Tag Archives: Booster fans

TLT-Turbo launches new range of ‘superfans’ for mine ventilation

Environmental, Mine ventilation, Mining consumables, Mining equipment, Mining services, Power supply for mines, , , , , , ,

TLT-Turbo GmbH has redesigned its auxiliary and booster fan range to improve both efficiency and cost-effectiveness for ventilation applications in the mining industry.

The development of the new fan range concept began in early 2015, according to the company.

Following a global study to gain an understanding of the market requirements, the range was defined in mid-2017, with the fabrication of the first units taking place shortly thereafter, the global ventilation fans and systems manufacturer said.

Michael Minges, Technical Director at TLT-Turbo Africa, who headed up the fans’ designs, said: “The development of the auxiliary and booster fan range would not have been possible without the input of clients. This ensured that we focused on key market-driven requirements including energy efficiency, noise reduction, cost-effectiveness and turnaround time.

“To sell these products, we needed to ensure close customer relationships and visibility. We are striving to change the industry’s mindset on the use of such fans to ensure proper fan selection for the ventilation required. In optimising mine ventilation, efficient, high-quality auxiliary and booster fans can add as much value as surface fan installations.”

TLT-Turbo started commissioning of the first iterations of the fan range towards the end of 2017 within the Sub-Saharan market through its Africa office. From there, it based the development of the various fan sizes of the new range on market interest.

The fan range is being rolled out in phases. The preliminary testing at sites located in Sub-Saharan Africa has been launched successfully. The next phase is globalisation as the new range will be rolled out in the USA, Canada, Europe, Russia and Australia.

Following this, product supply and support will be extended to TLT-Turbo offices in South America and India. In the interim, though, Minges said these fans can be supplied to clients worldwide from TLT-Turbo Africa.

Minges said as energy efficiency is one of the main drivers of industrial equipment usage, and minimum efficiency requirements on certain equipment are often legislated, TLT-Turbo identified the need and opportunity in the market for “more efficient mining fans compared to what is currently in use”.

The new designs include several innovative additions to enhance performance in order to provide “exceptional” underground ventilation, the company said.

“The fan range was developed using the latest in engineering flow technology which allowed TLT-Turbo to improve the aerodynamics, and thus the efficiency of the fans. A unique stator design and aerodynamic fairings, all manufactured from wear-resistant composite materials, resulted in improved efficiencies and reduced noise levels.”

Meanwhile, the modularity of the fan casings allow for quick and easy assembly with interchangeable ancillary fan parts, according to the company.

“The motor mounting, in coherence with a machined impeller track, ensures low and controllable blade tip clearances for improved performance and efficiencies,” TLT-Turbo said. “Pad mount motors are used for all fan sizes and help reduce vibration levels in the axial direction of the motor significantly which leads to longer motor bearing life and lower maintenance requirements.”
Minges said all possible measures are taken to ensure the highest quality and best possible performance of every fan supplied by TLT-Turbo.

“All fans are ISO 5801 tested unless the client agrees to type testing on higher volume orders,” he said. “We ensure the client quoted performance is met before the fans leave the factory. Test certificates on both raw data and calculated performance can be provided on request.

“Fan efficiency is determined with the performance test and this quality check ensures we deliver on what we promised the client. Clients are regularly invited to witness the performance tests to sign off on acceptance. The fans also come with pressure ports that can be hooked up to a calibrated handheld measuring device to measure performance in-situ.”

In addition to performance and efficiency, ease of maintenance was also a major consideration in developing the new range.

The modularity of the product design and the interchangeable standardised parts allows for quick turnaround time on parts supply, according to the company.

“For example, we only have two blade types for the full product range and generally only one motor barrel per fan size accommodating various motor sizes and types,” Minges said.

“Standardisation on the product is the key to successfully managing maintenance and repair as it allows ample supply of spares for companies certified to do the repair work. The design track record has indicated a longer mean time between failures than previous products.”

TLT-Turbo Africa has received a number of orders for these fans since the end of 2017. These orders include South Africa clients seeking a solution for deepening a gold mine and for Kamoa Copper in the DRC as an exclusive supplier.

Minges said: “The feedback that we have received, thus far, has been that the fans are meeting our and our client’s expectations. I am proud to say that one EPC consultant used the phrase ‘superfan’ to describe the new range and indicated that he has not heard a fan of this size so quiet before.”

TLT-Turbo Africa to bring fresh air to Kamoa-Kakula copper project

Base metals, Environmental, Mine ventilation, Mineral project development, Mining equipment, Mining services, Power supply for mines, , , , , , , , ,

TLT-Turbo Africa has been awarded the contract for the supply and installation of a turnkey solution for underground ventilation and fumes extraction at the Ivanhoe Mines’ majority-owned Kamoa-Kakula copper project, some 25 km outside of Kolwezi in the Democratic Republic of Congo.

The contract was awarded by Kamoa Copper SA, which forms part of the project, a joint venture between Ivanhoe, Zijin Mining Group and the Government of the DRC.

TLT-Turbo Africa is designing, manufacturing and supplying a Bifurcated Axial Flow Fan Station for the extraction of mine fumes as well as auxiliary and booster fans for Kamoa’s underground operation, it said. The company will also oversee the installation of the fans and provide assistance with commissioning. The project is the first of many of strategic importance within the Sub Saharan Africa region that the company is involved in, TLT-Turbo said.

The contract was secured in October, with commissioning due to begin in July. TLT-Turbo Africa was appointed by DRA Projects, which is handling engineering, procurement, and construction management (EPCM) on the project, the company said.

Kamoa Copper SA will develop the new copper mine, which is expected to yield an estimated 6 Mt/y in its first phase alone. The Kakula deposit has been independently ranked as the world’s largest, undeveloped, high-yield, high-grade copper discovery, according to DRA, with a resource measuring 174 Mt at an average grade of 5.62% Cu.

According to TLT-Turbo’s Madeleine Pretorius, the project presents unique challenges from a logistical point of view. The site is remote, and it involves multiple border crossings and often poor road conditions. “This means complicated logistic solutions. TLT-Turbo has the benefit of a broad suite of options to minimise the need for abnormal or complex loads,” she said.

The TLT-Turbo Africa offering and approach positions them as a preferred supplier for ventilation solutions in challenging locations, according to Pretorius. “We provide an energy-efficient solution where power costs are high, and availability can be erratic. Our product is designed for long-term reliability and durability, with simple maintenance requirements and minimal downtime, which is critical for our remote clients.”

Mike van Oerle, Sales Manager at TLT-Turbo Africa, said the company’s approach will provide several benefits to Kamoa’s operations. This includes standardised equipment designed for simple installation and maintenance, which means TLT-Turbo’s fans can be maintained by the client on site, without the need for costly expert inspections. “TLT-Turbo is providing highly-efficient products to meet Kamoa’s interim ventilation and power requirements, with flexibility for future redeployment at an alternative ventilation position.”

Both van Oerle and Pretorius assert TLT-Turbo Africa’s delivery of the scope of work on this specific project speaks to the company’s wider capabilities and expertise. The collaboration with DRA has paved the way for excellence in service delivery, according to them. Pretorius said: “Working with an experienced EPCM company, such as DRA, our project team is able to draw on their unparalleled knowledge of the Sub Saharan African mining environment. Both teams work together to provide solutions that address the challenges experienced by our customers.”

Oerle concluded: “Our ability to understand our customers’ requirements led to a cost-effective solution, focusing on total cost of ownership. Combining this solution with an experienced projects execution team, means that we can ensure Kamoa receives high-quality products and on-time delivery.”