Christo Visagie, Managing Director at Vuma Software, outlines how real-time underground conditions can be determined and managed using digital twins and ventilation-on-demand.
The concept of digital twins can sound abstract, but in mine ventilation, it has already become a practical tool. When detailed simulation models are paired with live sensor data, operators gain a reliable, real-time picture of underground conditions, such as shifting airflow, temperature changes, contaminant movement, and equipment relocation. Instead of snapshots or intuition, they see how the mine behaves moment-to-moment, with a clear view of expected versus actual performance.
This visibility sharpens decision-making, as anomalies surface earlier, scenarios can be tested before anything is physically adjusted, and emergency responses become faster and more informed. Fan and cooling settings, schedules, and maintenance windows move from educated guesswork to model-supported, data-driven choices.
Critically, a digital twin delivers a reliable, real-time view of what the ventilation system is actually delivering underground, rather than isolated sensor readings or a static model. It blends a calibrated simulation with live measurements of airflow, temperature and air quality, allowing engineers to compare expected and actual performance and understand the impact of any adjustment before it is implemented.
Beyond optimisation
In a Ventilation-on-Demand (VoD) environment, the value of a digital twin extends beyond optimisation. It supports active ventilation management by helping to optimise the supply, routing, and distribution of air within safe limits, rather than forcing primary fans to chase a theoretical ‘optimal’ setpoint continuously.
A common early-detected anomaly is an unexpected shift in ventilation balance, caused by a fan trip, a door left open, or a fan starting or stopping elsewhere in the network. Manual VoD, set once at the start of a shift, will not detect this quickly, but real-time monitoring flags the deviation immediately, enabling faster intervention.
Beyond sudden shifts, slow-burning risks also demand attention – air quality drifting the wrong way, rising dust or gas levels and increasing heat load. Real-time VoD or VUMA (ventilation simulation software) surfaces these patterns early, highlighting potential compliance or safety risks before they escalate. The real value lies in linking alerts to a clear control philosophy, especially when stagnant air or gas ingress is a risk.
Effective digital twins start with instrumentation: smart sensors, actuators, and remote starters to measure and adjust airflow in real time. Without reliable data, nothing can be automated or controlled. The second requirement is a robust communications network so that every underground device feeds into a central control layer without gaps. You can’t control what you can’t measure, so instrumentation and connectivity are the foundation of any successful system.
Starting small and scaling up
Because this infrastructure takes time to build, most VoD and ventilation control systems start small and scale as mine-capability grows. Once the foundations are in place, operators can simulate the impact of a damper or fan change minutes or hours ahead, shifting from reactive adjustments to proactive ventilation management and avoiding fixes that move the problem elsewhere.
In an emergency, the advantage is speed and shared situational awareness. A digital twin or real-time VoD system provides teams with an immediate view of airflow distribution and air quality, enabling decisions about evacuation routes, isolation zones, or re-entry with far greater confidence. This shared visibility improves coordination across teams during high-pressure scenarios.
It also allows operators to verify the consequences of any intervention, such as changing a fan setting, adjusting a damper, or isolating an area, before acting. That prevents well-intentioned fixes from starving another zone, creating stagnant air or worsening gas ingress risks. The same capability improves day-to-day operational decisions, as teams can see the likely impact of changes in advance, reducing guesswork and avoiding unintended knock-on effects.
Foundations matter
Digital twins are not difficult because the technology is exotic: they are difficult because the foundations matter. Three things are required: a surveyed mine, a calibrated network model, and trusted data. Operations already using VUMA have this groundwork in place, which makes it far easier to layer in real-time monitoring, add instrumentation and communications, and scale toward full digital-twin capability.
Once those basics are established, the benefits come quickly, with clearer expected-vs-actual insight, more predictable control, and a shift from reactive ventilation adjustments to proactive, model-based management. Mines that start without this foundation can still get there, but the journey is longer because the models and baseline data must be built first.
The direction, either way, is unmistakable. As mines strengthen their data, skills and systems, digital twins will become the backbone of safer, more efficient and more predictable ventilation management underground. Ultimately, the goal remains simple: safely delivering the right air to the right place at the right time.
