A NOVEL CHEMICAL COMPOSITION FOR ELECTRONICALLY ACTIVATED CHEMICAL ROCK BREAKING SYSTEM

Abstract

Disclosed is a chemical composition for electronically activated chemical rock breaking system, and it includes potassium chlorate with ratio of 20-55% by weight of the chemical composition, sodium perborate and/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.

Claims

1) A chemical composition for electronically activated chemical rock breaking system, 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.

2) A chemical composition for electronically activated chemical rock breaking system according to claim 1, wherein said sodium perborate in the chemical composition is either monohydrate or tetrahydrate.

3) A chemical composition for electronically activated chemical rock breaking system according to any one of claim 1, wherein said olive pulp powder in the chemical composition is grinded dry powder of green and/or black olive pulp.

4) A chemical composition for electronically activated chemical rock breaking system according to any one of claim 1, wherein said chemical composition comprises optionally non-explosive solid or liquid chemicals or some adhesives/glue or binders.

Description

DETAILED DESCRIPTION

[0029] This disclosure 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.

[0030] According to a preferred embodiment of the disclosure, 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.

[0031] Chemical composition according to the present disclosure 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.

[0032] This dry mixture is filled in the modules which are produced according to required sizes considering given specifications.

[0033] Necessary Explanation: For module filling, we also recommend a filling procedure and system that will lead to an efficient and safe operation.

[0034] The basic chemicals and ingredients that make up the chemical composition are; [0035] Potassium Chlorate [0036] Sodium Perborate (monohydrate or tetrahydrate) [0037] Carob Powder (Ceratonia siliqua powder) [0038] Olive Pulp Powder (pirina)

[0039] Besides, the chemical composition may further comprise any one or more of the following: [0040] TAED (Tetra acetyl ethylene diamine) [0041] Nut shell powder, coconut shell powder, pumpkin seed shell powder, sunflower seed shell powder (and similar shell powders) [0042] 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).

[0043] The chemical composition ratios by weight (formulation) to prepare the chemical composition of the present disclosure can be given on Table 1.

TABLE-US-00001 TABLE 1 Ratios of Chemicals/Ingredients of the mixture, by weight. % RATIO CHEMICAL / INGREDIENT (by weight) Potassium Chlorate- KCIO.sub.3 20-55% Sodium Perborate / TAED (Tetra acetyl ethylene 10-24% diamine- C.sub.10H.sub.16N.sub.2O.sub.4) Carob Powder / Grape/Currant/Date powder/ Coconut fruit powder/ Pumpkin powder / Sugarcane-Sugar beet powder / Tamarind powder / Fig powder * 9-28% Olive Pulp Powder / Nut shell powder / Coconut shell powder, Pumpkin seed shell powder, Sunflower seed shell powder ** 5-20%

[0044] 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: [0045] (*) These powders are from their original dried fruit or vegetable. [0046] (**) These powders are from their original dried fruit or vegetable.

[0047] Some embodiments of the disclosure regarding the contents of the chemical composition are given below.

TABLE-US-00002 Mixture Combinations of the Chemical Composition of The Present Disclosure Mixture -1 Potassium Chlorate - KClO.sub.3 45% Sodium Perborate Tetrahydrate - NaBO.sub.34H.sub.2O 20% Carob Powder 25% Olive Pulp Powder 10% TOTAL: 100% Energy output; Average: 525-540 cal / gr. Mixture -2 Potassium Chlorate - KClO.sub.3 55% Sodium Perborate Tetrahydrate - NaBO.sub.34H.sub.2O 16% Carob Powder 21% Olive Pulp Powder 8% TOTAL: 100% Energy output; Average: 630-650 cal / gr. Mixture -3 Potassium Chlorate - KClO.sub.3 39% Sodium Perborate Tetrahydrate - NaBO.sub.34H.sub.2O 24% Carob Powder 28% Olive Pulp Powder 9% TOTAL: 100% Energy output; Average: 540-560 cal / gr. Mixture - 4 Potassium Chlorate - KClO.sub.3 44% Sodium Perborate Tetrahydrate - NaBO.sub.34H.sub.2O 22% Carob Powder 27% Olive Pulp Powder 7% TOTAL: 100% Energy output; Average: 520-550 cal / gr. Mixture - 5 Potassium Chlorate - KClO.sub.3 55% Sodium Perborate Tetrahydrate - NaBO.sub.34H.sub.2O 18% Carob Powder 19% Olive Pulp Powder 8% TOTAL: 100% Mixture - 6 Potassium Chlorate - KClO.sub.3 34% Sodium Perborate Tetrahydrate - NaBO.sub.34H.sub.2O 23% Carob Powder 26% Olive Pulp Powder 17% TOTAL: 100% Mixture - 7 Potassium Chlorate - KClO.sub.3 38% Sodium Perborate Tetrahydrate - NaBO.sub.34H.sub.2O 24% Carob Powder 27% Olive Pulp Powder 11% TOTAL: 100% Mixture - 8 Potassium Chlorate - KClO.sub.3 28% Sodium Perborate Tetrahydrate - NaBO.sub.34H.sub.2O 24% Carob Powder 28% Olive Pulp Powder 20% TOTAL: 100% Mixture - 9 Potassium Chlorate - KClO.sub.3 50% Sodium Perborate Tetrahydrate - NaBO.sub.34H.sub.2O 15% Dried Date Powder 25% Olive Pulp Powder 10% TOTAL: 100% Mixture -10 Potassium Chlorate - KClO.sub.3 47% Sodium Perborate Tetrahydrate - NaBO.sub.34H.sub.2O 20% Dried sugar beet powder 28% Olive Pulp Powder 5% TOTAL: 100% Mixture -11 Potassium Chlorate - KClO.sub.3 45% Sodium Perborate Tetrahydrate - NaBO.sub.34H.sub.2O 23% Carob Powder 25% Nut shell Powder 7% TOTAL: 100% Mixture -12 Potassium Chlorate - KClO.sub.3 48% Sodium Perborate Tetrahydrate - NaBO.sub.34H.sub.2O 22% Dried Tamarind Powder 24% Olive Pulp Powder 6% TOTAL: 100% Mixture -13 Potassium Chlorate - KClO.sub.3 50% Sodium Perborate Tetrahydrate - NaBO.sub.34H.sub.2O 10% Carob Powder 20% Olive Pulp Powder 5% TAED - C.sub.10H.sub.16N.sub.2O.sub.4 15% TOTAL: 100% Energy output; Average: 510-540 cal / gr. Mixture -14 Potassium Chlorate - KClO.sub.3 40% Sodium Perborate Tetrahydrate - NaBO.sub.34H.sub.2O 15% Carob Powder 20% Olive Pulp Powder 5% TAED - C.sub.10H.sub.16N.sub.2O.sub.4 20% TOTAL: 100% Mixture -15 Potassium Chlorate - KClO.sub.3 45% Sodium Perborate Tetrahydrate - NaBO.sub.34H.sub.2O 15% Carob Powder 25% Olive Pulp Powder 5% Pumpkin Seed Shell Powder 10% TOTAL: 100%

[0048] According to the evaluations and measurements, the energy output of the tested mixtures varies between 350-650 cal/g on average.

[0049] The chemical composition of the present disclosure is designed and developed for rock breaking in different fields of construction and mining; [0050] Road construction [0051] Boulder breaking [0052] Trenching and canal opening [0053] Tunneling and shaft sinking [0054] Dimension stone splitting [0055] Foundation and infrastructure excavation [0056] Concrete and reinforced concrete breaking [0057] Underwater excavation of rock [0058] Blocked and clogged silo cleaning and rat hole opening [0059] Interior breaking of rock, etc.

[0060] The application of the chemical composition according to the present disclosure for electronically activated chemical rock breaking system can be given in 4 stages with necessary steps as follows:

AObservations and Preparations

[0061] 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. [0062] 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.). [0063] 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. [0064] 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).

BMaterial & Equipment Preparations

[0065] B.1) Select the module size (diameter, length, amount) according to the rock data and as per your preparations in Item (A).

[0066] Notice: the basic datarock type/hole diameter/hole length/burden/spacingare very important to select the correct size. [0067] B.2) Make sure that all selected modules and/or wire sets are active (use related testing device to check). [0068] 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. [0069] 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. [0070] B.5) When stemming is done, check the wires once more to be sure that they are active. [0071] 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., [0072] B.7) Check the wires to avoid any failure (be sure that they are active) once more.

Cthe Activation Stage

[0073] C.1) When all operations are completed; make sure that; modules are in place, stemming is done, wires are checked. [0074] C.2) Connect the energy supply cable to the ESU. [0075] C.3) Connect the Energy Supply Unit (ESU) to the power source (city mains or generator). [0076] 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). [0077] C.5) Examine the whole job site. Keep all people, vehicles, etc. away from the activation location (minimum 30 meters). [0078] 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. [0079] 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). [0080] C.8) Check the operation stop/cancel button. [0081] C.9) Select the initial waiting period (IWP), adjust the selected option for activation. [0082] C.10) Press the selected activation buttons (concurrent or with delay). Follow the count down and take the hand held remote countdown (IWP) unit. [0083] C.11) Take the remote Stop/Cancel reel with cable (that is connected to the remote Stop/Cancel socket on the ESU). [0084] C.12) Observe the activation till it ends and wait for an extra 30 seconds to move to the activation area.
Dafter the Activation [0085] D.1) Let all covers be removed and placed in a proper place. [0086] D.2) Examine all holes and be sure that all are activated. [0087] D.3) Then start excavation with an excavator with a back-hoe bucket. Pull all broken rock away from the main block. [0088] 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. [0089] 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.

[0090] To summarize, the chemical composition according to the present disclosure is related to an ELECTRONICALLY ACTIVATED CHEMICAL ROCK BREAKING SYSTEM characterized by comprising [0091] a. chemical composition in a module set comprising [0092] potassium chlorate with ratio of 20-55% by weight of the chemical composition, [0093] sodium perborate or Tetra acetyl ethylene diamine (TAED) or any combination of them with ratio of 10-24% by weight of the chemical composition, [0094] 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, [0095] 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, [0096] b. electronic ignition component inside the module set, directly in contact with the chemical composition, [0097] c. Energy Supply Set comprising at least one Energy Supply Unit (ESU).

[0098] In one embodiment of the present disclosure, 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.

[0099] In one embodiment of the disclosure, chemical composition comprises shell powders such as the olive pulp powder, nut shell powder and/or coconut shell powder.

[0100] In another embodiment of the present disclosure, the sodium perborate in the chemical composition is either monohydrate or tetrahydrate.

[0101] In another embodiment of the present disclosure, the olive pulp powder in the chemical composition is grinded dry powder of green and/or black olive pulp.

[0102] In another embodiment of the present disclosure, 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.

[0103] The chemical composition according to this disclosure is activated by an electronic ignition component by employing its unique energy supply set. The initial target of the disclosure 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.

[0104] 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-US-00003 TABLE 2 Basic and essential tests and their outputs Standard testing Result and/or method Definitions Explanations Comments if any A) CHEMICAL and PHYSICAL Properties of Chemical Composition Flammability Non- The material is not flammable in flammable at open flame for short durations. room When ignited by an outside temperature source, it gives an exothermic and higher reaction with a bright light at temperatures around 450-500 C. It burns with a fast cracking sound in a very short time. Self-Igniting No self- property igniting property Explosivity - BAM No explosive The impact energy up to max. UN Fall hammer property level of 50 J was applied and no Handbook (Impact) explosion was observed. Besides, Test series 3. the material was compressed by Type 3(a) 5000 psi (320 atm) and no STANAG observable change has been 4489 recorded. This 50 J level is far more above limiting energy (safe limit) as indicated in related standards. Explosivity - BAM No explosive Material is tested up to 110N UN Friction property friction load and no explosion or Handbook burning was observed. Test series 3. This friction load is above the Type 3(b) limiting force to be applied (safe limit) as indicated in related standards. Oxidative property It has no Because of its ingredients, in oxidative humid and aqueous media it property in its oxidizes and rusts the metals solid state. It is (chromium, nickel, copper and fairly a strong iron etc.). oxidant in humid and aqueous media for most of the metals. Effect of Electricity No change was No change, burning or explosive observed by behavior was observed upon application of applying 220 volts city potential city voltage and 10 ampere current. and current.

[0105] Also, the chemical composition of the present disclosure 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-US-00004 TABLE 3 C) The tests are done according to UN Handbook- CLASSIFICATION the procedures and definitions Section 34 Tests according to given in the UN Handbook. ADR and UN Considering the product Handbooks specifications, the target was to observe whether it falls in Class 5.1 (Sect. 34) as oxidizing substance Test Method for Tests to observe The tests are done according to UN Handbook Oxidizing Division 5.1 and the procedures and definitions Sub Section Substances Packing Groups, I-II- given in the UN Handbook, 34.4 Test O.1 for oxidizing III Section 34.4 solids Results proved that, Chemical composition of the present disclosure falls in; Class (Div) 5.1 -Packing Group II or III UN Code designation Search and evaluation Considering test results, ADR and UN of tests According to product specifications, UN Handbooks ADR and UN Code is given as UN3085 - (related Handbooks oxidizing solid, corrosive- sections) n.o.s. D) TEST SERIES 2 Tests according to Chemical composition of the UN Handbook Tests to observe the the UN Handbook- present disclosure to be Sect. 12 insensivity of the Section 12 excluded from Class 1, 3 tests CHEMICAL given in this section must give COMPOSITION OF negative results THE PRESENT DISCLOSURE for excluding from Class 1 Test Code/Name These 3 tests are the These 3 basic tests have been 2(a) Gap test essential ones carried out according to the 2(b) Koenen test required to observe a specifications and standards 2(c) Time/pressure chemical product in given in the related section, test or out of Class 1 (as using the devices and per ADR and/or UN apparatus manufactured as per Handbooks) the given specs and dimensions. Results of these 3 tests showed negative outputs for Chemical composition of the present disclosure, which means said chemical composition came out to be a product defined out of Class 1.