations in the Grasberg Mining District are
the GBC block cave mine (target 130-160 kt/d ore), the Deep Mill Level Zone (DMLZ) panel
cave mine (target 80 kt/d), and the Big Gossan open stoping operation (7 kt/d). The Deep Ore
Zone (DOZ) panel cave mine (80 kt/d) has been closed and is no longer in operation.
The KL orebody is a new large caving operation where development started in 2021 and pro
duction is due to begin in 2027. The Grasberg Open Pit commenced production in 1990 with
active pit production ending in late 2019. Figure 1 is a schematic view of the Grasberg District
orebodies. The concentrating plant has a peak capacity of about 240 kt/d. Peak production targets
from the underground district will remain at 240 kt/d and will be entirely from underground. The
GBC will be the primary source of mill feed targeted at 130-160 kt/d (Brannon et al. 2020).
DOI: 10.1201/9781003429241-3
25
KL mine. Five Howden mixed flow rated at 5 MW each are currently installed in a parallel in an
exhaust configuration to support the GBC mine. Fresh air from the mill valley is downcast to the
mine through four parallel primary intakes (GVD 1-4) mined at 6.8 mW × 9.0 mH, at 2.6 km
from the portals to the footprint. Air is distributed to the working areas of the mine using ventila
tion drifts and raises mined at various dimensions. The return air reports back to the under
ground main exhaust fans and out into the valley. Figure 2 displays the main components of the
ventilation system. The system capacity is 3500 m3/s when all five fans are running.
Based on the recent LOM baseline estimate, the current GBC mine (which will be operating
in parallel with KL block cave) consumes approximately 25 m3/s/ktpd. Other block cave
mines typically have ratios from 17 to 40 m3/s/ktpd (Brannon et al. 2020). while the ratio cur
rently sits at the lower end of the scale, a Ventilation On Demand (VOD) system has been put
in place to improve the efficiency of air distribution.
Air velocity and diesel exhaust dilution requirements form the main design criteria. The air
flow velocity requirements air primarily for dust control in the ore flow system, and diesel
dilution for development and production activities.
2 DESIGN SCENARIOS
The GBC mine production is scheduled to increase to 136 ktpd by 2024. KL mine develop
ment has commenced, with steady-state full production planned for 90 ktpd by 2033. The
mine will supplement GBC mine production which reduces to 103 ktpd by 2033, giving
a combined total tonnage from both mines from 2033 of 193 ktpd. Five scenarios were con
sidered as case studies for this design.
27
2.2 Scenario 2 - KL mine air resuse
An air reuse option redistributes 600 m3/s of cleaned infrastructure exhaust to the extraction
level, effectively reducing the airflow drawn to and from the surface by 600 m3/s. This permits
a reduction in primary main fan infrastructure requirements, and a resultant reduction in cap
ital and operating costs.
Infrastructure level exhaust is proposed for reuse as it is lower (per unit volume) in diesel
activity (DPM is more difficult to scrub and reduce). Reintroduction of the scrubbed air to
the extraction horizon is a form of ‘series’ ventilation meaning gases will not continue to build
as may be the case in a recirculated design.
This proposal is speculative, in that no effective validated air-reuse scrubber arrangement
has been proven for this mine. To do this, the characterization of dust and contaminants
would need to be performed, and available technologies evaluated for cost and efficiency.
A proposed arrangement is to parallel 80 m3/s capacity scrubbing units together in at least
two locations on the infrastructure air return level, linked by raises into the extraction level.
Several proven wet and dry technologies exist for removing fine silica and nuisance dust
from the air. Removal of DPM from the air requires dry filter scrubbing which should be
avoided from a likely cost and maintenance perspective. The most likely robust fine dust
removal technology is ultra-fine wet spray chambers, using water atomized with the assistance
of air compressors. For design purposes, power totaling 400 kW is assumed to overcome 2
kPa of filter media or sprays with collectors, and 1.5 kPa air reinjection into the mine extrac
tion level.
28
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