Foam Drilling in Fractured Rock for Mining Exploration

Chile

“The foam allowed us to clean the seabed continuously. The machine operated more smoothly, and our progress improved starting with the first section we treated.”

A drilling services company linked to the mining sector contacted QUIMACER while conducting a geotechnical survey in an area of fractured rock in Chile.

The work was carried out using rotary percussion and compressed air, with the aim of making rapid progress and keeping the bottom of the borehole clean.

The formation exhibited fractures, small cavities, and areas of airflow disruption, which reduced its capacity to transport detritus.

The customer was increasing the air pressure and flow rate without seeing a proportional improvement in performance.

The buildup of chips in the cutting zone caused a loss of feed rate, tool overheating, and the need for frequent cleaning.

Problems Identified

  • Low cleaning efficiency with dry air.
  • Accumulation of debris on the bottom and around the tool.
  • Irregular drilling performance due to fractured sections.
  • Increased temperature and wear on the hammer and crown.
  • High compressed air consumption without sufficient operational improvement.

Our Intervention

  • QUIMACER determined that the problem could not be solved simply by increasing the air flow rate, but rather by improving the method of transporting the cuttings.
  • It was proposed to switch from a dry air system to an air-water-foam system, which produces a dense, stable foam with good carryover capacity.
  • A high-performance, polymer-reinforced foaming agent was selected to increase foam retention and density.
  • It was recommended to adjust the injection based on the return: fine-bubbled, stable foam with a good amount of detritus.
  • Overfilling was avoided to prevent excessive back pressure and discharge difficulties at the surface.

Solution Implemented

  • QUIMAFOAM BIO at 3 kg/m³ as a high-performance foaming agent to produce dense, stable foam.
  • QUIMAPOL AL-60 at 1 kg/m³ to enhance foam consistency and retention.
  • Injection with an air-to-water ratio adjusted until a stable flow and sufficient transport capacity are achieved.
  • Visual inspection of surface foam: stability, solid load, and absence of premature collapse.

Target parameters: persistent foam, reduced dust, lower tool temperature, and continuous cleaning of the bottom.

Results and Improvements

More than a 60% improvement in debris removal compared to using dry air.

An approximate 30% increase in average drilling speed during fractured sections.

Reduction in shutdowns for deep cleaning.

Less heat generation and less tool wear.

Optimizing compressed air consumption by improving the efficiency of the drive system.

Parameter Technical Details
Sector

Geotechnical survey / mining
Land

Fractured rock with cavities
Method

Air-Foam Rotating Percussion
QC Products

QUIMAFOAM BIO, QUIMAPOL AL-60
Recommended dosage

3 kg/m³; 1 kg/m³
Key Improvement

+60% debris removal; +30% progress

WHY QUIMACER?

  1. Solutions for drilling with air, water, and foam.
  2. It improves the transport of detritus in fractured rock.
  3. Reduces wear and tear and unproductive downtime.
  4. It helps optimize compressed air resources.