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By Jorge Blázquez, Paulo Couceiro, Patricio Vergara, Luis Martínez, Juan Navarro

This study introduces the X-2Mill solution, a refined two-step methodology aimed at optimizing blast designs by aligning explosive energy with rock properties. The approach employs the X-4Traits Model, which uses drill-monitoring data from both autonomous and manual drilling modes to develop two critical indexes: the Drilling Rock Factor (DRF) and the Drilling SAG Power Index (DSPI). The DRF integrates the Size-Energy Fan Model with rock fragmentation results and blast design parameters, while the DSPI adjusts Specific SAG Energy (SESAG) based on Bond’s theory, incorporating ore X80 results, SAG mill capacity (TPH), and power draw to estimate milling difficulty. To enhance prediction accuracy, the X-2Mill solution incorporates, to a Principal Component Analysis of the normalized drilling data, a Meta Machine Learning model with a 3D spatial function, accounting for information from surrounding drill holes. This integration improves the precision of the DRF and DSPI estimates. The methodology unfolds in two main steps: Step 1: Bench-Scale Pattern Design, involves defining the target P80 size for ore based on the SESAG and the DSPI. It also establishes target X80 sizes for waste and oxide materials and iterates to determine the optimal Burden x Spacing (BxS) using the Size-Energy Fan Model and the DRF. Step 2: Blast-Scale Selective Explosive Density/Energy focuses on refining explosive density on a hole-by-hole basis to achieve the specified X80 values for ore, waste, and oxide materials. The X-2Mill Solution was developed at Minera Escondida Limitada (MEL) using data from 162,761 blastholes across 356 blasts conducted over three mine expansions. This solution addresses the challenges of blasting harder and more difficult rock, particularly in the lower levels of the mine. By adapting the blast pattern and explosive density to the specific rock properties and ore/waste designation, the X-2Mill Solution aims to achieve precise size distributions and improve overall blasting performance. The results demonstrate that the X-2Mill Solution balances ore fragmentation to meet SAG mill throughput requirements while optimizing powder factor costs for waste material and maintaining digging efficiency. By efficiently distributing explosive energy, the solution not only enhances throughput but also improves blasting efficiency while ensuring stable slopes and minimizing fault activation.

Jan 21, 2025

By Stephen Mansfield

In open-pit mining operations, the drill and blast processes have a significant impact on the downstream operational performance of crushing and grinding of ores and recovery of metal. The blast pattern parameters, combined with the material properties, defines the run of mine fragmentation, which in turn drives the subsequent energy requirements for further processing and mill throughput. A common parameter used to describe a single hole or collection of holes is powder factor, the ratio of explosives to the quantity of material blasted. One often-neglected aspect of calculating powder factor is the explosives contained within the length of hole drilled into the top of the bench from the previous bench, known as subdrill. Explosives in the subdrill directly affect the bench below and thus do not contribute significantly to the results of the upper bench, even though they are traditionally included in the powder factor calculation. This paper presents geospatial data modelling methods that link individual holes from an upper bench to the bench below. This enables a new method for the calculation of powder factor, whereby the explosives in the subdrill from the bench above are included in the powder factor calculation of the bench below. This method allows for a clearer understanding of the impact of subdrill on fragmentation, and how variations in blast designs in the upper bench, i.e. hole diameter, burden, spacing, subdrill length, explosive type, primer position, etc., and accuracy of implementation, i.e. actual hole depths and explosive mass per hole, affect the powder factor and blasting results in lower benches.

Feb 6, 2023

By Denard Brandt, Isidro Martinez, Greg Baker, Laura Slattery, Teddy French

The Dos Pobres Mine is a copper oxide heap-leach mine located near Safford, Arizona. Mine production is 180,000 tons (163,293 tonnes) per day with a stripping ratio of 2:1. During the startup phase of the mine, the required fragmentation size was easy to achieve as the ore was highly weathered and fractured near the surface. As the mine depth increased, the proper fragmentation size became harder to achieve due to less weathering and different rock types. Because copper recovery increases as crusher product size decreases, achieving the appropriate product size at the crusher is the operating priority.

Jan 1, 2010

By D. Lansburg

Electronic detonators are increasingly being used in today’s blasting in quarries, seismic, surface and underground mines. Electronic detonators offer several distinctive features over electric and non-el (shock tube) detonators including better timing accuracy resulting in excellent fragmentation and vibration control, field programmability and digital safety means. Because of the prerequisite electrical communications between the electronic detonators and the blasting machine, the layout or hook-up of these detonators can play an important role in obtaining the communication fidelity.

Jan 1, 2011

By R. Hazael, R. Alford, R. Critchley

The ability to compare explosives is fundamental. Numerous methods are used and while simple conversion factors are often used, the use of TNT Equivalency (TNTe) is not a simple subject as explosives exhibit very different equivalencies depending on whether the pressure or impulse are being considered as well as other conditions. The scaled distance has been found to have a significant effect on the TNTe but due to the difficulty of taking measurements at very close ranges, no TNTe have been quoted for charges in direct contact (Z=0). This paper describes the use of a ballistic pendulum to measure the impulse from contact charges and presents some surprising results that require a two-stage propulsion, as originally described by Backofen, to be explained.

Jan 1, 2024

By L C. Taylor

Both the U. S. Navy and the U. S. Army are interested in knowing more about the loading applied to vehicles which are unfortunate enough to encounter a detonation of a buried mine in the course of performing their normal duties. The Dynamic Effects Laboratory at the University of Maryland has been involved in small scale testing for ten years to assist the Navy and the Army in understanding the loads that are applied to personnel carriers when a buried explosive detonates beneath them. This paper describes results from small scale tests conducted to determine the loading mechanisms on target plates when subjected to loading due to the detonation of a buried mine in saturated sand, dry sand, and water. Transparent target plates were utilized in order to determine the loading process beneath a floor board on armored vehicles. Various charge sizes were scaled in the laboratory accordingly to a standardized full size threat encountered in the battlefield. Tests were conducted in saturated sand, dry sand, and water keeping the stand-off distance of the target and the depth of burial of the charge constant. In the case of water impacting a transparent PMMA plate the crack propagation was recorded and the crack velocity is determined. Additional tests were performed in saturated sand by varying the stand-off distance of the target but keeping the depth of burial of the charge constant. The small-scale test results could be scaled to full scale by using verified scaling laws.

Jan 1, 2016

By Steve Brace

Electronic detonators have been commercially available to the mining industry worldwide for over ten years. It is estimated that total cumulative global sales will have reached 25 million units by the time of the Conference in February 2004. This is below 0.2% of all detonator types sold during this period. Perhaps 20 million will have been used underground in South African gold, diamond and platinum mines. These will have been produced by South African companies, in South Africa for South African customers. Here efforts have met with greater success and in 2003 fully 5 million, or 3% of local detonators sold, could be of an electronic type. However, it is estimated that about US$7.00 (R50.00) has been expended on R & D, manufacturing facilities and marketing, for each unit so far sold. Large sums of money continue to be spent. Despite the apparent success in South Africa, is it justified? Electronic initiation systems have not produced significant technical benefits to the end-user underground nor corporate profits to the supplier. Some doubt they ever will (even from the large surface operations where the price per unit is much higher). A conclusion might be that they have failed. In 1998 Smit and Pistorius wrote a paper titled “Implications of the Dominant Design in Electronic Initiation Systems in the South African Mining Industry”. This ISEE paper seeks to summarise and review the conclusions of the earlier work. These were: that a dominant design had not yet emerged; the type of connector and the way in which detonators are connected and programmed would be a strong determinant influencing the development of a “winning” product; technical aspects rarely solely determine which becomes the dominant design (marketing, social and economic factors often have a strong influence); electronic initiation systems were an emerging technology for the underground gold mining industry in South Africa and because it was under severe cost pressure the mines would look to them to raise productivity and hence profits; finally, as a dominant design begins to emerge, one could expect a number of players to exit from the industry.

Jan 1, 2004

By Jeffrey Meissner, Charles Dowding

Cracking is one of the concerns cited by owners of structures adjacent to construction or mine blasting. During the past decade a large number of measurements have documented the low level of crack response produced by typical, ground motions compared to those produced by climatological effects. These data support the observation that there is a level below which ground motions do not cause even cosmetic cracking. As with all new findings, these crack response measurements need to be thoroughly investigated for all possible alternative interpretations. Among these alternatives is that uncracked locations are more affected than cracked locations. This paper presents measurements to shed light on the influence of existing cracks and the response of uncracked, but weak locations. Blast and weather induced responses of cracked and uncracked areas of gypsum wall board are compared in two structures: one near a surface coal mine in Indiana, the other near a limestone quarry in Florida. The ground motions that excited one of the structures were unusual in that the dominant excitation frequencies of 5 Hz were near the structure’s natural frequency and amplitudes exceeded 0.7 ips (18mm/s).

Jan 1, 2011

By Alan Hooper, James E. Mischler

Construction began in 1984 for a 5 megawatt hydroelectric power retrofit at the O'Shaughnessy Dam for the City of Columbus, Ohio. The construction necessitated excavation of limestone bedrock up to 27 feet below the normal water level of the river downstream of the dam. Proximity to the river and difficult terrain resulted in an interesting and challenging construction project.

Jan 1, 1986

By Robert McClure, Carlton Lehman

Rendering safe explosives in an urban environment presents a unique challenge due to the safety concerns and disruption to the general public. Potential damage to the surrounding homes, businesses, utilities and transportation infrastructure are some of the major concerns when planning the render-safe operation. Engineering controls to mitigate blast effects, such as damaging air over pressure levels, material ejection and ground borne vibration, need to be implemented as part of the operation. Monitoring of seismic and air overpressure during these operations are needed to protect against potential claims when controlled or unplanned detonations occur.

Feb 1, 2020

By G. Adderley, Rob. Farnfield, L. Bermingham

The benefits of using electronic detonators within the drilling and blasting process in both surface and underground mining operations are well established and the use of this technology is widespread in the minerals industry. However, many users of such devices will also have experienced misfires where an electronic detonator has malfunctioned and shows evidence of damage from either transient shock or gas pressure. This is typically exhibited as a detonator shell that has collapsed causing damage to the internal electronic components before the detonator has initiated. Users often describe such detonators as being “shrink-wrapped”. The excavation of a misfire is always a hazardous operation, and it is better to minimize the risk of one happening in the first place. As part of a programme to improve understanding of this phenomenon and to allow a comparison between differing designs of detonators, a simple practical test was developed. This process involves the firing of a booster near electronic detonators in water. This paper describes this test work and draws some tentative conclusions on pressures for onset of damage with detonator shells made from different materials. The investigation has also yielded data showing that for some designs there is little difference between the pressure resulting in complete malfunction and sympathetic detonation

Jan 1, 2024

By C. E. Johnson, R. L. Bauer, E. M. Johnson

In industry, the strength of a blasting cap is often equated to the type of explosive it can detonate. Comparable cap strength is becoming less important as nearly all caps manufactured today can initiate high explosives, such as primasheet, with ease. Previous studies were conducted to assess the quantity of energy released by various detonators into the directional propulsion of the detonator’s casing. However, the question of how much of this propulsion energy is needed to initiate an explosive remains unanswered. This study will assess the fragmentation size and velocity needed to initiate a high explosive when they are not in direct contact. For this study, primasheet was used as the main charge as it is relatively insensitive and can be situated in different positions relative to the detonator. Electric, non-electric and electronic detonators were used to evaluate initiation potential. The primasheet is observed in response to being in contact with a detonator, and not in contact with the detonator at various distances and angles. This allowed the quantity of energy transferred into the primasheet to be observed and for the initiation of the sheet to be recorded using high-speed video. This study will report the energy necessary to initiate the primasheet at various distances and angles from the charge from a number of widely used, commercial, hot wire blasting caps.

Feb 6, 2023

By Robert McClure, Carlton Lehman

Rendering safe explosives in an urban environment presents a unique challenge due to the safety concerns and disruption to the general public. Potential damage to the surrounding homes, businesses, utilities and transportation infrastructure are some of the major concerns when planning the render-safe operation. Engineering controls to mitigate blast effects, such as damaging air over pressure levels, material ejection and ground borne vibration, need to be implemented as part of the operation. Monitoring of seismic and air overpressure during these operations are needed to protect against potential claims when controlled or unplanned detonations occur. Two recent render-safe operations conducted in and around urban environments dealt with deteriorated, sensitive dynamite and damaged blasting caps. Utilizing innovative neutralization chemicals and processes to render-safe the deteriorated dynamite, while protecting the general public, proved to be the safest, most environmentally responsible and cost-effective way to approach the problem. In both cases, the explosives, old dynamite and detonators were found in abandoned, unlocked magazines. The dynamite was in a significantly deteriorated state, which was evident due to the nitroglycerine found leaking in,around and under the dynamite cartridges. Iron wire permissible electric blasting caps were also found in a corroded condition with exposed explosives and un-shunted lead wires. With occupied buildings within 180 feet (54.86 meters) of the magazines, any procedure (e.g. transporting, countercharging, burning) that could potentially cause a detonation was not an option. In the event of an unplanned detonation during neutralization operations, several blast mitigation methods were employed to safeguard the site. This operation and a similar one with over 1,000 pounds of crushed and buried leaky dynamite were unique since all the explosives were rendered-safe and neutralized on site. The use of advanced neutralization products and filtering processes allowed for a safer, more environmentally responsible way to resolve the problem. The magazines and all residual solids and fluids were tested and confirmed by independent labs to have no explosives residues. The effluents were treated on site, tested and met safe levels, so they were disposed of at a local municipal wastewater facility.

By Tristan Worsey, Nathan Rouse, Evan Thibaud

Electronic detonators allow for variability and accuracy with blast delay selection and timing sequence. However, a single published guideline for selection of electronic timing delays is not available on the OneMine database. There are published documents that present options for timing with electronic detonators, some of which provide great detail and scientific evidence, but there is no single document that presents several different approaches with simple instructions on how to apply the various timing approaches. This paper reviews published electronic timing approaches and results, then presents guidelines for electronic timing for alternative mining methods, which include: bench blasting (ie. quarries) and crater blasting (ie. metals mines). Most of the approaches are based on calculating milliseconds per meter for rock types, as quantified by the rock sonic velocity. Guideline calculations are provided for recommended hole-to-hole delays and row-to-row delays for both free-faced bench blasting and crater blasting approaches. These are the two most common blasting methods for mining operations. Typically, free-faced bench blasting is the approach used in quarries with a bench height to burden ratio of around 4, and crater blasting is typically used in large blasthole diameter/short bench blasting in metals mines with a bench height to burden ratio of around 1. Mines may focus on fragmentation, mucking rates, ore movement distance and movement direction. Recommendations are also included to provide general recommendations based on a mine’s preference for movement and fragmentation. References include twelve studies on bench blasting and six studies on crater blasting. In addition, a discussion is included on the application of these recommendations at a full-scale surface gold mine.

Jan 21, 2025

By Matthew Clay, Colin Chambers, Susan Hookham

Opencast (quarries) and underground mines around the world use blasting methods to mine valuable ore. Traditional blasting systems use technologies such as electric delay detonator systems (developed in the 1950s) and non-electric detonator systems (developed in the 1970s) to initiate a detonation train to blast rock more effectively, and so retrieve valuable product more efficiently. However, the lack of precise control over blast timings with these approaches can result in undesirable outcomes such as significant flyrock, excessive ground vibration, uneven grade of rock and misfires (in which sections of the blast can remain unfired). The development of Electronic Initiation Systems (EIS), first used in the 1990s, introduced a higher level of control over the blast. These systems greatly reduce the negative issues associated with blasting. However, this precision introduces complexity, and with this complexity comes difficulty in demonstrating the predictability, safety and reliability of such systems.

Jan 1, 2017

By Ankit Jha, RICHARD AMOAKO

In this paper, we examine the challenges associated with the use of empirical rock fragmentation models. We highlight key parameters omitted by these models, and propose a machine learning approach that incorporates these parameters, leading to a simple, yet more accurate approach to blast design.

Feb 1, 2020

1974 The Society of Explosives Engineers officially formed to “advance the art and science of explosives engineering” on August 20, 1974 in Pittsburgh, Pennsylvania.

Jan 1, 2010

By Auã Kiahla, Tomi Kouvonen, Vinicius Miranda

Through numerical mathematical processing (Taylor’s approach and numerical derivation) the original data supplied by the accelerometer’s sensors was transformed into velocity and, after the data mining, a statistics residue analysis was applied in order to evaluate if the data from the prototype and from the traditional seismographs were similar. The data from each system was used to estimate the attenuation law and the results are shown in this paper

Feb 1, 2020

By Z X. Zhang

If the iron ore loss is 15% in the process of mining, the total iron ore loss in the world will be about 461 million tons, this is equal to the total production of 230 iron ore mines each of which produces 2 million-tons of iron ore per year. Based on a series of blast tests in the Malmberget mine, this paper shows that ore recovery can be markedly increased by improving blasting technology such as choosing a correct primer position and making use of shock wave collision. The paper further suggests that a high ore recovery can not only reduce natural resource loss and mining cost but also prolong the life of a mine. In addition, the paper shows an example of reducing blast-caused rock damage in the roofs and walls of underground drifts (tunnels) by using new blasting methods in the Malmberget mine. Finally, the paper shows how the Malmberget mine has successfully reduced the ground vibrations, without adversely affecting fragmentation and ore recovery in sublevel caving mining.

Jan 1, 2014

By Italo Onederra, Miguel Araos

"Most of the current explosives for mining blasting activities are based on ammonium nitrate (ANFO, emulsions and watergels). AN-based explosives’ detonating properties were discovered in the 50’s and since then they have proven to be reliable, safe and cost effective. However, there is no current alternative raw material to replace AN. As part of a program of research initially funded by the Australian Coal Association Research Program (ACARP), Mining3 and the University of Queensland engaged in the search for potential oxidizing agent alternatives that could replace AN in the manufacture of mining explosives. Candidates included those that are produced in large quantities and that can be cost competitive with ammonium nitrate. The initial work identified hydrogen peroxide (HP), calcium ammonium nitrate (CAN) and sodium nitrate (SN). Explosives mixtures were prepared and sensitized using void sensitization techniques. The detonation properties results showed that explosives based onmixtures of HP/CN and HP/SN as the oxidizer were able to detonate in a range of 2000 – 5000 m/s, indiameters 50 and 102 mm, and densities in the range of 0.50 – 1.40 g/ml. Although more studies need to be conducted to fully understand these explosives, if successful, these explosives would be able to offer an alternative to the AN-based explosives in the mining industry."

Jan 1, 2017