World leader in the design, development and production of synthetic diamond advanced material solutions Element Six, part of the De Beers Group, and global leader in drilling technology solutions Master Drilling today announced a new global partnership for advanced tunnel development technology.

The collaboration combines Element Six’s leading patented polycrystalline diamond (PCD) cutting technology with Master Drilling’s fully mechanised services for the mining, infrastructure and energy sectors to deliver a new synthetic diamond-enabled tunnelling solution.

“Element Six’s new diamond-based technology, and our strategic partnership with Master Drilling, opens new possibilities for mining, construction companies and tunnel developers,” Element Six Head of Applications – Abrasives Dr Habib Saridikmen tells Mining Weekly.

“By using advanced PCD cutting tools, our technology significantly reduces tunnel development costs and waste. Diamonds, with their exceptional hardness, high thermal conductivity, and low friction coefficient, outperform traditional materials in cutting hard and high-strength rocks.

“The technology's ability to handle soft to ultra-hard and high-strength rock removal allows for higher productivity rates and longer cutter life compared to traditional cutter materials. This technology creates precise cut slots in the rock, which act as fracture initiation zones, allowing the rock to break with lower energy input in the secondary step through breakers,” he explains.

The new synthetic diamond-enabled tunnelling solution reduces waste rock generation (muck) by 17% compared with traditional tunnelling operations by applying the method to the precise corner section cuts of the tunnels. Further, the technology converts circular cross-sections to non-circular with a wider flat bottom, minimising the amount of muck produced in traditional rock excavation methods and generating more usable space for ventilation, electric cable systems and underground equipment movements.

Additionally, and remarkably, the blade consumes just 70 kW of energy, creating an energy efficient new technology that can function independently for face or side cutting on a mobile carrier or tunnel boring machine (TBM) for mechanised underground excavation.

Underground tunnels provide access to critical mineral resources, create efficient transportation routes and house essential utilities, all while reducing surface disruption. In mining, tunnels are key for accessing mineral resources and providing transportation and ventilation networks for underground operations.

“By combining the technologies and expertise of Element Six and Master Drilling, we can offer quality tunnel development with competitive productivity, lower costs and reduced waste, enabling safer, faster and more economical tunnel constructions,” states Master Drilling executive director Koos Jordaan.

Additionally, this novel technology supports the transition to lower-cost mobile electrification in underground operations. The lightweight and mobile solution requires a lower number of operational crew at the application site, reducing safety concerns.

The versatile operational capabilities in underground conditions, meanwhile, enables the technology to operate minimal reversing and movement restrictions in confined tunnel spaces. The absence of blasting and diesel requirements ensures safer working conditions and increased rock stability owing to the mechanised cutting and breakage process.

“Moreover, operators can combine the technology with traditional tunnelling processes such as drill, blast, TBM, or road-header, and it operates at a lower power rate compared to traditional mechanised rock cutting systems,” says Saridikmen.

LOCATION

The location of Element Six’s key manufacturing hub in South Africa contributes to the development and deployment of this innovative solution.

“Element Six, a De Beers Group company, has its birthplace in South Africa, a hub of innovation in synthetic diamond technology. Our PCD cutters are made in Springs, in Gauteng, and are crucial for this new technology.

“Being in South Africa allows us to quickly prototype and test new technologies near major mining and infrastructure projects on the continent. South Africa's rich mining history and skilled workforce support our technological advancements and help us achieve faster turnaround times during the research and development stages,” notes Saridikmen.

Master Drilling, meanwhile, is known for its innovative solutions and engineering expertise. Together, Element Six and Master Drilling use their engineering and innovative strengths from South Africa to address global challenges in mining and construction through this new technology.

SUSTAINABILITY

With sustainability as a major global focus, Element Six’s diamond-based technology reduces environmental impact through several key innovations.

The use of synthetic diamond cutting tools minimises the amount of rock that needs to be removed, significantly reducing waste generation. Additionally, the technology operates with a lower energy footprint, decreasing greenhouse-gas emissions associated with tunnel construction.

“By promoting more efficient resource use and reducing environmental disruption, this novel technology supports sustainable mining and infrastructure projects. This aligns with global sustainability goals and helps ensure that Africa's development is both economically and environmentally sustainable,” says Element Six global sales director for mining, road and wear Thomas Trott.

By developing the strategic partnership between Element Six and Master Drilling, all aspects of the technology, including the manufacturing of PCD cutters, equipment and operational teams, can be built and operated in Africa through local hubs.

“This localised approach reduces the carbon footprint of implementation across the continent and drives sustainability. By leveraging local resources and expertise, we can further enhance the environmental benefits of our technology, supporting Africa's commitment to sustainable development,” he concludes.