Under the equipment of ammunition is understood a series of successive operations for filling shells, mines, warheads of rockets and missiles, aerial bombs, etc. explosives. Explosives are produced in powder form. In ammunition, explosives are a monolith and are called a bursting charge. The explosive charge is made either directly in the ammunition chamber, or is made in advance, and then placed in the ammunition chamber in the form of ready-made checkers.
The filling of ammunition cases with explosives can be done in various ways: pouring, augering, pressing. Filling according to the first method is carried out by pouring molten liquid explosive into the projectile body in one or more steps, depending on the size of the ammunition and the configuration of the chamber. The larger the caliber of the projectile and the ratio of the diameter of the chamber neck to its largest diameter, the greater the number of steps to fill. A high-quality cast bursting charge must have a uniform fine-grained structure (without bubbles, shells and cracks) and high density. To obtain a homogeneous fine-grained structure of a bursting charge, pouring is carried out at the most favorable ratio of the liquid and crystalline phases in the molten explosive. The latter is achieved by the so-called shimozation of explosives, i.e. vigorous stirring of the molten explosive before pouring.
Stirring accelerates the cooling of explosives and the beginning of the process of its crystallization, promotes the formation of a large number of crystallization centers and, therefore, prevents the appearance of large crystals.
The fine-crystalline structure of the bursting charge provides it with high density, strength and safety when fired, which is very important, since such a bursting charge can withstand without destruction the stresses developing in it under the action of inertial forces during firing.
Charges of a coarse-grained structure have low strength and can be destroyed when fired, which leads to premature rupture of projectiles in the gun bore or on the trajectory due to ignition of explosives from friction during the destruction of charges.
To prevent the formation of bubbles and shells in the charge, the liquid explosive in the projectile body is periodically stirred with a brass rod, which helps to remove air bubbles.
Cracks in the explosive charge are not allowed, since when fired at the locations of the cracks, significant friction occurs between the particles of the charge, which can cause ignition of the explosive and premature rupture of the projectile in the bore during firing.
In order to avoid cracks in the charge, the bodies of the shells are preheated to the temperature of the room in which the filling is carried out before pouring, and the bursting charge is slowly cooled. Distinguish lump, vibration and vacuum pouring.
The essence of lump filling is the introduction of pre-prepared pieces of solid cast explosives into the ammunition chamber along with liquid explosive. Filling in a lumpy way is usually carried out as follows: first, liquid TNT is poured into the ammunition chamber by about 1/3 of its volume, into which pieces of explosive are then introduced, tamping with a wooden stick, until they are distributed throughout the entire volume of liquid explosive. This process is repeated until the chamber volume is completely filled.
The lump method speeds up the process of filling ammunition cases by about 2–3 times compared to the conventional method of filling with liquid explosives alone. But due to the uneven density of the casting obtained in this case, as well as due to poor soldering of pieces with a frozen explosive, this method is used only for filling air bombs, mines, hand grenades and other types of ammunition, explosive charges that are not subject to significant shaking.
Vibration pouring is a more advanced method of loading ammunition. Vibration filling consists in using the phenomenon of vibration for better distribution and compaction of explosive pieces in the ammunition chamber and accelerating the process of filling the chamber. The body of the ammunition is subjected to vibrations with a certain frequency during its filling with the help of a special device.
Vacuum pouring has the same purpose as vibration filling. To improve the quality of filling the case and labor productivity, the ammunition chamber is evacuated before filling with explosives.
Equipment by auger consists in filling the chambers of ammunition with powdered explosives using an auger-apparatus. This method is highly productive and mechanized. It is mainly used to fill ground artillery shells, as well as air bombs and mines. Screwing is not used to fill ammunition with hexogen and trinitrotoluene both in pure form and in phlegmatized, and in the form of their mixtures with other substances due to their high sensitivity to friction.
Pressing consists in the manufacture of explosives in special matrices (less often directly in the ammunition chamber) by simultaneously compacting the entire mass of the explosive with a punch. Thus, the bursting charge or its elements are made in advance, and the filling of the ammunition chamber consists in inserting a ready-made bursting charge.
The method of charge formation with its manufacture directly in the ammunition chamber is called inseparable. The method of making a charge outside the ammunition chamber and then fixing it in the chamber is called separate. The separate method, depending on the method of assembling and fixing the charge in the chamber, has two varieties: separate checker and separate case.
The separate checkered method of filling shells has been widely used in our country since the beginning of the Great Patriotic War and especially since the introduction of an explosive into the gross production, which cannot be filled into ammunition cases either by pouring or by screwing. The separate-block method of filling consists in inserting explosive blocks prefabricated by pressing or casting into the chamber of the projectile body on one or another fixer (usually on a 1:1 paraffin-ceresin alloy). With a large number of checkers, they are glued together with shellac-rosin varnish in assemblies of several pieces each.
The sequence of operations for filling shells in a separate checkered way is as follows. A certain amount of molten paraffin-ceresin alloy is introduced into the body chamber and the first block (or assembly of blocks) is inserted; in this case, the amount of alloy is selected so that it completely fills the gaps between the surfaces of the checker (block assembly) and the chamber. In the same way, the rest of the checkers or assemblies of checkers are inserted into the chamber. Then cardboard spacers are placed on the charge, and the bottom is screwed in. Cardboard spacers fill the gap between the charge and the bottom; they serve to compress the charge in the body of the projectile in order to prevent it from moving when fired.
The separate-case method of filling is used mainly for equipping armor-piercing shells. It differs from the separate checkered method in that the pressed explosive checkers are first inserted into the case, and then the already equipped case is inserted into the chamber of the projectile body, where it is fixed on an alloy of paraffin with ceresin. The amount of alloy is selected in such a way that it completely fills the gaps between the explosive blocks and the inner surface of the case, as well as between the surface of the equipped case and the projectile chamber. Materials for the manufacture of cases can be aluminum, cardboard, plastic, etc.
When processing a bursting charge, the final finishing of the charge is provided. During the final finishing of the shells, the outer surface of the shells is painted, and distinctive marking. The coloring of the outer surface of the shells is used as an anti-corrosion coating, and also serves as a means of recognizing shells by their combat purpose and equipment. Ready shells are corked.
A modular mobile production site is a compiled technical and technological developments that have been accumulated in the process of drilling and blasting. It cannot be argued that the well-known similar complexes, including the presented one, are the final solution to all problems, however, we have no doubt about the achieved performance indicators.
The first thing we pay attention to is practicality - a balance between:
Cost (later affects the final price of the product being produced);
Ease of operation (no need for long staff training and a large staff);
Maintainability (maximum use of inexpensive components in the manufacture of equipment);
Flexibility of technology in the production of the product (there is no rigid binding to a specific raw material, it is also possible to make structural changes up to the replacement of the main emulsification apparatus from dynamic to static).
Production safety is ensured by compliance with the requirements of supervisory authorities in terms of equipment design, as well as electronic system management that controls technological processes. At the same time, it is not forgotten modern approach to ergonomics and aesthetics. The applied components, materials and production technologies guarantee long-term stable operation throughout the entire service life of the equipment and can be carried out for decades.
Prepared mixtures and solutions:
Emulsion matrix (required viscosity from 15,000 to 60,000 centipoise (viscosity limit due to the conditions of the emulsion pumped through the charging hose))
Aqueous acid solution (GGD-1 (acidifier))
An aqueous solution of sodium nitrite (GGD-2 (sensitizer))
An aqueous solution of ethylene glycol (in winter period(charging hose lubricated))
Brief description of the proposed point of preparation and distinctive features:
1) The main performance criterion in the production of an emulsion matrix is the rate of dissolution of ammonium nitrate and the preparation of an oxidizing agent solution.
In the case of using steam from a steam boiler with a temperature of 110 ° C, the productivity of the emulsion matrix is 2.5 tons / hour, in terms of the total volume of the produced emulsion matrix for the year with a 12-hour one-shift five-day working week will be 7800 t/year
At a steam temperature of 140 ° C, the productivity of the emulsion matrix will be 5.0 tons / hour, in terms of the total volume of the produced emulsion matrix for the year with a 12-hour one-shift five-day working week, it will be 15600 tons / year. With round-the-clock work and a full working week, the productivity reaches 40,000 tons of emulsion per year.
In parallel with the manufacture of the emulsion matrix, the components involved in the preparation of the finished EV when charging wells (gas-generating additive, solution for lubricating and washing the charging hose) are prepared in the required amount.
2) It is more economical to use hard coal as an energy carrier for obtaining steam for dissolving ammonium nitrate, as well as heating domestic and technological premises, which is easy to store, less dependent on changes in the exchange rate, high economic return in the second year of operation of the point for preparing EHV components, safety of the total volume of coal, since there is a low probability of its theft.
For orientation in the cost of the energy carrier for the preparation of a hot solution of the oxidizer, reference information is given below in the text.
3) The specific water consumption for the preparation of 1 ton of emulsion is 0.25 m 3, taking into account losses for steam preparation, technological operations and preparation of aqueous solutions of HHD and lubrication. With a full load of production, the daily need for water will be 30 m 3 per day.
4) Installed total electric power 300 kW.
5) The service life of the emulsion preparation equipment and the modular steam boiler plant, with due attention from the operating personnel, is at least 20 years. Taking into account the aggressive environment inside the premises of MPP NK EVV, all technological tank equipment, pipelines, interior decoration and coatings are made of stainless steel, which guarantees no need for cosmetic repairs for the entire period of operation, ease of maintenance of cleanliness, as well as a high aesthetic factor.
layout solution
mobile production site for non-explosive components
emulsion explosives.
Purpose: The mobile station for the production of non-explosive components of emulsion explosives (hereinafter referred to as MPP NK EVV) is designed to carry out a full cycle of production of EVV components with their subsequent loading into mixing and charging machines.
The total installed electrical power of electrical equipment is 300 kW.
The amount of steam consumed is from 0.6 to 1.7 tons/hour at a temperature of 110 to 160 degrees Celsius.
The mobile station consists of four modules based on insulated 40-foot sea containers, which contain all the necessary technological equipment, as well as thermal rooms for heating the emulsifier, industrial oil and ethylene glycol in winter time:
- Module for heating components and preparing GGD-1, GGD-2 solutions and an aqueous lubrication solution
Module for preparation and storage of oxidant solution
Module for heating components and preparing a fuel solution
Emulsification module with compartment for electrical components
JSC GosNII Kristall is the leading organization in Russia in the field of development and mastering the production of new types of industrial explosives for mining blasting.
Since its founding in 1953, research on new explosives and technological processes for their production has been one of the most important links in the work of the Institute. In the 1980s, JSC GosNII Kristall led and launched research on domestic explosives, which came to replace granulotol and other TNT-containing materials.
At present, fourteen industrial productions EHV, which produce more than 250,000 tons/year of EHV (about 15% of the total consumption of EHV in Russia). EHV production has been launched in Ukraine, Tajikistan and it is planned to create EHV production in Kazakhstan and Vietnam.
The technology and installation for obtaining EHV received the gold medal of VDNKh (1989), diplomas international exhibitions IV forum "High technologies of the 21st century" (Russia, 2003) and Hannover (Germany, 2005). Laureate of the competition "100 Best Goods of Russia" (2006).
JSC "GosNII" Kristall "offers for delivery:
The basic technological line includes equipment for receiving, preparing and processing initial components into semi-finished products and loading them into a mixing-charging machine (SPM).
The equipment of the proposed installation is placed in a stationary version. Igdanite is produced in a screw mixer. Diesel fuel is dosed into the mixer. Fuel - by a plunger dosing pump is sprayed in the mixer through a nozzle located directly after the receiving hopper of ammonium nitrate.
A modular installation is a complex of technological apparatuses combined into a production line. The module equipment is enclosed in the frame of a standard 40-foot container, which ensures ease of transportation, quick installation and dismantling, and equipment safety.
V.B. Ioffe, Doctor of Technical Sciences, Technical Director of ZAO NITRO SIBIR;
L.A. Kruglov, journalist
NITRO SIBIR Group of Companies is the largest Russian market manufacturer of industrial explosives and technological equipment for their production and use, a recognized industry leader in the development and application of new drilling and blasting technologies.
The parent organization, CJSC NITRO SIBIR, was established in 1990. Currently, the group of companies includes more than 20 enterprises represented in all major mining regions of Russia, as well as in Finland, Mongolia, and Australia. Work is underway to implement projects in North America and Africa.
The area of specialization of the company covers:
- production of industrial explosives;
- design, creation and operation of industrial complexes for the manufacture of industrial explosives;
- development and creation of technological equipment for the use of industrial explosives, including mixing-charging and delivery equipment;
- conducting drilling and blasting operations based on the original methodology for calculating the rational parameters of drilling and blasting;
- supply of raw materials and spare parts for industrial complexes for the manufacture of industrial explosives.
The Group's manufacturing facilities include various types technological lines: stationary, mobile, for the production of cartridgeed and pouring explosives, ANFO and more than 100 units. mixing-charging and delivery equipment. The total volume of manufactured industrial explosives in 2013 exceeded 323 thousand tons, which accounted for 1/3 of all industrial explosives produced in the territory of the Russian Federation. The volume of drilling and blasting performed in 2013 amounted to 100 million m3 of blasted rock mass.
Not a single mining enterprise that develops semi-rocky and rocky rocks and ores, as well as coal, can do without drilling and blasting. On the one hand, from High Quality and the reliability of the explosives used depend not only on the productivity, but also on the industrial safety of these enterprises. On the other hand, the mining-geological and mining-technical conditions of various enterprises present corresponding specific requirements for explosives.
The development of industrial explosives, technologies for their application, equipment for production and delivery to places of use is a complex and multifaceted work, and there are few companies working in this area in Russia. The largest of them is the NITRO SIBIR Group of Companies, whose production volume of explosives in 2013 alone exceeded 323 thousand tons.
The Nitro Siberia Group of Companies includes 17 enterprises located in different regions of Russia and Finland, producing industrial explosives and drilling and blasting. In 2013, the production of cartridgeed emulsion explosives (EM) was launched in Australia at the facilities of the subsidiary NITRO SIBERIA - Australia (Kalgoorlie, Australia).
Production and nomenclature of EHV
The original formulations of emulsion explosives of the Sibirit type, owned by the know-how rights of ZAO Nitro Siberia, provide for the possibility of using both domestic and imported raw materials and materials in their production.
Sibirit-1000 and -1200 are class 1 industrial explosives manufactured in MSZ-type mixing and charging machines. They are intended for mechanized loading of blast holes of rocks of any strength and degree of watering in the production of mass explosions in quarries and in construction. 
Cartridged EVV "Sibirit PSM-7500" is intended for use in open-pit mining in conditions where the use of mechanized loading is difficult, in borehole charges at any degree of water cut in wells, including use in rocks and ores containing sulfides.
Explosives of the Sibirit SM family are designed for explosive breaking by borehole charges on the earth's surface of rocks that do not contain sulfides, and with downhole waters with an acidity index of pH more than 4.
The Sibirit SM family includes three grades representing a mixture of Sibirit-1200 and ammonium nitrate oiled with an oil product at a different ratio between them. For Sibirit SM-7500, designed for wells of any degree of water cut, the ratio is 75/25; for "Sibirit SM-5000", intended for the same purposes, - 50/50 and for "Sibirit SM-2500" intended for dry and drained wells - 25/75. Cartridged "Sibirit-1200P" is manufactured in stationary production and is intended for use in open pit mining in all mining and geological conditions and climatic regions of Russia as borehole charges at any degree of water cut in wells, incl. rocks containing sulfides. "Sibirit-2500 RZ" is manufactured in the process of simultaneous separate mechanized loading of the well from the day surface "Sibirit-1200" and NP or UP granulite, or igdanite. Designed for blasting dry and slightly watered (with a water column height of up to 3–4 m) blast holes, incl. for rocks and ores containing sulfides, if the pyrite content in them does not exceed 30%, and the pH of the well water is not lower than 4.0, in all climatic regions of Russia.
"Sibirit-P" is a substance intended for use in a cartridgeed form as intermediate detonators when initiating detonation in borehole charges at any degree of water cut in wells, as well as charges for secondary crushing of oversize.
Emulsion explosives "Sibirit" are distinguished by high water resistance and chemical compatibility with rocks, which allows them to be used in any mining and geological conditions. Low sensitivity to mechanical stress allows you to fully mechanize the processes of their production and loading with a minimum level of impact on environment and human health during their manufacture and use. The high level of terrorist protection of EVV, due to the division of operations, is extremely important. technological process at the stage of preparing a non-explosive emulsion and making an explosive composition from it by sensitization (controlling the sensitivity of the component to the initiating effect) in the process of the final stage - loading wells or boreholes.
The miners note the high efficiency of the Sibirit EE application, including for hard rocks, due to the high efficiency of explosive transformation. The completeness of energy release was the result of the development of formulations based on original emulsifiers and the use of special equipment to obtain an emulsion with optimal dispersion and other performance characteristics, as well as to control its sensitization mode.
Since for the production of "Sibirit" available domestic raw materials are used, which are distinguished by less price dependence on the commodity market.
The flexible technological process of Sibirit production developed by NITRO SIBIR CJSC is based on constant input, step-by-step and output control and allows to neutralize the instability of quality indicators of raw materials domestic production and ensure the production of EHV with high performance and safety levels. Along with the permission for use on the territory of the Russian Federation, Sibirit EEVs are certified for use in the EU countries.
Mechanization of charging wells with emulsion explosives
Emulsion explosives are a dangerous and difficult to deliver cargo that does not allow and does not forgive negligence in handling. The EVV components themselves (emulsion and gas-generating additive) are safe, but, mixed during transportation, they can cause trouble. In this regard, their delivery is always carried out in different capacities. For this, special mixing-charging and delivery machines have been created. 
At the site of preparation of blasting, the mixture is prepared in the process of loading the well completely automatically according to a given program, depending on the characteristics of the well and the requirements of the blasters.
At all stages of the EHV manufacturing process, the required temperature of the mixed components is maintained. Therefore, the block of tanks is equipped with thermal insulation made of non-combustible thermal insulation material, and the hoses through which the mixture is supplied to the well are heated with hot water in winter. The depth of the wells can reach 65 m, and the diameter from 75 mm to 320 mm. As the well is filled with mixture, the hose is automatically withdrawn from the well as the mixture level rises. In order for the mixture to flow freely through the hose, it is constantly moistened, and water for this is also delivered to the well by a mixing and charging machine. 
In order to reduce the consequences of emergency situations, machines are equipped with independent system fire extinguishing, the emulsion tank has melting hatches and a bursting disc, the automatic control system does not allow the process parameters to go beyond the permissible limits.
The accuracy of observing the proportions of the components should not have deviations of more than 1% (!). The NITRO SIBERIA company has produced several dozens of MSZs on the chassis of BELAZ, KAMAZ, MAZ, Scania, MAN vehicles, and the need for them is great! 
The production of vehicles for the transportation of explosives, SV and loading of wells began in 1996 with the creation of the MSZ-8 vehicle on the KrAZ chassis. The experience gained during its operation formed the basis for the development of operational and technical requirements to the design of machines and became the basis for the development of technology of subsequent generations.
This was followed by the MSZ-16 vehicle with a total mass of transported components of 16 tons. The design allows you to “roll up” under it both three-axle and four-axle KAMAZ, MAN or Scania chassis. In this case, the compliance of a fully loaded vehicle with the rules of the Rules for the transportation of oversized and heavy cargo will be ensured.
The total weight of the components transported by the MSZ-15 vehicle is 15 tons. It is capable of transporting all types of non-explosive components of Sibirit SM-2500, -5000 and j2500RZ mixtures (Sibirit-1000 or -1200 emulsions, gas generating additive, ammonium nitrate and oil products ), prepare EHV and charge wells in open pit mining. The design of the containers makes it possible to fully utilize the carrying capacity of the chassis at various ratios of emulsion and ammonium nitrate in containers installed on the weighing system, and to manufacture EHV of various compositions. Attachments can be mounted on KAMAZ, MAZ, Scania chassis and MAN 6k6 all-wheel drive chassis.
Mixing-charging machine MSZ-14MT is designed not only for transporting components, but, if necessary, for making an emulsion and reloading it into mixing-charging and delivery vehicles. The machine can also produce EHV at the site of loading wells in quarries. The machine allows you to autonomously produce the Sibirit emulsion directly on the block being blasted, in a quarry and on another site that meets the requirements industrial safety. The tank block of the machine includes tanks for the oxidant solution, oil phase, gas generating additive and auxiliary substances, as well as a compartment for process equipment. From a single component load to automatic mode the machine produces 14 tons of emulsion and charges the wells, and the process of making the emulsion is not interrupted while moving from one well to another. The machine can be based on the chassis of Scania 6k4 or MAN 6k4, 6k6 vehicles, prepared for the transport of dangerous goods.
Using all the accumulated experience, in 2013 the specialists of NITRO SIBIR created and started production of a new machine MSZ-16 (6872) on the MAN TGS 8k4 chassis, which differs markedly from the machines of previous generations. In the basic configuration, the chassis comes with a 16-speed gearbox from ZF, which ensures high efficiency and driving performance of the machine. In the course of finalizing the chassis for the MSZ complex, a special subframe, a spare wheel bracket, and radiator protection made of 9 mm thick steel were developed and installed.
The machine can also be produced on the basis of all-wheel drive off-road chassis MAN 6k6 or 8k8. 
The configuration of the emulsion tank ensures minimum residues after emulsion is discharged. In the lower part of the block of tanks on both sides is equipped with niches with technological equipment. To reduce heat losses, the outer surfaces of the tank block are covered with thermal insulation.
For especially severe arctic operating conditions, the MSZ-16 (6872) machine is equipped with an arctic package specially developed by Toni Maurer GmbH & Co. (Germany).
MSZ-16 (6872) - on the MAN 8k4 chassis received a ground circuit, an automatic engine fire extinguishing system, side and rear protection. The drives of the actuators and units of the machine, including the tank auger, are hydraulic.
The automatic dosing system (ADS) provides switching on, control and shutdown of technological equipment, automatic or manual maintenance of the flow rate of components within the specified values, shipment of a given amount of EHV into the well, and prevents the occurrence of dangerous operating modes of the machine. It is controlled from an operator panel located in the cab, equipped with a touch screen for input and output of information about the main parameters of the equipment operation with the possibility of manual duplication.
The machine is more compact and more maneuverable than its predecessors. This is extremely important - after all, wells have to be recharged in limited areas. On the novelty, a hose reel with a retractable boom was moved from the rear platform of the frame to the space behind the cab, in front of the emulsion tank, and the machine was equipped with a remote control panel.
All work processes are managed by one driver-operator, while earlier the MSZ crew consisted of two people.
The system for supplying emulsion and GHD to tanks in the field from tanks of delivery vehicles allows the machine to be operated at large (up to 1500 km) distances from stationary plants. Max speed 85 km / h is limited in accordance with the requirements of UNECE Regulation No. 89 and allows the car to be operated on federal roads common use for the delivery of explosives to any distance.
The most powerful machine MSZ-20 is based on a two-axle chassis of a BELAZ mining dump truck with a carrying capacity of at least 30 tons and is designed for loading watered wells with Sibirit emulsions in open-pit mining, including by the “under the water column” method.
As an auxiliary component to ensure the operation of the mixing and charging equipment, water irrigation (WA) is used. At ambient temperatures below -5°C, a special solution is used, and above -5°C, water is used. 
MSZ-16Gr on the chassis of a KAMAZ-6540 or MAN 8k4, 8k8 vehicle is designed to transport Granulite-type explosive components (granulated ammonium nitrate and petroleum products), prepare explosives from them and load wells in automatic mode. To load ammonium nitrate from plastic containers (big bags), the machine is equipped with a crane-manipulator with a lifting capacity of 900 kg. Bunkers for ammonium nitrate are equipped with weighing systems.
The design of attachments and chassis ensures that the machine with a gross load capacity of 16 tons complies with the rules for transporting oversized and heavy loads.
Machines for long-distance transportation of EBB components
In order to increase the autonomy of the MSZ family of machines in large open pits, NITRO SIBIR has developed and produces a series of tank semi-trailers for the delivery and storage of non-explosive components of Sibirit-type explosives on site.
In the early 2000s, several MT-20 delivery trucks were manufactured, on which the design and technological principles for the production and operation of equipment were developed, which should provide, maintain and strictly control the conditions for storing explosives in the field. 
MT-20 is designed for transportation of Sibirit non-explosive components from the plant to the mining enterprise: emulsion, gas-generating additive and water spray solution or water. The tank car with a carrying capacity of up to 20 tons is made of stainless steel and equipped with mineral wool thermal insulation with a casing made of aluminum or steel sheet with an anti-corrosion coating on the inside and outside. Thermal insulation with a thickness of up to 100 mm provides a temperature change of the emulsion of no more than 15°C in 24 hours at an ambient temperature of up to -40°C. Loading of the emulsion - by gravity, gas-generating additive and water - through pipes, unloading, respectively, by a pump and compressed air.
A delivery driver as part of a road train with a MAZ-642208 or KAMAZ-54115 tractor is allowed on public roads, quarry roads, and is able to work at an outdoor temperature of up to -40°C.
Now, the first generation of deliveries has been replaced by the ADR 20-1 tank semi-trailer model, designed for transporting non-explosive components and their subsequent reloading into mixing and charging machines operating at mining enterprises located at considerable distances from a stationary point. The carrying capacity of the tank semi-trailer reaches 27 tons.
The capacity of the emulsion tank made of corrosion-resistant aluminum is 20.0 m3; GGD - 0.7–1.2 m3 and water irrigation solution - 1.2 m3. Thanks to the use of light alloy, the curb weight of the delivery driver is significantly reduced, and the carrying capacity is increased. The shape of the emulsion tank ensures that the emulsion in it is completely discharged by gravity. 
The ADR 20-3 tank semi-trailer is designed for transportation across highways all categories of oil products and aqueous solutions of salts: dilute solutions of nitrates and nitrites in the ambient temperature range from -40°С to +50°С. The thermal insulation of tanks with a thickness of 150 mm prevents the temperature of the transported substances from dropping by more than 10°C in 8 hours at an ambient temperature of up to -40°C. At technological sites, the required temperature is maintained by electric heaters powered by an external electrical network of 380 V.
In three compartments of the 12X18H10T stainless steel tank, components with a total weight of 22.5 tons can be transported with a total weight of the deliveryman of 38 tons.
The tank semi-trailer is equipped with a service platform, a folding handrail, a ladder, three hose racks containing hoses of the respective compartments, an electric heater, bottom and safety valves, a flushing pipeline, loading pipelines, a compressed air supply pipeline with a pressure reducer in compartments 3.5 m3 and 6.5 m3, towing device, pipeline connectors.
The delivery truck is mounted on a three-axle semi-trailer equipped with a front axle lifting device, a parking brake, a supporting device, an axle lifting device and a parking brake switch panel, side and rear protection devices, heat-insulated cabinets for placing a pumping pump with drain pipes and a control panel.
The ADR 17-1 tank semi-trailer is designed to transport an aqueous solution of ammonium nitrate (ammonium nitrate) with a concentration of 80–93% (by weight).
To ensure maximum safety of transportation, loading and unloading of components, the design of the deliverer completely excludes their contact with combustible substances, reducing agents, acids, alkalis, soda ash, chlorides, chlorates, chromates, nitrates, wood, oil and other materials and substances.
The operability of the tank semi-trailer is maintained in the ambient temperature range from -40°C to +50°C, the temperature of the ammonium nitrate solution should not decrease by more than 10°C in 8 hours at an ambient temperature of up to -40°C. Unlike the ADR 20-3 delivery truck, this model uses a liquid heating system based on a diesel heater instead of electric heating of the components.
The ADR 17-1 is the heaviest of all model range carriers: with a weight of transported cargo of 21 tons, the maximum permitted weight of the complex reaches 46 tons! 
The volume of explosives used in the Russian mining industry exceeds 1.5 million tons per year. And it is necessary to deliver them to mines and quarries at any time, so that the technological chain of processes is not interrupted for a minute and not a single person is injured. That is why the development of machines manufactured by NITRO SIBERIA is focused on their high reliability and safety.
For loading and unloading operations in wagons and intra-warehouse premises, the domestic industry produces mechanical self-propelled loaders.
Battery Loader 4004(Fig. 26) with a carrying capacity of 0.75 tons is produced in series. The main parts of the loader are: body, front drive axle, steering axle, lifting mechanism, telescopic frame lifting and tilting hydraulic system, steering, brake system, battery, driving motor and control mechanisms.
The front part of the body is rigidly attached to the drive axle, and the rear part rests on the rear steering axle through two springs. The rear axle has a removable metal box, which houses a 26ТЖН-300V battery with a nominal voltage of 30 V, which supplies the motion electric motor, pump, lighting and sound signal.
Loaders 4004 use DC electric motors with constant excitation windings: to drive the DK-908B running gear and to drive the DK-907A forklift.
The wheels of the loader are equipped with solid rubber tires, ensuring the ease of movement of the loader on the floor with a flat and hard surface.
In front of the loader body there is a telescopic frame, consisting of two frames - fixed (external) and movable (internal). The fixed frame is hinged to the housing brackets above the drive wheels. A movable frame is mounted on the inside of the fixed frame,
Rice. 27. The operation of the forks of the electric forklift
inside which there are guides for the carriage. The movement of the carriage along the guides inside the movable frame, and the inner frame along the outer guides, is carried out with the help of special rollers.
The forklift carriage is designed to install a fork or other gripping device necessary to perform loading and unloading operations. The carriage is raised by means of a hydraulic cylinder and leaf chains mounted on a telescopic frame.
Turning on and stopping the loader, as well as switching speeds and changing the direction of movement are carried out using the KV-28A controller and contacts.
From the given technical characteristics, it can be seen that the 4004 loaders are maneuverable enough to perform loading and unloading work in cars and on cars. With the help of electric forklifts 4004, it is possible to perform almost complete loading and unloading of explosives from wagons (3 - 7% of explosives must be unloaded or reloaded manually).
To increase the maneuverability of electric forklifts 4004, it is necessary that their forks turn in a horizontal plane (Fig. 27). The forks are hinged to the cargo carriage in such a way that they turn with the help of hydraulic cylinders by 30-35 ° from the longitudinal axis of the electric loader in both directions. This makes it possible to fully mechanize all the operations involved in loading and unloading VMs into and out of wagons.
The mechanization of loading and unloading operations with the help of electric forklifts 4004 largely depends on the improvement of methods for loading and unloading explosives, as well as on the qualifications of machine operators.
612 and 614 Series Electric Forklifts designed for transportation work on a hard and even road surface in explosive premises and outdoor installations of all classes, which may contain an explosive concentration of gases or vapors with air belonging to categories 1, 2 or 3 and flammability groups A, B and D at relative humidity environment not higher than 80% and temperature from -20° to +40 °С.
MIXING-CHARGING EQUIPMENT AND MECHANIZATION OF BLASTING WORKS
Machines for charging wells with the simplest explosives of the MSZ series
Mixing and charging machines of the MSZ series are intended for:
Transportation of initial components (ammonium nitrate and diesel fuel), preparation of Igdanit or Granulite PS-2 explosive and loading of wells;
Loading wells of prefabricated explosives approved for use by the Goegortekhnadzor of Russia for mechanized loading.
Their area applications - charging dry or drained wells in quarries and open pit mining, for areas with an operating temperature of -45 - +45 ° C.
Despite the fact that machines of this class have been in operation for more than 25 years, their use is still relevant today, given their simplicity of design, unpretentiousness in operation and maintenance.
Equipping with modern hydraulic drive elements of both domestic and foreign production (high-torque hydraulic motors, hydraulic distributors with discrete or proportional control, fine filters, filtration fineness up to 10 microns) allows reducing power consumption and increasing the life of the internal combustion engine and gearbox by 10%.
Since the release of the first machines, the safety requirements for the device and the safe operation of charging machines have also changed, reflected in the requirements:
European Agreement concerning the International Carriage of Dangerous Goods by Road (ADR);
- "Unified safety rules for the development of mineral deposits in an open way";
- "Rules for the transportation of dangerous goods by road";
- "Rules for the device of charging, delivery and mixing equipment intended for the mechanization of blasting" (PB 13-564-03);
- "Safety rules for the transportation of explosive materials by road";
- "Uniform safety rules for blasting";
- Rules of the road.
JSC "Gormash" has been producing MSZ series vehicles for more than 5 years and during this period has mastered the entire model range based on domestic and near-abroad vehicles for public roads, and on the basis of a BelAZ mining dump truck that meets all the above safety requirements. The range of manufactured mixing and charging machines is presented in table 1.
Table - Technical characteristics of manufactured machines of the MSZ series.
|
Series name |
Base Chassis |
load capacity by components |
Productivity on VV, kg/min. |
Dosing accuracy |
Gross weight, no more, t. |
Dimensions, mm |
Wheel formula |
|
l | |||||||
|
KrAZ-6322 KrAZ-63221 | |||||||
|
BelAZ-7540A, BelAZ-7540V and others with a capacity of 30t. |
equipment with additional options:
Additional attachments for introducing energy additives and increasing: raising the energy of the explosion;
Heating oil in the hydraulic system in winter;
Anti-lock braking system (ABS);
A set of equipment for an autonomous fire extinguishing system;
-installation programmable controller with an adapted hydraulic system of the company « S1 MENS»;
Additional equipment for draining wells;
Special equipment a speedometer with a sensor that allows you to limit the speed of the car;
Additional remote control.
Figure 2 - Mixing and charging machine MSZ-V (on the KrAZ-6322 chassis)
Figure 3 - Mixing and charging machine MSZ-25 (on the BelAZ chassis)
The designs of all machines manufactured by Gormash OJSC are coordinated with the base chassis manufacturers and ensure stability when driving in a quarry, equipped with a rear protective device with a variable position for movement in quarries, side marker lights combined with retroreflectors, an emergency equipment shutdown button , a two-pole mass switch, safety devices against drive overload, sound and light signaling of the reversing of the machine, ensures the maintenance of a predetermined% ratio of explosive components or its adjustment, illumination of the working area of the explosive operator.
Folding railings with a height of 1.0 m are installed on the tank
Power take-off is possible both with standard NSh-50 pumps mounted on the chassis, and additionally equipped with gear or axial piston pumps. The use of imported high-torque hydraulic motors, at a cost equal to or lower than domestic axial-piston motors, makes it possible to abandon the use of planetary gearboxes in hydraulic drives of screw conveyors, which affects the cost of production and more compact placement of equipment.
The control panel, equipped with an electronic meter, allows charging the well in automatic and manual modes with the display of readings by the amount of explosive being charged or by the balance in the tank and provides full control over the operation of the actuators.
Possible installation:
Electronic-hydraulic control system based on a programmable controller, which ensures the charging process in automatic
semi-automatic and manual mode with information output to peripheral media, archiving;
An additional bunker with an auger for energy additives, which makes it possible to dramatically increase the energy of the explosion and expand the range of explosives used.
In the passport of the vehicle transferred to the customer, there are all the necessary marks of the traffic police on re-equipment.
Table 2 - Performance data
INSERT TABLE
"Granulite PS-2" and "Igdanit" are explosive and fire hazardous substances. According to the degree of danger during handling, "Granulite PS-2", "Igdanit" belong to class 1, subclass 1.1 and 1.5, respectively, compatibility group D. Fire and explosion hazard is determined by the properties of its constituent components.
A mixture of AC and DT is dangerous ONLY IN CASES:
high humidity, acidity - especially for sulfuric acid;
contamination of the NPP with substances and materials of organic origin that accidentally got into the product: paper (and other cellulose-containing materials), carbohydrates (starch, saccharides and glucose) - due to the exothermic reaction of their nitration
high content of sulfur and sulfur compounds in diesel fuel.
Machines of the MSZ series are equipped with hermetic loading hatches with gratings, which exclude the ingress of foreign objects and external precipitation.
In case of accidental fire, the main means of extinguishing should be water supplied in abundant quantities to the fire, since the dissolution of the AS occurs with a large absorption of heat and a decrease in temperature. For this purpose, a water tank with a capacity of 1 m 3, a high-pressure pump and a fire hose L = 10 m are installed in the insulated compartment at MSZ-25. In addition, water is supplied to the saltpeter bunker.
Cars for public roads can also be equipped with water tanks, but due to their size, their volume does not exceed 350-400 liters and the water supply without using a pump under pressure is not higher than 1 kgf / cm 3
It is planned to use water and carbon dioxide fire extinguishers to extinguish the ignited "Granulit" and "Igdanit".
"Granulite", "Igdanit" is electrified, so the machine is equipped with a grounding pin, grounding circuits.
Safety requirements when working with factory-prepared explosives - in accordance with the approved regulations for their use.
Machines manufactured by Gormash OJSC are operated in various regions of Russia: Aldanzoloto OJSC, Kuranakh village, Republic of Yakutia; JSC "Silver - Territory" Magadan region; CJSC "PVV" Kemerovo region.
These regions are distinguished by severe climatic conditions of operation, therefore, here especially high requirements to the operational characteristics of charging machines, special requirements for the used purchased products, to the increased cross-country ability of the base chassis in off-road conditions, when other vehicles will not pass. These requirements are met by MSZ-V vehicles based on Ural-4320, KrAZ-6322, KrAZ-63221.
Vehicles based on the KrAZ-65053, KrAZ-65055, KamAZ-6520, MAZ-630305 chassis are characterized by increased carrying capacity and are used for high mileage on public roads.
Emulsion mixing and charging machines
The production of emulsion explosives at mining enterprises in Russia and the CIS countries is becoming more and more widespread.
A significant reduction in the cost of blasting, increased safety and environmental friendliness of production, excellent water resistance, minimizing emissions of harmful substances into the atmosphere and water bodies - all this and many other factors caused the transition to emulsion explosives.
All major mining and processing plants are acquiring their own EHV production facilities. In this regard, the need for delivery mixing and charging equipment is also growing.
In 2005, OJSC "Gormash" developed technical documentation and produced the first batch of emulsion mixing and charging machines ESZM-12.
Machines of THIS series are designed for transportation of initial components (emulsion, GHD), preparation of EEV from the specified components by introducing a gas-generating additive into the emulsion, which ensures the formation of gas bubbles in the emulsion and loading wells, both dry and completely flooded, with the resulting explosive.
All equipment of the machine is mounted on the chassis of the KrAZ-65053-02 vehicle, which is used as a transport base, as well as a source of energy for actuators.
Technical characteristics of ESZM-12 are presented in table 1.
Table 1 - Specifications ESPM - 12
|
Name of indicator |
The value of a physical quantity or other data |
|
1 Carrying capacity (for explosive components and water), t, not more than by emulsion - by gas generating additive (GGD) - by water | |
|
2 Productivity for preparing and charging explosives in winter, l / min, not less than | |
|
1 Permissible maximum weight machine, agreed with the chassis manufacturer, kg, no more | |
|
4 Overall dimensions, mm, no more than length | |
|
5 Chassis type |
KrAZ-65053-02 |
The car has:
Emulsion container;
Tank for GGD;
Water tank;
Hydraulic oil tank.
The initial components for the formation of an explosive are the emulsion and GHD.
Water is used to lubricate the inner surface of the charging sleeve and flush the explosive paths, as well as in emergency cases for firefighting purposes.
The hydraulic oil tank is installed behind the chassis cab. A heater is installed on the tank, designed to cool the oil.
Filling with GGD and water is carried out in the filler necks, brought out of the tanks into the upper part of the emulsion tank (behind the left along the direction of the machine, the filler neck of the GGD, and behind the right along the course of the machine, the filler neck of water and can be carried out both at stationary points and in a quarry using delivery cars.
All actions for management and control of work are carried out from the control panel installed on the left side of the machine in the direction of travel.
The control cabinet for technological equipment is located behind the chassis cab on the right side.
The machine mechanisms are driven by individual hydraulic motors and hydraulic cylinders. The power source is the chassis engine.
The working fluid pumped by the pump enters the hydraulic system of the machine.
An emulsion explosive (finished product) is prepared from two components: an emulsion and a gas generating additive (GGD).
The emulsion is pumped from the emulsion tank by the emulsion dosing pump. The mixing of the emulsion with GHD begins in the emulsion dosing pump, where the GHD solution is dosed in doses by the GGD dosing pump. The sensitization of the emulsion begins when it is mixed with the HHD solution in a static mixer and ends in the charging well.
The emulsion dosing pump delivers the mixture of explosives through the hose extractor into the charging sleeve. There is a water supply ring at the inlet to the hose extractor
with a check valve, through which the incoming water lubricates the walls of the sleeve (if necessary), which helps to reduce the resistance to the passage of the mixture of explosives along the charging sleeve and, accordingly, reduce the supply pressure.
The charging sleeve is unwound and wound onto a drum driven by a hydraulic motor.
The oil pressure in the hydraulic system is created and maintained by an oil pump driven by the vehicle engine through a power take-off mounted on a two-stage gearbox-promotors of the chassis. The distribution and regulation of oil flow in the hydraulic motor lines (turning on, off and changing the speed of the hydraulic motors) is carried out by a sectional hydraulic distributor with proportional electrical control, which is carried out from a programmable controller according to a specific algorithm and feedback from the hydraulic motors.
A safety collapsing membrane is installed on the emulsion pipeline, which is triggered when the pressure in the pipeline exceeds 10 kg/cm 3 .
Devices of the automated control system (ACS) are mounted on technological equipment. The ACS is powered from the on-board network of the chassis with a nominal voltage of 24V DC. After the ACS is turned on by the technological equipment, the diagnostic program is launched. After 2-3 seconds, the start screen appears on the display, from which you can select the desired operating mode.
Particular attention in the development of ESPM was paid to the safety of machines during operation.
In addition to regular fire extinguishing equipment, the following is provided:
emergency fire extinguishing using the process water of the machine when the vehicle's power systems are turned off;<
the presence of a fusible insert in the emulsion tank, designed for the free flow of the emulsion when the temperature on the tank walls rises above 235 ° C;
The design of the loading hatch of the emulsion provides for depressurization of the container when the pressure inside it rises above 1 atm. and the flow of the emulsion through the top.
ESPM are equipped with a rear protection device to provide effective protection against being hit by a car in a rear-end collision.
ESZM-12 are intended for the preparation of EVV "Ukrainit" PP2B, where hydrogen peroxide is used as GGD, which caused certain difficulties with the choice of material in the manufacture of the GGD tank and transportation pipelines due to the decomposition of hydrogen peroxide upon contact with many materials. The designers of the plant successfully solved this problem.
The first batch of ESZM-12 (Fig. 1) passed acceptance tests at the mines of CJSC PPP "Krivbass vzryvishpytaniya" and received permission for all permanent industrial use
Figure 1 - Mixing and charging machine ESZM-12
ESPM of this series are also used for other EHV. Was designed and manufactured mixing-charging machine ESZM-12E, designed for the preparation of emulsion explosive Emulit "PVV-V".
Despite the outward resemblance to the ESZM-12, the ESZM-12E machine differs significantly in its design. Here, a screw pump manufactured by the German company "Netsch" is used, which is due to the longer length (50 m) of the charging hose, which allows charging wells in "two ledges". Changed the design of water tanks and GGD, changed the design of the static mixer, hose extractor. ^
At present, the acceptance tests of the mixing and charging machine ESZM-12E (Fig. 2) have been successfully completed at ZAO PVV, Kemerovo Region.
Figure 2- Mixing and charging machine ESZM-12E
The specialists of the plant are constantly working both to improve existing charging machines and to create new types of chargers.
noah technology. The model range of mixing and charging machines produced and developed by Gor-mash OJSC is presented in Table 2.
Table 2 - Model range of manufactured machines
|
Name of indicator |
Machine name |
|||
|
1 Carrying capacity, t | ||||
|
2 Productivity, kg/min | ||||
|
3 Chassis type | ||||
Multi-component charging machinesexplosives of the TSZM series
Today, the problems of reducing the cost of blasting due to the transition to relatively inexpensive explosives (HE) without reducing quality indicators are being brought to the fore. So, for example, studies carried out in recent years in open pits in Russia on non-watered blocks make it possible to abandon the use of the most common (more expensive, since the cost of TNT, the main component of waterproof explosives, has increased significantly in Russia recently) earlier than grammonite 79/21 in in favor of a cheap TNT-free emulsion industrial explosive (PVV) of the I-50 grade granemite type, and in flooded wells, waterproof PVV granemite grade I-30 (domestic development), "govan" 60/40 (foreign development - abroad for now For several decades, water-containing explosives (water-in-oil emulsion) have been widely used. Emulsion explosives have good quality characteristics: high water resistance and density; low sensitivity to mechanical and thermal influences. For their production, there are available and cheap raw materials, EVV is distinguished by high safety in manufacture and use, environmental cleanliness and low gas hazard during blasting. Such characteristics provide granemites with a favorable prospect for their use in mining.
The economic effect consists of the relatively low cost of explosives, the full mechanization of their preparation, transportation, loading at the places of use, increased safety, and high quality of rock crushing.
According to JSC "Mikhailovsky GOK" - In 2006, it is planned to produce 36.5 thousand tons of granite. what will be 95% from generalquantities . The use of EHM of its own preparation allowed the plant triple reduce the cost of explosives. Carrying out mass explosions in a quarry using explosives can significantly reduce the amount of harmful substances released during an explosion, in comparison with industrial explosives.
The correct oxygen balance significantly reduces the emission of harmful substances into the atmosphere due to more complete combustion of explosives - to water vapor, nitrogen and carbon dioxide).
Transport mixing-charging machines (TSZM) form the backbone of a complex of machines for the mechanization of blasting and increasing their efficiency.
Transport mixing-charging machines, in fact, are mobile mini-factories (“factory on wheels”) for the preparation of multicomponent industrial emulsion explosives (IEE).
Each component is individually explosion-proof. A distinctive feature of the TSZM series is the presence of an automated process control system with the ability to work in automatic, semi-automatic (adjustment) and manual (emergency) modes of operation. The scheme of the technological units of the transport mixing and charging machine is shown in Figure 1. A series of transport mixing and charging machines designed and manufactured at OJSC "Gormash" includes machines on various automobile chassis (BelAZ load-carrying capacity - 30t and 40t; KrAZ, MAZ) for preparation of EVV (does not contain TNT) from four initial components (ammonium nitrate, diesel fuel, emulsion, gas generating additive - an aqueous solution of sodium nitrite) - EVV (granemite, emulan), three components (ammonium nitrate, diesel fuel, govan emulsion) - EVV (tovan). Water in all cases is used as a lubricant to facilitate the transportation of the finished product after the screw pump to the well and washing the paths of the components and the finished product after charging is completed, followed by blowing with compressed air.
Machine for charging "dry" (non-watered) wells - TSZM-ZOPG-A. Vehicles for charging flooded wells (TSZM-11PG (Figure 2), TSZM-11E (Figure 3), TSZM-20PG, TSZM-30PG (Figure 4), TSZM-30).
In 2007, mixing and charging machines TSZM-11 and TSZM-30E were also developed.
Technical characteristics of TSZM series machines are presented in the table
1 . Charging of "dry" (non-watered) wells is carried out from above inmouth, and flooded wells from below "under the column of water." The dosing of the initial components into the finished product is determined by a strictly defined (constantly controlled by a programmable controller) number of revolutions of the executive bodies - screws, pumps - dispensers per minute. The flow rate is determined by the amount delivered by the screw, the pump per one revolution - it is specified for almost each specific actuator during the calibration process during commissioning and after repair (if necessary).
The design of the TSPM in the general case includes:
- Chassis upgrade:
Refinement of the exhaust system with their output forward and to the right;
Installation of power take-off for driving hydraulic pumps;
Installation of spars for mounting attachments of the machine;