CA2171364A1 - Controller and process for explosives mixing and loading - Google Patents
Controller and process for explosives mixing and loadingInfo
- Publication number
- CA2171364A1 CA2171364A1 CA 2171364 CA2171364A CA2171364A1 CA 2171364 A1 CA2171364 A1 CA 2171364A1 CA 2171364 CA2171364 CA 2171364 CA 2171364 A CA2171364 A CA 2171364A CA 2171364 A1 CA2171364 A1 CA 2171364A1
- Authority
- CA
- Canada
- Prior art keywords
- manufacturing
- explosives
- modular controller
- data processor
- process information
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 239000002360 explosive Substances 0.000 title claims abstract description 66
- 238000000034 method Methods 0.000 title claims abstract description 57
- 230000008569 process Effects 0.000 title claims abstract description 51
- 238000002156 mixing Methods 0.000 title description 4
- 238000004519 manufacturing process Methods 0.000 claims abstract description 55
- 230000004044 response Effects 0.000 claims abstract description 5
- 230000009056 active transport Effects 0.000 claims description 13
- 239000000463 material Substances 0.000 claims description 6
- 238000012546 transfer Methods 0.000 claims description 3
- 230000001960 triggered effect Effects 0.000 claims description 3
- 239000000203 mixture Substances 0.000 abstract description 23
- 239000000839 emulsion Substances 0.000 description 15
- PAWQVTBBRAZDMG-UHFFFAOYSA-N 2-(3-bromo-2-fluorophenyl)acetic acid Chemical compound OC(=O)CC1=CC=CC(Br)=C1F PAWQVTBBRAZDMG-UHFFFAOYSA-N 0.000 description 9
- 239000000295 fuel oil Substances 0.000 description 6
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 6
- 238000009472 formulation Methods 0.000 description 4
- 239000002243 precursor Substances 0.000 description 4
- 238000005086 pumping Methods 0.000 description 4
- 239000003795 chemical substances by application Substances 0.000 description 3
- 238000005065 mining Methods 0.000 description 3
- 239000007800 oxidant agent Substances 0.000 description 3
- 150000003839 salts Chemical class 0.000 description 3
- 239000007787 solid Substances 0.000 description 3
- 239000000446 fuel Substances 0.000 description 2
- 239000007789 gas Substances 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000012544 monitoring process Methods 0.000 description 2
- 239000012074 organic phase Substances 0.000 description 2
- 239000011435 rock Substances 0.000 description 2
- 230000032258 transport Effects 0.000 description 2
- 239000011800 void material Substances 0.000 description 2
- 239000007762 w/o emulsion Substances 0.000 description 2
- SPSSULHKWOKEEL-UHFFFAOYSA-N 2,4,6-trinitrotoluene Chemical compound CC1=C([N+]([O-])=O)C=C([N+]([O-])=O)C=C1[N+]([O-])=O SPSSULHKWOKEEL-UHFFFAOYSA-N 0.000 description 1
- QGZKDVFQNNGYKY-UHFFFAOYSA-O Ammonium Chemical compound [NH4+] QGZKDVFQNNGYKY-UHFFFAOYSA-O 0.000 description 1
- 229910002651 NO3 Inorganic materials 0.000 description 1
- NHNBFGGVMKEFGY-UHFFFAOYSA-N Nitrate Chemical compound [O-][N+]([O-])=O NHNBFGGVMKEFGY-UHFFFAOYSA-N 0.000 description 1
- SNIOPGDIGTZGOP-UHFFFAOYSA-N Nitroglycerin Chemical compound [O-][N+](=O)OCC(O[N+]([O-])=O)CO[N+]([O-])=O SNIOPGDIGTZGOP-UHFFFAOYSA-N 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- 239000008346 aqueous phase Substances 0.000 description 1
- 239000007864 aqueous solution Substances 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 238000009412 basement excavation Methods 0.000 description 1
- 239000011324 bead Substances 0.000 description 1
- 230000008901 benefit Effects 0.000 description 1
- 238000002716 delivery method Methods 0.000 description 1
- 238000005474 detonation Methods 0.000 description 1
- 238000005553 drilling Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000003995 emulsifying agent Substances 0.000 description 1
- 239000004794 expanded polystyrene Substances 0.000 description 1
- 230000006870 function Effects 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 229960003711 glyceryl trinitrate Drugs 0.000 description 1
- 239000004615 ingredient Substances 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 239000012071 phase Substances 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 239000012266 salt solution Substances 0.000 description 1
- 230000001235 sensitizing effect Effects 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 239000000015 trinitrotoluene Substances 0.000 description 1
- 230000000007 visual effect Effects 0.000 description 1
Landscapes
- General Factory Administration (AREA)
- Accessories For Mixers (AREA)
- Testing And Monitoring For Control Systems (AREA)
Abstract
The present invention relates to a controller and process for use in the manufacture of explosives compositions and delivery of said explosive compositions to a desired location. The invention provides a modular controller for an explosives manufacturing and/or loading process comprising:
a memory means for receiving and storing process information and calibration values;
a data processor means for performing calculations using said process information and/or calibration values and for comparing some of said process information and calculation results with target values; and a display unit which can display information and calculation results from said memory means and data processor, wherein said data processor can supply a control signal to an appropriate part of said manufacturing process in response to a target value being reached. Improved control of the manufacture of explosive compositions is achieved.
a memory means for receiving and storing process information and calibration values;
a data processor means for performing calculations using said process information and/or calibration values and for comparing some of said process information and calculation results with target values; and a display unit which can display information and calculation results from said memory means and data processor, wherein said data processor can supply a control signal to an appropriate part of said manufacturing process in response to a target value being reached. Improved control of the manufacture of explosive compositions is achieved.
Description
CONTROI I FR AND PROCESS FOR EXPLOSIVES MIXING AND LOADING
This invention relates to a controller and process for use in the manufacture of explosives compositions and delivery of said explosives compositions to a desired location.
Civilian mining, quarrying and excavation industries commonly use bulk or packaged explosive formulations as a principal method for breaking rocks and orefor mining, building tunnels, excavating and similar activities.
Explosive compositions comprising particulate oxidiser salts and a fuel have been known for many years as relatively inexpensive and reliable explosives and the most commonly used of these is ANFO, a mixture of ammonium nitrate (AN) and about 6% w/w fuel oil. ANFOis frequently used in dry conditions but less commonly in wet conditions because the AN particles absorb water, making the ANFO difficult to detonate and adversely affecting blast performance.
Emulsion explosives are preferred in areas where wet conditions are common because of their superior water resistance compared to ANFO, however they are significantly more expensive. Water-in-oil emulsion explosive compositions were first disclosed by Bluhm in United States Patent 3,447,978 andcomprise (a) a discontinuous aqueous phase comprising discrete droplets of an aqueous solution of inorganic oxygen-releasing salts; (b) a continuous water-immiscible organic phase throughout which the droplets are dispersed and (c) an emulsifier which forms an emulsion of the droplets of oxidiser salt solution throughout the continuous organic phase. Where these types of emulsions comprise very little water or adventitious water only in the discontinuous phasethey are more correctly referred to as melt-in-fuel emulsion explosives.
Generally the emulsions themselves are not detonable and to form an explosive they must be mixed with sensitising agents such as a self explosive (e.g trinitrotoluene or nitroglycerine) or a discontinuous phase of void agents. Suitable void agents include glass microballoons, plastic microballoons, expanded polystyrene beads and gas bubbles including bubbles of entrained air.
In order to take advantage of the low cost of ANFO and the superior water resistance of emulsions, ANFO and emulsions are often blended together to provide explosives which are commonly referred to as "heavy ANFO's".
` 2171364 -Compositions comprising blends of emulsion and AN or ANFO are described, for example in Australian Patent Application No. 29408/71 (Butterworth) and US
Patents 3,161,551 (Egly et al) and 4,357,184 (Binet et al).
When explosives are used in the mining industry, rock is fractured by 5 drilling blastholes then filling them with bulk or packaged explosive compositions which are subsequently detonated. Bulk explosives are generally less expensive per unit mass than packaged explosives hence bulk explosives are ~Jreferred, particularly at large mine sites where many hundreds of tonnes of explosives maybe needed for a single blast. Packaged explosives also suffer the drawback that 10 they must be manually loaded into blastholes whereas bulk explosives are loaded by mechanised means. Bulk explosives are either manufactured at a manufacturing facility and transported in a specially designed truck to the mine or mixed on-site in manufacturing units located on trucks (called mobile manufacturing units or MMU's). The transport trucks and MMU's are 15 provided with the mechanised means for loading bulk explosive into blastholes;
the loading is usually carried out by either by auguring, pouring, pumping or blow loading, the method used depending on the type of product. Loading by pumping is usually carried out by using a mechanical or pneumatic pump to push explosives compositions through a delivery hose into the blastholes. Blow loading 20 of an explosive composition typically involves the use of compressed gas to blow the explosive through a delivery hose into blastholes and is a commonly used delivery method for ANFO.
Both MMU's and fixed manufacturing facilities store relatively large quantities of chemical components which are eventually mixed together to form explosives 25 compositions. For example, MMU's comprise several large storage containers for storing fuel oil, emulsion, particulate oxidiser salts, water and other explosives components. These components can be mixed in differing proportions to provide ANFO, or various formulations of emulsion and heavy ANFO.
MMU's and fixed manufacturing facilities are expensive to construct and 30 maintain and are adapted for economy of scale. The larger facilities are designed to deliver hundreds of tonnes of explosive composition in a single manufacturingrun at a production rate of between 70 and 200 kg per minute. These manufacturing facilities are designed to fulfil the needs of high volume markets -such as large mine sites.
The low volume markets such as small quarries which may need only a few tonnes of exp'csives per blast are often supplied with explosives by small scale, portable manufacturing units such as those known as ASIAMASTER manufacturing 5 units. (ASIAMASTER is a trade mark of ICI Australia Operations Proprietary Limited.) Such units are small enough to be moved by being placed on a truck or trailer or they may be adapted to be towed.
Pre~iict~h'Q and optimal explosive performance requires an exact, even blending of components in specified proportions. Explosive manufacturers must 10 be able to reliably reproduce formulations to the specification and quality required by customers. In order to operate with maximum efficiency and economy they must also be able to precisely control the volume of explosives manufactured andwhere necessary, be able to accurately meter the required amount into each blasthole.
All explosives manufacturing units have control settings, meters and the like which are used by operators to monitor and adjust the flow rates of components and the rate at which the components are mixed. The small portable manufacturing units have built in meters, valves and the like for control of manufacture by an operator standing beside the unit. On MMU's these functions 20 are controlled by the driver/operator from the vehicle cabin using systems which are purpose built and integral with the truck.
These systems work by monitoring parameters of the manufacturing process, for example auger speed may be monitored by rpm counters while pumping rate may be monitored from pump speed. The operator needs to know 25 how these parameters relate to actual quantities of components delivered into the manufacturing process. Consequently, before commencing a manufacturing run, the operator carries out a calibration of a particular active transport means (such as pumps, augers and the like) by seeing how much material each delivers at a given speed. The operator uses these calibration values to calculate at what 30 speed each active transport means should be allowed to run to provide a certain blend of materials. He then sets appropriate timers and the process is commenced; each active transport means continuing to work until the timer signals that they stop.
One of the problems of this type of system is that it assumes that the rate of each active transport means is constant, which may not be correct.
Furthermore, the prior art relies on a separate control system being built into every manufacturing facility. It has now been found that a portable, self-contained 5 modular control unit, which is not vehicle specific can be used to provide more accurate control of explosives manufacturing processes.
The current invention therefore provides a modular controller for an explosives manufacturing and/or loading process comprising:
a memory means for receiving and storing process information and calibration values;
a data processor means for performing calculations using said process information and/or calibration values and for comparing some of said process information and calculation results with target values; and a display unit which can display information and calculation results from said memory means and data processor, wherein said data processor can supply a control signal to an appropriate part of said manufacturing process in response to a target value being reached.
The current invention further provides a method of controlling an explosives manufacturing process comprising connecting a modular controller to said process, the modular controller comprising:
a memory means for receiving and storing process information and calibration values;
a data processor means for performing calculations using said process information and/or calibration values and for comparing at least some of said process information and calculation results with target values; and a display unit which can display information and calculation results frorn-said memory means and data processor, wherein said data processor supplies an actuation or control signal to an appropriate part of said manufacturing process in response to a target value being reached.
The process information may comprise data monitored directly from the process including pump speeds, hydraulic pump pressures, material flow rates, temperatures and so forth. The target values may relate to maximum or minimum desired values for these process parameters and may be imputed to the memory or preprogrammed in the data processor.
In a preferred embodiment, the process parameters monitored relate to an active transport means, that is the means by which the explosives precursors are5 transported from storage containers to the desired point of addition to the process. For example, where the precursor is a solid, the active transport meansmay comprise an auger or the like and where the precursor is a liquid the activetransport means may comprise a pump or the like.
Where an active transport means is to be monitored, the process operator 10 carries out a calibration of the active transport means by measuring its delivery rate. For example, an auger may be found to have a calibration value of 5 kg perrevolution of the operating motor. The calibration factor obtained may then be input to the modular controller.
As the process information is monitored and the information fed to the 15 memory means of the control module the data processor takes the information from the memory means and using the calibration factor, converts the process parameter information into another form such as material flow rate. For example,if an auger has a calibration factor of 5 kg/revolution, monitoring the revolutions of the auger motor allows the exact mass of solid delivered by the auger to be 20 calculated by the data processor. By measuring the actual mass of solid delivered and stopping the process after the required amount has been delivered is inherently more accurate than using the time-based system of the prior art.
The process parameter monitored may also relate to maintaining the safe running of the process. For example a maximum and minimum target pressure 25 may be input to the controller for a given pump. If the pump pressure reacheseither of these target values the data processor may issue a control signal which stops the pump. Optionally an audible or visual alarm may also be triggered when a target value is reached. This provides a level of pump protection against"dry running" or "dead heading" which may lead to a detonation of entrapped 30 explosive.
The measured speed of each transport means is coriverted by its calibration factor into a flow rate in kg/min. These flow rates are summed together to give a total flow rate of ingredients being delivered at any point in time. While 217~364 -the process is running, this delivery rate is integrated with respect to time, until the quantity delivered equals the target quantity selected.
The control module of the current invention may be used to control the manufacture of any formulation of explosives, simply by changing the configuration 5 or selecting one of a range of configurations held in memory. The control module may be removably connected to any type of explosives manufacturing facility including fixed site manufacturing plants or relocatable plants including mobilemanufacturing units and units for use underground. Preferably the control modulemay be easily connected to a manufacturing facility by a multi-pin electrical 10 connection plug or the like.
The display means of the controller of the current invention may be of any convenient type known in the art. In a preferred embodiment the control module of the current invention can display a range of menus and different displays. For example one menu of the controller may be able to display a list of precursors 15 against the mass of each used in the process while another menu may display the various calibration factors entered. Preferably such information may also be stored in the memory means so that a history of several manufacturing runs may be kept.
The manufacturing facility for use with the control module of the current 20 invention may additionally have a delivery means for loading explosives compositions from the mixing device down a blasthole. The delivery means may comprise any apparatus known in the art for loading blastholes by auguring, pouring, pumping, blow loading or the like. It is particularly preferred that the control module be able to control the amount of explosive delivered into each 25 blasthole.
The control module of the current invention is preferably enclosed in a-robust, waterproof container so that it may easily be transported from place to place and resist damage in the relatively rough conditions of mine sites.
The control module of the current invention may optionally comprise means 30 for interfacing with printers, modems, radio-link data transfer systems and GPS
satellite navigation. Preferably data from the control module may be down loadedto a personal computer.
The control module of the current invention will now be described with -reference to the following non-limiting example;
EXAMPLE
A modular controller of the current invention was used to control a process for manufacture of an explosive composition comprising particulate ammonium 5 nitrate (AN) blended with a water-in-oil emulsion.
A modular controller was constructed using a commercially available process controller to measure inputs from flow/speed sensors located in the product, AN and emulsion pumps of an explosives manufacturing facility. A single9-core cable connected the modular controller to the manufacturing facility. The10 data processor displays via back lit graphical LCD display. The operator adjusted calibration values via a menu based calibration system into memory for each of the product, AN, fuel oil and emulsion pumps by using six push buttons and then pushed "G0" button to initiate the manufacturing process. An output relay in thedata processor opened a main hydraulic valve, starting the process pumps to run 15 at pre-determined speeds, set by manual hydraulic flow controls. The data monitored by the flow/speed sensors located in the product, AN, fuel oil and emulsion pumps were returned to memory and the data processor used the calibration values to convert the data to product, AN, fuel oil and emulsion flow rates. These flow rates were summed together to calculate the overall delivery 20 rate. When the amount of explosives composition delivered reach a pre-determined quantity a control signal issued by the data processor shut- down theAN, fuel oil and emulsion pumps.
A diagrammatic representation of the set up of the control module is depicted inFigure 1. The data processor, memory and display are components of the control 25 module. The operator, process and communications link are external to the -control module. The operator inputs directly to the data processor which may-process these inputs and feed various parameters and information into memory and/or the display means. The data processor is also responsible for sending control signals to the various elements of the process. Process information is 30 relayed back to the data processor to be processed, fed into memory or displayed for the operator. A communications link to the data processor can be used to input data, commands, information etcetera or accept same from the data processor. The communications link may comprise any suitable means for ._ transmitting and manipulating data including a personal computer.
While the invention has been explained in relation to its preferred embodiments it is to be understood that various modifications thereof will become apparent to those skilled in the art upon reading the specification. Therefore, it is 5 to be understood that the invention disclosed herein is intended to cover such modifications as fall within the scope of the appended claims.
This invention relates to a controller and process for use in the manufacture of explosives compositions and delivery of said explosives compositions to a desired location.
Civilian mining, quarrying and excavation industries commonly use bulk or packaged explosive formulations as a principal method for breaking rocks and orefor mining, building tunnels, excavating and similar activities.
Explosive compositions comprising particulate oxidiser salts and a fuel have been known for many years as relatively inexpensive and reliable explosives and the most commonly used of these is ANFO, a mixture of ammonium nitrate (AN) and about 6% w/w fuel oil. ANFOis frequently used in dry conditions but less commonly in wet conditions because the AN particles absorb water, making the ANFO difficult to detonate and adversely affecting blast performance.
Emulsion explosives are preferred in areas where wet conditions are common because of their superior water resistance compared to ANFO, however they are significantly more expensive. Water-in-oil emulsion explosive compositions were first disclosed by Bluhm in United States Patent 3,447,978 andcomprise (a) a discontinuous aqueous phase comprising discrete droplets of an aqueous solution of inorganic oxygen-releasing salts; (b) a continuous water-immiscible organic phase throughout which the droplets are dispersed and (c) an emulsifier which forms an emulsion of the droplets of oxidiser salt solution throughout the continuous organic phase. Where these types of emulsions comprise very little water or adventitious water only in the discontinuous phasethey are more correctly referred to as melt-in-fuel emulsion explosives.
Generally the emulsions themselves are not detonable and to form an explosive they must be mixed with sensitising agents such as a self explosive (e.g trinitrotoluene or nitroglycerine) or a discontinuous phase of void agents. Suitable void agents include glass microballoons, plastic microballoons, expanded polystyrene beads and gas bubbles including bubbles of entrained air.
In order to take advantage of the low cost of ANFO and the superior water resistance of emulsions, ANFO and emulsions are often blended together to provide explosives which are commonly referred to as "heavy ANFO's".
` 2171364 -Compositions comprising blends of emulsion and AN or ANFO are described, for example in Australian Patent Application No. 29408/71 (Butterworth) and US
Patents 3,161,551 (Egly et al) and 4,357,184 (Binet et al).
When explosives are used in the mining industry, rock is fractured by 5 drilling blastholes then filling them with bulk or packaged explosive compositions which are subsequently detonated. Bulk explosives are generally less expensive per unit mass than packaged explosives hence bulk explosives are ~Jreferred, particularly at large mine sites where many hundreds of tonnes of explosives maybe needed for a single blast. Packaged explosives also suffer the drawback that 10 they must be manually loaded into blastholes whereas bulk explosives are loaded by mechanised means. Bulk explosives are either manufactured at a manufacturing facility and transported in a specially designed truck to the mine or mixed on-site in manufacturing units located on trucks (called mobile manufacturing units or MMU's). The transport trucks and MMU's are 15 provided with the mechanised means for loading bulk explosive into blastholes;
the loading is usually carried out by either by auguring, pouring, pumping or blow loading, the method used depending on the type of product. Loading by pumping is usually carried out by using a mechanical or pneumatic pump to push explosives compositions through a delivery hose into the blastholes. Blow loading 20 of an explosive composition typically involves the use of compressed gas to blow the explosive through a delivery hose into blastholes and is a commonly used delivery method for ANFO.
Both MMU's and fixed manufacturing facilities store relatively large quantities of chemical components which are eventually mixed together to form explosives 25 compositions. For example, MMU's comprise several large storage containers for storing fuel oil, emulsion, particulate oxidiser salts, water and other explosives components. These components can be mixed in differing proportions to provide ANFO, or various formulations of emulsion and heavy ANFO.
MMU's and fixed manufacturing facilities are expensive to construct and 30 maintain and are adapted for economy of scale. The larger facilities are designed to deliver hundreds of tonnes of explosive composition in a single manufacturingrun at a production rate of between 70 and 200 kg per minute. These manufacturing facilities are designed to fulfil the needs of high volume markets -such as large mine sites.
The low volume markets such as small quarries which may need only a few tonnes of exp'csives per blast are often supplied with explosives by small scale, portable manufacturing units such as those known as ASIAMASTER manufacturing 5 units. (ASIAMASTER is a trade mark of ICI Australia Operations Proprietary Limited.) Such units are small enough to be moved by being placed on a truck or trailer or they may be adapted to be towed.
Pre~iict~h'Q and optimal explosive performance requires an exact, even blending of components in specified proportions. Explosive manufacturers must 10 be able to reliably reproduce formulations to the specification and quality required by customers. In order to operate with maximum efficiency and economy they must also be able to precisely control the volume of explosives manufactured andwhere necessary, be able to accurately meter the required amount into each blasthole.
All explosives manufacturing units have control settings, meters and the like which are used by operators to monitor and adjust the flow rates of components and the rate at which the components are mixed. The small portable manufacturing units have built in meters, valves and the like for control of manufacture by an operator standing beside the unit. On MMU's these functions 20 are controlled by the driver/operator from the vehicle cabin using systems which are purpose built and integral with the truck.
These systems work by monitoring parameters of the manufacturing process, for example auger speed may be monitored by rpm counters while pumping rate may be monitored from pump speed. The operator needs to know 25 how these parameters relate to actual quantities of components delivered into the manufacturing process. Consequently, before commencing a manufacturing run, the operator carries out a calibration of a particular active transport means (such as pumps, augers and the like) by seeing how much material each delivers at a given speed. The operator uses these calibration values to calculate at what 30 speed each active transport means should be allowed to run to provide a certain blend of materials. He then sets appropriate timers and the process is commenced; each active transport means continuing to work until the timer signals that they stop.
One of the problems of this type of system is that it assumes that the rate of each active transport means is constant, which may not be correct.
Furthermore, the prior art relies on a separate control system being built into every manufacturing facility. It has now been found that a portable, self-contained 5 modular control unit, which is not vehicle specific can be used to provide more accurate control of explosives manufacturing processes.
The current invention therefore provides a modular controller for an explosives manufacturing and/or loading process comprising:
a memory means for receiving and storing process information and calibration values;
a data processor means for performing calculations using said process information and/or calibration values and for comparing some of said process information and calculation results with target values; and a display unit which can display information and calculation results from said memory means and data processor, wherein said data processor can supply a control signal to an appropriate part of said manufacturing process in response to a target value being reached.
The current invention further provides a method of controlling an explosives manufacturing process comprising connecting a modular controller to said process, the modular controller comprising:
a memory means for receiving and storing process information and calibration values;
a data processor means for performing calculations using said process information and/or calibration values and for comparing at least some of said process information and calculation results with target values; and a display unit which can display information and calculation results frorn-said memory means and data processor, wherein said data processor supplies an actuation or control signal to an appropriate part of said manufacturing process in response to a target value being reached.
The process information may comprise data monitored directly from the process including pump speeds, hydraulic pump pressures, material flow rates, temperatures and so forth. The target values may relate to maximum or minimum desired values for these process parameters and may be imputed to the memory or preprogrammed in the data processor.
In a preferred embodiment, the process parameters monitored relate to an active transport means, that is the means by which the explosives precursors are5 transported from storage containers to the desired point of addition to the process. For example, where the precursor is a solid, the active transport meansmay comprise an auger or the like and where the precursor is a liquid the activetransport means may comprise a pump or the like.
Where an active transport means is to be monitored, the process operator 10 carries out a calibration of the active transport means by measuring its delivery rate. For example, an auger may be found to have a calibration value of 5 kg perrevolution of the operating motor. The calibration factor obtained may then be input to the modular controller.
As the process information is monitored and the information fed to the 15 memory means of the control module the data processor takes the information from the memory means and using the calibration factor, converts the process parameter information into another form such as material flow rate. For example,if an auger has a calibration factor of 5 kg/revolution, monitoring the revolutions of the auger motor allows the exact mass of solid delivered by the auger to be 20 calculated by the data processor. By measuring the actual mass of solid delivered and stopping the process after the required amount has been delivered is inherently more accurate than using the time-based system of the prior art.
The process parameter monitored may also relate to maintaining the safe running of the process. For example a maximum and minimum target pressure 25 may be input to the controller for a given pump. If the pump pressure reacheseither of these target values the data processor may issue a control signal which stops the pump. Optionally an audible or visual alarm may also be triggered when a target value is reached. This provides a level of pump protection against"dry running" or "dead heading" which may lead to a detonation of entrapped 30 explosive.
The measured speed of each transport means is coriverted by its calibration factor into a flow rate in kg/min. These flow rates are summed together to give a total flow rate of ingredients being delivered at any point in time. While 217~364 -the process is running, this delivery rate is integrated with respect to time, until the quantity delivered equals the target quantity selected.
The control module of the current invention may be used to control the manufacture of any formulation of explosives, simply by changing the configuration 5 or selecting one of a range of configurations held in memory. The control module may be removably connected to any type of explosives manufacturing facility including fixed site manufacturing plants or relocatable plants including mobilemanufacturing units and units for use underground. Preferably the control modulemay be easily connected to a manufacturing facility by a multi-pin electrical 10 connection plug or the like.
The display means of the controller of the current invention may be of any convenient type known in the art. In a preferred embodiment the control module of the current invention can display a range of menus and different displays. For example one menu of the controller may be able to display a list of precursors 15 against the mass of each used in the process while another menu may display the various calibration factors entered. Preferably such information may also be stored in the memory means so that a history of several manufacturing runs may be kept.
The manufacturing facility for use with the control module of the current 20 invention may additionally have a delivery means for loading explosives compositions from the mixing device down a blasthole. The delivery means may comprise any apparatus known in the art for loading blastholes by auguring, pouring, pumping, blow loading or the like. It is particularly preferred that the control module be able to control the amount of explosive delivered into each 25 blasthole.
The control module of the current invention is preferably enclosed in a-robust, waterproof container so that it may easily be transported from place to place and resist damage in the relatively rough conditions of mine sites.
The control module of the current invention may optionally comprise means 30 for interfacing with printers, modems, radio-link data transfer systems and GPS
satellite navigation. Preferably data from the control module may be down loadedto a personal computer.
The control module of the current invention will now be described with -reference to the following non-limiting example;
EXAMPLE
A modular controller of the current invention was used to control a process for manufacture of an explosive composition comprising particulate ammonium 5 nitrate (AN) blended with a water-in-oil emulsion.
A modular controller was constructed using a commercially available process controller to measure inputs from flow/speed sensors located in the product, AN and emulsion pumps of an explosives manufacturing facility. A single9-core cable connected the modular controller to the manufacturing facility. The10 data processor displays via back lit graphical LCD display. The operator adjusted calibration values via a menu based calibration system into memory for each of the product, AN, fuel oil and emulsion pumps by using six push buttons and then pushed "G0" button to initiate the manufacturing process. An output relay in thedata processor opened a main hydraulic valve, starting the process pumps to run 15 at pre-determined speeds, set by manual hydraulic flow controls. The data monitored by the flow/speed sensors located in the product, AN, fuel oil and emulsion pumps were returned to memory and the data processor used the calibration values to convert the data to product, AN, fuel oil and emulsion flow rates. These flow rates were summed together to calculate the overall delivery 20 rate. When the amount of explosives composition delivered reach a pre-determined quantity a control signal issued by the data processor shut- down theAN, fuel oil and emulsion pumps.
A diagrammatic representation of the set up of the control module is depicted inFigure 1. The data processor, memory and display are components of the control 25 module. The operator, process and communications link are external to the -control module. The operator inputs directly to the data processor which may-process these inputs and feed various parameters and information into memory and/or the display means. The data processor is also responsible for sending control signals to the various elements of the process. Process information is 30 relayed back to the data processor to be processed, fed into memory or displayed for the operator. A communications link to the data processor can be used to input data, commands, information etcetera or accept same from the data processor. The communications link may comprise any suitable means for ._ transmitting and manipulating data including a personal computer.
While the invention has been explained in relation to its preferred embodiments it is to be understood that various modifications thereof will become apparent to those skilled in the art upon reading the specification. Therefore, it is 5 to be understood that the invention disclosed herein is intended to cover such modifications as fall within the scope of the appended claims.
Claims (23)
1. A modular controller for an explosives manufacturing process, the modular controller comprising:
a memory means for receiving and storing process information and calibration values;
a data processor means for performing calculations using said process information and/or calibration values and for comparing some of said process information and calculation results with target values; and a display unit which can display information and calculation results from said memory means and data processor, wherein said data processor can supply a shut-off signal to an appropriate part of said manufacturing process in response to a target value being reached.
a memory means for receiving and storing process information and calibration values;
a data processor means for performing calculations using said process information and/or calibration values and for comparing some of said process information and calculation results with target values; and a display unit which can display information and calculation results from said memory means and data processor, wherein said data processor can supply a shut-off signal to an appropriate part of said manufacturing process in response to a target value being reached.
2. A modular controller according to claim 1 wherein the process information comprises process parameters relating to active transport means.
3. A modular controller according to claim 2 wherein the active transport means is an auger or a pump.
4. A modular controller according to claim 1 wherein said process information comprises one or more types of data chosen from pump speed, hydraulic pump pressure, material flow rate and temperature.
5. A modular controller according to any of the preceding claims wherein target values can be input to the memory or preprogrammed in the data processor.
6. A modular controller according to any of the preceding claims which further comprises audible or visible alarms which are triggered when a target value is reached.
7. A modular controller according to any of the preceding claims comprising a means for interfacing with any one or more printers and/or radio-link data transfer systems and/or satellite navigation systems.
8. A modular controller according to any of the preceding claims comprising a robust, waterproof container.
9. A method of manufacturing explosives comprising using a modular controller, the modular controller comprising:
a memory means for receiving and storing process information and a calibration values;
a data processor means for preforming calculations using said process information and/or calibration values and for comparing at least some of said process information and calculation results with target values; and a display unit which can display information and calculation results from said memory means and data processor, wherein said data processor supplies a shut-off signal to an appropriate part of said manufacturing process in response to a target value being reached.
a memory means for receiving and storing process information and a calibration values;
a data processor means for preforming calculations using said process information and/or calibration values and for comparing at least some of said process information and calculation results with target values; and a display unit which can display information and calculation results from said memory means and data processor, wherein said data processor supplies a shut-off signal to an appropriate part of said manufacturing process in response to a target value being reached.
10. A method of manufacturing explosives according to claim 9 wherein the process information comprises process parameters relating to active transport means.
11 11. A method of manufacturing explosives according to claim 9 or 10 wherein the active transport means is an auger or a pump.
12. A method of manufacturing explosives according to any of claims 9 to 11 wherein said process information comprises one or more types of data chosen from pump speed, hydraulic pump pressure, material flow rate and temperature.
13. A method of manufacturing explosives according to any of claims 9 to 12 wherein target values can be input to the memory or preprogrammed in the data processor of the modular controller.
14. A method of manufacturing of explosives according to any of claims 9 to 13 wherein the modular controller further comprises audible or visible alarms which are triggered when a target value is reached.
15. A method of manufacturing of explosives according to any of claims 9 to 14 wherein the modular controller comprises a means for interfacing with any one or more printers and/or radio-link data transfer systems and/or satellite navigation systems.
16. A method of manufacturing of explosives according to any of claims 9 to 15 wherein the modular controller comprises a robust, waterproof container.
17. A method of manufacturing explosives according to any one of claims 9 to 16 wherein the control module controls a fixed site manufacturing plant or a relocatable plant.
18. A method of manufacturing explosives according to claim 17 wherein the relocatable plant is a mobile manufacturing unit or a unit for use underground.
19. A method of manufacturing explosives according to claims 17 or 18 wherein the control module controls the delivery of explosives from the delivery.
20. A method of calibrating the modular controller of any one of claims 1 to 8 comprising;
(a) feeding monitored process information into the memory means, (b) having the data processor take the process information from the memory means, and (c) using a calibration factor, converting the process information.
(a) feeding monitored process information into the memory means, (b) having the data processor take the process information from the memory means, and (c) using a calibration factor, converting the process information.
21. A modular controller for an explosives manufacturing process substantially as herein described with reference to the drawing.
22. A method of manufacturing explosives substantially as herein described with reference to the example.
23. A method of calibrating a modular controller for an explosives manufacturing process substantially as herein described with reference to the example.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| AUPN1663A AUPN166395A0 (en) | 1995-03-10 | 1995-03-10 | Modular controller |
| AUPN1663 | 1995-03-10 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2171364A1 true CA2171364A1 (en) | 1996-09-11 |
Family
ID=3786018
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2171364 Abandoned CA2171364A1 (en) | 1995-03-10 | 1996-03-08 | Controller and process for explosives mixing and loading |
Country Status (5)
| Country | Link |
|---|---|
| CN (1) | CN1070284C (en) |
| AU (1) | AUPN166395A0 (en) |
| CA (1) | CA2171364A1 (en) |
| NZ (1) | NZ286126A (en) |
| ZA (1) | ZA961881B (en) |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102180752A (en) * | 2011-03-29 | 2011-09-14 | 大连海事大学 | Control system of field explosive mixed loading truck |
| CN119310932A (en) * | 2024-08-28 | 2025-01-14 | 山西鸿鹄专用汽车制造有限公司 | A control system and automatic agitator based on explosive vehicle |
Families Citing this family (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102608958B (en) * | 2011-08-05 | 2014-11-19 | 薛世忠 | Bulk explosive monitoring system and monitoring method |
| CN102607344B (en) * | 2011-08-05 | 2015-05-20 | 薛世忠 | Bulk explosive loading equipment information processor and bulk explosive loading equipment information processing method |
-
1995
- 1995-03-10 AU AUPN1663A patent/AUPN166395A0/en not_active Abandoned
-
1996
- 1996-03-06 NZ NZ28612696A patent/NZ286126A/en unknown
- 1996-03-07 ZA ZA961881A patent/ZA961881B/en unknown
- 1996-03-08 CA CA 2171364 patent/CA2171364A1/en not_active Abandoned
- 1996-03-11 CN CN 96103078 patent/CN1070284C/en not_active Expired - Fee Related
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102180752A (en) * | 2011-03-29 | 2011-09-14 | 大连海事大学 | Control system of field explosive mixed loading truck |
| CN102180752B (en) * | 2011-03-29 | 2012-08-22 | 大连海事大学 | Control system of field explosive mixed loading truck |
| CN119310932A (en) * | 2024-08-28 | 2025-01-14 | 山西鸿鹄专用汽车制造有限公司 | A control system and automatic agitator based on explosive vehicle |
| CN119310932B (en) * | 2024-08-28 | 2025-03-25 | 山西鸿鹄专用汽车制造有限公司 | A control system and automatic agitator based on explosive vehicle |
Also Published As
| Publication number | Publication date |
|---|---|
| CN1070284C (en) | 2001-08-29 |
| NZ286126A (en) | 1998-06-26 |
| AUPN166395A0 (en) | 1995-04-06 |
| ZA961881B (en) | 1996-09-10 |
| CN1134541A (en) | 1996-10-30 |
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