Preliminary ventilation design

for the Grasberg block cave mine

Ian Duckworth, Technical Expert Ventilation, Ketut Karmawan, Superintendent Ventilation,
P.T. Freeport Indonesia, West Papua, Indonesia
Timothy Casten, Senior Manager of Underground Planning, Freeport-McMoRan Copper & Gold Inc.

Abstract
P.T. Freeport Indonesia operates a mining complex located in the highlands of Papua, Indonesia. This complex consists
of both underground and surface operations. By approximately 2014 the existing Grasberg open pit will be exhausted,
and a new underground mine will have been brought into production to cave the deposit below the pit. This paper
describes pre-feasibility ventilation planning for the Grasberg Block Cave Mine. The mine is being designed based on a
nominal production rate of 115,000 tonnes/day with a panel caving footprint of approximately 1 km by 1 km. The
proposed ventilation design allows for the long production panels to be broken into five discrete ventilation zones, and
ensure the economic delivery of large volumes of air to the working regions. Discussion is provided on ventilation criteria,
network modeling, examination of shaft versus drifting options, proposed infrastructure requirements, and
recommendations for future study.

1 BACKGROUND ON PTFI mine support services will utilize diesel-powered mobile

P.T. Freeport Indonesia’s (PTFI) project site is located in
the Sudirman Mountain range of Papua (formerly Irian
Jaya). West Papua is the Eastern-most province of
Indonesia, which occupies the Western half of the island of
New Guinea.
PTFI acquired and have been developing the Ertsberg
district since 1967. The presently known ore reserves are
located approximately 100 km North of the Southwest coast
of Papua, between elevations of 2,800 m and 4,000 m
above sea level.
Total ore tonnage has increased from 15,000 tonnes/day
(tpd) in 1978, to 60,000 tpd in 1992, to the present tonnage
of about 230,000 tpd. At the time of writing this paper
approximately 45,000 tpd is being produced from the DOZ
Block Cave Mine. Present reserves consist of six copper-
gold-silver orebodies and several other resources located
within a 15-kilometer square area.
The Grasberg porphyry copper-gold deposit possesses
the world’s largest gold deposit and is among the five largest
copper deposits in an operating mine. The present reserves
for the Grasberg ore body are about 1.7 billion tons.
2 GRASBERG BLOCK CAVE MINE
equipment. Due to relatively cool virgin rock and ambient air
temperatures, mechanical cooling or heating of the air will
not be required. The main access for men and materials will
be via the AB Tunnels and a Service Winze.
The GRS BC operation will include the following
components:
• An 8 km long light rail passenger/freight system connecting
a surface station with an underground terminus. This supply
tunnel will also provide for three other proposed mines,
called the MLZ Block Cave Mine, Kucing Liar Block Cave
Mine and the Big Gossan Sublevel Stope Mine. It is likely
that all these operations will be developed during the period
of the GRS BC mine life.
• An underground crushing system with twin conveyor drifts
linking the crusher bins/feeders to the surface milling
facilities.
• A concrete-lined Service Winze with man cage providing
access between the rail terminus and block cave
operation. The length will be approximately 300 m.
• Single ramp linking the GRS BC rail terminus with the
orebins/conveyors and the production levels.
• Block cave operation consisting of 2840 m Undercut,
2820 m Extraction and 2790 m Service Levels (elevations
above sea level).

The Grasberg open pit is scheduled to cease production
in 2014. Since the orebody continues at depth below the
economic limits of surface mining, the reserve that is left
behind will be extracted using block-caving methods.
Development of the Grasberg Block Cave Mine (GRS BC)
is scheduled to commence during 2008 and will be
accessed via the Ali Budiardjo (AB) Tunnel system. The
mine will be a mechanized block caving operation with a
nominal production rate of 115,000 tpd. The option for an
increased production rate of 160,000 tpd was also
considered in the planning and design.
The GRS BC will be a high-tonnage mine utilizing electric
ore handling equipment on both the Extraction and Rail
Haulage Levels. Caving, development, pre-production and
2.1 GRS BC Design Overview
The mine design for the GRS BC utilized the VulcanTM
mine planning package. Output from VulcanTM was
imported to the VnetPCTM 2000 ventilation simulation
program to develop a three dimensional network
representation. Figure 1 shows a general isometric view of
the proposed GRS BC. This network includes all
components such as the tunnel access, ramp, Service
Winze and conveyors. Figure 2 shows a plan view of the
Extraction Level for the GRS BC. For 115,000 tpd there will
be approximately 870 active drawpoints that will be brought
online as the cave moves from the Northeast towards the
Southwest. The ventilation and track drifts comprise the
underlying Service Level. The Undercut Level overlies the

724 Santiago Chile, 22-25 August 2004 Massmin 2004

Figure 1. Schematic showing the layout of the GRS BC.
Extraction with the same general footprint. A schematic
layout of the proposed ventilation system for the Extraction,
Undercut and Service Levels is shown in Figure 3. The
airflow is delivered and exhausted via the ventilation service
drifts on the 2790 m Service Level. There will be four groups
of three service drifts, with each group comprising two
parallel ventilation drifts (intake or exhaust) and one-track
drift. Each group of service drifts will be connected to every
Extraction panel by two 4 m diameter smooth raises. One
raise will serve as a chute, and the other for ventilation. The
ventilation service drifts and connection raises allow the full
width of the Extraction Level to be segmented into five
separately ventilated zones.
The Undercut Level will be discretely ventilated. To avoid
the requirement for many ventilation raises interconnecting
the Undercut and Extraction Levels, two ventilation drifts will
be driven across the Undercut Level ahead of caving. These
drifts will be connected down to the Service Level exhaust
at the West end. As caving progresses, intake air will be
brought around the cave using temporary fringe drifts and
Figure 2. Plan view of 115,000 tpd Extraction Level with
underlying rail loops.
Massmin 2004 Santiago Chile, 22-25 August 2004
advance Drill Drifts (DDs). Auxiliary ventilation will be used
to supply air to the active DD headings from the perimeter.
The air will be exhausted via the advance Undercut
ventilation drifts as shown in the sketch. The Service Level
track drifts will be ventilated in the opposite direction to the
Undercut, which will help balance the air velocity through
the intake and exhaust service drifts.
The GRS BC area will be supplied and exhausted with air
via primary intake and exhaust drifts. To facilitate the large
quantity of air required, there will be four main intake drifts
and four exhaust drifts as shown in Figure 1.
2.2 Ventilation Design Criteria
PTFI adopt certain ventilation criteria to assist with
underground mine planning. Tables 1 and 3 present some of
the criteria that have been established based on Indonesian
Mining Regulations (Decree of the Minister of Mines and
Energy 1995), US Mine Safety and Health Administration
Figure 3. Sketch showing the proposed GRS BC ventilation
system.
725
(MSHA), and good engineering practice. Although the
Table 2. Atkinson friction factors.
design criteria do not specifically address diesel
particulates, PTFI has a comprehensive program in place to
Description Friction Factor (kg/m3)
monitor and minimize diesel particulates in all underground
Actual* Stnd
areas. This program integrates baseline monitoring of
worker exposures with reduction initiatives, including fuel
9 m2 to 15 m2 XSA - Drifting 0.0102 0.0132
changes, upgrade of equipment to tier-rated engines, and
15 m2 to 20 m2 - Drifting 0.0093 0.0120
increased ventilation. Table 2 provides a list of the Atkinson
20 m2 to 30 m2 - Drifting 0.0083 0.0107
friction factors used for the ventilation design. These values
30 m2 and Up - Drifting 0.0074 0.0095
have been obtained from detailed friction factor tests
conducted in PTFI’s existing underground operations, and Conveyor Drift (with 2.1 m Belt) 0.0093 0.0120
hence there is a good level of confidence in the data. Primary Raise – 6.0 m f+ 0.0074 0.0095
2.3 Airflow Requirements Typical ALIMAK Rse – 3.0 m f+ 0.0111 0.0143
Table 4 provides an estimate of the airflow requirements Drop Ventilation Rse+ 0.0148 0.0191
for the GRS BC operating at 115,000 tpd. This includes a
comprehensive list of all mobile equipment, with actual * At average mine air density = 0.93 kg/m3
engine power and estimated operating factors. To provide + Does not include shaft/raise entry and exit losses
for an economic ventilation design, every attempt has been
made to reduce the amount of diesel equipment operating in
the mine, and a significant component of the production Table 3. Other ventilation design criteria.
operation will be run remotely using automation techniques.
Major contaminant producing areas of the mine such as the Criterion Value*
crusher stations and shops will be established on separate
air splits direct to exhaust. The rail haulage and chute Min. Airflow per 100 Workers 7.1 m3/s
loading systems will be fully automated from a remote Design Airflow per 100 kW Diesel 7.9 m3/s
control station. The nature of the Extraction Level lends
itself to automation of the loader fleet although at this level Shops and Facilities – Exhaust
of the study it has been assumed that all mobile equipment Diesel Equipment Shop 40.1 m3/s
on the level will have an operator. Lube/Fueling Shop 28.3 m3/s
The total airflow estimate for the mobile equipment is "Hot" Shop or Rock Breaker Stn 23.6 m3/s
about 627 m3/s. The requirement for the active Extraction Explosives Magazine 9.4 m3/s
and Service Levels is 736 m3/s. Other fixed allowances Common Gas TLVs
include four shops, with a total airflow of 161 m3/s Oxygen > 19.5%
exhausting directly to return ventilation drifts. There is an Carbon Dioxide TWA=5,000 ppm
additional 189 m3/s intaking the AB Tunnels which is Carbon Monoxide TWA=50 ppm
exhausted via the GRS BC conveyors. This ventilation split STEL=400 ppm
requires an underground booster fan. Based on this list, the Hydrogen Sulfide TWA=10 ppm
total airflow provision for the mine, excluding leakage and Nitrogen Dioxide STEL=5 ppm
balancing, is about 1,755 m3/s. Sulfur Dioxide TWA = 2 ppm

2.4 Ventilation Modeling and Infrastructure *TWA = Time Weighted Average for 8-hr working shift
Ventilation analyses were conducted which included STEL = Short Term Exposure Limit for 15 minutes
modeling the GRS BC during two different phases in the
proposed mine life. The analyses took into account all
anticipated air leakage paths (doors, bulkheads, old panels, The basic ventilation model was established as shown in
etc.) to provide a realistic representation of the mine. The Figure 1. The model was adapted to simulate two different
modeling incorporated the AB Tunnel system and made scenarios:
allowance for interconnection with the proposed Big Gossan • Production from the first 12 panels, with a further 4 panels
and Kucing Liar Mines. The analyses assume primary under development or construction.
underground exhaust fan installations close to the main portals. • Final (most Westerly) 4 panels are under development or
construction, with the 12 adjacent panels in production.
The center of mining has shifted to the West, and leakage
Table 1. Air velocity design criteria. in the system has increased (termed Mature Mine.)
The predicted fan requirements for these two scenarios
Airway Air Velocity (m/s) are given in Table 5. For the early mine the total airflow is
Min Opt Max predicted to be 1,813 m3/s. Based on a nominal daily
tonnage of 115,000 tpd this equates to 0.0158 m3/s/tpd. The
Conveyor Drifts total installed fan motor power requirement is about 7,200
- Homotropal 0.8 2.0 4.0 kW with a predicted annual power cost of US$2,836,000.
- Antitropal 0.8 1.0 2.0 These values assume 75% efficiency for the main fan and
Truck Haulage Drifts 0.8 4.1 6.1 motor installation. For the mature mine the total airflow
quantity increases to 1,888 m3/s, or about 0.0164 m3/s/tpd.
Primary Ventilation Drifts 0.8 8.1 10.2
This is higher than the value shown in Table 4 due to the
Rough Large Raises (+4 m) - 14.2 19.8 system leakage. As a result of the efficient layout for the
Typical ALIMAK Raise - 12.7 19.8 ventilation system, with few connections between intake
and exhaust, the predicted leakage is less than 10%.
Drop Ventilation Raise - 6.6 19.8 The installed fan motor requirement for the mature mine
increases to 8,660 kW, with a projected annual operating
- Optimum values are used for design purposes. cost of about US$3,414,000. Both of these operating
- Velocity criteria are based on an economic assessment characteristics (Early and Mature cases) will be achievable
factoring in power and development costs. with the same fan installations.

726 Santiago Chile, 22-25 August 2004 Massmin 2004

 Table 4. Airflow Required - 115,000 tpd. Table 5. Predicted fan requirements
for 115,000 tpd operation.
Nº Op. Unit airflow Total
Factor Pow. per Unit Airflow Scenario/ Total Pres Quantity Input Pow Op. Cost.
(%) (kW) (m’/s) (m’/s) Location (Pa)* (m3/s) (kW)* (US$/yr)+
Mobile Equipment
Early Mine
LHD 6.0 m3 (Dev.) - Dsl 8 70% 186 14.7 82.6
Main Exhaust 2,990 1.624 6.474 $ 2,552,000
Truck 40 t (Dev.) - Dsl 3 80% 354 28.0 67.3
Booster Installation 2,860 189 721 $ 284,000
Drill Jumbo (Dev.) 5 30% 58 4.6 6.9
Totals For Mine - 1,813 7,195 $ 2,836,000
Production Drills 6 30% 113 9.0 16.1
Rock Breaker 13 30% 123 9.7 38.0
Mature Mine
LHD 6.0 m3 - Electric 45 80% - - -
Main Exhaust 3,490 1,699 7,906 $ 3,117,000
Truck 30 t (Dev.) - Dsl 8 70% 224 17.7 99.1
Booster Installation 2,990 189 753 $ 297,000
Drill Jumbo (Sec. Breaking) 16 60% 43 3.4 32.3
Totals For Mine - 1,888 8,659 $ 3,414,000
Commando Sec. Breaking) 26 60% 36 2.8 44.2
Drill Jumbo (Rockboting) 2 30% 42 3.3 2.0
* Systems pressure to be met by fan. Does not incluide fan llosses.
LHD 2.7 m3 (Clean-up) - Dsl 2 50% 138 10.9 10.9
* Assumes 75% efficiency for fans and motors
Scissor Lift 12 30% 61 4.8 17.4
+ Assumes 0.045 US$/kWh
Explosives Truck 4 70% 123 9.7 27.3
U/G Road Grader 3 30% 112 8.8 8.0
Shotcrete Jumbo 5 30% 58 4.6 6.9
Shotcrete Truck 10 30% 57 4.5 13.6
U/G Lube Trucks 6 30% 115 9.1 16.4
U/G Boom Truck 4 75% 115 9.1 27.3
U/G Flatbed 7 75% 115 9.1 47.7
U/G Service Truck 4 30% 115 9.1 10.9
U/G Electrical Truck 6 30% 115 9.1 16.4
U/G Fork Lift 4 15% 32 2.5 1.5
u/G Personmel Carrier 10 30% 115 9.1 27.3
U/G Tractor (General) 10 30% 24 1.9 5.7
U6G Tractor (Engineering) 2 30% 24 1.9 1.1
Rail Haulage Locomotives 8 80% - - -
Subtotal Mobil Equipment 626.7
Fixed Allowances
Development Panel Segment 45 100% - 14.2 637.2
Rail Haulage Drives 3 100% - 33.0 99.1
Personnel 600 100% - 0.1 42.5
Maintenance Shop 4 100% - 40.1 160.5
Crusher Bins and Belt Drifts 2 100% - 94.4 188.8
Subtotal 1.128.1
Figure 4. Relative pressure profile for the 115,000 tpd
Total Airflow Required 1.755 mature mine case.

The following drift sizes have been determined for the
115,000 tpd design (all ventilation drifts will be fully
shotcreted):
• Primary Ventilation Drifts from Portals to Service Level =
6.8 ¥ 6.8 m
• Ventilation Service Drifts below Extraction = 5.5 ¥ 5.5 m
• Ramp and Access Drifts = 4.5 ¥ 5.0 m
• Conveyor Drifts = 4.5 ¥ 5.0 m
• Extraction panels = 4.5 ¥ 4.5 m
• Undercut DDs = 3.6 ¥ 4.2 m
• Panel Raises = Raise-bored at 4 m diameter
• Service Winze = Smooth 8.5 m diameter
Figure 4 shows a graph of the relative pressure profile for
the mature mine case.
The relative pressure for this case is the difference
between ambient (surface) and locations underground. For
the profile a typical circuit has been chosen through the
mine, and the trend line plotted against linear distance
covered, including ventilation raises. The circuit chosen
was: intake portals Æ primary intake drifts Æ service intake
drifts Æ far Western panel region Æ service exhaust drifts
Æ primary exhaust drifts Æ underground primary exhaust
fans Æ exhaust portal. The trend is considered excellent,
remaining generally linear and averaging about 333
Pa/1,000 m. The one short steep section represents the
"open-split" in the ventilation circuit where the air exhausts
from the development panel region to the service exhaust
drifts. A linear profile is indicative of balanced air velocities
and frictional pressure losses, suggesting that drift and raise
sizes and numbers are correct for the system.
2.5 Adits Versus Shafts Design Comparison
A ventilation study was conducted comparing adits versus
shafts for the primary mine infrastructure. An initial shaft
layout was developed in which the intake air is brought
down two concrete-lined 7.5 m diameter shafts into the
orebody area and back out two similar 7.5 m diameter
exhaust shafts to surface. Due to the mountainous
topography, the shafts would be approximately 1.0 km long.
In order to place the shafts far enough away from the cave
influence, primary intake and exhaust drifts would still be
required, with each drift about 1,500 m long. It was assumed
that two sets of four drifts will be developed at 6.8 ¥ 6.8 m
connecting the shafts to the production area.
The maximum velocities for the 7.5 m diameter shafts
would be 18 m/s, which is 25% higher than the economic
optimum velocities used as the current basis of mine design
(see Table 1). However, it is noted that the economic
velocity given in the table is for a rough shaft (2.1 m bored
then slashed to size), not a fully concrete lined shaft, which
will be considerably more costly to construct per meter, and
have a higher optimum velocity.

Massmin 2004 Santiago Chile, 22-25 August 2004 727

 The shaft study showed approximately US$69 million in
Table 7. Fan comparison –
capital allocated to sink the intake and exhaust shafts and
115,000 tpd versus 160,000 tpd (mature mine).
develop the shorter drifts. The adit option required
approximately US$46 million in capital.
Scenario/ Total Pres Quantity Input Pow Op. Cost.
The mature mine 115,000 tpd scenario was used for a fan
Location (Pa)* (m3/s) (kW)* (US$/yr)+
power cost comparison. The results are provided in Table 6.
These results indicate that there is a significant power
115 ktpd Case
savings (approximately US$580,000/yr) associated with
Main Exhaust* 3,490 1,699 7,906 $ 3,117,000
drifting compared to shafts.
Booster Installation 2,990 189 753 $ 297,000
Totals For Mine - 1,888 8,659 $ 3,414,000

Table 6. Power cost comparison – 160 ktpd Case

drifting versus shafts. Main Exhaust 3,240 2,124 9,176 $ 3,617,000
Booster Installation 2,620 189 660 $ 260,000
Scenario/ Total Pres Quantity Input Pow Op. Cost. Totals For Mine - 2,313 9,836 $ 3,877,000
Location (Pa)* (m3/s) (kW)* (US$/yr)+

Shafts 3 RECOMMENDATIONS FOR FURTHER STUDY

Main Exhaust* 4,110 1,699 9,311
Booster Installation 3,240 189 816
Totals For Mine - 1,888 10,127
Drifts and Portals
Main Exhaust 3,490 1,699 7,906
Booster Installation 2,990 189 753
Totals For Mine - 1,888 8,659
* Atk. friction factor = 0.0037 kg/m3 (o.0048 kg/m3 stnd) for shafts
In addition to the economic benefits, the drifting option
was considered to have certain other advantages, including:
• Shafts require specialized equipment and crews to sink.
Drift development will be spread over the mine ramp-up
years with multiple headings.
• Shafts require specialized maintenance equipment and
trained crews. Repairs typically require a long time frame.
• Historically PTFI has encountered water in long vertical
shafts. In an exhaust shaft this counter-current water flow
acts as a permanent drag and increases resistance. In
such a long shaft it may also result in "blanketing" and
cyclic loading (even potential fatigue) of the fans.
• The fan installations will be more accessible for
construction, maintenance, inspections and power
delivery if placed near the proposed portals. Longer-term,
access to the shaft collars would be difficult being close to
the final cave line and remote from other mine facilities.
• In the case of an emergency, personnel can quickly
egress to a fresh air intake and if required walk completely
out of the mine using that primary escapeway.
• The drifts provide large tunnel diameter access to the
mine for occasional oversize pieces of equipment that
could potentially disrupt the tunnel rail system.
2.6 160,000 tpd Comparison
Ventilation analyses were also conducted assuming an
expanded production rate of 160,000 tpd. The simulation
incorporated an updated equipment list, and the number of
panel segments in production increased from 45 to 62. This
change resulted in an increase in the main fan airflow to
2,124 m3/s, with a total mine airflow of 2,313 m3/s (when
including the GRS BC oreflow ventilation system). Certain
infrastructure sizes were increased as follows:
• Primary Vent. Drifts = 6.5 ¥ 9.5 m
• 2790 m Vent, Service Drifts = 5.5 ¥ 6.5 m
Table 7 provides a comparison of the main fan operating
requirements for both the 115,000 tpd and 160,000 tpd
cases. Although the total airflow increases, there is an
actual reduction of about 0.002 m3/s/tpd. The fan pressures
are reduced slightly due to the increased drift sizes.
$ 3,670,000
$ 322,000 The work contained in this publication supports a pre-
$ 3,992,000 feasibility design of the GRS BC operation. As the study
progresses to feasibility level a more detailed analysis will
be conducted. Certain ventilation issues have been
$ 3,117,000 identified for special consideration.
$ 297,000
$ 3,414,000 3.1 Mine Total Airflow
The total predicted airflow in the mine is 1,888 m3/s,
which corresponds to approximately 0.016 m3/s/tpd.
This compares to about 0.028 m3/s/tpd for the existing
DOZ Mine ventilation system. The value for the GRS BC
Mine is significantly lower than this, however the
contaminants in the mine are expected to be less than
those presently encountered. The GRS BC will
incorporate electric panel loaders, electric oreflow
handling, low emission diesel development equipment
operating on underground mine fuel, and significantly
reduced Undercut drilling (room-and-pillar undercutting
methods). When combined it is anticipated that these
changes will allow compliance with gas and diesel
particulate criteria, however it will be important to
continue to revisit and revise airflow requirements as
the design progresses.
3.2 Airflow Control
One of the main ventilation challenges faced by
operators of large mines is control of airflow. This can be
particularly difficult in caving operations where there are
multiple open parallel splits. On Extraction Levels the
problem is compounded in longer panels, which often
have more than one ventilation zone. Experience at
PTFI suggests that automated regulation of the panel
raises on the Extraction Level will be difficult due to
damage from equipment and drawbell blasting activities.
Hence it is likely that remotely controlled heavy-duty
regulators will be designed and installed on the Service
Level.
3.3 Dust and Diesel Particulates
Control of dust in block cave mines can be extremely
challenging. Approximately 230,000 tpd of ore are presently
moved through PTFI’s site operations via loaders, trucks,
crushers, belts and orepasses. In certain areas, such as
panel drifts, belt transfers, orepass head chutes and
stockpiles particular attention must be given at the design
stage to ensure compliance with dust Threshold Limit
Values (TLVs). This may consist of a comprehensive plan
incorporating weather station data, belt moisture sensors,
foggers and sprays tied to the mine PLC network. The mine
design will also have to ensure compliance with MSHA’s
diesel particulate TLV, and as such the fuels, equipment,
and ventilation will factor this in.

728 Santiago Chile, 22-25 August 2004 Massmin 2004

3.4 Fans
The predicted main fan operating requirement is 1,699
m3/s at 3.5 kPa fan total pressure, which corresponds to 425
m3/s per exhaust drift. This assumes a single primary
exhaust fan installation. Further work will evaluate the
potential advantages of primary forcing fans and a push-pull
system with both primary forcing and exhausting fans. The
characteristic of 425 m3/s per drift can be achieved with
either centrifugal fans (portal structure) or underground axial
fans (vane or mixed-flow). The power demand will be high,
but it is anticipated that losses can be kept to a minimum
through careful design of the fans, layout, and electrical
supply. The underground booster fan for the conveyor drifts
is sized at 189 m3/s at 3.0 kPa fan total pressure. A similar
sized fan would also be required to handle the airflow
exhausting from the proposed Kucing Liar Mine oreflow
area.
3.5 Air Velocity
The airflow quantity in the twin exhaust conveyor drifts is
about 378 m3/s, corresponding to an air velocity of
approximately 6 m/s. This exceeds the maximum design
velocity of 4 m/s for a homotropal conveyor system. During
further study the GRS BC oreflow ventilation system will be
examined. It may be possible to significantly reduce the
airflow exhausting the belts, or even intake the belts with a
dedicated exhaust to the primary mine fans.
Depending on the active segment layout, the air velocity
at the East end of the service ventilation drifts may become
high (exceed 10 m/s). However, when considering the entire
length of these collection drifts the pressure losses are not
excessive. It is planned that the two ventilation drifts in each
set of three service drifts will be aerodynamically connected
with equalizing cross-cuts.
3.6 Upcast Air
In the ventilation design airflow upcasts both the lower
ramp and Service Winze. Based on experience at PTFI it is
likely that condensation will occur with the upcast air
(Calizaya et al. 2002). In the ramp this can result in fogging
and poor visibility. In the shaft this can cause fogging, water
collection, and in some cases more rapid deterioration of the
fixed facilities. For the shaft it would be possible to downcast
intake air. Further study will be devoted to the determination
of shaft resistances and the dynamic effects of cage
movement, and the optimization of airflow in the shaft. For
the lower ramp fixed fan-heaters may be required to dry the
air and maintain good visibility. Heaters have been used to
good effect in existing PTFI underground ramp systems.
3.7 AB Tunnels and Mine Fire
Approximately 189 m3/s is predicted to intake the lower
mine section from the AB Tunnels. This air then either enters
the ramp, Service Winze, and shop facilities (dedicated
exhaust). This represents a significant volume of air, with a
tunnel air velocity of about 5.7 m/s. During future study the
airflow requirements for the tunnels will be more accurately
determined, incorporating fire simulation to determine
contaminant spread in the event of a tunnel vehicle fire. Fire
Massmin 2004 Santiago Chile, 22-25 August 2004
analysis is an essential component of an overall mine
design. For the pre-feasibility design fire mitigation and
control philosophies were incorporated into the mine plan.
More detailed "hot-flow" fire analyses will be conducted as
the design progresses. For the preliminary design PTFI has:
• Made provision for all shops and hot-work areas to be
directly ventilated to an exhaust airway and to be
equipped with isolation fire doors.
• All conveyor belts will have independent airflow splits
directed to the belt portals, and will be equipped with
smoke sensors and fire-suppression deluge systems.
• The air from the AB Tunnels will be used for the lower
ramps, and will exhaust via the conveyor drifts. This air
will not enter any of the production areas.
• The air from the upper ramps will be used for ventilating
the conveyor drifts, and will not enter the block cave
working areas.
• Air critical velocity values (per Froude number analysis)
will be sufficiently high throughout the ramps as to prevent
backlayering of smoke against the direction of airflow in
the event of equipment fire. This is necessary to ensure
predictable smoke spread and provide a non-
compromised fresh air base for fire fighting.
4 CONCLUSIONS
The GRS BC will be a very large mine that will provide
many unique engineering challenges. It is anticipated that
like most block cave operations, there will be issues
associated with the balancing of the air, especially through
the production panels. Particular attention will also need to
be given to the integration of dust and diesel particulate
control strategies and systems within the ventilation design.
However, it can be stated that for a pre-feasibility study, the
proposed GRS BC Mine layout integrates good ventilation
design. The predicted pressure losses and air velocities
generally agree with PTFI optimum design criteria, and peak
values are within acceptable economic and operational
levels. When considering operating cost, there is a definite
benefit in developing the mine with portals, rather than
intake and exhaust shafts, and the drifting option has been
selected as the base case.
5 ACKNOWLEDGEMENTS
The authors would like to thank PTFI Management for
allowing publication of this paper.
REFERENCES
• Calizaya, F., Karmawan, K. & Wallace, K.G. 2002.
Utilization of Heater Fans to Control Mine Atmospheric
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NA/US Mine Ventilation Symposium. The Netherlands:
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