Escolar Documentos
Profissional Documentos
Cultura Documentos
Eric C. Gerst
Global Business Development Specialist
Flanders
Abstract
In this current era of soft commodity and coal prices the mining industry is turning towards optimizing
all levels of production to reduce operating costs. Part of this trend includes the automation of mining
machines. As the first tier of the mining process blast hole drill automation offers benefits through the
entire value stream from drill bench to material processing.
The primary function of drill automation is to control the drilling process and reduce the variabilities
introduced by manual operation. Variabilities in drill accuracy, operator proficiency, fuel efficiency, and
blast hole quality can affect productivity, fragmentation, mechanical wear on the drill, and premature
failure of the ground engaging tools. All of these affect the overall operating cost. By automating these
parts of the drilling process mining operations can improve overall productivity, reduce drill downtime,
lower operating cost, and improve blasting results.
A secondary function offered by automation is the monitoring and control of the various mechanical
systems on the drill. These monitoring and control systems are typically programmed to limit rotational
torque, pulldown, and engine speed to remain within OEM limits. By displaying and categorizing
system faults it can pinpoint impending system failures before they occur. The strategic use of this data
allows for scheduling preventative maintenance that reduces the amount of drill downtime. Increasing
the utilization of the drill means more bit-in-the-ground time.
A case study from an open pit iron ore mine illustrates the improvements gained from automation where
a fleet of six drills utilizes a One Touch type of drill automation. The data cycle begins with drill
automation utilization between 33%-70% to an average of 85% at the end of the study period. Through
this period the drill productivity for the fleet improved well over 50%.
Safety may be improved by the reduction of unplanned drill maintenance and extending the life of
ground engaging tools. For instance, increased bit life, reducing the incidence of bent drill rods, and
extending the life of the rods by automating rod changing all contribute to less maintenance and
downtime. This has the effect of reducing the exposure time of maintenance personnel to hazards on the
bench. Full automation that removes the operator from the drill altogether also offers a reduction to
hazard exposure and labor costs.
This paper will discuss the functionality of drill automation, identify the benefits, describe measurable
performance indicators, and share case study results that demonstrate the value of drill automation.
Drilling Cycle
Propel To
Next Hole
Drill Process
Figure 1. Breakdown of Drilling Cycle
Drill automation may be broken down into four basic levels:
1) Remote Control Typically limited to line of sight, the drill operator physically controls each
step of the drilling cycle via radio remote communication propel, leveling, air, rotation,
pulldown pressure, rod changing, hole finishing, string retraction, jack retraction, and tram to the
next hole.
2) Semi-Autonomous One or more steps of the Drill Cycle are automated while some require
human intervention. Tramming to the hole collar may be conducted manually or remotely.
Automation is limited to auto-leveling, beginning the drill cycle based on pre-sets, and jack
retraction. Rod changing and drill string retraction may be done manually from on board the
drill or remotely.
3) One Touch Automation Human intervention is required only for tramming from hole to hole
and instigating the steps via HMI for semi-autonomous rod changing. Once over the hole the
operator starts the drilling process by pushing one button. The Drill Control System (DCS)
dynamically controls leveling, hole collaring, rotation, pulldown pressure, and air pressure based
on monitored feedback of the drilling conditions, (See Figure 2). The DCS senses stalled or
Ground Detect (Collar Elevation Plan Bottom Hole Elevation) = Hole Depth
Collaring Phase - Dynamic Hole Collaring Function
Drilling Phase Dynamic Drilling Function Based on Geology
Drilling Phase - Plugged Bit & Collapsed Hole Detection
Drilling Phase - Stalled Rotary Protection
Drilling Phase - Finishing the Blast Hole
Retraction Phase - Drill String Hang-Up Protection
Retraction Phase - Clean Out Hole/Hole Check
60%
DrillingAccuracy
50%
40%
30%
20%
10%
0%
Jun15 Jul15 Aug15 Sep15 Oct15 Nov15 Dec15 Jan16 Feb16 Mar16 Apr16 May16 Jun16
DrillCyclePenetrationRate,Meters/Hour
FleetAverage
25
19.8
20 18.1 17.7
16.5 16.2 16.3
14.2 14.5
15 13.0 12.3
9.6
10
DrillStandownDuetoAccident
5
Aug15 Sep15 Oct15 Nov15 Dec15 Jan16 Feb16 Mar16 Apr16 May16 Jun16
FleetAverageMeters/Month
10000
7700 7609
8000
5695
6000 4369 4218
3879 3593 4088
4000 2543 2288
2000
DrillStandDownDuetoAccident 285
0
Aug15 Sep15 Oct15 Nov15 Dec15 Jan16 Feb16 Mar16 Apr16 May16 Jun16
Drill Productivity
The productivity of a drill is measured as the average drilling time per hole versus the available drilling
hours. The baseline for this mine prior to automation was 40%. Figure 8 illustrates how overall
productivity of the fleet has increased by over 50% since automation was implemented.
FleetAverageProductivity 75.5%
80% 71.9%
63.2%
54.7% 54.8%
60% 49.0%
48.1%
44.0%
40%
27.5%
15.6%
20%
DRILLCYCLEPENETRATIONRATES
40.0
35.0
30.0
25.0
20.0
15.0
10.0
5.0
0.0
ProductionHistoryAugust2015 June2016
6,000,000 50,000
DrilledMeters
5,000,000 40,000
4,000,000 30,000
Tons
3,000,000
2,000,000 20,000
1,000,000 10,000
0
2. Better Fragmentation
All levels of automation that utilize GPS and other field controls such as face profiling enable the
drills to optimize fragmentation. By introducing an automated dynamic drill process hole quality
is also enhanced. Ultimately, improving fragmentation at the mining face will result in improved
shovel productivity, faster loading times, reduced truck cycle-time, and increased throughput at
the crusher. Wear and tear on the loading, hauling, and crushing equipment is also reduced.
6. Safety
Unplanned repairs and maintenance are reduced through the use of automation. Minimizing the
time repair personnel are exposed to the hazards inherent to working on an active drill bench
reduces the probability of injury. With full automation the hazards of drilling beneath highwalls
or over underground works is eliminated. Full automation also requires hole loading to be
accomplished after the pattern is drilled. Removal of the powder crew from the hazards of
navigating around the drills further reduces the probability of accidents.
Acknowledgments