Tag Archives: Drill and blast

Orica keen to collaborate on path to blasting automation

Automation, Explosives and blasting, IoT, Mining consumables, Mining events, Mining safety, Mining services, Mining techniques, , , , , , , , , , , , , , , ,

Orica’s Angus Melbourne told a packed Austmine 2019 crowd in Brisbane this week that the blasting specialist is committed to developing automated solutions for both the underground and surface mining sectors and is working with both customers and industry partners to make this aim a reality.

During his speech on Wednesday, Melbourne, Orica’s Chief Commercial and Technical Officer, walked delegates through a number of achievements the company had achieved over its 140-year history, but also looked ahead to how Orica is focused on revolutionising the drill and blast operations of the future.

“Blasting is one of the few processes in the mining value chain that remains largely untouched by automation,” Melbourne said. “As mines go deeper and orebodies become more remote, the case for blasting automation becomes clearer.”

Among a number of benefits of blasting automation were the ability to remove people from harm’s ways, grant access to difficult ore reserves and reduce operational delays, he explained.

“Due to the complexities associated with a typical blast operation, this is no trivial endeavour,” he said.

Melbourne said progress was already being made with Orica’s automation efforts, singling out its Orica’s WebGen™ wireless initiation technology, in particular. Launched in 2018, WebGen improves safety by removing people from hazardous situations and enhances productivity through the removal of constraints previously placed on operations by wired connections.

“Since its release, more than 130 WebGen wireless blasts have been executed globally across four industry segments,” Melbourne told delegates.

Newmont Goldcorp’s Musselwhite mine has been an advocate of the wireless initiation technology, recently saying the blasting tests it has carried out at the Ontario mine were “a decisive step on the path towards full automation of drill and blast operations in the future”.

The wireless initiation technology is leading to the development of new blasting options, according to Melbourne, who said, in the last 12 months, Orica has co-developed more than seven new techniques that are “revolutionising the way our customers are planning and executing their mining operations”.

On stage, Melbourne then played a short video from CMOC Northparkes in New South Wales, Australia, a miner that recently converted its entire sub-level cave copper mine to WebGen wireless initiation blasting; an Australia and world first, according to Melbourne.

He said Northparkes has seen significant improvements in safety, productivity and ore recovery since the transition. Melbourne’s words were echoed later that day when Orica received the Austmine METS Innovation Award for the use of WebGen at Northparkes.

Melbourne pointed to a second collaborative development that was helping shape the company’s blast automation efforts during his time on stage; this time with an original equipment manufacturer.

The company has been working with MacLean Engineering out of Canada to test the first fully-mechanised drawpoint hang-up blasting solution, he said.

Capable of drilling and charging up to eight blast holes remotely, the solution is underpinned by WebGen wireless technology and, once again, removes people from harm’s way.

“Hang-up blasting is a major issue for block and sub-level cave mines around the world,” Melbourne said. “In fact, at any one time, up to 30% of all drawpoints can be unavailable due to oversize material. All current solutions are either high risk mining activities or are highly inefficient to implement.”

He then played a video highlighting this industry-first solution, before remarking: “This is a significant step towards fully-autonomous production in underground mines. It’s an exciting time for everyone involved and is just one example of an industry collaboration to deliver blast automation.”

Melbourne concluded his presentation by saying, in the future, integrated, automated and intelligent systems will deliver the critical data necessary for executing real-time change and quantifiable impact on all parts of the value chain “through an ‘ecosystem of insight’ never seen before in mining.

“To capture the full potential of rapidly-evolving technology will require new ways of thinking, new ways of working, and a new spirit of collaboration across the industry.”

VIST working on autonomous drilling project with SUEK

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VIST Group (a subsidiary of Zyfra Group) has started developing unmanned drilling technology using an Epiroc Pit Viper 271 for SUEK’s Tugnuysky open-pit coal mine in Buryatia, Russia.

The new system is intended to minimise the number of employees involved in hazardous and dangerous work, while maintaining or even reducing drilling costs, VIST said.

The drill rig will have a pre-set for independent performance of most operations usually performed manually by the operator. It will be furnished with additional functions: motion control, environment scanning (including the possibility of remote presence), automatic testing of the installed equipment, high-precision positioning and emergency shutdown, as well as two-way data transmission, VIST said. At the same time, manual control from the cabin will still be possible in normal mode.

The equipment installed on the rig will include a system of environmental scanning sensors (short- and long-range radars, 3D light identification detection and ranging device) to ensure early detection of any obstacles, bunded areas or cliff edges, and will prevent collisions. A multi-level automatic testing system will prevent the failure of various elements, according to VIST.

The controller will monitor the status of the assemblies and the connection to the server, and compare the data from different subsystems. The server will check the stability of communication with all elements and compare the data received from them.

VIST said: “It is anticipated that this innovative solution will significantly improve operational safety and efficiency in the Siberian mines, which rank among the world’s largest coal mining centres.

“Thanks to the new technology, it will be possible to move drills independently or in remote mode along the stack, drill shafts, assemble and dismantle the drilling assembly and level the platform. An algorithm will be used to determine the optimal sequence of drilling the shafts, taking into account their relative position and type of rock mass.”

The system will operate as follows: The drill operator will move the equipment to the required stack in manual mode. Another employee will then remotely set a drill plan for the rig in this area and engage the independent operation mode. At the same time, the system’s built-in safety algorithms will control the drill’s movement, taking note of the equipment and employees performing auxiliary work in the area. Personnel operating near the drill will be equipped with an emergency shutdown device, which, if necessary, will immediately stop the robotic equipment.

The operator will exercise remote control from his computer workstation located at the enterprise and, if necessary, will be able to quickly take control of the equipment during any process operation, such as in the event of complex non-standard situations. In this case, the digital system will actively help the human operator, warning of potentially dangerous factors while displaying the status and additional information.

Specialists will be able to remotely control the engines, compressors and controllers, moving, turning, mast raising and lowering mechanisms, assembly of the drilling unit, the braking system, drilling itself, etc. In addition, the dispatcher will deal with security issues such as the admission of equipment and people to the automated site.

“In general, however, the human role will be minimised, and if any intervention is required this will only be in rare specific cases,” VIST said.

“The automation systems themselves will cope perfectly well with the tasks. Satellite navigation and special drill control programmes that are activated when directly approaching a specific location will provide incredible pointing accuracy of up to 10 cm. The system will also develop routes for the drill’s movement between the wells, paying great attention to the optimal path and the absence of unnecessary actions and thereby minimising costs.”

The drill, without the intervention of personnel, will be able to level the platform and the mast independently with an accuracy of 1° in two planes, based on two-axis inclinometer readings, processing current data and generating commands to the alignment mechanisms on the basis of this data. Digital control of these mechanisms will be provided, and depending on their design, it will be possible to use mechanical actuators, electrical or control signals through the standard CAN industrial network.

A number of subsystems and algorithms will be created for independent drilling, according to VIST. In particular, a set of sensors for monitoring parameters (feed forces, rotation forces and speeds, gas-water mixture pressure, depths, etc) will be installed in the equipment, as well as a subsystem based on actuators and feedback sensors for assembly build-up and dismantling.

The robotic drill will fit into the enterprise’s existing data environment, VIST said. The existing MTC Karier management system will handle fuel consumption metering and reporting issues, with the newly developed solution becoming part of the Intellectual Karier system. This will make it possible in future to centralise control over several drills simultaneously, including simultaneous operation of these rigs in the same stack.

The company said: “VIST Group has no doubt that the automated solution being developed will prove its economic efficiency during the planned pilot operation and will significantly increase the safety of production processes.

“As we speak, experts are ascertaining the possibility of deeper digitalisation and more advanced operation of the enterprise, addressing all the challenges and tasks dictated by the new industrial revolution that is taking place before our eyes.”

Dyno Nobel and Mining3 technology development initiatives align

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Incitec Pivot Ltd (IPL) has announced that Dyno Nobel has entered an agreement with Mining3 to collaborate with global mining industry members to “develop and deliver transformational technology to improve the productivity, sustainability, and safety of the mining industry”.

As of March 1, IPL – parent company to Dyno Nobel – signed the membership deed to collaborate with, and leverage from the world-class research Mining3 offers, it said.

Mining3 Chief Executive Officer, Paul Lever, said: “Having this major global explosive supplier joining Mining3 strengthens the breadth of engagement within the mining industry, brings a fresh new perspective and an opportunity to participate in a wider range of innovations.”

Robert Rounsley, IPL’s newly appointed Chief Technology Development Officer, said: “We are actively building out Dyno Nobel’s technology development capability. We can offer our customers an even richer solution set, and we believe collaborating with Mining3 and its members will accelerate this undertaking.”

Dyno Nobel is a world-renowned explosives manufacturer with a strong customer focus, which prides itself in delivering practical innovation on the ground today and in the future for its mining and resources customers.

Dyno Nobel plans to leverage the Mining3 membership through the identification of, and collaboration for, the development of new technologies important to the industry.

Wayne Stange, Dyno Nobel’s Vice President of Mining Technology, said, “There are several Mining3 projects that are aligned with our technology development initiatives. Through our Mining3 membership, we will be able to work with a range of researchers and mining equipment and technology services to accelerate the development of transformational technology”.

One project Mining3 is working on, which will probably interest Dyno Nobel, is the pursuit of a non-toxic post-blast bulk alternative explosive.

Goldcorp’s Peñasquito mine seeing benefits of fully-autonomous drilling

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Goldcorp says it is seeing the multiple benefits of autonomous drilling at its Peñasquito gold mine in Mexico, with the company set to ramp up the use of this technology in the next few years.

In a site visit presentation, the company said using a fully-autonomous drill solution – where the drill is given instructions that it carries out automatically supervised by an operator in a safe and climate-controlled area – has been beneficial to the amount of metres drilled, the quality of drill holes and safety.

In 2017, Peñasquito pursued the use of automation by fitting two drill rigs with autonomous technology for a trial as it looked to reduce its workforce’s exposure to potential hazards associated with drilling in the open pit.

The company now has multiple rigs installed with this technology. In 2018, it retrofitted two Epiroc Pit Viper PV-351 rigs with autonomous features and it is set to retrofit another two this year, according to the site visit presentation. In 2019, it also intends to bring in two automation-ready Pit Viper PV-271s (pictured), and has another scheduled for delivery in 2020.

These are supervised in a control room where up to 12 rigs can be monitored.

The company’s current drilling fleet includes nine Pit Viper PV-351s, one Pit Viper PV-271 and four Flexiroc D65s, according to the presentation.

On the technology itself, Goldcorp said: “The drill can now operate through blasting and other interruptions, providing opportunities for additional drilling hours.”

In addition to this, the autonomous drills can achieve a consistent higher penetration rate, while improving metres per operating hour and reducing operating costs.

Goldcorp said operating hours per calendar day per drill had increased 25% since the introduction of fully-autonomous drilling, while the metres drilled per operating hour had risen 12%. This has amounted to a 40% productivity gain in metres per day, plus improved fragmentation, it added.

Just this week at an SME Annual Conference & Expo press briefing, Matthew Inge, Business Line Manager, Drilling Solutions for Epiroc, said companies were also achieving significant maintenance benefits from the use of autonomous drilling solutions.

Maintenance savings add to autonomous drilling business case, Epiroc says

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The application of autonomous drilling solutions at mine sites is resulting in more than just productivity improvements, Matthew Inge, Business Line Manager, Drilling Solutions for Epiroc, said at an SME Annual Conference & Expo press briefing this week.

Inge said the customer feedback the mining OEM had received from the 30 or so automated rigs it had at mine sites, which had drilled close to 7.5 million metres autonomously, had included significant cost savings on maintenance.

“When you talk to most customers, operators and mines they will tell you that autonomous drilling is a productivity resource,” Inge said. “One of the by-products we have seen is reduced cost of maintenance.”

He said some of the company’s biggest customers had estimated “some very large figures” for maintenance cost savings linked to, for example, reduced operator abuse of the rig and improved drill string component life.

Such savings were lowering the total cost of ownership that came with operating these machines, while also strengthening the business case for further automation on mine sites.

During the same press briefing, Epiroc announced its automation-ready Epiroc Pit Viper PV-231 would be available from Spring of this year following an 18-month field test at a Nevada gold mine. Inge said this test was probably one of the most successful trials the surface drilling team had ever experienced.

Goldcorp and Orica looking at further WebGen applications at Musselwhite

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Following successful trials of Orica’s WebGen™ 100 at the Musselwhite gold mine, Goldcorp says it is looking at further drill and blast geometries and mining methods using the wireless blasting initiation system at the Ontario mine.

Goldcorp said these blasting tests underground at Musselwhite indicate “a decisive step on the path towards full automation of drill and blast operations in the future”.

In 2016, in collaboration with Orica, Musselwhite began testing WebGen, a system which fires primers through hundreds of metres of solid rock. “The wireless system has been designed to fully integrate with a mine’s existing blasting systems and improves safety by removing people from harm’s way,” Goldcorp said.

The project was recently announced as an award winner, which recognised the development of the temporary rib pillar (TRP) mining method using WebGen.

“The TRP is a revolutionary mining method that uses WebGen technology to extract ore pillars that previously could not be recovered in underground operations,” Goldcorp said. “Using this new method, the main ore of the panel can now be blasted and extracted while the TRP holds back the waste rock backfill. The inaccessible pillars can be blasted, delivering reduced dilution, increased truck fill factors and improved overall productivity.”

The system tested at Musselwhite enables groups of in-hole primers to be wirelessly initiated by a firing command that uses an ultra-low frequency magnetic induction wave to communicate through rock, water and air, according to Goldcorp. “This removes constraints often imposed by the requirement of a physical connection (wires) to each primer in a blast,” the company said.

The magnetic induction wave is transmitted by an antenna at around 1,800 hertz, and received by disposable receivers in each borehole, according to Goldcorp. Each 51 mm-diameter, 320 mm-long disposable receiver has a tri-axis antenna array to receive the signal, supporting any blasthole orientation.

Goldcorp said: “Following the blast plan, each disposable receiver is encoded with the Group ID for its blast, and each detonator with a delay time, just prior to being loaded into the blastholes. A standalone Code Management Computer (CMC) – a tablet wiped of other software – is uploaded with a CSV file from Orica’s blast design software. The CMC assigns the encrypted firing codes and delay timing into a preload blast file. A handheld encoder takes the data from the CMC and encodes each disposable receiver and detonator.”

Three separate codes make up the Group ID, and all three must be received from the transmitter to initiate a blast, according to Goldcorp. First, a wake-up code activates the appropriate disposable receiver from sleep mode. Next, the activated disposable receiver receives an arm code, which calibrates and synchronises the units. Finally, following the mine central blasting protocol, the fire signal is sent, firing each detonator according to its programmed delay time. Other disposable receivers, having not received their wake-up code, remain dormant in their blastholes, ready for subsequent blasts.

Following these tests, further drill and blast geometries and mining methods using WebGen are being explored at Musselwhite, Goldcorp said.

Musselwhite’s Chief Engineer, Billy Grace, said: “Since starting the TRP trials with WebGen in late 2016, our level of comfort with the technology has reached a point that discussing possible wireless applications is an integral part of our mine planning process. The entire team is excited by the possibilities that WebGen opened up, and the new opportunities they are allowing for us to increase our productivity and safety.”

At Orica’s 2018 AGM, Alberto Calderon, Managing Director and Chief Executive Officer at Orica, called WebGen “the most exciting development our industry has seen since bulk explosives in the 1960s”.

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”.

MAXAM to showcase underground blasting solutions at Indaba

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MAXAM will be showcasing the latest blasting technologies on offer to its customers in Africa at Mining Indaba in Cape Town next week as it makes its third consecutive appearance at the event.

MAXAM has a workforce of more than 800 employees and projects in over 20 countries, and has the largest footprint in the Africa continent among the leading blasting solutions providers, it says.

“This position is cemented in its comprehensive range of technologies and local capabilities to support customers,” MAXAM said. “The company is also the leading supplier of packaged explosives and offers both watergel and emulsion bulk products, boosting a versatile portfolio to adapt to specific needs from its different customers.”

Brett Wheatcroft, Regional Director of MAXAM in Southern Africa, said Africa is one of the most important mining areas in the world and the company’s commitment to the continent is clear.

“We have been investing here for more than 40 years and the results couldn’t be better: we are a leading player within our segment of activity and have a growing customer base that more and more values our differential, high-value combination of technologies and technical support.”

MAXAM will take advantage of Mining Indaba to showcase its complete range of solutions for underground operations. Customers attending the event will have the chance to get to know more about one of its novel technologies, RIOFLEX, a highly energetic, robust and flexible density bulk product that, MAXAM says, achieves excellent performance in all types of rock. “This bulk watergel contributes to minimise the total cost of ownership due to the savings in the drilling and blasting application and the whole value chain of the mine as a result of a better fragmentation,” the company said.

RIOFLEX has been tested in more than 140 sites in 25 countries, becoming a benchmark for customers looking to improve the productivity of their mines, quarries and infrastructure projects, according to the company.

Fernando Beitia, Director of Bulk Products of MAXAM, will talk about the company’s emulsion and watergel technologies at a conference during the event.

MACA drafts up mining contract for Okvau gold project in Cambodia

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ASX-listed MACA has entered into a memorandum of understanding (MoU) with a subsidiary of Emerald Resources to supply equipment and contract mining services at the Okvau gold project in Cambodia.

The MoU with Renaissance Minerals is subject to a final investment decision to develop the project by the Emerald Resources Board of Directors, MACA noted. A draft mining contract between MACA and Emerald, agreeing on all material terms, conditions, schedules and rates, will be executed upon this decision.

MACA’s proposed scope of work under the mining contract includes load, haul, drill and blast utilising 100-t class dump trucks, with the initial term of the contract aligned to the current schedule of seven years with an option to extend. This equates to around $220 million in revenue, MACA said.

MACA Managing Director, Chris Tuckwell, said MACA will use the experience it gained in establishing both a foreign subsidiary and starting a new mine whilst working in Brazil over the last four years to Renaissance’s Cambodia project.

Emerald Resources’ Managing Director, Morgan Hart, said: “The board and management of Emerald have worked closely with the team at MACA over the past 20 years in a multitude of successful operations and are very pleased to continue the relationship on the Okvau gold mine development.”

On 1 May 2017, Renaissance announced the completion of the definitive feasibility study (DFS) on the development of a 2 Mt/y operation at Okvau. The DFS delivered an initial ore reserve of 14.3 Mt at 2 g/t Au for 907,000 oz of gold at an average all-in sustaining cost of $731/oz over an initial seven year life of mine.

Sandvik breaks new ground with introduction of industry’s fastest drill bit

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Sandvik thinks it has introduced the fastest drill bit in the industry with its new Speedy bit.

In addition to 10% higher drilling speed compared with standard bits with ballistic buttons, the Speedy bit also delivers great collaring accuracy and hole quality, according to the company.

Sandvik said the increased speed enables Speedy bit users to save one hour per day for each drill rig.

Robert Grandin, Product Manager for Underground Top Hammer at Sandvik Rock Tools, said: “Sandvik is continuing to break ground in the drilling business with the introduction of Speedy bit. With increased drilling speed, customers can expect significant cost savings. This can translate into more than $100,000/y.”

He added: “Since drilling faster also reduces machine-related costs per metre advanced, such as for operators and maintenance, the Speedy bit is an excellent example of our aim to always maximise the output of our customers’ investments.”

The Speedy bit, which features one of Sandvik’s new PowerCarbide grades, outperforms the standard bits in the industry with aggressive buttons that penetrate deeper with each strike and increased cutting size, according to Sandvik.

The patented elevated front breaks the rock in two levels and improves the flushing flow, while large sludge grooves enable quick removal of large cuttings.

Sandvik Speedy bits are available in three dimensions: 45 mm, 48 mm and 51 mm.

Grandin said the Speedy bit has proven its performance in the field during more than 20 trials in mine development and tunnelling. “On average, drill speed increased by 9% compared to bits with ballistic buttons, including several regrinds,” he said.

Sandvik offers a full drill string from shank adapter to bit, designed for reliability, performance and longevity. The Speedy bit, which is available to order, is developed to boost productivity in the whole drilling process.

The introduction of the Speedy bit comes a day after Sandvik released its new drilling tool system, the Alpha 360.