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Blasting Masterclass 30 September 2014
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Masterclass2014
Blasting Science – Energy in the science of blasting
WealthUnearthed
2020 WORLD VISION (O/P)• Applying large scale open pit mining to depths equal and/or
greater than current
• Approaching depths of 1000m and greater
• Ability to mine up to Gigatonne tonnes per-annum (ore and
waste)
Issues: Increased Depth, High Capacity Production And Lower Grade Mining
• A generational transformation in bulk mining (e.g. cave mining):
• Significantly Lower cost, Safe, Continuous and High Volume Cave
Mining Production
Issues: Increased Depth, High Capacity and Lower Grade Mining
2020 WORLD VISION (U/G)
Future of mass mining - 2020 Vision in Action
Probabilistic approach to risk
Probabilistic approach to risk
Probabilistic approach to risk
Challenges and Opportunities – Open Pit
Mining of steep to vertical walls (damage control)
Increased production via “mega” blasts
Enabling Grade Engineering through Fragmentation
Mine & Mill Integration (Next generation Mine to Mill)
Continuous mining and production (e.g. IPCC systems)
Lower cost waste rock mining
Mega Blasts – Differential Blasting/Grade Engineering
Blasting Science
“The Challenge”
The study of rock breakage:
bridge between:
• Rock Engineering
• Chemistry (thermodynamics of explosives)
• Detonation and Shock Physics
• Mathematics (numerical modelling)
• Explosive Engineering
The Future of Blast Modelling
Blasting Science
The Means – Blast Modelling
“The Challenge”
HSBM – The Blast Modelling Tool
What Started the HSBM Development?
Diamond Damage from open pit blasting
A De Beers / JKMRC (University of Queensland) 2 year study
Results – Diamond liberation
Undamaged Diamonds
Driver or MotivationThe ability to better predict the blasting process and results through better understanding of both detonation and rock breakage physics. Moving away from or empirical approaches.
End pointA numerical model (Software) of the complete blasting process combining a detonation code to a Geomechanical code (state-of-the approach).
Benefit
The ability to better control the blasting process and results and to better quantify impacts or benefits of blast design changes.
THE HSBM
HSBM – Project Achievements
Phase 1: Underpinning rock breakage and detonation physics
Phase 2: Validation of software –Recognition of potential as strategic tool(blast planning tool and scenario analysis)Tool for back analysis of “failed” blasts.
Phase 3 (current): Implementation of the HSBM by the sponsors to areas of interest and some enhancements to extend the HSBM range of application
Geomechanical code
Detonation codesIdeal and non-
ideal
VixenBlo-Up
Modelling EngineDetonation
Fracturing
Fragmentation
Displacement
Near-field Damage
Rock and fragment Conditioning
Back of
detonation
driving zone
(sonic surface)
Shock front
End of
reaction
zone
Detonation modelling The rock breakage engine
The Hybrid Stress Blasting Model (HSBM)
Questions we asked ourselves
Blasting to Customer Specification & Mine to MillAbility to achieve consistent & desired blast results
Excavator productivityShovel, truck productivity
Effective application of electronic detonatorsFragmentation, vibrations, movement, etc
Deep pits Pit wall damageOptimal limit blasting practices
Ore recoveries in sublevel cavingFragmentation and subsequent flow
Narrow vein mining and tunnel developmentDiamond damage
Kimberlite blasting
Vision - A blast planning or Scenario analysis (strategic) and Back analysis tool?? How HSBM can support tactical or operational teams.
Numerical modelling HSBM code not a tool for routine blast design.
However, it will embody the complete physics of the process, useful check and calibration on more empirical methods of blast design.
Utility of the code will increase as computer power increases, a date will certainly come when the HSBM can be used routinely and conveniently in design.
HSBM – Thought leadership
“We have a working tool” Version 2.7
PLUS
A unique and rich library of learnings (documents) from the
overall study
Pushing the Economic Boundaries
Damage Control:Higher Capacity, Lower Grades
Optimising the slope design with increased knowns
Damage Mechanisms Unpacked
Damage Mechanisms Unpacked
Rock type
Major joints
Joint orientation
Burden relief
Timing direction
Limit blast vs.
production blast
Decoupling
Spacing
Unpacked – Rock Types, Major Joints
Unpacked – Joint Orientations
Unpacked – Burden Relief
Unpacked – Timing, Standoff, Decoupling
Unpacked - Spacing
The Outcomes
The Outcomes –Optimisation of Controlled Energy
Reduced
waste
stripping
Pushback
with poor
blasting with
additional
catchments
Excessive
blast
damage
Increased
ore
recovery
Increased
ore
recovery
Ore body
Steepened
slope
Reduced
blast
damage, no
additional
catchments
Synergy
Blast Optimisation to achieve safe highwalls
Reality
Investigation
Recommendations
Results
Goal
Case Study
Dynamics of a coal mine
Financial DynamicsWhat Eskom doesn’t know…..
Coal Value – R 76M
Total Cost
R 2.1M + R 57.1M = R 59M
Total Loading cost – R 57M
Blasting Cost – R 2.1M Profit
R 76M - R 59.1M = R 17.1M
Coal @ R 788.40 / t
US$ / R 10.40
Pre-split: The benchmark
The GoalThis is what a coal operation should look like…
Recipe for highwalls
Pre-Split Bench Preparation and Drilling
Excellent Bench Prep
Straight Lines
Pre-Split Blasting
Good Pre-Splits
Simple Model for Blasting (SMB)
Previous papers
Model used for prediction of energy balance & throw
Assumption required of breakout angle…
What is the correct burden angle?
Solid sandstone rock mass
Parallel cracks initiating radially from blast holes
Breakout conforms to most theory
Massive Rock Mass
Highly Jointed Rock Mass
Highly jointed hard dolerite rock mass
No evidence of formation of radial cracks
Joints existing in rock mass define fragmentation
Does not conform to blasting theory of breakout
Hard Jointed Rock Mass
Jointed rock mass – HSBM; Results
Plan view of jointed rock mass for a range of burdens
0.5m
3m
5m
Critical burden 6.8m
Good Pre-Splits
Pre-split: The reality
What really happens out there…….
Oopsie.....
The results…..
Reality check….Costing
R 4.0M/ 100meters
Analysis unpacked
What we find in the field….Post mortem of a blast
Collapsed Holes
Short Drilled Holes
Out of Line holes
Incorrect Spacing
What we find in the field….Post mortem of a blast
What we find in the field….Post mortem of a blast
I think not...
Already blasted....
Explosive Engineer at work…
RecommendationsBest practices….
RecommendationsUse current designs and practices as a base….
Frozen material agains highwall
Did not split in the upper half
Replaced pre-split bag with gasbag
Achieved a proper split
More influences…
The relationship between Inter/Over Burden and pre-splits
The Mine - bankable value
Remember this…..
90% reduction in coal
losses
The Mine Manager’s Dream
A picture speaks a thousand words……
Partnering for synergistic benefits…change catalysts
Explosive Supplier
Mine
Technical Production
Reality
Investigation
Recommendations
Results
Goal
Thank You
Masterclass2014
Blasting Science – Energy in the science of blasting