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By G. Walsh, L. Wolkovitch, A. Savage, V. Romero, T. Zimmerly, G. Imahara, J. Hyneman, K. Byron, D Tapster, S. Belleci, J. Metzger, M. Stanley

Testing was conducted at the Energetic Materials Research and Testing Center for the MythBusters on three separate occasions. This testing included (1) an experiment designed to create diamond from graphite using the shock and pressure of a detonation, (2) the flattening of a car using a steel plate driven by a rocket sled, and (3) the bifurcation of a car also using a rocket sled. All tests were successful; diamond was produced following the detonation of ANFO, and extracted from a graphite / cobalt matrix. A plate was accelerated to 646 mph (1040 km/hr) using a two-stage sled system loaded with 5” (12.7 cm) high velocity aircraft rockets (HVAR) into a car, which was subsequently demolished. Finally, a steel wedge was pushed to 541 mph (871 km/hr) by a one stage sled using HVAR rockets, and was able to cleanly cut a target car in half.

Jan 1, 2010

By Chris Searing

An underground room-and-pillar limestone mine in Western Missouri acquired a new primary crusher, physically larger in every dimension than the unit it replaced. Due to the space constraints within the mine, resetting the truck dump and feeder to account for the larger crusher was unfeasible. Mine management determined the most practical solution was to increase the available area for the new crusher via blasting. Fitting the new crusher into the existing area required the removal of 6 feet (1.83m) of limestone from the original floor grade. Blast parameters had to be designed to effectively break this shallow depth of rock while controlling movement to avoid contacting the mine back 23 feet (7.01m) overhead, an apron feeder 13 feet (3.96m) above the southern extent of the area, and the original crusher which was still in place 15 feet (4.57m) from the first pattern. Additionally, work needed to be completed within an aggressive schedule set forth by the mine, allowing little room for delay or error. This paper will examine the efforts taken to safely and effectively blast the rock while protecting nearby equipment and integrity of the mine back. Subjects covered will include blast design, adjustments made to account for drilling and equipment-related constraints, and how seemingly small changes in load parameters can significantly impact performance with small-diameter blast design.

Feb 6, 2023

By Maja Franjic, Ian Tolliday, Chris Collins, James Wiltshire

Ammonium Nitrate Emulsions (ANE) are a large segment of the explosives market for the mining industry. These emulsions are generally designed to be very stable but when breakdown does occur, removal of the resulting thick, crystallized material can be difficult, hazardous, time consuming and costly. A heavily crystallized emulsion cannot be pumped, so manual removal often becomes necessary. Buildup of semi-solid layers of crystallized emulsion can occur in bulk storage tanks or in truck compartments. In these situations, a manual cleanup involving hazardous confined-space entry and a significant amount of downtime is usually required. Once the crystallized emulsion is removed from the equipment, there is very expensive disposal of the resultant waste via a licensed trade-waste company. A much more desirable solution for dealing with waste emulsion is to completely break the emulsion, allowing the oxidizer and fuel phases to separate into two distinct layers. These layers would then be readily pumpable and could be disposed of much more economically. It may even be possible that the separated oxidizer phase could be repurposed as fertilizer and the fuel phase could be used to manufacture granular ANFO explosives. There are some existing products on the market for breaking emulsion explosives, but these generally need a high degree of mixing into the emulsion to achieve adequate breakdown. The aim of this study was to identify surfactants systems (demulsifiers) capable of effectively breaking a range of waste emulsions with minimized agitation. This paper describes the development and performance testing of novel demulsifier products. The test work involved a comprehensive series of laboratory screening tests, where the demulsifier formulations were optimized. A highly efficient formulation was identified, and field trials were conducted on real world, full-scale waste emulsions. Results will be presented that demonstrate a viable solution for the disposal, and potential re-use, of waste ANE in the explosives industry.

Jan 21, 2025

By Jair Alarcón, Lucas Steffen, Leopoldo Muñoz

Flyrock is one of the most significant hazards associated with blasting in open pit mining, especially for blasting operations near communities. Flyrock can lead to severe injuries, fatalities, and property damage, compromising the license to operate. For this reason, defining exclusion zones is critical to ensure the safety of people and equipment. A very large radius will reduce the risk of flyrock; however, excessive exclusion zones can significantly impact the productivity of the operation and, in some cases, compromise the extraction of ore in critical sectors. Many mine sites use distances derived from pre-established standards, experiences from other mines, or still use simple methods for analysis, like recording blasts with a terrestrial camera and performing deterministic calculations to determine exclusion areas, applying an arbitrarily safety factor for people and equipment. In this paper we present a new approach that allows the calculation of the exclusion zone by measuring critical flyrock parameters with a high degree of accuracy through a new video analytics technology, this data then is used as input to calibrate probabilistic flyrock models to have more robust calculations, allowing optimized and safe exclusion zones. The proposed methodology leverages high-accuracy data and continuous monitoring to dynamically adjust D&B designs and exclusion zones, ensuring maximum safety without unnecessarily restricting operational efficiency. A case study is presented where the application of these new digital technologies allows precise prediction and control of flyrock trajectories, enhancing the accuracy of exclusion zone boundaries. In this case we successfully reduced the exclusion zone radius to 100m, allowing the ore extraction in a critical region close to the community safely. The study shows notable improvements in safety and productivity, including zero flyrock incidents and enhanced protection for nearby communities. The adaptive nature of these digital tools offers scalable solutions for various blasting environments. The paper concludes by recommending the integration of these tools into standard blasting protocols, highlighting the potential for widespread adoption in the industry to mitigate flyrock risks effectively.

Jan 21, 2025

"Large scale open pit mining and quarrying operations dictate safe and reliable pit wall stability. The current approach of employing the particle velocity-scaled charge distance approach to estimate and minimize damage to residential structures is considered inadequate to protect rock slopes. This study utilizes close-in blasting vibration data as input to an advanced 2D numerical code to study its applicability to serve as a predictive tool in terms of blast-induced rock slope failure. Two tri-axial accelerometer stations, consisting of high-frequency and high-amplitude (20 kHz, 100g) sensors, located within ~100m of the blast, but at two different bench levels, were used to monitor a production blasting in a quarry. The production blast consisted of double-decked explosive loads in 155 mm (6 in) diameter holes, with an inter-deck delay of 42 ms, and each deck consisting of 130 kg (285 lb) of emulsionexplosive. The blasting vibration data obtained at the two bench levels were critically analyzed, and thevibration results served as input to the numerical model consisting of a single rock block with a 45 degree persistent joint plane but with specified strength properties, significantly different from that of the intact rock. The model was able to characterise progressive accumulation of damage in the form of micro-cracks along the joint surface as a function of the vibration load from successive explosive decks. The results showed that such a numerical model can serve as a very good diagnostic and predictive tool, when backed up by careful vibration monitoring and further supported by detailed slope monitoring."

Jan 1, 2017

By Alejandro Ferrada Vergara, María Jesús Barros Godoy

The need for a basic method for selecting explosives based on rock mass or intact rock properties for mining and construction arises from the limited consideration given to these factors when choosing among products and also an implicit overestimation of the explosive power to fragment the rock. This study highlights the importance of evaluating different properties such as rock strength, deformation, fracturing, detonation velocity and energy release when selecting explosives. The concept of characteristic impedance, which considers rock strength against shock waves generated by explosive detonation, is introduced. Understanding this concept is crucial for assessing explosive behavior according to various rock types. The study concludes with a practical guide table that categorizes rock properties and provides recommendations for selecting explosives based on rock mass and rock properties. However, it is important to consider other relevant factors, such as the presence of water or nearby instabilities, which can influence the final choice of explosives.

Jan 21, 2025

By Tom Watts

The practice of pumping bulk blasting agents is regulated by many agencies around the world. The explosives manufacturers have done an excellent job of hazard and operability studies allowing criteria to be established for the safe pumping of water based blasting agents. The challenge of a Bulk Trucks or Mobile Manufacturing Units (MMUs) manufacturer is to take the objectives of the regulatory agencies and the explosives manufacturers and responsibly design and build MMUs that are safe, compliant, and cost effective without compromising serviceability.

Jan 1, 2011

By Brad Bockey

Whether you are a driver, blaster, or are in charge of filing, you must recognize the importance associated with DOT-required recordkeeping. As various agencies become intertwined with rules governing the explosives industry, the records we produce must be as accurate as possible. The time is right for reviewing your paperwork process from start to finish.

Jan 1, 2011

By James Stuart

A man died when the primed charge he was holding against his chest exploded. He was doing legitimate explosive work, and he was following all the safety procedures he had been taught. He and his colleagues had done this, thousands of times previously, with no ill effects.

Jan 1, 2007

By D. Scott Scovira, Thomas Gustavsson

The potential of hydrogen peroxide explosives was introduced to Thomas Gustavsson and Robert Håkland by Dr Miguel Araos through his development of hydrogen peroxide gel compositions (HPG). In 2020, Thomas and Robert developed a concept project with Boliden Minerals and received Swedish government funding to evaluate HPG technology in a mine environment. The project showed HPG reacted violently with mine mineralization and concluded that HPGs did not offer a commercial solution due to safety concerns. Thomas and Robert engaged with Stefan Nilsson to develop hydrogen peroxide emulsion (HPE) compositions and the process techniques to manufacture them. In 2021, laboratory work produced a promising low carbon intensity, nitrate free, ammonia free, emulsion formulation based on industrial grade hydrogen peroxide and a fuel-emulsifier phase. Design and construction of an HPE pilot plant and underground charging unit commenced. The manufacture of hydrogen peroxide emulsion shares several similarities with the production of nitrate-based emulsions in that the plant is a facility to blend a strong oxidizer solution with a liquid fuel phase into a finished emulsion. A key differentiator between HPE and nitrate-based emulsion is that the manufacture of HPE is a cold production technology in that neither the oxidizer phase (HP) nor the fuel-emulsifier phase requires high temperature heating to prepare raw materials. A successful proof-of-concept HPE evaluation ran from April 2022 to October 2022 at Boliden’s Kankberg underground mine in Sweden. This evaluation demonstrated HPE technology's safety, performance, production, handling, and indicative environmental benefits.

Jan 21, 2025

The quiet banks of the Maumee River in Toledo, Ohio, received a wake-up call July 16 as two smokestacks in the Marina District were leveled with dynamite. B&B Wrecking, Inc. of Cleveland contracted the project with the city to bring down the twin stacks, both measuring over 250 feet tall. The structures were part of the Toledo Edison Steam Plant and were erected nearly a hundred years ago. A week’s worth of preparation went into final planning, drilling and loading holes with over 80 pounds of explosives. The felling went precisely as planned as onlookers cheered as the stacks were reduced to rubble.

Jan 1, 2015

By Carl E. Jones

This presentation discusses the properties of the two-component explosive, KinePak, and how it is used by the utility industry.

Jan 1, 1978

By David Flores, Benjamin Cebrian

This paper describes extensive engineering approaches to achieve both dilution control while not hurting fragmentation in the very hard, massive ore sections of a mine case study. Ore Tracker microchips are used to correlate performance of these designs at the SAG mill (bottleneck of this specific operation). Another gold mine uses the same technology to detect when and where operational dilution is happening. The system tells where flagging of the different ore bodies has been followed in order to detect which operators pass the excavation limits beyond ore control flagging.

Feb 1, 2020

By Adrian Moore, Alan Richards, Andrew Brodbeck

Structural blast vibration limits should be based on the strength of the structure, the stress induced by blasting, and a responsible factor of safety. In this paper a methodology that uses direct strain measurements to determine the stress induced by blasting is described

Feb 1, 2020

By E. McCullough, D. Preece, M. Ortel

The mining and oil industries employ techniques such as geologic mapping, core drilling and electromagnetic field techniques to explore for new deposits. New discoveries of major near-surface ore bodies are becoming progressively rare and traditional exploration methods are unable to resolve ore bodies deeper than about 500 m (1640.4 ft). Consequently high-resolution seismic reflection techniques show great potential for exploration to much greater depths down to almost 3 km (1.9 mi).

Jan 1, 2013

By Tacio Ferreira

A surface copper mine in the Western United States faced challenges in recovering rock and ore from final walls because of geotechnical constraints that require restrictions on methods for loading blastholes adjacent to the pit boundaries to preserve wall conditions. The operation had been using the same drill and blast designs for years. With changing geology, such as harder rock, as mining progressed, material was being left unmined in final walls because of poor breakage. The amount of unrecovered, unprocessed ore was estimated at approximately 380,000 tons a year generated from an average of 60 final wall blasts performed annually. The mine engineering team and Dyno Nobel engaged to minimize the amount of material left on the final pit walls. In this paper we present how we collected data, reviewed design standards, and found opportunities to improve ore recovery from pit final walls without increasing drilling and blasting costs. The results collected from implementing the new design on two benches showed the potential for extra revenue of approximately $3.6 million generated annually from reducing final wall unrecoverable underbreak by nearly 71% on the mine’s highwalls.

Jan 21, 2025

By Charles Clark, Mark Mukhija, Jaime Klein

Comminution – the reduction in size of solid materials – is the most energy intensive component of the mining process (Bauer, 2015). It is estimated that comminution consumes around three percent of all electricity generated in the world (Ceecthefuture.org, 2017). On an energy equivalent basis, downstream processing consumes six times more energy than drilling and blasting (Kanchibotla, Sarma et al., 2014).

Jan 1, 2018

By Jacqueline Berendzen

Summer internships are a great way for students to explore different career paths in the industry and get first hand experiences with potential employers. As a junior in mining and explosive engineering, my 2009 summer internship gave me a behind the scenes view of the actual workings of an explosive company and the role they play in the mining industry.

Jan 1, 2010

By G. A. Walsh, M. Timm, S. M. Geerts

This paper will discuss the effectiveness and the general use of improvised shaped charges. Testing was conducted by the New Mexico Tech Student Chapter of ISEE and held at EMRTC. The first series of tests conducted was to illustrate the performance of different features of the shaped charge. A PVC pipe filled with C4 with no cavity, PVC with an unlined conical cavity, PVC with a copper lined conical cavity and no standoff, and lastly a PVC pipe with a copper lined cavity and a 1.5 cone diameter standoff.

Jan 1, 2010

By Jhon Silva

"Signature Hole and Waveform Superposition techniques used to predict and control mine blast ground vibrations require a clearly defined information collection configuration. The collection of this information determines the scope and success of the ground vibration prediction. Application of the Improved Signature Hole technique using the Silva-Lusk equation requires the collection of at least two informational elements from any specific production shot. The first required element is a signature waveform, and the second element is the overall production blast waveform. The signature waveform depends on detonated charge variables such as the amount of explosive in use, use of decking, the possible detonation of several holes at the same delay, and many others. The production blast waveform is beneficial to the Improved Signature Hole methodology when used to calibrate the model, and toobtain accurate vibration predictions for different timing configurations."

Jan 1, 2017