Improving blasting operations using data management and analysis

C. P. Parihar
Ultra Tech Cement Limited, Chittorgarh, Rajasthan, India
S. Bhandari
Earth Resource Technology, Jodhpur, Rajasthan, India

ABSTRACT: Data collection: pre-blast, during the blast and post-blast is critical to the blasting process, for
planning purposes, statutory requirements and/or environmental compliance. The review and analysis of past
data can improve blast design, execution and help in the achievement of desired blasting outcomes, down-
stream productivity and process improvement. Based on the database and its search and analysis capabilities,
the system can provide opportunities for taking corrective steps by changing charge distribution, initiation
timing and sequence for controlling fragmentation size, flyrock, and ground and air vibrations.
This paper shows importance of data collection and analysis. A case study has been provided where data
from 1995 till date has helped a limestone open pit mine in improving drill factor from 45 tons/m to 75
tons/m, breakage of limestone from 6.5 tons/kg to 14 tons/kg thus reducing costs by 50% while improving
crusher productivity from 764 tons/hour to 932 tons/hour and controlling vibration, flyrock and dust.

analysis capabilities, the system can provide oppor-

1 INTRODUCTION
Drilling and blasting is made up of groups of
tasks, which are performed to produce broken rock
with specific fragmentation and muck pile shape &
displacement while ensuring that safety, statutory
requirements and/or environmental compliance are
met. Procedures need to be defined for carrying out
drilling and blasting to obtain desired results. Data
collection: pre-blast, during the blast and post-blast
is critical to the blasting process -- for blast design,
for prediction of impacts, for taking corrective steps
at execution stage and for further analysis and plan-
ning purposes.
Generally blasting related information is poorly
managed with disjointed and unrelated information
technology systems managing parts of blasting data.
Data is often moved from one system to another,
sometimes manually. A data management system
not only ensures information storage, but also acts as
an intelligent system for optimization of blasting and
overall operation. The review and analysis of past
data can improve blast design, blast execution and
help in the achievement of desired blasting outcomes
and downstream productivity, and process im-
provement by adjustment of drilling and blasting pa-
rameters. Based on the database and its search and
tunities for taking corrective steps by changing ex-
plosive charge distribution, initiation timing and se-
quence for controlling fragmentation size, vibration
and flyrock. Data obtained from blast face profiling
tool, vibration, flyrock and fragmentation prediction
tools, can be directly linked to a database incorporat-
ing explosives and accessories used. Modular soft-
ware may use information to create specific hole by
hole explosives loading and create load sheets ac-
cording to geotechnical zone characteristics and re-
sults required.
An important component to the management of
any process is the measurement of key parameters,
which in turn are used to monitor, control and pro-
vide the feedback necessary to improve the process.
Any “optimization” (or improvement) of blasting
should not only look at the blast itself, but also to all
consequences of blasting results. These considera-
tions lead to overall-integrated concept. It is obvious
that such approach not only provides data for blast-
ing improvement, but will also be helpful for im-
provement of all other operations as well.
Several commercial database systems for mining
and blasting are available for storing and analyzing
data. However, blasting related data base systems
have not found to be popular at the mine level by In-
dian mining and blasting organizations. Organiza-
tions are either recording data in registers and/or are
#
using excel sheet. Difficulty is about customizing
$ %
imported software and also updating the database.
Further, blast execution is not similar in different
countries while using similar explosives and initiat-
ing systems. In general, mines are keeping blast data
in paper based system and have generally not bene- Figure 1 Blast Information Database
fitted from recent technology advancement. Draw-
! !" #
backs of the system include that record retrieval is .Blast Designer !

time consuming, record cannot be used for analysis, A large number of measurements
Explosive & initiation such as
•Flyrock Predictor
and insufficient data are recorded. Advantage of us- Results
•Face Profiler info including photographs
Management and videos
•Vibration Predictor
ing information technology data base are systematic •Design pattern based • Vibration Monitoring info
recorded
on geotech. & • during
Report, blasts
Search and Zone & •Wave front
reinforcement
storage of data, retrieval of data over a long time enviroment info and Benchwise Analysis
• Fragmentation
• Evaluation of results
period, analysis of data for improving efficiencies, best Past Practices
•Actual Hole position • Fragmentation analysis predictor
automated reports, view and analysis at distant loca- • Flyrock, •Dynamic adjustment
•Initiation sequence
• Accident Records
tion if desired. In general separate reports have to be
prepared/ submitted to different regulatory authori-
ties, to management and also needed for own re- Figure 1. Blast information integration
quirement of mine operators. This paper discusses
how computerized data collection and analysis can flyrock, vibration record and information for vibra-
provide improved blast accuracy and performance tion analysis. Video and photographic records also
achieved through a more intelligent blast design, provide opportunity to analyze displacement and fly-
made possible by combining with distinct data base. rock. These also indicate face movement and hole by
This is accomplished by focusing on key perfor- hole behavior. Integration of the following also
mance indicators derived from the historical perfor- needs to be accomplished:
mance of drill and blast events. The searchable data • Vibration monitoring results.
base of blasting information drives incremental im- • Blast simulation and airblast and
provement in performance. ground vibration reinforcement
• Flyrock and safe zone for personnel and
equipment.
2 DATA MANAGEMENT • Fragmentation size distribution
• Blast dust plume movement
A data management system not only ensures in-
formation storage, but also acts as an intelligent sys-
tem as an aid for blast design, prediction of impacts Data obtained from blast hole face profiling tool,
and analysis. Database can be integrated with mine vibration prediction tool, and direct data link to a da-
planning, drill guidance, field survey, load design tabase incorporating all the major manufacturers
parameters and post-blast evaluation (Figure 1). Da- products and an interface allows the user to add new
tabase is foundation for optimization of blasting and product ranges and create custom products. Directly
overall mining, tunneling or quarrying operation. import drill patterns and pit shells from the mine
Based on the database and its search and analysis planning packages. By linking with geological data/
capabilities, the system can provide opportunities for chemical data the blast block can provide quality as-
getting dynamic drilling and blasting parameters, vi- sessment.
bration constants and predictions, flyrock predic- Performance and cost of blasts can be monitored
tions, fragmentation size predictions. This informa- and Key Performance Indicators can be determined.
tion helps in adjustment of drilling and blasting Appropriate blast designs for particular areas of
parameters based on optimized results. mine and different zones can be identi-
Besides measured parameters related to blasting fied. Optimizing the blasting process involves drill-
parameters, explosives accessories, geotechnical in- ing accuracy and efficiency, profiling of exposed
formation, environmental information are required faces for mining applications, tailored loading ex-
for planning and design of blast block (Birch, et al., plosives according to face profile and rock condi-
2002 Hutchins, 2004; Bhandari and Bhandari, tions at depth, and designing proper parameters, de-
2006, Bhandari, 2011). Blast data management sys- lay timing and initiation sequence. Reports can be
tem stores blast details, blast parameters, blast pat- generated as per various requirements of the organi-
tern, face profile, explosive consumption, charging zation or statutory authorities. Blast records must be
details, costs, weather information, pre-blast survey, held for statuary purposes and would be useful in
post-blast evaluation data, fragmentation informa- case of litigations.
tion, photograph(s), videos, accidents, misfires,
 3 CASE STUDY -- ADITYA LIMESTONE
MINE
Aditya limestone openpit mine belongs to Ultra
Tech Cement Ltd group which has several lime
stone openpit mines spread across India. Aditya
mine is designed to produce 6.6 million tonnes li-
mestone per annum for its cement plant, situated
around 2 km away (Parihar et al, 2009). The ore to
overburden ratio is 1:0.33. Thus, total rock handling
is around 9 million tonnes per annum. Presently,
there are two working pits. The mine is surrounded
by small villages.
draulic excavators. At a time two excavators are
used for this operation. Transportation of limestone
from working face to crusher hopper is carried out in
35/60 tonner dumpers. Before crushing, the limes-
tone from crusher hopper is passed through grizzly
screen or screening out intrusive clay.
The mines have kept blasting records since the
beginning of mining operations in 1995, initially in
hand written format and thereafter have been main-
taining records in Excel sheet format ( Figure 3 &
4) for its blasting operations, explosive consump-
tions, drilling performance, blasting costs. These da-
ta show considerable improvement in blasting per-
formance and at the same costs have also reduced.
This has been possible in spite of much increase in
costs of explosive, accessories and labour and other
input. Continuously several new techniques have al-
so been adopted with indigenous and local methods.

Figure 2. Blast result in Aditya Mines

Geology: Aditya Limestone deposit belongs to

Nimbahera limestone formation: limestone, shale
and clay are the major rock types. Limestone is fine
grained, thinly laminated to massive in structure.
Aditya limestone mine deposit is highly jointed. The Figure 3. Written records of each blast
joints are multi-directional. Some of them are filled
with overburden soil and clay. The deposit was sub-
jected to structural disturbances of moderate intensi-
ty as evidenced from numerous minor and major
folds and joints.
Broadly, the structure of the entire deposit can be
classified as a synform. In spite of the above folds,
study of dip and strike readings indicates N - S trend
with maximum of 10o deviation on either side. The
amount of dip varies between a narrow range of 0o
to 20o. Dip direction changes from East to West due
to folding. There is plunge of about 5o in strike di-
rection.
Mining: Mining is carried out by fully mecha-
nized open pit mining method. The working pit is
below the general topography of the area. Working
pits have been developed with working benches of Figure 4. Records using Excel Sheet
9.0 m. height. At present, the work is going on in
three benches. Drilling is done with the help of ROC . Data collection and adoption of many scientific
L6 and IBH-10 drill machines of 100mm-115mm techniques such as Indian indigenous air gap, indi-
diameter. A set of about 25 holes is blasted. Excava- genous stem plug, indigenous rock plug techniques
tion and loading operations are carried out by hy-
and tools have helped in achieving thee above
a stated 4 BLAST INFORMATION
N MANAGEMENT
results. An example of charging with indigenously
in SYSTEM (BIMS)
developed wooden spacers for giving airgap
air (Figure
5). Blast Information Managem ement System (BIMS)
Blast records from 1995 till date has
as helped the provides information to meet the
th strategic and opera-
mine in improving rock breakage of limestone tional needs for planning, cont
ntrolling and decision-
powder factor from 6.5 tons/kg to 14 tons
ns/kg (Figure making for optimizing miningg operations (Bhandari
6) drill factor from 45 tons/m to 75 ton
ons/m (Figure and Bhandari, 2006). BIMS provides
p methods to
7), thus reducing costs by 50% (Figuree 8)
8 while im- store, manage, document and retrieve
r drill and blast
proving crusher productivity from 764 tons
to per hour related information The system
em stores blast details,
to 932 tons per hour and controlling vibration,
vib fly- actual blast parameters, blast
st pattern, face profile,
rock and dust. explosive consumption, chargin
ing details (Figure 9),

Figure 5 Use of airdeck Wooden spac

acer

16.00
14.94
14.64 14.71 14.56

14.00 13.47
14.44

13.63
Figure 7 Blasting cost reduc
uced
13.10 1
13.14 13.15
12.94 12.93
12.52

12.00
11.38

90.00
10.00

79.81
Tons / KG

80.00 77.47
74.98 75.21
73.48 72.49 72.43 72.26 73.68
8.00
70.22 70.91 71.59 70.38
6.57 70.00
5.84
6.00
60.50
60.00

4.00
48.75
50.00
Tons / Mtr

44.84
2.00
40.00

0.00
30.00
95-96 96-97 97-98 98-99 99-2K 2K-01 01-02 02-03 03-04 04-05 05-06 0
06-07 07-08 08-09 09-10 10-11

20.00

Figure 6. Tonnage per kg of explosive

ive improved 10.00

0.00
The mine is now using blast relatedd information 95-96 96-97 97-98 98-99 99-2K 2K-01 01-02 02-03 03-04 04-05 05-06 06-07 07-08 08-09 09-10 10-11

data management system for record, anal alysis and re- Figure 8 Drilling per meter
er also improved
porting. This indigenously developed syssystem is reli-
able, easy to use, stores large data andd provides
p re-
trieval and analysis of the stored dat ata and also Recorded videos and stored in the database can also
provides costs, weather information, pre-blast
pr sur- be used for observing face momovement and hole by
vey, post-blast evaluation data, fragment
entation infor- hole behavior.
mation, photograph(s), videos, accident nts, misfires, The stored blast information
on data can be retrieved
flyrock, vibration record and informatioion for vibra- quickly and easily. Performanc
ance and cost of blasts
tion analysis records (Figure 9). Softwaare also pro- can be monitored and appropr priate blast designs for
vides opportunity to analyze displaceme ment and fly- particular areas or different zones
z can be identi-
rock, back break/over break recor ords to be fied. The data management andnd retrieval is easy and
maintained and analyzed. simple to use which can be cararried out in a few mi-
nutes instead of days for maanual methods which
helps in optimizing various operations. Readily
available past data in a logical format and blasting
data analysis tools are the key features of the data-
base.
Figure 9 Details of explosive charge distribution
and initiation used for the holes
The database can be extended to integrate with
other systems such as ERP, CMMS etc. If the soft-
ware is operated in conjunction with a comprehen-
sive monitoring program, it can contribute to the ef-
ficient running of an operation and reduce
environmental effects to a minimum. Importing data
using .csv file, Excel and other popular mining soft-
ware makes it is possible to reduce input work. En-
tered data can be edited through Edit Parameters.
Figure 10. Result of blasting along with Photo-
graph & Video
This tool provides a way of trapping the expe-
rience of drilling and blasting personnel to better
control critical parameters such as dilution, vibra-
tion, fragmentation, and flyrock and fines genera-
tion.
Integration with other software such as that used
for vibration monitoring and analysis, fragmentation
analysis etc. can be carried out so as to provide sim-
plified management system.
Many central and state agencies, concerned with
Explosives Security, Mines Safety and the Environ-
mental Protection (DEP), are increasing their expec-
tations for strict accounting of inventory and blast
documentation. Blasting company executives and
managers are now facing the possibility of incarcera-
tion, fines and suspended operations if their docu-
mentation is not in order. The database can be tai-
lored according products and practices, to customer
requirements and can be maintained.
This database has also searching options using
which the user can look for the records of blasts as
per his defined criteria. Currently, the software uses
the following criteria for the search option: between
dates, by performance of explosives or initiating sys-
tem, by vibration limits, by fragmentation size, by
location of blasting zone or accident etc.
Presentation of analysis of data, compliance re-
ports suitable for regulatory bodies, archiving and
viewing of data at distance location, costs can be de-
veloped. Reports suitable for Occupational Health
and Safety (i.e. incident reports) can be compiled.
Key performance indicators are derived.
Figure 11. Reporting and Searching of Information
Calculation of costs related to blasting, drilling
cost, explosives cost, accessories cost, and manpow-
er cost all as separate entity, so that each & every
step of the mining activity could be optimized by us-
ing this information. Mine has to provide returns to
regulatory authorities PESO, Indian Bureau of
mines, Director General of Mines regarding con-
sumption of explosives quarterly, monthly and year-
ly. Besides management also want end of the month
reports. Many records have to be maintained for sta-
tutory requirement. Stored information also helps in
providing information in cases of litigations.
The data base application is password protected
as such restricting the use of the software. The data-
base is protected; as such no unauthorized access to
the data is possible.
Inventory control & stock management gives
knowledge of amount of explosive or initiating de-
vices available for the blast is left after the blast.
This could help in keeping a track of consumption of
material in the mine and to maintain the quality of
explosives as not to have too little or excessive
stock.
The program also records all the important analy-
sis data like those of vibration monitoring, fragmen-
tation analysis etc. Further functionalities like VOD
measurements can be added.
5 BLAST DESGN AND PREDICTION TOOLS
Based on data base information about geotech-
nical, environmental requirements, planning out-
come a separate Blast Design module can design
blasts. Design software can create and edit drill pat-
terns using geotechnical and environmental informa-
tion data base. Blast patterns are individually de-
signed for every blast block taking into
considerations for quality. Based on past best prac-
tices it provides blast calculations, specific blast de-
sign and blast hole data, priming details, hookup and
timing analysis calculations. Charging appropriate
quality and quantity of explosive and using appro-
priate initiating system is provided. This design has
already taken into consideration ground vibration,
flyrock, dust limits, fragment size distribution and
other requirements while providing blast design.
After drilling has been carried out actual hole po-
sitions, dip and face profile are measured. Design
data is separated from measured data. Prediction
tools are again used to see if any of the limits are ex-
ceeded with regard to ground and air vibration lim-
its, flyrock limit etc. Software may use information
to create charge standards to design specific hole by
hole explosives loading and create load sheets ac-
cording to geotechnical zone characteristics and re-
sults required.
The software can be used to assess the likely im-
pact or effect of a particular design. Vibration rein-
forcement analysis (Richards and Moore, 1995)
(Figure 12), flyrock predictor (Richards and Moore,
2004) are used to see if charging and initiation tim-
ing and sequence need to be changed to meet with
flyrock, fragmentation, vibration limits. This is in
conjunction with field observations, experimentation
and monitoring.
Simulation of initiation design including, angle of
initiation, direction of movement are given. Design
initiation sequences for electronic detonator systems
and applying timing to defined zones to enable mul-
tiple independent deck firing.
Figure 12. Reinforcement of vibration before
blasts helps in changing delays
6 CONCLUSIONS
Database connects all information related to
blasting operation to provide reporting, trends and
analysis. Custom graphs and reports reduce work for
providing reports to any desktop and can be fully
customizable to meet key production indicators, and
daily reports. Software based data base provides
valuable time for engineering and mining profes-
sionals by integrating disparate mining data capture
software systems and removing dependencies on
Excel spreadsheets. This information stored and ana-
lysed helps in better control and optimization of
mining operations. Data base helps to quickly re-
spond to information and remain successful in to-
day’s competitive market place. Web based versions
and tablet PC would make data acquisition easy.
Use of database helps in improving blast efficiencies
and demonstrate that an improvement has been
achieved there needs to be a comprehensive mea-
surement system, which is capable of setting base-
line, and then tracking the changes made to the
process.
 7. REFERENCES

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