Optimized mine ventilation system

Abstract

The optimized mine ventilation system of this invention supplements mine ventilation basic control systems by establishing a dynamic ventilation demand as a function of real-time tracking of machinery and/or personnel location and where this demand is optimally distributed in the work zones via the mine ventilation network and where the energy required to ventilate is minimized while totally satisfying the demand for each work zones. The optimized mine ventilation system operates on the basis of a predictive dynamic simulation model of the mine ventilation network along with emulated control equipment such as fans and air flow regulators. The model always reaches an air mass flow balance where the pressure and density is preferably compensated for depth and accounts for the natural ventilation pressure flows due to temperature differences. Model setpoints are checked for safety bounds and sent to real physical control equipment via the basic control system.

Claims

1. A method of optimizing mine ventilation in an underground mine having airflow control equipment and a plurality of defined mine areas, the airflow control equipment comprising a plurality of surface fans, a plurality of booster fans, and a plurality of airflow regulators, the method comprising: monitoring, in real-time, the plurality of defined mine areas to detect machinery and personnel present inside the plurality of defined mine areas; determining, in real-time, a quantity of ventilation required for the plurality of defined mine areas as a function of the machinery and the personnel present in the plurality of defined mine areas, the determining including: correlating real-time physical air flow measurements to calculated air flow rates in real-time; and based on the correlating, automatically calibrating the calculated air flow rates, the air flow measurements, or both the calculated air flow rates and the air flow measurements to account for discrepancies in the correlating and/or automatically triggering an alarm indicative of the discrepancies in the correlating; and automatically adjusting, based on the determining, at least one of a speed of the plurality of surface fans, a speed of one or more of the plurality of booster fans, and an opening position of one or more of the plurality of airflow regulators to provide the determined quantity of ventilation to the plurality of defined mine areas in real-time.

2. The method of claim 1, wherein the determining of the quantity of ventilation further comprises calculating the quantity of ventilation required for the plurality of defined mine areas based on an air flow rate and an air pressure for air inside the plurality of defined mine areas as a function of density and temperature variation.

3. The method of claim 1, wherein the determining of the quantity of ventilation required for the plurality of defined mine areas is further based on an operating status of the machinery present inside the plurality of defined mine areas.

4. The method of claim 3, wherein the monitoring of the plurality of defined mine areas further comprises gathering data related to machinery and personnel using a monitoring and communication system covering the plurality of defined mine areas.

5. The method of claim 4, wherein the data related to machinery and personnel further comprises an engine or hydraulic-electric operating status of the machinery present inside the plurality of defined mine areas when the machinery present inside the plurality of defined mine areas is diesel operated.

6. The method of claim 5, wherein the data related to machinery and personnel further comprises data related to engine characteristics that allows for determining a total amount of horse power of the machinery present inside the plurality of defined mine areas when the machinery present inside the plurality of defined mine areas is diesel operated.

7. The method of claim 6, wherein the total amount of horse power of the machinery present inside the plurality of defined mine areas is a maximum amount of the horse power of the machinery present inside the plurality of defined mine areas.

8. The method of claim 1, wherein the machinery present inside the plurality of defined mine areas is detected using a wireless communication system.

9. The method of claim 8, wherein the wireless communication system comprises a radio frequency identification system.

10. The method of claim 1, wherein the personnel present inside the plurality of defined mine areas is detected using a wireless communication system.

11. The method of claim 10, wherein the wireless communication system comprises a radio frequency identification system.

12. The method of claim 1, wherein the opening position of the one or more airflow regulators is adjusted to a position that is smaller than or equal to 80% of a maximum opening position of the one or more airflow regulators.

13. The method of claim 1, wherein the determining is further based on data entered by an operator.

14. The method of claim 1, wherein the determining is further based on a ventilation system model.

15. The method of claim 1, wherein the automatically adjusting provides the determined quantity of ventilation to the plurality of defined mine areas in real-time while optimizing air flow distribution and energy consumed by the plurality of surface fans and the plurality of booster fans.

16. A system for optimizing ventilation in an underground mine having airflow control equipment and a plurality of defined mine areas, the airflow control equipment comprising a plurality of surface fans, a plurality of booster fans, and a plurality of airflow regulators, the system comprising: a controlling unit configured to be in communication with the plurality of surface fans, the plurality of booster fans, and the plurality of airflow regulators to control a speed of the plurality of surface fans, a speed of the plurality of booster fans, and an opening position of the plurality of airflow regulators; a simulating unit configured to: calculate an air flow rate and an air pressure for air in the plurality of defined mine areas as a function of density and temperature variation, which is a function of depth, while accounting for natural ventilation pressure flows; correlate real-time physical air flow measurements to the calculated air flow rates in real-time; and automatically calibrate, in real-time, the calculated air flow rates to account for discrepancies in the correlating; a calculating unit for automatically calculating a quantity of ventilation required for each of the plurality of defined mine areas in real-time as a function of machinery and personnel present in each of the plurality of defined mine areas and the calculated air flow rates that are calibrated in real-time; and an optimizing unit configured to optimize air flow distribution and energy consumed by the plurality of surface fans and the plurality of booster fans.

17. The system of claim 16, wherein the controlling unit: automatically controls at least one of the speed of the plurality of surface fans, the speed of the plurality of booster fans, and the opening position of the plurality of airflow regulators based on the quantity of ventilation automatically calculated, in real-time, by the calculating unit.

18. The system of claim 16, further comprising a graphical image generating unit and a monitoring unit, the monitoring unit being configured to receive the physical air flow measurements, the graphical image generating unit being in communication with the monitoring unit and being configured for generating, as a function of the calculated air flow rates and the received physical air flow measurements, a graphical image of a current ventilation status of at least one of the plurality of defined mine areas.

19. The system as claimed in claim 18, wherein the graphical image generating unit is further in communication with the calculating unit for generating a graphical image of a required ventilation status of the at least one of the plurality of defined mine areas as a function of the quantity of ventilation automatically calculated, in real-time, by the calculating unit.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The above and other objects, features and advantages of the invention will become more readily apparent from the following description, reference being made to the accompanying drawings in which:

(2) FIG. 1 is background information on a mine ventilation typical layout and related air flow modulation equipment such as fans and airflow regulators within bulkheads. The optimized mine ventilation system invention models the ventilation air flow of the network and controls physical air flow modulation equipment.

(3) FIG. 2 is a block diagram summary of all ventilation control components inclusive of an optimized mine ventilation system.

(4) FIG. 3 is a detailed block diagram of the optimized mine ventilation system invention components and links to external elements. Dashed components are external elements to the optimized mine ventilation system.

DESCRIPTION OF THE PREFERRED EMBODIMENT

(5) A novel optimized mine ventilation system will be described hereinafter. Although the invention is described in terms of specific illustrative embodiment(s), it is to be understood that the embodiment(s) described herein are by way of example only and that the scope of the invention is not intended to be limited thereby.

(6) An embodiment of the optimized mine ventilation system according to the present invention will be described below in detail with reference to the drawings.

(7) The following describes a summary of the optimized mine ventilation system functionality and links to external systems with references to FIG. 3.

(8) A third party machinery and personnel tracking system provides real-time data on the machinery location and operating status and on personnel location [FIG. 3, item (55)].

(9) From the dynamic tracking status of each machinery a ventilation demand is calculated for each defined mine work zones as per the following [FIG. 3, items (56, 57)]:

(10) CFM or m3/s per diesel hp when diesel is “On”.

(11) CFM or m3/s per diesel hp when diesel is “Off”. This permits operations to have air available for machinery stopped at a location with personnel around.

(12) CFM or m3/s per diesel hp when the diesel is “Off” and its hydraulic-electric is “On”.

(13) Those three parameters are configurable per machinery by the surface or underground operators.

(14) The system calculates the aggregate demand for each zone parent-child relationship from the zone definition database [FIG. 3, item (57)]. For example, the total demand for a level is equal to the total demand for all related ore extraction zones and service areas plus the total demand related to machinery and personnel directly tracked on the level.

(15) The system sets to a minimum the personnel ventilation demand requirement per zone and overrules the machinery calculation if the personnel demand is higher.

(16) If the calculated personnel and machinery total demand while on VOD control mode, the VOD controller will set the zone flow to a minimum air flow as defined by the ventilation engineer.

(17) The mine ventilation layout, fans and air flow regulators are created in the form of an electronic process and instrumentation diagram using the Simsmart™ Engineering Suite modeling and simulation tool. Parametric information for all layout and control elements present on the diagram is configured in the diagram database [FIG. 3, item (52)]. The diagram is compiled into a run-time engine execution environment [FIG. 3, item (51)]. The run-time engine environment executes in real-time all physics, characteristic, mathematics and logic based equations.

(18) The Simsmart™ Engineering Suite run-time engine is responsible for the following tasks:

(19) As described above, to calculate the dynamic ventilation air flow demand and summarized per defined mine area such as an ore extraction zone, a level, a service area and other workplaces.

(20) To model the ventilation network and establish an air flow mass balance. The air density, pressure and temperature are preferably compensated for depth. The real-time model execute real-time calculations for pressure, fluid velocity, flow, temperature, several other fluid properties, fan speed and regulator position [FIG. 3, items (53)].

(21) To execute controls in manual, semi-automatic and VOD mode to optimize the air distribution and fan energy consumption based on the calculated dynamic air flow demand [FIG. 3, item (54)].

(22) To provide the required logic for fans and air flow regulators setpoint scheduling [FIG. 3, items (63)].

(23) To declare and handle alarm and special event conditions.

(24) The following physics calculation assumptions describe the basic concepts and equations used for the simulation model components and the real-time resolution of the differential equations matrix [FIG. 3, item (51)]:

(25) The simulation model uses compressible air flow with a polytropic process. This is a process which occurs with an interchange of both heat and work between the system and its surroundings. The nonadiabatic expansion or compression of a fluid is an example of a polytropic process. The interrelationship between the pressure (P) and volume (V) and pressure and temperature (T) for a gas undergoing a polytropic process are given by Eqs. (1) and (2),

(26) $\begin{array}{cc}{\mathrm{PV}}^a=c& \left(1\right)\\ \frac{P^b}{T}=c& \left(2\right)\end{array}$

(27) where a and b are the polytropic constants for the process of interest. These constants, determined from mine surveys. Once these constants are known, Eqs. (1) and (2) can be used with the initial-state conditions (P1 and T1 or V1) and one final-state condition (for example, T2, obtained from physical measurement) to determine the pressure or specific volume of the final state.

(28) Because density varies significantly, the air weight effect is not negligible. In this case there is an auto compression effect. Pressure variation not only causes density variation but also causes temperature variation accordingly based on the polytropic index.

(29) The calculations account for Natural Ventilation Pressure (NVP). NVP is the pressure created in a ventilation network due to the density difference between air at the top and bottom of the downcast and upcast shafts. In deep hot mines there is usually a large difference between surface and underground temperatures—there is a difference in density between air on surface and underground and this causes air to move from high to low density. The NVP will either assist or retard fans in the system. When NVP assists a fan, it tends to move air in the same direction as the fan. The NVP can be the to lower the system resistance curve against which the fan operates. This means the fan will handle more air at lower pressure.

(30) The actual tunnel air resistance is calculated using the entered standardized Atkinson resistance or the standardized Atkinson friction factor.

(31) The air pressure, air velocity, flow resistance and air flow rate are calculated at all points in the system.

(32) The pressure and density calculation accounts for air weight (air potential pressure) and the Bernoulli Equation accounts for potential energy.

(33) Correction of fan specification curves with the density variation effect.

(34) Calculation of variable speed fan flow, pressure, power and efficiency curves.

(35) Ducting junctions, dovetails or transitions can calculate process pressure and flow resistance for each port.

(36) Transitions, junctions and fan calculation accounts for positive and negative flow resistance.

(37) All components calculate air properties: temperature, pressure, viscosity, humidity, dew point temperature, particles, and contaminant concentrations.

(38) An iteration convergence method is used for transient simulation modes.

(39) Latent heat calculation is not available.

(40) The ventilation demand calculation commands controllers to modulate fans and air flow regulators [FIG. 3, item (54)].

(41) There are four types of regulatory controls for fans and air flow regulators in the optimized mine ventilation system:

(42) Auxiliary fans control.

(43) From the air mass flow balance calculations, the auxiliary fans speed is modulated so the output flow at the exit of the ducting section meets the calculated target demand flow for each work zone.

(44) Air Flow Regulator Controls for Levels.

(45) From the air mass flow balance calculations, the air flow regulator opening position is modulated so the regulator output flow meets the calculated target demand flow for each work zone.

(46) If an air flow regulator is in manual mode or if the regulator is a fixed bulkhead opening, an intake compensation cascade controller will modulate the surface fans in order to meet the calculated target demand flow.

(47) Surface Fans Controls.

(48) The surface fan controller is a cascade controller [FIG. 3, items (58, 59)] that optimizes the surface fan speeds in order to minimize energy consumption while assuring all levels to obtain their calculated target demand flow and maintaining a set maximum regulator opening. This maximum regulator opening is the cascade controller setpoint.

(49) It is assumed that all surface fans are driven by a variable frequency drive. As an example, if the surface fans cascade controller setpoint is set at 80% opening maximum for any air flow regulator, the surface fans will be modulated in order to assure that any level air flow regulator will be at and not exceed this 80% maximum opening.

(50) The surface fans cascade controller calculates a common modulated fan speed for all fans. This speed is then split by a ratio to intake fans and to another ratio to exhausts fans.

(51) Booster Fans Controls.

(52) The booster fan controller is a cascade controller over the air flow regulator controller. It will modulate the booster fan speed based on set maximum air flow regulator opening. For example if the cascade controller setpoint is set at 70%, this means that when the booster fan will be modulated upward when the regulator position exceeds 70%.

(53) The optimized mine ventilation system has the following control modes [FIG. 3, item (54)].

(54) Surface Operating Mode:

(55) MAN: A fixed fan speed or regulator position setpoint is entered by the surface operator. The fan speed and/or regulator position not modulated automatically. The simulation model does not modulate the fan speed or the airflow regulator position to meet a CFM value. The machinery tracking has no effect on the control. The local underground controller requires to be in “Surface” mode.

(56) AUT: This Mode Activates the Selected VOD or CFM Modes.

(57) a. VOD: The CFM setpoint is calculated from the dynamic machinery tracking results. The fan speed and/or regulator position is automatically modulated to meet the CFM demand setpoint as per the calculated actual flow by the simulation model. The modulated fan speed or airflow regulator position setpoint is sent to the underground physical device. The controller also needs to be in AUT mode for the VOD mode to be active. The controller also requires to be in “Surface” mode. A minimum flow setting is available for the VOD mode. Therefore, a dynamic tracking ventilation demand setpoint may never be lower than a defined pre-set. The minimum flow presets are defined in a purpose built HMI page.

(58) b. CFM: The CFM setpoint is a fixed value and is entered by the surface operator for fans or airflow regulator. The fan speed and/or regulator position is automatically modulated to meet the fixed value CFM setpoint as per the calculated actual flow by the simulation model. The simulation model will modulate the fan speed or the airflow regulator position to meet the desired CFM value. The equipment tracking has no effect on the control. The controller also needs to be in AUT mode for the CFM mode to be active. The controller requires to be in “Surface” mode.

(59) Underground Operating Mode:

(60) Control is normally achieved from the surface, but an underground operator via a tablet PC may acquire a control mode called “Underground”. When he acquires control he can operate the selected controller in Manual mode.

(61) The surface operator receives an alarm when control is acquired by the underground operator. The surface operator is requested to acknowledge the alarm. When the alarm is acknowledged, the alarm condition disappears.

(62) When the underground operator releases control back to the surface operator, an alarm is displayed to the surface operator. The surface operator is requested to acknowledge the alarm. When the alarm is acknowledged, the alarm condition disappears.

(63) When the control is released by the underground operator, the selected controller goes back to the previous mode in use before he acquired control.

(64) The following describes each mode:

(65) SUR: A fan speed and/or regulator position is set by the surface operator in MAN, AUT(VOD/CFM) modes (see above).

(66) UND: When a controller is set to UND, a fan speed and/or regulator position is manually set by an underground operator via a WIFI tablet PC HMI control page.

(67) The VOD control mode setpoints are filtered [FIG. 3, item (65)] for stability, minimum time between up and down changes, ramp-up, ramp-down and deadband before they are sent to the basic control system and physical fans and air flow regulators via OPC connection [FIG. 3, items (66, 67)].

(68) Since not all mine ventilation operating procedures call for work zone flow setpoints being calculated on machinery location, operating status and personnel location, controller modes and setpoints are also subject to scheduled or ad-hoc events [FIG. 3, item (63)]. Therefore, presets for each controller modes and setpoints can be configured for an array of user definable events [FIG. 3, item (64)]. Optionally, an autoswitch to tracking based ventilation (VOD mode) can be enabled when a minimum ventilation demand has been detected by the dynamic tracking. Likewise, another autoswitch to tracking based ventilation can be enabled when a defined period of time has elapsed.

(69) Scheduling presets can also cover specific events such as pre-blast and post-blast events. The optimized mine ventilation system will warn the operator if pre-blast event is set with remaining personnel and machinery activity in the mine.

(70) The optimized mine ventilation system monitors critical key air flow measurements [FIG. 3, item (60)] and will alarm when a correlation deviation to the measurements calculated by the model [FIG. 3, item (61)]. The optimized mine ventilation system will call for a flow survey to verify if the measurement instrument or the calculated flow are in error. If it is concluded that the calculated flow must be calibrated, the ventilation engineer will set the related flow controller in calibration mode. Then, it will automatically adjust the related system portion calculated k factor to match the survey data.

(71) While illustrative and presently preferred embodiment(s) of the invention have been described in detail hereinabove, it is to be understood that the inventive concepts may be otherwise variously embodied and employed and that the appended claims are intended to be construed to include such variations except insofar as limited by the prior art. Indeed, the system of the invention can be used in any confined environment where there is a need for ventilation as a function of the presence of humans, animals and/or equipment, for example: tunnels.

(72) The foregoing description is provided to illustrate and explain the present invention. However, the description hereinabove should not be considered to limit the scope of the invention set forth in the claims appended here to.