Technology-driven mining and industrial fan and ventilation manufacturer TLT Turbo Africa on December 4 launched its new sustainable monitoring and airflow response technology (SMART) Fan for mining operations.

TLT Turbo Africa debuted a demo version that it has been developing over the past six months, TLT Turbo Africa sales director Vusi Madlopha told Mining Weekly.

Following the demo launch, the company was bullish that it would be able to start full-scale production and deliver on any orders that came through by the first quarter of next year, he informed.

These would be produced at the company’s 2 700 m² warehouse facility in Pretoria, with Madlopha highlighting that a high amount of local content would be used. The offering is also customisable and the company plans to install safety controls and maintenance programmes into this. 

The SMART Fan automatically adjusted airflow to changing mine conditions, negating the need for a human interface, with this aimed to ensure safer, more efficient and more sustainable operations, TLT Turbo Africa CEO Jurie Theron explained to the publication.

TLT Turbo Africa mechatronics engineer Natascha Minges Freitas explained that the mining environment was constantly changing, owing to ever-evolving chamber geometries and layouts, leading to the need for increased duct length and changes in air density.

“What we currently have in place to provide airflow for these areas are fixed fans with a single duty point, designed to perform at peak performance for the worst-case scenarios. With no ability to run at lower flows, these fans often supply more than what is required, leading to higher power consumption,” she pointed out.

Therefore, the SMART Fan aims to solve this challenge, with the technology being a retrofit electronic control package that can be supplied with, or integrated into, any existing TLT auxiliary fan, for this to become a self-adjusting auxiliary fan system.

It was designed to autonomously control a set air flow with real-time response to any changes in mining conditions, and in so doing, optimising power use as well as improving the consistency of the air quantity safety, Freitas explained.

The SMART Fan’s core components are a variable speed drive, which is controlled by a programmable logic controller, using inputs from both sensors and user inputs.

“The SMART Fan control system uses the fan curve along with the fan laws to adjust revolutions per minute in order to deliver the desired air flow at the end of our system, therefore minimising power consumption. This system automatically compensates for the resistance change, leakage and variations in air density,” Freitas expounded.

She was the lead designer for the SMART Fan.

Theron echoed her point that one of the main benefits of the solution was long-term cost savings for mining companies.

Madlopha elaborated that between 60% to 70% of operational costs are ventilation equipment-related. “At the moment, mines are paying R1.44/kW, and any shave off from that bill is quite significant. We’ll be seeing savings of around R14-million to R20-million in any small-scale mine operation annually,” he estimated.

Madlopha highlighted that mining companies could, therefore, expect to benefit in terms of a return on investment on the fan system they bought, as well as in operational cost savings.

Benefits are also expected in terms of safety.

“Mine ventilation is designed around providing a safe environment for miners. Without reliable equipment, we will have fatalities underground. This fan guarantees operational efficiency, while also guaranteeing reliability.

“At the touch of a button, the ventilation officer would have a view of what air is available for the team underground, so that they don’t get exposed to nauseous gases and any other dust that’s underground,” Madlopha outlined.

Theron highlighted that the new offering was aligned to the company’s ethos of developing innovative solutions and promoting sustainable practices.

“. . . We continue to explore new demands out in the market, and channel our efforts towards what clients need and what will be effective. We also try and keep abreast with new technology, to be market leaders in the segment of mining and ventilation fans.”

The company was targeting any underground mining operation, especially deep-level mines where considerable control, air flow and reliability were required, with the product able to provide continuous clean airflow underground, he mentioned.

The company will also provide after-sales support, with 24/7 availability.

Moreover, the high local content ensured that parts were readily available if needed, Madlopha highlighted.