Drilling in Open Pits DRILLING

Drilling
Surface Mine Design
Dr. Kadri Dagdelen

Drilling Methods
• Top hammer drilling

Hydraulic self-contained drills
Pneumatic drills with portable air compressors
Surface Mine Design
• Down-the-hole (DTH) drilling

Pneumatically operated carriers with portable air compressors
Hydraulically operated self-contained carriers
• Rotary drilling
Drills for rotary crushing
Drills for rotary cutting
2
Surface Drilling Methods and
Applications
Surface Mine Design
3
Components of Surface Drilling
Methods
Surface Mine Design
4
Top Hammer Drilling
• Soft to hard rock

• Diameter from 7/8” to 10”
• Top hammer drills can be classified according to their size
and principle of operation:
Surface Mine Design
Hydraulic or pneumatic handheld drills

Light hydraulic drills mounted on feeds for mechanized drilling in
different types of boom applications
Pneumatic crawler drills operated by a separate portable air
compressor
Hydraulic crawler or wheel-based drills operated by a powerpack
onboard
5
Principle of Top Hammer Drilling
• It can be hydraulic or pneumatic

• It combines four functions
Percussion
Surface Mine Design
Feed
Rotation
Flushing
• Parameters that affect the penetration rate:

Impact energy, impact frequency, rotation speed, feed force, and
flushing of the hole
6
Relative Penetration Rate as a Function
of Percussion Pressure
Surface Mine Design
7
The Optimal Adjustment of Drilling
Parameters Means Maximum Penetration
Surface Mine Design
8
Surface Mine Design
Flushing
9
Surface Mine Design
Flushing
10
Penetration Rates Between Pneumatic
and Hydraulic Top Hammer Drilling
Surface Mine Design
11
Bench Drilling Rig
Surface Mine Design
12
Bench Drilling Rig
A modern surface crawler drill should fulfill the

following requirements, to make the operation
economical:
Surface Mine Design
• High penetration rate

• Short cycle times
• High quality holes
• High availability
• Low operating cost
13
Choice of Bit Type
Surface Mine Design
14
Application Range of Tube Drill Steels
Surface Mine Design
15
DTH Drilling
• It is more efficient than top hammer drilling

• A DTH hammer follows immediately behind the bit
• Good drilling accuracy
Surface Mine Design
• DTH drills are used in bench drilling of 3½” to 6½” holes

on benches up to 150 feet
• DTH hammer life is dependent on:
Hammer size, operating pressure, rock abrasiveness, and rock
drillability
16
Principle of DTH Drilling
Surface Mine Design
17
A Typical DTH Hammer
Surface Mine Design
18
Features of DTH Hammer
Surface Mine Design
19
Truck Mounted DTH Drill
Surface Mine Design
20
Surface Mine Design
DTH Bit Designs
21
Rotary Drilling
• It is used in most major open pit mining operations

• Diameter from 4” to 17½”, depth up to 150 feet
• The key elements in rotary drilling are:
Surface Mine Design
Sufficient torque to turn the bit in any strata encountered

Sufficiently high bit loading capability (pulldown force) for optimum
penetration
Sufficient flushing air volume to remove the cuttings during
penetration, as well as to provide cool air to the drill bit bearings
Selection of the proper type of bit for the material being drilled
22
Principle Rotary Drilling
Surface Mine Design
23
Surface Mine Design
Rotary Drills
24
Surface Mine Design
Rotary Drills
25
Principles of Rotation
Surface Mine Design
26
Rotary Power versus Hole Diameter
Surface Mine Design
27
Pull Down versus Hole Diameter
Surface Mine Design
28
Principles of Feed Systems
Surface Mine Design
29
Thrust and Pulldown Force
Surface Mine Design
30
Flushing Air Compressor Size
Surface Mine Design
31
Carrousel Type Pipe Changer
Surface Mine Design
32
Rotary Drilling Accessories
• Drill bits
• Drill pipes
Surface Mine Design
• Shock subs
• Stabilizers
• Saver subs
• Bit subs
33
Rotary Drill Bit Components
Surface Mine Design
34
Rotary Bit Selection Parameters
Type of ground Tooth or insert spacing Tooth depth Cutting action

Soft formations with low
compressive strengths and Large: Inserts Mostly gouging and scraping by
high drillability: shales, High extended chisel skew cone action, with little
unconsolitaded sands, shaped chipping and crushing
calcites
Surface Mine Design
Partly by gouging and scraping

Medium Formations: harder Medium: Inserts
but with significant chipping and
shales, limestone, Medium, close short or blunt
crushing action especially at
sandstones, dolomites chisel shaped
harder end of type
Hard formations: siliceous
Low: Inserts
limestones, hard Mostly by chipping and crushing
Close with low intermesh spherical or
sandstones, porphyry by cutter rolling action
conical
copper ores
Very low: Insert

Very hard formations: Very close with low Nearly all excavation by true
hemispherical
taconites, quartzites intermesh rolling action of cutters
conical or ovoid
35
Bit Selection for Rotary Drilling
Surface Mine Design
36
Insert Shapes for Tricone Bits
Surface Mine Design
37
Penetration Rate versus Bit Load
Surface Mine Design
38
Principles of Rotary Cutting
Surface Mine Design
39
Drilling
Surface Mine Design
Dr. Kadri Dagdelen

Penetration Rate
W rpm
P = (61 − 28 log10 Sc) ⋅ ⋅
φ 300
Surface Mine Design
Where:
P = penetration rate (ft/hr)
Sc = uniaxial compressive strength, in thousands of psi
W/F = Weight per inch of bit diameter, in thousands of pounds
rpm = revolutions of drill pipe per minute
Bauer and Calder, 1967 (Surface Mining Handbook)

2
Horse Power
hp = K ⋅ rpm ⋅ D 2.5
⋅W 1.5
Where:
Surface Mine Design
D = bit diameter (in.)

W = weight on the bit in thousands of pounds
K = constant that varies with rock type.
As material strength decreases, the value of K increases. This caters for the
greater teeth penetration experienced in soft rocks. Values vary from 14 x 10-5
for soft rocks down to 4 x 10-5 for high-strength materials.
Surface Mining Handbook

3
Balancing Air Velocity
Um = 264 p 1/ 2
⋅d 1/ 2
Where:
Um =
Surface Mine Design
2420 fpm for 13 mm (1/2 in.) diameter platelets with a

density of 2.7 g/cc
d = diameter of the chip in inches
p = density of the chip in lb/ft 3
Surface Mining Handbook

4
Bailing Velocities
Surface Mine Design
5
Bailing Velocities
Surface Mine Design
6
Air Requirements Chart
Surface Mine Design
7
Optimal Bit Load
C×D
OptimumBitLoad =
5
Where:
Surface Mine Design
C = Rock compressive strength

D = bit diameter in inches
Source: R. Baker, Tamrock
8
Total Work
Total Work (WT ) = W × R × 2π × N × T
Where:
Surface Mine Design
W = bit load (lbs)

R = penetration rate (feet/min)
N = bit rotation speed
T = torque (foot lbs)

9
Rotary Horsepower
4.95 × D × R × (W / 1000)1.6
Horse Power (hp) =
C
Where:
Surface Mine Design
hp = rotary horsepower
R = bit rotational speed
D = bit diameter (inches)
W = optimum bit load (lbs)
C = rock compressive strength

10
Maximum Bit RPM
hp × C
Maximum Bit RPM ( R ) =
4.95 × D × (W / 1000)1.6
Where:
Surface Mine Design
hp = rotary horsepower
R = bit rotational speed
C = rock compressive strength

11
Volume CFM
 0.25πD 2   0.25πD 2 
Volume CFM =  P ×  × SF +  P × 
 144   144 
Where:
Surface Mine Design
P = penetration rate
SF = swell factor (0.6 sedimentary or 0.4 Igneous/metamorphic)
12
Air Velocity
183× CFM
Air Velocity =
D2 − d 2
Where:
Surface Mine Design
d = pipe diameter (inches)

CFM = effective compressor volume (CFM)
13
Compressive Strength
2.18 × W × R
Compressive Strength (C ) =
0.2 × (1 / 10000) × P × D 0.9
Where:
Surface Mine Design
P = average pure penetration rate (feet/hour)

W = average bit load (lbs)
R = average bit rotation

14
Pure Penetration
2.18 × W × R
Pure Penetratio n ( P ) =
0.2 × C × D 0.9 × (C / 10000)
Where:
Surface Mine Design
P = average pure penetration rate (feet/hour)

R = optimum bit rotation speed
C = average compressive strength

15

Drilling in Open Pits DRILLING

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Drilling

Surface Mine Design

Dr. Kadri Dagdelen

• Top hammer drilling

• Down-the-hole (DTH) drilling

• Soft to hard rock

Hydraulic or pneumatic handheld drills

• It can be hydraulic or pneumatic

• Parameters that affect the penetration rate:

A modern surface crawler drill should fulfill the

• High penetration rate

• It is more efficient than top hammer drilling

• DTH drills are used in bench drilling of 3½” to 6½” holes

DTH Bit Designs

• It is used in most major open pit mining operations

Sufficient torque to turn the bit in any strata encountered

Type of ground Tooth or insert spacing Tooth depth Cutting action

Partly by gouging and scraping

Very low: Insert

Dr. Kadri Dagdelen

Bauer and Calder, 1967 (Surface Mining Handbook)

D = bit diameter (in.)

Surface Mining Handbook

2420 fpm for 13 mm (1/2 in.) diameter platelets with a

Surface Mining Handbook

C = Rock compressive strength

Source: R. Baker, Tamrock

Total Work (WT ) = W × R × 2π × N × T

W = bit load (lbs)

Source: R. Baker, Tamrock

Source: R. Baker, Tamrock

Source: R. Baker, Tamrock

Source: R. Baker, Tamrock

d = pipe diameter (inches)

Source: R. Baker, Tamrock

P = average pure penetration rate (feet/hour)

Source: R. Baker, Tamrock

P = average pure penetration rate (feet/hour)

Source: R. Baker, Tamrock

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