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By Peter Moser

The average annual consumption of raw minerals in Europe is 10 ton per person. About 50 % is produced by blasting. For a population of 450 million (including the population from the countries of the new member states) this makes 2.25 billion tons of blasted rock, 80 % being building industry aggregates and industrial minerals. In aggregate quarries 10-15 % of the rock blasted can’t be sold, as the material is too fine, i.e. smaller than 4 mm. This ‘fines problem’ is worse in the quarries of limestone and cement producers where up to 30 % of the material is useless. Thus about 450 million tons of useless rock fines are produced and put on waste dumps every year, i.e. 1 ton/person. This problem is addressed by the research project LESS FINES - “Less Fines production in aggregate and industrial minerals industry” which is funded by the European Union under the project contract G1RD-CT-2000-00438. The project consortium, formed of nine partners from 5 EU countries, works on the following two main research subjects: 1. The determination of the natural breakage behavior (NBC) of the rock mass, which is defined as the particle size distribution curve for a certain rock mass with the maximum uniformity and thus for a given maximum particle size that fragmentation curve which gives the minimum amount of unusable fine material. The comparison between the NBC and an actual blast fragmentation curve allows to quantify the fines reduction potential. 2. The adaptation of explosives properties, charging techniques and timing in order to produce only the minimum, inherently unavoidable percentage of fines. With about 15 full time working persons the project is estimated to be one of the largest blast related research activities in Europe at the time of the project period. The project is coordinated by the Department of Mining Engineering& Mineral Economics of the University of Leoben.

Jan 1, 2004

By Kirlk Yeager

"Ammonium nitrate (AN) is commonly mixed with a wide variety of additives to produce specialty formulations. Two additives commonly utilized are sodium nitrate (SN) and sodium nitrite (SNi). Application of the nitrite is primarily limited to gassing of emulsions. The nitrate, however, is incorporated in a wide variety of formulations. The effect of both these materials on the thermal stability of AN was examined. Experiments initially utilized lab-scale testing methods (sub-milligram sample size), such as differential scanning calorimetry (DSC), with scale-up to cook-off analyses (16 g) eventually applied. Labscale testing indicated that the presence of SN and SNi (both at 5 wt%) produced no harmful effects on the thermal stability of AN. The cook-off results did not agree with those from the lab-scale analyses, with both SN and SNi creating tremendous thermal destabilization of AN. These effects were seen at additive levels as low as 0.1 wt%. When SNi was employed as the additive, cook-offs became violent enough to create explosions in the testing apparatus. Although SN did not create as spectacular a destabilization, it did lower cook-off temperatures to approximately the same level as SNi. The dangerous situation created by SN andSNi seemed to be limited to cook-offs conducted in sealed vessels. If the SN/AN or SNi/AN formulations were allowed to cook-off in vented vessels, the thermal destabilization of AN did not occur. These results seemed to indicate that even “trace” amounts of what might ordinarily be viewed as benign additives could create significant destabilization of AN-based explosives under proper circumstances. Conditions created by blocked pumps, or deep boreholes could well overlap those produced in sealed cook-off vessels. In addition to showing the hazards potentially created by “benign” additives, the study also stressed that experiments designed to evaluate thermal hazards must include duplication of field variables to the fullest extent possible. "

Jan 1, 1999

By Paul L. Matrin

This paper will discuss the recent and on-going drill and blast optimization measures at the Sparkhule Limestone Quarry, which have resulted in a 44% reduction of drill and blast unit costs per ton of broken limestone. This amounts to approximately $240,000 of drill and blast saving per year at current annual production rates of about 2.5 million tons (2.3 million tonnes) total material shot. The reduction of drill and blast costs were accomplished by a detailed and controlled in-the-mine drill/blast experimentation and cost evaluation using 8 different blast pattern designs and shots totaling approximately 267,000 tons (242,200 tonnes) of shot and mucked material. A careful review of the geology of the deposit was performed to determine the different rock classification/strengths/structural properties and to adjust blast designs to optimize fragmentation for the different rock types. Equipment loading productivity and crusher throughput performance were monitored as part of the evaluation process to assure that an optimal fragmentation of broken rock was achieved with the new blast designs. The study included the review of bulk explosive and accessory selection criteria (ammonia nitrate/fuel oil mix - ANFO, mini prills (high density ANFO), sensitized and un-sensitized emulsions at a 30% emulsion/70% ANFO blend), blast pattern design, charge diameter and the cost of drilling. Laser profiling technology was used to assure proper bench heights, stemming and sub-drill footage and front row burdens. High speed photography, video and still photos were taken of the different designed shots to assist in the evaluation of the performance of each blast. Powder density checks, size distribution, back break, detonation velocity and pressure measurements were taken. Different borehole diameters were used for the drill optimization study and drilling cost and productivities determined. A detailed cost comparison between in-house blasting and complete shot service was prepared to evaluate if shot service is a cost effective alternative to current in-house loading and blasting including a review of the new and pending United States Bureau of Alcohol, Tobacco and Fire Arms (ATF) regulations and associated owner costs/risks and potential benefit of shot service.

Jan 1, 2004

By A. Ribeiro

The effective utilization of resources and process optimization play a crucial role in the sustaining and growth of overall businesses. This principle holds true in the mining sector, where particular attention is required during the comminution steps. This necessity arises from the fact that mining operations often consume substantial amounts of energy in mineral processing. Therefore, it becomes imperative to thoroughly study the integration of comminution steps. In many instances, an approach to be studied is the operation commencing with the drill and blast phase and culminating in the grinding product process. Nevertheless, establishing an optimal integration between drill and blast operations and the grinding phase is a complex undertaking due to the direct influence of rock characteristics on this process. And in many cases, the complexity and variability of such physical characteristics makes mining operations to ignore such influence. Consequently, Enaex Mining Technical Solutions (EMTS), in collaboration with Lundin Mining's Chapada Mine engineering team, and with the assistance of Hatch Consulting and Technology, has undertaken a comprehensive study aimed at enhancing mill throughput at the Chapada operation. The basis of this study lies in characterizing the rock masses present in the Chapada Mine to gain a deep understanding of the material that needs to be comminuted. Subsequently, the mineral processing team determined the most suitable size distribution for the Run-of-Mine (ROM) material. With this information, the drilling and blasting team built a site-specific blast fragmentation model, able to simulate various blast design scenarios. This approach enabled to optimize the utilization of available drilling and blasting resources while striving to achieve the optimum ROM characteristics. Since 2021, the Mine to Mill methodology has been progressively implemented at the Chapada Mine. As a result, the blasting engineering team now utilizes the blast plans generated by the fragmentation model simulations as a foundation for designing blast plans that align with the operational and financial capacities of the mine. Overall, it was predicted that this implementation could lead to an average increase in mill throughput of 13-22 % depending on blend feed, once all recommendations are implemented. Even with partial implementation, plant results demonstrate a 5 % increase compared to the period before the Mineto-Mill project, without any coarsening of the associated grinding product size.

Jan 1, 2024

By B. Corrêa, M. Cavalcante

A large open pit iron ore mine in Brazil, which has a heterogeneous lithology, faces a challenge in defining drill and blast patterns to achieve the expected results. The mine needed to obtain an automated representation of the fragmentation curves and correlate them to the respective blasts, lithologies and quality parameters, seeking the continuous optimization of the fragmentation process and its benefits to the subsequent comminution processes. Trials were carried out for 5 months to demonstrate the functionality of an autonomous fragmentation monitoring system that analyzes the granulometric curve of the material throughout the muckpile and makes the results available online and in real time. The system, which contains a binocular camera, a processing unit and an antenna, was installed in a shovel, to evaluate the following KPI's: monitoring failures, monitoring capacity, physical availability and reportability of oversized boulders. The system analyzed 33,060 samples, with an average capacity of 285 photos every 24 hours, 127 during the day and 158 at night, all measured, analyzed, stored, and made available on its online platform, reporting 223 alerts of P80 above 400mm (15.7 in) and 38 particle sizes above 900mm (35.4 in). The inactive and operational hours of the monitoring system corresponded, respectively, to the idle and worked hours of the shovel, according to dispatch data. There were no camera or processor failures, and rain, dust or poor internet conditions did not impact sampling and fragmentation analysis, indicating 100% physical availability of the system. The autonomous monitoring analyzed 139 times more samples compared to the currently used manual method. In addition to increasing sampling representativeness and automating the process, it increases the safety, quality, and productivity of granulometric analysis, eliminating the exposure of people in the mine and human bias in the analyses. Additional analyses were performed by correlating digitally centralized drill and blast data, data from autonomous drills and fragmentation results. Automated obtention of granulometric curves favors quick decision-making and optimization of blasts to achieve better results in productivity and cost reduction in the plant and mine operation. The autonomous fragmentation monitoring system met the need presented by the mine, proving to be a key tool in continuous improvement projects, including Mine to Plant.

Jan 1, 2024

By Richard Mainiero, James H. Rowland III

For many years there have been small scale tests available for evaluating the toxic fumes production by capsensitive explosives (DOT Class 1. l), but these could not be used with blasting agents due to the large charge sizes and heavy confinement required for proper detonation. Considering the extensive use of blasting agents in construction and mining, there is a need to determine the quantities of toxic ti,tmes generated by blasting agents. At the International Society of Explosive Engineers Twenty Third Annual Conference on Explosives and Blasting Technique in 1997, the authors reported on a facility for detonating large (4.54 kg), confined blasting agent charges in a controlled volume that had been constructed at the National Institute for Occupational Safety and Health’s Pittsburgh Research Lab’s Experimental Mine. Since 1997, this facility has been used to collect data on toxic fumes produced by the detonation of various ammonium nitrate/fuel oil (ANFO) mixtures and several cap-sensitive explosives. ANFO composition ranging from 1 to 10 percent (pet) tieI oil have been studied. As expected from previous studies, with an increase in fuel oil content the carbon monoxide production increases, while nitric oxide and nitrogen dioxide production decrease. The detonation velocity varies from 3,000 to 4,000 m/set for the 1 to 10 pet range of fuel oil content, suggesting that ANFO mixes with improper fuel oil content may appear to detonate properly, while their fume production differs significantly from optimum. The study also considers such factors as degree of confinement, water contamination, and aluminum content on blasting agent fume production. Results indicate that water contamination of the ANFO has little effect on carbon monoxide production, but causes significant increase in nitric oxide and nitrogen dioxide production. Decreasing confinement from Schedule 80 steel pipe to 0.4~mm thick sheet metal also has little effect on carbon monoxide production, but significantly increases nitric oxide and nitrogen dioxide production. Adding 5 and 10 pet aluminum to the ANFO had no clear effect on carbon monoxide, nitric oxide, or nitrogen dioxide production.

Jan 1, 2000

By Ery Wardhana, Fathur Rozaq, Jeff Averett, Nella Lubis, Carl Lager, Herry Saputra, Rudolf Sitorus, Relinda Sanistrya, Hormat Sinaga, Andhiko Maharjono

Efficient drill and blast operations are crucial for achieving optimal fragmentation, productivity, safety, and operational efficiency for the mining industry. However, conventional methods face significant challenges, including manual borehole marking and retrieval by survey teams, limited real-time data monitoring, excessive borehole collar deviation affecting blast quality, suboptimal drill productivity impacting person-hours and fuel usage, subjective judgment by drill operators on voids during drilling, and limitations in explosive charging design that do not match rock hardness. Rock hardness determination using lithological data from exploration models is often inaccurate due to the interpolation effect of wide drilling distances and depths, necessitating manual field verification using drill cuttings and historical blasting results. Furthermore, using single-density bulk emulsion throughout blast holes leads to suboptimal results due to varying rock properties. This study introduces an integrated approach that combines smart drilling technology with advanced emulsion technology to enhance drilling and blasting efficiency. The method utilizes smart drilling technology with GPS for precise borehole placement, Measure While Drilling (MWD) loggers, and real-time performance monitoring. Additionally, it integrates a smart Mobile Processing Unit (MPU) featuring a digital system and an automated gassing system (AGS). This setup allows for multiple emulsion densities within a single blast hole, customized to match the hardness index parameters determined from MWD data, addressing the challenges in drilling and blasting operations. The study evaluates the effectiveness of this innovative approach through comprehensive field trials and data analysis. While maintaining the digging rate according to production targets, key metrics such as drilling productivity, drilling accuracy, fuel consumption, powder factor, drilling and blasting cost, and fragmentation size were compared between conventional and new methods. Results showed a 56% increase in drilling accuracy, a 23% increase in penetration rate, a 19.6% increase in drilling productivity, and a 29% reduction in fuel consumption. This new method decreased the powder factor by 5.2%, impacting the drill & blast cost reduction by 2.3%. Moreover, fragmentation size improved by 12.8%, demonstrating the effectiveness of rock hardness-adjustable emulsion density in achieving better blast energy placement. In conclusion, integrating smart drilling and advanced emulsion technology significantly enhances drilling and blasting efficiency. This approach offers substantial cost savings and operational improvements, providing a strong rationale for adopting this innovative method in drilling and blasting activities.

Jan 21, 2025

By Pierre Auger, Benoit Levesque, Richard Martel, Guy Sanfacon, Louis-Charles Boutin, Marc-Andre Lavigne, Patrick Brousseau, Luc Trepanier, Louise Galarneau

Explosives used for blasting operations in civil engineering works, like construction of piping systems under roads, of pools, of houses and buildings can generate large volumes of carbon monoxide (CO). Carbon monoxide can represent between 1 to 3% of the gases produced by usual explosives. The production of 10 to 24 1 of CO by kg of explosives blasted is theoretically anticipated. CO is a gas that has no characteristic colour, smell or taste. It can migrate in the fractured rock of the blasted areas on fair distances, and then infiltrate in closed spaces like sewage systems, manholes, but also in basements of houses. In Quebec, in the last 10 years, 7 people were poisoned by CO in their houses to the point that they had to be treated in hyperbaric chambers. In the USA, many accidents have occurred and one worker died in a manhole. From the review of intoxication cases, the distance of migration of CO may reach 55 m if a conduit is present underground. Underground conduits broken by blast, tilling around underground conduits in road or house trenches, or fractured rock created by blasts between houses or between a house and a road, are the different pathways identified in the Quebec incidents. Field tests were performed at sites close to CO intoxication locations in order to evaluate the behaviour of CO in fractured rock following blasting operations. From these tests, the following conclusions may be drawn. The structural geology of the rock formation (schistosity, family of joints, fractures) plays a role in the direction and extent of gas migration in fractures generated when rock is blasted with explosives. The confinement of the rock can affect the quantity of gas migrating in the fractured rock. Significant concentrations of CO may persist in the fractured rock even 7 days after a blast. Advection is the initial mechanism of CO migration in fractured rock generated by the blasts or naturally occurring before the blast. The distance of migration with this mechanism is short (5 to 8 m). In trenches of muck (equivalent to tills under roads) the distance of CO migration by advection is 12 to 20 m. In the 2 to 3 days following the blasts, further CO migration up to 15 m is made by diffusion in the induced fractures, or up to 30 m in the trenches. To minimise CO production and migration in the fractured rock during blasting, special procedures can be applied by the blasting contractors: (1) do the complete excavation of the overburden before drilling and put mats for each blast; (2) do the complete excavation of the muck after each blast; (3) the last blasting should be the one for the private services entrance of the house and the excavation of the muck should begin at the junction between the road trench and the services entrance trench. Another technique consists in the pumping of interstitial air in the muck with a vacuum truck immediately after each blast.

Jan 1, 2002

By Enver Alan

In this study of applied explosives engineering the blasting applications are evaluated, which were carried out for research and development purposes at Yenisahra Station tunnels in Kartal Formation which was built with the aim of solving İstanbul's transportation problem within the framework of the Kadıköy-Kartal Metro Project. Twenty-four shots were made by using explosives in 60 blastholes that were drilled in the tunnel faces, which were located between and outside of two different faults. S

Feb 1, 2020

By Braden Lusk

This paper includes results from analysis of recorded Acoustic Responses of Structures to Blasting. The analysis was performed to determine specific characteristics of sounds experienced inside homes during blast events. Data was collected in a typical house within the Boone North No.2 Coal Surface Mine in Ashford, WV which was instrumented for several blast vibration and acoustic responses. The instrumentation consists of four acoustic microphones distributed throughout the internal areas of the house and three geophones buried near the house. Two additional channels collect the trigger signal and Air Blast information. For each blast event recorded by the system, the mine blast reports were used to obtain major blast characteristics such as distance from the blast to the instrumented house, weight of explosive used, number of boreholes, delays, and other important parameters. This information allowed study the relationship between the acoustic response and the blast design. From a database of 43 records, five records were chosen for complete analysis. These records were chosen based on distance from the blast to the house, and specific blast parameters. This paper presents the result of the relationship between the frequencies and amplitudes for the entire trace of acoustic records, the response due to ground vibration (GV), and the response due to air-blast (AB). Frequency content was obtained through Fast Fourier Transforms (FFT), using D-Plot software. The records have a typical shape that permits cutting and analyzing each part of the signal with respect to GV and AB separately. Some conclusions are reported concerning the relationship between blast parameters and acoustic response of structures.

Jan 1, 2009

By Remi Proulx, Ruilin Yang

The effectiveness of presplit in soft or fractured ground is hard to visualize or quantify. There have been many attempts by the blasting community to measure and quantify the effectiveness of presplit blasts. Various methods have been adapted by different researchers, and the results are debatable.

Jan 1, 2019

By Ricardo González Dumuihual, Carlos Scherpenisse

A monitoring campaign to record dynamic pressures generated by detonation of a single blasthole was implemented at Barrick Gold´s Pueblo Viejo Open Pit mine (PVDC), located in the Dominican Republic . Pressure amplitudes beyond the dynamic compressive strength of the electronic detonator´s capsules have the potential to damage these electronic devices, generating misfires along with all the associated risks and entailed safety implications. In most instances, misfires generated from high dynamic pressures are a direct consequence of drilling deviations resulting in blasthole distances smaller than originally designed.

Feb 1, 2020

By AK Chakraborty, AK Raina

Burden of drill hole is third most sensitive parameter effecting the ground vibration in blasting apart from maximum charge per delay and distance. Various types of burdens can be seen in practical bench blasting situations. Burden can be expressed as drilled burden and initiation burden. Drill holes may have various front row burdens (toe burden), which may be different from the designed burden. In order to ascertain the impact of front row burden as well as the initiation burden on intensity of ground vibration and air overpressure experiments were conducted in sandstone overburden benches of an opencast coal mine and limestone quarry. Blast trials were carried out in cognisance of both drill and initiation burden while keeping all other parameters constant. Effect of front row burden was also extensively studied by keeping almost all other parameters constant. The results of the study reveal that there is substantial influence of front row burden on the vibration and air overpressure. The statistical analysis of vibration and air overpressure data with drilled burden and initiation burden gives significant evidence that the level of peak particle velocity of vibration (Vmax)) is reduced by reducing effective burden with modification of initiation. Data analysis carried out for air overpressure versus initiation burden shows that reducing effective burden with modification of initiation results in increasing the level of P. The study reveals a qualitative assessment of the influence of burden on the blast induced vibration and air overpressure. The study also recommends to modify the initiation pattern to reduce the effective burden in order to reduce the vibration, without disturbing the fragmentation.

Jan 1, 2004

By Mathias Jern, Ruilin Yang

A blast vibration model has been developed that simulates effects of almost all blast design parameters on the blast vibration peak particle velocity (PPV) from a production blast with multiple blastholes at a given point of interest in the rock. The velocity of detonation (VoD), initiation points, explosive types (density, VoD, energy), charge decoupling, and decking in each blasthole are simulated along with other blast design parameters. The information from signature hole blast vibration and the blast design are the input to the model. The model can be used to assess blast damage in proximity of blastholes as well as far field vibration PPV.

Jan 1, 2019

By A. S. Romphf, C. K. McKenzie

Recent full-scale field studies involving single-hole charges fired to free faces under a wide range of operating conditions have delivered precious insights into airblast characteristics and propagation. The field tests involved production blasthole diameters in the range 89 to 406 mm (3 ½ to 16 in), bench heights in the range 9 to 24 metres (30 to 79 ft), burden ratios (burden/hole diameter) in the range 14 to 51, stemming ratios (stem height/hole diameter) in the range 11 to 36, explosive types of ANFO, heavy ANFO and pumped emulsion, and both solid-column and double-decked charge configurations. Around 700 measurements of peak amplitude and wave shape were made in all directions (0 to 360 deg) from the free face, from 38 single-hole tests in nine North American operating quarry/mine environments. The most striking observations were the strong dependence on directionality of the wave propagation parameters and wave frequency, the consistency of wave shape which resembled the modified Heelan wavelet, and the occasional appearance of distinct, multiple pulses from single events, shown to be echoes/reflections from quarry faces. In-hole deck charging failed in this study to achieve expected peak overpressure reductions, with the peak overpressure levels in Pascals/psi/millibars being approximately 40% higher than the as-charged weights. Inter-deck delay times in excess of around 25 ms are required for effective reduction of peak overpressure levels from front-row holes. Simple linear-superposition models based on synthetic wavelets applied to large production blasts produce composite waveforms which capture the important features of the actual pressure-time history, and correlate well with measured waveforms.

Jan 26, 2026

By Luis Huaroc, Augusto Sotomayor, Erick Rodriguez, Paulo Fernández, José Ricaldi, Luis Alejandro

The application of the Kuz-Ram model for the prediction of fragmentation is used worldwide, in Coimolache Mine it was used to determine blast domains and optimize the process by obtaining drilling patterns that meet a required X80 and reducing the uncertainty of drilling.

Feb 1, 2020

By W. De Graaf, C. Mkumbo

Bulyanhulu Gold Mine Limited (BGML) commissioned a project of sinking a Bulk Air Cooling Shaft during its programme to improve the ventilation system on the mine. As part of this project, a ventilation drift had to be developed and holed into the Main Shaft at 4920 Level. AEL Mining Services (AEL) were requested to provide a technical solution, which included monitoring of blast induced vibrations and to design drilling and timing plans to ensure blasting activities on the vent drift were conducted without disrupting the main shaft’s infrastructure.

Jan 1, 2011

By C. Mick Lownds, Dale S. Preece, Ali Bhuiyan

FDM (Fracture Density Model) is a three-dimensional mechanistic model of blast induced rock fragmentation. FDM uses several computational mechanics algorithms to simulate the effect of blasting in different rock types. Earlier, FDM was successfully exercised to simulate 29 small scale shots from the United States Bureau of Mines (USBM), and 6 full-scale bench blasts at the Bararp dimensional stone quarry in Sweden. Excellent agreement was obtained for those shots, and the results were documented in earlier publications. One of the drawbacks of previous ver- sions of FDM was its inability to predict the fines, specifically in Bararp quarry simulations. Ac- curate predictions of fines can be very useful in reducing energy consumptions during down- stream comminution processes and improve the mine-mill operation efficiencies. In this paper, we propose a newer algorithm that can predict the fines as well as the coarse fragments in Bararp with reasonable accuracy. The model was also applied to an open-pit Copper mine with heavily jointed rocks, and it produced very good fragmentation predictions for the full range of fragment sizes. Comparisons with the sieved fragmentation data (for both Bararp stone quarry and the open- pit Copper mines) show great potential for this updated version of FDM in modeling the entire range of fragment size distributions in mining and quarrying applications.

Feb 6, 2023

By C. Zuniga, S. Combrinck, C. Peters

Agnico Eagle Gold have partnered with Enaex Australia at their Fosterville gold mine to leverage a combination of drill and blast technologies to optimise underground development mining. The mine is the first site globally to collaboratively develop and trial Enaex SWIFT electronic development detonators, which utilise a novel approach to the user interface, simplifying implementation and enabling the benefits of electronic initiation without the complexity of a conventional system. This has been combined with the use of a Sandvik 422i smart jumbo, and the Enaex underground emulsion charging unit with the capability to tailor the delivery of explosives as required and report on a hole-by-hole basis. The combination of these technologies enables full engineering oversight of the development cycle, in turn enabling optimisation of this process in a historically conservative application. The methodology for leveraging these technologies is to bore a controlled and defined blast pattern through using a smart jumbo, load the blast holes utilising lace loading to deliver a desired quantity of ammonium nitrate emulsion per hole, with the ability to reduce chargeweight for perimeter control, and utilising Enaex SWIFT electronic detonators with flexible template type pre-defined delays to initiate the blast holes. Subsequent to firing and excavation the performance of the blast in fragmentation, advance efficiency, and overbreak and underbreak is measured and reviewed. This is then used to optimise the development cycle and apply to other parts of the mine.

Feb 6, 2023

By Emily Johnson, Catherine Johnson, Ben Sonpon, Kelly Williams

The effect of length to diameter of the detonator is compared using Ansys/Autodyn 2-D simulations, the results of which are validated experimentally. It was found that higher pressure comes with a larger diameter, because it will result in more explosive energy being allocated out the end of the detonator.

Feb 1, 2020