Analyzing ventilation requirements and the utilization efficiency of the Kidd Creek mine ventilation...

Analyzing ventilation requirements and Analyzing ventilation requirements and the utilization efficiency of the Kidd the utilization efficiency of the Kidd Creek mine ventilation systemCreek mine ventilation system

1212thth North American/U.S. Mine Ventilation Symposium North American/U.S. Mine Ventilation SymposiumReno, Nevada, U.S.A., June 9-11, 2008Reno, Nevada, U.S.A., June 9-11, 2008

Analyzing ventilation Analyzing ventilation requirements and the requirements and the utilization efficiency of the utilization efficiency of the Kidd Creek mine ventilation Kidd Creek mine ventilation systemsystem

• Stephen Hardcastle, Charles Kocsis & Gary Li,Stephen Hardcastle, Charles Kocsis & Gary Li,CANMET – MMSL, Sudbury, CanadaCANMET – MMSL, Sudbury, Canada

• Kingsley HortinKingsley HortinHatch Associates, Sudbury, CanadaHatch Associates, Sudbury, Canada(Formerly with Xstrata Copper, Kidd Creek, Timmins,(Formerly with Xstrata Copper, Kidd Creek, Timmins,Canada)Canada)

Kidd Creek Mine

• Northern Ontario

• Started as Open Pit in 1966

• Mines #1, #2, #3 & now Mine D(Planned to Level 102 @ 3,110m)

• Developed to Level 91 (2,770m)

• >7,000 tpd copper sulphide from Mines #3 & D

• 200 diesel units (>38,000hp)50 Production units (>14,000hp)

Kidd VentilationSurface

New NVS Exhaust Fans2 x 2,600kW (3,500hp)

Open Pit(Cold Stope Intake)

7.5MWR

#1 Shaft(7.5MWR Bulk Air Cooler)

#2 Shaft

SVR Exhaust Fan1,300kW (1,750hp)

PortalRamp Access

• Total Installed Primary System FanMotor Power 13,600kW (18,300hp)

• Operational Capacity 1,220m3/s(2.6Mcfm)

• New Underground Booster Fans,2 x 3,000kW (4,000hp) at 60 Level1,800m below surface

Kidd VentilationUnderground/Combined

• Very Significant Operating Cost

• Exhaust Air Plug (@7m Ø) wouldwrap around the Earth 25x per year

X 25X 25

Ventilation ReviewsObjective - to reduce cost/improve efficiency

Initial brainstorming review:

• Need to address routing of air to avoidhigh resistance fan assisted routes

• SVR system redundant with respect toMines #3 & D

• More detailed review needed to assessefficiency and the need for increasedventilation management

• 1,500kW (2,000hp) Fan Power removedXX

Detailed ReviewsAvailable Data

• Long-term production plans such as- a month by month, 18-month schedule of activity- a year by year, 10+ year tonnage plan

• Historical data of daily equipment activity recordedby mines personnel

Design Criteria

• 0.06 m3/s per kW diesel engine power(100cfm/bhp)

Generalized Activities• PRODUCTION

Toro 1400 LHD (325hp) 14.5m3/sShotcrete Hauler (240hp) 10.7m3/s

• DRILLINGCubex Aries ITH (147hp) 6.6m3/sKubota M6800 Tractor (68hp) 3.0m3/s

• MISCELLANEOUS14.5m3/s sufficient for standard LHD

Future RequirementsIteration #1

• Predictive based upon 18-month plan

• Global 20% allowance for leakage & non-activelevels

• Extrapolated based upon tonnage

• Minimum flowm3/s

• 1,220m3/s capacity should be sufficient

20142006Year763641Activity916769Total with Leakage

Future RequirementsIteration #1 – Possible Caveats• Leakage of auxiliary systems ignored• No allowance to prevent recirculation at auxiliary

fans• 20% allowance to inactive areas/leakage may be

insufficient considering number of leaks• Failing to provide sufficient air to non-productive

areas for support activity• Assumes timely redistribution of airflow• Experience indicates 2 production LHD’s as a

regular occurrence

Iteration #2

• Predictive: 18-month plan & extrapolation

• Production 29m3/s, Drilling 14m3/s,Miscellaneous 20.7m3/s & Non-active 3.5m3/s

• System leakage 20%

• Minimum flowm3/s, Total includingleakage

Future Requirements

916769Iteration #1

• 1,220m3/s capacity remains sufficient

• Still based upon working to an idealized plan

20142006Year

1,093918Iteration #2

Past RequirementsRetrospective based upon production records

• SIMS end of shift dataWork

LocationDiesel Unit

Work Duration

Shift

• Data exportable to Microsoft Excel

Past RequirementsPivot Table conditional analysis

1. Equipment identified and associated airflowrequirement allocated to a mining level (or levels)

2. Assume concurrent activity and sum requirementsper level per shift

3. Adjust to prevent recirculation at auxiliary fani.e. where only a single vehicle operated

4. Allot minimum leakage flow – sufficient for smallservice vehicle (tractor)

5. Determine maximum flow needed for each levelper averaging period: month, week, day

Past RequirementsPivot Table month based analysis of 36 Levels

• On average - each level “active”: 316 days/year &31 of 36 levels “active”/day

• Flow requirements, 3.5 to 114m3/s, average 27m3/s

Mine Level Ja

nu

ary

Feb

ruar

y

Mar

ch

Ap

ril

May

Jun

e

July

Au

gu

st

Sep

tem

ber

Oct

ob

er

No

vem

ber

Dec

emb

er

Jan

uar

y

Feb

ruar

y

Mar

ch

Mo

nth

sIn

acti

ve

46 21.4 6.9 27.9 25.8 25.8 14.7 10.6 3.5 14.0 21.4 3.5 6.9 14.7 32.1 17.4 247 25.7 3.5 18.6 23.6 3.7 3.5 3.5 18.6 10.1 20.7 20.5 23.1 21.9 17.4 6.9 348 3.5 18.6 18.6 17.4 21.4 3.5 3.5 20.7 20.7 28.3 22.5 14.7 18.6 37.9 21.3 349 3.5 35.9 23.6 16.6 14.7 16.1 23.6 29.0 3.5 21.1 23.6 18.2 20.7 21.4 12.2 251 23.6 20.7 20.7 3.7 18.6 20.7 20.7 26.9 3.5 14.7 3.5 3.7 3.5 3.5 19.2 452 18.6 14.0 31.6 14.7 3.5 21.4 3.5 3.5 3.5 14.0 3.5 3.5 14.0 17.4 3.5 753 46.2 21.4 14.7 14.0 17.4 21.4 3.5 21.3 19.2 14.0 3.5 3.5 14.7 3.5 18.2 4

MinimalFlows

MaximumFlows Limited

Inactivity

Past RequirementsPivot Table week based analysis of 36 Levels

• On average - each level “active”: 252 days/year &25 of 36 levels “active”/day

• Lower average level airflow requirement of 19m3/s

Mine Level W

eek

1

We

ek 2

We

ek 3

We

ek 4

We

ek 5

We

ek 6

We

ek 7

We

ek 8

We

ek 9

We

ek 1

0

We

ek 1

1

We

ek 1

2

We

ek 1

3

We

ek 1

4

We

ek 1

5

We

eks

Ina

ctiv

e

46 21.4 3.5 17.4 14.7 6.9 3.5 3.5 3.5 3.5 13.4 27.9 27.9 27.9 25.8 3.5 3547 3.7 11.8 18.6 25.7 3.5 3.5 3.5 3.5 18.6 18.6 3.7 3.5 14.0 15.0 14.0 3248 3.5 3.5 3.5 3.5 3.5 18.6 3.5 3.5 3.5 18.6 3.5 3.5 3.5 3.5 3.5 3349 3.5 3.5 3.5 3.5 3.5 18.6 20.8 35.9 14.2 23.6 19.7 18.6 19.7 12.2 14.0 1951 3.7 20.7 20.7 23.6 20.7 20.7 20.7 18.6 20.7 18.6 3.5 3.5 3.5 3.5 3.5 3952 17.4 18.6 3.5 17.4 14.0 14.0 3.5 3.5 3.5 3.5 10.1 31.6 3.5 3.5 3.5 4453 37.2 24.8 27.3 46.2 24.8 18.6 18.6 21.4 3.5 3.5 3.5 14.7 14.7 14.0 3.5 41

More MinimalFlow

Shorter DurationMaximum Flows

IncreasingInactivity

Mine Level D

ay 1

Day

2

Day

3

Day

4

Day

5

Day

6

Day

7

Day

8

Day

9

Day

10

Day

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Day

12

Day

13

Day

14

Day

15

Day

sIn

acti

ve

46 3.5 3.5 3.5 3.5 21.4 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 38747 14.0 3.5 3.5 3.5 3.5 3.5 3.7 3.7 3.7 3.7 11.8 3.7 3.5 14.0 14.0 34948 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 34549 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 24651 3.5 3.7 3.7 3.7 3.7 3.7 3.7 3.7 3.7 3.7 3.5 3.7 20.7 3.5 3.5 35952 3.5 3.5 3.5 3.5 17.4 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 18.6 39753 23.6 18.6 18.6 26.9 20.7 20.7 26.9 37.2 24.8 24.8 23.6 16.1 18.6 19.6 17.4 358

Past RequirementsPivot Table daily based analysis of 36 Levels

• On average - each level active: 174 days/year &17.5 of 36 levels active/day

• Level airflow requirement now averages 11m3/s

Minimal Flow The Norm

Short DurationMaximum Flows

IncreasingInactivity

Past RequirementsPivot Table Analysis Differences/Caveats• Potential double accounting – same vehicle more

than one location – this can happen• Multiple vehicles, up to 5, generate high demands• Available data provides duration but no time-stamp • Consequently it was not possible to determine

whether the activity was concurrent or sequential• This backward analysis, based upon observed

discontinuous activity, highlights maximum demand• The previous forward analyses were based upon

idealized continuous averaged activity

Efficiency/RedundancySystem Efficiency ≠ Utilization Efficiency• An efficient “System” is one with minimal leakage

regardless of whether the air distribution is appropriate

• Utilization/redundancy is a function of whether the distribution meets/exceeds production demands

All a question of definition:• Today’s production air could be tomorrow's leakage• Production demand – is that by day, week or

month?

0

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Date 2005-06

Air

flo

w, m3 /s

Airflow RequirementsLower Mine – Mines #3 & D

Airflow requirement based upon monthly distribution with diesel based backfill

Mine Delivery Capacity 1,220m3/s

Monthly average with diesel backfill 1,261m3/s

Demand greater than available supply hence

perceived problems

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Date 2005-06

Air

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m3 /s

Capacity 1,220m3/s


Airflow requirement based upon monthly distribution with pastefill

Monthly average with pastefill 983m3/s


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Date 2005-06

Air

flo

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m3 /s


Capacity 1,220m3/s


Airflow requirement based upon weekly distribution with pastefill


Weekly average with pastefill 681m3/s

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Date 2005-06

Air

flo

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m3 /s



Capacity 1,220m3/s


Airflow requirement based upon daily distribution with pastefill

Daily average with pastefill 400m3/s


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Date 2005-06

Air

flo

w,

m3 /s




Capacity 1,220m3/s

Daily average with pastefill 400m3/s

Production plan based monthly requirement with diesel placed backfill, average 642 m3/s


Analysis Findings

• Historical analysis shows the dynamic nature of production in a base metal mine – constant change

• Hence perceived under performance/inadequacy• Future plan based requirements are optimistic• Airflow distribution need to be managed to limit

total volume of air supplied - significant benefits• More frequent redistribution lowers the redundancy

- the optimum would be daily• Redistribution frequency needs to be more often

than future planning period to operate within the design capacity

Ventilation Management• Primary system is automated• Secondary system control is being considered

Ventilation ManagementMine introduced more frequent redistribution of secondary airflow & adjustment of primary system1. Production Engineering schedule upcoming

activities automatically producing airflow demands Level Tag Board Calc. Volume Dev Rehab CB-Drill CB-Install Rse Bore Prod Drill Blast Muck Paste CWF Dia Drill Transfer

4600 40 40 1 1 14700 30 04800 30 15 14900 26 05100 26 05200 30 15 15300 26 15 15400 26 05600 15 05700 26 10 15800 26 10 16000 25 25 1 1 16100 25 06200 30 10 16300 30 10 16400 25 15 26500 25 25 1 16600 25 25 1 1 1 16700 25 25 1 1 16800 25 10 1

P1

P22. Ventilation Department reviews requirements and

produce an action plan3. Operations Group implement changes prior to the

commencement of the next week’s work activities

Level Tag Board Calc. Volume Dev Rehab CB-Drill CB-Install Rse Bore Prod Drill Blast Muck Paste CWF Dia Drill Transfer4600 40 40 1 1 14700 30 04800 30 15 14900 26 05100 26 05200 30 15 15300 26 15 15400 26 05600 15 05700 26 10 15800 26 10 16000 25 25 1 1 16100 25 06200 30 106300 30 106400 25 156500 25 256600 25 256700 25 25

P1

Realized BenefitsPower Savings from ….• Elimination of a surface fan (initial review)• Numerous auxiliary fans turned off on inactive levels• Reduced demand/lower operating point for the

2 x 3000kW boosters• On average the mine now operates on 930 m3/s

which is 23% less than delivered at the start of the review process

The number of ventilation related complaints has decreased

Conclusions• Base metal mining is never constant• Ventilation needs vary with changing activity • Overall demand depends on how often the ventilation

is adjusted• Significant differences between operational needs if

airflows are redistributed daily, weekly or monthly• Long range plans are idealized averages

- actual operation is different• Both Forward and Backward analyses have a place -

both can have limitations • Ventilation management can save power & money

- it can also be simple

Acknowledgements:Acknowledgements:Xstrata Copper – Kidd Creek MineXstrata Copper – Kidd Creek Mine

Analyzing ventilation requirements and the utilization efficiency of the Kidd Creek mine ventilation...

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