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Benefits of Blend Programs in Surface Coal Mines

Written by:  Scott Giltner, Dyno Nobel Inc., Louisville, Kentucky, USA
                   Rufus Flinchum, Dyno Nobel Inc., Christiansburg, Virginia, USA

Abstract:

This paper discusses the findings of a 9 month and 4 month evaluation of operating costs at two coal operations.  These evaluations were part of a blast optimization program designed to demonstrate how using a 40/60 blend to replace ANFO could reduce overall mining costs.  ANFO has traditionally been the explosive of choice at most surface coal operations due to its ease of use and low cost compared to other explosives.  However, in many operations, a more expensive ANFO/emulsion blend, when properly applied, as the potential to lower the total drilling/blasting costs and stripping costs.

The presented studies consisted of two phases.  The first phase established a baseline where ANFO was used as the principal explosive.  In the second phase, a 40/60 blend was used in an optimized pattern.  During both phases of the studies, the following were monitored:  amount of explosives used, volum of rock shot, muckpile characteristics, number of holes drilled, stripping rates and total drilling/blasting cost.

The two operations discussed differ in mining conditions and equipment.  Therefore, the blend programs were customized to optimize the blasting based on the specific needs of each operation.  One operations benefited from expanded patterns and reduced drilling requirements while the other operations benefited from increased throw and framentation.  Other benefits, such as increased stripping rates and improved drilling flexibility, are included.

In conclusion, the paper provides a direct comparison of the operational and economic advantages of a 40/60 lend over ANFO.  More specifically, the paper discusses how these advantages can be achieved based on specific mining requirements.
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