OPTIMUM BLAST FRAGMENTATION

OptimumBlastFragmentation

TARGETP80ATEACHSHOT?
(Doweknowwhatclientswant?)

HOWTOGETTHEP80?
(Howcanwegetthetargetfragmentation?)

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 EconomicAnalysis
OptimumBlastingEnergy
RelativeEnergyCost

Bottleneck?

Productionincrease?

OptimumBlastingEnergyRange
 OptimumBlastFragmentation

1.DecidingTargetP80s
(TargetP80ateachrock
type)

3.ControllingP80 2.MonitoringP80
(OptimumBlastDesign) (P80ateachrocktype)

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TargetP80 ComminutionEnergy(Eachrocktype)

TargetP80/
Burden&Spacing

EnergyConsumptionateachrocktype/
ThroughputChange

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PhaseI 1.BaselineTests
(SixMonths)

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PhaseI 1.Baselinetest GENERAL INFORMATION

BlastDesign/Fragmentation

Blast
Operation
Whereweare???

Rock
Properties
RockProperties(Lab.Testing)

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TargetP80 ROCKPROPERTIES

PenetrationRate
(Drill)
TensileStrength
(Blasting/Crushing)

BondWorkIndex
(Grinding)

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TargetP80 ComminutionEnergy(Eachrocktype)

TargetP80/
Burden&Spacing

EnergyConsumptionateachrocktype/
ThroughputChange

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CaseStudy Baselinetest ANALYSIS WITH GIVEN DATA

EXPLOSIVES BLASTINFORMTAION&ANALYSIS
Type BULKANFO Drill&Blast hasbeenoperatedbythecontractor Arizona
Density 0.74 1.20 gram/cc drillingandblasting.TheoriginalANFObulkdensityis0.74gr/cc,
Energy 4.184 MJ/Kg butthedensitycouldbeincleased upto1.2gr/ccatthebottom
ofdrillholeduetothecompactionofexplosives.
RWS 114
5hole appx.4880m/s
VOD
(16,000fps)
*RWS:RelativeWeightStrength
DetonationPressure 33.57kbar *VOD:VelocityofDetonation

STEMMING

Crushedaggregateisusedasthestemmingmaterial.
Accordingtotheimageanalysis,theaveragestemmingmaterialsizeis0.66inches.
Byanalyzinghistoricalrecords,stemminglengthvaries.Thiscouldbeproblematic.

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 STEMMING MATERIAL IMPACT

InfluenceofaggregatestemminginblastingontheSAGmillperformance
(Kojovic,2005)

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BLASTINFORMTAION&ANALYSIS
ANALYSIS WITH GIVEN DATA
SPECIFICEXPLOSIVESENERGY
Theconceptofspecificexplosivesenergyistheusedexplosives
energy(kcal)perunitweight(tonne).The2014recordshowsthe
highfluctuationofspecificenergyinbothhighlimestoneandlow
limestone.
Averagespecificenergy
High Limestone = 256 kcal/t
Low Limestone = 288 kcal/t

COSTPERSPECIFICENERGY(AsReference)
BlastCost Energy Volume $/ Total cost was calculated based on contractors
Date RockType #ofHoles $/m3
($) (103kcal) (m3) 103 kcal report. This table shows cost per unit energy
11/7/2014 HLimestone 73 39,544.8 10,780 14,189 3.7 2.8 consumptionofdrill&blast.
11/19/2014 HLimestone 69 34,777.6 7,570 13,411 4.6 2.6
11/26/2014 HLimestone 67 31,965.8 10,509 12,772 3.0 2.5
2/13/2015 HLimestone 248 41,279.3 6,681 11,896 6.2 3.5
2/20/2015 HLimestone 82 28,266.8 8,898 11,187 3.2 2.5 Averagecostperunitspecificenergy
3/27/2015 LLimestone 157 39,112.8 8,602 17,925 4.5 2.2 CostforHLime=$3 $6/103 kcal
4/7/2015 HLimestone 70 35,704.6 10,404 13,998 3.4 2.6 CostforLLime=$4.5/103kcal
4/13/2015 Basalt 296 27,968.0 4,237 8,147 6.6 3.4 CostforBasalt=$6.6/103kcal

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BLASTINFORMTAION&ANALYSIS
IMAGE PROCESSING
5/13 BLASTING
PREBLASTING POSTBLASTING

ExplosivesCharging

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BLASTINFORMTAION&ANALYSIS
FRAGMENTATION ASSESSMENT
ANALYSISPROCESS
Fragmentation analysis was carried out by using image processing technology (Split desktop software).
4~7smallmuckpiles witharound3bucketsofloader(40tonnes ateachmuckpile)werecreatedtorepresentthewhole
blastfragmentation.Thesampleswereobtainedfromover3ft belowofmuckpileduetolargebouldergenerationonthes
urfacefromstemmingarea.Typically,over20picturesweretakenateachmuckpile.

Date RockType # ofMuckpile # ofPhotoAnalyzed

11 May2015 HighLimestone 4 69

13May2015 HighLimestone 7 193

28May2015 HighLimestone 5 135

Photoimage Editedimage Individualfragment Combinedfragment

distributiongraph distributiongraph

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BLASTINFORMTAION&ANALYSIS
BLASTING EVENTS SUMMARY
11MayBlast 13MayBlast 28MayBlast
118holes 120holes 131holes
SpecificEnergy(kcal/t)
RealValues
269
260 1.08
Relative

3FreeFaces 1 FreeFace 1.05 Values

2 FreeFaces
248
1.00

Blast11May Blast13May Blast28May

RelativeP80size(in)
RealValues

7.44
1.00 6.18
SpecificEnergy SpecificEnergy SpecificEnergy
Relative 4.32 0.83
Values
248.0kcal/t 260.3kcal/t 269.0kcal/t
0.58

FragmentationP80 FragmentationP80 FragmentationP80

Blast11May Blast13May Blast28May

7.44in 4.32in 6.18in

*Avaluefor11Mayblastisreference

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LABTESTRESULT
LAB TESTING
SAMPLINGPOSITIONS

BL1 BL3
Basalt H1
S2 H2
H4 S4 S3
BL2
H3

Rock sampling was performed in various areas.

4blocksamplesofhighandlowlimestone
werecollectedfromstockpileandmuckpile,and
HighLimestone Basalt LowLimestone 3blocksamplesofhighlimestonewerefrom3bla
DENSITYOFROCK stingeventsperformedinMay.
HighLimestone:H1~H4,BL1~BL3
Basalt 2.74
LowLimestone:S1~S3
LowLime 1.87 Basalt
HighLime 2.65 The left figure shows the average density of three
rock types.

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 ROCKPROPERTIES

PenetrationRate
(Drill)
TensileStrength
(Blasting/Crushing)

BondWorkIndex
(Grinding)

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LABTESTRESULT
TEST PROCEDURE
Labtest
Hardness
Sampling Coring/Cutting Crushing GrindingTest
Drilling
BrazilianDisc

HARDNESSTEST DRILLINGTEST
Penetrationrateisan
Leeb hardnesstestis indicatorofdrillability.
aportableandfast Penetrationratecould
methodtoestimate beusedtoestimate
4TYPES rockhardness. rockmassandcommi
LABTESTS nutioncharacteristics.

40specimentested
97specimentested

HighLimestone
11types BRAZILIANDISCTEST BONDGRINDABILITYTEST

LowLimestone Grindabilityhasbeen
Tensilestrengthisafunda widelymeasuredby
3types mentalrockproperty BondWorkIndex(BWI)
forcomminutionprocess. This measurement
Basalt Braziliandisctestisthe representsrawmillfine
1type mostpopularmethodto grindingoflimestone.
measuretensilestrength.
14samplestested
97specimentested
9 hourspersample
(includingcrushing)

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LABTESTRESULT
TEST RESULTS
Blasting/Crushing Whatwecanhave
SUMMARYGRAPH GrindingEnergy
Energy beforeblasting!
Density TensileStrength UCS PenetrationRate BondWorkIndex
(t/m3) (MPa) (MPa) (cm/min) (kWh/t)

19.0 178.4 11.2

7.6
2.7 8.3
2.6 112.1 5.3
6.4
1.8 4.0
5.5
3.0 20.3

Low High Basalt Low High Basalt Low High Basalt Low High Basalt Low High Basalt
Lime Lime Lime Lime Lime Lime Lime Lime Lime Lime

RELATIONSHIPBETWEENROCKPROPERTIES

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LABTESTRESULT
TEST RESULTS

SUMMARYGRAPH

Density TensileStrength UCS PenetrationRate BondWorkIndex

(t/m3) (MPa) (MPa) (cm/min) (kWh/t)

19.0 178.4 11.2

7.6
2.7 8.3
2.6 112.1 5.3
6.4
1.8 4.0
5.5
3.0 20.3

Low High Basalt Low High Basalt Low High Basalt Low High Basalt Low High Basalt
Lime Lime Lime Lime Lime Lime Lime Lime Lime Lime

RELATIONSHIPBETWEENROCKPROPERTIES

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LABTESTRESULT
TEST RESULTS

SUMMARYGRAPH

Density TensileStrength UCS PenetrationRate BondWorkIndex

(t/m3) (MPa) (MPa) (cm/min) (kWh/t)

19.0 178.4 11.2

7.6
2.7 8.3
2.6 112.1 5.3
6.4
1.8 4.0
5.5
3.0 20.3

Low High Basalt Low High Basalt Low High Basalt Low High Basalt Low High Basalt
Lime Lime Lime Lime Lime Lime Lime Lime Lime Lime

RELATIONSHIPBETWEENROCKPROPERTIES
BlastPatterns BlastPatterns
1 2 3 1 2 3

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 PhaseI 2.Improvingtheblastingoperation
Whats the Next?

1stYear

Improvingtheblastdesign
(Energydistributionproblemsduetothegivenrockcondition,
TrialandErrorprocess)
Tryingthesuggestedblastdesigns.
Analyzingtheblastfragmentation(P80)ateachshot.

Morelab.testing
Collectingmorerockpropertydataisnecessaryduetothechangeablerockcondition.
PredictingthedownstreamcomminutionenergychangebasedonthedrillPRdata.
(Modifyingtheblastdesignbasedonthegraphs)

FeasibilityStudies(PreparationtodecidetheinitialtargetP80s)
(MonitoringPRinthefieldandthedownstreamcomminutionenergy)
MountingthePRmonitoringsystemonthecurrentdrill.
BuildingtheSystemtomonitorthecrushingandgrindingenergy.

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 PhaseI 3.FindingtheinitialtargetP80ateachrocktype And Then,
2ndYear

FindingtheinitialtargetP80(max.)ateachrocktype(realtimeprocess)
(TrialandErrorprocess)
Collectingtheenoughdata.
DecidingtheinitialtargetP80ateachrocktype(ProperB&Ss).
TargetP80couldbechangedasthegeologicalconditionischanged.
(PRmonitoringsystemwillbeutilizedforthechangeablerockmassconditionandproperties)

Monitoringthewholecomminutionenergy
(Includingblasting,crushingandgrinding)
Monitoringtheimpactofblastingenergychangeonthedownstream.
Collectingtheenoughdata.

Morelab.rocktesting
Collectingmorerockpropertydataisnecessaryduetothechangeablerockcondition.
PredictingthedownstreamcomminutionenergychangebasedonthedrillPRdata.
(Modifyingtheblastdesignbasedonthegraphs)
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Thank You!

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