FOR ELECTRONICALLY ACTIVATED CHEMICAL ROCK BREAKING SYSTEM

TECHNICAL FIELD

This invention relates to a novel chemical composition for electronically activated chemical rock breaking system.

PRIOR ART

This invention relates to a novel chemical composition for the complete system defined as “ELECTRONICALLY ACTIVATED CHEMICAL ROCK BREAKING SYSTEM”, to break rock and hard formations, in the safest way avoiding any risk encountered by breaking products like; explosives, pyrotechnical products, and also in the quickest and cheapest way when compared to products like; chemical, mechanical and/or hydraulic rock breaking machinery and equipment.

One of the main targets of the invention is to have a complete system which will be totally away from the definition of explosives and pyrotechnical products as well as to be away from those regulations and documentation such existing products require.

The chemical composition of the present invention is designed and developed to be used for the fields of construction, mining, manufacturing industry where there is a need of breaking all sorts of hard formations and structures.

Today, there are several products and techniques for breaking rock. These are basically; Chemical, Hydraulic, Mechanical or Explosive. Among these, the major ones can be given as follows;

1 . Expanding Grouts

These products are generally mixture of oxides and are composition of inorganic and organic compounds. In order to use them, they have to be mixed with water at certain proportion; slurry is obtained and then poured into the drilled holes.

The pressure obtained is relatively low, they can create only cracks, time to break takes long time (10-20 hours), requires too many holes to crack.

2. Pyrotechnical Rock Breaking Products These rock breaking products are generally mixtures of some compounds like; nitrate based chemicals and/or peroxides. These mixtures are filled in cartridges. Almost all of them are ignited with fuses, detonators or propellants. Besides, due to the chemicals and ignition components, they are under UN No. 0432 and Class 1.4S or 1.4G. These products generally require special certification and permission for import, transport, usage and storage. Meanwhile, permissions from local authorities are also required in many countries.

3. Hydraulic Rock Splitters

Basically, these are mechanical products. The product generates its breaking action with the hydraulic pressure exerted by the steel elements placed into the holes.

Generally, mechanical failures cause the system to stop and face delays in operations. Requires many holes to break and accessories in the system lead to slow mobility.

4. Hydraulic Rock Breakers

These are very common mechanical hammers mostly used coupled to excavators. They get their hydraulic power from the units embedded in the excavators. While creating a continuous noise for hitting the rock, their breaking capacities are relatively low.

5. Hand-held Rock Breakers

These machines are almost the oldest mechanical tools for breaking rock. Generally, they are used for very small jobs, each tool requires an operator. Besides, their capacities are very low compared to all other products and equipment.

6. Explosives

Among all products mentioned, explosives are the most risky products. Today, use of any sort of explosives is forbidden within the limits of rural areas. Besides, all related actions and operations are subject to strict permission and certifications. Meanwhile, the pressure they create on the atmosphere lead to very high detonation velocity and impact pressure.

Each one above or in combined way of using, the target has always been same; breaking rock according to the demands of the sectors like, construction and mining. As a prior art document, EP 2651855 B1 entitled “ROCK AND CONCRETE BREAKING (DEMOLITION - FRACTURING - SPLITTING) SYSTEM” discloses a chemical mixture (34), comprising potassium chlorate with ratio of 30-70 % by weight of mixture, ammonium oxalate, with ratio of 15-35 %, by weight of mixture, sugar or lactose or starch or any combination of them with ratio of 15-20 % by weight of mixture, boron oxide (boroxide) (B2O3) with ratio of 5-10 % by weight of mixture, borax decahydrate (Na2B4O?.10H2O) with ratio of 3-5 % by weight of mixture. We would like to draw attention to the fact that the inventor of the present invention, Mr. Yusuf Vasfi Ozalp is one of the two inventors of this aforementioned EP 2651855 B1 patent. When the ingredients of the previous chemical mixture of EP 2651855 B1 and the chemical composition of the present invention is compared, it will be easily understood that with the present invention, a totally new chemical composition for electronically activated chemical rock breaking system is found.

US patent publication No. US4565579A entitled “Nonexplosive chemical composition for gently breaking rock or concrete mass” discloses a nonexplosive chemical composition for gently and noiselessly breaking a rock or concrete mass. Said composition comprises a principal component which is prepared by calcining a starting mixture comprising 100 parts by weight of quick lime and 1 -20 parts by weight of calcium fluoride.

As another prior art document, British patent publication No. GB2296270A entitled “Nonexplosive breaking composition” discloses a non-explosive breaking composition for breaking rock or concrete. Said composition includes 100 parts by weight of a thermit mixture which consists of 15-30 wt% of aluminum powder, a dust scattering preventing agent and an antioxidant, and 70-80 wt% of copper oxide; and 80-120 parts by weight of a cracked gas generator.

THE TECHNICAL PROBLEM AIMED TO SOLVE AND AIMS OF THE INVENTION

The basic aims of the chemical composition of this invention - by introducing a technology for construction and mining sectors and to all others that requires rock breaking - can be defined as follows: a) That has to be away from all types of explosives and such components, products, etc. and away from those that are accepted as explosives. b) That has to be as simple as possible to learn and apply. c) That has to be as universal as possible so that; it can be produced/manufactured at almost all regions of the world. d) That has to be as efficient, productive as possible so that; it should let the end users to gain time and money. e) That has to be as safe as possible so that; there should be no shock waves, no fly rock and insignificant level of ground vibrations. Meanwhile, it must be possible to transport the system by all means of transport (air-road-sea-rail). f) That has to be as compact as possible so that, all system can be placed in a box of sizes max. 50 x 60 x 50 cm (= 0.15 m ³ ). g) That has to be as environmental friendly as possible. h) That has to be as economic as possible to drop the excavation costs.

SUMMARY OF THE INVENTION

This invention relates to a chemical composition for electronically activated chemical rock breaking system, and it comprises potassium chlorate with ratio of 20-55 % by weight of the chemical composition, sodium perborate or Tetra acetyl ethylene diamine (TAED) or any combination of them with ratio of 10-24 % by weight of the chemical composition, at least one fruit and/or vegetable powder selected from the group consisting of carob powder, dried grape powder, dried currant powder, dried date powder, dried coconut fruit powder, dried pumpkin powder, dried sugarcane, sugar beet powder, dried tamarind powder and dried fig powder with ratio of 9-28 % by weight of the chemical composition, at least one powder selected from the group consisting of olive pulp powder, nut shell powder, coconut shell powder, pumpkin seed shell powder, sunflower seed shell powder with ratio of 5-20 % by weight of the chemical composition.

DETAILED DESCRIPTION OF THE INVENTION

This invention relates to a chemical composition for electronically activated chemical rock breaking system, and it comprises potassium chlorate with ratio of 20-55 % by weight of the chemical composition, sodium perborate or Tetra acetyl ethylene diamine (TAED) or any combination of them with ratio of 10-24 % by weight of the chemical composition, at least one fruit and/or vegetable powder selected from the group consisting of carob powder, dried grape powder, dried currant powder, dried date powder, dried coconut fruit powder, dried pumpkin powder, dried sugarcane, sugar beet powder, dried tamarind powder and dried fig powder with ratio of 9-28 % by weight of the chemical composition, at least one powder selected from the group consisting of olive pulp powder, nut shell powder, coconut shell powder, pumpkin seed shell powder, sunflower seed shell powder with ratio of 5-20 % by weight of the chemical composition.

According to a preferred embodiment of the invention, said sodium perborate in the chemical composition is either monohydrate or tetrahydrate. Also, said olive pulp powder in the chemical composition is grinded dry powder of green and/or black olive pulp. In addition, said chemical composition may further comprise non-explosive solid or liquid chemicals or some adhesives/glue or binders.

Chemical composition according to the present invention is the result of mechanical mixing of dry powder of all ingredients taking part in the chemical composition. Before, during and after the preparation, there is not any reaction or a specific process. Necessary Explanation: The chemical composition is obtained by mixing all powder ingredients with a suitable mixer. In order to get the required final homogenous mixture, we recommend using the mixer designed and manufactured by us. This mixer is rotating at 2 axes at a certain revolution per minute (rpm) and can be operated manually. It is tested several times and has specific fixed mixing drum volume vs. fixed amount of mixture at a specified time.

This dry mixture is filled in the modules which are produced according to required sizes considering given specifications.

Necessary Explanation: For module filling, we also recommend a filling procedure and system that will lead to an efficient and safe operation.

The basic chemicals and ingredients that make up the chemical composition are;

- Potassium Chlorate

- Sodium Perborate (monohydrate or tetrahydrate)

- Carob Powder (ceratonia siliqua powder)

- Olive Pulp Powder (pirina)

Besides, the chemical composition may further comprise any one or more of the following:

- TAED (Tetra acetyl ethylene diamine) - Nut shell powder, coconut shell powder, pumpkin seed shell powder, sunflower seed shell powder (and similar shell powders)

Dried grape powder, dried currant powder, dried date powder, dried coconut fruit powder, dried pumpkin powder, dried sugarcane and sugar beet powder, dried tamarind powder, dried fig powder (and similar dried fruit or vegetable powders).

The chemical composition ratios by weight (formulation) to prepare the chemical composition of the present invention can be given on Table 1.

TABLE 1

Ratios of Chemicals/lngredients of the mixture, by weight.

There are selected combinations of the given chemicals and ingredients from which we can arrive to different energy levels that lead the invented product to break different types of rock. Below, one can find some of these combinations selected (ratios by weight) to lead to a highest level of breaking: (*) These powders are from their original dried fruit or vegetable.

(**) These powders are from their original dried fruit or vegetable. Some embodiments of the invention regarding the contents of the chemical composition are given below.

Mixture Combinations of the Chemical Composition of The Present Invention

Mixture -1

Potassium Chlorate - KCIO3 45%

Sodium Perborate Tetrahydrate - NaBOs.4H2O 20%

Carob Powder 25%

Olive Pulp Powder 10%

TOTAL: 100%

Energy output; Average: 525-540 cal I gr.

Mixture -2

Potassium Chlorate - KCIO3 55%

Sodium Perborate Tetrahydrate - NaBOs.4H2O 16%

Carob Powder 21 %

Olive Pulp Powder 8%

TOTAL: 100%

Energy output; Average: 630-650 cal / gr.

Mixture -3

Potassium Chlorate - KCIO3 39%

Sodium Perborate Tetrahydrate - NaBOs.4H2O 24%

Carob Powder 28%

Olive Pulp Powder 9%

TOTAL: 100%

Energy output; Average: 540-560 cal I gr.

Mixture - 4

Potassium Chlorate - KCIO3 44%

Sodium Perborate Tetrahydrate - NaBOs.4H2O 22% Carob Powder 27%

Olive Pulp Powder 7%

TOTAL: 100%

Energy output; Average: 520-550 cal I gr.

Mixture - 5

Potassium Chlorate - KCIO3 55%

Sodium Perborate Tetrahydrate - NaBOs.4H2O 18%

Carob Powder 19%

Olive Pulp Powder 8%

TOTAL: 100%

Mixture - 6

Potassium Chlorate - KCIO3 34%

Sodium Perborate Tetrahydrate - NaBOs.4H2O 23%

Carob Powder 26%

Olive Pulp Powder 17%

TOTAL: 100%

Mixture - 7

Potassium Chlorate - KCIO3 38%

Sodium Perborate Tetrahydrate - NaBOs.4H2O 24%

Carob Powder 27%

Olive Pulp Powder 11 %

TOTAL: 100%

Mixture - 8

Potassium Chlorate - KCIO3 28%

Sodium Perborate Tetrahydrate - NaBOs.4H2O 24%

Carob Powder 28%

Olive Pulp Powder 20%

TOTAL: 100% Mixture - 9

Potassium Chlorate - KCIO3 50%

Sodium Perborate Tetrahydrate - NaBOs.4H2O 15%

Dried Date Powder 25% Olive Pulp Powder 10%

TOTAL: 100%

Mixture -10

Potassium Chlorate - KCIO3 47% Sodium Perborate Tetrahydrate - NaBOs.4H2O 20%

Dried sugar beet powder 28%

Olive Pulp Powder 5%

TOTAL: 100% Mixture -1 1

Potassium Chlorate - KCIO3 45%

Sodium Perborate Tetrahydrate - NaBOs.4H2O 23%

Carob Powder 25%

Nut shell Powder 7% TOTAL: 100%

Mixture -12

Potassium Chlorate - KCIO3 48%

Sodium Perborate Tetrahydrate - NaBOs.4H2O 22% Dried Tamarind Powder 24%

Olive Pulp Powder 6%

TOTAL: 100%

Mixture -13 Potassium Chlorate - KCIO3 50%

Sodium Perborate Tetrahydrate - NaBOs.4H2O 10% Carob Powder 20%

Olive Pulp Powder 5%

TAED - C10H16N2O4 15%

TOTAL: 100%

Energy output; Average: 510-540 cal I gr.

Mixture -14

Potassium Chlorate - KCIO3 40%

Sodium Perborate Tetrahydrate - NaBOs.4H2O 15%

Carob Powder 20%

Olive Pulp Powder 5%

TAED - C10H16N2O4 20%

TOTAL: 100%

Mixture -15

Potassium Chlorate - KCIO3 45%

Sodium Perborate Tetrahydrate - NaBOs.4H2O 15%

Carob Powder 25%

Olive Pulp Powder 5%

Pumpkin Seed Shell Powder 10%

TOTAL: 100%

According to the evaluations and measurements, the energy output of the tested mixtures varies between 350 - 650 cal / g on average.

APPLICATION AREAS OF THE INVENTION

The chemical composition of the present invention is designed and developed for rock breaking in different fields of construction and mining;

- Road construction

- Boulder breaking

- Trenching and canal opening

- Tunneling and shaft sinking - Dimension stone splitting

- Foundation and infrastructure excavation

- Concrete and reinforced concrete breaking

- Underwater excavation of rock

- Blocked and clogged silo cleaning and rat hole opening

- Interior breaking of rock, etc.

HOW SYSTEM WORKS

The application of the chemical composition according to the present invention for electronically activated chemical rock breaking system can be given in 4 stages with necessary steps as follows:

A - OBSERVATIONS AND PREPARATIONS

A.1 ) Examine the field in terms of distance from the nearest critical place (building, road, people, etc.). Considering the level of sensitivity, prepare all necessary equipment, safety materials to be used at site.

A.2) Examine the field to set the correct burden vs. spacing. The shape of the rock to be removed must let you decide the correct way of breaking (module per hole, no’s of holes per each activation, etc.).

A.3) Examine the field to set the correct hole diameter and length. Correct hole diameter and length will lead you to a complete consumption of modules, thus; correct volume of rock breaking.

A.4) Drill the holes and keep them safe (away from any stone/debris or water to go in). Depending on the site condition, holes should be vertical or at certain angels (generally in parallel with the free face).

B - MATERIAL & EQUIPMENT PREPARATIONS

B.1 ) Select the module size (diameter, length, amount) according to the rock data and as per your preparations in Item (A).

Notice: the basic data - rock type I hole diameter I hole length I burden I spacing - are very important to select the correct size.

B.2) Make sure that all selected modules and/or wire sets are active (use related testing device to check). B.3) Place all modules inside the holes one by one gently always being very careful. After being sure that all is placed well and safely, hold wires out of holes keeping them along the walls of the holes to avoid any failures, wire cuts, etc.

B.4) When the module is at the bottom, start stemming by dropping ready-made small stones, then placing ceramic mud and finally complete it by pouring stemming material/just the surrounding debris and material came out from hole carefully.

B.5) When stemming is done, check the wires once more to be sure that they are active.

B.6) When all is completed, place the covers carefully and logically over the holes and over the free faces that will break away, avoiding any drop off, open sections, etc..

B.7) Check the wires to avoid any failure (be sure that they are active) once more.

C - THE ACTIVATION STAGE

C.1 ) When all operations are completed; make sure that; modules are in place, stemming is done, wires are checked.

C.2) Connect the energy supply cable to the ESU.

C.3) Connect the Energy Supply Unit (ESU) to the power source (city mains or generator).

C.4) At this stage, check all wires and energy supply cable; they should be laid on the ground as a line (not in bundles or on each other).

C.5) Examine the whole job site. Keep all people, vehicles, etc. away from the activation location (minimum 30 meters.).

C.6) Place enough men at critical locations to stop people and vehicles when there is a need to stop them (for safety) during the activation period.

C.7) Put the on/off key at “on” position. Select the power from power source selection switch; either start the generator or turn on the power source from the city mains. Make a final check for all points (wires, cables, cover, and environment).

C.8) Check the “operation stop/cancel button”.

C.9) Select the initial waiting period (IWP), adjust the selected option for activation.

C.10) Press the selected activation buttons (concurrent or with delay). Follow the count down and take the hand held remote countdown (IWP) unit. C.11 ) Take the remote Stop/Cancel reel with cable (that is connected to the remote Stop/Cancel socket on the ESU).

C.12) Observe the activation till it ends and wait for an extra 30 seconds to move to the activation area.

D - AFTER THE ACTIVATION

D.1 ) Let all covers be removed and placed in a proper place.

D.2) Examine all holes and be sure that all are activated.

D.3) Then start excavation with an excavator with a back-hoe bucket. Pull all broken rock away from the main block.

D.4) After clearing the broken rock, if you think that a rock hammer is necessary, then employ it to sections where there are not hole signs.

D.5) After all activation, always clear the area for the next operation. Never drill and do all operations on the broken rock or debris left from the previous operation.

To summarize, the chemical composition according to the present invention is related to an ELECTRONICALLY ACTIVATED CHEMICAL ROCK BREAKING SYSTEM characterized by comprising a. chemical composition in a module set comprising

- potassium chlorate with ratio of 20-55 % by weight of the chemical composition,

- sodium perborate or Tetra acetyl ethylene diamine (TAED) or any combination of them with ratio of 10-24 % by weight of the chemical composition,

- at least one fruit and/or vegetable powder selected from the group consisting of carob powder, dried grape powder, dried currant powder, dried date powder, dried coconut fruit powder, dried pumpkin powder, dried sugarcane, sugar beet powder, dried tamarind powder and dried fig powder with ratio of 9-28 % by weight of the chemical composition,

- at least one powder selected from the group consisting of olive pulp powder, nut shell powder, coconut shell powder, pumpkin seed shell powder, sunflower seed shell powder with ratio of 5-20 % by weight of the chemical composition, b. electronic ignition component inside the module set, directly in contact with the chemical composition, c. Energy Supply Set comprising at least one Energy Supply Unit (ESU).

In one embodiment of the present invention, chemical composition comprises dried fruit powders and/or dried vegetable powders such as carob powder, dried grape powder, dried currant powder, dried date powder, dried coconut fruit powder, dried pumpkin powder, dried sugarcane, sugar beet powder, dried tamarind powder, dried fig powder.

In one embodiment of the invention, chemical composition comprises shell powders such as the olive pulp powder, nut shell powder and/or coconut shell powder.

In another embodiment of the present invention, the sodium perborate in the chemical composition is either monohydrate or tetrahydrate.

In another embodiment of the present invention, the olive pulp powder in the chemical composition is grinded dry powder of green and/or black olive pulp.

In another embodiment of the present invention, the chemical composition is a dry bulk mixture or dry mixture or mixed with other non-explosive solid or liquid chemicals or with some adhesives/glue or binders.

The chemical composition according to this invention is activated by an electronic ignition component by employing its unique energy supply set. The initial target of the invention is to break rock in the safest way avoiding the risks and problems faced with the existing products. In connection with such an idea, the basic aims can be given with an expression we have generated, namely “SEPPECS”. This expression is derived from the first letters of; Simple, Economic, Powerful, Practical, Efficient, Competitive, Safe.

In order to support the targets and show the proof of the facts, several basic and essential tests have been generated. Below, these tests, results and related comments can be observed on Table 2. TABLE 2

Basic and essential tests and their outputs Also, the chemical composition of the present invention is tested according to ADR and UN Handbooks for “International Carriage of Dangerous Goods by Road”. The test results are given in Table 3.

TABLE 3