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The Teutschenthal backfill mine in Thüringen, Germany, processes 200,000 tons of mineral waste annually at depths reaching 700 metres. Originally a salt extraction facility until 1982, this modern operation now serves environmental protection through secure waste disposal.
Underground mining demands robust ventilation systems that maintain air quality whilst minimising energy consumption. This project required a solution capable of handling extreme depth conditions with maximum efficiency.
Key project metrics
Operating depth requiring robust ventilation system
Annual mineral waste processing capacity
ZerAx fan combined with IE5 motor and frequency converter
Fan design secured state subsidies for environmental benefits
Integrated chimney system simplifies installation
Main contractor Jeremias® Chimney Systems implemented a comprehensive ventilation upgrade featuring a 36 m tall chimney with steel construction and integrated ductwork systems. The installation needed to withstand harsh underground conditions whilst delivering consistent airflow performance.
NOVENCO® ZerAx® axial flow fan was selected for this critical application. The 98% recyclable fan design helped secure state subsidies, providing both environmental and financial benefits for the project. This sustainability advantage proved crucial in meeting regulatory requirements and reducing overall project costs.
Integrated system components
The complete installation features four integrated components that work together to deliver maximum performance throughout operation with precise control across varying demand conditions.
Technical specifications
The ZerAx fan, sized at Ø2 m, provides optimal airflow capacity for the shaft depth with efficiency up to 92%.
An IE5 class Nidec PM motor type Dyneo+ ensures maximum efficiency throughout operation with 220 kW motor power.
The Danfoss VLT frequency converter enables precise control across varying demand conditions.
The EC+ configuration combines these elements to deliver superior system performance.
50 %
Weight reduction67 %
More power in same footprint20 +
Year lifetimeHalf-tonne weight reduction eases handling
The lightweight design yielded immediate practical benefits during installation. The system weighs half a ton less than traditional IE3 motors of 220 kW, which significantly reduced crane requirements and handling complexity. The higher power density means traditional 4-pole AC motors of identical dimensions provide only 132 kW maximum, so this compact solution delivered 67% more power in the same footprint. The integrated EC+ technology further simplified installation by reducing component count and connection points.
Half-tonne weight reduction eases handling
The lightweight design yielded immediate practical benefits during installation. The system weighs half a ton less than traditional IE3 motors of 220 kW, which significantly reduced crane requirements and handling complexity. The higher power density means traditional 4-pole AC motors of identical dimensions provide only 132 kW maximum, so this compact solution delivered 67% more power in the same footprint. The integrated EC+ technology further simplified installation by reducing component count and connection points.
Long-term operational benefits extend well beyond the installation phase. The ZerAx fan's efficiency of up to 92% reduces operating costs throughout the system's lifetime. Its 98% recyclability rate supports environmental compliance and contributes to corporate sustainability targets. The 20+ year lifetime minimises replacement requirements and reduces total cost of ownership.
This installation demonstrates how advanced fan technology reduces both installation complexity and long-term maintenance demands for underground applications. The combination of efficiency, durability, and compact design makes it particularly suited to challenging environments where every technical advantage matters.
