Tag Archives: blasthole drilling

Epiroc Pit Vipers pass automation test at Boliden Aitik

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To help increase productivity, efficiency, and safety at its Aitik copper mine, in Sweden, Boliden has looked to leverage advances in autonomous drilling.

The mine has plans to raise production at the open-pit copper mine to 45 Mt/y this year, from 36 Mt/y previously.

To meet this target, Boliden needed to increase production from its fleet of five Epiroc Pit Vipers at the operation, the mining OEM said.

“The traditional and obvious solution would be to invest in additional Pit Vipers,” Epiroc said. Instead, Boliden looked to see if utilising automation and operating its fleet with teleremote, and semi-autonomous single-row Pit Vipers, could provide the needed boost.

“One reason to convert to remote and autonomous operations is the opportunity to reduce non-drilling time, increase utilisation and gain productivity,” Epiroc said.

Aitik is one of Europe’s largest mines with a massive pit visible from space, according to the equipment maker.

Peter Palo, Project Manager at Boliden Aitik, explained: “Its depth is 450 m and it has a width of several kilometres, requiring 15-20 minutes of driving time for operators to travel to and from the surface level. There is also a satellite mine even further away. Lunch breaks in production can last for an hour.”

Another factor taken into consideration is the harsh arctic winter climate, with snowstorms and biting cold that reduces visibility, and increases the need for safe workplace conditions. Both Boliden and Epiroc were curious to see whether automated Pit Vipers could handle these conditions, Epiroc remarked.

The first step in this transition was to perform a test with one of the Pit Vipers, converting and upgrading the machine for remote operation.

A meeting room in the mine office building was converted into a temporary control room, and the WLAN in the pit was updated and fortified to increase coverage and bandwidth.

Boliden staff were trained to operate the Pit Vipers by remote control, with the primary key performance indicators yielding positive results, according to Epiroc. On top of this, the Pit Viper automation technology received positive feedback from the operators.

Fredrik Lindström, Product Manager Automation at Epiroc, said: “There’s more to converting to automated operations than you’d think. To enjoy the full advantages of automation, you have to systematically change and improve routines, adapting them to the new processes. The lion’s share of the work involves getting people to change their habits to reach the common goal.

“Boliden has done a tremendous job laying the groundwork for the necessary process changes.”

The next step involved converting the other four Pit Vipers for remote operation while upgrading the first Pit Viper to handle single-row autonomous operation. The automation, in this case, entails the operator initiating the process, leaving the Pit Viper to drill a whole row of blast holes on its own and moving autonomously between drill holes. Once the row is completed, the operator moves and prepares the machine for the next row of holes.

Comparing the semi-autonomous single row Pit Viper with a fully manually operated machine, under optimal conditions, Boliden has measured a utilisation increase from 45-50% to 80%, as well as a 30% increase in productivity, Epiroc said.

Palo said: “We’re very pleased with the results, which is why we’re converting the rest of the Pit Viper fleet to remote operation as a step towards further automation.”

The operators handled the transition to remote operations exceptionally well, Epiroc said, explaining that the onsite operations control system was designed to mimic the Epiroc Pit Viper onboard controls with the same configuration.

Palo added: “We’ve been running by remote for a year now, and everyone is happy.

“Some of the operators were wary about learning to use the technology, but that settled quickly. They appreciate working together in a control room in the office building. It’s a better work environment, easier to exchange experiences and socialise.

“Handling the winter climate was also a cinch, despite heavy snowfalls and low temperatures for days on end. Even the laser-based Obstacle Detection System coped splendidly during snowfall. The automated systems seem to withstand arctic conditions very well.”

acQuire optimises blasthole sampling with new app

Explosives and blasting, IoT, Mining services, Mining software, , , , , ,

Global software company acQuire has introduced mobile blasthole sampling in its latest release of GIM Suite 4.2.

The update extends acQuire’s mobile app to include mobile data capture for blasthole sampling in open-pit mines, it said.

acQuire explained: “The app, called acQuire Arena, gives miners a better way of working when capturing blasthole samples. Samplers and pit technicians can position themselves on the blast pattern, capture samples on simple, user-friendly forms and instantly validate their data at the point of capture.”

This speeds up the time it takes data logged in the pit to become available to downstream grade control processes like modelling and ore blocking, according to the company.

“In the current global climate, where many are affected by COVID-19 restrictions through either reduced or paused operations, it’s becoming crucial for miners to use new technology solutions to their advantage,” acQuire said.

Steve Mundell, Director of Product, said enhancements to the acQuire Arena app extended its data capture capabilities for grade control so pit samplers could work faster and more accurately.

“Miners who are still logging on paper, or using more manual methods of data collection, now have a reliable and modern mobile solution that works in the pit and seamlessly synchronises data back to the central database,” he said.

The acQuire Arena app is purpose-built for GIM (Geoscientific Information Management) Suite, with full integration across desktop, web and mobile, according to the company. “Its modern, user experience designed interface dynamically changes across different device sizes and it is optimised for Android and iOS operating systems, giving geologists more freedom to choose the device they prefer to use,” it said.

The GIM Suite 4.2 software release marks a significant step on acQuire’s technology roadmap, it said. “With greater functionality added across web and mobile, customers will continue to benefit from more and more features introduced in the future,” the company added.

acQuire says it provides geoscience data management software and services for the global mining industry with five offices worldwide and customer support centres operating in each major time zone.

Caterpillar releases new blasthole rig for large-scale mining

Automation, Equipment maintenance, Explosives and blasting, Mining equipment, Mining safety, Mining services, Mining software, , , , , ,

Caterpillar says its newest ultra-class rotary blasthole drill rig provides the optimal mix of on-board air, feed force, rotary torque and machine mobility.

Designed for large blasthole production drilling, the MD6380 can deliver a hole diameter range of 251-381 mm, single-pass hole depth of 19.8 m and multi-pass hole depth of 39.5 m, according to the company.

The MD6380 powertrain is designed to efficiently manage loads generated by the compressor and hydraulics, delivering superior fuel economy, Cat says. The compressor is configured with electronic regulation and variable volume air control, allowing the driller to match compressor output with drill tool and application needs. It also lowers standby pressures while the machine is in idle, further improving fuel efficiency.

The MD6380 is capable of pulldown force of 49,895 kg and rotation torque of as much as 20,880 Nm, Cat says, adding that the Cat 3512C diesel engine produces 960 kW and delivers emissions performance equivalent to US EPA Tier 2 and EU Stage II. The powertrain offers extended durability and high availability to help boost use and lower costs, the company added.

Controlled through Cat electronics, the MD6380 has integrated machine protective features and interlocks to help keep operators safe and the machine up and running by preventing potential failures or misuse. Cat Electronic Technician makes troubleshooting quick and easy, the company said. Drill electronics also provide a common platform for the integration of automation solutions.

The MD6380 features a spacious cab that offers superior operator comfort and machine control, Cat says, while an intuitive multi-function joystick controls and touchscreens promote efficient operation.

Display screens are adjustable to suit the driller’s reach and line of sight, and the driller can easily tram from a seated position, according to the mining OEM. “With a full-length driller window, large pane glass around the cab and four standard high-definition cameras, operators have excellent views of key areas,” Cat says.

The machine also features Drill Assist, which delivers automated functions including auto level, auto retract jacks, auto raise and lower mast, and auto drill. The drill depth monitoring system helps to reduce both over- and under-drilling.

The MD6380 incorporates Cat Terrain for drilling, with the MineStar™ technology providing precise hole location, production reporting and strata reporting. Terrain seamlessly connects to Cat Command, offering a path to remote operation and autonomous drilling, Cat added.

“The drill features a best-in-class working envelope with a low centre of gravity and ample approach angles,” Cat claims. These attributes aid manoeuvrability, allowing it to navigate quickly and efficiently hole-to-hole and bench-to-bench.

The Cat excavator-style undercarriage has grease lubricated track pins, positive pin retention and automatic track chain tensioning – all to help the undercarriage deliver extended durability and optimal performance on grades and in tough operating conditions, the company says.

The MD6380 is designed to be rebuilt multiple times for lowest lifecycle costs.

“With parts, maintenance services, condition monitoring and component rebuilds, Cat dealers help ensure high productivity and lowest cost per tonne,” the company said.

CR Digital to tackle fragmentation optimisation with Thunderbird buy

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CR Digital has agreed terms to acquire Seattle-based Thunderbird Mining Systems in a transaction that, it says, further expands CQMS Razer’s digital technology division’s product offering, IP, sales/marketing and technical support activities.

Thunderbird founder, John Vynne, and his team have been pioneering measurement while drilling (MWD) technologies since founding the company and have a rich history in drilling technology and guidance for surface mining, CR Digital said.

Damian Assaillit, Head of CR Digital, said: “Thunderbird Mining Systems were highly regarded in the mining technology sector, providing world-leading blasthole drill optimisation technologies to mining customers for over 30 years.”

Vynne added: “There is immense appetite for digital knowledge of drill planning and blast outcomes, and the Thunderbird technology combined with CR Digital’s Load Haul Optimization creates a unique and compelling combination that our mining customers will be able to leverage.

“Thunderbird’s technology is proven to increase mine productivity, reduce drilling costs and improve blasting effectiveness.”

The addition of blasthole drill optimisation and rock knowledge systems reflects a strategic move by CR Digital to expand its product range across fragmentation through to load and haul optimisation, it said.

Assaillit said: “Thunderbird Mining Systems products complement our existing CR Digital product range, including our market-leading Titan 3330™ Load Haul Optimization technology. Optimised fragmentation is a key variable in the productivity of load haul circuits and being able to offer our customers more real-time knowledge is a great opportunity to further enhance mining productivity using technology.”

The Titan 3330 technology uses sophisticated instruments and patented algorithms to calculate and display the payload of each bucket, accurately, in real-time and during motion, before it is dumped into the truck, according to CR Digital.

CR Digital said Thunderbird Mining Systems’ customers will benefit from the enhanced capability of the global CR group, CR Digital’s proactive technical support, the data analytics capability of its Orion platform, and access to a broader technology portfolio providing enhanced value to their operations.

Cat DTH hammers and bits up the ante in blasthole drilling

Equipment maintenance, Explosives and blasting, Mining consumables, , , , , ,

Caterpillar has introduced its first Cat® down-the-hole (DTH) hammer and bits for blasthole drilling as it looks to speed up penetration rates and reduce drilling costs in difficult conditions.

The new Cat DTH Hammer is 152 mm (6 in) in diameter and is the first to be introduced in the new DTH line. Its valved design provides reliable operation, low air consumption, easier maintenance and cost effective rebuild, according to the company. The piston design, meanwhile, delivers long life and efficient energy transfer.

The new hammer is rated to run with compressed air systems driving working pressures up to 34.5 bar (500 psi). Cat explained: “This additional back-head pressure, when combined with corresponding airflow demanded, generates more blows-per-minute to generate faster penetration rates in the hardest of materials.”

Caterpillar also is introducing bits for DTH drilling. Several different configurations of 171 mm (6.75 in) bits are now available in both standard and heavy-duty versions to allow matching the bit to the rock characteristics and job requirements. The bit selections include a variety of carbide shapes (spherical, ballistic) and face shapes (concave, flat, convex).

“Cat Bits are optimised for high wear resistance and improved rock chipping,” the company says. “The aggressive, long-lasting cutting structure in conjunction with the efficient Cat DTH Hammer delivers a superior rate of penetration.”

Caterpillar’s advanced materials and heat treatment technology used in the DTH products yield longer life and result in lower overall drilling costs in demanding conditions, it says. In head-to-head tests conducted in iron ore and quarry applications, Cat says its hammers and bits demonstrated significantly lower total cost of drilling.

Epiroc lifts the lid on automation success in Q2 results

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After many years of automation talk, the mining industry finally appears to be investing in this new technology judging by Epiroc’s latest financial results.

The Stockholm-based company reported record revenue of SEK 10.6 billion ($1.13 billion), alongside a 25% year-on-year operating profit increase to SEK 2,263 million in its June quarter financials, but the most interesting elements from this release were comments from the company on automation.

Epiroc says it is a market leader in automation, connectivity and battery-electric vehicles, with the company noting customer interest in, and demand for these solutions, is growing quickly.

In the quarter, the company launched 6th Sense, its new offering of solutions to enable customers to optimise processes by connecting machines, systems and people using automation, information management and system integration, and to achieve higher production at lower operating costs.

Even though it is early days for this initiative, Per Lindberg, President and CEO of Epiroc, said the company has more than 2,500 connected machines on its books; a number that is rapidly increasing.

“For example, for production drill rigs, the number of connected machines has doubled in the last year. We also see that connectivity is an enabler for increased utilisation,” Lindberg said.

In underground drilling, Lindberg said more than 550 of its drill rigs are equipped for complete automation of the drilling process and, in surface drilling, it has the largest installed base of autonomous rotary drill rigs. On the latter, the world’s first fully autonomous SmartROC D65 down-the-hole drill rig is now operating in Canada, it said.

“Also, the interest in our next generation underground battery-electric vehicles continues to be strong and we received more orders for these machines in the quarter,” the company said.

Epiroc provides the next ‘evolutionary step toward fully autonomous mining’

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Epiroc has introduced the fifth generation of its Rig Control System (RCS) on Pit Viper blasthole drills as it looks to equip miners with all of the tools to embrace full automation.

RCS 5 for Pit Viper blasthole drill rigs is the next “evolutionary step toward fully autonomous mining”, the company said upon launch of the system earlier this month at the Bauma fair in Munich, Germany.

Features such as Machine-to-Machine Communication, sharing real-time drill plan updates between drills, Auto Tower Angle and Integrated Camera View advanced awareness are some of the early features introduced, Epiroc said.

“Whether operating from a remote location or on-board the drill, the new and improved RCS 5 intuitive main menu creates a user-friendly experience that ultimately increases productivity. This new design allows the operator to focus on the task-at-hand and switch seamlessly between screens in a well-organised and dynamic environment.”

RCS 5’s new Drill Plan Generator function allows for creation and editing of drill plans on-board the rig or from a remote location quickly and easily, according to Epiroc. The new Drilling Data Screen, meanwhile, features real-time depth and penetration rate feedback with histogram for easy in-hole monitoring.

Tyler Berens, Product Line Manager, Automation at Epiroc Drilling Solutions, said: “We’re excited to continue our automation journey, pushing the limits in sustainable productivity. Launching the RCS 5 platform will allow our customers and partners to further advance their operations, saving valuable time and dollars while increasing predictability and safety with either on board or autonomous operations.

“Autonomous operations began with RCS 4, wait until you see where we take it with RCS 5.”

Paradigm Shifters qualify for round two of Canada’s Crush It! Challenge

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A group of companies called ‘The Paradigm Shifters’ has made it to the next round of a challenge aimed at reducing the amount of energy that crushers and grinders use in the mining process.

The Crush It! Challenge is spearheaded by the federal government (Impact Canada), in cooperation with Natural Resources Canada (NRCan), the Centre for Excellence in Mining Innovation (CEMI), and Goldcorp.

Crushing and grinding account for upwards of 50% of mine site energy consumption and up to 3% of all the electric power generated in the world.

iRing Inc is the lead partner within The Paradigm Shifters and has coordinated the effort with proposal partners to respond to the challenge, it said.

The company explained: “Essentially the team proposes to bring together the processes and technology that could reduce or even eliminate the need for expensive primary crushers, and reduce the energy required by secondary crushing (potentially eliminating it as well) and grinders in both mines and quarries globally.”

The Crush It! Challenge has several qualifying rounds and, if successful in getting to Round 3, then the team will be eligible to receive C$800,000 ($605,397) in seed funding to further prove the concept over a one-and-a-half-year period. At the end of that period, if the team wins the chance to move forward, the project would be eligible to receive an additional C$5 million in funding to commercialise the products and concepts.

The Paradigm Shifters team consists of:

  • iRing Inc (North Bay) Challenge Project Lead – Drill and blasting software;
  • Nexco Inc (North Bay) – Producer of the energy-variable explosive product;
  • Boart Longyear (North Bay and global) – Global supplier of market leading drilling products and services;
  • Paige Engineering Ltd (PEL) (North Bay) – Design and fabrication of explosive manufacturing and loading equipment;
  • Seneca (Montreal) – Explosive plant engineering, design and build;
  • Maptek (Denver and Global) – 3D laser scanner/fragmentation measurement capabilities, and;
  • Bomon Capital (Toronto) – Long term financing should the team succeed.

The savings that could accrue to mines and quarries annually is C$12.8 billion (25% reduction) to C$25.6 billion (50% reduction), according to iRing.

“If all mines in the world adopted this solution, it would represent a reduction equivalent to 7-13% of all the carbon released in Canada, and 20-41% of Canada’s contribution to meeting the Paris Accord agreement.”

iRing will use its software, Aegis, to design the blasting patterns based on the fragmentation requirements. Boart Longyear will deploy recently developed high speed diamond drilling technologies and instrumentation solutions to quickly and accurately drill and validate high-quality blast holes, while using significantly less energy. iRing said: “Boart Longyear’s drills utilise drilling data logging to interpret rock density and strength etc, while drilling.”

The company continued: “With Seneca’s help, Nexco will build a demonstration plant that will produce an energy-variable explosive mixture that can be fuelled while being loaded into the blastholes, and the blast energy would be based on the ore strength information provided by Boart Longyear’s drills and iRing’s software.”

Troy Williams, Vice President of Development of iRing, said: “The challenge will provide a once-in-a-life-time opportunity to reach the mining industry and demonstrate that it is possible to produce consistent results from the blasting operations.”

PEL will design and fabricate the explosive manufacturing and loading equipment required to change the explosive’s energy during loading, according to iRing. Energy reduction is done by adding additional water content into the explosive formulation during loading. Maptek’s laser scanner, meanwhile, will be used to verify fragmentation results by scanning the muck pile and producing a 3D point cloud which can be analysed for a measured fragmentation distribution. Those results will be used by Aegis to further calibrate the fragmentation models.

Mark Sherry, President of iRing, said: “We are really excited by this opportunity as it is directly in iRing’s wheelhouse. The Paradigm Shifters bring together the best in the industry when it comes to drilling and blasting. By working together, we will create a paradigm that is more efficient, effective, cleaner, and safer”.

Sandvik builds on rotary blasthole drill foundations with new xSeries

Automation, Equipment maintenance, Mining consumables, Mining equipment, Mining services, , , , , , , , ,

Sandvik has launched the xSeries family of rotary and DTH drills, as it looks to offer a “migration path” to its iSeries of drill rigs.

The xSeries is built upon the proven design and reliability of Sandvik’s diesel-powered rotary blasthole drills and features added intelligence and improved operator ergonomics, according to the company. “This provides operators with the right balance of reliability and technology to drill the perfect hole safely,” Sandvik said.

Highlights of the xSeries, according to Sandvik, include:

  • Touch screen GUI interface featuring the Sandvik Automation Module (SAM) offering the following options:
    • Health monitoring system – replaces old style shutdown switches and enables continuous, real-time measurement, allowing the operator to take the necessary actions in advance of any alarm situation;
    • Same hardware and software components as the iSeries machine including a 7 inch (17.8 cm) mobile-grade rugged touch screen and latest generation PLC;
    • Improved user experience – enhanced control system features (as found with the iSeries machines) reduce troubleshooting time and increase availability. Familiar Sandvik “look and feel” graphical user interface reduces the learning curve.
  • Compressor Management System (CMS) Lite electronic controlled compressor system;
  • Oversize driller’s window offers a “superb view” of the drill table during operation and improved visibility during tramming;
  • Bolt-on mast locks eliminate cutting and welding, making mast change-outs easy;
  • Swivel-enabled operators seat with integrated electrohydraulic controls simplifies operation and offers improved visibility of operating environment.

Jacques Britz, Vice President, Surface Pedestal Drills, Sandvik Mining and Rock Technology, said: “For decades, customers have counted on Sandvik to develop the most durable products in the market – rigs that will be able to work at a mine site for decades.

“In developing the xSeries, we’ve taken our customers’ feedback into our research and development efforts and are proud of the newest addition to our product line.”

Sandvik says the xSeries offers a migration path to the iSeries “should the customers’ business needs dictate”.

iSeries drill rigs are equipped with Sandvik Intelligent Control System Architecture, which provide a wide range of functions for maximising performance and precision in drilling, and have features for fully-automated face drilling, optimised penetration, boom control systems and comprehensive tools for drill planning, reporting and analysis, the company said.

Caterpillar looks to solve transportability issues with MD6200 rotary blasthole drill

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The new Cat® MD6200 rotary blasthole drill has flexibility at its core; being designed as a production drill with the flexibility to do pre-split drilling. And, all of this is in a package that is Caterpillar’s most transportable rotary drill yet.

The MD6200 can perform rotary or DTH drilling in single-pass or multi-pass modes and can drill holes of 127 mm to 200 mm (5-7.87 in) in diameter.

It can drill at a negative angle up to 15°, which enables matching the slope of the highwall for pre-split drilling. This results in cleaner highwalls with less waste material going to downstream operations, according to Cat.

For traditional production drilling, the mast can tilt from vertical out to 30°, while the operator can adjust the mast angle in increments of 5° from the touch screen in the cab — with no special setup required.

Transport

The MD6200 can be transported over the road with the mast on, so can roll onto a truck when it’s time to move to another site. The new drill also has the smallest shipping envelope of any drill in its class, says Cat. In some configurations, parts outside the shipping envelope can be removed without the use of lifting tools, allowing two people to prepare it by hand for shipping.

“The drill also offers best-in-class manoeuvrability,” the company says. “Its compact working envelope and powerful undercarriage get it into position faster, reducing the time spent accessing drill patterns and moving between holes.”

A Cat 336 excavator-style undercarriage provides superior durability, tractive effort and drawbar pull, Cat adds.

The MD6200 also benefits from the integration of a Cat C18 engine, available in US EPA Tier 4 Final configuration and in US EPA Tier 2-equivalent configuration to suit regional needs.

Both high pressure and low-pressure compressor configurations offer variable volume air control, matching the compressor output to the drill tool and application needs. The system also lowers stand-by pressures while the machine is idle, further improving fuel efficiency, according to Cat.

The MD6200 also comes with Cat electronics, offering technicians the same architecture used on the company’s other machines. They also provide a platform for automated controls.

“Integrated machine protection features and interlocks help keep operators safe and the machine up and running by preventing potential failures and operating errors,” Cat says.

Product Link™ Elite allows drill health metrics and performance to be easily downloaded and tracked in real time.

The Cat cab

When it comes to the cab, the MD6200 is designed to promote operator comfort and productivity.

Ergonomic controls help the operator remain productive and efficient through the entire shift, while optional upgrades, such as a heated, ventilated seat with heavy-duty suspension and dual-pane glass, provide comfort on long shifts, according to Cat.

“Multifunction joystick controls and touchscreens are intuitive to use, and three standard cameras give the operator awareness of the work area,” Cat says.

The technology options that come with the MD6200 make it more productive and efficient. Drill Assist offers a number of automated functions, including auto level, auto retract jacks, auto raise and lower mast, and auto drill. Meanwhile, the drill depth monitoring system helps to reduce over- and under-drilling, boosting productivity and fragmentation.

The MD6200 is also ready for Cat Terrain for drilling, which uses guidance technologies to help operators drill holes in the exact location specified by the plan, resulting in smoother, safer and more efficient blasting.