Towards Ecoefficiency in Mining: Potential of Straight Drilling ......2019/05/13  · R&D Manager, Sandvik Mining and Construction Rock Tools Towards Ecoefficiency in Mining: Potential

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Hamid-Reza Manouchehri (Ph.D)

Global Manager, Process Intelligence and Development,

Sandvik Mining and Rock Technology

Jonas Gustavsson

R&D Manager, Sandvik Mining and Construction Rock Tools

Towards Ecoefficiency in Mining: Potential of Straight Drilling to Improve Productivity

MINING INDUSTRY AT A GLANCE

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Mining Production >2400 Mt, →→→ value of 1000 BUS$Fuel Production > 14000 Mt →→→ value of 1300 BUS$

INVESTMENTThe total investment in Mining Industry during last recent years has been in a range of 150 to 180 BUSD per annual and is predicted to be sustainable for next few years

OPERATIONAL COSTMore is spent on operational cost (just cost exceed 100 BUSD)

CHALLENGES IN MINING INDUSTRY

Innovation Managing Joint Ventures

Ore Complexity, Decreasing Grade, Access to and Optimizing of Energy and Water

Digital Effectiveness Social License to Operate Regulatory Risk Balancing talent requirements New World Commodities Competitive shareholder return Cash Optimization Cyber and Cybersecurity

Sandvik Mining and Rock Technology Activities

4 Sustainable Activities, from Face of the Mine to final stage of Crushing

MINING INDUSTRY: ENERGY

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World’s Energy Consumption ̴160*1012 kWh (2015)

Energy consumption will be increased by 28% in 2040

Energy and Cost?

Energy consumption in Mining Industry is about 6-7% of total world’s

energy (the main part, ≥50%, is consumed by Comminution)

Drilling and Blasting consumes about 2%, however, however, theses

processes account for 15% of total mining costs

(Modified from http://www.visualcapitalist.com)

EFFICIENT DRILLING & BLASTING

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• Many studies have shown that both mechanical impact and blasting loading produce micro cracks in rocks, and such cracks in fragments have a beneficial effect ongrinding. Thus, an optimum fragmentation from mine to mill is necessary

• “Mine to Mill” concept by controlled blasting: Optimal fragmentation to

benefit crushing and milling. Improvement can be attributed

by enhanced rock fragmentation and reduction in inherent rock strength

BLASTING IN MINING AND PROCESSING Fragmentation has a significant impact on all mine production systems

Smart blasting helps in obtaining the optimal size distrubition:Load and haul Transporting Comminution

Good for SAG/AG milling Good for crushing and transportation

ECO-EFFICIENT DRILLING STRAIGHT DRILLING: Many factors affecting the straightness of a drill hole:

Rock propertiesDrilling methodThe condition Power and set-up of drilling rig Design of drilling tollsMonitoring systems (proper and sophisticated) – not only on

straightness, but on service and life of the tools (stiffer connections)

Accordingly by considering all factors and having appropriate drilling tools deflection of less than 2% can be reached

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ECO-EFFICIENT DRILLING

STRAIGHT DRILLING DEVICE: CASE STUDY

• The study was done based on “discretized model to measure deviation in layers of RL for each given distance” model and field data in collaboration with Mining Department, University of British Columbia

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ECO-EFFICIENT DRILLING

STRAIGHT DRILLING DEVICE: CASE STUDY

• Baseb on the field survey data a part of study was completed: • Summary of the study

Conventional O/P Mining7000 tpd productionMine Life: 8 Years @2017 EstimatesBit size: 152 mm28 Drillholes

• Test cases Guided with SK20693 Adapter Unguided

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RESULTS AND ACHIEVEMENTS

Guided Drills• Total deviation (W) @ 0.67 m• Over-drill: 0.003 m per m drilled−W: 0.004 m per m drilled

Unguided Drills• Total deviation (W) @ 2.073 m • Over-drill: 0.020 m per m drilled• W: 0.012 m per m drilled

Summary:Unguided Drills Yield

• 6.67 times more over-drilling length per m drilled• 3 times more deviation per m drilled

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ROUGH ESTIMATION FOR BENEFITS: Life Time

− Estimated remaining mine life: 6 years @ 2019− Daily production: 7,000 tpd− Assume 3.5 x 3.5 m B and S and 13 m depth per drillhole, then;

3.5𝑚𝑚 × 3.5𝑚𝑚 × 13𝑚𝑚 = ~160𝑚𝑚3 𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟

𝑂𝑂𝑂𝑂 ~415 𝑡𝑡𝑟𝑟𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 @ 𝜌𝜌𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟 = 2.6𝑡𝑡𝑚𝑚3 𝑝𝑝𝑡𝑡𝑟𝑟 𝑑𝑑𝑟𝑟𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑟𝑟𝑑𝑑𝑡𝑡

Shortly, this means*:• ~15.3 M tonnes to be mined• ~462,500 m² area to be drilled• ~37,000 drillholes to be sunk• ~480 km of drilling is needed

*Rough estimates. Over the course of mine life.

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SAVINGS: IN DRILL DESIGN • Assume 3.5 m x 3.5 m Burden (B) and Spacing (S) @ 152 mm drill

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

0 0,2 0,4 0,6 0,8 1

Savings in Design ParametersW=0.67 m per Drillhole W=2.073 m per Drillhole

Observe improvement in 80% passing sizefor two cases with (W=0.67 m deviation-Guided) and W=2.073 m deviation -Unguided))

Important note:For some flexible scenarios, the particlesize achieved with the unguided drill canstill be within the acceptable range. Thenconsider savings with larger B and Sdistances for less life-of-mine drilling. Seenext page.

Almost 50% particle size reduction in pit, before crushing!2019-05-2713

SAVINGS: IN DRILL DESIGN

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• Burden & Spacing “metrage” shouldn’t exceed (25-30 x ddrillhole)=4.60m MAX,which translates into 42% reductions in the number of drillholes and all theirassociated costs:→ Huge potential to savings on operating parameters, consumables and parts:

ANFOBitsRodsUtilization and personnel hoursEnergy etc.

• Study revealed good improvement in using the new tool• However, it is an indispensable window of opportunity to reconsider the drill

design.

DRILLING STUDY SUMMARY & FUTURE WORK• Provided data has shown significant savings are possible with straight

drillingSignificant (up to 42%) potential savings may be achieved with a new

optimum design due to less deviation.8,160 m overall drilling saving is guaranteed.

• Future work will focus on the savings associated with: Finer particle size distribution Less hang-up time Higher efficiency loading and hauling Less load on crushers and energy savingsPotential improving in downstream comminution (throughput)

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SANDVIK MINING & ROCK TECHNOLOGY (SMRT)

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Strategy for Eco-Efficiency (summary-general)

Efficient, reliable and durable machines and tools

Instrumentation, measurements, control and process optimization

Efficient drilling and blasting, material handling sizing and classification (towards effective fine comminution from mine to mill)

Towards fully Automation and Digitalization for Mining activities (My Sandvik Concept)

Materials engineering and development to reduce wear, increasing productivity and accuracy in (choice of material by application, incorporating mineralogy and ore competency, etc., life cycle management for productivity)

Development expert team(s) and smart machines and tools for smart and innovative mining operations

Train and educate, and consultancy to the Mining Industry (customers)

THANK YOU17

Smart Thinking?!