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Italian One Minetek fan ventilated a 1,500m decline.
Minetek completed a project for an underground mine, located near the town of Nyngan in central New South Wales, which was a significant operation with a combined ore production of 1.8 million tonnes per annum between two mines for our client. The client extended drilling to depths of up to 4,921 feet (1,500 meters), where they faced the challenge of finding an effective ventilation solution for the development of the decline. Minetek stepped in to provide a unique and innovative solution.
Industry – Mining
Mine type – Underground
Mineral – Copper
Location – Nyngan, New South Wales, Australia
Product/Scope – 1 x 375kW Auxiliary High Output Axial Fan and 1 x 250kW fan starter for development fan including soft starter and automation – Turn-key project manufacture, supply and commissioning.
Brief
Minetek completed a project for an underground mine located near the town of Nyngan in central New South Wales. The combined ore production from both two mines based at the same site is 1.8 million tonnes per annum. The client has continued drilling extensions to the deposit, at a depth of up to 4,921 feet (1,500 meters). This extension required a ventilation solution for the development of the decline. The decline length and fresh air raise scheduling posed a unique challenge. Standard fans would not meet the requirements due to high pressure and drive size limitations. Minetek has been able to support the Mine by providing a unique patented ventilation solution using only a single fan, delivered within a tight time frame. This allowed operations to meet and exceed development targets, minimise shutdowns and reduce operational and energy costs.
"We didn't think one fan could ventilate 1,000m (3,280 ft) underground. We were preparing for multiple shutdowns and fan installs."
- Client
Solution
After conducting research and analysis of the site, Minetek provided one 375kW auxiliary High Output Axial Fan, with integrated Performance-on-Demand (POD) system, Soft Starter, Programmable Logic Controller (PLC), and programming. The High Output Axial fan is designed with the mining industry in mind, and the steel fabricated impeller allows for operation at pressures previously thought impossible for an Axial Fan. This style of fan has been designed to withstand extreme amounts of dust and will have a prolonged life in even the harshest conditions. Minetek’s POD patented system allowed the Nyngan mine to have performance, power, and pressure on demand. The ability to adapt the fan to match the exact activity underground, coupled with the quality of the fan, were both vital components when choosing Minetek.
"Controlling the fan from the surface saves us time planning, operational costs and wasted power. We can regulate the fan, see the operation status all from the shift boss' desk." - Client
Results
The standard 55" (1400mm) diameter size of Minetek’s fan allowed for a single installation. Minetek’s fan is inherently quiet compared to traditional fans, plus the overall length is minimised from 22 ft (7m) to 13 ft (4m). The shorter size improved install as it is safer to lift, economic to install, with no need to excavate extra for head height. Minetek continued supporting the client with best practise for installation which helped to expedite the project. It was also important that the programming could bridge between the existing systems on site. Minetek developed a tailor-made solution to assist with the integration.
Speed - The site needed the solution engineered and installed urgently.
Agility - Minetek were agile, adapting to last minute specification changes and delivering on time.
Efficiency - The Minetek solution negated the need for larger or multiple fans that would complicate installation and require maintenance shutdowns.
Key features of the fans
- POD: “Performance on Demand” vane inlet controls to adjust vent flow and power usage.
- Impulse bladed impeller equipment with an anti-stall chamber to ensure optimum fan performance.
- 1475 HP (1,100 kW) / 1,000 V individual fan motors (all run off the renewable power station).
- Flow rate of 593,286 CFM (280 m³/sec) @ 14.9 in.wg (3700 Pa) for current production needs with a maximum airflow capability of 741,608 CFM (350 m³/sec) @ 16.9 in.wg (4,200 kPa).
Choosing Minetek Air
The challenging conditions drove several essential requirements for the ventilation system. The solution needed to meet the required duty points for air flow and pressure. The diameter and number of fans required also had to be considered, as larger fans would be challenging to install and come with higher costs during install and ongoing power usage. Installing many fans would interrupt operations and include multiple shutdowns as boosters would need to be installed as the decline extended. The additional features that Minetek could offer became paramount to the client’s decision. Variable power, pressure and performance without the need for VSD, controllable from the surface of the mine, and the integration into the existing software system were all elements considered in the decision-making process. The mine had initial concerns that a single Minetek fan would not be able to meet their requirements, as larger or multiple fans would traditionally be used for projects of this length and depth. Minetek provided technical data that guaranteed the solution would be able to meet the projects needs.
“A single fan installation allowed us to progress quicker and have the available power when we needed it.” – Client
Business drivers delivered
- Long development decline ventilation.
- Save through smart power usage.
- Reduction in re-entry times after drill blast.
- Sustainable use of power.
- Surface control saves on operational costs.