Further Field Applications of Electronic Detonator Technology

The increasing use of the Daveytronic digital programmable detonators is continuing to yield data reinforcing earlier studies concluding that accurate timing will provide substantial performance and economic benefits. This study quantifies performance increases as they relate to fragmentation, excavation, vibration control and productivity in a limestone aggregate mining operation. High levels of field controls were adhered to during the drilling and blasting process as they related to blast design, bench preparation, pattern layout, drilling and blasthole loading. Following each blast, the fragmentation composite of the post-blast muckpile was quantified. The excavation and crushing procedures were then studied to quantify any down stream advantages due to improvements in fragmentation. This study will help provide the industry with more information as to the advantages of high accuracy electronic blasting systems over conventional pyrotechnic systems.     

Effects of joint orientation and rock mass quality on tunnel blasting

It is a well known fact that rock mass properties influence the process of fragmentation considerably. Model blasts and field investigations were carried out to find the effects of rock mass quality and joint orientation on tunnel blasting. Propagation of shock waves are partially restricted by joint planes. It was observed that the blast results (i.e., average fragment size and depth and cross-sectional area of the broken zone) were considerably influenced by joint orientation. Accordingly, it has been concluded that loading equipment with a larger capacity and deeper blast holes are required in formations with joint planes perpendicular to the tunnel axis. The number of blast holes, however, should be greater when joints are parallel to the tunnel axis. Furthermore, the powder factor (kg/m³) has been found to be directly related to rock mass quality (Q). Optimisation of pull, powder factor and overbreak is required in the case of weak formations with joints perpendicular to the tunnel axis. The use of contour blasting technique seems to be essential in poor and fair rock masses to minimise the overbreak, reduce the support cost and improve the stability of the opening.     

Controlled blasting in a limestone mine using electronic detonators: A case study

Except for very deep-seated deposits, open cast mining method has been recognized as the safest and most productive mode for mining minerals. Ever growing demand in minerals and coal has compelled the mine operators to increase the size of mine, which has resulted in an increasing trend towards large capacity open cast projects. Explosives and blasting techniques play a significant role in efficient opencast mining operations. There have been constant technological developments towards safer, faster, economical and more efficient blasting systems. Further, globally increased competitiveness has necessitated to carryout blasts in such a way that the desired degree of fragmentation is achieved in the primary blast, with minimum undesired side effects such as ground vibration, air blast/noise, flyrock, generation of oversize boulders, formation of toe, and over break or back break. Hence, the ultimate objective of the blasting engineer is to ensure that the blasts are carried out in an eco-friendly manner. This paper presents a case study of limestone mine where a controlled blasting was conducted near a green structure of wagon tippler (at 2 m) being constructed for foundation work of belt conveyor as the mine management wants to double the existing production. This paper deals with controlled blast design and its implementation using electronic detonators with signature hole technique.     

Timing effects on the fragmentation of small scale blocks of granodiorite

A series of small scale tests, simulating multi-hole blasts have been performed to establish the effect of delays on blast fragmentation. The blasts were performed in high quality granodiorite blocks, which were cut from stone prepared by dimensional stone quarry operations. The pattern used was equilateral triangular, with a distance of 10.2 cm between boreholes, which had a diameter of 11 mm, were loaded with detonating cord and the coupling medium was water. The delays used were achieved using different lengths of detonating cord for the cases of delays between 0 and 100 μs between holes and a sequential blasting machine firing seismic detonators for larger delays up to 4 ms. All fragments were collected and screened. The experiments showed that the worst fragmentation was achieved with simultaneous initiation of all charges. Fragmentation improved with the delay time between holes up to 1 ms between holes. If the experiments are scaled up, the results show that in granodiorite, fragmentation optimization requires delays of few milliseconds per metre of burden. The findings, agree with previously published work, involving larger scale experiments and other rock types.     

Application of Air Decks in Production Blasting to Improve Fragmentation and Economics of an Open Pit Mine

In blasting with air decks, repeated oscillation of shock waves within the air gap increases the time over which it acts on the surrounding rock mass by a factor at between 2 and 5. The ultimate effect lies in increasing the crack network in the surrounding rock and reducing the burden movement. Trials of air deck blasting in the structurally unfavourable footwall side of an open pit manganese mine has resulted in substantial improvements in fragmentation and blast economics. Better fragmentation resulted in improved shovel loading efficiency by 50–60%. Secondary blasting was almost eliminated. Use of ANFO explosive with this technique reduced explosive cost by 31.6%. Other benefits included reductions in overbreak, throw and ground vibration of the order of 60–70, 65–85 and 44% respectively. This paper reviews the theory of air deck blasting and describes in detail the air deck blast trials conducted in a manganese open pit mine in India. The blast performance data have been analysed to evaluate the benefits of air decking over conventional blasting.     

Improvements in Blast Fragmentation Models Using Digital Image Processing

One of the fundamental requirements for being able to optimise blasting is the ability to predict fragmentation. An accurate blast fragmentation model allows a mine to adjust the fragmentation size for different downstream processes (mill processing versus leach, for instance), and to make real time adjustments in blasting parameters to account for changes in rock mass characteristics (hardness, fracture density, fracture orientation, etc). A number of blast fragmentation models have been developed in the past 40 years such as the Kuz-Ram model [1]. Fragmentation models have a limited usefulness at the present time because: 1. The input parameters are not the most useful for the engineer to determine and data for these parameters are not available throughout the rock mass. 2. Even if the input parameters are known, the models still do not consistently predict the correct fragmentation. This is because the models capture some but not all of the important rock and blast phenomena. 3. The models do not allow for 'tuning' at a specific mine site. This paper describes studies that are being conducted to improve blast fragmentation models. The Split image processing software is used for these studies [2, 3].     

Unlocking possibility of blasting near residential structure using electronic detonators

Ever since development of human civilization, mining and agriculture has been the backbone of growth. Today the most developed countries of the world are the ones focused on core economical development, be it power generation, steel making, oil and gas production, or agriculture. Mining has been gaining importance over the years both from the economic perspective and as an area of sustained research. With the advent of globalization, things have changed very fast and today it is an industry that is driving the economies of several nations. Global competition has propelled countries to reach higher production levels through better techniques of drilling and blasting, excavation and mineral processing. We now have bigger and faster drill machines and excavators. In Explosives technology too significant progress has been made towards having safer explosives and accurate initiating systems that have increased overall control over blasting in terms of vibration, fragmentation, throw, fly rock and overall blast economics. Explosives and Rock Blasting Technology has advanced so much in the last few decades that blasting can now be precisely performed, controlled and predicted. Development of new tools like electronic blasting systems and advanced simulation software has made it possible to customize blasting results as per requirement. These developments have helped mining engineer worldwide in reaping huge productivity benefits besides making it possible to meet the environmental norms even in most demanding conditions. Inability to blast large size shots on account of proximity of mines to human habitation have always constrained mine management in fully leveraging the strength of large size production equipments. Mine managers have been forced to conduct small blasts on increased frequency to provide feed to large capacity shovels while compromising on Shovel productivity on account of undesirable movement of shovels during blasting. This paper deals with a case study at SEB quarry of Tata Steel wherein it was difficult to fire a big blast due to existing nearby structures. A critical scientific study was conducted before successfully firing of one of the biggest shot of 83 tonnes in the history of quarry. The paper discusses the issues being faced, alternate solutions opted and the final outcome.     

Modelling Rock Blasting Considering Explosion Gas Penetration Using Discontinuous Deformation Analysis

Explosion gas plays an important role in rock mass fragmentation and cast in rock blasting. In this technical note, the discontinuous deformation analysis method is extended for bench rock blasting by coupling the rock mass failure process and the penetration effect of the explosion gas based on a generalized artificial joint concept to model rock mass fracturing. By tracking the blast chamber evolution dynamically, instant explosion gas pressure is derived from the blast chamber volume using a simple polytropic gas pressure equation of state and loaded on the blast chamber wall. A bench blasting example is carried out. The blast chamber volume and pressure time histories are obtained. The rock failure and movement process in bench rock blasting is reproduced and analysed.     

The Use of Lagrange Diagrams in Precise Initiation Blasting. Part I: Two Interacting Blastholes

Using the concept of Lagrange diagrams this contribution details the calculation of the delay time between blastholes in a row and rows of blastholes with respect to precise initiation timing within the new advanced blasting technology which is based on the use of electronic detonators. After introducing the representations of stress waves and cracks, this contribution focuses on the role of stress wave interaction in optimal fragmentation in surface blasting and bench blasting. Part I of the paper considers two interacting blast-holes, Part II will be devoted to three or more out of plane interacting blastholes, whereas Part III will treat the interaction with a free face such as encountered in bench blasting. A few simplifying assumptions have been made in this paper with respect to the rock mass as well as the mechanical treatment. The essential assumptions include that the rock mass is treated as a continuum with finite tensile and compressive strength and the effects of structural geology are not taken into account. In addition, the analysis in Part I is simplified by two 'educational' assumption, that all waves are plane (i.e., one-dimensional) waves and three-dimensional effects of finite size blastholes and charges are not taken into account. This contribution will also show that knowledge in wave propagation and fracture mechanics is essential for the successful application of the new blasting technique in industry. In particular, the delay time, the wave speeds in the rock mass, the shape of the wave pulse and the acoustic impedance mismatch (not considered in this paper) have become decisive parameters in advanced blasting. Utilizing the wave speed and wave shapes of detonations, large scale tests in various countries (Australia, Chile, etc.) have shown that optimal delay timing requires shorter delay times in conjunction with allowing for a wider drilling pattern and the use of a grossly reduced amount of explosives , i.e., a lower powder factor. This seemingly contradictory arrangement is fully justified by using scientific principles in blasting, and converting blasting from an art to a scientific discipline .     

A three dimensional model of muckpile formation and grade boundary movement in open pit blasting

Summary Formulation and case studies of a three dimensional kinematic model are presented. Thein situ overburden geometry can be simulated accurately and various initiation patterns of blasts can be modelled. The overburden geometry, hole patterns and explosive distribution are all explicit model inputs. Because the effect of explosive properties, rock mass condition and inter-row delay are very difficult to measure in terms of blast performance, these are represented in the model by control parameters which are left for calibration using field data. The output of the model is a three dimensional muckpile shape of any cross section and a contour map of grade distribution within the muckpile. Two case studies are presented which have shown that the model is a valuable tool for optimizing production blasting as well as for controlling grade dilution during blasting.     

Pre-Set Delay Electronic Detonators: Merits Opposite Programmable Systems

The South African mining industry first experienced en-masse use of electronic detonators in the Narrow Reef environment using AEL's Electrodet™ pre-set delay system. In recent years, programmable systems such as AEL's Smartdet™ have also established their position, and within both AEL and the mines there has been important learning around the strengths and weaknesses of these systems. In general, the fixed delay systems tend to be more easily appreciated by less-skilled work teams, and are very well suited to simple layouts, especially long, narrow blasts. However, development of programmable row controllers and series delay inserts has greatly expanded the field of usefulness of these systems while retaining most of the simplicity of use. The programmable systems are immensely flexible and therefore able to function under any condition, but require a higher level of discipline and knowledge. Much has been done to address this issue and make the systems user friendly, so the systems have converged to some extent. These systems are both valuable tools for achieving control over blasting in underground and surface applications. The choice of system is very dependent on the prevailing conditions. Accurate timing with electronic enhancements continues to show an increasing range of benefits to mining operations. There is a strong parallel with non-electronic initiation systems which helps to understand the appropriate use of the systems.     

Tunnel blasting techniques in difficult ground conditions

Summary The quality of tunnelling can be improved by proper blast design which takes into account the rock mass conditions. The effects of different rock mass properties on tunnel blast performance need to be assessed. The strength of the formation and joint orientation critically affected fragmentation and overbreak in a model study of blasting. Similar effects were noted in situ when the performance of a blast pattern in different rock mass conditions in the Tandsi inclines (Bihar, India) were analysed. Accordingly, the on-going blast pattern was modified for the poor ground conditions prevailing in the rest of the inclines. Improved fragmentation and smooth profile were obtained as a result; the rate of drivage improved considerably and the cost of excavation was reduced. Based on the observations in the model studies and the investigations at Tandsi, some guidelines for optimum blast design in difficult ground conditions are suggested.     

An RES-Based Model for Risk Assessment and Prediction of Backbreak in Bench Blasting

Most blasting operations are associated with various forms of energy loss, emerging as environmental side effects of rock blasting, such as flyrock, vibration, airblast, and backbreak. Backbreak is an adverse phenomenon in rock blasting operations, which imposes risk and increases operation expenses because of safety reduction due to the instability of walls, poor fragmentation, and uneven burden in subsequent blasts. In this paper, based on the basic concepts of a rock engineering systems (RES) approach, a new model for the prediction of backbreak and the risk associated with a blast is presented. The newly suggested model involves 16 effective parameters on backbreak due to blasting, while retaining simplicity as well. The data for 30 blasts, carried out at Sungun copper mine, western Iran, were used to predict backbreak and the level of risk corresponding to each blast by the RES-based model. The results obtained were compared with the backbreak measured for each blast, which showed that the level of risk achieved is in consistence with the backbreak measured. The maximum level of risk [vulnerability index (VI) = 60] was associated with blast No. 2, for which the corresponding average backbreak was the highest achieved (9.25 m). Also, for blasts with levels of risk under 40, the minimum average backbreaks (<4 m) were observed. Furthermore, to evaluate the model performance for backbreak prediction, the coefficient of correlation (R ²) and root mean square error (RMSE) of the model were calculated (R ² = 0.8; RMSE = 1.07), indicating the good performance of the model.     

Theory and Practice of Air-Deck Blasting in Mines and Surface Excavations: A Review

The mechanism by which the explosive energy is transferred to the surrounding rock mass is changed in air-deck blasting. It allows the explosive energy to act repeatedly in pulses on the surrounding rock mass rather than instantly as in the case of concentrated charge blasting. The air-deck acts as a regulator, which first stores energy and then releases it in separate pulses. The release of explosion products in the air gap causes a decrease in the initial bore hole pressure and allows oscillations of shock waves in the air gap. The performance of an air-deck blast is basically derived from the expansion of gaseous products and subsequent multiple interactions between shock waves within an air column, shock waves and stemming base and shock waves and hole bottom. This phenomenon causes repeated loading on the surrounding rock mass by secondary shock fronts for a prolonged period. The length of air column and the rock mass structure are critical to the ultimate results. Several attempts have been made in the past to study the mechanism of air-deck blasting and to investigate its effects on blast performance but a clear understanding of the underlying mechanism and the physical processes to explain its actual effects is yet to emerge. In the absence of any theoretical basis, the air-deck blast designs are invariably carried out by the rules of thumb. The field trials of this technique in different blast environments have demonstrated its effectiveness in routine production blasting, pre-splitting and controlling over break and ground vibrations etc. The air-deck length appropriate to the different rock masses and applications need to be defined more explicitly. It generally ranges between 0.10 and 0.30 times the original charge length. Mid column air-deck is preferred over the top and bottom air-decks. Top air-deck is used especially in situations, which require adequate breakage in the stemming region. The influence of air-deck location within the hole on blast performance also requires further studies. This paper reviews the status of knowledge on the theory and practice of air-deck blasting in mines and surface excavations and brings out the areas for further investigation in this technique of blasting.     

Characterization of underground rock fragmentation

Summary This paper focuses on the methodology and techniques developed to characterize the rock fragments produced by blasting in an underground environment. This work formed part of an integrated approach to the optimization of blasting design at a Canadian mine. Details are given of the photographic and image analysis techniques adopted, together with data from a program of full scale, study blasts in the mine. Features of the observed fragmentation are reviewed which related to controlled variation in the blast designs, together with other factors which were observed both to influence fragmentation characteristics and to interact with loading equipment productivity.     

The BLAST-CODE model - A Computer-Aided Bench Blast Design and Simulation System

Blast design is a critical factor dominating fragmentation and cost of actual bench blasts. However, due to the varying nature of rock properties and geology as well as free surface conditions, reliable theoretic formulae are still unavailable at present and in most cases blast design is carried out by personal experience. As an effort to find a more scientific and reliable tool for blast design, a computer-aided bench blast design and simulation system, the BLAST-CODE model, is developed for Shuichang surface mine, Mining Industry Company of the Capital Iron and Steel Corporation Beijing. The BLAST-CODE model consists of a database representing geological and topographical conditions of the mine and the modules Frag + and Disp + for blast design and prediction of resultant fragmentation and displacement of rock mass. The two modules are established in accordance with cratering theory qualitatively and modified quantitatively by regression of the data collected from 85 bench blasting practices conducted in 3 mines of the Shuichang surface mine. Blasting parameters are selected based upon quantitative and comprehensive evaluation on the effect of the factors such as rock properties, geology, free surface conditions and detonation characteristics of the explosive products in use. In order to ensure practicality and reliability of the system, the BLAST-CODE model allows automatic adjustment to the selected parameters such as burden B and spacing S as well as explosive charge amount Q of any blasthole under irregular topographic and/or varying blastability conditions of the rock mass to be blasted. Simulation of the BLAST-CODE model includes prediction of fragmentation and displacement that are demonstrated in terms of swell factor, characteristic rock size x c and size distribution coefficient n by Rossin-Ramler's equation, and 3-dimentional muck pile profile. The BLAST-CODE model also permits interactive parameter selection based on comparison of the predicted fragmentation and displacement as well as the cost for drilling, explosives, and accessories until the most effective option can be selected.     

Micro-sequential contour blasting—how does it influence the surrounding rock mass?

The optimal delay time between the contour holes in rock blasting has been studied by theoretical and empirical research in Sweden, regarding ground vibrations, increase in crack frequency, radial crack length and finally overbreak (half cast factor). The model test presented in this paper concerns controlled contour blasting in tunnelling and the full-scale blasts concern tunnelling, road cutting, and dimensional stone quarrying. The results indicate that the microsequential contour blasting technique (contour holes fired in sequence and with a delay in the order of 1–2 ms) is superior to simultaneous initiation both regarding blast-induced ground vibrations and crack frequency increase in the rock mass. Both these evaluation methods reflects the conditions deeper in the remaining rock mass. Simultaneous initiation, however, is superior to micro-sequential contour blasting both regarding the half cast factor and the length of radial cracks emanating from the blastholes. These two parameters are more related to the surface conditions after blasting. The industrial applications of this new knowledge are the use of micro-sequential contour blasting when ground vibrations are of greater concern than the contour, for example, in trench blasting or quarrying in urban areas, and the use of simultaneous initiation when an even rock surface is of high priority.     

Studies on the Effect of Burden on Blast Damage and the Implementation of New Blasting Practices to Improve Productivity at KCGMs Fimiston Mine

Wall control blasting practices arc necessary to reduce the impact of blasting on mine faces but can also have a significant negative impact on mine productivity and operating costs. The conventional practice in deep open pit mines is to use so-called trim blasts adjacent to pit walls. To provide burden relief these trim blasts have fewer rows than full production blasts and are fired to a cleared free-face: hence they are termed 'unchoked.' This practice leads to scheduling constraints on the pit operations and can cause ore dilution due to excessive muckpile movement. The use of such trim blasts stems from the perception that increased wall damage results from 'choked' blasts. These concerns are based on the unproven assumptions that blast vibration levels and explosive gas penetration increase with increased blast burden and face confinement. This paper describes work undertaken as part of a major investigation into wall control blasting at the KCGM Fimiston Mine, Kalgoorlie, Western Australia. It details a study to assess damage effects due to blast burden. Borehole air pressure measurements and borehole video camera inspections owere done behind a series of single blastholes drilled owith varying burden distances, as owell as behind a dedicated trim blast and a full production blast. It was found that the measured damage effects, including visible rock cracking, dilation, and the limited extent of gas penetration behind the blastholes, did not vary significantly with burden or blast type for the cases tested. This result was in complete agreement with detailed vibration measurements conducted by Blair and Armstrong [1] during the study, which found that vibration was independent of blast burden. As a result of these investigations, changes to the blasting practices at the mine were implemented. Dedicated trim blasts and free-face blasting have been replaced by modified production blasts and the practice of 'choking' blasts has been introduced. This has resulted in a significant improvement in productivity and cost savings without compromising pit wall integrity.     

Prediction of blast fragmentation using multivariate analysis procedures

An extensive multivariate analysis procedure for prediction of blast fragmentation distribution is presented. Several blasts performed in various mines and rock formations in the world are brought together and evaluated. Blast design parameters, the modulus of elasticity, in situ block size are considered to perform multivariate analysis. The hierarchical cluster analysis is used to separate the blasts data into different groups of similarity. Group memberships were checked by the discriminant analysis. The multivariate regression analysis was applied to develop prediction equations for the estimation of the mean particle size of muckpiles. Two different prediction equations were developed based on the rock stiffness. Validation of the proposed equations on various mines is presented and the capability of the prediction equations was compared with one of the most applied fragmentation distribution models appearing in the blasting literature. Prediction capability of the proposed models was found to be strong. Diversity of the blasts data used is one of the most important aspects of the developed models. The models are not complex and suitable for practical use at mines. Copyright © 2010 John Wiley & Sons, Ltd.     

Fragmentation Energy in Rock Blasting

The theoretical explosive energy used in blasting is a common issue in many recent research works (Spathis 1999; Sanchidrian 2003). It is currently admitted that the theoretical available energy of the explosives is split into several parts during a blast: seismic, kinetic, backbreaks, heave, heat and fragmentation energies. Concerning this last one, the energy devoted to the breakage and to the creation of blocks within the muckpile can be separated from the microcracking energy which is devoted to developing new and/or extending existing micro cracks within the blocks (Hamdi et al. 2001; López et al. 2002). In order to investigate these two types of energy, a first and important task is to precisely study the main parameters characterising the two constitutive elements of the rock mass (rock matrix and discontinuity system). This should provide useful guidelines for the choice of the blasting parameters (type of explosive, blasting pattern, etc.), in order to finally control the comminution process. Within the frame of the EU LESS FINES research project, devoted to the control of fines production, the methodology was developed in order to: (1) characterize the in situ rock mass, by evaluating the density, anisotropy, interconnectivity and fractal dimension of the discontinuity system and (2) evaluate fragmentation (both micro and macro) energy spent during the blasting operation. The methodology was applied to three production blasts performed in the Klinthagen quarry (Sweden) allowing to estimate the part of the fragmentation energy devoted to the formation of muck pile blocks on one side and to the muckpile blocks microcracking on the other side.