Scalable Secondary Ventilation Solution to Support Mine Expansions

Publish date: 29 July 2025

In the dynamic landscape of underground mining, where operational efficiency and safety are paramount, the need for robust and adaptable ventilation systems is crucial. As mines expand deeper and wider to meet growing production demands, secondary ventilation remains a critical element in maintaining safe and efficient operations. Minetek’s Raptor™ Secondary Series Fan builds on the proven approach of traditional secondary fans, offering a superior solution that is more powerful and compact. While utilizing the same fundamental methodology as existing systems, the Raptor delivers enhanced airflow, improved energy efficiency, and a smaller footprint, helping mining operations scale seamlessly while boosting both productivity and worker safety.

Understanding the Role of Secondary Ventilation in Mine Expansions

Secondary auxiliary fans and ventilation systems play a critical role in underground mining environments, particularly during expansions. These systems are typically deployed in development headings, stopes, and auxiliary areas where primary ventilation may not suffice. They ensure the delivery of fresh air to dilute harmful gases, remove dust, and maintain breathable conditions for workers. As mines expand, the demand for flexible, high-performance ventilation increases exponentially. Longer duct runs, tighter spaces in declines, and the need for compliant airflow become essential to sustain production targets without compromising safety.

Minetek’s Raptor™ Secondary Series Fan is engineered precisely for these applications. Unlike conventional secondary fans, it provides high-pressure and high-flow capabilities, enabling extended duct runs while maintaining optimal ventilation compliance with minimal fans required. This makes it ideal for mines undergoing phased expansions, where new headings require rapid deployment of ventilation without halting operations.

Secondary Fan Key Features and Benefits

At the heart of the Raptor™ Secondary Series Fan is its single-stage motor design, which sets it apart from industry standards. This configuration absorbs significantly less power, requiring 50 kW less than the typical twin 110 kW fan, while delivering equivalent performance in airflow. The result is a more energy-efficient secondary ventilation system that reduces operational costs without sacrificing output.

One of the standout features is its compact and lightweight build. Measuring 2500 mm shorter and 1300 kg lighter than comparable twin-motor fans, the Raptor™ enhances installation efficiency. It can be lifted and installed as a single unit, eliminating the need for piecewise assembly that is common with heavier alternatives. This not only accelerates setup times but also minimizes risks associated with handling heavy equipment in confined underground spaces. For mines with limited access or steep declines, the smaller footprint allows installation in tighter areas, ensuring ventilation reaches even the most challenging zones.

These attributes further amplify safety and ease of relocation. The lighter design reduces strain on personnel and equipment during transport and repositioning, which is particularly beneficial in dynamic mining environments where ventilation needs shift frequently. Additionally, the fan’s aluminum impeller contributes to reliable, long-term performance under harsh conditions.

From a compliance perspective, the Raptor’s high-pressure and high-flow output supports longer duct extensions, ensuring that airflow meets or exceeds government standards. This directly translates to improved mine site efficiency, allowing operations to achieve production targets with fewer disruptions.

Addressing Common Challenges in Secondary Ventilation

Many mining operations adhere to familiar twin 110 kW fans as the default choice, often unaware of alternatives that could alleviate subtle inefficiencies. These include higher energy consumption, cumbersome installations, and the logistical burdens of multi-piece setups. Minetek’s Raptor™ Secondary Series Fan introduces a superior pathway by leveraging a single-stage architecture, which inherently makes the unit lighter and shorter, without the need for additional silencers or dual motors. Importantly, it achieves the same airflow as competitors, providing a direct upgrade for those seeking optimization.

Elevating Mine Safety and Efficiency with Minetek

Minetek is committed to raising the bar in mine ventilation through straightforward, reliable solutions, such as the Raptor™ Secondary Series Fan. By prioritizing energy efficiency, ease of use, and uncompromised performance, this secondary ventilation system not only supports current operations but also future-proofs expansions. Mining professionals can expect safer working conditions, reduced downtime, and cost savings that contribute to overall sustainability.

For mining operations seeking a more efficient secondary ventilation option, the Raptor™ represents a pivotal advancement. Contact Minetek today to learn how this scalable secondary ventilation solution can transform your site.

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Air | Driving down costs & impact with efficient underground ventilation

Publish date: 17 April 2025

Driving down costs & impact with efficient underground ventilation

The mining industry is evolving rapidly, and forward-thinking operators are already capitalising on energy-efficient innovation.

Underground ventilation alone can account for 42 – 49% of a mine’s total energy spend. With rising energy prices, growing ESG (Environmental, Social, and Governance) pressures, and the global demand for more sustainable operations, mining leaders are being pushed to challenge the status quo.

Minetek Air is meeting this challenge head-on. Our underground ventilation solutions, incorporating technologies like Ventilation on Demand (VoD), high-output axial fans, and Performance on Demand (POD) are engineered to reduce energy consumption, cut operational costs, and align with evolving ESG expectations.

This article explores how our systems are transforming ventilation from a cost centre into a competitive advantage for modern mining operations.

The evolution of underground ventilation

Underground mining has always been a battle against the elements. From confined working conditions to toxic gases and extreme heat. Effective ventilation is critical to safety and productivity, clearing hazards such as methane, diesel particulates, and dust.

In the early days, systems were rudimentary, relying on natural airflow or simple fans. As mines grew deeper and regulations tightened, ventilation systems became more sophisticated. By the mid-20th century, electric fans were standard, but many were inefficient, oversized, and operated continuously, significantly inflating energy usage.

The turning point: Sustainability and efficiency take the lead

As energy costs surged in the 21st century, the mining industry faced a critical turning point. At the same time, ESG pressures mounted—PwC’s 2023 Mine Report revealed 35% of mining CEOs now rank climate risks among their top concerns. This convergence of environmental and economic demands ignited a wave of innovation. Minetek Air responded with underground ventilation solutions that go beyond simply moving air—they optimise it. Today, technologies like VoD and high-output axial fans are reshaping industry standards, proving that performance and sustainability can thrive together underground.

This convergence of environmental and economic pressure sparked a new wave of innovation. Minetek Air responded by engineering smart ventilation solutions designed not just to move air, but to optimise it.

Technologies like VoD and high-output axial fans are now transforming how ventilation is managed, proving that performance and sustainability can thrive together underground.

Minetek Air’s four pillars of impact

1. Energy-efficient mining solutions: Cutting costs at the core

Mining energy consumption is a beast, but Minetek tames it with precision. Traditional ventilation systems run at full tilt 24/7, wasting power in areas where no one’s working. Minetek energy-efficient mining solutions flip that script. Our high output axial fans, paired with the Mine Air Control (MAC) system, deliver airflow only when and where it’s needed, slashing power usage by up to 50%. A 2024 Straits Research report projects the mine ventilation market to hit $1.86 billion by 2032, driven by demand for such technologies. For a typical underground mine, where ventilation eats up nearly half the energy budget, this translates to millions in savings annually – money that can be reinvested into operations or ESG initiatives. It’s not just cost-cutting; it’s strategic resource management.

2. Ventilation on Demand (VoD): Smart airflow, smarter savings

Ventilation on Demand (VoD) is the brain behind Minetek Air’s brawn. Integrated with mine communication systems, VoD uses RFID trackers to monitor worker and vehicle locations, adjusting airflow in real time. No more blasting air into idle tunnels – Minetek’s systems sync with schedules and activity, reducing energy waste. The Canadian Mining Journal reported in 2023 that VoD can cut energy intensity by 20-50%, with payback periods as short as two years. At a Gold Mine in Western Australia, Minetek’s VoD-enabled primary fans (1,100kW, 280-350 m³/sec) met production needs while slashing power costs. This isn’t just about efficiency; it’s about giving mine managers control to optimise underground mine ventilation without compromising safety or output.

3. High Output Axial Fans and POD technology: Power meets precision

Minetek’s high output axial fans are engineering marvels – compact, yet packing double the pressure of standard fans, with a steel impeller built for harsh conditions. Coupled with Performance on Demand (POD) technology, these underground ventilation fans adapt airflow without pricey variable speed drives (VSDs). Need to clear blast gases fast? Surge past the duty point. Idle time? Dial it down. A 2024 Minetek case study showed these fans cut re-entry times at development ends, boosting productivity while trimming energy use. Unlike traditional setups requiring multiple units, Minetek’s design – 40% shorter, 10% lighter – reduces capital costs and installation headaches. It’s a one-two punch: high performance, low footprint.

4. Mining ESG solutions: Sustainability without sacrifice

ESG isn’t a buzzword – it’s a mandate. Minetek’s mining ESG solutions align with this shift, reducing environmental impacts while keeping operations profitable. Ventilation accounts for a hefty chunk of a mine’s carbon footprint, but Minetek’s systems shrink it. By halving fan numbers and power draw, they lower emissions – critical as 70% of U.S. metal mines adopted advanced ventilation controls in 2024, per the Mine Safety and Health Administration. Public opinion on LinkedIn echoes this: a 2023 poll by Mining Technology showed 82% of industry pros prioritise sustainability in vendor choices. Minetek delivers, helping mines like Agnew Gold hit net-zero targets without gutting budgets. It’s proof that reducing mining energy costs and environmental harm can go hand in hand.

A smarter, leaner future for mining

Minetek’s underground ventilation technologies represent more than innovation, they’re a new standard for efficient, ESG-aligned mining. With VoD, POD, and high-output axial fans, operations can slash energy costs by up to 50%, enhance safety, and meet the demands of a sustainable future.

Now is the time to rethink ventilation, not just as a necessity, but as a strategic advantage.

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Air | Engineering the future of mine ventilation

Publish date: 27 March 2025

In the early days of mining, operations were relatively simple, and ventilation systems were primarily designed to deliver large volumes of air to underground workers. Ventilation shafts and fans were standard, operating in a straightforward manner to provide fresh air while removing hazardous gases. However, these early systems lacked flexibility—they couldn’t easily adapt to changes in mine layouts or activities, leading to inefficiencies.

As mining technology progressed, so did the complexity of operations. Mines became deeper and more intricate, with multiple levels and extensive tunnel networks. This increased depth introduced new challenges, including rising temperatures, higher concentrations of hazardous gases, and the need for more advanced ventilation to reach remote and complex areas of the mine. What was once a simple task of pushing air underground evolved into a highly demanding operation, requiring strategic planning and real-time airflow adjustments to ensure both safety and efficiency.

With these growing demands, ventilation systems had to evolve. Mines required not only greater air supply but also systems capable of actively controlling where and when air was delivered. Modern ventilation solutions needed to respond dynamically to shifts in mining activity, adapt to temperature fluctuations, and effectively manage emissions from machinery and blasting operations.

The shift toward real-time ventilation control

This transition toward more sophisticated ventilation systems wasn’t just a technological advancement—it became a necessity for ensuring the safety of underground workers. The ability to rapidly respond to changing conditions, such as sudden spikes in harmful gases or drops in oxygen levels, provides a level of security that earlier systems simply could not offer. This reflects the industry’s unwavering commitment to worker safety.

However, progress has come with its own set of challenges. Today’s mines must carefully balance providing adequate airflow to maintain worker safety while managing energy consumption. Modern mining environments are vast, featuring both active and inactive zones, each requiring different levels of ventilation at different times. Beyond supplying fresh air, ventilation systems must also manage exhaust gases from diesel-powered machinery, control heat generated by both equipment and surrounding rock, and minimise dust distribution.

This balancing act is further complicated by ventilation being one of the most energy-intensive aspects of mining operations. In deep mining, ventilation can account for an astonishing 42% to 49% of total energy consumption. With rising energy costs, mining companies face mounting pressure to reduce their energy footprint without compromising safety.

Stricter regulations and the push for sustainability

Mining companies are also subject to increasingly stringent regulations, with governments and industry bodies enforcing stricter occupational exposure limits for gases, dust, and noise. Allowable concentrations of hazardous gases have been significantly reduced, while noise levels must remain below designated thresholds to protect workers’ hearing. While worker health and safety have always been a top priority, today’s regulations demand even greater precision in monitoring and controlling underground conditions. As a result, ventilation systems must be not only powerful but also highly adaptable and precise.

Simultaneously, the mining industry faces growing public and investor scrutiny, driving the adoption of more sustainable and environmentally friendly practices. Rather than resisting this shift, the industry has embraced innovation. Mining operations are expected to cut carbon emissions, lower energy consumption, and operate with a reduced environmental footprint. This demand has fueled significant advancements in ventilation technology, leading to the development of more energy-efficient and intelligent solutions. The industry’s proactive approach to sustainability is a positive indicator of the future of mining.

One of the most promising innovations in this space is Ventilation on Demand (VOD). This advanced system is revolutionising airflow management in underground mines. Unlike traditional ventilation setups that deliver a constant airflow across the entire mine, VOD leverages sensors to detect where and when fresh air is needed, adjusting airflow accordingly. This optimised approach not only enhances energy efficiency but also provides a safer and more comfortable working environment for miners.

How Minetek Air is redefining industry standards

A prime example of VOD in action is Minetek’s Mine Air Control (MAC) technology. MAC utilises advanced sensors and RFID tracking to monitor the movement of personnel and machinery throughout a mine. Based on this real-time data, the system automatically adjusts ventilation to ensure fresh air is directed exactly where it’s needed, eliminating the need for manual intervention. This intelligent airflow management not only ensures optimal ventilation in critical areas but also enhances productivity by allowing miners to focus on essential tasks.

By continuously responding to underground conditions, MAC and similar systems enable a more adaptive and efficient approach to mine ventilation. For instance, if a particular zone is unoccupied or inactive, the system can reduce airflow to that area, conserving energy and extending the lifespan of ventilation equipment. This on-demand approach significantly reduces operational costs while improving overall worker safety.

One of Minetek’s most groundbreaking innovations is its Performance on Demand (POD) technology. Traditionally, mine ventilation systems relied on Variable Speed Drives (VSDs) to adjust fan speeds, offering some level of flexibility but also presenting limitations. Minetek’s POD technology eliminates the need for VSD controls altogether, enabling direct airflow adjustments without relying on intermediary speed controls.

This next-generation approach ensures that airflow is precisely regulated—delivering exactly what is required, no more and no less—resulting in an ultra-efficient system. The precision of POD technology allows mines to maintain safe and effective ventilation while significantly reducing energy consumption. In fact, this method can achieve energy savings of up to 50%, offering substantial cost reductions while supporting environmental sustainability goals. By aligning with the broader movement toward greener mining practices, POD technology underscores the economic viability of sustainability in the industry.

With advancements like MAC and POD, Minetek Air is setting a new benchmark for efficiency, safety, and sustainability in underground ventilation. These technologies not only address the industry’s most pressing challenges but also pave the way for a more innovative, cost-effective, and environmentally responsible future in mining.

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Breathing in danger: How poor underground air quality is suffocating your site operations

Publish date: 17 February 2025

Underground mining is essential for resource extraction, but it comes with unique challenges—air quality being one of the most critical. The confined nature of underground spaces, combined with restricted natural airflow, makes them prone to the buildup of toxic gases such as methane and carbon monoxide. Diesel exhaust from machinery only worsens these risks. Without effective ventilation, these hazards can accumulate quickly, transforming a mine into a dangerous, even life-threatening, environment.

The Hidden Dangers of Poor Air Quality

One of the most severe threats in underground mining is the accumulation of flammable gases like methane. At high concentrations, methane can ignite, causing catastrophic explosions. Equally hazardous is carbon monoxide—an invisible, odourless gas that silently endangers lives. Even small doses can hinder oxygen delivery in the bloodstream, leading to poisoning and potentially fatal consequences.

Inhalation of fine dust particles, particularly in coal mining, can also lead to pneumoconiosis (black lung disease), causing long-term respiratory damage and irreversible lung conditions. This underscores the critical need for advanced ventilation systems to protect workers’ health.

The Crucial Role of Ventilation in Temperature Control

Air quality management extends beyond gas and dust—it’s also about temperature regulation. Depending on a mine’s depth and location, underground conditions can swing from dangerously hot to freezing cold. In deep mines, geothermal heat can cause extreme temperatures, raising the risk of heat exhaustion or heatstroke. Conversely, in colder regions, poor ventilation can result in hypothermia. Effective ventilation systems help regulate temperatures, creating safer, more productive work environments.

Meeting Legal and Regulatory Standards

Proper ventilation isn’t just best practice—it’s a legal requirement in many mining jurisdictions. For example, regulations in Western Australia mandate detailed ventilation plans tailored to each mine’s unique conditions. These plans factor in mine depth, mineral type, and equipment used, all to disperse harmful gases, control temperatures, and maintain airflow that protects worker health and safety.

Minetek: Pioneering the Future of Mining Ventilation

For nearly four decades, Minetek has been a global leader in developing innovative, efficient, and cost-effective ventilation systems for underground mining. Our commitment to advancing technology and delivering customised solutions has helped mining companies worldwide optimise ventilation strategies, meet regulatory standards, and prioritise worker safety.

Revolutionising Airflow with Performance On Demand (POD) Technology

One of Minetek’s most revolutionary innovations is our Performance On Demand (POD) technology. Unlike traditional systems that rely on Variable Speed Drive (VSD) controls requiring constant monitoring and manual adjustments, our POD system uses single-speed fans that automatically regulate airflow based on real-time conditions. These intelligent fans adjust dynamically to provide the exact amount of air needed, enhancing safety through consistent circulation and effective dispersion of toxic gases and heat.

Maximising Energy Efficiency and Reducing Costs

Minetek’s ventilation solutions are designed with energy efficiency at their core. By eliminating the need for continuous high-speed fan operation, our systems can cut energy consumption by up to 50%. This not only reduces operational costs but also supports sustainability goals, delivering a strong return on investment while advancing environmental, social, and governance (ESG) objectives.

Engineered for the Toughest Conditions

Our ventilation fans are built to endure the harshest underground environments. With steel-fabricated impellers, they achieve pressure levels once thought impossible for underground operations. This rugged construction ensures exceptional durability, reduces maintenance needs, and minimises operational downtime—crucial for maintaining productivity in demanding mining conditions.

Minetek: Redefining Underground Ventilation Standards

At Minetek, we’re redefining what’s possible in underground ventilation. Our solutions not only enhance safety and regulatory compliance but also improve operational efficiency, allowing mining companies to boost productivity while reducing their environmental impact.

Whether it’s managing toxic gases, regulating temperatures, or improving energy efficiency, Minetek’s innovative approach ensures underground mining operations remain safe, sustainable, and profitable.

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Introducing Minetek’s Next Generation of Underground Ventilation Fans: the Raptor Series

Publish date: 28 January 2025

As underground mining operations become more complex and energy-intensive, the demand for effective ventilation has never been higher. Minetek, a global leader in industrial and mining solutions, has addressed this need with the launch of the Raptor Series, a groundbreaking line of underground ventilation fans specifically designed for hard rock mining environments. With this innovation, Minetek is setting a new standard in ventilation technology, tackling the industry’s most critical challenges while optimising energy consumption and performance.

The Raptor Series is built to withstand the harsh and demanding conditions of underground metalliferous mines. These fans are not only engineered for peak performance in extreme environments but are also highly adaptable, making them suitable for a wide variety of mining applications. What distinguishes the Raptor Series is its emphasis on energy efficiency. By significantly reducing energy consumption, mine operators can cut operational costs without compromising on airflow. This is crucial, as ventilation typically represents a major portion of energy usage in mining operations.

The Raptor Series reflects Minetek’s over 40 years of expertise in fan engineering, underscoring our long-standing commitment to quality and innovation.

A New Standard in Ventilation Performance

The Raptor Series fans mark a major advancement in both performance and energy efficiency, reinforcing Minetek’s reputation for delivering cutting-edge solutions in the industrial and mining sectors. Built on Minetek’s renowned high-efficiency technology, the Raptor Series surpasses industry standards, offering superior airflow with reduced power consumption to meet the evolving demands of modern mining.

Notably, the Raptor Series is 10% more efficient than the previous HO Series, a key achievement in energy conservation for an industry where power costs are directly tied to operations. This boost in efficiency helps mining companies lower energy expenses, a crucial factor since ventilation accounts for up to 40% of a mine’s energy consumption.

In addition to energy savings, the Raptor Series fans run more quietly, significantly reducing noise pollution. This quieter operation minimises stress on both workers and equipment, contributing to a safer and more comfortable work environment.

The true strength of the Raptor Series lies in its versatility. The base model can be purchased as a standalone high-performance fan, delivering exceptional airflow, quieter operation, and a more compact, lightweight design compared to traditional twin-stage fans. This space-saving design is especially beneficial in mining environments where tunnel space is limited, allowing for greater operational efficiency without sacrificing ventilation quality.

The compact design also streamlines installation, maintenance, and system integration, reducing downtime and ensuring that mining activities continue without interruption.

Unlocking Unmatched Efficiency with VoD & POD

For operations with more complex ventilation requirements, such as mines with extended duct systems or those aiming to implement a Ventilation-on-Demand (VoD) solution, the Raptor Series offers full customisation.

A key feature of the Raptor Series is the integration of Minetek’s Performance on Demand (POD) system, delivering advanced control over ventilation. Unlike traditional fans that run at full capacity even when it’s unnecessary, leading to excessive energy use, the Raptor Series with the POD system changes the game. The POD system allows operators to fine-tune airflow, pressure, and power consumption in real-time to meet specific mine needs without the need for expensive Variable Speed Drives (VSDs).

This flexibility is crucial for modern mining operations, where ventilation demands often fluctuate due to shifts in production, temperature, or safety requirements. By dynamically adjusting fan performance, the POD system can cut energy costs by up to 50%, a significant reduction that directly benefits a mine’s bottom line. It also helps mines achieve their Environmental, Social, and Governance (ESG) goals by lowering carbon emissions and optimising energy consumption—key considerations in today’s environmentally-conscious market.

As Benjamin Fletcher, Minetek’s Regional Sales Manager, explains, “Mining operations don’t always need full fan performance, but most fans in the industry lack the flexibility to adjust airflow. With the POD system, mine sites have full control over airflow, pressure, and energy usage, making it an ideal match with the high-efficiency Raptor fan.”

Another standout innovation in the Raptor Series is the Anti-Stall Chamber, which enhances fan performance and reliability. In many traditional ventilation systems, airflow can become turbulent, leading to inefficiencies and potential fan stalls. The Anti-Stall Chamber counteracts this by capturing turbulent flows and stabilising the airflow before it reaches the fan, preventing disruptive pre-swirls and ensuring smooth operation.

Minetek’s Global Reach & Unparalleled Support

The Raptor Series is available globally and is manufactured and tested at Minetek’s state-of-the-art facility in Australia. This allows Minetek to deliver its industry-leading ventilation solutions faster than competitors while ensuring each product meets the highest quality standards.

Download Minetek’s comprehensive Raptor Series eBook for more information on how the Raptor Series can benefit your operation. Learn more about our cutting-edge ventilation solutions and how they can transform your mining operations.

Click here to download the brochure and get started with the next generation of underground ventilation.

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Minetek’s Innovative Solutions Improve Efficiency and Sustainability at WA Gold Mine.

Publish date: 22 November 2024

For over three decades, Minetek has led the way in innovation, delivering tailored solutions for air ventilation, water management, sound attenuation, and power supply and distribution. Our dedication to providing cutting-edge technology, combined with a strong commitment to sustainable practices, has enabled us to build global partnerships with mining companies, helping them achieve both commercial success and environmental sustainability.

One of our key partnerships is with an underground gold mine in Laverton, Western Australia. Recognised as one of the nation’s largest and most productive gold mines, it was originally discovered in 1979 and boasts a rich mining history. The site continues to show significant promise, with ongoing brownfield and extensional exploration activities suggesting a Life of Mine (LOM) extension beyond current expectations, pointing to a bright future ahead.

When this client needed to upgrade their ventilation system to meet evolving demands and ensure long-term performance, Minetek stepped in with our expertise and bespoke solutions. The site posed a unique challenge due to its highly saline air conditions. Recognising the importance of maintaining optimal air quality and circulation, we engineered a comprehensive ventilation solution specifically designed to overcome these challenges.

Minetek’s Expertise in Advanced Mine Ventilation Solutions

With decades of experience and specialised expertise in airflow management and power distribution, Minetek engineers were instrumental in the success of this project. They designed a ventilation system that not only met the mine’s immediate operational requirements but also anticipated and addressed the needs for sustained long-term performance. Their dedication and technical proficiency ensured a solution that was both reliable and efficient, significantly contributing to the project’s overall success.

A key element of this solution was the strategic selection of three High Output Series 2650mm 1100kW Fans, chosen for their exceptional durability, adaptability, and efficiency. Engineered to withstand the corrosive effects of saline air, these fans were seamlessly integrated into the mine’s ventilation infrastructure, ensuring reliable and consistent airflow to safeguard the safety and wellbeing of personnel working underground.

Their robust construction and advanced design not only provided consistent ventilation but also reduced the need for frequent maintenance, enhancing operational efficiency and delivering significant long-term cost savings for the client.

Minetek’s Methodical Approach to Ventilation System Installations

Minetek implemented a meticulously planned and executed installation process. Recognising the critical importance of maintaining uninterrupted mine production, the team of engineers and technicians approached the task with precision and care. The primary goal was to transition to the new ventilation system with minimal disruption to ongoing mining activities. This required detailed planning and coordination to avoid any delays or interruptions that could impact the mine’s productivity and safety.

To ensure a seamless transition, Minetek utilised a phased installation approach for the new fans. This carefully managed sequence allowed the new fans to be installed and brought online without ever compromising ventilation. By keeping the old fans operational during the process, the mine avoided any interruptions to airflow that could impact the environment or safety. This meticulous approach was vital to maintaining air quality and ensuring the wellbeing of personnel throughout the transition.

Once the new fans were fully functional, Minetek swiftly removed the previous fans, streamlining the ventilation infrastructure to enhance reliability and efficiency.

The Benefits of Minetek’s Ventilation System

Minetek’s fans, integrated with the Performance on Demand (POD) system, delivered a cutting-edge solution that optimised performance, reduced energy consumption, and improved overall operational efficiency—all without the need for Variable Speed Drive (VSD) controls.

The WA gold mine client has realised numerous benefits from Minetek’s advanced ventilation system, including:

Precise Airflow Control: The POD system allows operators to fine-tune airflow levels, ensuring optimal ventilation across varying operational demands.
Energy Efficiency: By eliminating the need for VSD controls, the system significantly reduces power consumption, cutting costs and lowering environmental impact.
Operational Flexibility: The dynamic ability to adjust power usage and pressure levels enables the mine to adapt to changing needs, maximising productivity.
Reduced Maintenance Costs: The robust fan design and streamlined POD system reduce the need for frequent maintenance, offering long-term savings.
Real-Time Monitoring: Integrated monitoring capabilities provide continuous tracking of performance, airflow, and energy consumption, enabling data-driven decisions and proactive maintenance.

Minetek’s innovative solutions have not only improved the mine’s overall performance but have also set a new standard for efficient and sustainable mining operations.

The integration of Minetek’s POD system with their advanced fans has proven to be a significant game-changer for our client. Our innovative solution’s precise airflow control, energy efficiency, operational flexibility, and reduced maintenance costs have not only significantly improved the mine’s overall performance but also set a new standard for modern mining operations. The real-time monitoring capabilities mean that the mine can maintain optimal ventilation conditions, adapt to changing demands, and make informed, proactive decisions, inspiring the potential of advanced technology in the mining industry.

This comprehensive approach drives productivity and efficiency, delivers substantial cost savings, and provides environmental benefits, positioning our client at the forefront of modern mining operations.

Minetek Empowers Mining Companies with Cutting-Edge Technology

Minetek has equipped this WA Gold mine with an advanced underground ventilation system that fulfils the current and future airflow and power requirements of the site. This results in reduced downtime, increased production, and significant capital savings.

This integration of cutting-edge technology highlights Minetek’s dedication to providing sustainable and cost-effective solutions customised to meet the specific demands of mining operations.

Click below to download our eBook on Minetek Air’s underground ventilation solutions eBook to find out more about what our solutions can do to help your site.

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The Transformative Power of VOD in Underground Ventilation

Publish date: 12 November 2024

It should go without saying the integral role ventilation systems play in supporting the safety of underground mining operations. Primarily, these systems fulfil three primary functions:

Supplying fresh air to miners,
Diluting hazardous and particulate substances, and
Controlling temperature and humidity levels within the mine.

Yet, as mines expand and age, ventilation becomes more challenging. With deeper tunnels and complex layouts, airflow must be precisely managed and adapted to changes in mining activity and fluctuating gas levels.

To meet these demands, mines rely on large, surface-based fans that continuously push fresh air into various sections. This nonstop operation consumes a significant amount of energy, making ventilation one of the most energy-intensive aspects of mining.

Ventilation on Demand (VOD) has emerged to address these challenges, enabling smarter, more energy-efficient airflow management.

In today’s article, we dive into how VOD works, its benefits for mining operations, and how Minetek Air can support a seamless transition to this innovative system.

What is Ventilation on Demand (VOD)?

Ventilation on Demand (VOD) is a transformative solution for mining ventilation, delivering fresh air to specific areas of a mine only when and where it’s needed. This shift from a static to a dynamic, intelligent air supply makes ventilation more efficient, significantly reducing the total airflow required across the mine.

Traditionally, mine ventilation operated on fixed schedules, often leading to over-ventilation during low-activity periods, wasting energy and reducing air quality. VOD changes this by using real-time data and advanced algorithms to continuously monitor variables like airflow velocity and temperature. This technology enables precise ventilation adjustments, allowing operators to meet each area’s requirements as conditions change.

Benefits of VOD for Mining Operations

Resource Efficiency
VOD’s intelligent air system activates ventilation only where and when it’s needed, avoiding the unnecessary operation of the entire system. This selective approach conserves energy and reduces equipment wear, extending the life of ventilation infrastructure and lowering maintenance costs.

Energy Savings
By reducing the volume of air pumped through the mine, VOD lowers electricity use, one of the largest costs in mining. Optimising airflow cuts energy expenses, leading to substantial financial savings and helping mines meet sustainability goals by reducing their carbon footprint.

Improved Air Quality
Through real-time monitoring and advanced algorithms, VOD delivers precise ventilation, preventing both under-ventilation, which can lead to unsafe conditions, and over-ventilation, which can disrupt the underground atmosphere. This precise control enhances air quality, supporting better health and safety for miners.

Safety and Comfort
VOD enhances the mining work environment by maintaining essential oxygen levels and reducing harmful contaminants. This positively impacts miners’ well-being, helping reduce health-related absences and boosting productivity. Comfortable conditions are vital in high-stress environments like mines, where physical and mental strain can be significant.

Cost Effectiveness
VOD increases ventilation system efficiency, minimising operational costs tied to energy consumption and maintenance. Reduced airflow needs often allow for smaller, more affordable ventilation equipment, cutting both initial setup costs and ongoing expenses.

Ultimately, VOD represents the future of mining ventilation, where technology and necessity come together to create safer, more efficient mining practices.

Minetek’s VOD-Ready High Output Axial Fans

With nearly four decades of experience, Minetek leads in innovative, modular air management solutions for global industry leaders. Minetek is committed to advancing mining solutions through top-tier engineering, cutting-edge technology, and thorough research and development—all our fans are designed to support VOD.

Our High Output Axial Fan, built specifically for the mining sector, delivers robust and reliable underground ventilation with a broad operational range. Its steel-fabricated impeller, engineered to withstand pressures once thought impossible for an axial fan, enables operation in even the harshest mining environments.

Minetek’s powerful single-speed fans are proven to cut power consumption costs by up to 50% while improving underground mining ventilation systems. These compact units surpass the performance of traditional larger fans and can be swiftly and effortlessly relocated to new areas as mining operations expand.

Engineered to the highest standards, each fan operates over a broad range and is regulated by an integrated Performance On Demand (POD) system. Significantly, they do not require complex or expensive VOD controls, allowing for smooth integration into existing systems.

This positions Minetek’s High Output Axial Fan as not only a cost-effective choice but also a user-friendly solution that boosts operational flexibility. With Minetek’s technology, mining operations can realise substantial energy savings and adopt a more versatile ventilation approach without the need for major modifications or intricate installations. This makes Minetek’s High Output Axial Fan not only a cost-effective solution but also a user-friendly option that improves operational flexibility.

As mining operations continue to evolve, embracing these advanced systems will be key to achieving higher productivity and environmental responsibility. Minetek’s longstanding commitment to quality and innovation positions it as a leader in the push towards more sustainable and effective mining practices, ensuring that its solutions lead the way in meeting the challenges of modern mining environments.

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Minetek’s Legacy of Innovation & Excellence in Air Management Solutions

Publish date: 22 October 2024

Since 1984, Minetek Air has been delivering cutting-edge, modular air management solutions tailored specifically for underground mining operations. Our dedication to innovation has continually pushed the envelope in mine ventilation technology, setting new standards for safety and operational efficiency in the industry. Minetek’s advanced ventilation systems are meticulously designed to ensure optimal airflow, mitigate hazardous gas build-up, and substantially improve air quality, thereby safeguarding worker health and boosting overall mine productivity.

Our achievements stem from decades of experience and a commitment to excellence in project delivery. We emphasise meticulous documentation, clear communication, and rigorous supply chain management supported by expert local teams for seamless implementation. Our global network of strategically positioned resources means we can tackle complex mining and industrial projects, offering comprehensive, turn-key solutions prioritising quality, service, and timely execution.

Australian Copper Mine

A prime example of this innovative mindset is our collaboration with one Australian Copper Mine. The client embarked on drilling extensions to the deposit at unprecedented depths of up to 1,500 meters, they encountered a significant challenge: the need for a specialised ventilation solution capable of supporting the extended decline development. The standard ventilation fans proved inadequate for the high-pressure conditions and size constraints at this depth. In response, Minetek Air provided a bespoke, patented ventilation solution that employed a single, high-efficiency fan specifically engineered to address these challenges.

This innovative solution delivered within a tight schedule enabled the mine to meet and exceed its development targets. The integration of our 375kW Auxiliary High-Output (H.O.) Axial Fan, equipped with a Performance-on-Demand (P.O.D.) system, Soft Starter, and Programmable Logic Controller (P.L.C.), optimised operational efficiency. As a result, the mine minimised shutdowns, reduced operational and energy costs, and experienced a remarkable 30% increase in production.

This achievement is just one of many examples showcasing Minetek’s unwavering commitment to advancing air management technologies in the mining sector—there are many more.

Australian Gold Mine

A Gold Mine in Orange, NSW, approached Minetek with a challenging problem: the need for a more durable ventilation solution to handle the severe dust conditions caused by their underground dumping and crushing processes. The mine’s existing 110kW single-stage axial fans struggled with high abrasion rates from airborne dust, resulting in rapid degradation and reduced operational lifespan, typically ranging from 6 to 12 weeks. The impellers in these fans wore down quickly, leading to frequent replacements and downtime.

Minetek stepped in to provide a tailored solution. We proposed our 90kW H.O. axial flow fan as a more robust alternative. This fan was designed to meet the demanding duty requirements while offering enhanced longevity and performance. The Minetek fan outperforms the standard axial fans in several key areas. It operates more quietly, is more compact, and features a unique design that allows dust to pass through with minimal impact on the equipment.

Our custom-designed fan incorporates a heavy-duty steel impeller capable of withstanding the toughest conditions without compromising on performance. The result was a ventilation solution that is estimated to last nearly seven times longer than the previous fans, significantly reducing the need for frequent replacements and associated downtime.

The success of this solution led the Mine to place an order for five Minetek fans, demonstrating the effectiveness and reliability of our technology. This project highlights Minetek’s ability to address complex ventilation challenges with innovative solutions, improving operational efficiency and longevity in even the harshest mining environments.

Western Australian Gold Mine

Another compelling example of Minetek’s innovative approach is our project with a Gold Mine in Western Australia, which sought to boost production and expand exploration capabilities. It was essential to address a bottleneck in the existing primary ventilation circuit to achieve these objectives.

Minetek was entrusted with the critical task of designing and implementing a primary booster fan system of unprecedented size and technology for the Australian mining industry. This project involved developing a new fan system, removing outdated equipment, and installing the newly designed fans.

Our team of experts worked tirelessly around the clock to meet the project deadlines, accomplishing the removal of the old equipment, the installation of the new fans, and their commissioning in just four days. Given the substantial size of the new fans, seeking approval from the Power Supply Authorities for testing before shipping was necessary.

The key features of the installed fans at the Mine include:

● P.O.D.: This system incorporates vane inlet controls that dynamically adjust ventilation flow and power consumption, optimising performance according to real-time needs.

● Impulse Bladed Impeller Equipment: Designed with an anti-stall chamber, this advanced impeller ensures consistent and efficient fan operation, maximising airflow while minimising performance issues.

● High-Power Motors: Each fan is equipped with a robust 1100kW/1000V motor, which uses power from the renewable power station, reflecting our commitment to sustainable energy solutions.

● Exceptional Airflow Capabilities: The fans deliver 280m³/sec at 3700Pa to meet current production requirements, with the capacity to achieve a maximum airflow of 350m³/sec at 4200kPa.

The successful completion of this project at the Mine not only met their immediate ventilation needs but also set a new benchmark for fan technology in the mining sector, demonstrating Minetek’s influence and leadership in the industry.

Conclusion

Our commitment to advancing air management technology continues to drive us to develop and implement solutions that meet the evolving needs of the mining industry, ensuring that we consistently deliver high-quality, effective, and durable solutions.

If you’re looking to optimise your air management strategies and ensure a safer, more efficient mining operation, connect with our AIR team today to discover how our innovative solutions can meet your needs.

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News & insights

The Role of Automation in Modern Mining Ventilation

Publish date: 4 October 2024

Automation leads the way in innovation, enhancing efficiency, safety, and productivity across multiple industries. It covers a broad spectrum of technologies, such as robotics, artificial intelligence, and advanced control systems, which are transforming traditional workflows and operational models. By reducing human involvement in repetitive, dangerous, and precise tasks, automation boosts productivity while greatly lowering the chances of accidents and mistakes.

The mining industry, in particular, can greatly benefit from automation to address these risks. Automated systems, especially in air ventilation, are crucial for enhancing safety in mining, a field that, while essential, remains highly dangerous.

Importance of Air Ventilation in Underground Mines

Clean, reliable air ventilation is crucial for maintaining the health and safety of miners in underground mines. Mining operations often release hazardous gases like methane and carbon monoxide, which, if not effectively managed, can pose serious risks. Methane is highly flammable and can cause explosions, while carbon monoxide, a colourless and odourless gas, can lead to poisoning or death with prolonged exposure. Effective ventilation systems are essential for diluting and removing these dangerous gases, preventing their buildup, and ensuring a safe working environment.

Dust generated during mining can also pose significant health risks to workers if inhaled over time. For instance, silica dust can cause silicosis, a serious lung disease. Proper ventilation controls dust levels, reducing the risk of respiratory issues among miners.

Temperature regulation is another critical factor in mine safety. Deeper mines tend to have higher temperatures, which can lead to heat stress or heat stroke. Ventilation systems help manage these temperatures by bringing in cooler air from the surface and expelling hot air from inside the mine.

Automating ventilation systems can greatly enhance the management of air quality and temperature in mines, leading to a safer environment for miners. Automated systems can adjust ventilation in real time based on changing conditions within the mine, ensuring optimal working conditions and reducing energy consumption by operating only when necessary.

Minetek air team installing HO Axial fan in underground mine

Minetek Air’s Cutting-Edge Ventilation Solutions

Technology has been pivotal in enhancing mining operations and ensuring clean air for years. However, traditional ventilation systems often lack the adaptability and efficiency that modern mines demand. Minetek Air addresses these challenges with its advanced ventilation fans, engineered to enhance air quality and boost ventilation efficiency.

Since 1984, Minetek Air has provided innovative, modular air management solutions tailored for underground mining. Our world-class ventilation range is proven to increase productivity and lower operating costs, all while offering the flexibility to deliver air exactly when and where it’s needed.

Performance On Demand (POD) Technology

With rising energy costs and a growing emphasis on energy conservation, mining companies are increasingly examining their operations for potential savings. Ventilation systems, particularly in deep mines, account for a substantial share of energy consumption—typically between 42% and 49% of total mining energy costs. Minetek’s advanced mine ventilation system is revolutionising how mining companies operate by reducing power wastage through its ability to automatically adjust the air volume required for any specific heading.

The POD feature is designed to maximise return on investment. Unlike traditional systems that run at full capacity constantly, Minetek’s POD technology dynamically adjusts power, pressure, and performance to meet the mine’s exact needs without relying on Variable Speed Drive (VSD) controls. This precise management of airflow significantly cuts energy costs while maintaining high efficiency.

Mine Air Control (MAC) System

Integrated with the Performance On Demand (POD) technology in Minetek’s fan range, the Mine Air Control (MAC) system automatically adjusts airflow based on real-time needs. Many mines are required to monitor and manage air pollutant levels as part of their development approvals and environmental protection licenses issued by the EPA. Minetek’s MAC system helps ensure compliance by providing precise control and reporting of air quality.

The MAC system’s computerised controller dynamically manages airflow—from minimal flow during low-activity periods to more than double the capacity of traditional vane axial fans during peak demand. This ability to control high-pressure ventilation from the surface enables the rapid removal of gases or dust, ensuring quicker and safer re-entry into the mine.

Conclusion

Minetek’s advanced technology ensures the optimal amount of air is delivered in real time, maintaining a safe and stable environment for miners at all times. This level of automation not only enhances safety but also boosts operational efficiency by reducing downtime and enabling faster re-entry after blasting activities.

From a financial perspective, Minetek’s adaptive ventilation systems offer significant cost advantages. Traditional systems often run at constant capacity, resulting in unnecessary energy use and higher costs. In contrast, Minetek’s system adjusts power and performance according to the mine’s real-time demands, reducing energy consumption and costs. This intelligent management leads to lower energy bills, crucial since ventilation is a major component of a mine’s energy expenses. Additionally, reduced strain on ventilation equipment can decrease maintenance costs and extend equipment life.

If you’re looking to enhance operational efficiency in your underground mine with advanced ventilation systems, connect with our Air team today to learn how our innovative solutions can meet your needs.

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News & insights

A sustainable underground ventilation solution for Agnew Gold Mine

Publish date: 5 July 2024

Located just 30km from Leinster, Western Australia is the Northern Norseman-Wiluna Greenstone Belt. This mining region is home to the Agnew Gold Mine, owned by the international mining corporation Gold Fields. Agnew mine houses the Waroonga and New Holland underground deposits, the last two remaining gold mines in the Goldfields-Esperance region. Both Agnew mines have been operational since the 1880s, with a resurgence in production over the past decade. Between 2021 and 2022 Agnew Mine produced between 232,000oz -240,000oz of gold [1].

Net-zero Underground Ventilation.

The Agnew Gold Mine required a complete ventilation upgrade to meet Life Of Mine (LOM) requirements. This solution involved future-proofing for continuing production, mine extensions and brownfield exploration throughout under-explored sections of the tenements. This Gold Mine was experiencing challenges with the existing primary ventilation circuit. The air volume flow rate was not achieving the required free air volume or pressure. Therefore, debottlenecking was required to achieve their goal of increased production and expanded exploration.

Agnew Gold Mine commissioned Minetek to help achieve their long-term vision and demands by developing a customised underground ventilation solution. Minetek’s solution was a Primary Booster Fan which included the removal of redundant equipment and installing the new fans. This unique solution was an Australian first for a fan of this combined size and technology, powered by Agnew’s renewable grid network. Discover the full case study by requesting a free PDF copy.

Sustainable Ventilation Solution.

Agnew Gold Mine favoured a low energy, high volume ventilation solution with low energy consumption. Minetek’s Primary Fans required energy output of 1,100kW / 1,000 V and a flow rate of 280 m³/sec – 350 m³/sec at a pressure of 3,700 Pa – 4,200 Pa meeting both current and future production and development needs.

Minetek’s Performance On Demand (POD) technology enabled a seamless operation with the ability to adapt pressure and power consumption without using Variable Speed Drive (VSD) controls. Our impulse bladed impeller controls the POD system with anti-stall technology installed to capture turbulent air flow and unstable pre-swirls, to ensure optimal fan performance.

Due to their sheer size, Minetek’s Primary Fans had to be tested prior to shipping. We gained approvals from the Power Supply Authorities, and all other facilities within the Minetek complex had to be shut down to provide enough power for testing. The performance of the Primary Booster fans was pilot tested in Minetek’s testing chamber which happens to be the largest fan test chamber in the southern hemisphere. This unique environment was built to conform with AMCA standards and can simulate the most challenging conditions in any underground mining scenario.

Minetek engineers and key personnel kept all project goals on track, achieving the installation within a short timeframe. The previous fans were removed and replaced with new fans in just four days of commissioning. Originally, we anticipated this project to be completed within 10 shifts however our seamless project management enabled a turn-key installation in only 7 shifts.

1100Kw Primary Booster Fan

Engineered with the mining industry at the forefront, Minetek’s High Output Axial Primary Booster Fans are a robust and reliable ventilation solution with a broad operating range. Our unique steel impeller allows for operation at high pressures with prolonged life, in even the harshest of underground mining environments.

Primary Booster Fan Specifications

Power range – 1100 kW (kilowatts) / 1,000 V (volts)
Volume flowrate – 350 m³/sec (cubic metres per second) / 742,000 CFM (Cubic Feet Per Minute) (cubic feet per minute)
Pressure – 4,200 Pa (pascals) / 16.9 in.wg (inch of water)

Minetek’s primary fans, have been proven to reduce power consumption costs by up to 50%, by regulating flow rates from the integrated POD system. Our fans have the capability to outperform larger alternatives and then be re-deployed quickly and easily to other locations as the mine workings evolve. Underground mines can reduce on ventilation capital costs with less fans required to meet underground flow rates and pressure requirements. Achieve safe, reliable operations while delivering guaranteed reductions in power consumption and increased profitability, assisting green mines achieve net-zero emission targets.

Minetek has expanded with a new operations hub located in Perth, servicing the Western Australian Mining regions. Our world-class service has expanded to meet the demand and responsiveness needed to support our clients’ requirements. Our technical team is now close by and readily available to help with your site. The team at Minetek are confident and ready to provide solutions that match your requirements. Contact us to find out more about our primary and secondary ventilation solutions.

Resources

https://www.goldfields.com/pdf/investors/presentation/2022/australia-site-visit-nov-2022-agnew.pdf

https://edlenergy.com/project/agnew/

https://www.nsenergybusiness.com/news/arena-agnew-gold-mine/

https://www.goldfields.com/pdf/investors/social-media/2022/newsflash-agnew-hybrid-project.pdf

https://edlenergy.com/wp-content/uploads/2021/10/EDL-Fact-Sheet-Agnew-Hybrid-Renewable-Microgrid.pdf

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Conclusion

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Mine Air Control (MAC) System

Conclusion

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1100Kw Primary Booster Fan