Revolutionizing tunnel development: Synthetic diamond technology for mining and infrastructure applications

A new strategic partnership promises to transform tunnel development technology. The recently announced collaboration introduces a novel diamond-enabled cutting system designed to enhance tunnel development speed, reduce costs, and minimize environmental impact across the mining, infrastructure, transportation, and energy sectors.

Element Six (E6), a member of the De Beers Group, has been at the forefront of synthetic diamond innovation for over seven decades. The company specializes in the development and manufacturing of polycrystalline diamond (PCD) and other advanced materials. As Thomas Trott, sales director for road, mining, and wear at Element Six said, “With more than 70 years of sustained investment and expertise, E6 was one of the first companies in the world to commercialize PCD industrial materials. Today, we continue to harness these capabilities to deliver novel solutions that can revolutionize critical industrial applications.”

Master Drilling, established in 1986, is a global company specializing in drilling technology solutions. The company provides a range of mechanized services to the mining, infrastructure, and energy sectors and is known for its innovative solutions and tailor-made engineering designs.

The strategic partnership

Both companies joined forces to develop a novel, synthetic diamond-enabled tunneling solution to develop high-tech solutions for industrial applications.

The innovative tunneling solution reduces waste rock generation by more than 17% compared to traditional methods. The technology has been tested in various mining and construction sites across the U.K. and South Africa and has demonstrated improved performance and efficiency compared to traditional solutions.

Patented tools and application techniques of cut and break method have been applied to different manufactured and natural materials, including concrete, reinforced concrete, granite, kimberlite, limestone, and chromite-containing ore and waste rock materials in end-users ’ applications.

Key benefits delivered by this cutting-edge

PCD-enabled technology include:

Safety and rock-stability: The absence of blasting and diesel requirements ensures safer working conditions and increased rock stability owing to the mechanized cutting and breakage process.

Enhanced productivity: Synthetic diamond cutting tools can manage soft to ultra-hard and high-strength rock removal, resulting in higher productivity rates and longer cutter life.

Reduced waste generation: The technology minimizes muck production, converting circular cross-sections to non-circular with a wider flat bottom, creating more usable space for ventilation and electric cable systems.

Operational simplicity: The lightweight and mobile solution requires fewer operational crew members and offers versatile capabilities in confined underground conditions.

Cost effectiveness: The shorter tunnel development period allows for quicker ramp-up of mining and construction projects, reducing capital costs and shortening investment return times.

Why is this technology important?

Underground tunnels are essential for accessing mineral resources, creating efficient transportation routes, and housing utilities while minimizing surface disruption. Achieving high-quality, nonexplosive tunnel construction with various aspects of value generated compared to traditional rock excavation methods is a key global challenge for tunnel builders.

Synthetic diamond innovation holds immense potential to shape the future of industrial applications. By extracting a lower amount of rock during tunnel development, the new technology will significantly reduce waste and environmental impact, ensuring a better tomorrow for generations to come.

By using PCD cutting tools, this novel cut-break technology provides an innovative development platform for tunnel builders. Synthetic diamonds, with their exceptional hardness, high thermal conductivity, and low friction coefficient, outperform traditional materials, such as carbide and steel, in cutting hard and high-strength rocks. This leads to higher productivity with a minimal rate of cutting element wear during the excavation of hard-to-ultra-hard rocks.

Sustainability and prospects

This synthetic-diamond-based technology also aligns with a broader sustainability effort, reducing environmental impact through efficient resource use and lower energy consumption.

The use of synthetic diamond technology in tunneling not only improves operational efficiency but also contributes to the overall sustainability of mining and construction projects. By reducing the need for blasting and diesel-powered equipment, the technology minimizes greenhouse gas (GHG) emissions and enhances the safety and stability of tunnel structures. This innovative approach aligns with the global need to push towards more sustainable and environmentally friendly industrial practices.

Furthermore, the technology’s potential applications extend beyond mining and construction to include trenching for fiber-optic cables or pipes. Additionally, the solution holds promise for general tunneling, widening, and custom excavations from tunnels that require non-explosive excavation, enlarging current tunnels for larger equipment or because of closure, excavation of overcuts to tunnels to fit equipment such as water doors and barriers, undercutting tunnels to allow for grouting barriers to be installed, breakaway tunnels for existing tunnels, without damaging camelbacks owing to ripping cable anchors and rock support out, and excavating niche excavation in TBM tunnels, such as laybys or chambers for services installation.

Conclusion

The introduction of this synthetic-diamond-enabled cutting technology stands for a major advancement in tunnel development. As industries continue to seek more efficient and sustainable solutions, innovation and progress can be fostered through strategic partnerships. The novel technology promises to revolutionize tunnel construction, delivering significant potential benefits to the mining, infrastructure, transportation, and energy sectors for years to come. 

Habib Saridikmen is head of applications at Element Six, and Koos Jordan is executive director of Master Drilling.

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