Variable Density Explosives

Miguel Angel Lamadrid

Deliverance Project Lider Latinamrica,
Orica Mining Services, Explosivos Mexicanos, S.A. de C.V.

Marco Arellano Alvarez

Orica Mining Services, Santiago, Chile

Abstract
For many years low-density explosives have been used in the mining industry as a way of reducing overall blasting
costs whilst not adversely affecting blast outcomes. The limitations of these products have been around water
resistance, inability to vary explosive bulk density easily in a blasthole and failure to compete with ANFO on a cost
basis. The development of Flexigel, a two component emulsion based variable density explosives (VDE) has solved
the above mentioned problems and through its chemistry/formulation and blasting mechanism, it has been able to offer
solutions to traditional mining problems of post blast fume, fines reduction, wall control, ore dilution and in some
instances a reduction in blasting costs whilst still operationally being easily adapted to differing ground conditions (hot
and reactive, soft and hard and wet ground).
VDE products (manufactured at 0.50 g/cm3, 0.60 g/cm3, 0.80 g/cm3, 1.00 g/cm3 and 1.10 g/cm3) can be delivered in
a variety of conditions. The higher density products (1.00 g/cm3) are water resistant and can be pumped into wet holes
that would normally use chemically sensitized explosives. VDE at 0.80 g/cm3 and above can be used in dewatered
blastholes that would generally use a 1.3 g/cm3 density product, without comprising explosive performance. VDE at
0.6 g/cm3 have been used to replace ANFO. Operationally the product density can be changed up to three times in a
blasthole, this can be achieved whilst still loading the blasthole in a single pass.
In Australia there has been a rapid take-up of this VDE mainly to reduce blasting costs but also to address
environmental problems in the coal industry. For example reducing post blast fume, controlling air-blast in cast blasting
and controlling ground vibration. This VDE allows the blast designer to reduce powder factors whilst maintaining blast
results and lowering blasting cost.
An additional benefit is the reduced security requirements on the raw materials used. In light of the changing
international laws governing the storage of ammonium nitrate, this is becoming critical to the mining industry.

INTRODUCTION requirements for bulk explosives, Flexigel a Variable

Orica Mining Services since the late 1990s have been
developing a variable density explosive based on mixtures
of Ammonium Nitrate Emulsion (ANE) and Expanded
Polystyrene (EPS). This VDE series of products are the
current offering for bulk explosive based on this product
formulation mix. This paper will discuss specific case
studies from Australia and Chile where it is possible to get
improvement in mine to mill cost, fume reduction, wall
control, and many technical applications using our
premium products and savings with our base products,
used in regions with extensive exposure to all types of
mining geology and process conditions.
BACKGROUND
Low Density Explosives
Low-density explosives have been used extensively in
the mining industry for more than 30 years. Pioneering work
in the field of low-density explosives, focused on reducing
the density of ANFO with a variety of bulking agents. Today,
whilst this technique is still employed another commonly
used method for manufacturing low density explosives has
been to take an existing Bulk product containing porous
prill, ANE and Process Fuel and diluting this matrix with
bulking agents. Examples of commonly used bulking
agents are Sawdust, Peanut Shells, Rice Hulls and various
organic inerts. Orica Mining Services has been developing
a VDE that matches with several mine necessities and to
give technical solutions.
Variable Density Explosives (VDE)
To address these product limitations of low-density
explosives and also some of the technical/commercial
Density Explosive (VDE) based on Expanded
Polystyrene (EPS) and ANE has been developed. The
benefits for this type of product include a
comprehensive listing of densities including 0.50 g/cm3,
0.60 g/cm3, 0.80 g/cm3, 1.00 g/cm3 and 1.10 g/cm3
product and the provision of technical solutions to
traditional mining problems of:
Post Blast Fume: Elimination of the dual
denotation mechanism with Prill based explosives
ensures a more efficient complete detonation. As
the whole product series is emulsion rich the
products water resistance is excellent and
eliminates low order denotation due to Prill
softening which can lead to post blast fuming, this
feature makes the 1.00 g/cm 3 and 1.10 g/cm 3
products excellent for use in de-watered blasting
applications, the 0.6 g/cm 3 and 0.8 g/cm 3 product
can be used in application where ANFO and liners
were used (see case study). In addition to this when
using the 0.6 g/cm 3 product, this product is
hydrostatic (self supporting) which eliminates the
post blast fuming mechanism.
Reduction in toe (applicable to O/C Coal): This VDE
can be manufactured at 0.5 g/cm 3 and 0.6 g/cm 3 the
ability to drill every blasthole to coal or reduce coal
stand off to ensure all toe material is blasted is
realised.
Fines reduction: Due to the less level of shock
energy, this VDE does not create several radial joints
around the borehole, and because of the Energy
distribution displayed in the massive rock it generate
less fines giving savings and improvements in the
heap leach process in copper mines.

Fragblast-8 Santiago Chile, May 2006 35

 Caprock: Due to the products lower, stable VoD
characteristics and also the density benefits the product
provides, explosive can be loaded higher in the hole
which reduces stemming height at 30 % of the normal
stemming.
Flexigel can also be used as a cushion on top of
higher density products in the top of the hole in a similar
way that air decks were previously used, the difference
being you have product in that portion of the hole.
Wall Stability: In the pre-split situation, VDEs can provide
the user with the ability to load a buffer line without having
to deck charges due to the increased column rise. Using a
0.5 g/cm3 product in the back row of a shot can provide the
user with cleaner walls. In a coal shot or interburden shot
situation, 0.50 g/cm3 and 0.60 g/cm3 product can be used
to reduce vibration transferred into the adjacent highwall.
Lower powder factor: Due to the lower density (0.6
g/cm3) allows the blast designer to reduce powder factors
while maintaining blast results and at the same time the
ability to maintain powder factors in dewatered/damp holes
that were designed for ANFO reducing blasting cost.
Reduction of dilution: Due to the formulation and energy
distribution, this product is designed to reduce the heave
and having a flat surface expression used as a benefit in
metalliferous mines.
Environmental (Airblast and Vibrations): This VDE has
several main properties that contribute to reducing
30% of airblast over ANFO and traditional Prill, ANE,
Fuel based bulk explosive mixtures. Firstly the
products lower VoD results in less borehole pressure
that leads to a reduction of pressure released upon
detonation. An outcome of this mechanism has led to
VDEs being used in face holes where face bursts are
an issue (see case studies). In addition to this the 0.6
g/cm 3 product will reduce the velocity of face
movement compared to ANFO (whilst not adversely
affecting blast outcome), thus less overpressure is
transmitted into the air (piston effect). From a vibration
perspective this VDE has several main properties that
contribute to reducing vibration over ANFO and
conventional bulk explosives.
Further Benefits from an Operational / Commercial
Perspective include:
Density on Demand: The VDE product density can be
changed up to three times in a blasthole and still be
loaded in a single pass. This enables faster and simpler
loading.
The product offering is completely compatible with
Oricas Existing Mobile Manufacturing Fleet (MMU).
The series cost is competitive when compared to ANFO,
Heavy ANFO and gassed products. This is critical to the
acceptance of VDE In the market place.
To complement the technical and commercial benefits
VDE provides - running parallel to this has been the
development of specialised handling systems which are
fully sealed and compatible with Oricas existing
explosive delivery systems.
HANDLING SYSTEM
With manufacture of VDE comes the requirement of
efficiently transporting, handling and storing the bulking
agent. In the case of this VDE the transfer of EPS is of
critical importance both from an economical and
environmental perspective. Completely containing the
EPS in all stages of handling up to product manufacture
36 Santiago Chile, May 2006
is vital. As a result Orica has developed several types of
Mobile plant equipment, which allow rapid mobilisation
of handing systems that have the ability to transfer EPS
and ANE via sealed systems. The handling systems for
EPS are based on lean phase mass transfer (high
volumes of air).
AUSTRALIA CASE STUDY A
The situation:
Orica Mining Services approached a large Queensland
mining operation to assist them in reducing their costs in
comparison to their traditional ANFO and Heavy ANFO
products. This truck shovel operation has been blasting in
weathered material for many years and Orica believed
there was a more efficient and cost effective approach.
Technical solution:
Considering the type of rock in the zone of interest, an
analysis was performed using a variable density explosive
under the same parameters of design used with ANFO and
Heavy ANFO. The analysis results demonstrated that a VDE
Coal Formulation (0.6 g/cm3 density) was the most
appropriate product for this application.
In June 2005, 310 holes were loaded with VDE (0.6 g/cm3
density) in a pattern of 10 m burden, 11 m spacing,
diameter hole of 270 mm, 24 m bench height with a powder
factor of 0.22kg/m3. There were 27 rows stitched with 25 ms
through the center and back along the echelons with 100
ms center lift.
Results:
The blast produced efficient and outstanding
fragmentation. Based on the typical excavator operated in
this area with budgeted standard digging production rates
of approx 1,600 bcm/hr, the digging production rate
obtained was 20% higher than what was obtained with
ANFO and Heavy ANFO for the same area (Fig. 1). The
average production rate in this blast was 1,914 bcm/hr.
Figure1: Productivity comparison.
After the excellent results, further VDE Coal
Formulation (0.6 g/cm3 density) blasts have taken place
in the same area with productivity peaking at 2400
bcm/hr. These results demonstrated to the customer
that this VDE offers a solution in higher productivity at a
lower cost.
Fragblast-8
AUSTRALIA CASE STUDY B
The situation:
The environmental effects resulting from blasting are
some of the most important keys in blasting improvements
in an Open Cut Coal mine operation located in Hunter
Valley, NSW, Australia, with a production of 3.5 million tones
of saleable coal per year to Japan, Europe and Australia.
To decrease these effects, the mine currently uses the
buffer blasting technique minimizing the risk of overpressure
effect. The extra burden limits digging productions and in
some cases fragmentation issues in the first row.
Orica Mining Services has been engaged to improve this
environmental situation while reducing airblast levels in this
particular area where ANFO and heavy ANFO is normally used.
Technical solution:
Face profiling ensured that the face burden was sufficient
to minimize the risk of flyrock, a VDE Control Formulation
(density: 0.6 g/cm3) was loaded in the first row to reduce the
face acceleration and velocity of the face material. Fig.2
shows the effect of excessive face velocity immediately in
front of the blast holes loaded with ANFO and Heavy ANFO.
This results in excessive airblast as well as a waste of energy
which is not being effectively utilised to move the rock mass.
Figure 2: Excessive shock energy in the front row.
Normally the initiation hole results in peak overpressure
due to the high acceleration of the face movement, and in
most cases it persists in the second row as a consequence
of the timing used between both.
A three free face blast was loaded in a 270 mm. hole
diameter, 60 m. deep hole, with a VDE Control Formulation
(0.6 g/cm3 density) in the first front row instead of using air
decks and other buffer techniques.
This VDE product provided the opportunity to load a full
explosive column, minimizing the previous fragmentation
and airblast problems through the improved application of
energy in the blasthole. Fig 3. shows the reduction of face
acceleration and subsequently face velocity, giving uniform
movement in the blast.
Figure 3: VDE Control Formulation in the first front row.
Fragblast-8 Santiago Chile, May 2006
Controlling the maximum amount of energy in the blast
improves fragmentation, minimizing the fly rock hazard in the
shot.
Results:
The use of VDE Control Formulation (0.6 g/cm3
density) in this open cut coal operation, provides an
alternative solution and blasting performance by
maintaining productivity without overpressure
exceeds.
CHILE QUEBRADA BLANCA CASE STUDY
The situation:
Orica Mining Services has been working in
Quebrada Blanca Mine since the very beginning of
this mine. It is an Open pit with Copper Oxides. The
ore is processed through bacterial leaching. It is very
important at this stage the quantity of fines provided
to the muckpile. In this case if the percentage of fines
is greater than 12% under 100# it means a reduction
in the metallurgical recovery due to the creation of
impermeable points in the leach pile that are not
irrigated by the acid solution, and this becomes an
important loss for the mine.
Technical solution:
By working together with the mine it was defined
the objective and it was to generate less fines by
each blasting. But the very first thing was to identify
the uncontrollable and controllable variables that
affect the generation of fines. The uncontrollable
ones are those which we can not interact with such as
the hardness, alteration and lithology of the ore, and
the controllable ones are; the drill pattern Burden x
Spacing, bench height, drilling diameter, powder
factor and low energy explosive.
In the controllable variables there were implemented
and assessed all changes. There were reductions in
the bench height, the drilling diameter, change of
pattern BxE, the powder factor, and the last variable,
the low energy explosive called Flexigel with a density
of 0.6 g/cm 3 and 0.9 g/cm 3 for dried and wet zones,
respectively.
Results:
With all the changes carried out to the drilling and
blasting designs, the results indicated an improvement of
fines in the feeding of the leach pile, from 14% -100# to
12% - 100#. This meant for the mine a significant additional
revenue of 2% .
During this process it was possible to measure and
ratify the significance of using the correct quantity of
explosive in the solid rock, the velocity of
propagation of the rock versus velocity of detonation
of the explosive ratio (V p /VOD), for example for a
solid rock with V p = 2500 m/s, it was obtained a VOD
of approximately 2500 m/s, compared with a high
VOD of the Anfo and emulsion of 4500 m/s,
approximately. The most relevant data were obtained
when all parameters of the controlled variables were
changed. The mine decided to go back to Anfo from
Flexigel. During the monitoring of the fragmentation in
the zone from the muckpiles of lixiviation it was
immediately detected a change from 10% -100# to
14% - 100# (20 of October, 2005). This was a clear
indication that the quantity of energy provided to the
solid rock plays a significant role in the generation of
fines. The final result was a better annual profit for the
mine.
37
REFERENCES
Lamadrid M., 22/08/05, Case study Flexigel Coal 60,
Higher Productivity and Lower Blasting Cost , ANFO and
Energan Coal Replacement
Lamadrid M., Rock J., Moffitt S., 26/09/05 Flexigel
Clear Solution in Environmental Restrictions, ANFO and
Energan Coal Replacement
Alvarez M,. 11/07/05, Quebrada Blanca Fine
Reduction.

38 Santiago Chile, May 2006 Fragblast-8