MININ G & C O N S T R U C T I O N
Mining Tools
SUPERIOR
PERFORMANCE DRIVES
PRODUCTIVIT Y
——-----— Element Six works in partnership with customers to deliver state-of-the-art
cutting and drilling products that increase productivity in the mining industries.
INNOVATOR IN
MANY INDUSTRIES
———---— Developing cutting-edge products and
materials to give customers competitive advantage.
From our global network and unique state-of-the-art
Global Innovation Centre near Oxford (UK), Element
Six works in partnership with customers to develop
cutting-edge products and materials that give them a
competitive advantage.
C ON T EN T S
In the Mining industry, Element Six has developed
Percussive Diamond Inserts (PDIs). Thanks to our
specially engineered 3D PCD technology, PDIs drill
10 times the depth achieved with conventional tungsten
carbide inserts.
Unequalled materials expertise
in mining applications
P4
How quality tools improve productivity
P5
A wide range of mining picks
A comprehensive range of rotary
drilling products
Our innovative product portfolio ranges from readyto-press powders for localised product fabrication to a
variety of wear parts in the form of fabricated products
for the oil and gas, chemical and pharmaceutical,
agriculture, recycling, industrial machining, extraction,
steel and manufacturing industries.
By working closely with road contractors, Element Six
has developed the most advanced type of road picks
currently available. D Power™ Road Cutters, tipped
with polycrystalline diamond (PCD), one of the hardest
materials on the planet, deliver over 40 times the life of
a standard carbide cutters.
Mining Tools
2
P 6-7
P 8-11
WORLD CL AS S COMPE T ENCE IN MINING
W ORL D L E A DER S IN SY N T HE T IC DI A MOND A ND
C A R BIDE INNO VAT ION
Element Six has the application engineering
competence to deliver the most productive and cost
efficient tools for any given mining challenge thanks to
our ability to combine:
–– Unrivalled material know-how
–– Innovative tungsten carbide compositions
–– High tech, diamond-based supermaterials
–– A sound understanding of modern mining methods
Element Six, the market leader in synthetic diamond
has been pioneering the manufacture of synthetic
diamond for industrial purposes for over 50 years.
Today Element Six offers customers an unequalled
portfolio of synthetic diamond and tungsten
carbide products. All Element Six solutions are
designed to extend tool and component life and to
dramatically improve industry productivity. Our global
representation network enables Element Six to offer
world-class customer service and supply chain support
to partners in a variety of industries:
–– Mining and tunnelling
–– Textiles
–– Construction
–– Chemicals
–– Oil & Gas
–– Recycling
–– Automotive and
transportation
–– Agriculture
Our product solution offering covers the entire range of
mining tools including:
–– Flat and round-shank picks with optimised insert
geometries for all types of holder systems on mining
machinery
–– Rotary drill bits for roof-bolting applications, for both
wet and vacuum drilling systems
–– Accessories such as tool holders, drill string
components and change-out tools
Our extensive R&D activities enable us to provide
innovative leadership for real-world solutions. These
solutions allow us to tackle the challenges our mining
customers are constantly faced with:
–– Productivity optimisation for entire production
systems
–– Delivering significant and measurable cost benefits
–– Improving the health and safety of operating
personnel
Element Six has been producing high-performance
cutting tools and drill bits for the mining and
tunnelling industries for more than 50 years. Element
Six’s products are used globally whenever mining
operators look for solutions when “the going gets
tough”.
Supermaterials developed by Element Six show the
way in which materials technology can challenge the
accepted boundaries of performance and deliver
unprecedented levels of efficiency in many different
industries.
Element Six tools for drilling applications dramatically increase the
productivity per meter drilled.
Element Six provides step-change mining picks that deliver superior
performance in underground mining applications.
Mining Tools
3
UNEQUALLED MAT ERIAL S E X PERT ISE
IN MINING APPLICAT IONS
Element Six can offer customers unequalled materials
expertise for mining tools and accessories. With the
broadest materials portfolio in the industry we deliver
optimal tool performance at minimise total cost.
PICK DI S C A R D L IF E C OMPA R I S ON
TONS MINED
UNIQUE C OBA LT BINDER T E CHNOL OGY F OR HIGH
W E A R RE S I S TA NCE
Our mining grades of tungsten carbide are based on
innovative carbides for maximum wear resistance with
cobalt binder content to optimise fracture toughness
for any given application. The patented MasterGrade®
carbide takes this concept to the next level of
performance.
S TA N D A R D C A R B I D E
INCRE A S ING W E A R RE S I S TA NCE W I T HOU T
R EDUCING F R AC T UR E T OUGHNE S S
MASTERGRADE®*
PCD*
*Performance can vary from one application to another.
DIAMOND/
BORON
NITRIDE
HARDNESS
By infusing nano-carbides into the cobalt binder Element
Six reduces binder wear resulting in an even higher
level of wear resistance without sacrificing fracture
toughness. With more than 50 years of diamond
synthesis experience and a wide range of diamond
supermaterials in our portfolio, we manufacture tools
with unprecedented performance for use in the most
severe conditions.
SY N T HE T IC DI A MOND - BA S ED S UPERM AT ERI A L S
F OR E X T RE ME PE RF ORM A NCE
CERAMICS
Synthetic diamond, the hardest material known to man,
is ideally suited for drilling and mining in highly abrasive
and very hard conditions. If extreme performance
is required, such as in remote mining situations, our
technical team can configure customised tools with PCD
(polycrystalline diamond) tips. These extend tool life
dramatically and can also be combined with our patented
hard-facing technology for further system performance
gains.
CEMENTED
CARBIDES
TOUGHNESS
R A N G E O F C A R B I D E G R A D E S F O R M I N I N G A N D C O N S T R U C T I O N T O O L S
Code
WC SINTERED
GRAIN SIZE
C o in %
(±0,2)
DENSIT Y
g / c m 3 ( ± 0 ,1 )
HARDNESS
HV (±50)
HARDNESS
HRA (±0,3)
COERCIVIT Y
Oe
TRS
ISO B N/mm2
B20
coarse
8.0
14.70
1,250
88.7
90-110
2,800
B25
coarse
10.0
14.50
1,230
88.5
75-100
2,900
B30
coarse
11.0
14.40
1,150
87.7
75-100
2,900
B20 N
extra-coarse
8.6
14.65
1,050
86.5
45-60
2,300
B25 SN
extra-coarse
9.5
14.55
1,050
86.5
50-64
2,300
B30 SN
extra-coarse
11.0
14.40
1,000
85.8
50-70
2,300
B15 MN
extra-coarse
6.5
14.90
B25 MN
extra-coarse
9.5
14.55
MASTERGRADE®
The innovative MasterGrade® technology is an enhancement of the
hardmetal binder with infused nano carbides
Mining Tools
Further grades available upon request.
4
HOW QUALIT Y T OOL S IMPROV E
PRODUC T I V I T Y
IMPR O V E HE A LT H & S A F E T Y
Tools that stay sharper longer have a direct effect on
productivity. This reduces downtime for tool changes,
increases sump and shear rates resulting in increased
tonnages and profit.
Having the best and sharpest tools – even after long
engagement times – also has a direct effect on health
and safety. Sharp tools produce:
–– Less fines, reducing explosion risk and dust
HOL E S DR IL L E D PER S HIF T
–– Lower machine stress
( R O O F B O LT I N G I N H A R D S A N D S T O N E )
–– Less vibration, reducing operator fatigue and
improving machine lifetime
3
Fewer tool changes also translate in less human
exposure to dangerous conditions.
2.5
2
HO W C U S T OMER S BENEF I T F R OM PA R T NER ING
W I T H EL EMEN T S I X
1.5
1
Element Six possesses a broad material portfolio:
–– High-quality tungsten carbide suitable for the
majority of operating conditions
0.5
0
CARBIDE DRILL
–– Speciality and premium-performance tungsten
carbide materials for difficult and challenging
situations
PCD DRILL
MINIMI S E REL AT I V E T OOL C O S T S
–– A variety of diamond-based supermaterials when
nothing else gets the job done
With the combination of Element Six’s tool design
expertise and materials know-how, we develop the right
tool to get the job done - at the lowest relative cost.
Element Six understands customers’ applications and
can draw on an extensive expertise to develop the right
solutions for new applications.
The extensive practical experience in mining of our
industry expert and engineer teams, gives Element Six
the competitive advantage where it comes to delivering
unmatched performance at the lowest possible cost.
R EL AT I V E T O OL C O S T PER ME T ER DRIL L ED
( R O O F B O LT I N G I N H A R D S A N D S T O N E )
1.2
1.0
0.8
0.6
0.4
0.2
0
CARBIDE DRILL
PCD DRILL
Element Six sharpest mining tools can improve health and safety in a mining
environment.
Mining Tools
5
A W IDE R ANGE OF MINING PICKS
Both the economic and technical efficiency of a mining
project is affected by where the tip of the pick hits
unbroken rock. That is why using mining picks that
maximise the efficiency of the machinery and deliver
the optimum balance between toughness, impact and
wear resistance for the rock formations encountered
make a vital difference.
T HE R IGH T T OOL F OR T HE R IGH T C U T T ING
A PPL IC AT ION S
Drawing from more than 50 years of expertise in
synthetic diamond and tungsten carbide materials and
tool manufacturing know-how, Element Six can develop
for a given application or set of conditions the right
tool:
–– Mining picks, available in standard and customised
sizes
–– Cutting inserts, from robust tungsten carbide grades
to PCD especially developed for mining applications
–– MasterGrade® picks, utilising the innovative
MasterGrade technology for optimal performance in
highly abrasive conditions
–– Pick tips in shapes and dimensions that are optimised
and adapted to the material to be cut
–– Retainers and securing elements, available in
different types
–– Pick bodies, made from hardened steel to provide
long tool life
–– Pick holder series for acceptance of all types of picks
–– Heavy duty holders, also available with wear-resistant
bushing
E L EME N T S I X OF F ER S MINING PICKS
S UI TA BL E F OR :
–– Longwall Shearer Drums
–– Continuous Miners
–– Surface Miners
–– Mining Road Headers
– Tunnelling Road Headers
RM8 T UNNEL L ING
RM7
KEY
DC
55, 60, 65, 70
DC
55, 70
LH
64, 70, 77
LH
75
D TC
15 17 19 21 22 25
D TC
15
17 19
21
24
LTC
23 23 28 30 32 35
LTC
21
23 28 30
34
D c
L H
D T C
L T C
Collar Width
Head Length
D i a m e t e r o f T. C . I n s e r t
L e n g t h o f T. C . I n s e r t
All dimensions in mm.
Mining Tools
6
THE RIGH T PICK FOR YOUR
APPLICAT ION
R M5
DC
R M8 MINING
RM35
40, 50, 55
DC
48, 50, 60
DC
55
LH
64, 74
LH
64, 70, 76, 80, 87, 89
LH
89, 90, 92, 100, 102
D TC
13
15
17
D TC
17
19
21
22
D TC
17
18
19
21
LTC
23
21
23
LTC
23
28
30
32
LTC
23
26
28
30
RM 3 8
RM38
DC
65, 70, 80
DC
55, 58, 60, 65
LH
70, 80
LH
70, 77, 80, 90, 100
D TC
19
21
22
25 30
D TC
19
21
22
25 30
LTC
28
30
35 35 40
LTC
28
30
35
35 40
Appropriate holder systems
for all types of picks, with
optional high wear resistant
sleeve.
All dimensions in mm.
Mining Tools
7
A COMPREHENSI V E R ANGE OF RO TARY
DRILLING PRODUC T S
Element Six manufactures a wide range of drill bits for
rotary drilling applications. Based on a standard range
of products, Element Six works closely with customers to
create customised solutions that deliver high efficiency
and productivity with low product lifetime cost.
T HE R IGH T T OOL F OR T HE R IGH T DR IL L ING
A PPL IC AT ION
Element Six rotary drilling products include:
– Tungsten Carbide drill bits
– PCD drill bits
– Drilling systems
– Accessories
Element Six’s rotary drilling tools can be used for:
– Roof bolting
– Blast hole drilling
– Gas extraction drilling
– Exploration drilling
That can be used in:
– Wet drilling
– A ir flushing
– Dry drilling
– Vacuum drilling
Drawing from 50 years of experience in synthetic diamond and tungsten
carbide, Element Six can develop the right tool for all drilling applications.
DR IL L BI T S F OR W E T DRIL L ING
ØD
L
THREAD
2 7m m
47, 5 m m
M16m*
28mm
47, 5 m m
M16m*
32mm
49,0mm M16m*
2-Wing Drill Bit
Semi-spade and W-shape types
DR IL L BI T S F OR A IR F L U S HING
ØD
L
THREAD
35mm
7 1,0mm
KW 20m*
38mm
7 1,0mm
KW 20m*
40mm
70,5mm
KW 20m*
42 m m
7 1,0mm
KW 20m*
46mm
75,0mm
KW 20m*
2-Wing Drill Bit
* Key: m - Male f - Female
Mining Tools
8
RO TARY DRILLING
DR IL L BI T S F OR W E T DRIL L ING
W-Shaped Drill Bit
3-Wing Drill Bit
ØD
L
THREAD
28mm
7 1,0mm
B 17 f*
32mm
72,0mm
B 17 f*
43mm
90,0mm
B 17 f*
43mm
90,0mm
B 25 f*
45mm
84,5mm
B 25 f*
5 1m m
66,0mm
B 25 f*
ØD
L
THREAD
65mm
95,0mm
M 39 f*
80mm
110,0mm
M 39 f*
65mm
95,0mm
Tr 3 9 f *
80mm
135,0mm M 45 f*
95mm
140,0mm M 45 f*
ØD
L
THREAD
26mm
51,0mm
Rd 16 f*
ØD
L
THREAD
25mm
53,0mm
Rd 16 f*
26mm
53,3mm
Rd 16 f*
3 7m m
7 1,0mm
Rd 20 f*
2-Wing Drill Bit
VACUUM DR IL L BI T S
Semi-spade Type
2-Wing Drill Bits
* Key: m - Male f - Female
Mining Tools
9
POLYCRYS TALLINE DIAMOND RO TARY
DRILLING PRODUC T S
P CD DRIL L BI T S
2-Wing PCD - Drill Bits
2-Wing PCD - Drill Bits
ØD
L
THREAD
25mm
47,0mm
M 12 m*
26mm
47,0mm
M 16 m*
29mm
44,5mm
M 16 m*
32mm
49,0mm
M 16 m*
35mm
49,0mm
M 16 m*
35mm
65,0mm
KW 20 m*
38mm
80,0mm
KW 20 m*
ØD
L
THREAD
25mm
78,0mm
B 17 f*
26mm
80,0mm
B 17 f*
28mm
80,0mm
B 17 f*
32mm
80,0mm
B 17 f*
35mm
68,5mm
B 20 f*
38mm
80,0mm
B 20 f*
38mm
94,0mm
Hex 20 m*
PCD drill bits up Ø 35 mm with calibre protection.
ØD
L
THREAD
40mm
78,0mm
B 25 f*
43mm
80,0mm
B 25 f*
45mm
80,0mm
B 25 f*
5 1m m
80,0mm
B 25 f*
5 1m m
68,5mm
Rd 25 m*
3-Wing PCD - Drill Bits
* Key: m - Male f - Female
Mining Tools
10
RO TARY DRILLING
P CD DRIL L BI T S
ØD
L
THREAD
76mm
165,0mm
Gg 46 m*
95mm
208,0mm
API m*
98mm
208,0mm
API m*
103mm
208,0mm
API m*
112mm
214,0mm
API m*
125mm
250,0mm
API f*
PCD drill bits with calibre protection.
3-Wing PCD - Drill Bits
DR IL L ING SYS T E M DOL OMI T E
Each Dolomite System consists of
Pilot Bit, Reamer, Pin and Rod
Connector. Components can be
varied to meet the required bore
hole diameter.
DRILLING SYSTEM M 39
D I A M E T E R 8 0 -1 15 M M
PILOT BIT
*REAMER T YPE F
*REAMER
Ø 65 mm
Ø 80 mm
-
-
-
1
Ø 65 mm
Ø 80 mm
Ø 95 mm
-
-
2
Ø 65 mm
Ø 80 mm
Ø 95 mm
Ø 105 mm
-
3
Ø 65 mm
Ø 80 mm
Ø 95 mm
Ø 105 mm
Ø 115 mm
4
D R I L L I N G S Y S T E M M 4 5
PIN
D I A M E T E R 1 2 5 -2 0 0 M M
PILOT BIT
*REAMER T YPE F V
*REAMER
PIN
Ø 95 mm
Ø 125 mm
-
-
-
1
Ø 95 mm
Ø 125 mm
Ø 150 mm
-
-
2
Ø 95 mm
Ø 125 mm
Ø 150 mm
Ø 175 mm
-
3
Ø 95 mm
Ø 125 mm
Ø 150 mm
Ø 175 mm
Ø 200 mm
4
* Special reamer for other drilling diameters available upon request.
For appropriate rod connectors please specify connection thread, male /
female thread type as well as rod diameter. All commonly used thread types
are available.
* Key: m - Male f - Female
Mining Tools
11
E L EME N T S I X
Element Six is a synthetic diamond supermaterials
company and part of the De Beers Group of
Companies.
Element Six designs, develops and produces synthetic
diamond supermaterials, and operates worldwide with
its head office registered in Luxembourg, and primary
manufacturing facilities in China, Germany, Ireland,
Sweden, South Africa, US and the UK.
Element Six supermaterial solutions are used in
applications such as cutting, grinding, drilling, shearing
and polishing, while the extreme properties of synthetic
diamond beyond hardness are already opening up new
applications in a wide array of industries such as optics,
power transmission, water treatment, semiconductors
and sensors.
If you would like to know about Element Six please
visit our website at www.e6.com, or contact us at the
address below.
Element Six US Corporation
24900 Pitkin Road
Suite 250, Spring
TX 77386
USA
Tel: +1 281 364 8080
Fax: +1 281 419 8311
Email: [email protected]
Element Six GmbH
Staedeweg 18
36151 Burghaun
Germany
Tel: +49 (0) 6652 82 300
Fax: +49 (0) 6652 82 390
Email: [email protected]
Copyright © Element Six 2014. 11/14 All images courtesy of Anglo American. Photo source page 1: RAG Deutsche Steinkohle.