IMCET 2017 / ANTALYA / TURKEY / April 11-14

Blasting Optimization in a Phosphate Rock Mine in Brazil

A. C. Silva¹, L. T. B. Mendonça¹, P. A. A. Martins², R. A. G. Silva², G. Birro², H.

C. S. Nadler²
1 Federal University of Goiás, Catalão, Brazil
2 CopeBrás, Catalão, Brazil

ABSTRACT The cost reduction in mines is always welcome and a permanent goal all around
the world. In search of better fragmentation in blasting with the use of explosives and an
optimization in the subsequent stages of comminution, tests in different mine fronts in a
phosphate rock mine (Chapadão Mine, located in the municipality of Ouvidor, state of Goiás,
Brazil) were carried out. The tests were realized modifying operational parameters of the blast
layout plan such as stemming, blast layout and explosive type. After basting digital images
analysis using Split Desktop 3.1 were conducted to evaluate the fragmentation of the rocky
massifs and its size distribution. It is important to highlight that the comparisons in this study
were realized focusing the reduction of the particle size distribution over the P80 for each
blasting.

1 INTRODUCTION
This paper presents a project developed at
Chapadão mine, in the municipality of
Ouvidor-GO Brazil, coordinates 18°08'S
latitude and 47°48'W longitude, the figure 1
presents the map with the location of the
municipality. The Copebras Industries Ltd
one companies of the CMOC international’s
portfolio. The Copebras phosphate mine has
been in operation since 1976 and has a target
for the production of 1,200 tph of crushed
ore. Currently in operation, there are two
processing plants in operation in Ouvidor
and two chemical plants. In specifically, the
two chemical plants are located in the city of
Catalão-GO and in Cubatão-SP. Moreover,
the Copebras main products are GTSP, SSP, Figure 1. Location Ouvidor-GO.
TSP fertilizers and dicalcium phosphate, one
of the components utilized in animal feed. The Copebras Phosphates Mine is located
Beyond these products, by-products such as not in the Catalão I alkaline complex, but
barium sulphate (Barite) and Niobium are inserted in the tectonic context of the
obtained over the process. Igneous Province of Alto Paranaíba. This
mineral province consists of a shallow
alkaline ultramafic magma chamber, with
polyphase evolution, with predominance of
bebedourites and phlogopitites in the borders

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A. C. Silva, L. T. B. Mendonça, P. A. A. Martins, R. A. G. Silva, G. Birro, H. C. S. Nadler

and phoscorite and nelsonite veins in the (1980), the use of explosives is common in
centre, stock works of carbonatites and mining activities that precede the mining
picrites cutting all lithologies, exemplified in stage, is a fast and economical method as
figure 2. The phosphate ore from the they produce a high-energy release in
Chapadão mine results from a supergenic fractions of seconds and can contemplate
residual concentration on ultramafic alkaline bulk large to be disaggregated at one time.
phoglopitized rocks, intruded by rocks from
Table 1. Lithotypes tenacity scale.
the series phoscorites and carbonatites
(GIBSON et al., 1995).
Friable

Tenacity (+)
Hardest Semi-Compact Apatite
Hardest Compact Apatite
Hardest Semi-Compact Silexite
Hardest Compact Silexite

The rock blasting is a crucial operation as it

has a direct influence on downstream
process. As the first step of rock
fragmentation, where the in situ rock is
Figure 2. Stock work of dolomitic (whitish) reduced resulting in best conditions for the
carbonatite dikes in phoscorite (grey) next operations that most commonly are:
showing the incidence of dikes and veins of loading, hauling, ore crushing, milling and
different compositions. mineral processing (STIEHR, 2011).
Due to the high relevance of blasting, the
Three main different series of rocks occur at expected results for the phosphate rock at
the Copebras mine: the phoscorite series is Chapadão mine are defined to achieve a P80
represented by phoscorites, nelsonites, value lower than 400 mm, which means that
apatitites and magnetitites; the carbonatite 80% of the blasted fragments passing in 400
series is represented by dolomite carbonatite mm, the grizzle dimension of the primary
and calcite carbonatite; the bebedourite crusher system. In order to achieve this
series is represented by metasomatic result blast designs must be accurately
phoglopitites, derived from metasomatism of defined and followed.
primary ultramafic rocks and by late-stage Aiming to achieve the target, the blasting
conduitbreccias. (PALMIERI et al., 2011). team has been assessing in detail the benefits
Due to the large amount of The NW portion of changing different parameters of the blast
of the dome, mainly in the Phosphate from plan considering the geological
Copebras and in the two niobium Mining, it characteristics of each blast domain and
is suggested to adopt the name of carbonatite measuring the fragmentation using the
phoscorite I complex, as it is used in Kovdor, software Split Desktop 3.1.
on the Kola island (KRASNOVA et al.,
2004).The table 1 shows the lithotypes 2 METHODOLOGY
according to their tenacity rate. To ensure a structured and analytical
The material from the crushing is used in approach, the technical team have defined
the formation of two piles homogenization, which historical data should be used and
one of 64,000 tons and another 80,000 tons compared with the field tests following as
of maximum capacity, the composition of the main premise the changing in only one
these piles ranges from 20 to 50% of parameter per time. The data were organized
detonated material. According to Clark
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in a standard database elaborated by the blast Table 2. Fixed Parameters for tests
team comprehending 20 variables, with 10
blast plan parameters and three blast Key Fixed parameter Value
Performance Indicators (KPI’s). The main Hole Diameter (m) 0.1016
performance indicators are the P80 and the Bench Inclination Angle (º) 0
blast unit cost (US$/t).
Bench Height (m) 5.00
The principal target of the Project was a
Surface Delay Time (ms) 17
20% reduction in the rock blasting unit cost.
For this purpose, 56 testing blasts were Depth Delay Time 500
realized between 13/06/2016 and Booster (g) 225
23/11/2016. Some of these tests were peers Stemming Material Rock Dust
compared fixing all variables and changing ANFO 0.80
Explosive
only one parameter per time comprehending Density (g/cm³) Emulsion 1.15
three operational steps as showed on the
flowchart in figure 3. Each step was
composed by two tests that included two
distinct blasts totalizing the quantity of six
tests and nine blasts.

• Explosive Type
1

• Stemming Size
2

• Drilling Mesh Figure 4. Example of tie-in sequence.

3
Figure 3. Test Steps.
Table 2 shows the fixed parameters. The tie-
in sequence defined was a closed diagonal or
closed “V” as is showed in figure 4 and did
not suffer any change during the tests period.
However other parameters were changed
according to it respective test, but only
changing one parameter per time fixing it for
post analysis.
The changed parameter will be always be
indicated in the last line of its respective
tables.
2.1 Explosive Type
The first step of the tests was planned
exclusively by a comparison of the granular
explosive ANFO 3500 and a pumped
emulsion with a detonation velocity (VOD)
about 50% higher than the previous one.
Table 3 present tests A and B and their
respective results (blasts 1, 2, 3 and 4).
2.2 Stemming Size
The second step was compounded by the
assessment of the blasting results using
different sizes for stemming.
The goal of this kind of evaluation is to
ensure that the energy and gases from the
explosives detonation are confined, avoiding
energy losses in the hole collar region, what

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A. C. Silva, L. T. B. Mendonça, P. A. A. Martins, R. A. G. Silva, G. Birro, H. C. S. Nadler

would affect negatively the rock On table 5, the tests “E” and “F” are
fragmentation. presented and its respective blasts. The
presented blasts 2, 5 and 8 were already
Table 3 – Tests A and B
showed on tables 2 and 3; however, the focus
Test A Test B
on this step is the comparison of a different
Number variable.
1 2 3 4
Blast
Date Blast 10/06 11/07 06/10 24/10 Table 5- Tests E and F
Number
248 143 129 143
Holes Test E Test F
Drilling Number
5.20 5.20 8.75 8.75 2 8 5 9
Mesh (m²) Blast
Sub Date Blast
0.50 0.50 0.30 0.30 11/07 03/08 21/07 04/08
Drilling
Number
Hardest Hardest 143 245 132 170
Hardest Hardest Holes
Semi- Semi-
Litothype Compact Compact Sub
Compact Compact 0.50 0.50 0.50 0.50
Silexite Silexite Drilling
Silexite Silexite
Stemming Hardest Hardest Hardest Hardest
1.40 1.40 2.00 2.00 Litothype Compact Compact Compact Compact
Size (m)
Loading Silexite Silexite Silexite Silexite
453.54 651.97 215.05 309.14 Stemming
Rate (g/t)
1.40 1.40 2.00 2.00
Explosive Size (m)
ANFO Emulsion ANFO Emulsion Explosive
Type
Emulsion Emulsion ANFO ANFO
Type
Loading
Table 4 – Tests C and D Rate (g/t)
651.97 387.46 377.95 224.61
Test C Test D Drilling
5.20 8.75 5.20 8.75
Number Mesh (m²)
5 6 7 8
Blast
Date Blast 21/07 27/06 01/08 03/08 2.4 Digital Images Analyses
Number
132 235 253 245
Holes After the three steps, the natural sequence of
Drilling
Mesh (m²)
5.20 5.20 8.75 8.75 the assessment was peers comparisons
Sub among blasts taking in to account the same
0.50 0.50 0.5 0.5
Drilling variations on blast design parameters.
Hardest Hardest Hardest Hardest As the focus, the team recorded the total
Litothype Compact Compact Compact Compact
Apatite Apatite Silexite Silexite
explosives costs by blasted tonnage, the P80
Stemming
results, which quantified the rock
Size (m)
ANFO ANFO Emulsion Emulsion fragmentation differences and by the end, the
Loading
377.95 453.54 344.40 387.46 crushing plant productivity was inferred
Rate (g/t)
Explosive using the amount of ore directing passing
2.00 1.40 1.80 1.40
Type through the grizzle.
The ideal target defined for P80 was 400
2.3 Drilling Pattern mm. This value was defined accordingly the
dimensions of the grizzle opening that feeds
For the last step of the Project, a drilling
the primary crusher at the crushing plant. To
pattern expansion was defined resulting in a
ensure that most of the blasted fragments
powder factor reduction. The expansion
achieved the expected result, photo analysis
presented very satisfactory results achieving
were token at the muck piles (blasted ore)
the expressive number of 40% compared
using a digital camera and the images treated
with the average pattern used in the first
in the Split Desktop software.
period of 2016.
The muck pile pictures were acquired
immediately after the blasts and imported to
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IMCET 2017 / ANTALYA / TURKEY / April 11-14

the software respecting the constraints such

as lack of luminosity, correct angle and
scale. The two scale reference spherical
objects used have 25.40 cm of diameter and
were positioned accordingly the guidelines
and after acquisition, the images were edited
and delineated. The quantity of images
acquired for each blast variated with the
dimensions and other characteristics of the
blasted ore; however, the range was limited
by 4 to 6 pictures that best represented the
muck pile following a zigzag pattern through
the blasted muck pile, as is showed in figure (a)
5.

Figure 5. Correct strategy to get images from

the blasted rock.
After carefully follow the previous steps, the
taken images were imported, edited and
delineated in the Split Desktop software, an
example is showed in figure 6, where is
presented a comparison among the
delineated and non-delineated image.
The process of photo analysis is ended
when the previously described edition
process is made for all selected pictures and
the set of all results is condensed to build the
general particle size distribution (PSD) curve
that represents the analysed blast. By this
curve, the amount (percentage) of passing
particles for a determined size was indicated
in a millimetre scale, configured in the
software.
(b)
Figure 6. (a) Blasted muck pile and (b)
Delineation of blasted fragments.
3 RESULTS AND DISCUSSION
The results originated from the blasts were
assessed in terms of cost variations, P80
results from the PSD and real powder factor.
A pre-estimation of the powder factor for
each blast is presented on tables 2, 3 and 4,
however this variable can be changed for
operational reasons, that is why were
considered only actuals powder factor
avoiding the impacts of in field variations.
The vertical line in the position of 400 mm
highlights the defined target.
3.1 Tests A and B
Table 6 summarizes the results for tests A
and B, which compares fragmentation and

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costs results after the change of explosive (7,000 m/s) can achieve best results against
used in the column. ANFO, but is important to mention that both
In this test, there were a significant results are below the proposed P80 target of
powder factor reduction where around 48% 400 mm.
(334.30 g/t) less explosives were consumed There is an important consequence related
on blast 1. It can be explained looking with the quantity of material that passes
exclusively to the type of explosive, as in directly through the grizzle without the
blast 2 was used emulsion that has a 30% second break by the hydraulic hammer. This
higher density compared with ANFO process can result in delays and increase the
(ammonium nitrate and fuel oil) and the trucks cycle time (waiting time) and for
characteristic of fill all spaces in the hole. some moments, the oversized blocks are left
Figure 7 shows the respective PSD curves to receive a secondary blast in the pit.
from tests 1 and 2. Therefore, it is possible to conclude that 82%
of the fragments on blast 1 passed directly in
Table 6. Tests A and B results
the grizzle while on blast 2 the number was
Test A Test B
90% that is, both blasts had an excellent
Number
productivity because the major volume of its
Blast
1 2 3 4 fragments did not ask for a second breakage.
Loading
359.84 694.14 217.17 369.74
As the last assessment, the total blasts
Rate (g/t) costs were compared and observed that blast
P 80 (mm) 383.16 290.63 254.54 359.74 1, despites its small advantage in terms of
< 400 mm 82% 90% 95% 85% fragmentation and productivity, presented a
Cost
Variation - + 45% - + 40%
45% higher cost than blast 2. This was
($/t) considered an extremely elevated variation
indicating that the utilization of emulsion is
economically unfeasible up to now.
On figure 8, the PSD curves for blasts 3
and 4 are showed, both regarding test B.

Figure 7. PSD curves for blasts 1 and 2.

Regarding fragmentation, the P80 from blast

2 was more satisfactory, resulting in a
fragmentation around 24% (92.53 mm) Figure 8. PSD curves for blasts 3 and 4.
inferior than blast 1. The litothype of this test
was compact silexite, which represents a Analysing the results from test B it is
high tenacity when compared with the others possible to conclude that the powder factor
litothypes presented in the mine. However, on blast 4 was around 41% (152.57 g/t)
the high detonation velocity of the emulsion
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IMCET 2017 / ANTALYA / TURKEY / April 11-14
higher than on blast 3, which is justified by
the same conditions mentioned on test A.
The fragmentation on blast 3 showed a
better result, 39% (105.22 mm) lower than
the fragmentation on blast 4. On this case,
the geological litothype presents a lower
resistance, indicating that ANFO is more
efficient for blasting this kind of rock as
suggested by (Jimeno et al., 2003).
The productivity on blasts 3 and 4 were
respectively around 95% and 85% of
passing, highlighting the very significant
result originated from blast 3 where only 5%
of the fragments did not passes directly
through the grizzle.
The total blasts costs variation were 40% as
blast 4 presented a higher cost.
Test B presented the best results with
ANFO utilization in all analysed criteria,
which means a better fragmentation,
productivity and lower cost.
Comparison between both tests A and B
presented significant advantages for the use
of ANFO, mainly in terms of costs, where
was achieved up to 40% of reduction.
Regarding fragmentation, all blasts achieved
the proposed target.
3.2 Tests C and D
Table 7 present the results of tests C and D
and its respective performance indicator,
including the P80 showed in the PSD curves
in figures 9 and 10.
Table 7. Tests C and D results
Test C
Number
5 6
Blast
Loading
694.14 359.84
Rate (g/t)
P 80 (mm)
219.41 351.33
< 400 mm 100% 80%
Cost
Variation - + 19%
($/t)
The test C was composed by blasts 5 and 6,
both in the litothype apatitic compact with
different stemming sizes. On blast 5, the
stemming size was 30% (0.60 m) higher than
blast 6 and consequently the powder factor
from blast 6 was 17% (75.59 g/t) higher than
blast 5.
Even with a higher powder factor, blast 6
did not achieve a better rock fragmentation
probably because the excessive energy
ejected the stemming material affecting the
efficiency of keeping the explosives and
gases confined in the hole during the
necessary time to act in the rock breakage.
(Cavadas, 2012).
Figure 9. PSD curves for blasts 5 and 6.
The fragmentation on blast 5 presented
advantageous, as it was 48% (131.92 mm),
lower than blast 6. The percentage of passing
fragments (lower than 400 mm) on blast 5
represents the total efficiency that is 100% of
material passing in the grizzle while on blast
6 only 80% of the material passed directly
Test D through the grizzle.
Regarding the blast total costs, blast 6 was
7 8
19% higher than blast 5, which is justified by
the higher charge column length when used
217.17 369.74
the stemming size of 1.40 m. The increasing
236.59 357.13
95% 85%
in the stemming size showed to be extremely
satisfactory for both productivity, due to the
- + 13% better fragmentation, and blast cost
reduction.
The test D was composed by blasts 7 and
8 and its PSD curves are presented in figure
10.
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A. C. Silva, L. T. B. Mendonça, P. A. A. Martins, R. A. G. Silva, G. Birro, H. C. S. Nadler

Table 8 – Results from tests E and F.

Test E Test F
Number
8 2 9 5
Blast
Loading
383.09 694.14 230.86 361.04
Rate (g/t)
P 80 (mm) 357.13 290.63 208.21 219.41
< 400 mm 85% 90% 100% 100%
Cost
Variation - + 42% - + 32%
($/t)

The blast 2 presented a better fragmentation

result, around 19% (66.50 mm) lower than
Figure 10. PSD curves for blasts 7 and 8. blast 8, and the percentage of passing
fragments was 90% on blast 2 and 85% on
On blasts 7 and 8, there were also variations blast 8, as can be observed on figure 11.
in the stemming size, however on that case However, the total cost of blast 2 was 42%
the variation was 23% (0.40 m) with blast 7 higher than the costs on blast 8.
performed with a higher length.
Similarly test C, the higher stemming
length blast presented advantageous for all
performance indicators.
The fragmentation on blast 7 showed a
P80 34% (117.54 mm) lower than blast 8.
Considering the quantity of passing
fragments, blast 7 also had better results as it
presented 95% compared with 85% from
blast 8.
Once again, the increasing in the
stemming size has improved the productivity
in the crushing plant reducing the breakage
by hydraulic hammer and it costs was 13%
lower than blast 8. Figure 11. PSD Curves for blasts 2 and 8.
The gains obtained in both tests clarify the
great relevance of stemming size as an The fragmentation to the smaller drilling grid
individual parameter for blast efficiency, that was more efficient, but the total explosives
is, its correct definition is intrinsically and accessories costs by blasted tonnage
connected with good fragmentations results were very higher, which could not justify its
that were observed on blasts 5 and 7, where a implementation because the P80 results for
30% more efficient comminution was both blasts achieved the expected
achieved when compared with its peers. productivity with similar crushing
productivity.
3.3 Tests E and F The PSD curves for blasts 5 and 9 from
test F are showed in figure 12.
The last step comprehended the results from
blasts E and F presented on table 8.

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IMCET 2017 / ANTALYA / TURKEY / April 11-14
Figure 12. Fragmentation curves for blasts 5
and 9.
Once again, the results of a 40% of increased
drilling grid on test F were assessed. The
higher grid blast presented a fragmentation
result around 8% (11.20 mm) lower than the
blast 5. Both blasts showed the maximum
expected efficiency that is 100% of the
material passing directly in the grizzle and
improving the crushing productivity.
Compared with blast 9, blast 5 resulted in
32% higher costs. However, the expansion of
the drilling grid was very advantageous for
this geological litothype, as it presented
better fragmentation result and blasting
lower costs.
The comparison between tests E and F
could prove that a cost reduction is obtained
by expanding the drilling grid and still keep a
desired fragmentation. A special attention is
given to blast 9 which showed a lower
fragmentation when compared with blast 5,
contradicting the definition of (Cavadas,
2012) who defends that a drilling grid
reduction is totally related with the necessity
of achieve better fragmentations.
There were designed comparatives tests
for different rock blasting which were based
on changes of specific parameters of the
blast design. However, they only indicates
some directions for future improvements in
the blast process.
The changes in some variables were
implemented according to the gains achieved
172
and demonstrated in the tests and can be
better expressed by comparing the scenarios
before and after the optimization.
The graphic presented in figure 13 shows
in percentage the gains achieved with
fragmentation considering the grizzle feed
size of 400 mm and the total costs reduction
achieved in the blasting operation.
By adopting the new blast design
parameters it was possible to reduce the
fragmentation by 31%, increase the crushing
productivity by 12% and reduce blast costs
by 42%, surpassing the previous expectation
defined at the beginning of the project.
Figure 13. Before and after blasting
optimization analysis
4 CONCLUSIONS
The definition of blast design parameters is
essential to achieve the desired results in the
rock blast process. By changing only one
parameter, the blast result can be very
different and it was confirmed as expected
analysing how the P80 results are different
after just one change. However, some
parameters have more influence than others
do.
It was also noticed that some changes in
the blast design could improve the quality
and fragmentation compliance and still
obtain significant cost reduction for
explosives and accessories.
The application of emulsion showed good
fragmentation results for hardest rocks as the
compact silexite, but the elevated emulsion
A. C. Silva, L. T. B. Mendonça, P. A. A. Martins, R. A. G. Silva, G. Birro, H. C. S. Nadler

cost when compared with ANFO and the low GIBSON, S.A., THOMPSON, R.N., LEONARDOS,
demand for the detonation of this litothype O.H., DICKIN, A.P., MITCHELL, J.G., 1995.
The Late Cretaceous impact of the Trindade
(less than 20%) are considered barrier for its
mantle plume - evidence from large-volume,
implementation. The explosive ANFO mafic, potassic magmatism in SE Brazil., 1995.
presented best fragmentation results for most Journal Petrol 36, pp. 189-229.
of the rocks, and it is justified by the lower CLARK, G.B., Industrial High Explsoives:
cohesive force and tenacity of the rock Composition and Claculations for Engineers.,
massifs, that is, the percentage of passing 1980. Colorado School of Mines,Golden, v.76,
pp. 11-16.
fragments and consequently the percentage
JIMENO, C.L., JIMENO., E.L., BERMÚDEZ, P.G.
of material that directly passes through the Manual de Perfuracion y Voladura de Rocas,
grizzle that feeds the crushing plant. 2003. Instituto Tecnológico Geominero de
However, the comparison between which Espanã, Madri, 88 p.
types of explosive to be used for rock blasts STIEHR, J.F. Blaster’s Handbook 18th., 2011.
on Chapadão Mine was favourable to ANFO International Society of Explosives Engineers,
Cleveland,. pp. 76-77.
utilization, as it resulted in a balance between
CAVADAS, P.M.M., Optimização do Desmonte
costs and fragmentation. numa Mina a céu aberto com aplicação de Air
The proposed change of increasing the Decks, 2012. Faculdade de Engenharia
stemming size presented expressive Universidade do Porto, Porto, pp. 70-83.
fragmentation gains and is viewed as very ORICA. Technical Data Sheet, 2010. Orica Mining
simple operational strategy for reducing the Service, Melbourne. pp 1-2.
SPLIT. Manual de uso do software. 2011. Split
explosive consumption by hole and at the
Engineering, LLC. v.2, pp. 30-88.
same time improves the explosive energy
confinement. The operation adopted the
stemming size length of 2.00 m.
By the end, it was noticed that the drilling
grid expansion in the tests of the third step
had as a result the fragmentation lower than
400 mm besides to reduce significantly the
explosive and accessories consumption. The
methodology applied was proved very
efficient for aleatory changes based on field
experiences and systematic assessment using
the presented tools.

ACKNOWLEDGEMENTS
The authors thank financial support from the
Brazilian agencies CNPq, CAPES, FAPEG
and FUNAPE. In addition, we like to thank
Copebras for the allowing this research and
Federal University of Goiás.

REFERENCES
KRASNOVA, N.I., BALAGANSKAYA, E.G.,
GARCIA, D., 2004. Kovdor – classic phoscorites
and carbonatites. In: Wall, F. e ZAITSEV, A.N.
(eds), Phoscorites and carbonatites from mantle to
mine: the key example of the Kola alkaline
province. Mineralogical Society. pp. 99-132.

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