Optimization of Blast Fragmentation at Kısladag Gold Mine

Ozkan Duzgun, Ekin Gungor, Erkan Bayrak, Serkan Erkara

ELDORADO Gold Corporation / Tüprag, Usak, Turkey

Abstract

This paper presents part of the outcomes of the drill and blast optimization project carried out at
Kisladag Gold Mine in Turkey. Kisladag Gold Mine is the largest gold mine in Turkey with a low-
grade, bulk-tonnage, open pit operation that uses heap leaching for gold recovery. After blasting, the ore
is fed to a three-stage crushing circuit which prepares crushed ore approximately -10 mm (0.39 in) for
heap leaching. Crusher downtime analysis showed that blocky material and insufficient feed are causing
significant downtimes with the primary crusher. This was supported by the fragmentation data collected
to date. It was decided to initiate a fragmentation project to understand the variation in the run-of-mine
(ROM) size with a view to provide a consistent feed to the crushing circuit. The study includes the
analyses of the ore strength and structure, image analysis of the fragmentation pictures acquired from
blasts, blast auditing and quality assurance and quality control (QA/QC) analyses. During this project,
over 200 fragmentation pictures were acquired from 47 blasts to optimize ore and waste blasts. Ore
strength varies between 30 and 120 MPa and rock quality designation (RQD) ranges between 30 and
100. A site-specific fragmentation model was used to calibrate the fragmentation for blast domains
formed. In addition, alternative cases were simulated to achieve blasts designs with consistent ROM
fragmentation size distribution. Alternative blast designs that include stemming length and powder
factor changes were suggested. Long stemming length, drill cuttings use, free faced blasts, small shot
sizes and poor stemming length control were some of the key issues causing coarse fragmentation.

Introduction
Kışladağ gold mine is the largest gold mine in Turkey. It is operated by Tüprag Limited which is a
subsidiary of Eldorado Gold Corporation. The mine site is located in southwest of Uşak, west-central
Turkey (Figure 1). Kışladağ Mine is located between major cities Ankara and Izmir.

The Kisladag deposit consists of porphyry-style gold mineralization centered on a series of overlapping
sub-volcanic and extending outward into the surrounding volcanic and volcaniclastic rocks. The
crushing circuit consists of a three-stage circuit with the crush size of 80% passing approximately 8 mm.

Drilling and blasting activities conducted at Kisladag Mine include: a) ROM to leach b) ore, c) waste
blasts, d) wall-control (presplit and trim) blasts. The site owns 7 drill rigs, 5 excavators (2xHitachi
EX3600-6, 1xHitachi EX5600-6, 2xLE'TOURNEAU L1350), 1xCat 993K loader, 14xCat 785C trucks,
9xHitachi EH4000-AC trucks.

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 Figure 1. Kisladag Mine
Crusher Downtime Analysis
Crusher downtime analysis is a powerful analysis and can show if there are any pit-related issues
affecting the crusher downtime. The analysis is focused on the downtime. Crusher key performance
indicators (KPIs) were not evaluated as part of the project and may be considered later as an extension to
this project.

A detailed downtime analysis for crushers’ downtime was carried out as shown in Figure 2. The top two
issues were insufficient feed and blocky material. These two issues were mining related and indicates
that coarse (blocky) fragmentation is causing significant downtime. In addition, insufficient feed may
indicate issues with the broken stock in the pit during this time period.

Figure 2. Primary crusher downtime analysis

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Ore Strength and Structure
Table 1 lists the main lithologies present at the mine with the depth of oxidation and alteration types.
The mine classifies the ores into sulphides and oxides. In general, there is a large variation in the
uniaxial compressive strength (UCS) data and INT-2 and INT-3 sulphides have higher strength values as
compared to their oxides (Figure 3). The site constructed a 3-D model based on the RQD which is called
Geotechnical Blockiness Index (GBI). There are three groups in GBI model: Friable, Blocky and Semi
Massive.

Table 1. Summary of lithology, depth of oxidation and alteration types

Lithology Depth of Oxidation Alteration

Rock_codes Description

PYCL Pyroclastic Oxide (OX) Potassic-Biotite (P-B)

INT-1 Intrusive - 1 Sulphide (SUL) Tourmaline-Sericite (T-S)

INT-2 Intrusive - 2 Argillic (A)

INT-2A Intrusive - 2A Advanced Argillic (AA)

INT-3 Intrusive - 3 Combined Clay (CC)

INT-3 DYKE Intrusive - 3 Dyke Intrusive 3 (INT3)

SCHIST Schist Schist (SCH)

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 Box & Whisker Plot
220

200

180

160

140

120
UCS (Direct), MP a
100

80

60

40

20

-20

-40

-60

P Y CL,OX ,A RG
P Y CL,OX ,A DV

P Y CL,S UL,A DV

P Y CL,S UL,A RG

S CHIS T,S UL
P Y CL,OX ,WMT

P Y CL,S UL,WMT
INT-2A ,S UL,A ll
INT-2A ,OX ,A DV
INT-2CE ,S UL,P OT
INT-1,OX ,A RG

INT-1,OX ,A DV

INT-1,S UL,A DV
INT-1,S UL,A RG

INT-3,S UL
INT-2NW,S UL,P OT
INT-1, OX /S UL

INT-1,S UL,P OT

INT-3,OX
INT-2NW,S UL,Other
INT-1,S UL,WMT
INT-1,OX ,Others

Mean
±SD
±1.96*SD

Figure 3. UCS data from direct UCS (University) tests

Fragmentation Measurements and Modelling
The site has been mining 10 m (32.8 ft) production benches drilled using 152 and 165 mm (6 and 6.5 in)
drills (152 mm (6 in) for trims and 152/165 mm (6/6.5 in) for production blasts). Typical powder factors
are approximately 0.36 kg/m3 (0.6l lbs./yd3) for pit top ore and waste blasts; 0.60 kg/m3 (1.01 lbs./yd3)
for pit bottom ore blasts.

In general, fragmentation in the middle of the muckpile appears reasonable. However, coarse
fragmentation was observed especially around the stemming zone (Figure 4) and edges/free faces.

Figure 4. Coarse fragmentation and blocky material falling from top to the floor while digging
(left picture). Also note the tight muckpile (right picture).

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The site initiated a project to identify the causes of the coarse fragmentation and establish the blast
domains. During this project, over 200 fragmentation pictures were acquired from 47 blasts to optimize
ore and waste blasts. All images were processed using Split-Desktop software to determine the ROM
size distributions. Fines correction was applied with the help of the primary crusher product size
distribution.

This paper summarizes the ore blasts only. Ore blasts were divided into two groups (pit bottom where
bulk emulsion is used and pit top where ANFO is used). At pit bottom, there was a poor control over the
stemming length and the authors asked operators to stop pumping emulsion when the target stemming
length (4.5 m (14.8 ft) before gassing) is achieved. There was a good control with the cup densities.
Fragmentation improved significantly with better QA/QC and slight increase in powder factor (Table 2).
Before audit, average F80 and top size were 258 mm (10.16 in) (198-311 mm (7.8-12.24 in)) and 622
mm (24.5 in) (463-893 mm (18.23-35.16 in)) respectively. After audit, average F80 and top size were
148 mm (5.83 in) (123-185 mm (4.84-7.28 in)) and 334 mm (13.15 in) (223-417 mm (8.78-16.42 in)),
respectively. The site wanted to reduce the top sizes below 500-600 mm (19.69-23.62 in) and achieve
F80 around 200 mm (7.87 in). It was shown that while top size was reduced significantly, F80 was
smaller than target value indicating a possible pattern expansion with 165 mm (6.5 in) holes.

At pit top, stemming length was controlled using a plastic pipe. Coarse fragmentation was mainly due to
poor fragmentation at the stemming zone. Muckpile was also very tight. Table 3 shows the
fragmentation data. Some ore blasts were free faced. Majority of the coarse fragments were originating
from free face. Historically, 46% of the blasts at the pit top (ore blasts) had blast volumes less than
20,000 m3 (26,159 yd3). Free-face, long stemming length, drill cuttings use and small shot sizes were
identified as some of the issues causing coarse fragmentation.

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Table 2. Fragmentation measurement results for crushed ore – Pit Bottom

Table 3. Fragmentation measurement results for crushed ore – Pit Top

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Although the site chooses crushed aggregate at the pit bottom as a stemming material due to the wet
holes, drill cuttings have been mostly preferred at the pit top blasts. A few issues were identified with
the stemming:

 Coarse crushed aggregate use: A few images were collected and analyzed using Split Desktop
software which showed that it was too coarse (Top size and F80 were determined as 62 and 33
mm (2.44 and 1.3 in) respectively) for the hole diameter.
 Drill cuttings use: It is well-known that drill cuttings are inefficient for locking the detonation
gases.
 Long stemming lengths: Scaled depths of burial (SD) calculations (Chiappetta et al., 1983) are
well-accepted in the industry to calculate the optimum stemming length (See Figure 5).
According to these calculations, SD should be within 0.92-1.40 (1.30 is a good start). Our
stemming lengths at pit bottom were at the upper recommended range; however, pit top blasts
had significantly high SD’s (see Table 3) causing inefficient breakage at the stemming zone.

Figure 5. Scaled depth of burial (SD) (Chiappetta et al., 1983)

In order to adjust the drill patterns for the required size specification considering the ore strength and
structure, Kuz-Ram model (Cunningham 1987, 2005) with Swebrec function (Ouchterlony 2005) was
used. The model was calibrated using the measured data. As it is seen in Figure 6 as the SD decreases
breakage around the stemming zone in other words fragmentation at stemming zone increases.

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 Figure 6. Scaled depth of burial (SD) difference

Figures 7-8 show the base case and cookbook modeling cases for pit bottom and pit top blasts
respectively. It is shown that target F80 and top sizes were achieved according to the model. Some of the
key changes to the design were the stemming length and powder factor to achieve the target F80 and top
sizes. For stemming length, the target SD’s were 1.33 and 1.41, respectively for pit bottom and pit top.
Once better quality aggregate is sourced, it is planned to target SD of 1.2-1.25. Drill and blast
cookbooks based on rock structure and strength were prepared as shown in Figures 9-10.

Figure 7. Size distributions for Pit Bottom – Base case and cookbook cases

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 Figure 8. Size distributions for Pit Top – Base case and cookbook cases

Figure 9: Cookbook for Pit Bottom (Emulsion used at 1.20 g/cc density). Crushed aggregate for
stemming.

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Figure 10: Cookbook for Pit Top (ANFO used at 0.82 g/cc density). Crushed aggregate for
stemming.
Conclusion and Future Work
This paper summarized the fragmentation project carried out at Kisladag Mine. During this project,
over 200 fragmentation pictures were acquired for 47 blasts to optimize ore and waste blasts. This paper
deals with the ore fragmentation optimization conducted on-site and the following conclusions can be
drawn from this work:

 In general, fragmentation in the middle of the muckpile appears reasonable. However, coarse
fragmentation was observed especially around the stemming zone (Figure 5) and edges/free
faces.
 Free-face, long stemming length, drill cuttings use, small shot sizes and poor stemming length
control were identified as some of the key issues. To overcome these issues, the site is firing into
the broken ground, using the appropriate scaled depth of burial (<1.4) for stemming lengths and
larger shot sizes. In addition, stemming lengths are controlled for the entire pit.
 At pit bottom, before audit, average F80 and top size were 258 mm (10.16 in) (198-311 mm (7.8-
12.24 in)) and 622 mm (24.5 in) (463-893 mm (18.23-35.16 in)) respectively. After audit,
average F80 and top size were 148 mm (5.83 in) (123-185 mm (4.84-7.28 in)) and 334 mm
(13.15 in) (223-417 mm (8.78-16.42 in)) respectively. There was a remarkable fragmentation
improvement.
 Excluding free-faced blast (940-166), average F80 and top size were 213 mm (8.39 in) (192-245
mm (7.56-9.65 in)) and 531 mm (20.91 in) (382-713 mm (15.04-28.07 in)) respectively. While
F80 data was reasonably within the expected range, top sizes were slightly coarse.
 A site specific blast fragmentation model was developed and the cookbooks were developed
based on the ore structure and strength.

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  We are currently testing the cookbooks and would revise them when required to achieve
consistent ROM size distribution. We are planning to extend this project to include crusher KPIs
(power draw and throughput) in the following years.

Acknowledgements
The authors would like to thank to Kisladag Gold Mine Management including Serkan Yuksel, Richard
Miller and Berkant Ozdemir for their support during the project. We would also like to thank the mine
staff and engineers for their support.

References
Chiappetta, R., Bauer, A., Dailey, P. and Burchell, S. (1983). “The Use of High-Speed Motion Picture
Photography in Blast Evaluation and Design”, Proceedings of the Ninth Annual Conference on
Explosives and Blasting Technique. Dallas, TX. International Society of Explosives Engineers,
pp 258-309.
Cunningham, C.V.B. (1987). Fragmentation estimations and the Kuz-Ram model - Four years on.
Proceedings of the second international symposium on rock fragmentation by blasting,
Keystone, Colorado, 475-487.
Cunningham, C.V.B. (2005). The Kuz-Ram fragmentation model—20 years on. In R. Holmberg (ed.),
Proc. 3rd EFEE World Conf. on Explosives and Blasting, Brighton, UK, 13–16 September, pp.
201–210. Reading, UK: European Federation of Explosives Engineers.
Ouchterlony, F. (2005). The Swebrec function: linking fragmentation by blasting and crushing. Mining
Techn. (Trans. of the Inst. of Mining & Met. A) 114:A29–A44.

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