Blast Plan Control System Optimizing Rock Fragmentation
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Solution Overview
Problem
Drill and Blast (DB) events face challenges in achieving optimal rock fragment sizes, leading to inefficiencies and increased costs due to either overly pulverized or excessively large rock fragments, which require additional processing steps.
Innovation Solution
A blast plan control system and method that optimizes rock fragment sizes by generating customized blast plans based on specific rock bench and equipment characteristics, using simulation variables and models like the Kuz-Ram rock fragmentation model to determine optimal drill and blast event specifications, ensuring precise rock fragmentation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional drill and blast methods are used without optimization, then the blasting process can be completed, but the rock fragment size cannot be controlled precisely, leading to either overly pulverized or excessively large fragments
Solution Approach 1:
The system performs preliminary simulation and optimization of blast plans before actual execution. Multiple blast scenarios are simulated using the Kuz-Ram model to predict rock fragment size distributions, and the optimal plan is selected in advance, ensuring precise fragment size control while avoiding rework from improper fragmentation
Solution Approach 2:
The system incorporates feedback loops where actual blast results are compared against predicted outcomes, and this information is used to refine future blast plan simulations. This continuous improvement process enhances the accuracy of rock fragment size prediction and optimization over time
2Strength
If rock fragments are made too small through intensive blasting, then complete rock breakdown is achieved, but the mineral extraction process becomes slower due to excessive pulverization
Solution Approach 1:
The system optimizes key blasting parameters including hole diameter, hole depth, burden distance, spacing, and explosive charge weight to achieve the desired balance. By carefully adjusting these parameters, the Kuz-Ram model predicts optimal fragment size distributions that provide sufficient breakdown while avoiding excessive pulverization that would slow extraction
3Ease of manufacture
If rock fragments are made too large to simplify processing, then additional breaking steps are required, but the blasting process becomes less complex
Solution Approach 1:
The system performs preliminary simulation and optimization of blast plans before actual execution. Multiple blast scenarios are simulated using the Kuz-Ram model to predict rock fragment size distributions, and the optimal plan is selected in advance, ensuring precise fragment size control while avoiding rework from improper fragmentation
4Manufacturing precision
If multiple blast plan options are considered to achieve optimal results, then the chance of finding the best solution increases, but the system complexity and decision-making time increase
Solution Approach 1:
The system creates simplified digital representations (models) of the physical blasting system and environment. The Kuz-Ram model and simulation software generate virtual blast scenarios that replicate real-world conditions, allowing multiple options to be evaluated computationally without requiring complex physical prototypes or trial-and-error field testing
Data Source
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AI summary
A blast plan control system and method used to control a drill and blast event is disclosed. The system and method customizes results for specific conditions. The system can receive certain inputs, such as conditions of the area to be blasted and the desired rock fragment size, and use these inputs to output a plurality of blast plans characterized by a set of characteristics that achieve the desired fragmentation size. A user can select a blast plan for execution from the plurality of blast plans. When the control system receives a selected blast plan, the control system can generate a work order for the selected blast plan and communicate the work order to operators and/or drilling equipment associated with execution of the drill and blast event. The operators and/or drilling equipment can then prepare for and execute the selected blast plan.