Product Training

Alachua Plant
Hanoi, Vietnam
February 5 - 10, 2007
Rules of Thumb
 Drilling input

 Bit type (cutting tool)

 Bit load (pull down + string weight)
 Bit rotation (rotary head RPM)
 Air (hole flushing/cuttings removal)

 Operator

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 Drilling type

 Identify the rock (compressive strength),

 Optimize bit load and type,
 Optimize rotation speed RPM and,
 Optimize hole flushing.

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 Identify the rock

 FROM:
a.- Core samples
b.- From drilling results 
2.18 X W X R
 Compressive strength C =
0.2 X (1/1,000) X P X D.9
 Where:
P = Average pure penetration rate (feet/hr)
W = Average bit load (lb.)
R = Average bit rotation speed (RPM)
D = Bit diameter (inches)
 Result will be a true average of rock strength
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 Rock types

Compressive Strength
Rock type MPa psi
Igneous Andesite 300 400 43,500 58,000
Igneous Basalt 250 400 36,250 58,000
Sedimentary Conglomerate 140 150 20,300 21,750
Igneous Diorite 170 300 24,650 43,500
Sedimentary Dolomite 150 160 21,750 23,200
Igneous Gabbro 260 350 37,700 50,750
Metamorphic Gneiss 140 300 20,300 43,500
Igneous Granite 200 350 29,000 50,750
Sedimentary Limerock 30 100 4,350 14,500
Sedimentary Limestone 120 130 17,400 18,850
Metamorphic Marble 100 200 14,500 29,000
Metamorphic Quartzite 160 220 23,200 31,900
Igneous Rhyolite 120 130 17,400 18,850
Sedimentary Sandstone 160 255 23,200 36,975
Metamorphic Schist 60 400 8,700 58,000
Metamorphic Serpentine 30 150 4,350 21,750
Sedimentary Shale 70 80 10,150 11,600
Metamorphic Slate 150 160 21,750 23,200
Igneous Trachyte 300 330 43,500 47,850

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 Rock Types

 Igneous
 Sedimentary
 Metamorphic

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 Rock Types

Igneous
 Magma is essentially a hot silicate melt (600° – 1,200°C) and is the
parent material of igneous rocks. Magmas and the formation of
igneous rocks can be observed in volcanic regions. Usually, magma
solidifies within the crust, and the formed rocks are later exposed at
the surface due to erosion or earth movements – hence their
classification as plutonic (intrusive), hypabyssal or volcanic
(extrusive), depending on the depth and rate of cooling which affects
texture and crystal size.

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 Rock Types

 Sedimentary
 Sedimentation is the result of atmospheric and hydrospheric
interaction on the earth’s crust. The original composition of the crust,
igneous rock minerals, are more or less readily attacked by air and
water. Having been formed at high temperatures, and occasionally
high pressures, they do not remain stable under significant varying
conditions. Silicates vary considerably in chemical stability.

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 Rock Types

Metamorphic
 Metamorphism is defined as the result of the process that, beyond
weathering, causes the recrystallization of either igneous or
sedimentary rock material.During metamorphism, the rock remains
essentially solid; if re-melting takes place, magma is produced, and
metamorphism becomes magmatism. Metamorphism is indiced in
solid rock as a result of pronounced changes in temperature (200° -
800°C), pressure and chemical environment. These changes affect
the physical and chemical stability of a mineral assemblage, and
metamorphism results from the establishment of a new equilibrium.

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 Mechanical Rock Properties

 Strength
 Resistance to failure under elementary stresses such as compression, tension
or shear
 Effect of confining pressure, temperature, starin rates, pore-fluid pressure,
specimen size, etc. on strength properties

 Deformability
 Resistance to change of shape or volume
 Elastic and thermal expansion constants

 Hardness
 Resistance to a local (surface) failure by indentation or scratching

 Fracture toughness
 Resistance to fracture propagation

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 Mechanical Rock Properties

 Coefficients of friction
 Resistance to sliding of two bodies with planar surfaces in contact

 Crushability and millability

 Resistance to comminution (reduction of a substance to a powder)

 “Extractability”
 Resistance to fragmentation and disruption by different extraction process
such as rock cuttability, drillability, blastability, loadability of blast rock and
pumpability of cuttings under certain “idealized” or standard operating
conditions.

 Abrasivity
 Ability of rock to induce wear on mechanical tools and apparatus

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 Drilling types

Hard

DTH hammer

Top hammer
Rock hardness

percussive Rotary

Blasthole

Drag bit rotary

Soft

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 in

25 51 76 102 127 152 178 203 229 254 279 305 330 356 381 mm
Hole diameter

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 Maximum bit load

 Formula 1
 Maximum bit load = 810 x D²
Where-
D = Bit diameter (inches)

 This is the maximum load a bit can withstand

 Always compare to manufacturer’s load range

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 Optimum bit load

 Formula 2
Defines the balance of energy between bit load and rock
compressive strength.
 C x D
Optimum bit load = W =
5
 Where:
C = Rock compressive strength (psi)
D = Bit diameter (inches)

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 Rotation power requirements

 Formula 5
4.95 x D x R x (W/1,000)1.6
Power required =
C
 Where:
R = Bit rotation speed (RPM)
D = Bit diameter (inches)
W = Optimum bit load (lb.)
C = Compressive strength (psi)

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 Rotation power requirements

Horse Power requirements for 15,000 psi material

for various bit sizes varying rotation speed

300
250

200
HP

150
100

50
0
50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200
Bit RPM

6 3/4 9 7/8 10 5/8 12 1/4

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 Rotation power requirements

Horse Power requirements for 97 RPM

for various bit sizes varying compressive strenght

160
140
120
100
HP

80
60
40
20
0
5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Rock compressive strenght (1,000 psi)

6 3/4 9 7/8 10 5/8 12 1/4

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 Penetration rate

 Input optimum data

 Pure penetration rate
2.18 x W x R
P=
0.2 x C x D0.9 x (C/1,000)
 Where:
W = Optimum bit load
C = Compressive strength (psi)
D = Bit diameter (inches)
R = Bit rotation speed

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 Penetration rate

Penetration rate for 9 7/8" OD bit

varying rotation speed for 15,000 psi compressive strenght

400
350
Penetration rate (fpm)

300
250
200
An increase of 20 RPM in rotation speed
150
provides 36 fpm increase in penetration rate
100
50
0
50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200

Rotation speed RPM

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 Drilling Cycle

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 Drilling Cycle

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 Drilling Cycle

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 Terminology

Spacing

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 Terminology

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 Why is air used?

 To remove the cuttings

 To clean the bit
 To cool the bearings in air bearing bits
 To clean cone mouth in sealed bearing bits

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 Why is air used?

 Bailing or up-hole velocity

 Velocity of air up the annulus of the hole

Air volume
Annular area

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 Why is air used?

 Up-hole (bailing) velocity

 The up-hole (bailing) velocity is effected by:
 Air density
• Elevation about 3.4% per 1,000 ft (305 m)
• Temperature about 2.0% per 10°F (5.6°C) above
60°F (15.5°C)
 Drill steel wear
 Rock conditions
• Unconsolidated – fractured rock

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 Why is air used?

 Elevation influence

Altitude Correction factor

1.000
0.900
0.800
0.700
0.600
0.500
0.400
0.300
0.200
0.100
0.000
10,000
11,000
12,000
13,000
14,000
15,000
16,000
17,000
18,000
19,000
20,000
1,000
2,000
3,000
4,000
5,000
6,000

7,000
8,000
9,000

Elevation above sea level (ft)

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 Why is air used?

 Ambient temperature influence

Temperature Correction factor

1.00
0.90
0.80
0.70
0.60
0.50
0.40
0.30
0.20
0.10
0.00
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150
Ambient temperatrure (°F)

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 Why is air used?

Air up-hole (bailing) velocity for 1,000 cfm compressor, 6" OD drill
pipe and 9 7/8" bit

7,000
Up-hole (bailing) velocity (fpm)

6,800
6,600
6,400
6,200
6,000
5,800
5,600
5,400
5,200
0 1/8 1/5 1/4 1/3 3/8 4/9 1/2

Pipe wear (in)

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 Why is air used?

 Hole clearance

Difference between
drill pipe OD and
bit diameter to be ½” - 1½”
between 1” and 3”

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 Why is air used?

 Fine drill cuttings and light materials require an up-hole (flushing)

velocity of approximately 5,200 fpm (26 m/sec).
 Coarse drill cuttings and heavy materials require a flushing
velocity of approximately 7,200 fpm (36 m/sec).
 Coarse drill cuttings with water content and heavy materials
require flushing velocities of up to 10,000 fpm (50 m/sec).

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 Optimum drilling

 1.- Hole size

 Select the diameter that gives the best end product
• Match the burden and spacing to bench height
• Get better powder distribution
• Improve fragmentation
 2.- Drill pipe size - bit diameter
 Use the largest possible drill pipe for the hole size
• Minimize hole deviation
• Maximize flushing capacity
• Increase drill pipe life
 3.- Compressor size
 Match compressor size to flushing requirements

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 Key energy inputs

 Feed pressure (bit load)

 Rotation speed (RPM)
 In order to achieve proper rotation speed it is required to have the
right torque to keep the bit turning. This requires enough rotation
power.
 Hole flushing (air up-hole velocity)

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 Rotation power

 To rotate the bit at a constant speed it is required to have

adequate power
63,025 x P
Torque = T =
RPM
 Where:
P = Rotary head power (HP)
RPM = Rotation speed
T = torque (in-lb)

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 Rotary head torque

Power (HP) required to provide torque at various RPM

300

250
60,000
200
Power (HP)

72,000
150 84,000
96,000
100
108,000
50

0
90 100 110 120 130 140 150 160
RPM

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 Rotary head torque

Power (kW) required to provide torque (N-m) at various RPM

250

200
6,000
Power (kW)

150 8,000
10,000
100 12,000
14,000
50

0
90 100 110 120 130 140 150 160
RPM

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 Rules of thumb

 Burden
 25 to 35 hole diameters
 Spacing
 Hole size greater than 140 mm (5½”)
• 1.2 to 1.5 burden
 Hole size smaller than 140 mm (5½”)
• 1.5 to 1.8 burden
 Stemming
 0.7 to 1.3 burden.

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 Rules of thumb

Bench Height
40 to 50 hole diameters
Sub-drill
8 hole diameters
10 to 12 hole diameters for face rows

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 Rules of thumb

Powder factor
Governed by:
• Mine to mill process
• Budget
• Rock hardness
Hole diameter
Governed by:
• Required material size which is influenced by the
loading and hauling equipment
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