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Reduce fan noise with acoustic ventilation systems

Publish date: 23 April 2024

In the mining industry, employees work with a wide range of machines and equipment with a loud noise output. One of the main sources of environmental noise on mines is the ventilation fans used to circulate air through the mine. These fans are critical to mining operations, supplying miners with refreshing air, diluting and removing contaminants, and preventing machines from overheating.

You can reduce noise exposure by eliminating or treating noise from the source, using protective equipment (PPE), and applying engineering modifications. Some of these options are simply not feasible as mine sites are legally required to have ventilation systems in place, and you cannot simply remove ventilation systems. The best solution is proactive sound attenuation for your underground ventilation system or replacing your current fans with Minetek’s HO Axial Fans.

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Reduce Your Ventilation Fan Noise

While mining is an essential industry that supplies the raw materials for many products used in our everyday lives, it can also be a major source of noise pollution, impacting local communities. Ventilation systems and fans used in underground mining operations can be incredibly noisy. These fans tend to be high-capacity axial or centrifugal fans, with direct exposure to the outdoors via the air intake or exhaust duct openings, causing significant noise for miners and nearby communities.

Mining companies are legally required to meet certain sound requirements set by state and federal agencies to protect the health and safety of workers and nearby residents. Failure to comply may result in large fines and lasting reputational damage. What truly concerns mining companies is that if their mining site receives too many complaints, it may impact plans for expansions or exploration of newly found ore deposits.

While we cannot completely eliminate the negative effects of mining on local communities, there are steps that mining companies can take to reduce the impact of noise pollution while keeping their fans fully functional and workers safe. For instance, mining companies can invest in sound suppression solutions and create buffer zones between mines and residential areas. This can be quite costly; however, sound attenuation is a more affordable yet equally effective solution.

Attenuate Underground Ventilation Fans

Noise attenuation reduces the sound intensity emitted by machinery and other industrial equipment. Sound attenuation is achieved through various means, one of which is the absorption of the energy from the sound waves and converting it into heat, which reduces the noise level. Various factors play a role in the effectiveness of this technique, including the type of material used for absorption and the angle at which the sound hits the surface.

The most effective materials for sound absorption are those with a high heat capacity, which means they can store more heat energy before breaking down. The angle at which sound waves hit a surface also affects how effectively they are absorbed. A surface that is perpendicular to the direction of the sound wave will absorb more energy than one that is at an oblique angle.

As with most pieces of rotating equipment, fans produce elevated sound levels. Noise radiating from the outlet and the inlet of the centrifugal or axial fan often requires attenuation. As such, inlet and outlet silencers are frequent additions to fan installations.

  • Inlet silencers. Inlet silencers reduce the noise of air being drawn into the mining equipment. This type of attenuation is typically accomplished using a specialised muffler or silencer. By reducing the noise of air drawn into the equipment, workers will be protected from exposure to hazardous noise levels.
  • Outlet silencers. Outlet silencers reduce the noise of exhaust escaping from the equipment. This type of attenuation is also typically accomplished using a specialised muffler or silencer. By reducing the noise of exhaust escaping from the equipment, workers will be protected from exposure to hazardous noise levels.

Each silencer is designed and built for a specific pressure loss and airflow velocity to meet your exact noise attenuation requirement.

Minetek HO Fans & Ventilation Systems

At Minetek, we understand the specific ventilation challenges that mining companies face ranging from exposure to contaminants to sound attenuation. Our fans are designed with the mining industry in mind with fan technology engineered from many years of research and development. Minetek fans are among the quietest available, proven to operate 11dBA quieter than comparable twin fans in the same operating conditions and air flow. In underground mining, the effects of unwanted noise can be amplified by the enclosed conditions. Minetek fans are engineered to reduce overall operating noise and potential long-term hearing imapcts.

Our fans are engineered to be durable and long-lasting, even in the most hostile environments. By using steel impellers, we’ve ensured that our fans can withstand blade wear without any issues. As a result, our fans have a much longer lifespan than other fans on the market while also minimising noise and providing the powerful ventilation needed in mines. Minetek’s high-pressure fabricated steel impeller is at the forefront of ventilation technology, operating at pressures previously thought impossible for an axial fan. With on-demand energy efficiency features halving the required power consumption and saving 50% on operating costs. If you’re looking for high-quality, low-noise underground mining fans, look no further than Minetek Air.

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At Minetek, we understand that many mining companies have existing ventilation systems, which is why we offer attenuation solutions for your current solution. With over 25 years of experience, Minetek is a globally recognised leader in noise management and underground ventilation solutions. With over 1,500+ installations, our solutions keep your equipment within regulatory and community expectations without compromising machine integrity, airflow, or operating ability.

Minetek’s innovative solutions are specifically designed to meet the needs of the mining industry, and we are committed to providing our customers with equipment that will help them create a safe and productive work environment. Contact us today if you are interested in learning more about our fans or ventilation attenuation solutions.

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Minetek Air underground ventilation systems

Publish date: 23 April 2024

Aside from supporting thousands of jobs worldwide, the mining industry provides raw materials, minerals, and metals critical to the global economy. For countries such as Australia, resources corresponds to a large proportion of their export share, with resources equating to 68% of global exports in 2023. Natural resources provide the foundations for modern living, innovation, the transition to renewable energy and global engineering achievements.

Despite the rewards, it is important to recognise that underground mines are high-risk work environments, posing many physical, chemical, and biological hazards for the workers. As with any risks, however, there are ways to mitigate the risks associated with underground ventilation. Air ventilation is critical to any mining operation, diluting and removing toxic and potentially explosive gases. They’re also necessary for regulating the temperature inside the mine, which can get searing hot due to the heavy machinery used.

Underground mining ventilation can control the air quality by providing fresh air to dilute and remove contaminants such as dust, diesel fumes, heat, and stagnant air. Different types of ventilation fans are available depending on the application, but they all share the same goal – supplying air to keep miners safe while working underground.

Primary Ventilation Fans

Adequate ventilation is essential for any mine to ensure the safety of workers and the persevation of machines and equipment. The primary ventilation system provides the necessary paths for air to flow in and out of the mine. This system composes of Primary Fans (also known as Main Fans), which pump fresh air into the mine and remove contaminated air from the mine.

Large fans typically mounted on the surface or below ground, suck the air through the mine at 150 cubic metres per second with the aim of replacing the air underground every 20-40 minutes. In larger or deeper mines, this may require more than one return airway or an additonal Booster Fan. Large underground mines in Australia can move anywhere between 450 – 900 cubic metres of air per second through their main decline.

Minetek has a proven track record of supplying the largest available Primary Fans for underground mining ventilation. Our innovative Primary Fan solutions can deliver economic savings, durability and flexibility not thought achievable with traditional fans.

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Secondary Ventilation Fans

Secondary ventilation systems involve the provision of ventilation to development ends, stopes and services facilities that constitute secondary circuits tapped off the primary circuit or main through the flow of air. These may be “dead end” in configuration or be “parallel or “series in parallel” circuits.

Secondary Fans also known as Auxiliary Fans, are used to supplement the primary ventilation system where airflow is stagnant. Whereas primary ventilation systems are typically located above the surface, Secondary (Auxiliary) Fans are smaller, portable fans capable of going deep into the mines. Secondary Auxiliary Fans are critical components of ventilation systems, helping to regulate airflow throughout all working areas of a mine. The deeper and more extensive the mine, the greater in importance secondary fans become.

Minetek’s Secondary Axial fans are like no other. They’re compact in size, 40% shorter, and 10% lighter than standard fans, while the high-pressure capability of Minetek’s High Output (HO) Axial Fan is double that of standard fans comparable in size. This results in fewer fans needed overall, saving costs in the long run, while the low-profile ducting makes installation much easier than other fans on the market.

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Booster Fans

Mines can be ventilated solely using primary fans or in combination with booster fans. A Booster Fan is a large underground fan installed in series with the main surface fan and is used to boost the air pressure of the ventilation passing through the air ducts.

Adequate design and utilisation of a Booster Fan provides benefits to reduce the main fan pressure, leakage, and consequently ventilation cost; especially with a high resistance network due to the deep and extensive working area in a mine. The installation of a Booster Fan may create uncontrolled recirculation if it is not sized and located correctly with respect to the Primary Fan.

Primary Fans are often installed as Booster Fans – the same fan, with a different application – for both return and intake airways. With Minetek’s ventilation solutions, you can strategically optimise underground airflow by connecting them with the main ventilation system, making it an optimum choice for booster ventilation.

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Bulkhead Fan

Primary Fans are often installed onto bulkheads, which are retaining walls commonly used in mines to contain flooding. Bulkhead Fans are inflexible and highly durable wall structures and are, as such, one of the more costly elements of mine development due to the number of units required, the loss of efficiency, and installation costs.

Minetek can half the number of fans required on Bulkhead Fans, while their smaller size, lighter design and durable impeller allow for easier installation. Our innovative Performance on Demand (POD) and Mine Air Control (MAC) system will enable you to synchronise the Bulkhead Fans so they work in unison to create the ideal airflow for your underground mining operations.

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Long Duct Runs

In underground mines, it is common for duct-fan auxiliary ventilation to extend over hundreds, in some cases thousands of metres. Typically, they are push systems made of either a single or twin vent line with one or two head fans in series, while some systems also use Booster Fans to supply the additional pressure to maintain the airflow. Such long vent lines require more careful design to ensure that the needed air volume is carried across the entire system with minimal losses.

The concentrated power of Minetek’s High Output (HO) Axial Fans makes them the ideal solution for Long Duct Runs. Installing a single Auxiliary Fan that can ramp up to the increasing duty point needed as the project expands can save time and money on installing additional fans. The fans also can surge past the required duty point to clear gases and dust for fast re-entry making Minetek the ideal choice for underground mines.

Minetek’s Air Solutions

Minetek is a global leader in providing innovative and cost-effective air solutions for the mining industry. With over 150 years of combined experience, Minetek specialises in engineering, designing, manufacturing, and implementing advanced solutions. Having successfully delivered over 3,000+ projects worldwide, Minetek has the experience and expertise to help your mining company achieve sustainable ventilation management outcomes.

Our comprehensive range of Auxiliary Fans has been proven to deliver increased productivity and reduce operating costs, all while granting flexibility to control the delivery of air when and where it is needed. Our innovative POD technology allows operators to precisely manage pressure and power to optimise airflow circuits without needing VSD control. The ability to integrate with all mining Ventilation On Demand (VOD) and mine communication systems creates a seamless, responsive solution. This optimises performance, reduces power consumption costs, and increases overall operational efficiency.

At Minetek, we are dedicated to helping our clients achieve sustainable ventilation management outcomes. We offer a comprehensive range of solutions designed to meet your mining operation’s unique needs.

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Western Australian mining legislation and regulations

Publish date: 23 April 2024

Mining in Western Australia has long been one of the state’s most crucial industries, but it has grown to historic proportions in recent years, contributing over $100 billion to the economy and supporting more local jobs than ever [1]. According to a DMIRS report, since 1997-98, the number of miners working in the mining sector has tripled from 43,466 to 132,144 from 2019-2020 [2].

While this impressive growth continues to power Western Australia’s (WA) economy forward, it brings a greater risk of Lost-Time Injuries (LTIs). In response to the growing sector, the Australian government has recently passed new legislation requiring mine sites to assess risks and develop controls to mitigate them. This is essential to ensuring WA’s miners stay safe and compliant with all mine safety and inspection regulations.

Western Australia’s Work, Health, and Safety Regulations 2022 (WHS Regulations) came into full effect on 31 March 2022, granting the Mining Industry of Western Australia a great deal of needed protection. The introduction of this new system would bring the Work, Health, and Safety Act 2020 into full force, accompanied by several subsidiary regulations specific to industries such as Petroleum and Geothermal Energy Operations and Mines [3]. These regulations provide an improved framework to ensure employers fulfil their obligations and create safer workplaces for both employees and visitors.

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Work Health And Safety Mine Regulations 2022 Update

The WHS Act introduced a new primary WHS duty for a ‘person conducting a business or undertaking’ (PCBU) to ensure, so far as possible, the health and safety of workers and other personnel arising from the conduct of their business or undertaking [3]. The duty requires a PCBU to eliminate risks to health and safety so far as is reasonably practicable and, where it is not, minimise identified risks as much as possible. What is considered ‘reasonably practicable’ will depend on several considerations, including the likelihood of a hazard or risk occurring, the degree of harm that might result from the hazard or danger, and the availability and suitability of ways to eliminate or minimise identified risks.

Another critical change is that penalties for breaching health and safety regulations have significantly increased. Not only is there now an offence of industrial manslaughter, which carries heavy penalties if a breach causes serious harm or, worse, death, but the WHS Act also voids the option of purchasing insurance to cover these penalties.

In relation to mines, a key component of the new regulation is the extensive set of guidelines that dictate a hierarchy of control measures involving specific steps implemented in a specified order. Broadly speaking, employers are required to guarantee the safety of their working environment for miners and other personnel by providing safe facilities, systems, information, training, and instruction needed to protect workers from health and safety risks.

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What Impact Will These Regulations Have On The Mining Industry In Western Australia?

Mine operators are under significant regulations to avoid dangerous, high-risk mining activity. Notably, they must provide written notification to the regulator 15 days before single entry development beyond 200m from through ventilation is commenced [4]. However, there is an exception to this regulation: applicants are exempted if their details of the high-risk mining activities are already included in either a mining commencement notice or additional operations notice. Mine operators should be aware of these requirements when conducting the required operations and ensure compliance with the regulations enforceable by the respective regulator.

The new regulations apply to all mines beyond 200 metres underground, requiring them to assess risks and develop mitigation controls [5].m [5]. The new rules have also been designed to ensure that mine operators are taking proactive measures when it comes to health and safety instead of simply relying on workers to avoid hazardous areas. It is now mandatory for mines in Western Australia to have controls that can prevent accidents or minimise harm if they occur.

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In lieu of the monthly status report forms previously submitted to the department, the new regulations require mining operators to give the regulator a work health and safety report at least once a quarter. The mine operator is responsible for upholding these regulations, allowing for improved safety standards at their mine site.

Before this new legislation came into effect, managers of mining sites faced little accountability. They only had to offer warnings of dangers, such as opening holes, without any form of control in place to protect miners. Western Australian mines must now conduct risk assessments and be equipped with management and control plans that mitigate dangers according to the region’s local government. For the above example, this might include closing the hole, adding ladders, or blocking tunnels. Mining sites must also now have an escape plan with designated ventilation points and additional chambers with clear pathways in the event of an emergency. These measures are all designed to reduce risk and keep miners safe, meaning fewer accidents and more successful practices.

The most notable change brought about by this new legislation is regarding ventilation. Mines must now have a ventilation plan cover the assumption that all their underground fleets could be underground at any time [3]. This means that if a mine usually has five trucks operating, but has twenty available, and the ventilation plan must cater for those extra fifteen, adding considerable cost to the operation. Many mining operations across Western Australia have turned to Mine Air Control (MAC) Systems equipped with RFID trackers to reduce the costs associated with additional vehicles. This technology can automatically detect new vehicles entering a mine and adjust ventilation accordingly. Not only is this system able to provide improved safety measures, but it also offers significant cost savings compared to traditional methods.

Underground Ventilation Control Systems

Minetek’s High Output Axial Fan system has been designed completely with the underground mining industry in mind. The Mine Air Control (MAC) system is designed to provide the most efficient ventilation for miners working underground. Minetek’s patented Performance on Demand (POD) technology is an innovative approach to optimising performance and reducing power consumption costs for operators. POD enables operators to tailor pressure and power consumption without having to use VSD (Variable Speed Drive) control, providing a more responsive solution. This simplifies the process of controlling output while also increasing overall operational efficiency.

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Our sophisticated computerised control system helps keep operations running smoothly and efficiently by regulating underground airflow. This includes optimisation of low flow during less high-activity times and increasing up to double the duty point of a traditional vane axial fan. Such capacity helps ensure that dangerous gases or dust can be quickly removed from entry sites, thus reducing risks associated with entering such conditions while also eliminating much of the power traditionally wasted in such applications and meeting broad regulatory compliance parameters.

The Minetek High Output Axial Fan system is modular and comes up with additional benefits:

  • Vastly reduced energy costs
  • Adequate air at the face
  • High levels of control
  • Large operating range
  • Sensor tracking to automatically adjust to real-time demand
  • High volume compliance
  • Blast dust removal rapidly
  • Reduced noise output

With an increased focus on risk assessments and control management across Western Australia, the mining industry must take proactive steps to ensure maximum safety for workers and compliance with stringent regulations. Minetek’s innovative MAC system offers an improved ventilation capacity that surpasses competing systems – helping ensure air quality standards are met while reducing potential costs. The MAC system is ideal for creating safer work sites with improved ventilation capacity while ensuring cost efficiency and meeting regulatory guidelines.

References

  1. Department of Mines, Industry Regulation and Safety Western Australia – https://www.dmp.wa.gov.au/About-Us-Careers/Latest-Statistics-Release-4081.aspx
  2. ABC (Australian Broadcasting Corporation) News – https://www.abc.net.au/news/2021-01-29/wa-mine-workers-seriously-injured-at-rate-of-more-than-one-a-day/13104168
  3. Western Australia Work Health and Safety Regulations 2022 – https://www.legislation.wa.gov.au/legislation/prod/filestore.nsf/FileURL/mrdoc_44753.pdf/$FILE/Work%20Health%20and%20Safety%20(Mines)%20Regulations%202022%20-%20%5B00-a0-01%5D.pdf
  4. Government of Western Australia – https://www.wa.gov.au/government/publications/notification-of-high-risk-mining-activity-single-entry-development-beyond-200-metres-through-ventilation