FIGURE 1

Schematic
showing
DO2 main
airways.
quired quantity would be equal to 11.8 m3/s (25 thousand
cfm). For a D-type of drift, 4.0 x 4.4 m (13.1 x 14.4 ft), this
value is equal to 13.7 m3/s (29,000 cfm).
Diesel exhaust fumes: This is based on the amount of
air needed to dilute the diesel products to their threshold
limit values. Based on previous ventilation studies (Area
I1 and intermediate ore zone or IOZ), the age and type
of loaders and trucks used and the relative elevation of
the mine, i.e., 3,000 m (9,800 ft) above sea level), a flow
rate of 7.9 m3/s per 100 kW (125 cfm per hp) was chosen.
This quantity is about 14 % higher than stated by the In-
donesian Mining Law (6.9 m3/s per 100 kW). If more
than one diesel unit is operated in a working, this re-
quirement was modified to reflect varying machine utili-
zation rates. For instance, if two adjacent headings were
developed using a 231-kW (310-hp) loader and a 163-kW
(219-hp) truck, the air quantity requirement per heading
would be equal to 15.6 m3/s [=(231+ 163)*0.079*0.5]. This
is the minimum quantity that must be supplied to each
heading. At PTFI, diesel units are used during mucking
and hauling. These activities often lasts for 4 h per shift.
Based on the proposed mining method (block cav-
ing) for the production stage, the following activities
were identified: undercut drilling (undercutting), ore
drawing (panels), rock breaking (breakers), primary
crushing (crushers), ore transportation (conveyors) and
equipment maintenance (shops). A fixed quantity of air
is required for each activity. For panel drifts, this quantity
was estimated based on the derated diesel power re-
quirement, minimum air velocity and number of work-
ers. On the average, this is equal t o 21.7 m3/s (46,000
cfm). For other activities, including those carried out at
crushers, shops and transfer points, the requirements
were estimated based on the contaminant concentra-
tions measured in the IOZ mine. When the concentra-
tions were too high, the estimates were corrected t o
lower the concentrations t o the threshold limit values
stated by the Indonesian Mining Law (CO = 50 ppm,
NO, = 3 ppm, H,S = 10 ppm, and 0, = 19.5%).
Table 1 summarizes the airflow requirements for the
FIGURE 2
Panel and conveyor
drift ventilation.
Intake
Fringe Drift
/ /-- Panel DIM
7
Breaker
=t zP *""
fi-7 Conveyor Drift
MINING ENGINEERING . AUGUST 1999 55
production stage. Based on this table, to produce 25 kt1 raise). It varies with a number of factors, including the
day (27.5 thousand stpd) of ore and to maintain safe and size and length of the opening, its surface roughness and
healthy working conditions, the airflow requirement will wetness factor. Here, this parameter was determined
be equal to 738.2 m3/s (1.56 million cfm). based on the Atkinson's resistance equation and the
Square Law (McPherson, 1993).
Estimation of airway resistances. In the ventilation Atkinson's equation: This equation was used to esti-
design, in addition to the flow requirements, another pa- mate the resistance of shafts and drifts with
rameter is needed, the airway resistance (R). This param- cross-sectional areas other than those found in the IOZ
eter is uniquely defined for each airway (drift, shaft or mine.
Square Law: This equation was
used for existing airways in which
TABLE 1
the frictional pressure drops and air-
flow quantities can be measured. In
Air quantity requirements - production stage.
this study, the equation was used for
the MLA and DOZ intake drifts,
Area description Q, , m3/s vent raises and conveyor drifts, in
which the airways resistances can be
Undercut drifts
determined from ventilation sur-
Four undercutting C-type drifts and two
veys.
development-headings (=4*11.8 + 2*15.6) 78.4
Table 2 shows a summary of re-
sistances and K-factors for the main
Production panels
intakes and returns. These values
Thirteen panels and three development drifts
were determined from pressure1
(= 13" 21.7+ 3* 15.6) 328.9
quantity surveys in the I OZ mine
(MVS, 1996).
LHD and maintenance shops
Three shops and two fixed facilities
(=33+2*18.9+ 11.8+7.5)
Rock breakers
Six rock breakers supported by
exhaust vent systems (= 6*16.5)
Underground crushers
Two primary crushers including
ore dumping points (= 2*23.6)
Conveyors
Two main conveyors with a minimum air
velocity of 1.0 mls (= 2*23.6)
Three gathering conveyors (3*15.7)
Total quantity = 738.2'
*This is strictly fresh air, and it does not include the leakage flow.
TABLE 2
Airway resistances for DOZ mine openings.
X-section,
Airway description m
DOZ intake, drift 1 5.6 x 4.5
DOZ intake, drift 2 5.6 x 4.5
Third intake drift 5.8 x 5.4
Intake cross-cuts 4.5 x 4.5
Horizontal drifts* 4.4 x 4.0
Ramps* 5.2 x 3.9
CMM vent raises* d = 3.1
Exhaust shafts d = 6.0
Conveyor drifts* 4.3 x 4.3
Fan drifts -
Panel drift* -
Length,
m
1950
1980
1810
20
30
30
20
810
100
-
* Determined from pressurelquantity surveys in IOZ mine.
Resistance
Ns2/m8
0.02043
0.02074
0.01095
0.00064
0.00070
0.00049
0.00502
0.00492
0.00353
0.00104
0.01856
Economic airway dimensions.
For a given mine layout and airflow
requirements, the size and number
of main airways (intakes and re-
turns) are often determined using
an optimization algorithm (Hart-
man, 1982). With this algorithm, the
economic diameter of an airway is
determined as a function of the air
quantity, length of the opening, sur-
face roughness, power cost, fan effi-
ciency, excavation cost, interest rate
and life of the opening. To facilitate
the calculations, the algorithm was
coded as an EXCEL program and
run separately.
Table 3 shows a summary of
economic sizes (equivalent diam-
eter) for two main airways. The ex-
cavation costs shown in this table
were determined based on PTFI's
cost estimates and those provided
by outside contractors.
Mine ventilation model
This is a numerical model for-
mulated on existing and projected
mine openings. It was developed to
determine the number of main air-
ways and to estimate the duties of
main fans. The core of this model is a
line diagram or ventilation network.
This was constructed based on the
main intakes, returns and secondary
airways used to distribute the air to
the workings. Hence, sealed off ar-
eas of insignificant leakage were not
represented in the network. In the
diagram, each airway is character-
56 AUGUST 1999 . MINING ENGINEERING
ized by two nodes and a parameter, the airway resis-
tance. Each branch representing a working, in addition
to the resistance, it requires another parameter, the mini-
mum airflow rate. Dummy branches were used to repre-
sent the connections to atmosphere and complete the
network.
Once the network was completed, possible fan loca-
tions were identified and added into the network. Then
this was solved for airflow rates and fan duties numeri-
cally. A commercially available computer software
(VNETPC) was used to this purpose.
Ventilation network. The input parameters and
simulated results are as follows:
Inputparameters: For the production stage, the sim-
plified ventilation model includes 370 branches and 236
nodes. Out of these, 49 branches were labeled as fixed
quantity branches and five were labeled as fan branches.
The fixed quantity branches represent active workings to
which fixed volumes of air must be supplied. To fulfill the
company's objectives, it was estimated that the system
will require at least forty active workings. These work-
ings will be distributed on three levels: six on the under-
cut level (CMM drifts), twenty five on the production
level (sixteen panel drifts, six breakers and three shops)
and nine on the conveyor level (two crushers, five con-
veyors and two shops). Based on the design principles
stated previously, the air quantity requirement for the
mine will be equal to 738.2 m3/s (1.56 million cfrn).
To complete the formulation, two other parameter
are needed, the airway resistance and the fan character-
istic curves. For this model, the airway resistances were
determined based on the parameters shown in Table 2.
When applicable, the estimates were modified to reflect
the actual size of the new openings. To simulate the exist-
ing fans (centrifugal) and those purchased for the IOZ
expansion, the fan characteristic curves shown in Table 4
were used.
This condition was imposed to minimize the capital
requirement. By 2003, it is expected that, while the DOZ
mine output ramps up to 25 kt/d (27,500 stpd), the IOZ
mine output will decline to less than 6 kt/d (6,600 stpd).
At this time, there is a strong possibility for reusing the
existing "Tuan" fans.
Simulation results: Following the network formula-
tion, the size and number of main airways were deter-
mined, the location of the main fans were chosen and the
network was solved numerically by VNETPC. The re-
sults were then checked for flow recirculation and com-
pared against the flow requirements. If the requirements
were not fulfilled, then the fan curves were adjusted and
the network solved again. After a few trials, a solution to
the problem was found. For the requirements stated pre-
viously, it is predicted that the vent system will require
three surface and two underground booster fans. Table 5
shows a summary of the fan operating points. Based on
these results, the total air quantity circulated through the
mine will be equal to 966.3 m3/s (2.047 million cfrn), i.e.,
the sum of surface fan flow rates. Out of this quantity,
738.2 m3/s (1.56 million cfrn), will be directed to the ac-
tive workings and the remainder, 228.1 m3/s (0.48 million
cfm), will be lost through leakage paths (volumetric effi-
ciency: 76%). To overcome high airway resistances, espe-
cially those of the exhaust drifts, two booster fans will be
required. These will be installed on the 3,100 exhaust
TABLE 3
Economic airway diameter - main intakes
and returns.
Description Intake drift
Length (L), m 1,810
Friction factor, kg/m3 0.0074
Airflow rate (Q), m3/s 354
Power cost (C), $/kW-h 0.07
Fan efficiency (n), % 70
Excavation cost (E), $/m3 114
Interest rate (I),% 15
Economic life (N), years 15
Optimum diameter (Dl, m 6.1
Return
shaft*
800
0.0074
354
0.07
70
206
15
15
5.6
* The system will require two shafts of at least this
size.
TABLE 4
Fan characteristic curves used t o simulate
the existing fans and those purchased for the
IOZ expansion.
Single 450-kW fan Two 725-kW fans
(in parallel)
H, Pa Q, m3/s H, Pa Q, m3/s
2,790 125 2,990 280
2,290 157 2,190 38 1
1,494 190 1,590 423
level. At 70% efficiency, the total power requirement for
the main fans will be equal to 3,124 kW (4,188 hp). Based
on this figure and a power cost of 7$/kWh, the power
cost for the main fans (primary ventilation) will be equal
to US$1.92 million/year.
Conclusions and discussions
Based on the Indonesian Mining Laws, the experi-
ence gained in the IOZ mine and the guidelines used in
the mining industry, to achieve the PTFI's ore produc-
tion goal, the DOZ mine ventilation system must handle
at least 966 m3/s (2.05 million cfm) of air. The system pre-
sented in this study can fulfill this objective.
This study is based on the necessity of supplying 21.7
m3/s (46,000 cfm) of fresh air to each production panel.
This figure compares well with the 23.7 m3/s (50,200 cfm)
per panel used at the others similar mines in the United
States (Brunner, 1988; Flint, 1996). With a good machine-
maintenance program, this quantity can be decreased to
probably 18.9 m3/s (40,000 cfm) per panel, leaving a suf-
ficient quantity of air to ventilate at least another panel.
The airway resistance for new openings were calcu-
lated using friction factors ranging from 0.0074 to 0.0148
kg/m3 (40 t o 80-lo lbf min2/ft4). This was determined
based on pressure/quantity measurements m the IOZ
mine and preliminary surveys in the DOZ mine open-
ings.
To handle 966.3 m3/s (2.05 million cfm) of air, in ad-
dition to the existing openings, the DOZ ventilation sys-
MINING ENGINEERING . AUGUST 1999 57
TABLE 5
At 7$/kWh, this represents US$1.92
million dollars per year in operating
Summary of fan operating duties. costs..
Fan Pressure Quantity Op. Cost
References
Brunner, D., 1988, "Ventilation plan-
No. From To Pa m3/s US$/year
ning study of El Teniente block caving mine
1 * 446 450 872 377.7 287,413
in Chile," 4th Intl. Mine Ventilation Congress,
2 * 402 400 872 353.4 269,788
Brisbane, Queensland, Australia, pp.
3 60 61 1,643 388.2 558,463
603-610.
62
Flint, D., 1996, personal communica-
4 63 1,459 191.4 244,37 1
5 610 61 5 1,643 386.7 556.423
tion.
Hartman, H.L., 1982, Mine Ventilation
Total quantity handled by the system = 966.3 m3/s
Input power (at q = 70 %) = 3,124 kW
Total operation cost (at 7$lkW-qr) = US$1.92 million/year
* Underground booster fans.
tem will require two 6-m- (20-ft-) diam, 800-m- (2,600-ft-
) long main exhaust shafts, a third 6 x 6-m (20 x 20-ft) in
cross section, 1,810-m- (5,940-ft-) long intake shaft and
several interconnecting drifts and cross-cuts. In addition,
it will require the purchase and installation of five main
fans and more than 20 auxiliary fans.
For the selected design, the input power require-
ment for the main fans will be equal 3,124 kW (4,188 hp).
and Air Conditioning, 2nd Ed., Krieger Pub-
lishing Co., Malabas, Florida, 791 pp.
Jurani, R., 1991, "Preliminary Ventila-
tion Analysis, ESF Construction Phase,"
Raytheon Services, Nevada, Las Vegas, NV,
60 PP.
Marks, J.R, 1991, "Ventilating a long,
deep-level exploration drift," Proceedings of the 5th US Mine Ventila-
tion Symposium, SME, Littleton, CO, pp. 376-383.
McPherson, M., 1993, Sub-surface Ventilation and En ironmental
Engineering, Chapman & Hall, London, 905 pp.
MVS, 1996, "Final Report on the Sizing of an Exhaust Booster
Fan for Freeport Indonesia's Ore Handling System," Mine Ventilation
Services Inc., Fresno, CA, 29 pp.
58 AUGUST 1999 MINING ENGINEERING