GLİ Tunçbilek açık ocak işletmelerinde farklı nozul boyutu ve matkap tiplerinin sondaj makinaları verimliliğine etkisi
Effects of different nozzle sizes and bit types on efficiency of drilling machines in GLI Tunçbilek open pit mine
Yazar: CANER KÜNDEM
Danışman: DOÇ. DR. ÖMÜR ACAROĞLU ERGÜN
İstanbul Teknik Üniversitesi / Fen Bilimleri Enstitüsü / Maden Mühendisliği Ana Bilim Dalı / Maden Mühendisliği Bilim Dalı
Derece: Yüksek Lisans, 2019
Konu: Maden Mühendisliği ve Madencilik = Mining Engineering and Mining

Özet:
Açık ocak madenciliğinde delme patlatma amaçlı döner veya döner darbeli sondaj makinaları kullanılmaktadır. Büyük açık ocak madenciliğinde patlatma amaçlı geniş çaplı delikler açmak için döner deliciler kullanılmakta olup bu delicilerde üç konili matkap kullanımı yaygındır. Bu makinalarının delme verimliliğine üç ana parametre etki etmektedir. Bunlar delinen formasyonun jeolojik özellikleri, makina parametreleri ve çalışma koşullarıdır.
Döner sondaj makinalarında dönme ve baskı kuvveti ile delinen delikten kazılan kayaç parcaçıkları kompresörler aracılığıyla gönderilen basınçlı hava ile dışarı atılmaktadır. Uygulanacak optimum baskı kuvveti ve devir değerleri formasyon ve matkabın özellikleri ile belirlenmektedir. Bu amaçla bu çalışmada Tunçbilek havzasında kullanılmakta olan 622 IADC kodlu 9 inç çapındaki matkaba uygulanması gereken optimum baskı kuvveti değerini bulmak için belirli bir aralık içinde farklı baskı kuvvetleri uygulanmıştır. Bu sırada makinadaki baskı kuvveti, ana pompa basıncı, hava basıncı değerleri ölçülmüş ve formasyondan nokta yük numuneleri ve elek analizi için kayaç parçacıkları alınmıştır. Sonuç olarak yapılan bu çalışmada optimum baskı kuvvetinin 12 ton civarı olmasının delme hızını artırmak ve yakıt tüketimin düşük tutmak için uygun olacağı belirlenmiştir.
Döner sondaj makinalarında üç konili matkapların değişik tipleri kullanılmakla birlikte özellikle hava soğutmalı tipleri patlatma amaçlı deliklerin açılmasında kullanılmaktadır. Delik dibini iyi temizlemek ayrıca rulmanları daha iyi soğutmak matkabın ısınması azaltır ve ömrünü uzatır. Üç konili matkaplarda havanın %25'nin rulmanlardan geçmesi gerekmektedir. Bu amaçla Tunçbilek havzasında matkaplarda 16, 14.5 ve 13 mm nozul boyutu için ölçümler yapılmıştır. Delme hızı ve yakıt tüketiminde çok büyük değişiklik olmamasına rağmen 14.5 mm'de verimli kazı olduğu görülmüştür.
Tunçbilek havzasında kullanılan üç konili matkaplarda verimliliğin artırılabilmesi için farklı IADC nolu matkaplar karşılaştırılmıştır. Tunçbilek havzası yumuşak-orta sertlikte bir formasyona sahip olup burada daha çok 622 ve bazen de 522 IADC nolu matkaplar kulllanılmaktadır. Bu çalışmada 622, 522 ve 422 IADC nolu üç farklı matkabın verimliliğine bakılmıştır. Verimlilik parametrelerinde benzer sonuçlar elde edilmiş olmakla birlikte 422 IADC nolu matkapta delme hızı artmış ve yakıt tüketimi azalmıştır. Bu sonuç bize Tunçbilek havzası için 422 IADC nolu matkapların da kullanılabileceğini göstermektedir.

Abstract:
Drilling applications are commonly used in many areas of underground and open pit mining. In open pit mines, drilling is one of the most used application for blasting purpose. Both rotary and rotary percussive drilling machines are used for drilling and blasting operations. Rotary drills are usually used to open large diameter holes in big open pit mines for blasting purposes.
There are several types of drill bits which are used in the rotary drilling system. It is possible to classify them as drag type bits, PDC (Polycrystalline diamond compact) bits and tricone bits. The most commonly used type of bits are tricone bits. Tricone bits are divided into two types: steel and tungsten carbide. Generally, in the soft and non-rigid formations, steel tricone bits are used. On the other hand, tungsten carbide tricone bits are used in abrasive and hard formations.
There are many factors affecting the parameters that determine the efficiency of a drilling machine, and these are generally divided into three main parts. This classification include physical, mechanical and mass properties of the drilled formation, design parameters of bits (diameter, type, etc.) and also machine operating parameters such as pressure force, RPM (revolution per minute) and equipment maintenance, logistics etc.
In this study, in the Tunçbilek coal basin of GLI, optimum feed force to be applied on the tricone bits, appropriate nozzle size of bits and efficiency of different IACD bit types were examined. In these purposes drilling machine efficiency parameters were measured and comparisons were made during this study.
Drilling process is carried out by breaking the rock under a bit depending on the structure of the rock and its mechanical properties. The breakage mechanism of rocks also changes according to the type and size of the forces and the duration of these forces. Rotary drilling systems have only feed force (pull down force ) and torque force applied by different RPM (revolution of per minute). Optimum feed force and RPM value to be applied to a tricone bit are determined by the characteristics of the formation and the bits. For this purpose, different feed forces were applied in a certain range in order to find the optimum feed force value to be applied to the 622 IADC coded 9 inch diameter tricone bit which is commonly used in Tunçbilek coal basin of GLI. At this time, the pressure of feed force, the pressure of the main pump, the air pressure values were measured and the samples were taken from the drilled formation for point load experiment and sieve analysis. As a result of this study, it was found that the optimum feed force around 12 tons would be suitable for increasing the drilling speed and keeping fuel consumption low.
In order to perform the drilling process efficiently, the rock particles should be removed from the blast hole bottom. Particles that cannot be removed sufficiently from the bottom of the blast hole will be drilled again. As a result of this situation, the depth of the teeth within the rock reduces and unnecessary energy consumption and rapid wear of the bits occurs.
In drilling, the media (drilling fluid) used to remove the particles from the bottom of the blast hole depends on the formation of the drilling, the type of drilling machine (rotary, rotary-percussive), the characteristics of the machine and the hole characteristics (depth, diameter, duration of use etc.). Drilling fluid is usually obtained by adding air and water and / or foam, oil, clay, minerals and various chemicals added to them. Air provides an easy-to-use and clean working environment; It is used for drilling holes which are not long and stay for short time.
Tricone drill bits can have different designs according to different drilling operations, especially difference of bearing types. Tricone drill bits used in open pits are generally air cooled. At least 30% of the compressed air in the air-cooled tricone drill bit types goes to the bearings and provide the necessary cooling.
For this purpose, measurements were made for 16 mm, 14.5 mm and 13 mm nozzle sizes on bits used in Tunçbilek area. Although there was no significant change in drilling speed and fuel consumption, more efficient drilling process was achieved with a 14.5 mm nozzle size.
Tricone drill bits have a classification system called IADC (International Assocition of Drilling Condactors). According to this system is made using 4 characters. The first three of the classification are numerical and the last one is alphabetical. The numerical characters of classification system are represent series, type and bearing/body protection, respectively. The last alphabetic character consists of 16 different alphabetic characters and shows the other characteristics of the drill bit.
The first of the numerical characters is classified as the formation series and takes a value between 1 and 8. The first three of them show the tricone drill bits with steel cutters, while the others show tungsten carbide drill bits. We can describe the hardness and abrasiveness of the formation from low to high according to these numbers. The second of the numerical characters is also classified as the formation type and takes a value between 1 and 4. These values are lined up to show the 1 softest and 4 most hard formations. We are able to get information about bearing design and housing protection by classification of third and last numerical character which has values between 1 and 7.
In this study, the efficiency of three tricone bits with different IADC were compared in the Tunçbilek area of GLI. Tunçbilek has a soft medium hardness formation. Generally, tricone drill bits with IADC 622 and sometimes IADC 522 are used here. In this study, the efficiency of three different tricone drill bits which have IADC 622, IADC 522 and IADC 422 were investigated. Although sometimes similar results were obtained in the efficiency parameters, the drilling speed in the IADC 422 tricone drill bit increased and the fuel consumption decreased. This result shows us that IADC 422 tricone drill bits can also be used for Tunçbilek area.