HMINE - 324 PROJECT

TITTLE:

FINANCIAL OPTIMISATION OF THE SABI GOLD MINE VENTILATION SYSTEM

USING VENTSIM VISUAL SOFTWARE CONSIDERING THE FULL VENTILATION
SYSTEM MECHANIZATION DRIVE.

By:

KEANE B SIZE R1913494W

FAITH NAVONIKA R1913534G

TAVONGA BUDA R1913908M

HAZELDON T MUCHONO R1915417W

TINASHE DEMBURE R1917684B

BRANDON M MERO R197278Y

A project submitted to the department of Mining Engineering, Faculty of Engineering and

Geosciences in partial fulfilment of the requirements for Bachelor of Engineering Honours
Degree in Mining Engineering

Supervisor : Mr L. Ndlovhu

Zvishavane

June 2022

1
I. Declaration

The following students declare that this is their own unaided work, that this report has not
been submitted for examination to another department or institution, and that they understand
plagiarism is a punishable offence.

Keane B Size R1913494W Signature : ………… Date : …………

Faith Navonika R1913534G Signature : ………… Date : …………

Tavonga Buda R1913908M Signature : ………… Date : …………

Hazeldon T Muchono R1915417W Signature : ………… Date : …………

Tinashe Dembure R1917684B Signature : ………… Date : …………

Brandon M Mero R197278Y Signature : ………… Date : …………

Chapter 1

Introduction

This chapter gives an overview of the project. The background of the mine, project
background, problem statement, justification, aim and objectives of carrying out the project
are explained in this chapter.
1.0. Background

Sabi Gold Mine currently uses negative pressure ventilation system where they make use of
an exhaust fan to drive air from the underground environment to the surface. Air is drawn in
through the main shaft (Anglo shaft) and exhausted through the exhaust shaft. The exhaust
fan is placed 12m from the exhaust shaft in the 6-Level. When blasting is carried out,
compressed air is blown at development ends to exhaust blast fumes. The re-entry at Sabi
mine is scheduled to be 4 hours after blasting is carried out.

1.1. Mine Location

Sabi Gold Mine is located in the Midlands province of Zimbabwe about 15km South-East of
Zvishavane along the Rutenga-Beitbridge road in the Mberengwa Greenstone Belt. The
Greenstone belt is associated with minerals like gold, asbestos, nickel and copper. The belt
lies along the famous Great Dyke which is well known for hosting various minerals in
Zimbabwe.

(South, 2014)

Figure 1.0 Map showing location of Sabi Gold Mine

1.1.4 Sabi Gold Mine cross-sectional lay-out

Figure 1.1; Sabi Gold mine layout

1.2 Problem Statement

The scheduled re-entry time of 4 hours is currently not being met as traces of noxious gases
will still be detected in the exhaust shaft even after the specified time. This is mainly as a
result of the less efficient compressed air system being utilized and leakages from open old
stopes, raises and crosscuts in abandoned working areas. This unplanned extension of the re-
entry time is affecting the overall production. The lashing and hoisting shift is failing to meet
production targets due to limited time. Failure to meet the production targets is causing the
mine to incur financial losses.
1.3 Project Justification

An efficient mine ventilation system plays a major role in the provision of fresh air and
removal of contaminants as a result increasing the morale of the working personnel. It also
facilitates in capital and operating costs, yield and safety. The major operations of a mine
include blasting which produces dust, toxic fumes and heat. A properly ventilated mine
speedily dilutes all noxious elements in time for production and safety. At Sabi Gold Mine,
this does not practically occur since the scheduled re-entry time is not met.

Figure 1.2; Actual and Budgeted targets

Production targets for the year 2022 have not been able to be met. The graph above clearly
shows how Sabi gold mine is failing to meet production targets for the first four months of
2022. This project will optimize the Sabi Mine ventilation system by introducing fans and
curb the air leakages in old stopes to minimize production losses.
Level Velocity(m/s) Area(m2) Q(m3/s)

1 0.378 8 3.025

2 0.356 8 2.845

3 0.332 8 2.655

4 0.331 8 2.650

5 0.329 8 2.635

6 0.318 8 2.540

7 0.266 8 2.130

8 0.264 8 2.115

9 0.263 8 2.100

10 0.261 8 2.090

11 0.258 8 2.065

12 0.258 8 2.060

28.910

Table 1.0; Velocity, Area and Air Quantity

 Air quantity decrease from 3.025m3/s at level 1 to 2.060m3/s at level 12 and the
velocity also decreases due to air leakages from open old stopes, raises and crosscuts in
abandoned working areas, airway resistance.
 Level CO(ppm) NxOy (ppm) O2

Limit 100ppm Limit (5 ppm) (Limit ≥19%)

1 0 0 20

2 0 0 22

3 0 0 23

4 0 0 20

5 2 4 19

6 8 5 17

7 35 7 15

8 90 6 14

9 128 8 15

10 125 7 13

11 130 8 12

12 135 9 10

Table 1.1; Contaminants found in the different levels

Gas concentration readings at the standard re-entry time of four hours in table 1.2 shows that;

 Carbon monoxide (CO) in 9-level to 12-level is above the minimum permissible

quantity of ≤ 100 ppm of air as per mine ventilation standards. CO levels are
increasing down the mine levels, it is evident that there is limited fresh air hence the
morale of workers is negatively affected.

 Oxides of nitrogen are above the required limit of ≤ 5 ppm of air from 7-level to 12-
level. NO levels increase also as we go down the mine in working areas because air
distribution poor since most fresh air is lost in upper levels due to airflow leakages
resulting in accumulation of NxOy. Moreover, NxOy components are also denser than
air so they amass in the lower levels.
  From 6-level to 12-level, oxygen percentage is below 19% which is the minimum
required percentage in the air because compressed air is reaching lower levels in short
supply.

1.4 Aim

To optimize the Sabi mine ventilation system in order to meet the scheduled re-entry time of
4 hours

1.5 Objectives

In light of the aforementioned problem description, the following major goals have been
defined in an effort to address the issue;
 3-Dimensional modelling of Sabi gold mine ventilation system.
 Contaminant simulation of the ventilation system to figure out how much air is
needed to reduce the overall contaminants load. Specify the kind of ventilation system
that should be utilized for mining deep portions.
 To improve the quantity and direction of air in the current working area.

1.6. Limitations
The project should be finalized and submitted by August 2022. To deal with constraint, we
had to pursue the project with much dedication and focus. More-over COVID restrictions
proved to be a hurdle in our pursuit to acquire the relevant data to carry out the project thus
we had to be vaccinated and be tested for the Covid-19 virus 24 hours before our mine visit
in order to be granted entry into the mine. Only the materials provided to us during the
conduction of the project served as the basis for the analysis that was done. Consequently,
there may be some additional information, that is already available that could slightly modify
the final result of the research and, ultimately, change the conclusion.

1.7. Project Significance

This project will help in increasing the lashing and hoisting time thereby meeting production
targets. In addition, this research will help to increase the overall efficiency of the Sabi Mine
ventilation system by sealing old stopes, raises and crosscuts where production is no longer
taking place by the adoption of brattices and ventilation doors. The mine management will
benefit from the high productivity of the workers as they will be able to hit production
targets. This project will educate third parties who would want to venture into underground
mining on the benefits of reducing re-entry time.

1.8. Delimitations
The study focuses on mine ventilation issue of contaminate build up in relation to the depth at
which mining operations are occurring. Since all additional difficulties the mine encounters
are deemed outside the purview of the investigation, they have not been included in the
research but have nonetheless been properly acknowledged.

Chapter 2
Literature Review
2.0 Introduction
A safe and affordable ventilation system is an essential component of all underground mines.
The goal of any underground ventilation system is to provide adequate quantity and quality
air to airflows in order to mitigate air contaminants and achieve safe concentrations in
underground workplaces where workforce is required (McPherson, 2009). It is the
responsibility of ventilation engineers to understand mine ventilation practices, escape and
rescue design, and mine ventilation economics (Wallace, 2015). The efficiency of a mine
ventilation system eventually limits mine production.

There is evidence of a trend in metal mines toward larger diesel equipment, increased
production targets, and increased regulations to reduce respirable particulate dust (silica
and/or DPM) (Brake, 2013). As mines get deeper, the need for refrigeration grows (Du
Plessiss, 2014).VOD theory is based on applying airflow only to working areas while
limiting airflow to the remaining areas. The system necessitates variable frequency drive fan
motors, air gas sensors, regulator and fan control systems, and tagging systems. Monitoring
of fan performance and air quality should be required. Explosive gases should be monitored
in closed gobs and entries. Other parameters such as air temperature and humidity should be
monitored at strategic underground locations and via fan systems.
2.1 Negative Pressure Ventilation System
Natural ventilation pressure is the pressure created by opposing air masses of differing
densities in a closed circuit with a height difference. It is known as natural ventilation flow
when it forms. The difference in air density on either side of the loop under the influence of
earth's gravity creates the natural ventilation pressure, which is in accordance with the law of
energy conservation. A unique variation of the natural ventilation pressure is the pressure
during a fire. One aspect of a mine's ventilation power is its natural ventilation pressure,
which is influenced by the weather on the ground as well as the mine's production and design
elements. The instability of subsurface air flow, which could compromise public safety,
could be brought on by a shift in atmospheric pressure (He Z. Y., Ran. S., and Li. Z. S., et al.)

Figure 2.0; showing a typical underground natural ventilation system.

In order to effectively ventilate underground mines, air currents must be completely

controlled so that workers can always have access to enough moving air to perform at
maximum capacity without suffering health problems. In addition, in the event of an
underground fire or a surface fire close to mine openings, underground air currents may be
quickly reversed as needed, or air may be sent into or excluded from any region, and fire
fumes may be contained to only a portion of the mine.
Proper ventilation of mines (both coal and metal) is so closely related to the health and safety
of mine workers, as well as the proper safeguarding and operational effectiveness of mining
properties, that they are interdependent.

Without ventilation, a mine would be an extremely inhospitable place for both working
people and machines. As a result, mining ventilation is essential to the day-to-day operations
of mining. It has been shown that mine ventilation has played a crucial role in mining
systems since the very beginning (Hartman, H. L., Mutmansky, Ramani, and Wang, 1997).

2.0.1 General principles of mine ventilation

The general principle of mine ventilation in an underground mine is that fresh air enters the
system through one or more downcast shafts, addits, drifts, or other surface connections. Air
flows through intake airways to the working sections, where the majority of the pollutants are
added to the air. This controls dust, heat, and many potentially hazardous and toxic
flammable gases, as well as humidity and radiation. The contaminated air returns to the
system via return airways. In most cases, the concentration of contaminants is not allowed to
exceed mandatory legal thresholds and is safe for people in all parts of the system. The return
airway eventually returns to the surface via one or more up-cast shafts. 

2.1 Ventilation Requirements

 All the ventilation air entering the mine should be dust, smoke and impurity free.
 All the working areas were mining personal is expected to work is supposed to be
properly ventilated in order to keep a healthy and safe environment for the mining
personal.

2.1.1 Permissible Gas, Dust Quantities

 The quantity of (Carbon Dioxide) CO2 should not exceed 0.5% of the air volume.
 The quantity of carbon monoxide (CO) should not go beyond 0.01% of the air volume
underground.
 The quantity of Hydrogen Sulphide (H2S) should not go beyond 0.002% of the
underground air volume.
 The quantity of inflammable gases should be insignificant to show a significant gas
cap on a flame of an approved safety.
 The quantity of Ammonia (NH3) should not go beyond 0.005% of the underground
air.

2.2 Fans in general

A fan is an air-moving turbo-machine or a mechanical device that creates an air pressure
difference between two points, causing air to move from one point to another, or a device
that uses the mechanical energy of a rotating impeller to produce both movement of the air
and an increase in its total pressure. Fans are classified based on their location, mechanical
design, use, and the direction of air through their impeller. The following are some of the
fans.

2.2.1 Main fans

Both axial and centrifugal fans are used to circulate air in mine ventilation systems, with
efficiencies exceeding 70%. The choice between axial and centrifugal flow for main fans is
determined by cost, size, pressure, efficiency, robustness, and performance variations. In
mines where fan failure could result in dangerous gas emissions, additional fan capacity is
installed to ensure ventilation continuity. Where it is not as critical, and with twin fan
installation, about two-thirds of mine air flows are used for low pressure applications, while
centrifugal fans are used for high pressure systems. Either option is suitable for the
intermediate pressure. Where it is not as critical, and with twin fan installation,
approximately two-thirds of mine air flows are used for low pressure applications, while
centrifugal fans are used for high pressure systems. Either option is appropriate for the
intermediate pressure. A centrifugal fan is a more reliable choice when robustness is
required, such as exhaust with air velocities above the critical range and water droplets are
carried up and out of the system. Water droplets may remain suspended at critical air
velocities ranging from 7.5m/s to 13m/s, depending on their size. With this range, the amount
of suspended water in the system can build up and cause the fan to stall.
This is the region where some air recirculation occurs around the blades, causing the fan to
become unstable. Though undesirable for any fan type, the possibility of centrifugal fan
blade failure in the region of flow fluctuations is significantly lower than that of axial blade
failure.
It is uncommon for a main fan to be required to operate at the same duty point throughout the
mine's life, so an effective method of varying fan performance is desirable. Although variable
speed results in the most efficient operation for both axial and centrifugal fans, the cost is
high, especially for large fans. The performance of an axial flow fan can be altered by
adjusting the blade angle, which can be done either when the fan is turned off or at a
significantly higher cost when it is turned on. The performance of a centrifugal fan can be
varied while it is running by imparting a swirl to the air entering the fan casing variable inlet
vanes. A centrifugal fan's efficiency decreases faster away from its design point than that of
an axial flow fan, so if high performance over a wide range of operating points is required
and the pressure is suitable, an axial flow fan can be chosen.
The main fans are typically installed on the surface, which has the advantages of not adding
heat to the air underground or allowing for the recirculation of foul air, easy accessibility in
the event of a fire, and ease of service.
2.2.2 Booster fans
Booster fans are common in metal mines but are typically prohibited in coal mines. Booster
fans are used in metal mines to either divert air flow or provide additional air movement
power where it is needed. Booster fans are used in areas that are too far apart to be served by
the main fan. For air distribution to remote areas of the mine, booster fans will be required, or
a large fan will be required to pressurize all areas. If a large main fan is used, restrictions will
be required to maintain pressure in non-remote areas. When booster fans are used, the second
solution may be an unnecessary expense. A picture of a booster fan is shown below.

Figure 2.1; Booster Fan with inbuilt Silencer

2.2.3 Auxiliary fans
These are smaller fans used to direct air to specific faces or areas. Where dead end faces are
to be ventilated, air is delivered to the faces via ducts connected to the fan. In the case of
large openings, auxiliary fans are frequently hung in main air streams to divert air into these
openings with little or no duct connected to the fan. The figures below depict jet fans.

Figure 2.2; Auxiliary Fan

2.3 Fan laws
Certain laws apply to fans, making it possible to calculate characteristic curves for a fan at
various speeds and air density. For varying air speed while maintaining a constant density;
1. Quantity varies in direct proportion to speed.
2. Pressure is proportional to the square of the speed.
3. Power is proportional to the cube of speed.
4. Efficiency is constant.
For variable density but constant speed;
2 The quantity is constant.
3 Pressure varies in direct proportion to density.
4 Power varies in direct proportion to density.
5 Efficiency does not change.
During fan testing, it is critical to know the fan's speed. Any change in fan speed will result
in a markedly different performance profile. As a result, when the fan curves from the fan
test are plotted, the results vary only at the speed at which the fan was running during the
test. If the fan is to be used at a speed other than that specified in the curve, the curves must
be corrected to the appropriate speed. Fan speed can be used to modify the fan performance
curves.
2.4 Fan performance curves
There are always losses in a fan, so the real pressure-quantity curves are lower than their
theoretical counterparts. When the fan operates on open circuit, that is, with no external
resistance, friction and shock losses produce pressure-Quantity curves that tend toward zero
pressure, as indicated by the line AB. The useful performance curve DE is obtained after
subtracting the friction losses represented by the area ABC and the shock losses represented
by the area ACED from the Ideal curve AB. Figure 10 depicts a typical pressure-quantity
characteristic curve for a fan with backward blades.

Figure 2.3; Theoretical Actual Pressure - Quantity Curve.

Frictional losses occur as a result of the fluid's viscous drag on the Vanes' faces. As the fluid
moves through the impeller, a diffuser effect occurs in the diverging area available for flow.
This causes an additional loss of available energy. The pressure on the front face of a vane
must be greater than the pressure on the back face in order to transmit mechanical work. As a
result, the fluid velocity near the trailing face is greater than that near the front face. These
effects produce an eddy loss by causing an asymmetric distribution of fluid velocity between
two successive vanes at any given radius. It should also be noted that the two pressures must
become equal at the outlet tip. As a result, while the tip has the greatest influence on the
outlet vector diagram, it does not contribute to mechanical energy transfer. The power
transmission is not uniform along the length of the blade. The shock (or separation) losses
occur primarily at the inlet and reflect the abrupt 90° turn of the fluid as it enters the
impeller's eye. In practice, as the fluid approaches the inlet, wall effects create a vortex. At
the optimum design flow, shock losses can be minimized by selecting an appropriate inlet
blade angle.
The combined effect of these losses on the three different types of centrifugal impellers
results in the characteristic curves depicted in Figure 3.4. The non-overloading power
characteristic, as well as the steepness of the pressure curve at higher flows, are major
reasons why the backward impeller is preferred for large installations.
Figure 2.4; Actual pressure and shaft power characteristics for centrifugal impellers

REFERENCE
Fox projects reports, September, 2014.
Hartman, H. L., Mutmansky, J. M., Ramani, R. V., & J., W. Y. (1997). Mine Ventilationand
Air conditioning Ed 3. Canada: John Wiley & Sons.
Burrows, J., et al., eds., 1982, Environmental Engineering in South African Mines,Mine
Ventilation Society of South Africa, Johannesburg
Hartman, H.L., Introductory Mining Engineering, 1987, Wiley Interscience, New York.
Hartman, H.L., Mutmansky, J.M., and Wang, Y.J., eds., 1982, Mine Ventilation and
AirConditioning, 2nd ed., Wiley Interscience, New York.
A Guide to Mining Regulations,
Chambers of Mines of South Africa, Measurements in Mine Environmental
Control,Johannesburg, 1982.