Maximizing energy savings in coal mines industrial ventilation: strategies and analysis for power reduction

Discussion about affinity laws to optimize fan speed in underground mining ventilation systems. A 10% reduction in fan speed saves roughly 30.59 kW, a 50% reduction of 97.03 kW, and yearly savings ranging from Rs 368,456 to Rs 2,337,453. The fan speed drop improves mechanical wear performance, doubles bearing life at a 20% drop in speed, and increases motor longevity. © The Author(s) 2025.; In underground mining, ventilation systems account for a significant portion of total power consumption. In this study, axial fans have been considered a primary target for energy-saving strategies. Affinity laws have been applied to analyze the energy-saving potential of axial fan speed reduction in underground mining ventilation systems. Real-time data monitoring was conducted to assess fan performance, energy consumption, and mechanical behaviour. Mathematical models were developed to evaluate the effects of speed reduction on mechanical wear, bearing life, and motor longevity. The results demonstrate that reducing fan speed by 10 and 50% save approximately 30.59 and 97.03 kW of power respectively and annual savings range from Rs 368,456 to Rs 2,337,453, depending on operational hours. Additionally, reducing fan speed improves mechanical wear performance, nearly doubles bearing life at 20% speed reduction, and significantly extends motor lifespan. By reducing fan speed using VFDs, substantial energy savings, improved equipment longevity, and lower operational costs can be achieved, contributing to both economic and environmental goals in mining operations. © The Author(s) 2025.