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435 CHAPTER 7.2 Blasthole Drilling Jamal Rostami and Douglas F. Hambley INTRODUCTION Drilling is an important unit operation in mining. Drilling is required for a variety of mining or mining-related activities including blasting, ground support installation, utility installa- tion, dewatering, exploration, and much more. The term drill- ing is used for smaller-diameter holes, with a few exceptions such as shaft drilling and raise drilling, where larger excava- tions are created by special machines including cluster drills. This chapter is primarily concerned with mine production. Most boreholes drilled for mine production are blastholes for explosives. However, boreholes drilled for use in solution mining will also be discussed. The majority of blasthole drilling is performed by two primary methods: 1. Percussive drilling • With smaller hole sizes (diameters up to 150 mm [6 in.]), the impact and rotation of the bit used to fracture the rock is transmitted from the drill (top hammer) to the bit through a drill rod or series of drill rods coupled together (referred to as a drill string). • With larger hole sizes (diameters from 75 mm to 508 mm [3 to 20 in.]), the hammer is located down- the-hole (DTH) or in-the-hole (ITH) at the bottom of the drill string immediately above the bit, and the impact is transmitted directly to the bit. 2. Rotary drilling • Drag bits are used for 75–250 mm (3–10 in.) holes in soft rock. • Tricone bits are used for 75–300 mm (3–12 in.) holes in medium and harder rock. • Larger roller bits are used for holes larger than 300 mm (12 in.). A third drilling method, jet piercing, which was formerly used to drill blastholes in taconites and other very hard, abrasive rocks, has largely been superseded by rotary drilling with tri- cone bits with tungsten carbide (TC) buttons. PERCUSSIVE DRILLING In percussive drilling, the rock is broken by a combination of rotation of the bit and high-frequency percussive impacts transmitted by the bit to the rock. The percussive impact is delivered by either pneumatic or hydraulic pressure. Percussive drills were originally powered by compressed air. Since the mid-1970s, however, hydraulically powered drills have supplanted pneumatic ones, except in the case of small, handheld equipment such as stopers and jackhammers. The advantages of hydraulic drills over pneumatic drills are the fewer moving parts and the significantly higher penetration rates. The depth of percussive drilling with top hammer drills is limited to approximately 76 m (250 ft), due mainly to losses in energy transfer at joints in the drill string. Larger and deeper holes can be achieved using DTH drills. In DTH drilling, compressed air is supplied through the drill string to drive the hammer, which is located immediately behind the bit. The compressed air activates a hammer that delivers impact directly to the bit. This eliminates the loss of impact energy in joints and is a more efficient mechanism of percussive drilling. Rotation of the bit is provided by the motor at the top and transferred through the drill string. The diameter of the drill string, usually 150 mm (6 in.) or more, helps limit deviation of the hole, which improves drilling accuracy. As an example, at a Canadian uranium mine in 1978–1979, the sec- ond author of this chapter supervised the drilling with a DTH drill of 200-mm (8-in.) and 311-mm (12¼-in.) holes to depths of approximately 490 m (1,600 ft), with an error of less than 4.5 m (15 ft) at the target depth. Percussion Drill Bits Bits for top hammer percussion drills come in various shapes, as shown in Figure 7.2-1. The drill steel with an integral “chisel” bit and a single TC insert is used with handheld jackhammer (sinker) drills in shaft sinking. More common are the hammer-on or screw-on cross-shaped bits with four chisel-shaped TC inserts. However, in harder rocks especially, the chisel-shaped bits are being replaced with button bits, of Jamal Rostami, Assistant Professor, Energy and Mineral Engineering, Pennsylvania State University, University Park, Pennsylvania, USA Douglas F. Hambley, Associate, Agapito Associates, Inc., Golden, Colorado, USA 436 SME Mining Engineering Handbook which the retrac bits are an example. (Retrac bits are designed to facilitate removal of the bit and steel from the hole, which is crucial in soft or squeezing ground.) The shape of the buttons is selected based on the application and the type of rock to be drilled. Longer, pointed inserts are used for softer rock, while shorter, rounded inserts are used in harder rock. A bit can be initially selected using charts from commercial bit manufac- turers; however, optimum bit geometry and button shape is usually determined by trial and error at the job site. DTH drills were introduced by Ingersoll Rand Company in 1955, and the concept has changed little since then. Figure 7.2-2 shows a cutaway view of a DTH hammer and bit. The weak link in the DTH system is often the plastic foot valve between the piston and the bit, which can break easily if not seated properly. Cluster drills are extra-large impact drill heads that incor- porate a number of DTH hammers and bits. They can be as large as 2 m (6½ ft) in diameter. Depending on the size of the hole, the drills may have various numbers of hammers at the face, with the individual bits receiving impact energy from their individual hammers. The entire drill head is rotated via a drill string so that the hammers will cover the entire face. Cluster drills are often used in very hard and abrasive rocks, where a limited number of holes are planned, or in sink- ing small, shallow shafts less than 300 m (1,000 ft) deep. Figures 7.2-3 and 7.2-4 show a typical cluster drill. Percussive Drilling Equipment for Underground Use Handheld jackleg and stoper drills are lightweight percussive drills powered by compressed air. They are used for drill- ing small blastholes that are generally 35 mm (1.375 in.) or smaller in diameter. They are typically used to drill holes from 1.8 to 3 m (6 to 10 ft) in length, in 0.6-m (2-ft) increments, as that is the approximate extension of the piston in the air leg; holes up to 3.3 m (12 ft) long can be drilled by a skilled driller. Advance rates are generally inversely proportional to the rock strength and the cross-sectional area of the drill hole. Typical drilling rates for handheld drills range from 0.3 to 0.5 m/min (1 to 1.7 ft/min), depending on the rock mass properties. Drilling rigs for underground mining applications can be divided into face drilling and production (or long-hole) drill- ing rigs. Face drilling is performed by mobile rigs equipped with drills mounted on one boom or multiple booms. A two- boom jumbo is shown in Figure 7.2-5. The number of booms and drills depends on the opening dimensions and rock mass properties, the number of holes to be drilled per blast round, and the number of faces to be drilled in a shift. In hard rock metal mining, two-boom or three-boom jumbos are used, whereas in limestone mining, two- or single-boom drill jumbos are common. Hole diameters typically range from 35 mm to 51 mm (13⁄8 to 2 in.) with the exception of the reliever holes used in burn cuts, which are somewhat larger. Drill feeds are typically 3.7 to 4.3 m (12 to 14 ft); however, drill feeds of up to 6.4 m (21 ft) are available. Drill jum- bos were historically powered by compressed air. Since the late 1970s, however, electric/hydraulic and diesel/hydraulic units have almost completely supplanted the older pneumatic (compressed air) units because of the much faster penetra- tion rates that are achievable with the larger, more powerful hydraulic drills. Ring-drilling production drills are used in underground metal mines to drill the long inclined or vertical blastholes (typically >6.1 m [20 ft] long) used in sublevel stoping, sub- level caving, and vertical crater retreat mining. Figure7.2-6 A. Drill steel with integral chisel bit B. Cross bit C. Retrac button bit Source: Sandvik 2009. Figure 7.2-1 Top hammer percussive drill bits Courtesy of Atlas Copco. Figure 7.2-2 Cutaway view of a DTH hammer and bit Source: Atlas Copco 2007. Figure 7.2-3 Cluster drill head Blasthole Drilling 437 shows a typical production drill unit in operation drilling an inclined uphole. In such operations, the drilling operation may include both long production blastholes and ground support installation (primarily cable bolts). To ensure good fragmenta- tion, it is imperative for these holes to have the correct length and direction. To achieve this, it must be possible to easily rotate the drill boom to various positions, maintain the proper hole alignment, and minimize the deviation from the proper location. A bit with a flat or concave front face will create a straighter hole than a bit with a convex front face. Retrac bits with long bit skirts were introduced to improve drilling accuracy and reduce hole deviation. Another method to reduce hole wandering is to use larger-diameter drill strings, whereby the small difference between the diameter of the bit and the drill string limits the amount of bending of the drill string and thus keeps the hole straighter. Because of the need to flush drill cuttings from the borehole, the drill string on a noncoring drill cannot be the same diameter as the bit. For upholes, drills often use an ITH drilling system that delivers the impact directly to the bit. Combined with the larger-diameter drill tube, this allows for much higher accu- racy and lower deviation. For example, in a hole that is 30 m (100 ft) long, drill-hole deviation may be as much as 3 m (10 ft), or 10%, when a top hammer and a conventional rod and bit are used. When the same drill is used with a retrac bit and guide tube behind the bit, the deviation can be reduced to 1.5 m (5 ft), or 5%. With an ITH hammer, however, that devia- tion can be reduced to 0.5 m (1.7 ft), or 1.7%. For very long holes, a stabilizer/reamer behind the ITH hammer will reduce deviation even further. For shaft sinking applications, specialized jumbo drills can be used. Shaft drill jumbos use the same drilling equip- ment and bits as other drilling rigs—the only difference is that instead of a drill carriage, they are mounted on a work platform that hangs on a set of ropes. The jumbo is lowered Source: Atlas Copco 2010a. Figure 7.2-4 Cluster drill in a shaft excavation Source: J.H. Fletcher and Company 2007. Figure 7.2-5 Two-boom jumbo for face drilling Source: Atlas Copco 2010b. Figure 7.2-6 Typical ring-drilling production drill for underground metal mining 438 SME Mining Engineering Handbook to drill at the face and raised a safe distance above the face to minimize damage from flyrock from the blast. Typical hole diameters for production drilling with regu- lar top hammer systems range from 50 to 100 mm (2 to 4 in.); with the ITH system, the range is from 100 to 254 mm (4 to 10 in.). The drill string diameter for regular rods varies from 38 to 51 mm (1½ to 2 in.), and the lengths of individual drill rods typically range from 1.2 to 1.8 m (4 to 6 ft), but can be up to 3.0 m (10 ft). For tube drilling in conjunction with ITH, drilling rods range from 45 to 87 mm (1¾ to 3½ in.) in diam- eter and from 1.5 to 3.6 m (5 to 12 ft) in length. (With ring drilling, the length of the rod is constrained by the height and width of the mine opening.) Penetration rate is a function of the impact energy imparted to the bit, frequency of impacts, feed pressure, rotational speed, drill bit type, and rock mass properties. A typical drill unit is capable of delivering 10 to 25 kW of energy to the drill string with an impact frequency between 20 and 70 Hz (impacts per second). The drill rotational speed ranges from 0 to about 100 rpm, with the maximum for a given hole size defined by an angular speed at the bit perimeter of approximately 0.4 m/s (1.4 ft/s). Depending on the rock mass properties, penetration rates of 0.5–2.5 m/min (1.6–8 ft/min) can be achieved. It should be noted here that the penetration rates given previously in this paragraph do not account for the time required to retract the drill from a hole, reposition the boom, and collar a new hole, which can take from 30–60 seconds per hole, depending on the type of equipment. For the sizes of blastholes normally encountered under- ground (35–100 mm [13⁄8–4 in.]), jointing doesn’t usually affect the ability to drill blastholes unless the rock is very closely jointed, as in a shear zone, or the drill hole is in the zone of back break behind the previous blast in the case of benching. Hence, other things being equal, the penetration rate in underground blastholes can be considered to vary inversely with the rock strength. Percussive Drilling Equipment for Surface Use Drilling equipment for surface mining applications can be categorized into two classes—percussive drills for small to medium-sized holes of up to 200 mm (8 in.) and rotary drills for larger sized holes of up to 450 mm (18 in.). Surface drill- ing units are generally crawler mounted. Older percussive drills (known as air tracks) may use compressed air as their power source; however, newer machines use hydraulic drills and are diesel powered. Percussive drilling for surface blast- ing typically uses holes ranging from 89 to 150 mm (3½ to 6 in.). Both top hammer and DTH drills are used. Figure 7.2-7 shows a crawler-mounted, surface percussive drill. The lengths of drill rods used in surface drilling are selected to minimize the time for adding or removing the rods. Typical drill rods for percussive surface drilling range from 50 to 150 mm (2 to 6 in.) in diameter, and from 4 to 6 m (13 to 20 ft) long. The weight loading on the bits ranges from 1 to 4 t (1.1 to 4.4 st). Drilling rates for typical surface drills vary from 2 to 80 m/h (6 to 240 ft/h). They increase with increased power of the rig, and decrease with increasing hole diameter and rock mass strength. Small, handheld drilling equipment has all but disap- peared from surface mining applications, except for breaking oversize boulders or drilling sinking cuts for starting a bench in very inaccessible places in the mine. Most surface mines use impact hammers for breaking large or oversized boulders to avoid secondary blasting. Percussive Drilling Penetration Rate Typical penetration rates for various sizes and types of percus- sive drills are presented in Table 7.2-1. ROTARY DRILLING With the exception of special applications that use cluster drills, larger holes are typically drilled by rotary drilling. A typical rotary drilling rig used in surface mining is presented in Figure 7.2-8. With rotary drilling, the drill bit is rotated by applying torque at the end of the drill string, which results in removal of chips from the face of the hole. Power for bit rota- tion and penetration is either diesel or electric. Since their introduction in the early 1900s by the Hughes Tool Company, tricone bits have been the traditional type of bits used in rotary drilling. They remain the most popular bits for blastholes ranging from 150 to 444 mm (6 to 17½ in.) in Source: Atlas Copco 2010c. Figure 7.2-7 Crawler-mounted top hammer percussive surface drill Blasthole Drilling 439 diameter. Drag-type bits have gained an increasing share of the market since the introduction of polycrystalline diamond compact (PDC) bits in 1976 (Baker Hughes 2008). PDC drag bits are more expensive than tricone bits, but for relatively deep holes, the time saved due to longer intervals between bit changes may justify the price. Bit selection is based on hole size and depth, rock type, and operational requirements. Sources of information to guide selection of the proper bit include manufacturers such as Atlas Copco and Sandvik for percussive drill bits, and Smith Internationaland Baker Hughes for tricone and drag bits. Figure 7.2-9 shows typical drag and tricone bits used in rotary drilling. The weight loading on the bits ranges from 10 to 74 t (11 to 81.6 st). The rate of advance for rotary drilling is a function of the rate of rotation, bit diameter, weight on the bit, and rock mass properties, and is well predicted by the following empirical equation (Calder 1973): P = (61 – 28 log10 Sc) W R/(250 D) (7.2-1) where P = penetration rate (ft/h) Sc = rock compressive strength (thousands lb/in.2) W = pulldown weight of drill (thousand lb) R = drill rotary speed (rpm) D = hole diameter (in.) In metric units, Equation 7.2-1 becomes P (214 – 98 log10 (0.145 Sc)) W R/(250 D) (7.2-2) where P = penetration rate (m/h) Sc = rock compressive strength (MPa) W = pulldown weight of drill (t) R = drill rotary speed (rpm) D = hole diameter (mm) Table 7.2-2 provides a general guide to surface blasthole drill productivity in various rock types. It is assumed that the work is performed on a reasonably prepared bench and includes the following operations: • Moving the drill from prior hole to next hole location • Jacking/leveling the drill • Aligning the mast/feed for plumb or desired angle orientation • Collaring and advancing the first rod • Adding additional rods and advancing them until the required hole depth is reached • Tripping out the drill string until it is clear of the hole • Checking the hole/collar for depth/condition • Retracting the jacks and making the drill ready to tram Table 7.2-1 Comparison of different percussive drilling systems and their production rates Drilling Method Range of Diameter, mm Typical Depth, m Typical Drilling Rate, m/h* Accuracy, % or cm/m Application Top hammer pneumatic jackleg 25–50 <4 60 2–5 Used in small tunnel and drift development, small-scale stoping, surface operations as starter, shallow trenching, bolt installation, etc. Jumbo 37–100 4–10 100–200 1–3 Tunneling, stoping, fan drilling, bolt installation, and probe drilling Surface crawler- mounted drills 50–150 5–30 20–150 1–3 Surface and bench drilling Top hammer hydraulic jumbo drills 37–125 4–20 30–120 2–3 Tunneling, stoping, fan drilling, bolt installation, and probe drilling Down-the- hole 75–150 10–50 20–80 3–5 Surface and bench drilling * Drilling rates are for actual drilling and do not include time for drill retraction, boom relocation, collaring, etc. Drilling rates decrease as rock mass strength increases and may increase or decrease depending on the number and orientation of joints/blocks. Source: P&H Mining Equipment 2010. Figure 7.2-8 Large rotary drilling equipment for surface A. Milled-tooth B. TC insert C. PDC insert tricone bit tricone bit drag bits Courtesy of Bit Brokers International, Logan, Illinois. Figure 7.2-9 Three types of rotary drill bits 440 SME Mining Engineering Handbook The need for a stable drill setup with the jacks in place and activated cannot be overemphasized. In addition, for long holes, it is important to place centralizers at intervals in the drill string, especially if the rods are significantly smaller in diameter than the drill holes. DRILL HOLES FOR SOLUTION MINING Boreholes drilled for solution mining are not production holes in the same sense as blastholes; however, they are production holes in the sense that they are used to either inject or remove the fluid used to dissolve the rock and have a limited life span. Another difference is that after the holes have been advanced to their ultimate depth, they are cased and cemented and fitted with production tubing, a process known as well completion. Several different well-completion types are found in solution mines. The Frasch process for solution mining of sulfur uti- lizes concentric pipes, with hot water injected in one pipe and the sulfur-bearing pregnant solution removed in another. In solution mining of salt and potash, concentric pipes are used to develop the injection and recovery wells. When the wells have reached the target depth and the sumps have been excavated, mining proceeds laterally until the two wells are connected. At this point, one well is converted to an injection well and the other becomes the recovery well. Wells used for solution mining are generally drilled using oilfield equipment and mud-rotary drilling techniques. As with oil and gas drilling, selection of the proper chemistry and den- sity of the mud is important. In evaporite zones, the saturated saline brines used for mud in normal oilfield drilling will dis- solve potash minerals and should be replaced with oil-based invert mud. The outside diameter of solution mine wells typi- cally ranges from 219 to 346 mm (85⁄8 to 135⁄8 in.) and depends on the completion configuration and tubing diameters required to transport the fluids. NEW DEVELOPMENTS IN PRODUCTION DRILLING The most important advance in drilling equipment since 1990 has been the development of computer-controlled drilling systems. These systems automatically locate and collar the holes, based on a preprogrammed blast round design, and incorporate real-time monitoring and optimization of the drill- ing. In surface mining, drill rigs have been fitted with Global Positioning Satellite systems, allowing for better control of the drill-hole locations. Drills have been fitted with computer control systems that allow for optimization of drilling parameters such as feed rate, weight on bit, and torque to achieve the highest possible drilling rates. These systems allow for uploading of the drill- ing pattern into their computer via storage devices or, more recently, via wireless communication. In underground mining, multiboom jumbo drills can be programmed to drill the desired blasthole patterns automati- cally, through coordination with an automated surveying and guidance system, and simultaneously monitor the drilling parameters and optimize the control parameters. Interfaces also exist that allow for ground characterization while drilling by comparing the current drilling rates and other parameters with stored data for drilling in similar rock types (Atlas Copco 2004; Schunnesson 1998; E. Tanner, personal communica- tion). In this manner, the instrumentation system can provide an estimate of the rock properties. Directional drilling has also made significant progress and is used with high speed and an advanced degree of accu- racy for applications in oil well drilling, coal mine degasifi- cation, as well as civil engineering. Direction changes are effected using a bent sub together with a downhole mud motor drive unit to rotate the bits. The mud motor drive works in conjunction with rotary bits and receives the thrust force and torque reaction from the drill string, which in this case does not rotate. Coil tubing, where the drill string is rolled on a reel and dispensed rapidly as needed, has been used extensively in oil/ gas well drilling to eliminate the need for breaking and assem- bling the drill steels. This technique is only possible with mud motors, since there is no need to rotate the drill string. These systems are capable of making bends with radii as tight as 6–10 m (20–30 ft) in holes 75–100 mm (3–4 in.) in diameter. Because of this capability, coil tubing is commonly employed on workover rigs used to rehabilitate wells used for solution mining and oil production. REFERENCES Atlas Copco. 2004. Atlas Copco Face Drilling Options: Rig Control System—RCS. Product brochure. Fagersta, Sweden: Atlas Copco Rock Drills AB. Available at http://pol.atlascopco.com/SGSite/SGAdminImages/ PrintedMatters/5470.pdf. Accessed February 2010. Atlas Copco. 2007. Cluster drill. In Secoroc Rock Drilling Tools Product Catalogue—DTH Equipment. Fagersta, Sweden: Atlas Copco Secoroc AB. p. 31. http://pol.atlas c o p c o . c o m / S G S i t e / S G A d m i n I m a g e s / P r i n t e d Matters/5126.pdf.Accessed February 2010. Atlas Copco. 2010a. Rock drilling tools: DTH equipment, cluster drills. On-line product information. http://pol .atlascopco.com/SGSite/default_prod.asp?cookie_test=1. Accessed February 2010. Table 7.2-2 Generalized production rate of drilling units in surface mining Drilling Conditions Soft Rock Medium Soft Rock Medium Hard Rock Hard Rock Rock strength, MPa 70–100 100–175 175–225 225–300 Rock strength, 1,000 psi 10–15 15–25 25–35 35–45 Rock fabric condition Drilling rate, m/h* Stable, uniformly competent ground conditions 55 33.5 30.5 24.5 Competent rock, fractured collar zone (top 0.6 to 1.2 m of bench) 49.5 30 27.5 22 Rock with closed joints, fractured collar zone (top 0.6 to 1.2 m of bench) 42 25.5 23.5 18.5 Rock with open joints, fractured collar zone (top 0.9 to 2.4 m of bench) 33.5 20.5 18.5 15 Heavily jointed, poorly cemented rock, fractured collar zone (top 1.2 to 3 m of bench) 27 16.5 15 12 Courtesy of W. Hissem. *To obtain drilling rates in feet per hour, multiply by 3.28. Blasthole Drilling 441 Atlas Copco. 2010b. Blasthole drilling rigs: Production drilling rigs, Simba M4C. http://pol.atlascopco.com/SGSite/default _prod.asp?cookie%5Ftest=1. Accessed February 2010. Atlas Copco. 2010c. Blasthole drilling rigs: Surface crawler drill- ing rig, ROC D7. http://pol.atlascopco.com/SGSite/default _prod.asp?cookie%5Ftest=1. Accessed February 2010. Baker Hughes. 2008. Quantec PCD drag bit. www.baker hughesdirect.com/cgi/hello.cgi/HCC/public/diamond/ pdf/quantec_brochure.pdf. Accessed February 2010. Calder, P.N. 1973. Rock mechanics aspects of large hole bor- ing machine design. In Proceedings of the 8th Canadian Rock Mechanics Symposium, Toronto, ON. Ottawa, ON: Canadian Department of Energy, Mines and Resources. pp. 159–175. J.H. Fletcher and Company. 2007. Model J-352-LS dual boom jumbo. www.jhfletcher.com/jumbos.htm. Accessed February 2010. P&H Mining Equipment. 2010. P&H 250XP blasthole drill. www.phmining.com/PHMining/Mining-Equipment/ Blasthole-Drills/250XP.htm. Accessed February 2010. Sandvik. 2009. Top Hammer Drilling Tools: Product Catalogue. Sanviken, Sweden: Sandvik Mining and Construction Tools AB. Available at www.miningandconstruction .sandvik.com/Sandvik/0120/Internet/Global/S003713 .nsf/Alldocs/Brochures*2ALinked*Top*Hammer*PDF/ $FILE/TH2009_lowres.pdf. Accessed February 2010. Schunnesson, H. 1998. Rock characterisation using percus- sive drilling. Int. J. Rock Mech. Min. Sci. 35(6):711–725.
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