Large hole rotary drill performance

Large hole rotary drilling is one of the most common methods of producing blastholes in open pit mining. Large hole drilling generally refers to diameters from 9 to 17 inch (229 to 432 mm), however a considerable amount of rotary drilling is done in diameters from 6 1/2 to 9 inch (165 to 229 mm). These smaller diameters are especially prevalent in gold mining and quarrying. Rotary drills are major mining machines having substantial capital cost. Drill bit costs can also be high, depending on the bit type and formation being drilled. To keep unit costs tow the drills must perform at a high productivity level. The most important factor in rotary drilling is the penetration rate. This paper discusses the factors affecting penetration rate. An empirical factor is given for calculating the penetration rate based on rock strength, pulldown weight and the RPM. The importance of using modern drill performance monitoring systems to calibrate the penetration equation for specific rock formations is discussed. Rotary horsepower is an important characteristic of the drill because it affects parameters that in turn affect penetration rate. The horsepower requirement is discussed and an equation is provided for calculating the horsepower, given rock conditions, pulldown, RPM and bit diameter. Adequate air delivered to the bottom of the hole is very important to achieving maximum penetration rates. If there is insufficient bailing velocity cuttings will not be transported from the bottom of the hole rapidly enough and the penetration rate is very likely to decrease. An expression for the balancing air velocity is given. The amount by which the air velocity must exceed the balancing velocity for effective operation is discussed. The effect of altitude on compressor size is also provided.