This month’s Spotlight Feature Article delves into the world of rock tools, where the level of R&D and innovation continues to climb. This is down to the potential to reduce drilling costs, increase drilling productivity and integrate with new rig designs.
Sandvik is introducing what it believes is an industry-first ‘opt-out’ recycling program for customers of carbide drill bits, aiming to transform the use of a material expected to run out within 40 to 100 years if consumption rates continue unabated.
Tungsten, a key component in cemented carbide, is a scarce and finite material. Making tools from recycled carbide requires 70% less energy and emits 64% less CO2. It also reduces nitrous oxide emissions, according to the OEM.
Sandvik aims to collect 90% of its own used bits by 2025, while other manufacturers’ used bits can also be recycled within the scope of the new initiative.
Jens Holmberg, President of Sandvik Mining and Rock Solutions’ Rock Tools division, said: “Our breakthrough opt-out program supports our customers’ drive to mine more sustainably and demonstrates our commitment to delivering on Sandvik’s ambitious sustainability goals to halve CO2 emissions by 2030. We are determined to lead the industry into a new era, fully committed to embed circularity across an essential component of mining.”
The recycling of drill bits is an important part of making the mining industry more sustainable, yet, historically, carbide recycling has faced several challenges. Collection of used products has been limited while carbide extraction has been cumbersome, inefficient and involved hazardous ways of working, Sandvik says. The zinc recycling process has not returned the same quality of carbide performance, either.
Sandvik says it is now able to help customers overcome these challenges through its new opt-out program.
“Customer response has been overwhelmingly positive,” Holmberg said. “We need to transition our industry at an unprecedented speed. Our recycling program is one of many new initiatives you will see from Sandvik’s Rock Tools division moving forward. We are an industry leading supplier in mining globally, and we need to do everything in our power to support and push the industry forward.”
To further underline the importance of cemented carbide recycling, Sandvik is offering its customers an industry-first extraction support. This will make it easier, faster and safer to recycle dull drill bits with a new patent-pending method that will reduce emissions from transportation by 93%, it says.
Sandvik has chosen to gather its range of rock tools with cemented carbide into a new group called Power Carbide.
The range comes with a combination of strength, hardness, toughness and wear resistance. All of these properties significantly enhance both drilling performance and cost effectiveness, Sandvik said.
Sandvik was the first company to produce rock tools with cemented carbide, which is one of the most successful composite engineering materials ever produced, it said.
Marie Lundbäck, R&D Manager Hard Materials, Rock Tools, Sandvik Mining and Rock Technology, said the introduction of PowerCarbide enables the company to showcase the importance of carbide grades in drilling operations. “Our key strengths in this area lie in our innovations in advanced material compositions and production processes,” she said.
Sandvik’s leading position in the cemented carbide tool market is down to a focus on R&D, continuous investments and close customer collaboration, according to the company. Sandvik also controls its entire production chain – from its own tungsten mine to the production of drill bits – which is unique in the market, it said.
Lundbäck said: “As we have the most comprehensive range of advanced carbide tools, we can offer our customers tailored solutions to meet their specific drilling needs. At the same time, we are able to contribute to a more sustainable future through our unique global carbide recycling system.”
The Sandvik PowerCarbide family currently consists of the grades DP55, DP65, GC80, SH70, XT49, XT70 and XT90. New grades will be launched and added to the family as Sandvik continues to develop the range, it said.
Sandvik is introducing a new drilling tool system, the Alpha 360, which it says is an improved and amplified version of the company’s best-selling Alpha 330 top hammer system (pictured).
With a reinforced design, Alpha 360 can last twice as long as a standard industry thread. Its hole accuracy also enables higher productivity in tunneling and mine development, according to Sandvik.
The system has been developed to deliver “unprecedented rock tools performance” and, at the same time, boost productivity in the whole drill-and-blast cycle, Sandvik said.
Robert Grandin, Product Manager for Underground Top Hammer, at Sandvik Rock Tools, said: “Alpha 360 is yet another example of our aim to provide customers with products that will maximise the output of their investments.
“High drilling accuracy is crucial to ensure that the tunnel gets the desired direction and profile. Straight and parallel holes also improve the advance per blast.”
The Alpha 360, which is designed for Ø48-51-mm-hole sizes in face drilling and bolting, features a strong thread design. The short thread on the round rod gives superior resistance towards bending stresses, improved bit guidance and excellent energy transfer, according to Sandvik.
The sturdy thread is guided inside the bit skirt, which enables high precision collaring also in complex rock formations and against uneven surfaces.
Grandin said: “As a leading supplier to the rock drilling industry, Sandvik continues to drive the technology forward. We always offer a full drill string from shank adapter to bit, designed for excellent reliability, performance and longevity.”
