Search Documents

By M. Adnan Goksel

A blast furnace test of approximately 5,000 tons of PelleTech Corporation (PTC) cold bond pellets was successfully run at Kaiser Steel Corporation (Kaiser) Steel Manufacturing Division at Fontana, California. The pellets were produced from mill scale, BOF dust and blast furnace flue dust. A 15 day base period, during which time the metallic burden was 2/3 heat indurated pellets and 1/3 sinter, preceeded the test. During the test period the metallic bur- den was 10% cold bond pellets, 56.7% heat indurated pellets and 33.3% sinter. A 15 day post test base period followed during which the PTC pellets were replaced by conventional pellets. The pellets were produced in the 3.C Semi-works Facility located on Kaiser property. The facility incorporates the Michigan Technological University Hydro-Thermal Agglomerating Process.

Jan 1, 1979

By Peter K. Strangway

During 1973, a 20,000 net ton (18 100 metric ton) formcoke test was carried out at Inland's 26.5-foot (8.08-meter) hearth diameter on NO. 5 Blast Furnace. The formcoke briquettes were produced from Elko1 coal by FMC at their pilot plant in Kemmerer, Wyoming. The briquettes were shipped to Inland in open railroad cars and most of them were placed in an outside storage field until a sufficient amount was available for the actual blast furnace test. The test consisted of three phases: an initial four-week base period; the actual 33-day formcoke test period; and a final three-week post-test base period. During the formcoke test period, the regular coke skip loads were gradually replaced with skips of formcoke until, after a three-week period, the replacement ratio reached 80%. The furnace operated smoothly and quality hot metal was produced. The burden remained permeable and it was possible to maintain wind rates 9 of over 100,000 scfm (47 Nm3/s) without significant blast pressure increases. Dusting from the formcoke was not a problem either in the stockhouse or in the top gas. The formcoke briquettes maintained their original shape and density as they descended through the furnace. When the 80 percent replacement level had been reached, the inwall temperatures became higher than normal (about 2000 ºF (1090 ºC)) and followed an unusual steady pattern. In addition, the top gas temperature became higher than normal, and the hot metal analyses and temperatures began to fluctuate unacceptably. In general, it is felt that the high inwall temperatures were a result of channeling of the hot furnace gases along the stack walls. This channeling appears to have been promoted by a change in distribution of the burden in the top of the furnace which, undoubtedly, was caused by the increased increments of formcoke. Since it was felt to be unsafe to operate the furnace for an extended period of time with the inwall temperatures at the high level, a decision was made to remove the formcoke from the furnace. When this was done, the inwall temperatures returned to normal. Once the inwall temperatures had returned to normal, the remaining 3,800 net tons (3450 metric tons) of formcoke were used in the furnace at a nominal 40% replacement level for five continuous days. The furnace operated smoothly during this period, and the results were representative of satisfactory furnace operation with partial replacement of regular coke with formcoke. The test was successful in proving that formcoke can replace up to about 50% of the regular coke in a large furnace operating at high wind rates. However, additional work will be required to develop acceptable charging practices for using higher levels of formcoke replacement.

Jan 1, 1977

By J. S. Young

During 1975, the Reclasource Corporation constructed and commissioned a plant for the recovery of mill scale, coke breeze, blast furnace dust, blast furnace sludge and basic oxygen furnace dust at the site of Crucible Alloy Division, Midland, Pennsylvania. The Reclaform Process was employed as the criteria for plant design. This Process takes the solid in-plant fines as listed above, commonly found in integrated steel mills, sizes and forms them through the use of a carbonaceous binder briquetting system and cures the binder through a final heat-treating step. 15,000 tons of Reclaform briquets have been tested in the Crucible blast furnace in several campaigns structured to assess material handling properties, burden feasibility and finally culminating in an iron and carbon assessment campaign. Data are presented from the records of the blast furnace operation and conclusions are drawn that both iron and carbon utilization have been demonstrated.

Jan 1, 1977

In blasting large tonnages of ore or material, the economy of the operation 'depends mainly on the mine manager's judgment in placing the holes to the best possible advantage and in determining the most effective size of hole to suit the conditions and requirements.The placing of holes is often looked upon as a problem involving so many uncertain factors that the application of simple mathematics is impossible. The uncertain factors arise when dealing with strata of different character, in hardness toughness and resistance to shearing.A study of the practice at many mines where all types of strata from hard ore to relatively soft overburden, and even coal, is being mined, suggests that the problem is not as complex as generally believed. There is, without doubt, some uniformity in the amount of burden given to holes of equivalent dimensions, regardless of the material being mined. The reason is simple. With too great a burden hard rock will not break out and soft rock will "bull". The nature of the strata is taken care of by the strength, quantity and distribution of the explosive charge and, to some extent, the spacing of the holes.It is because burdens are uniform in all classes of strata met with in mining, that a formula can be used to design blast hole layouts.The formula introduced in this paper is empirical as it is based on prevailing practice. It has been tested and proved remarkably accurate against every example available to the writer. Many thousands of blast holes, at many different mines, are represented by the examples given in the attached tables; to give further examples would only mean, unnecessary repetition. At the Mount Morgan Mine...

Jan 1, 1952

By Creelman C. A

With the technique and data obtained in using the blast hole diamond drill for "Removal of Horizontal Level Pillar by means of Blast Hole diamond drilling at New Occidental Gold Mines N.L.," as described in Proceedings No. 133 of 1944, and a series of experiments using the blast hole diamond drill for stoping at New Occidental and New Cobar Mines over the past two years, a benching method of stoping has been developed using 2 inch coring diamond drill bits, resulting in efficient and economical ore extraction in these large ore bodies.During the experimental stages the standard H-inch blast hole was used, but the deflection of the holes, when using this solid bit, either decreased or increased the burden of the hole when it became necessary to drill holes deeper than 45 feet.It was found that after blasting vertical holes deeper than 45 feet, the ore did not break satisfactorily over the full length of the hole; on one occasion as much as 30 feet of bench was left at the bottom of the face, which had to be subsequently re-bored andblasted.As this defect was also noticeable to some extent even when the holes did not deflect, it was then obvious that the explosive had become less sensitive in the lower section of the hole. This was probably brought about by pressure being built up ahead of the detonation wave in H-inch hole, resulting in desensitization of the explosive.Another series of experiments were carried out, using 2-inch solid bits, which enabled a much greater burden on the holes, and the use of primacord for the full length of the hole.This gave satisfactory results regarding breaking and fragmentation, but was uneconomic owing to the excessive consumption of diamonds, and the slow rate of drilling.Further experiments were then carried out using 2-inch coring bits, (Fig. 1) which allowed holes of 90-feet to be bored with little deflection, and proved to be entirely satisfactory as to cost and speed of drilling.

Jan 1, 1945

By T. E. Scartaccini

A drill recorder is a permanent data collecting instrument. In open pit blast hole drilling the application of a drill recorder is that of data collection, drilling control, and drilling education. The various drilling parameters (weight, RPM, penetration, torque, and air) have a drilling correlation which can be demonstrated and documented by a recorder graph. When the correlation is physically put to use during the process of drilling, then the recorder has become a drilling tool and is no longer just a data collecting instrument, per se. By being able to maintain accurate records and drilling control, comprehensive studies of changes both operational and technological can be made. These are based on in-progress facts and not after-the-fact logs. To determine total drilling efficiency, drilling conditions must be documented and controlled. Field operations at American Smelting and Refining Company's Mission Mine have proved that by increasing drilling control, demonstration of parameter relationships, and drill monitoring, more economic efficiency can be obtained. In comparing results obtained with recorder control and conventional control a decrease of 14 percent to 36 percent of drill footage costs were obtained. The percentage of variance is dependent upon whether drilling is milled-tooth or carbide-insert bit drilling.

Jan 1, 1970

By Dwayne D. Tannant

The Fox Pit at EKATI Diamond Mine reached a depth of approximately 150 m as of September 2005. The pit is designed with 11 m wide benches excavated using a double benching technique leaving 30 m high bench faces. A series of blasting tests were conducted to improve catch bench reliability and increase the percentage of benches that meet an 11 m catch width. The design changes focussed on reducing damage to the bench crest because maintaining the bench crests is the most important factor in achieving good bench reliability. The most significant improvement was obtained by raising the bottoms of the lower trim blastholes by 0.5 m. This change decreases the depth of broken rock below the final bench elevation, and consequently reduces damage to rock that forms the bench crest below. Another improvement was the use of smaller diameter (165 mm vs. 270 mm) blastholes in the A and B rows for the upper trim blast. This change reduces the charge per delay during detonation, reduces the powder factor slightly, and reduces the energy affecting the final pit wall and crest. As mining and the blast testing progressed, the portion of the bench with crest achievements (>11 m) increased from 57% to 75%.

May 1, 2006

By Grigor Mishev, Georgi Petrov, Benjamin Cebrian

Before designing a single blast or all the blasts on a pit level, it is critical to assess the main goal on each. To do this, a series of constraints must be taken into account: wall protection, vibration control, flyrock hazards, fragmentation required, desired displacement as well as economy, equipment efficiency. The tool to do this is the Blast Master Plan. Many mines fail to integrate on its elaboration key stakeholders such as planning, operations, geology/geotechnical and milling departments. Designs not only have to provide consistent behavior of the blasts, but have to make sense all in one with the geological and geotechnical conditions as a starting point. Once blasts are designed under an organized set of priorities, and complemented with quality controls, optimization is possible on a large scale.

Jan 1, 2016

By Shonn K. McNeill, Joshua Micah Hoffman

Security engineering is similar to other forms of engineering – the design is guided by the loads, materials, and desired function. For facility design, the load is the threat. Facilities that are designed with considerations for explosive hazards are designed with a shot, or series of shots, of a given size and distance from key locations. These facilities range from office buildings and industrial sites in developed nations to military and police stations in contingency areas. The challenge is the design shots are not often communicated to facility owners and managers. If the hazards change, whether it’s due to an increased capacity to cause damage by a threat or a decrease in capacity by a structure, not knowing the design shot means not knowing if security design needs to change. Blast modeling is an engineering tool that can be used to reverse engineer what a facility is suitable for, as well as be a tool for modifying security design for new conditions. This paper will examine military and civilian examples, including a case study of a military facility that did not know their as-built conditions and had to be rapidly closed; due to the determination their security engineering shortcomings could not be mitigated.

Jan 1, 2019

By Gordon K. Jorgeonson

Much of the modelling of blasting operations has been devoted to simulating blasts in open pit mines and quarries . This has been the most obvious application and has been reported in many papers and discussions in the past.

Jan 1, 1990

By Stephen H. Chung

The blasting performances identified above are considered to be the most practical ones for judging the effectiveness of a design combining explosives / rock / drill pattern. In a total blast design process, productivity relates closely to both fragmentation and heave / displacement of muck. In cast blasting, the more overburden displaced by explosives, the less blasted material there is left to be removed with mechanical equipment such as draglines or trucks. For wall protection and dilution control, estimates of the maximum extent of cracks / damage generated in situ due to blasting will help determine the location for drilling and loading perimeter blastholes.

Jan 1, 1994

By Stephen H. Chung

The SABREX computer blast simulation program permits the study of the effective use of explosive energies and predicts the total performance of a blast in terms of:fragment size distribution: muckpile profile; breakage at grade, column and collar with respect to the control case; crack penetration; damage envelope behind and beneath blastholes; a complete cost analysis including explosives, drilling and accessory costs

Jan 1, 1995

By M Fitzgerald

Fimiston Open Pit is operated by Kalgoorlie Consolidated Gold Mines (KCGM) as a joint venture between Barrick Gold and Newmont Mining. Over 110 years of underground mining resulted in the development of nearly 3500 km of underground workings including backfilled and open stopes up to half a million tonnes in size. These voids significantly complicate blasting processes at KCGM, influencing blast movement direction and magnitude. Blast movement monitoring to improve mine reconciliations was identified as an improvement project in the business plan for the geology team in 2008. Following successful trials in 2008 to 2009, blast monitoring and translation of ore blocks were implemented as a permanent grade control program from late 2009 and is now part of the Management Operating System (MOS) of the mine. This paper presents a summary of results from the Blast Movement Monitoring (BMM®) data collected to date. Ore blocks at KCGM are translated primarily using BMM® data. This data is obtained from the BMM® system which measures the movement of a radio transmitter installed in a blast pattern from a preblast position to a post-blast position. The application of the data collected by the BMM® tends to be both mine site and blast specific. At KCGM, an average distance obtained from the BMM® data within a given shot is the primary method used for translation. In the case that BMM® data is unavailable, a theoretical movement vector established from Orica Shotplus with distances gained from the historical BMM® database is used. Data is presented in an ore loss and dilution exercise for a bench undertaken at KCGM to understand the potential effects on reconciliations. Improvements that have flowed from implementing blast monitoring include improved reconciliations when combined with other grade control improvement projects. The increase in liaison between the geology and blast personnel at KCGM has been a significant improvement gained from the implementation of the blast monitoring program. This has allowed a better understanding of blast movement and the effects on ore dilution and ore loss by the mine geology team. In addition, the discussion of blasting tie-in plans between geology and blasting personnel has been improved which leads to more favourable blasting practices that take ore movement into account.

Aug 22, 2011

By Rene A. Morin, John K. Kebe

"As explosives become more widely used in urban and other congested areas, governmental regulations pertaining to their use are becoming more pervasive and stringent. This is forcing the blasting industry to review its entire spectrum of operations. Greater attention is now being paid not only to the design and layout of blasts, but also to the monitoring and recording of their after-effects for both legal and business reasons.Current PracticesThe major users of explosives in urban areas are quarry operators and construction companies. A characteristic of both of these industries, at least in recent years, is a relatively low margin of profit. This, coupled with the fact that their use of explosives is relatively intermittent, prevents them from having the kind of professional consulting services that blasting operations really warrant in today's regulatory environment. When such services are obtained, they tend to be directed more at the design and execution of the blast than at the recordkeeping function. The records that are kept tend to be more in the form of a summary of the consultant's design data as opposed to the kind of after-effect detail that is necessary.The more experienced consultants and operators now realize that at least as much attention must be paid to the record-keeping as to the design work. Regulatory bodies at all levels of government are insisting on the availability of such records.Unfortunately, the instrumentation in use today for taking such measurements does not lend itself to the practice of intermittent consulting. Current monitoring and recording instruments are based on so-called analog technology of the type that has traditionally been applied to the monitoring of earthquakes. They require set-up and calibration procedures which must be repeated each time the instrument is moved, or the blasting parameters are changed, as well as complex total analysis of the recorded data. This can lend to confusion and a dilution of responsibility for anything other than the design work and possibly some summary reporting."

Jan 1, 1985

By D J. P Jordan, C V. B Cuningham, A J. Rorke, C G. Ladds, O L. Davey

"During the early stages of the boxcut mining at the Arthur Taylor Colliery, Open Cast Mine(ATCOM), problems were experienced with blasting results. Very large boulders andportions of completely unfragmented rock were commonly encountered. A full blastmonitoring programme was instigated by the mine and the explosive supplier to solve theproblems and to optimise future blasting operations at the mine."

Jan 1, 1993

By Ian R. Firth

For the majority of open pit precious metal mines in the western United States, grade control practices have evolved as a direct result of the variable geology of the ore body and the lack of a clear visual or geologic distinction between ore and waste material. These practices often include the extensive use of buffer or choke blasting, in an attempt to minimize lateral movement of the muckpile. The Mackay School of Mines is conducting ongoing research, which aims to develop a practical method of measuring the movement of discrete “targets” placed within the body of the blast. The movement experienced by these targets can then be used to interpolate the movement of the blast as a whole. Typically, the boundaries between different material types are known as digging limits or polygons and are marked using colored flagging on the muckpile. If material movement can be measured using targets placed in the blast, these digging limits can be altered to reflect the blast-induced rock movement, reducing dilution and improving value recovery.

Jan 1, 2002

By G. W. Harris, P. Mousset-Jones, J. Daemen

"To minimize ore dilution induced by blast movement in surface mines, it is necessary to quantify such movement. This will enable more accurate location of the grade boundaries beneath the surface of a blasted rock pile before excavation. A method has been developed and tested to accurately measure the direction and magnitude of subsurface blast movement. This technique uses a cesium vapour gradiometer and a real-time, differentially corrected GPS system to locate pre- and post-blast position of magnetically enhanced target objects placed within blastholes inside a bench. The procedure developed does not require the blasted rock to be disturbed, and the movement information is available within a sufficient time to allow for modification of the selective mining boundaries for each surveyed blast. It was found that the maximum depth of target detection was 18 m, with the overall accuracy being measured as ±1 m (horizontally) and ± 1.2 m (vertically). IntroductionOre dilution is a critical concern for many mining operations. In some instances, it may be the cause of considerable mineral loss. Where the mineralization is finely grained, sedimentary and disseminated in nature, and exhibits no clearly defined visual ore/waste boundary, there is a heightened possibility for ore grade dilution. In most modern open pit gold mines, it is economically desirable to minimize dilution in the production process through the practice of selective mining by defining pre-blast ore digging boundaries, called digging polygons, on the preblast bench area. The polygons’ positions are defined by sampling the production drill holes, with the resultant assay and survey data being used to estimate the areas of specified grade content within the bench. Once the ore is blasted in the bench, the pre-blast locations of these digging polygons are flagged as designated areas on the broken ore pile. The purpose is for the loader operator to be able to recognize which areas of blasted rock are to be sent to the appropriate processing facility or to the waste dump."

Jan 1, 2001

By D Thornton

Geologists use large data sets and spend many hours and much computing time modelling the distribution of minerals throughout a rock mass. Significant investments in drilling, assaying and quality assurance and quality control (QA/QC) are made before sophisticated geostatistical techniques are applied to the collected data. A large amount of research has been done in this field such that the ore control model is a reasonably accurate reflection of the mineral that is actually in the ground. However, after all this effort, the mining engineers then work just as diligently to blast the in situ rock mass to a particle size that can be efficiently handled and further reduced by downstream comminution processes. In open cut mines, this invariably requires large amounts of explosive energy that displaces the ore boundaries from where the geologists originally defined them. Failure to accurately account for blast movement will result in misclassification, whether that is ore to waste; low grade to high grade; sulfide to oxide; or other contaminates û collectively referred to as ore loss and dilution. The financial consequence of getting this wrong is substantial and not well quantified. This diminishes all of the good geological QA/QC done in defining the ore. This paper discusses various technologies used to physically measure blast-induced orebody movement and the difficulties in modelling this with a purely theoretical approach. Rock mass structure, blast energy, design and timing contours all have significant and interrelated effects on blast movement vectors. Measured blast movement has a large variance due to the uncertainly of many of the controlling parameters û arguably dominated by the heterogeneous nature of the rock mass. Although there have been significant advances in blast movement modelling capability in recent years, this unpredictable blast movement limits their use in the context of production ore control. Certainly, without physical field measurements, accurate predictions of movement are near impossible.Limitations of traditional surface markers in determining three-dimensional (3D) blast movement within the orebody are also reviewed, and advancements in accurately measuring these vectors within blasted ore discussed

Sep 26, 2011

By M E. Watson

Minimising dilution and ore loss is an important part of ensuring profitability of a gold mining operation. White Foil open pit gold deposit is a low-grade deposit and therefore managing ore quality is a high priority. Ground movement through blasting can displace ore and waste boundaries up to 10 m from their in situ location and therefore requires stringent ore movement monitoring and adjustment. There are currently only two options for monitoring blast movement – utilising visual targets (commonly lengths of polypipe) but this has widely been replaced by electronic blast movement monitors (or BMM). Regardless of the technology used, the basic principle is to compare the pre- and post-blast locations of the targets to determine the movement of the rock mass during blasting, which is then used to determine the final location of ore and waste boundaries.The Blast Movement Technologies (BMT) BMM system has been used at White Foil since June 2014. The system has been effective and reliable during that time; however, the annual cost of using the BMM system is greater than other monitoring alternatives. As such, the open pit geology team conducted a study comparing the BMM system against the conventional polypipe technique. The objective was to quantify the profit and loss that would occur based on the ore block transformations from both methods. Eight blasts were selected where polypipes were installed in additional holes adjacent to the BMM monitoring holes. The resulting movement vectors from the respective methods were used to create post-blast ore blocks by transforming the in situ ore blocks. While polypipe is a cheaper alternative, the BMM system tracks ore and waste boundaries more effectively resulting in better quality control, enhanced ability to minimise dilution and ore loss thus maximising profit. For these eight blasts, it is calculated that the BMM system resulted in A$664 978 extra profit through a reduction of ore loss. The total cost of a yearly BMM package was recovered in the first two blasts of this study. The primary reason for the difference is that polypipe had a poor recovery rate of 32 per cent compared with 92 per cent for BMM at White Foil. Therefore, the data used to transform the ore blocks was less representative, resulting in inaccurate post-blast ore block boundaries when using polypipe.CITATION:Watson, M E, 2017. Blast movement monitors or polypipe? A study into cost-effective blast movement monitoring at White Foil gold mine, Western Australia, in Proceedings Tenth International Mining Geology Conference 2017, pp 433–440 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 20, 2017

By Sam Taoum, Omar Riahi

Few tools allow for accurately tracking ore dilution after blasting. Existing methods often rely on data analysis or linear interpolation of velocity, which can be imprecise and less effective in varied geological settings. A promising alternative is the use of numerical simulations, which involve complex mathematical calculations incorporating real physical data about explosives and geological characteristics. These simulations can model blast-induced fragmentation and subsequent ore dilution with greater accuracy, providing detailed insights into blast dynamics by considering factors such as explosive type, blast pattern, and rock properties. Numerical simulations integrate data from sources like seismic sensors, blast monitoring equipment, and geological surveys, offering a holistic view that single-method approaches cannot match. By simulating different scenarios, mines can predict the outcomes of various blasting strategies, optimize blast designs to minimize ore dilution, and maximize recovery. Advanced numerical simulations enhance the prediction of fragmentation distribution and size post-blast, crucial for effective dilution control and maximizing ore recovery rates.

Jan 21, 2025