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An estimation of the penetration rate of rotary drills using the Specific Rock
Mass Drillability index

Article  in  International Journal of Mining Science and Technology · March 2012


DOI: 10.1016/j.ijmst.2011.09.001

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International Journal of Mining Science and Technology 22 (2012) 187–193

Contents lists available at SciVerse ScienceDirect

International Journal of Mining Science and Technology


journal homepage: www.elsevier.com/locate/ijmst

An estimation of the penetration rate of rotary drills using the Specific


Rock Mass Drillability index
Cheniany Alireza a, Hasan Khoshrou Seyed a, Shahriar Kourosh a, Khademi Hamidi Jafar b,⇑
a
Department of Mining and Metallurgy Engineering, Amirkabir University of Technology, Tehran, Iran
b
Mining Engineering Department, Faculty of Engineering, Tarbiat Modares University, Tehran, Iran

a r t i c l e i n f o a b s t r a c t

Article history: The main purpose of the present study was to provide a practical, convenient drillability prediction model
Received 2 July 2011 based on rock mass characteristics, geological sampling from blast holes, and drill operational factors.
Received in revised form 10 August 2011 Empirical equations that predict drill penetration rate have been developed using statistical analyses
Accepted 15 September 2011
of data from the Sarcheshmeh Copper Mine. Seven parameters of the rock or rock mass, including uniaxial
Available online 24 March 2012
compressive strength (UCS) of the rock, Schmidt hammer hardness value, quartz content, fragment size
(d80), alteration, and joint dip, are included in the model along with two operational parameters of the
Keywords:
rotary drill, bit rotational speed and thrust. These parameters were used to predict values of the newly
Rotary drilling
Penetration rate
developed Specific Rock Mass Drillability (SRMD) index. Comparing measured SRMD values to those pre-
Specific Rock Mass Drillability (SRMD) index dicted by the multi-parameter linear, or nonlinear, regression models showed good agreement. The cor-
Sarcheshmeh Copper Mine relation coefficients were 0.82 and 0.81, respectively.
Ó 2012 Published by Elsevier B.V. on behalf of China University of Mining & Technology.

1. Introduction compressive strength is not directly related to the drilling rate of


a drag bit [4]. Selim and Bruce developed a penetration rate model
An accurate prediction of the blast hole drilling rate helps make for percussive drilling using stepwise linear regression analysis [5].
the planning of drilling operations more efficient. Drillability can- The model is a function of the drill power and the physical proper-
not be calculated by measuring a single quantity in a single test. ties of the rocks penetrated: operating conditions like thrust, rota-
It is influenced by many variables that include both controllable tional speed and flushing conditions influenced the drilling process
and uncontrollable parameters. The bit type and diameter, the greatly. Singh stated that penetration rate responds only slightly in
rotational speed, the thrust, the blow frequency, and flushing are the low thrust range [6]. However, a specific thrust is achieved
the controllable parameters. On the other hand parameters such where the response ‘‘penetration rate’’ becomes constant with re-
as the rock properties and geological conditions are uncontrollable. spect to change in ‘‘thrust’’. Clark noted that drilling strength is
Drillability related studies are mainly based on an empirical ap- mainly dependent on the hardness and triaxial strength of the rock
proach developed from historical field data of drill performance [7]. Rabia determined the surface area and rock impact hardness
for various ground conditions. Many researchers have theoretically number from the results of percussive drill cuttings that had failed
or empirically investigated rotary or percussive drilling. They cor- to correlate with the drill variables [8]. Clark correlated compres-
related the penetration rate of drills with various rock properties. sive strength with penetration rate and found that the penetration
Pfleider and Blake tried to correlate penetration rate with the size rate increased with a decrease in compressive strength [9]. There
range of the cuttings and concluded that, roughly speaking, the was enough scatter in this data to show that the correlation was
penetration rate increases with the particle size [1]. Maurer stud- weak, however it appears that the optimum thrust increased with
ied crater formation under an indenter and identified three distinct increasing operating pressure. Howart and Rowland correlated
phases for brittle rocks [2]. These included the crushing of surface rock texture with rock strength and drillability [10]. They con-
irregularities and elastic deformation, the extension of the crush- cluded that the texture coefficient could be used as a predictive
ing zone beneath the indenter, and the formation of chips. Fish tool for the assessment of drillability and rock strength properties.
developed a model for rotary drills giving a penetration rate di- Bilgin et al. developed a mathematical model for predicting the
rectly proportional to thrust but inversely proportional to the uni- drilling rate of rotary blast hole drills using the drillability index
axial compressive strength of the rock [3]. Singh showed that obtained from indentation tests [11]. Thuro and Spaun have intro-
duced a new rock property called ‘‘destruction work’’ that relates
⇑ Corresponding author. Tel.: +98 21 82884956. toughness to drillability: the area under the stress–strain envelope
E-mail address: jafarkhademi@modares.ac.ir (J. Khademi Hamidi). gives the destruction work [12]. Ersoy and Waller found that the

2095-2686/$ - see front matter Ó 2012 Published by Elsevier B.V. on behalf of China University of Mining & Technology.
doi:10.1016/j.ijmst.2011.09.001
188 A. Cheniany et al. / International Journal of Mining Science and Technology 22 (2012) 187–193

wear rate of bits depends upon the particle size produced during
the drilling: the longer the size the faster is the wear [13].
Kahraman performed a regression analysis to develop penetra-
tion rate models for rotary drills, down the hole drills, and hydrau-
lic top hammer drills [14]. In that study the uniaxial compressive
strength was included in the rotary drill model. Altindag illustrated
an exponential relationship between penetration rate and coarse-
ness index: high coarseness index correlated with high penetration
rate [15].
The main objective of this study is the development of an
empirical model for predicting rotary blast hole drill performance
using a newly developed drillability index. The relationships be-
tween the drillability index and pertinent rock properties were
studied. Field work included geological mapping, discontinuity
surveying, and rock sampling. Laboratory tests to determine the
unit weight, the point load strength index, and the particle size
Fig. 2. An image of the Sarcheshmeh Copper Mine.
of the drill cuttings were performed on samples collected from
the bench areas.

3. Drilling performance field studies


2. Sarcheshmeh Copper Mine and database
A database consisting of 59 data sets was developed for used in
Sarcheshmeh Copper Mine is situated 160 km southwest of the statistical analysis. The database contains information on alter-
Kerman, about 50 km south of the city of Rafsanjan, in Kerman ation, joint dip, Schmidt hammer rebound value, uniaxial compres-
province. It is the largest open pit mine in Iran (Fig. 1). sive strength of the rock material (UCS), sieve analysis (d80), quartz
The area belongs to the central part of an elongated NW–SE content (Qmicro), and pyrite content (FeS2). For each record the pen-
mountain belt, which is principally composed of folded volcano- etration rate is also known. During these performance studies the
sedimentary rocks. The geology of the Sarcheshmeh porphyry de- bit type and diameter, the hole length, the feed pressure, the rota-
posit is very complicated and various rock types are found there. tional pressure, the air pressure, and the net drilling time were re-
Mineralization in this deposit is associated with the Late Tertiary corded. The depth of the holes was taken from the machine digital
period. The mine is exploited by open-pit mining where the height indicator panel. A descriptive statistical distribution of the vari-
and slope of the working benches are 12.5 m and 62.5°, respec- ables in the database and the input parameters for generating
tively. The angle of the overall slope ranges from 32° to 34° [16]. the models is summarized in Table 1.
Fig. 2 shows the study area in Sarcheshmeh Copper Mine. The influence of each variable in each model was found by per-
In this region the volcanic and associated confirmable sedi- forming multiple linear, or non-linear, regression analyses. The
ments form a series of gently westerly oriented folds. A Late Ter- main alteration of lithotypes at the internal pit elevations is the pot-
tiary intrusion occurs near the axis of the anticline fold; copper asic–philic alteration type. In this study the severity of weathering
mineralization is associated with some of these intrusions. The vol- was used to rank the three alteration types from the highest to
canic rocks in the Sarcheshmeh area are principally fine-grained the lowest. The types include sericite–quartz (SQ), quartz–sericite
andesite porphyries. (QS), and silicified (SiF), which are respectively quantified in groups
The oldest host rock in this mine is Eocene andesite. Other min- 1, 2, and 3. Each category was divided into three sub-classes. The net
eralized rock is Sarcheshmeh granodiorite stock. The waste rocks drilling time was measured by using a chronometer. The depth and
are mainly granodiorite dykes including porphyric hornblends, diameter of the blast holes were 15 and 23 cm, respectively. The bit
porphyric feldspar, and porphyric biotite. This study deals mainly types used in the rotary drills were tri-cone bits with tungsten car-
with drillings in the western segment of the mine, which is charac- bide inserts. The drill feed pressure and rotational pressure (in psi)
terized by various lithological units including the Sarcheshmeh were converted to thrust (MN) and rotational speed (r/min), using
porphyry (SP), the late fine porphyry (LF), the hornblende porphyry the production catalogs from the manufacturing firms. Fig. 3 shows
dike (HD), and andesite (AN). the rotary drill when drilling a blast hole in the late fine porphyry.
The main specifications of the machine used are listed in Table 2.
The engineering geological properties of the rocks located in the
Caspian sea
study area were determined from both field observations and mea-
N surements and from laboratory tests. All tests were performed in
Tehran accordance with the ISRM suggested methods [17]. A total of
approximately 200 samples were collected from the field for sub-
sequent laboratory testing of rock strength parameters and miner-
Sarcheshmeh alogical examination. The physical and mechanical properties of
mine the drilled rock were determined in situ by conducting Schmidt
Kerman hammer (N-type) tests. Block samples were collected as near as
possible to the drilling sites and standardized test samples were
prepared from these block samples. Tests were done on these sam-
Persian ples to measure compressive strength, point load strength, quartz
500 km Gulf content, and d80 fragmentation. In addition to the experimental
tests blast hole parameters such as hole depth, blast pattern, and
Central lranian volcanic province
Cu mineralizations mainly porphyries hole number were recorded along with the corresponding geo-
graphic coordinates. The machine parameters recorded included
Fig. 1. Location of the Sarcheshmeh Copper Mine. the net drilling time and the rotational bit speed of the drilling
A. Cheniany et al. / International Journal of Mining Science and Technology 22 (2012) 187–193 189

Table 1
Descriptive statistics of the Sarcheshmeh Copper Mine database.

N Range Minimum Maximum Mean Std. deviation Variance


Alteration 59 1.75 1.25 3.00 2.2314 0.48671 0.237
Dip (°) 59 81.00 6.00 87.00 53.3220 21.07330 444.084
Schmidt hammer rebound value 59 43.86 14.50 58.36 37.3377 9.86417 97.302
UCS (MPa) 59 103.11 23.03 126.14 63.3456 24.70967 610.568
d80 (mm) 59 2.34 4.12 6.46 5.3759 0.54862 0.301
Qmicro (%) 59 80.00 0.0 80.00 27.5763 31.19030 972.835
FeS2 59 12.47 1.12 13.59 4.4946 2.55806 6.544
SRMD (mm/rev/MN) 59 76.93 9.44 86.37 32.3151 18.61638 346.569

Fig. 3. A rotary drill at work in the mine.

Table 2 Discontinuity analysis was performed on the natural rock expo-


Rotary drill (Model DM-H) specifications. sures by setting up line scan surveys over the bench face during
Average of drilling speed (m/min) 22.8 face mapping. After cleaning the surface of rocks at the blast hole,
Thrust (kN) 40.01
those rocks were hit 20–30 times with Schmidt hammer and the
Bit rotational speed (r/min) 0–150 observed results are reported as mean values (Fig. 4).
Diameter of hole (mm) 229–311 The point load index (Is(50)) was performed in accordance with
Depth of hole (m) 19.8 ISRM and is used as an indication of the uniaxial compressive
Compressor capacity for hole cleaning 1050–2000
strength of the lithotypes within the database [17]. The tested
(with pressure 110 ft3/min)
samples were asymmetric lumps and in only a few cases the rods
were taken of the holes. Fig. 5 shows the point load test laboratory
experiments.
machine as well as the machine pressure. Drilling fragments next Thin sections of rocks were analyzed to determine mineral
to the blast hole were submitted to mineralogical study for evalu- types. The recognizable number of grains within standard net-
ation of the effect mineral content has on the drilling time. The works, as observed by a microscope having a 2.5x objective, was
analysis shows that pyrite is the most effective mineral because estimated. The percent quartz and other highly abrasive minerals
of its high specific weight. The pyrite holds particles of rock to- was determined and is recorded here as quartz content. For exam-
gether. The equivalent percent of quartz was determined by anal- ple, in the first section depicted in Fig. 6a the quartz content is esti-
ysis of thin sections as was the amount of highly abrasive material mated to be 15%.
present.

Fig. 4. Measurement of in-situ rock hardness by Schmidt hammer. Fig. 5. Point load index test.
190 A. Cheniany et al. / International Journal of Mining Science and Technology 22 (2012) 187–193

Fig. 6. Quartz content in thin sections of six rock specimens (P, Plagioclase; Q, Quartz; Py, Pyroxen; OP, Opaque; F, Feldspar Alkaline; Bi, Biotite; Ol, Olivine; Cal, Calcite).

Fig. 7. Preparing drill cuttings for sieve analysis.

Half the collected detritus was used for determining d80 while illustrates cementation behavior. This causes the rock have more
the remained half was used for determining the influence of metal resistance to penetration. An increased percent of pyrite decreased
mineral content. This collection of rocks includes a little amount of the drillability.
covellite, cuprite, chalcocite, chalcopyrite, hematite, magnetic, and Drill cuttings from different parts of the blast hole were care-
a greater quantity of pyrite. Pyrite having a density of about 5 g/ fully collected for sieve analysis in the laboratory. Each sample
cm3 is among the heavy metal minerals. When the volume of pyr- contained approximately 1 kg of rock chips. This drilling detritus
ite is high it surrounds all the granular minerals of the rock, e.g., was collected for each of the blast holes. The drilling detritus
was then sieved through a series of sieves (sizes 5.745, 2.83,
1.68, 1.19, 0.841, 0.595, 0.500, and 0.297 mm). Fig. 7 shows how
Table 3 the drill cuttings are prepared for sieve analysis. The cumulative
A typical sieve analysis used for determining d80. weight percentages undersize and oversize of the particles were
Mesh No. Size (mm) Weight (g) Cumulative weight (%) calculated for each blast hole (Table 3).
3.5 +5.745 44.3 16.5
7 5.745 + 2.83 61.0 22.7 4. Specific Rock Mass Drillability (SRMD)
12 2.83 + 1.68 47.5 17.7
16 1.68 + 1.19 25.5 9.5
20 1.19 + 0.841 37.2 13.8
Various drill performance indices have been introduced and
30 0.841 + 0.595 18.5 6.9 used by many researchers to assess the drillability of a rock mass.
35 0.595 + 0.5 4.3 1.6 A new drillability index, namely the Specific Rock Mass Drillability
50 0.5 + 0.297 9.2 3.4 (SRMD) (the units are mm/rev/MN) was developed during this
50 0.297 21.1 7.8
P study. The advantage of the SRMD compared to other performance
100
indices is the elimination of the effect of two major drill operational
A. Cheniany et al. / International Journal of Mining Science and Technology 22 (2012) 187–193 191

70 However, lacking a detailed analysis of the machine thrust-RPM


60
y=0.437x+0.899 data the SRMD index has been used to simplify the subsequent anal-
R2=0.183 ysis of drills. This is especially true for analysis of relative perfor-
Penetration rate (m/h)
50 mance in jointed rock masses. Figs. 8 and 9 illustrate the
40 relationship between penetration rate and bit RPM and thrust,
respectively, for four lithotypes found in the Sarcheshmeh mine.
30
As shown in these figures the penetration rate increases linearly
20 Linear with increasing bit RPM and thrust.
(series 1)
10
4.1. Multiple linear regression analysis
0 50 100 150
RPM Drillability is affected by many factors. Relationships between
these independent factors are poorly defined. Hence, simple
Fig. 8. Relationship between penetration rate and bit RPM.
regression models are inappropriate and the analysis must be
carried out by using multiple regression methods. A predictive
model of rock drillability was formulated from multiple linear,
parameters: the drill thrust and the drill RPM. Using this index, the and nonlinear, regression analyses. The mathematical form of the
drill performance can be compared and evaluated in the drilling multiple linear regressions is y = a0 + a1x1 + a2x2 +    + anxn, where
process as performed by similar drills. This is true even though the ai values are the regression coefficients. In this paper the model
the effect of other drill specifications such as bit diameter and shape parameter a0 is assumed to be constant. The specific multi-linear
is not accounted for. Using SRMD implies a linear relationship be- regression model used for this study is:
tween thrust and penetration, which is not true since a nonlinear
SRMDl ¼ a0 þ a1 Alt þ a2 Dip þ a3 Schmidt þ a4 UCS þ a5 d80
relationship between these two has been established both in the
laboratory environment and in the field by many researchers. þ a6 P FeS2 þ a7 Q micro ð1Þ

60 50
Penetration rate (m/h)
Penetration rate (m/h)

Penetration rate (m/h)

Penetration rate (m/h)


60 60
40
40
40 30 40
20
20 20 20
10

0 500 1000 1500 0 200 400 600 0 1000 2000 0 1000 2000
Pressure HYD (psi) Pressure HYD (psi) Pressure HYD (psi) Pressure HYD (psi)

(a) AN (b) SP (c) HD (d) LF

Fig. 9. Relationship between penetration rate and bit thrust.

40 40 40 40
35 35 35 35
Measured SRMD

Measured SRMD

Measured SRMD

Measured SRMD
(mm/rev/MN)

(mm/rev/MN)

(mm/rev/MN)

(mm/rev/MN)

30 30 30 30
25 25 25 25
20 20 20 20
15 15 15 15
10 10 10 10
20 40 60 80 100 120 25 30 35 40 45 50 55 0 20 40 60 80 2.0 2.2 2.4 2.6 2.8 3.0
UCS (MPa) Schmidt hammer value Qmicro (%) Altration

40 40 40
35 35 35
Measured SRMD

Measured SRMD

Measured SRMD
(mm/rev/MN)

(mm/rev/MN)

(mm/rev/MN)

30 30 30
25 25 25
20 20 20
15 15 15
10 10 10
4.0 4.5 5.0 5.5 6.0 6.5 20 40 60 80 2 3 4 5 6 7
d80 (%) Dip FeS2 (%)

Fig. 10. Relationship between measured SRMD and seven input parameters.
192 A. Cheniany et al. / International Journal of Mining Science and Technology 22 (2012) 187–193

Table 4
Multi-linear regression models for four lithotypes.

R R2 Adjusted R2 Std. error of the estimate F change Sig. F change

SRMDl ¼ 68:432  4:518Alt  0:004Dip þ 0:103Schmidt  0:264UCS  2:723d80  0:022Q micro  1:294P FeS2 (2)
LF
0.903 0.815 0.728 3.86219 9.431 1.6010-4
SRMDl ¼ 79:264  11:215Alt  0:077Dip  1:249Schmidt þ 0:197UCS þ 6:180d80  0:389Q micro þ 0:386P FeS2 (3)
HD
0.946 0.895 0.711 8.33862 4.865 0.0073
SRMDl ¼ 330:992 þ 12:820Alt þ 0:328Dip  1:641Schmidt þ 0:304UCS þ 62:128d80 þ 18:774P FeS2 (4)
SP
0.927 0.86 0.44 10.49492 2.047 0.0034
SRMDl ¼ 60:273  23:461Alt  0:290Dip þ 0:557Schmidt þ 0:285UCS þ 4:979d80 þ 0:980P FeS2 (5)
AN
0.790 0.625 0.343 8.95447 2.221 0.0014

Fig. 10 illustrates the correlations between the independent vari- 100

Measured SRMD (mm/rev/MN)


ables and the measured response, SRMD, for lithotype of late fine.
Y=X
In these figures the best fit line is plotted as a thick line, the inner 80
dotted lines indicate a 95% confidence level for the interval contain- R=0.816
ing the regression line. 60
The figure also includes the coefficients of determination (R2)
that are an indication of correlation strength. For the late fine 40
lithology the UCS has the highest R2 value, 0.693. The R2 value
decreases in the order percent FeS2 (0.582) > Schmidt hammer va- 20
lue (0.527) > d80 (0.372) > Qmicro (0.335) > Alteration (0.318) > Dip
(0.289). Accordingly, the uniaxial compressive strength of the rock 0 20 40 60 80 100
material, the percent of FeS2 present in the mineral, and the Estimated SRMD (mm/rev/MN)
Schmidt hammer value are seen to be the most significant vari-
ables. The dip of the discontinuity shows the least correlation with Fig. 11. A comparison of measured and estimated SRMD index values: linear
the SRMD. All these results are agreement with those of Thuro and regression model.
Spaun, and Kahraman [12,14]. As shown in Fig. 10 the dip discon-
tinuity is inversely related to SRMD. This is because the shear
stress decreases with an increase in the angle of the dip. For the 100
Measured SRMD (mm/rev/MN)

Sarcheshmeh porphyry and andesite the quartz content is Y=X


negligible. 80 R=0.813
The multi-linear regression equations, along with regression
coefficients, for four lithotypes are given in Table 4. As shown 60
there, the hornblende porphyry dike (HD) shows the highest R
value, 0.946. The R value decreases in the order Sarcheshmeh 40
porphyry (0.927) > late fine porphyry (0.903) > andesite (0.790).
20
From this statistical analysis a predictive linear multiple regres-
sion model including seven independent variables usable for all
lithotypes was found to be: 0 20 40 60 80 100
Estimated SRMD (mm/rev/MN)
SRMDl ¼ 113:609  17:870Alt þ 0:021Dip  0:579Schmidt
Fig. 12. A comparison of measured and estimated SRMD index values: nonlinear
 0:099UCS  1:932d80  0:115PFeS2  0:137Q micro ð6Þ regression model.

A comparison between the measured results and predictions from


Eq. (6) is shown as Fig. 11. The correlation coefficient (R) between  
the predicted and measured SRMD is 0.816, showing a nearly a 1 1
SRMDNon;l ¼ 22:015 þ ð98:776  Þ þ 615:342 
1:1 correlation. Alt UCS
 ð0:131  Q micro Þ ð7Þ
4.2. Multiple nonlinear regression analyses
A comparison between measured and nonlinear regression model
Multiple regression methods can be divided into two types: lin- SRMD estimates is illustrated as Fig. 12. As shown there, the corre-
ear and nonlinear. In this study a combined mathematical model, lation coefficient of the model function is 0.813.
which is the one of the nonlinear methods, was used. Nonlinear
regression involves estimating the coefficients of a nonlinear rela- 5. Conclusions
tionship between independent and dependent variables. In this
case the relationship between the response and at least some of Rock mass drillability depends on a number of parameters
the predictors is nonlinear [18]. The nonlinear regression model including intact rock/rock mass properties, machine specifications,
found for the prediction of rotary drill SRMD index was and operational parameters. A convenient model is proposed herein
A. Cheniany et al. / International Journal of Mining Science and Technology 22 (2012) 187–193 193

to predict the rotary Specific Rock Mass Drillability index. Multiple References
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