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By R R. Dimock

A goal of all mine operators is to optimize the breakage of the inplace rock to achieve maximum excavating efficiency. The use of the seismograph at Kennecott Copper Corporation's Nevada Mines Division, open pit mine in Ely, Nevada, has demonstrated that optimum blastability can be predicted by knowing the seismic velocity of the inplace rock. The relationship of seismic velocity to the quantity of the explosive required to achieve adequate breakage of the material can be determined. Once quantified, this relationship can be used by the mine operator to obtain the optimum drill pattern and powder factor for breaking the material to be excavated. A substantial savings in primary and secondary drilling and blasting costs can result from using the seismograph for blastability determination.

Jan 1, 1976

By Rakesh Raghavaraju, Bibhu Mohanty

The paper analyzes the decay of shock pressure as a function of distance from the borehole, and its implication on shock-induced fracture properties of the target rock as the first step in predicting fracture and fragmentation behaviour in a well-characterized rock.

Feb 1, 2020

By Scott Giltner, Allan Koski

Blasting is one of the lowest cost yet most critical parts of the mining cycle. This paper discusses the findings of an audit conducted on the blasting operation at an iron ore mine. The purpose of the audit was to review current blasting practices in order to identify opportunities for production/cost improvements. The approach taken in the audit was to observe general blasting practices, their related downstream effects and to compare current procedures to established best practices.

Jan 1, 2009

By Paul L. Matrin

This paper will discuss the recent and on-going drill and blast optimization measures at the Sparkhule Limestone Quarry, which have resulted in a 44% reduction of drill and blast unit costs per ton of broken limestone. This amounts to approximately $240,000 of drill and blast saving per year at current annual production rates of about 2.5 million tons (2.3 million tonnes) total material shot. The reduction of drill and blast costs were accomplished by a detailed and controlled in-the-mine drill/blast experimentation and cost evaluation using 8 different blast pattern designs and shots totaling approximately 267,000 tons (242,200 tonnes) of shot and mucked material. A careful review of the geology of the deposit was performed to determine the different rock classification/strengths/structural properties and to adjust blast designs to optimize fragmentation for the different rock types. Equipment loading productivity and crusher throughput performance were monitored as part of the evaluation process to assure that an optimal fragmentation of broken rock was achieved with the new blast designs. The study included the review of bulk explosive and accessory selection criteria (ammonia nitrate/fuel oil mix - ANFO, mini prills (high density ANFO), sensitized and un-sensitized emulsions at a 30% emulsion/70% ANFO blend), blast pattern design, charge diameter and the cost of drilling. Laser profiling technology was used to assure proper bench heights, stemming and sub-drill footage and front row burdens. High speed photography, video and still photos were taken of the different designed shots to assist in the evaluation of the performance of each blast. Powder density checks, size distribution, back break, detonation velocity and pressure measurements were taken. Different borehole diameters were used for the drill optimization study and drilling cost and productivities determined. A detailed cost comparison between in-house blasting and complete shot service was prepared to evaluate if shot service is a cost effective alternative to current in-house loading and blasting including a review of the new and pending United States Bureau of Alcohol, Tobacco and Fire Arms (ATF) regulations and associated owner costs/risks and potential benefit of shot service.

Jan 1, 2004

By Tom BoBo, Seth Gering, Jeff Loeb

Presenting a D&B feedback loop built on a well-designed blast, proven fragmentation analysis and blast monitoring solutions, underpinned by technology that not only increases profit from every blast, but also increases a mine’s purchasing power over one of the most expensive part of the process – explosives.

Feb 1, 2020

By D. Goodings, W. L. Fourney, Bonenberger, R., Uli Leiste

The Dynamics Effects Laboratory at the University of Maryland conducted a series of very small scale tests to measure the impulse delivered to a plate by the detonation of an explosive charge which was buried in saturated sand. These tests were conducted to support a full scale tests series being supported by the Navy (NSWC Indian Head Division) to learn more about loads applied to structures by explosive detonation. For each of the tests being predicted, a series of three tests were conducted at Maryland, one with a 0.203 gm charge, one with a .609 gm charge, and one with a 3.3 gm charge. A high speed digital camera (500 frames per second) was used to record the displacement of the plate as a function of time. From this the initial velocity of the plate was determined and then the impulse delivered to the plate by the explosive. A best fit line through the data was determined for the three model tests conducted and this equation was used to extrapolate the predicted impulse for the full scale tests.

Jan 1, 2005

By Mark Roberts

Automation, data analytics and optimisation are key trends in the mining industry. Doing more, and better, while expending less resources targets KPIs around efficiency and productivity. With the explosion of data, the next step is to develop an optimal level of processes and systems to harness this data to support value-in use decisions. Typically, significant amounts of resources and effort are invested to develop realistic simulation models. However, models are frequently not integrated with existing systems, and therefore are underutilised. When we consider the specialised process of blasting, integration with upstream and downstream processes is a significant driver to realise sustained improvements and value. The application of genetic algorithms and cloud computing to solving complex mining problems has advanced over the last 15 years, in particular with mine scheduling. Genetic algorithms are unique in that they support true multi-objective optimisation, utilising population-based methods to present trade-offs between multiple solutions. Secure in-cloud processing speeds up the processing, with results delivered in timeframes that are not feasible with desktop computing.

Feb 6, 2023

By Dr. Zach Agioutantis, Elliott Morgan

The explosives, mining, and heavy civil industries consistently battle the uncertainty that is associated with working with a heterogenous medium like rock in blasting. This has led to studies to increase fundamental understanding of material response under dynamic loading that is associated with blasting. This study looks at the dynamic strain associated with blasting the lab Split-Hopkinson Pressure Bar (SHPB) testing while also building off of previous studies with the goal of better understanding the dynamic forces that are enacted on a geologic body during a blast loading event. This is required in order to advance geologic blast response modeling. This is achieved through analyzing the stress and strain values for each specimen that are calculated from strain data collected with a SHPB. Based on this data, the dynamic material response characteristics are able to be determined. Tests were conducted on five Berea Sandstone specimens with a rough length to diameter ratio (L/D) of 1.0. The strain data from these tests were then used to create stress strain curves as well as charts depicting failure stress to both strain rate and failure particle velocities. The tests conducted returned similar results to previous tests results on Berea Sandstone while also showing a correlation between strain rate at failure and failure particle velocities. While further research is needed, there is evidence that SHPB test data could be used in conjunction with the MBF model. The MBF model states that the peak particle velocity (PPV) of blast vibrations can be correlated with deformation (strain) at a given point. With a further understanding of dynamic material response correlated to PPV measurements, further refinement could allow for better prediction of blast performance.

Jan 21, 2025

By Doug Wathen, Philip M. E Thomas

The City of Fort Myers needed to replace a 40-year old 42-inch storm sewer line in downtown Fort Myers with a new 54-inch line to accommodate population growth. The old line had to be kept operational while a new line was installed. the contractor spent two months using a drop ball, a hoe ram, and large rippers trying to break the three to four feet of rock that needed to be removed to accommodate the new pipe. Mechanical trenching was considered but was proven to be overly expensive. On very short notice, Ireco of Florida was asked to design and execute a blasting procedure that would allow this project to proceed. Nearby buildings were over 80 years old, three of them containing antique shops specializing in glass antiquities with attorney offices above them. High water table compounded problems with a 20-year old steel water main and clay drainage pipe 15 feet from the new sewer line. Holes had to be drilled within six inches of the edge of the existing pipe to four feet below the pipe on either side of the pipe and blasted. No interruption in the sewer line flow was to be tolerated.

Jan 1, 1996

By W. Boas, R. Silva, D. Yumi, L. Steffen

The continuity of the flow and stages within the mining process is essential to achieve success in its operation and results, especially when it comes to a gold mine. During the first seven months of 2022, crushing at the Morro do Ouro Mine had 19 stops in the primary crusher due to equipment blockage/obstruction, this could be due to the size of the material that was blasted with explosives and fed. The feeding of coarse material to the crushing plant impacts the operation in several ways, for example, premature wear of the equipment, reduction in the supply of the remainder of the beneficiation, reduction of the buffer pile and damage to the conveyed belt. In a mine located far from the community, the fragmentation improvement is mainly related to load increments or some other relatively simple change. However, when it comes to a mine located close to communities, alterations of this type must be analyzed in detail, as it can have an impact mainly in relation to vibration and flyrock. Aiming to improve the efficiency of the blasting, mainly in relation to the result of fragmentation, a project was created to improve the efficiency of the blasting with a focus on reducing the crushing stoppage and reducing the amount of material discarded due to inadequate granulometry. During the evolution of the project, several improvement solutions were proposed, for example adjustment of the power factor in relation to the geological characteristics of the rock mass, drainage, blasting geometry, vibration reduction techniques and several operational improvements. By using the techniques and methods identified as improvements during the project, it was possible to observe and quantify improvements in relation to the fragmentation of the blast. During the months of January to July 2022 there were 19 events. It was estimated that at this rate there would be 14 more blockage events, but there were only 3 events and that meant a 79% reduction in blockage. In addition to the reduction in crushing shutdown events, there was also a 53% reduction in the amount of ore that is discarded due to inadequate granulometry and, with that, the feed rate of the grinding system was able to reach the maximum feed limit due to the material being fed to the mill well fragmented, contributing to increase the production and productivity of the beneficiation process at the Morro do Ouro Mine in Paracatu-Minas Gerais-Brazil.

Jan 1, 2024

By Shazad Hosein, Rob Farnfield, Bill Birch, Liam Bermingham

The propagation of a shock wave through air as a result of quarry blasting consists only of one type of wave, the compression wave. This is in marked contrast to seismic waves where a number of different types of wave are generated by the one blasting event. Even so the interaction of the burn time of a single hole and the resulting air overpressure is still too complicated to be able to be accurately modelled from first principles. It is considered that the best way forward is to monitor an individual single hole to obtain a signature wave form that has resulted from this complex interaction. Once this wave form is known, the variation in geometry of a mutli-hole blast and the timings of the successive detonations can be modelled to give a sufficient degree of accuracy to recreate the likely magnitude, duration and wave form of a multi-hole quarry type blast. This can then be directly compared with actual air overpressure wave forms from quarry blast to verify the model.

Jan 1, 2012

By Joshua Hoffman, Braden Lusk, David McLane, John Rathbun

The research conducted previously on Shock-Tunnel Waveform Analysis gave a brief insight into the propagation of a shockwave within a shock-tunnel compared to that of an open air arena test. As a refresher, a shock-tunnel is an energy channeling device used to simulate the effects of a large scale detonation with significantly smaller charge weights; having the ability to conduct tests in this fashion can greatly reduce the costs of testing products.

Jan 1, 2012

By Chantale Doucet, Yves Lizotte, Alan Cameron

A joint Federal Government-Industry research project on the effect of geology on the fragmentation of rock excavated by blasting in underground developments was conducted at the CANMET Experimental Mine, near Val d’Or, Quebec. A total of thirteen (13) blasts were studied from November 1994 to February 1995. The analysis of each blast was divided into three stages: pre-blast characterization, including structural mapping, assessment of Rock Mass Ratings (RMR), Tunneling Quality Indices (Q), blast design documentation; blast characterization comprising blast vibration monitoring and analysis; and post-blast assessment comprising fragmentation assessment by digital photoanalysis, calculation of half cast factors and measurements of bootlegs.

Jan 1, 1996

By Stephen Chung, John Carpenter, Scott Gosch, James Breedlove

While controlling fly rock and ground vibration in quarrying in the neighborhood of a residential area, producing good fragmentation and keeping different grades of material separated in a muckpile are important in maintaining the productivity of quality aggregates. This paper describes a single row production blast for the study of fragmentation and displacement in the grade control carried out at a quarry of Barrett Paving Materials Inc. in Sylvania, Ohio. Digital video imaging was used to monitor the blast-induced motion of the bench face as input to the DMC_Blast (Distinct Motion Code), for the analysis of the formation of the muckpile. The actual digitized blast video and the DMC_Blast simulation are compared. The displacement and mixing of all the inter-bedded limestone layers are made visible in the simulated cross-section of the muckpile. The apparent fragmentation analysed with PowerSieve is also discussed.

Jan 1, 2001

By Scott G. Giltner, Paul N. Worsey

During the short duration of an explosive blast, many events occur which are too quick to be detected or observed in detail with the naked eye or by normal photographic techniques. Through the use of "hightech", high speed video, many of these events can be observed, instantly played back and recorded for later use. The use of a Spin Physics SP 2000 Motion Analysis System at a blast casting operation is presented. The variable range of recording speeds offered by the SP 2000 allowed it to be used for examination of different areas of blasts. At its maximum full frame rate of 2000 frames per second the SP 2000 can easily pick up the flame front as it travels down a nonel tube and the flash from the surface delays as they fire. The system was used for a variety of tasks including, but not limited to,the determination of delay accuracy to within 0.5 ms, the velocity and trajectory of the faces during blasts, and pinpointing geological problem areas. The effectiveness of the system as used on site is discussed along with detailed method of set up, recording, playback and data processing. Other details including site specific environmental and lighting problems are also covered.

Jan 1, 1986

By N. Paley

An engineering project was undertaken at the Cominco Alaska Red Dog Mine to determine the extent that Semi-Autogenous Grinding (SAG) mill throughput could be increased by blasting differently. The Julius Kruttschnitt Mineral Research Center (JKMRC) blast fragmentation, jaw crusher, and SAG mill breakage models were used to relate changes in the blast design to the SAG mill performance. For optimum performance a SAG mill requires a particular size distribution; a number of large rocks to facilitate breakage by impact, as few as possible middle size rocks that become critical size, and the maximum fines which will pass quickly through an open-circuit mill. Physical constraints of drill and charging equipment size limit the extent that pattern geometry can be changed and the powder factor increased to maximize fines. However, JKMRC research had shown that it appeared possible to increase primary breakage by blasting to such an extent that SAG mill throughput could reach a plateau or even begin to decrease. Modeling was carried out on a range of blast pattern geometries and emulsion explosive blends to determine if a plateau existed and at what powder factor it would be reached. It was found that the relationship between powder factor and grinding throughput was nonlinear. Modeling was also used to compare the SAG mill throughput which could be expected from different emulsion explosive blends to determine which blends should be used in dry and wet holes to provide similar fragmentation. For heavy-ANFO mixtures, the highest modeled throughput was at a ratio of 30/70, with ratios on either side indicating lower throughput. For emulsion blends, the highest modeled throughput was at a ratio of 80/20; however, ratios from 80/20 to lOO/O were similar. Crusher product size distributions were obtained from belt cuts early in the analysis to confirm model predictions. At later stages, actual SAG mill throughput was compared to predicted. The economic benetit from the different blast designs was calculated by accounting for the reduction in recovery due to the higher throughput and the additional drilling and blasting costs. Increasing the powder factor by 150% from the 0.29kg/t {0.58lb/st] being used to 0.72kg/t { 1.44lb/st}, the maximum feasible with mine equipment, could provide a sign&ant net benefit of $3OWyr due to the increased concentrate production. However, because the relationship between throughput and recovery is affected by other factors which were not modeled, a more conservative approach was taken. The powder factor was instead increased by 50°h, providing 45% of the gain. This was possible because the relationship between powder factor and grinding throughput was nonlinear.

Jan 1, 2001

By Robert B. Hopler

Hercules Incorporated has developed and introduced a totally new non-electric delay blasting cap system which utilizes a low energy gas detonation to activate the caps. Unlike any other initiation system, there is no hole-to-hole connection other than empty plastic tubing until the blast is to be set off. Only at that time, when all personnel and equipment are in the clear, is the special gas mixture introduced through the tubing. The actual time of firing is completely under the control of the operator, by pressing the fire button on the blasting machine.

Jan 1, 1977

By Paulo Couceiro

Highly non-ideal explosives usually tend to react expressively below their ideal detonation velocities. In these cases, dimensional effects and product heterogeneities become important to proper model the detonation state. Although Direct Numerical Simulation (DNS) techniques can provide a complete and exact solution for this problem, its actual computation cost is still not practical for industrial applications. In order to minimize these constrains, a simplified two-dimensional steady non-ideal detonation model for cylindrical stick explosives is developed.

Feb 1, 2020

By Ruilin Lang

This paper presents an application of 3-D plots and non-linear regressions to define a sitespecific form of the charge weight scaled distance. The PPV (PPA) of single hole blasts is normally considered as a function of two independent variables - the charge weight and the distance. It is of great importance to obtain the relationship of the function accurately for a concerned site in terms of blast vibration analysis and modeling. However, in pre-computer time it was difficult to plot 3-D graphs. Consequently, a charge weight scaled distance was used to plot the PPV (or PPA) against the scaled distance as 2-D graphs. Blast vibration investigators use several forms of the charge weight scaled distances to plot data. We can exemplify them with the cube root of charge weight scaled distance, the square root of charge weight scaled distance, and other forms (Hossaini and Sen, 2004). Each of these scaled distances assumes relative contributions of the charge weight and the distance to the vibration attenuation. For example, the charge weight is assumed to have a less contribution to vibration in the cube root scaled distance than it is assumed in the square-root scaled distance. In reality, for different sites the relative contribution of the charge weight and the distance may be different and site-specific. This may explain that in some cases, the blast vibration data plots using these charge weight scaled distances are scattered. This could be largely due to the fact that the definition of the form of the charge weight scaled distance is not adequate for the particular site condition.

Jan 1, 2006

By Paulo Couceiro

Highly non-ideal explosives usually tend to react expressively below their ideal detonation velocities. In these cases, dimensional effects and product heterogeneities become important to proper model the detonation state. Although Direct Numerical Simulation (DNS) techniques can provide a complete and exact solution for this problem, its actual computation cost is still not practical for industrial applications. In order to minimize these constrains, a simplified two-dimensional steady non-ideal detonation model for cylindrical stick explosives is developed. Based on an ellipsoidal shock shape approach, the proposed model uses the quasi-one dimensional theory for the axial flow solution and combine the post-shock sonic flow criteria with some limiting conditions for the explosives’ unconfined radius determination. Due to its attractive fitting capability for unconfined detonation experimental data, the model offers the possibility to predict the non-ideal detonation state for any diameter, resulting in a full mapping of the diameter-effect curve of the explosive. Thus, the proposed engineering approach is used to model the main properties of some of the most common ammonium nitrate-based explosives used in mining and quarrying industries, including the complete axial flow solution.