The mining and construction sectors are on the cusp of a revolution, thanks to a groundbreaking partnership between Element Six (E6) and Master Drilling. This alliance promises to transform tunnel development technology, offering a novel diamond-enabled cutting system that could redefine industry standards. The implications of this technology are vast, touching on productivity, cost-efficiency, environmental impact, and safety.
At the heart of this innovation lies E6’s expertise in synthetic diamond technology. With over seven decades of experience, E6 has been a pioneer in developing polycrystalline diamond (PCD) and other advanced materials. Thomas Trott, sales director for road, mining, and wear at Element Six, emphasizes the company’s long-standing commitment to innovation: “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.” This legacy of innovation is now being leveraged to create a cutting-edge tunneling solution that could dramatically alter the landscape of various industries.
Master Drilling, a global leader in drilling technology solutions, brings its own set of strengths to the table. Established in 1986, the company is renowned for its innovative solutions and tailor-made engineering designs. Together, E6 and Master Drilling have developed a synthetic diamond-enabled tunneling solution that reduces waste rock generation by over 17% compared to traditional methods. This technology has already been tested in various mining and construction sites across the U.K. and South Africa, demonstrating improved performance and efficiency.
The benefits of this PCD-enabled technology are manifold. Safety and rock stability are significantly enhanced due to the absence of blasting and diesel requirements. The mechanized cutting and breakage process ensures safer working conditions and increased rock stability. Enhanced productivity is another key advantage, as synthetic diamond cutting tools can manage the removal of soft to ultra-hard and high-strength rocks, resulting in higher productivity rates and longer cutter life. The technology also 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 is another standout feature. The lightweight and mobile solution requires fewer operational crew members and offers versatile capabilities in confined underground conditions. Cost-effectiveness is also a significant factor, as the shorter tunnel development period allows for quicker ramp-up of mining and construction projects, reducing capital costs and shortening investment return times.
The importance of this technology cannot be overstated. Underground tunnels are crucial for accessing mineral resources, creating efficient transportation routes, and housing utilities while minimizing surface disruption. Achieving high-quality, non-explosive tunnel construction is a global challenge, and synthetic diamond innovation holds immense potential to address this need. By extracting a lower amount of rock during tunnel development, the new technology will significantly reduce waste and environmental impact, paving the way for a more sustainable future.
Sustainability is a key driver behind this innovation. The synthetic-diamond-based technology aligns with broader sustainability efforts, reducing environmental impact through efficient resource use and lower energy consumption. By minimizing the need for blasting and diesel-powered equipment, the technology reduces greenhouse gas (GHG) emissions and enhances the safety and stability of tunnel structures. This aligns with the global push towards more sustainable and environmentally friendly industrial practices.
The potential applications of this technology extend far beyond mining and construction. It holds promise for trenching for fiber-optic cables or pipes, general tunneling, widening, and custom excavations. The solution can be used for non-explosive excavation, enlarging current tunnels, excavating overcuts, undercutting tunnels for grouting barriers, and creating niche excavations in TBM tunnels. The versatility of this technology makes it a game-changer for various industries.
As industries continue to seek more efficient and sustainable solutions, this strategic partnership between E6 and Master Drilling sets a precedent for innovation and progress. The novel technology promises to revolutionize tunnel construction, delivering significant benefits to the mining, infrastructure, transportation, and energy sectors. The future of tunnel development looks brighter and more sustainable, thanks to the power of synthetic diamonds and the vision of these industry leaders.