Ventilation is one of the most energy-intensive systems in an underground mine, yet it is often operated far below its optimized potential. As mines digitize their operations, ventilation automation is no longer a binary choice between manual control and full Ventilation on Demand (VoD). Instead, it is a stepwise journey, where each level builds on the previous one.
This article proposes a five-level automation pyramid for mine ventilation systems, helping operations understand where they stand today and what capabilities are unlocked at each stage.
Level 1: Remote Control of Ventilation Assets
At the base of the automation pyramid lies basic control. This first level puts fans, soft starters, variable frequency drives (VFDs), and regulators and shutters under remote operation, so assets that were traditionally handled locally can be started, stopped or adjusted from a control system.
Decision-making stays manual, but the groundwork matters. Operators stop travelling underground to turn things on and off, response times shorten, and control moves into the control room. It is also where air demand first gets chained in a parent and children tree architecture, which is what stops you pulling a vacuum or blowing out ducts.
Ventilation behavior is still reactive and operator-driven at this point, with limited consistency across shifts or crews.
Level 2: Scheduling and Macros
The second level marks the true beginning of automation. Digital control systems bring in scheduled actions, meaning planned fan or shutter commands, along with macros or rule-based sequences and the ability to drive several ventilation assets at once.
Instead of issuing individual manual commands, operators trigger predefined actions that would otherwise be repetitive: raising airflow for a planned production shift, dropping it during a maintenance window, running a standardized startup or shutdown sequence.
This is still largely static and not data-driven, but it introduces repeatability, predictability and operational efficiency, which are prerequisites for anything above it. Mostly it is a quality of life step, and it often comes bundled with Level 1.
Level 3: Sensors and IoT-Driven Reactions
Level 3 is where ventilation systems begin to respond to real-world conditions. Data from airflow sensors, gas sensors, environmental monitoring devices and basic equipment telematics gets integrated into the control logic.
Against predefined thresholds, the system acts on what it measures: raising airflow as gas levels approach limits, adjusting regulators from measured air velocity, running safety routines when something abnormal shows up.
How well this works depends heavily on data availability and quality. The more relevant data you can gather and trust, the more efficiently the ventilation system reacts.
Level 4: Ventilation on Demand (VoD)
Ventilation on Demand represents a shift from reactive control to operational optimization. The ventilation system gets integrated with higher-level platforms: real-time location systems (RTLS), fleet management systems (FMS), personnel and asset tracking, and telemetry.
Once you know where people and equipment are and what they are doing, airflow can go only where and when it is required, sized to what that equipment actually needs. Safety requirements still get met, inactive areas stop being over-ventilated, and energy consumption drops significantly.
Rather than ventilating the entire mine at peak capacity, airflow is aligned with real demand, which is what makes VoD a major milestone in both sustainability and cost control.
Level 5: Optimization and Simulation Through Telematics
The highest level of the pyramid focuses on continuous optimization and predictive capabilities. Using advanced telematics and data streams, ventilation demand is modulated in real time from how assets are actually operating rather than from the fixed fan manufacturer curve. The curve itself adapts to real-world data: engine ignition signals, operating modes such as idle, tramming and loading, and utilization and duty cycles.
With that insight, airflow gets adjusted not just on location but on actual emissions and activity intensity. Beyond real-time control, the accumulated data supports scenario simulation, demand forecasting, what-if analysis for production planning, and ventilation curve adjustments driven by airflow sensor feedback.
This level transforms ventilation from a support system into a data-driven optimization lever for the entire operation.
A Progressive Journey
Ventilation automation is not an all-or-nothing proposition. Each level of this pyramid delivers tangible operational value while laying the groundwork for the next stage. Understanding where their current systems sit lets mining operations prioritize investments, reduce implementation risk, and build toward VoD and optimization in a structured, scalable way.
The most successful automation strategies are the ones that treat ventilation as an evolving system, one that grows smarter as data, integration and operational maturity increase. VoD is often added once energy savings become critical for energy capacity and cost reduction, but it can deliver savings from the beginning of the mine’s life. These systems evolve and scale with the mine.
Typical Mine Maturity Across the Pyramid
In practice, most underground mines currently operate between Level 1 and Level 3 of the ventilation automation pyramid. While many operations have implemented remote control and some level of sensor-based reaction, full Ventilation on Demand integration remains less common due to the complexity of integrating fleet management systems, location tracking, and ventilation controls.
However, as mines deploy more connected equipment and operational data platforms, the transition toward Level 4 and Level 5 capabilities is accelerating.
This reinforces the importance of viewing ventilation automation not as a single project, but as a progressive operational journey.
Working out where your own operation sits on this pyramid, or what the next level would actually take? That’s the kind of evaluation I do. Get in touch. No pitch.
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