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Is Drill And Blast Important?
Most mining starts with breaking ground that has been undisturbed for many millions of years. Any metal or mineral that is extracted from the earth, requires the ground to be broken up before this process can begin. Including gold, most metals and minerals are locked up inside the earth’s rock.
In some cases, the ground can be dug by hand or with the use of mechanical devices such as front-end loaders, large mobile scrapers, hydraulic excavators or large 100 tonne rope shovels. This softer, weathered ground is known as “free dig” as it doesn’t require the use of explosives to break it up.
The deeper we go into the earth, the ground gets harder and harder, to the point where it can no longer be “freely dug”. It then requires greater energy to break the rock into manageable pieces, which is currently done in the most efficient way by using explosives. In order to get the explosives into the ground, the holes must be drilled first.
The holes are drilled using drill rigs with either a cutting tool rotating at the bottom of the drill pipe or through pneumatic pressure driving a hammer that strikes the rock. Both methods act to chisel away at the rock.
Explosives break the ground through the rapid expansion of gases in a confined space that cause the rock to break as the gases gain an equalizing pressure with the atmosphere. Appropriate design is used to ensure that the diameter of the holes matches the spacing and burden between them. This ensures the energy distributed by the expanding gases from the explosives will sufficiently break the rock.
When blasting, the idea is to break the rock and leave it as close to the original position as possible. This is for grade control purposes to delineate ore and waste and to limit contamination with surrounding areas.
Breaking the ground serves two purposes, firstly it enables the relocation of the ground to a place where it can be processed and secondly it serves to start the process of further breaking the ground down to smaller and smaller parts to extract the metals and minerals. Once the ground can be moved, it can then be processed through mechanical crushing, then a milling process and finally a chemical extraction process to extract the desired metal or mineral.
Appreciating the enormity of a mine site and that every square metre of rock needs to be broken, efficiency becomes a major part of the process. The efficiency should be considered as the least amount of energy needed to maximise the breakage of the rock. Therefore, the least amount of energy is generally in line with the least amount of time taken from start to finish of the process.
The main steps in the process being;
1. Planning and designing the area to be broken2. Access to the area3. Drilling the holes4. Charging the holes with explosives5. Firing or exploding the ground6. Checking the shot (blasted ground) for completeness
Using the best machinery and parts during this process will greatly increase the efficiency of the drill and blast process and therefore increase the efficiency of mining. Ultimately lowering the overall cost of mining. The first process of breaking the ground makes the start of the whole mining process extremely important!
In some cases, the ground can be dug by hand or with the use of mechanical devices such as front-end loaders, large mobile scrapers, hydraulic excavators or large 100 tonne rope shovels. This softer, weathered ground is known as “free dig” as it doesn’t require the use of explosives to break it up.
The deeper we go into the earth, the ground gets harder and harder, to the point where it can no longer be “freely dug”. It then requires greater energy to break the rock into manageable pieces, which is currently done in the most efficient way by using explosives. In order to get the explosives into the ground, the holes must be drilled first.
The holes are drilled using drill rigs with either a cutting tool rotating at the bottom of the drill pipe or through pneumatic pressure driving a hammer that strikes the rock. Both methods act to chisel away at the rock.
Explosives break the ground through the rapid expansion of gases in a confined space that cause the rock to break as the gases gain an equalizing pressure with the atmosphere. Appropriate design is used to ensure that the diameter of the holes matches the spacing and burden between them. This ensures the energy distributed by the expanding gases from the explosives will sufficiently break the rock.
When blasting, the idea is to break the rock and leave it as close to the original position as possible. This is for grade control purposes to delineate ore and waste and to limit contamination with surrounding areas.
Breaking the ground serves two purposes, firstly it enables the relocation of the ground to a place where it can be processed and secondly it serves to start the process of further breaking the ground down to smaller and smaller parts to extract the metals and minerals. Once the ground can be moved, it can then be processed through mechanical crushing, then a milling process and finally a chemical extraction process to extract the desired metal or mineral.
Appreciating the enormity of a mine site and that every square metre of rock needs to be broken, efficiency becomes a major part of the process. The efficiency should be considered as the least amount of energy needed to maximise the breakage of the rock. Therefore, the least amount of energy is generally in line with the least amount of time taken from start to finish of the process.
The main steps in the process being;
1. Planning and designing the area to be broken2. Access to the area3. Drilling the holes4. Charging the holes with explosives5. Firing or exploding the ground6. Checking the shot (blasted ground) for completeness
Using the best machinery and parts during this process will greatly increase the efficiency of the drill and blast process and therefore increase the efficiency of mining. Ultimately lowering the overall cost of mining. The first process of breaking the ground makes the start of the whole mining process extremely important!
The Benefits Of Utilising Drilling Consumable Technical Site Visits
Do you get the most value from technical site support?
The relationship with many drill consumable product suppliers ends when the customer receives the goods onsite. Many suppliers do not offer the value add of onsite technical support, whether it be a free or a charged-out service. So, what is the added value that onsite technical support offers to drill and blast departments?
There are many benefits to having drilling consumable technical representatives frequently visit site. Generally, technical representatives have been in the drill and blast industry for a number of years, they have drilled on multiple rigs, in varying ground conditions and with numerous applications (Rotary, DTH, THH, RC, Diamond, Waterwell). They bring their vast experiences and prior knowledge to your business. Their job as a technical representative requires travel between multiple clients, sites, and across numerous resources (iron ore, coal, gold,nickel etc). Above all, they keep a professional level of confidentiality.
If your site is experiencing drilling difficulties, unusual consumable wear, premature failures and increased drilling costs, the chances are a technical representative has seen the same issues somewhere else. But more importantly, they would have seen different resolutions to these issues. The solution to your problem, could be standing right in front of you.
In the circumstance where a representative cannot get to site, chances are they are part of a greater team who they can call upon to assist with problem solving solutions. By sharing your situation with your technical representative, a whole team of experts will be working in the background to help get your operation back on track with productivity.
Regular visits will lower the risk of unexpected consumable failures. Technical representatives are able to identify devaluating drilling practices and offer instant recommendations and instruction, including:
· Best practices with regards to drilling parameters· Adjustments required when changing between different diameter drilling· Drill consumable awareness; when to discard consumables· How over running consumables can lead to other component failures· Understanding the manufacturing process which leads to proper care and maintenance
Technical representatives are part of their company’s Research and Development team as they are the evidence and feedback collectors for product improvement. By completing regular analysis on dull drill bits and used hammers and pipe, a record of failures is compiled, with high reoccurring failures then becoming the focus for improvement. Technical representatives are the means of communication between your site and the factory. They are the first step in the cycle to making changes specific to your site.
The more time people in your operation spend with the technical representatives, the stronger the relationship becomes between the supplier and the consumer. They will come to personally care about your operation, your people and your problems.
Technical visits are a proactive service to maximise product performance and minimise unexpected downtime.
The relationship with many drill consumable product suppliers ends when the customer receives the goods onsite. Many suppliers do not offer the value add of onsite technical support, whether it be a free or a charged-out service. So, what is the added value that onsite technical support offers to drill and blast departments?
There are many benefits to having drilling consumable technical representatives frequently visit site. Generally, technical representatives have been in the drill and blast industry for a number of years, they have drilled on multiple rigs, in varying ground conditions and with numerous applications (Rotary, DTH, THH, RC, Diamond, Waterwell). They bring their vast experiences and prior knowledge to your business. Their job as a technical representative requires travel between multiple clients, sites, and across numerous resources (iron ore, coal, gold,nickel etc). Above all, they keep a professional level of confidentiality.
If your site is experiencing drilling difficulties, unusual consumable wear, premature failures and increased drilling costs, the chances are a technical representative has seen the same issues somewhere else. But more importantly, they would have seen different resolutions to these issues. The solution to your problem, could be standing right in front of you.
In the circumstance where a representative cannot get to site, chances are they are part of a greater team who they can call upon to assist with problem solving solutions. By sharing your situation with your technical representative, a whole team of experts will be working in the background to help get your operation back on track with productivity.
Regular visits will lower the risk of unexpected consumable failures. Technical representatives are able to identify devaluating drilling practices and offer instant recommendations and instruction, including:
· Best practices with regards to drilling parameters· Adjustments required when changing between different diameter drilling· Drill consumable awareness; when to discard consumables· How over running consumables can lead to other component failures· Understanding the manufacturing process which leads to proper care and maintenance
Technical representatives are part of their company’s Research and Development team as they are the evidence and feedback collectors for product improvement. By completing regular analysis on dull drill bits and used hammers and pipe, a record of failures is compiled, with high reoccurring failures then becoming the focus for improvement. Technical representatives are the means of communication between your site and the factory. They are the first step in the cycle to making changes specific to your site.
The more time people in your operation spend with the technical representatives, the stronger the relationship becomes between the supplier and the consumer. They will come to personally care about your operation, your people and your problems.
Technical visits are a proactive service to maximise product performance and minimise unexpected downtime.
How Diamond Bits Work
The original diamond drill bits first came into existence in the 1860’s with ‘hand-set’ diamonds in the face of the bit. Anywhere from 6 large ‘black diamonds’ up to sometimes 20. The stones were approximately 4 to 5mm in diameter. By the mid 1900’s the diamond drill bit had evolved to something like the picture you see above using synthetic diamonds set in a matrix of cemented carbon and other metals. The diamonds are arranged symmetrically and protrude out of the matrix as little nodes. This type of bit is seldom used today, with less and less drillers having the knowledge to use them effectively. During the 1970’s the very fashionable impregnated bit or ‘Impreg’ bit was developed, using much smaller synthetic diamonds, which were impregnated into the matrix. As one layer of diamonds wears away, another is exposed to continue cutting. A much more forgiving drill bit.
The drill bit cuts by rotating at high speeds from 600 to 1200 rpm with water flushing down the center of the bit, across the diamond bit face or through waterways and up the outside of the bit, taking the rock fragments with it. The edges of each diamond piece cuts across the rock as the drill bit is rotating. Because it is rotating at high speeds, the bit can penetrate from 1 inch per minute in very hard rock, up to 12 inches per minute in softer abrasive rock formations. However, penetration rates are very dependent on drill bit size, ground conditions, water used, feed pressure from the rig and the quality of the bit. As the bit is penetrating, it leaves a core of rock in the center of the bit which can later be retrieved, generally in 3 metre lengths.
Impregnated drill bits are generally a slightly lower cost to manufacture. The crown height comes in several different sizes usually 16mm high. The crown can be produced in many different configurations and comprises a matrix made of differing materials to produce different hardness’s. The tougher the matrix, the harder it is to wear away, exposing new diamonds.
The drill bit cuts by rotating at high speeds from 600 to 1200 rpm with water flushing down the center of the bit, across the diamond bit face or through waterways and up the outside of the bit, taking the rock fragments with it. The edges of each diamond piece cuts across the rock as the drill bit is rotating. Because it is rotating at high speeds, the bit can penetrate from 1 inch per minute in very hard rock, up to 12 inches per minute in softer abrasive rock formations. However, penetration rates are very dependent on drill bit size, ground conditions, water used, feed pressure from the rig and the quality of the bit. As the bit is penetrating, it leaves a core of rock in the center of the bit which can later be retrieved, generally in 3 metre lengths.
Impregnated drill bits are generally a slightly lower cost to manufacture. The crown height comes in several different sizes usually 16mm high. The crown can be produced in many different configurations and comprises a matrix made of differing materials to produce different hardness’s. The tougher the matrix, the harder it is to wear away, exposing new diamonds.
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The Importance of Quality Control in Mining Drill Consumables
In the mining industry, where precision and efficiency are of great importance, the quality of equipment and consumables plays a crucial role in the success of operations. When it comes to mining drill consumables, maintaining stringent quality control measures are paramount. From drill bits to rods and other essential components, ensuring the highest level of quality in these consumables can significantly impact drilling performance, productivity, and ultimately, the bottom line.
In this article, we will explore the significance of quality control in mining drill consumables and how it contributes to operational excellence. Reliability and Performance: By maintaining consistent quality in the manufacturing process, consumables are less likely to fail prematurely or underperform. High-quality drill consumables deliver reliable performance, allowing mining companies to optimise their operations and achieve their production targets efficiently. Durability and Longevity: Mining drill consumables are subjected to harsh and demanding conditions, including abrasive rock formations, extreme temperatures, and high-pressure drilling environments. Quality control ensures that these consumables are manufactured using durable materials, such as tungsten carbide or diamond, that can withstand these challenging conditions. Precision and Accuracy: Accurate drilling is crucial in mining operations to achieve desired outcomes, such as specific hole sizes, precise depths, or targeted mineral extraction. Poor-quality drill consumables can lead to inconsistencies in hole dimensions, affecting the overall accuracy of the drilling process. Quality control measures focus on maintaining precise manufacturing tolerances, ensuring that consumables meet the required specifications. Supplier Reputation and Collaboration: Maintaining quality control in mining drill consumables involves collaboration with reputable suppliers who prioritise quality in their manufacturing processes. Choosing reliable suppliers with a strong track record in quality control ensures a consistent supply of high-quality consumables. Collaborating with these suppliers can also provide access to expertise, technical support, and customised solutions tailored to specific drilling requirements. Building strong relationships with reputable suppliers contributes to a sustainable supply chain and fosters a culture of continuous improvement. Maintaining rigorous quality control in mining drill consumables is vital for achieving operational excellence in the mining industry. By prioritising reliability, durability, precision, and safety, high-quality consumables optimise drilling performance, minimise downtime, and reduce overall costs. Collaborating with reputable suppliers and adhering to industry standards further reinforces the commitment to excellence.
In this article, we will explore the significance of quality control in mining drill consumables and how it contributes to operational excellence. Reliability and Performance: By maintaining consistent quality in the manufacturing process, consumables are less likely to fail prematurely or underperform. High-quality drill consumables deliver reliable performance, allowing mining companies to optimise their operations and achieve their production targets efficiently. Durability and Longevity: Mining drill consumables are subjected to harsh and demanding conditions, including abrasive rock formations, extreme temperatures, and high-pressure drilling environments. Quality control ensures that these consumables are manufactured using durable materials, such as tungsten carbide or diamond, that can withstand these challenging conditions. Precision and Accuracy: Accurate drilling is crucial in mining operations to achieve desired outcomes, such as specific hole sizes, precise depths, or targeted mineral extraction. Poor-quality drill consumables can lead to inconsistencies in hole dimensions, affecting the overall accuracy of the drilling process. Quality control measures focus on maintaining precise manufacturing tolerances, ensuring that consumables meet the required specifications. Supplier Reputation and Collaboration: Maintaining quality control in mining drill consumables involves collaboration with reputable suppliers who prioritise quality in their manufacturing processes. Choosing reliable suppliers with a strong track record in quality control ensures a consistent supply of high-quality consumables. Collaborating with these suppliers can also provide access to expertise, technical support, and customised solutions tailored to specific drilling requirements. Building strong relationships with reputable suppliers contributes to a sustainable supply chain and fosters a culture of continuous improvement. Maintaining rigorous quality control in mining drill consumables is vital for achieving operational excellence in the mining industry. By prioritising reliability, durability, precision, and safety, high-quality consumables optimise drilling performance, minimise downtime, and reduce overall costs. Collaborating with reputable suppliers and adhering to industry standards further reinforces the commitment to excellence.
A Brief Guide To Choosing The Best Drill Bits For Exploration Drilling
In the realm of exploration drilling, selecting the right drill bit is crucial for efficient and productive drilling operations.
Choosing a drill bit will be driven predominantly by the desired purpose of the borehole, the type of drilling method used and the sample quality sought.
For example, if drilling for grade or mineral content, then pneumatic drilling is a cost effective and efficient option, however it provides a partially contaminated sample as it travels back up the borehole. Whereas diamond drilling is more expensive but provides an ‘insitu’ competent sample for a higher degree of analysis.
Once the style of drilling has been established choosing the best drill bit for the job can significantly impact performance, cost-effectiveness, and overall project success.
In this brief guide, we will delve into the key factors to consider when choosing drill bits for exploration drilling.
Rock Formation: Different formations, such as hard rock, soft rock, abrasive formations, or mixed formations, require specific drill bit designs and materials. Understanding the geology of the site and choosing a drill bit that matches the rock’s hardness and abrasiveness is essential for efficient drilling. Bit Design: The design of the drill bit plays a crucial role in its performance. Key design elements to consider include the bit profile and cutter layout including cutting edges, cutting tips and faces. Cutter types from diamond to carbide of varying grades. Other factors such as the number and arrangement of cutters, cutter sizes, and cutter shapes impact the drilling efficiency, rate of penetration, and durability of the bit. Cutter Materials: The materials used for the drill bit cutters significantly affect their performance and longevity. Common cutter materials include tungsten carbide, coated carbides, diamond (synthetic and natural), and polycrystalline diamond compact (PDC). Each material has its advantages and limitations. Bit Body: The optimal design of the bit body will affect the overall performance of the bit. Appropriate material is needed to withstand the abrasiveness of the rock formation and the drilling medium used for flushing. The efficient configuration of the body will allow the cuttings to be removed whilst maintaining the integrity of the bit’s strength. Gauge Protection: Gauge protection is essential for maintaining the stability and gauge diameter of the borehole. Gauge wear can lead to poor hole quality and increased drilling costs. Consider drill bits with effective gauge protection mechanisms such as carbide inserts or hard-facing to ensure longevity and optimal drilling performance. Additional reamer subs may be used to maintain hole gauge. Hydraulic Efficiency: Efficient hydraulics play a vital role in drilling performance and cuttings removal. Drill bits with optimised hydraulic features, such as flushing channels and nozzles, improve the cleaning and cooling of the bit and enhance drilling efficiency. Evaluating the hydraulic design of the drill bit is fundamental for achieving maximum productivity and life of the drill bit. Bit Size: Selecting the appropriate bit size is essential for achieving the desired wellbore dimensions and accommodating casing requirements. The bit size should be determined based on the target hole diameter and the drilling equipment's capabilities. It is crucial to strike a balance between the desired borehole size and the drilling rig's capacity. Manufacturer Reputation and Support: Choosing drill bits from reputable manufacturers with a proven track record is essential. Established manufacturers often have extensive research and development capabilities, ensuring continuous product improvement and innovation. In addition, reliable technical support and after-sales services are invaluable when it comes to troubleshooting and optimising drilling operations. Choosing the best drill bit for exploration drilling is a critical decision that directly impacts the success of drilling operations. By considering factors such as rock formation, bit design, cutter materials, gauge protection, hydraulic efficiency, bit size, cost considerations, and manufacturer reputation, drillers can make informed choices and achieve optimal drilling performance. Investing time and effort in selecting the right drill bit is an investment in the efficiency, productivity, and overall success of exploration drilling projects.
Choosing a drill bit will be driven predominantly by the desired purpose of the borehole, the type of drilling method used and the sample quality sought.
For example, if drilling for grade or mineral content, then pneumatic drilling is a cost effective and efficient option, however it provides a partially contaminated sample as it travels back up the borehole. Whereas diamond drilling is more expensive but provides an ‘insitu’ competent sample for a higher degree of analysis.
Once the style of drilling has been established choosing the best drill bit for the job can significantly impact performance, cost-effectiveness, and overall project success.
In this brief guide, we will delve into the key factors to consider when choosing drill bits for exploration drilling.
Rock Formation: Different formations, such as hard rock, soft rock, abrasive formations, or mixed formations, require specific drill bit designs and materials. Understanding the geology of the site and choosing a drill bit that matches the rock’s hardness and abrasiveness is essential for efficient drilling. Bit Design: The design of the drill bit plays a crucial role in its performance. Key design elements to consider include the bit profile and cutter layout including cutting edges, cutting tips and faces. Cutter types from diamond to carbide of varying grades. Other factors such as the number and arrangement of cutters, cutter sizes, and cutter shapes impact the drilling efficiency, rate of penetration, and durability of the bit. Cutter Materials: The materials used for the drill bit cutters significantly affect their performance and longevity. Common cutter materials include tungsten carbide, coated carbides, diamond (synthetic and natural), and polycrystalline diamond compact (PDC). Each material has its advantages and limitations. Bit Body: The optimal design of the bit body will affect the overall performance of the bit. Appropriate material is needed to withstand the abrasiveness of the rock formation and the drilling medium used for flushing. The efficient configuration of the body will allow the cuttings to be removed whilst maintaining the integrity of the bit’s strength. Gauge Protection: Gauge protection is essential for maintaining the stability and gauge diameter of the borehole. Gauge wear can lead to poor hole quality and increased drilling costs. Consider drill bits with effective gauge protection mechanisms such as carbide inserts or hard-facing to ensure longevity and optimal drilling performance. Additional reamer subs may be used to maintain hole gauge. Hydraulic Efficiency: Efficient hydraulics play a vital role in drilling performance and cuttings removal. Drill bits with optimised hydraulic features, such as flushing channels and nozzles, improve the cleaning and cooling of the bit and enhance drilling efficiency. Evaluating the hydraulic design of the drill bit is fundamental for achieving maximum productivity and life of the drill bit. Bit Size: Selecting the appropriate bit size is essential for achieving the desired wellbore dimensions and accommodating casing requirements. The bit size should be determined based on the target hole diameter and the drilling equipment's capabilities. It is crucial to strike a balance between the desired borehole size and the drilling rig's capacity. Manufacturer Reputation and Support: Choosing drill bits from reputable manufacturers with a proven track record is essential. Established manufacturers often have extensive research and development capabilities, ensuring continuous product improvement and innovation. In addition, reliable technical support and after-sales services are invaluable when it comes to troubleshooting and optimising drilling operations. Choosing the best drill bit for exploration drilling is a critical decision that directly impacts the success of drilling operations. By considering factors such as rock formation, bit design, cutter materials, gauge protection, hydraulic efficiency, bit size, cost considerations, and manufacturer reputation, drillers can make informed choices and achieve optimal drilling performance. Investing time and effort in selecting the right drill bit is an investment in the efficiency, productivity, and overall success of exploration drilling projects.