Heated Compressed Air Blasthole Drill Rig Flushing
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Solution Overview
Problem
Current blasthole drill rigs consume a substantial amount of fuel to generate compressed air for flushing bit cuttings from boreholes, leading to high operating costs.
Innovation Solution
Incorporating a heating element to increase the effective pressure and flow rate of compressed air, reducing the need for a large air compressor and subsequently decreasing fuel consumption, while also using vent apertures to control airflow and prevent overheating of the drill bit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a large air compressor is used to generate compressed air for flushing bit cuttings, then the flushing effectiveness is improved, but the fuel consumption increases
Solution Approach 1:
The patent changes the temperature parameter of the compressed air by introducing a heating element. Heated compressed air has lower density and higher expansion, which improves flushing effectiveness without requiring a larger compressor, thus reducing fuel consumption while maintaining productivity
Solution Approach 2:
The patent converts the typically harmful heat into a beneficial factor by using the heating element to warm the compressed air. This thermal energy enhancement improves the air's flushing capability and reduces the compressor size needed, thereby converting what would be wasted energy into a productivity-enhancing factor
2Power
If the compressed air is heated to increase flow rate, then the air compressor size can be reduced, but the complexity of the system increases
Solution Approach 1:
The patent segments the air delivery system into two independent functional components: the compressed air generation system and the air heating system. This modular approach allows the compressor to be sized for base requirements while the heating element provides incremental performance enhancement, managing system complexity through functional separation
3Productivity
If heated compressed air is directed through the drill pipe, then the flushing efficiency is improved, but the drill bit may overheat
Solution Approach 1:
The patent applies local quality by heating the compressed air in specific zones along the drill pipe rather than uniformly throughout. The heating element is positioned to warm air at specific locations, creating temperature gradients that improve flushing where needed while avoiding excessive heat accumulation at the drill bit
Solution Approach 2:
The system uses periodic or controlled heating intervals to prevent thermal accumulation. By regulating when and how the heating element operates, the system maintains flushing efficiency while allowing thermal management to prevent drill bit overheating
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The heating element enhances the efficiency of air flushing, reducing fuel requirements and allowing for a potentially smaller air compressor, thereby lowering operating costs and improving drilling performance.
Implementation Method 1
a heating element that heats the compressed air
Implementation Method 2
a plurality of vent apertures spaced between the upper end and the lower end along the body, wherein each of the plurality of vent apertures extends through the body and is in communication with the internal cavity
Data Source
AI summary
A blasthole drill rig includes a base, a drill tower extending from the base, a drill pipe coupled to the drill tower, a drill bit coupled to a lower end of the drill pipe, an air compressor that directs compressed air through the drill pipe, and a heating element that heats the compressed air.