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12 th North American/U.S. Mine Ventilation Symposium Reno, Nevada, U.S.A., June 9-11, 2008

Analyzing ventilation requirements and the utilization efficiency of the Kidd Creek mine ventilation system. 12 th North American/U.S. Mine Ventilation Symposium Reno, Nevada, U.S.A., June 9-11, 2008.

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12 th North American/U.S. Mine Ventilation Symposium Reno, Nevada, U.S.A., June 9-11, 2008

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  1. Analyzing ventilation requirements and the utilization efficiency of the Kidd Creek mine ventilation system 12th North American/U.S. Mine Ventilation Symposium Reno, Nevada, U.S.A., June 9-11, 2008

  2. Analyzing ventilation requirements and the utilization efficiency of the Kidd Creek mine ventilation system • Stephen Hardcastle, Charles Kocsis & Gary Li, • CANMET – MMSL, Sudbury, Canada • Kingsley Hortin • Hatch Associates, Sudbury, Canada • (Formerly with Xstrata Copper, Kidd Creek, Timmins, • Canada)

  3. 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)

  4. #2 Shaft #1 Shaft(7.5MWR Bulk Air Cooler) PortalRamp Access Open Pit (Cold Stope Intake)7.5MWR Kidd VentilationSurface SVR Exhaust Fan1,300kW (1,750hp) New NVS Exhaust Fans2 x 2,600kW (3,500hp)

  5. Kidd VentilationUnderground/Combined • New Underground Booster Fans,2 x 3,000kW (4,000hp) at 60 Level1,800m below surface • Total Installed Primary System FanMotor Power 13,600kW (18,300hp) • Operational Capacity 1,220m3/s(2.6Mcfm) X 25 • Very Significant Operating Cost • Exhaust Air Plug (@7m Ø) wouldwrap around the Earth 25x per year

  6. Ventilation Reviews Objective - 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 removed X

  7. Detailed Reviews Available 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)

  8. Generalized Activities • PRODUCTIONToro 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

  9. Year 2006 2014 Activity 641 763 Total with Leakage 769 916 Future Requirements Iteration #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

  10. Future Requirements Iteration #1 – Possible Caveats • Leakage of auxiliary systems ignored • No allowance to prevent recirculation at auxiliaryfans • 20% allowance to inactive areas/leakage may beinsufficient considering number of leaks • Failing to provide sufficient air to non-productiveareas for support activity • Assumes timely redistribution of airflow • Experience indicates 2 production LHD’s as aregular occurrence

  11. Year 2006 2014 Iteration #1 769 916 Iteration #2 918 1,093 Future Requirements 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 • 1,220m3/s capacity remains sufficient • Still based upon working to an idealized plan

  12. Retrospective based upon production records SIMS end of shift data Diesel Unit Work Location Past Requirements Work Duration Shift • Data exportable to Microsoft Excel

  13. Past Requirements Pivot Table conditional analysis • Equipment identified and associated airflowrequirement allocated to a mining level (or levels) • Assume concurrent activity and sum requirementsper level per shift • Adjust to prevent recirculation at auxiliary fani.e. where only a single vehicle operated • Allot minimum leakage flow – sufficient for smallservice vehicle (tractor) • Determine maximum flow needed for each levelper averaging period: month, week, day

  14. Minimal Flows Maximum Flows Limited Inactivity Past Requirements Pivot 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

  15. More Minimal Flow Increasing Inactivity Shorter Duration Maximum Flows Past Requirements Pivot 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

  16. Minimal Flow The Norm Increasing Inactivity Short Duration Maximum Flows Past Requirements Pivot 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

  17. Past Requirements Pivot Table Analysis Differences/Caveats • Potential double accounting – same vehicle morethan 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

  18. Efficiency/Redundancy System 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?

  19. Airflow RequirementsLower Mine – Mines #3 & D Monthly average with diesel backfill 1,261m3/s Mine Delivery Capacity 1,220m3/s Demand greater than available supply hence perceived problems Airflow requirement based upon monthly distribution with diesel based backfill

  20. Monthly average with diesel backfill 1,261m3/s Capacity 1,220m3/s Airflow RequirementsLower Mine – Mines #3 & D Monthly average with pastefill 983m3/s Airflow requirement based upon monthly distribution with pastefill

  21. Monthly average with diesel backfill 1,261m3/s Capacity 1,220m3/s Monthly average with pastefill 983m3/s Airflow RequirementsLower Mine – Mines #3 & D Weekly average with pastefill 681m3/s Airflow requirement based upon weekly distribution with pastefill

  22. Monthly average with diesel backfill 1,261m3/s Capacity 1,220m3/s Monthly average with pastefill 983m3/s Weekly average with pastefill 681m3/s Airflow RequirementsLower Mine – Mines #3 & D Daily average with pastefill 400m3/s Airflow requirement based upon daily distribution with pastefill

  23. Monthly average with diesel backfill 1,261m3/s Capacity 1,220m3/s Monthly average with pastefill 983m3/s Weekly average with pastefill 681m3/s Daily average with pastefill 400m3/s Production plan based monthly requirement with diesel placed backfill, average 642 m3/s Airflow RequirementsLower Mine – Mines #3 & D

  24. 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

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

  26. Ventilation Management Mine introduced more frequent redistribution of secondary airflow & adjustment of primary system • Production Engineering schedule upcoming activities automatically producing airflow demands • Ventilation Department reviews requirements and produce an action plan • Operations Group implement changes prior to the commencement of the next week’s work activities

  27. Realized Benefits Power 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

  28. 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

  29. Acknowledgements: Xstrata Copper – Kidd Creek Mine

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