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Modified Kuz-Ram Fragmentation Model and Its Use at The Sungun Copper Mine
Modified Kuz-Ram Fragmentation Model and Its Use at The Sungun Copper Mine
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Modified Kuz—Ram fragmentation model and its use at the Sungun Copper
Mine
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International Journal of
Rock Mechanics & Mining Sciences
journal homepage: www.elsevier.com/locate/ijrmms
a r t i c l e in fo abstract
Article history: Rock fragmentation, which is the fragment size distribution of blasted rock, is one of the most important
Received 9 March 2008 indices for estimating the effectiveness of blast work. In this paper a new form of the Kuz—Ram model
Received in revised form is proposed in which a prefactor of 0.073 is included in the formula for prediction of X50. This new
27 April 2009
equation has a correlation coefficient that is greater than 0.98. In addition, a new approach is proposed
Accepted 8 May 2009
to calculate the Uniformity Index, n. A Blastability Index (BI) is used to correct the calculation of the
Available online 21 June 2009
Uniformity Index of Cunningham, where BI reflects the uniformity of the distribution. Interestingly, this
Keywords: correction also can be observed in the Kuznetsov—Cunningham—Ouchterlony (KCO) model, which uses
Rock fragmentation In situ block size as a parameter for calculating the curve-undulation in the Swebrec function. However,
Blasting
it is in contrast to prediction of X50 as the central parameter in Swebrec and Rosin–Rammler distribution
Kuz—Ram model
functions. The new model is a two parameter fragmentation size distribution that can be easily
Image processing
Geomechanical properties determined in the field. However, it does not consider the timing effect, or upper limit for sizes, as does
the original Kuz—Ram model. The model is used at the Sungun Mine, and it does a good job of
predicting the fines produced during blasting.
& 2009 Elsevier Ltd. All rights reserved.
1. Introduction related to the fines fraction, and the other two are related to fines
part of the distribution.
The Kuz—Ram model, which was proposed by Cunningham, In addition, by replacing the original Rosin—Rammler equation
has been used as a common model in industry for predicting rock with the Swebrec function, the Kuznetsov—Cunningham—
fragmentation size distribution by blasting [1,2]. Although it has Ouchterlony (KCO) model is arrived at to predict the ROM size
been used extensively in practice, it has some deficiencies; one is distribution [5]. Like Rosin—Rammler, it uses the median or 50%
timing effect, the other is lack in prediction of fines. passing value X50 as the central parameter but it also introduces
There are some models that proposed to improve the an upper limit to fragment size Xmax. The third parameter, b, is a
Kuz—Ram’s model’s inability to predict the fragment size curve-undulation parameter. The Swebrec function removes two
distribution. The CZM [3] and TCM [4] models are two examples of Kuz—Ram’s drawbacks—the poor predictive capacity in fines
of extended Kuz—Ram models to improve the prediction of fines; range and the upper limit cut-off of block size.
they are known as JKMRC models. Spathis suggested that X50 should have the prefactor
In the CZM model, the size distribution of rock fragments ðln 2Þ1=n =G½1 þ ð1=nÞ. He claimed that the correction indicates
consists of coarse and fine parts. According to CZM, two different that the original implementation of Kuz—Ram will overestimate
mechanisms control the rock fragments produced by blasting. The the size of the rock fragments which may say that the original
coarse part is produced by tensile fracturing, and the Kuz—Ram Kuz—Ram underestimates the fines faction when the uniformity
model is used to predict this part of the size distribution. index is 0.8–2.2 [6].
However, fines are produced by compressive fracturing in the Riana et al. [7] presented a new method to determine the rock
crushed zone, for which the Rosin–Rammler function gets a factor A in the Kuz—Ram model. This factor was correlated to
different value of n and XC. drilling index for two different types of Indian rock types,
In the TCM model, two Rosin—Rammler functions are used for sandstone and coaly shale [7].
ROM size distribution. TCM is a five-parameter model in which
two of the parameters are related to the coarse fraction, one is
2. Review of blast fragmentation models
Corresponding author. Tel.: +98 412 344 4312; fax: +98 412 344 4311. An empirical equation for the relationship between the mean
E-mail address: babaei@sut.ac.ir (H. Aghababaei). fragment size and applied blast energy per unit volume of rock
1365-1609/$ - see front matter & 2009 Elsevier Ltd. All rights reserved.
doi:10.1016/j.ijrmms.2009.05.003
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predicts fragmentation from blasting in terms of mass percentage JPS Vertical joint spacing
passing through versus fragment size. Kuznetsov’s equation is [8]
o0.1 m 10
0:8 0.1 m to MS 20
V0
Xm ¼A Q 1=6 (1) MS* to DP* 50
Qe
JPA Joint plane angle
where Xm is the mean fragment size (cm), A is the rock factor,
(7 for medium hard rocks, 10 for hard highly fissured Rocks, 13 for Dip out of face 20
Strike perpendicular to face 30
hard, weakly fissured rocks), V0 is the rock volume broken per Dip into face 40
blast hole (m3), and Qe is the mass of TNT containing the energy
RDI Rock density influence
equivalent of the explosive charge in each blast hole (kg) and
the relative weight. The strength of TNT compared to ANFO RDI ¼ 25 RD*50 RD; rock density (t/m3)
(ANFO ¼ 100) is 115. Hence, Eq. (1) based upon ANFO instead of
HF Hardness factor (GPa)
TNT can be written as
0:8 Y/3 If Yo50
V0 Sanfo 19=30 UCS*/5 If Y450
Xm ¼A Qe1=6 (2)
Qe 115 * Meaning Unit
where Xm is the mean fragment size (cm), A is the rock factor, V0 is MS Oversize m
the rock volume broken per blast hole (m3), Qe is the mass DP Drilling pattern size m
Y Young’s modulus GPa
of explosive being used (kg), Sanfo is the relative weight strength of
UCS Uniaxial compressive strength MPa
the explosive to ANFO (ANFO ¼ 100). Since
JF ¼ JPS+JPA
V0 1
¼ (3)
Qe K
where K is the powder factor (kg/m3), Eq. (2) can be rewritten as following expression for the characteristic size:
19=30 X
115 Xc ¼ p ffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi (8)
X m ¼ AðKÞ0:8 Q e1=6 (4) n
Sanfo lnð1 Rm Þ
Eq. (4) can now be used to calculate the mean fragmentation (Xm) Since the Kuznetsov formula gives the screen size Xm for which
for a given powder factor. Solving Eq. (4) for K gives 50% of the material would pass, substituting the values X ¼ Xm
and R ¼ 0.5 into Eq. (8) gives
" #1:25
A 1=6 115 19=30 Xm
K¼ Qe (5) Xc ¼ p ffiffiffiffiffiffiffiffiffiffiffiffi
ffi (9)
Xm Sanfo n
0:693
One can calculate the powder factor required to yield the desired A useful indirect check on the index of uniformity has
mean fragmentation. In his experiments, Cunningham indicated been performed by Cunningham [2]. He based his prediction
that lower limit for A was 8, even in very weak rock mass, whereas of fragmentation on the Kuznetsov equation and used the
the upper limit was A ¼ 12. relationship between fragmentation and drilling pattern to
The Blastability Index, which was first proposed by Lilly [9], calculate the blasting parameter of the Rosin–Rammler formula.
has been adapted for Kuznetsov’s model (Table 1), in an attempt The blasting parameter, n, is estimated by
to better quantify the selection of rock factor A [2]. Cunningham
B 1 S 0:5 W L
stated that the evaluation of rock factors for blasting should at n ¼ 2:2 14 þ 1 (10)
D 2 2B B H
least take into account the density, mechanical strength, elastic
properties and structure. The equation is where B is the burden (m), S is the spacing (m), D is the borehole
diameter (mm), W is the standard deviation of drilling accuracy
A ¼ 0:06 ðRMD þ JF þ RDI þ HFÞ (6) (m), L is the total charge length (m) and H is the bench height (m).
Where there are two different explosives in the hole (bottom
The Rosin–Rammler formula is then used to predict the fragment
charge and column charge), Eq. (10) is modified to:
size distribution. It has been generally recognized as giving
a reasonable description of fragmentation in blasted rock. This sffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
ffi
B W 1 S
equation is [10]: n ¼ 2:2 14 1 þ
D B 2 2B
n 0:1
Rm ¼ 1 eðX=X C Þ (7) BCL CCL L
0:1 þ abs (11)
L H
where Rm is the proportion of material passing the screen, X is the
screen size (cm), XC is the characteristic size (cm), and n is the where BCL is the bottom charge length (m) and CCL is the column
index of uniformity. The characteristic size XC is one through charge length (m). When using a staggered pattern, this equation
which 63.2% of the particles pass. If the characteristic size XC and must be multiplied by 1.1. The value of n determines the shape
the index of uniformity n are known, a typical fragmentation of the Rosin–Rammler curve. High values indicate uniform sizing.
curve can be plotted. Eq. (7) can be rearranged to yield the Low values, on the other hand, suggest a wide range of sizes
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S. Gheibie et al. / International Journal of Rock Mechanics & Mining Sciences 46 (2009) 967–973 969
including both oversize and fines. This combination of the where Pfines(x) is the passing percent for fines, X is the size of
Kuznetsov and Rosin—Rammler equation results in what has particles, K is the Top size or rock fragments, and n is the material
been called the Kuz—Ram fragmentation model. constant.
After merging the fines and coarse size distributions obtained
by Eq. (12) and image analysis, as a result Fig. 2 shows the
3. Research method corrected size distribution which is almost closer to sieving
result. By assuming that the rock fragmentation size distribution
3.1. Prediction of ROM size distribution follows the Rosin—Rammler distribution, thus, the two formulas
proposed by Chung and Katsabanis can be used to calibrate the
Based on a modified blastability index, the geomechanical distribution [13]:
properties of ten blast sites were collected prior to blasting.
X c ¼ eð0:565LnX m þ0:435LnX 80 Þ (13)
Several laboratory tests were carried out according to ISRM
standards to determine the mechanical and physical parameters n ¼ 0:842=ðLnX 80 LnX m Þ (14)
such as Young’s modulus, density and uniaxial compressive
strength and the overall results of these tests and collection have where Xm is the sieve size at 50% material passing (cm), X80 is the
been shown in Table 2. The flowchart (Fig. 1) shows the steps sieve size at 80% material passing (cm), XC is the sieve size at
in the ROM size distribution prediction, image processing, 63.2% material passing (cm), and n is the uniformity index. The
modification and validation of the modified model. values obtained from Eqs. (10) and (11) can be seen in Table 2.
As Table 3 shows, the Kuz—Ram model overestimates the size
distribution. This confirms that the mean fragment size (Xm)
3.2. Fragmentation assessment and uniformity index (n) as the model’s inputs are not true
(obtained from image analysis) values. Thus, the Kuz—Ram model
After estimating the ROM size distribution for each case of is modified in this paper with the aim of having a better
blasting at the Sungun Mine, image processing studies were prediction of ROM size distribution. Results obtained at the
carried out for 10 blast sites muck piles. All blasts results were Sungun Mine show that Kuznetsov’s model underestimates the
analyzed after conducting blasting operation at three positions of mean fragment size (Table 3). Also, the predicted uniformity
muck pile (soon after blasting, after loading around half of muck indexes for each blast site were different from those obtained by
pile and end of muck pile). For image processing, 15 digital image analysis.
photographs were taken from each muck pile position and then
processed by the Goldsize program. The analyzed photo results
were merged to get a better analysis of the photo analyses. 4. Proposed model
3.3. Fines correction and distribution calibration By analyzing the data from Sungun the two equations below
are proposed to predict ROM size distribution. The Rosin—Rammler
Since there are some fine particles that are hidden, the results function is used as the size distribution with Xm as central
obtained by image analysis are always different from those of by parameter and n, as the uniformity index for:
sieving. Fines correction usually is the common deal to overcome 0:8
V0 Sanfo 19=30
this problem in practice. Some methods that can be used to X m ¼ 0:073BI Qe1=6 (15)
Qe 115
correct fines have been discussed in the literature [5,11,12].
In this paper, for correcting the fines a representative sample
n0 ¼ 1:88 n BI0:12 (16)
was provided from muck pile. The sample was analyzed by sieving
and image processing. There were some differences between the All parameters in Eq. (15) are similar to those described in Eq. (2),
sieving and imaging methods. Actually, image analysis did not where n0 is the modified uniformity index, n is the uniformity
include particles below 40 mm in this sampling and the fines ratio index (Cunningham) and BI is the blastability index. The r2 values
was nearly 7%. Since the distribution of sizes below 40 mm at for Eqs. (15) and (16) were 0.98 and 0.96, respectively.
the Sungun was a straight line in log–log plot, therefore, a Gaudin-
Schuhman distribution can be adopted to plot the size distribu-
tion curve [11]: 5. Validation of proposed model
x n
P fines ðxÞ% ¼ (12) To validate the proposed model, five blast sites were studied
k
(Table 4). All the steps in the flowchart (Fig. 1) including fines
correction discussed in the Section 3.3 were carried out in the
verification study. Results show that the proposed model has
Table 2 the acceptable ability to predict the ROM size distribution at the
Rating of geomechanical parameters collected from field.
Sungun Copper Mine (Table 5). Fig. 3 shows the reliability of the
Blast site BI n00 (Modified model) n0 (Image analysis) n (Uniformity index)
results.
− −
− −
−
−
Fig. 1. Steps of Run of Mine (ROM) size distribution prediction, Kuz—Ram modification and validation.
Rock masses are an anisotropic and inhomogeneous media, angle, etc. Therefore, geomechanical properties as the most
with different physical and mechanical behaviors in different important parameters in rock blasting are not considered
directions. There are many parameters used in the technical explicitly [14,15]. Therefore, it seems that Kuznetsov’s equation,
description of rock masses, of which the blastability index uses theoretically and practically, will not predict the mean fragment
some, such as rock mass description, joint spacing, joint plane size accurately.
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S. Gheibie et al. / International Journal of Rock Mechanics & Mining Sciences 46 (2009) 967–973 971
100 Table 3
Predicted and actual size distribution for each blast site.
80 MO-1
Kuz-Ram 10 17 33.4
Image analysis 13.8 22 38.7
Proposed model 13.5 21.3 38
60 MO-2
Fines Ratio = 7%
Kuz-Ram 10.6 18 35.3
End fine size 40 mm
%
Fig. 2. Fragment size distribution obtained by image analysis, fines and fines DI-1
corrected distribution. Kuz-Ram 11.8 20 39.3
Image analysis 16.7 26.5 48
Proposed model 16.1 25.8 47
As the blast geometry and the explosive used were equal for all DI-2
blasts, it can be concluded that these differences arise from the Kuz-Ram 12.9 22 43.2
incomplete description of rock mass properties. Image analysis 17 27 49.2
The blastability index is representative of rock mass properties Proposed model 17.38 27.3 48.4
in the Kuznetsov’s equation. Paying attention to the parameters DI-3
used in the BI system, it is known that RMD, JPS, JPA, etc., alone Kuz-Ram 13.5 23 45
are not able to describe rock mass properties completely. As an Image analysis 18.8 28.5 51.7
Proposed model 17.7 28 50.9
example, joint aperture is one of the important properties
of joints, which affects the rock mass blastability [14,16], but is DI-4
Kuz-Ram 14 24 47
not considered in the BI system. Joint aperture controls the
Image analysis 18 29 53
outgoing gases and energy retention time in rock mass. If this Proposed model 18.3 29.5 53.8
parameter as an increasing parameter in BI system is considered,
DI-5
the BI value will increase, and the mean fragment size will be Kuz-Ram 15.3 26 51
closer to true value. Since the correction of BI and insertion of any Image analysis 19.8 32 58.7
effective parameter or development of a new classification system Proposed model 19.7 31.7 58.1
requires extensive researches in different mines and conditions,
these corrections are beyond the scope of this paper.
In addition, exponent n in the Rosin—Rammler model is the Table 4
uniformity of fragmentation distribution. The uniformity index Rating of geomechanical parameters collected from field for validation.
proposed by Cunningham depends on blast geometrical para-
Blast site BI n00 (Proposed model) n0 (Image processing) n (Uniformity index)
meters. As Eq. (10) shows, there is no parameter to describe the
rock mass properties. Although the uniformity index is deter- M-1 81.75 1.932 1.898 1.8
mined by blast geometry, in some methods, such as those M-2 73.75 1.136 1.223 1.032
proposed by Lilly [17] and Moomivand [16], blast geometries are M-3 80 1.606 1.612 1.400
M-4 78.75 1.525 1.552 1.400
determined on the basis of rock mass properties. M-5 92.5 1.506 1.482 1.554
As the only variable in all 10 blasts is the rock mass
geomechanical parameters, it seems that there may be a relation
between rock fragmentation uniformity and rock mass properties. blasting creates just few new fracture surfaces; it just produces
Certainly, assessment of rock mass properties effects on size blocks whose external surfaces are altered. These results strength-
distribution of rock fragments is difficult. Existence of disconti- en the theory of rock mass properties effects on uniformity of size
nuities with different properties, anisotropy and inhomogeneity of distribution of rock fragments.
rock mass media, adds to the blasting mechanisms complexity. In this research, a relation between real uniformity of rock
This complexity indicates that separation of gas pressure and fragments and blastability index was obtained. Through decreas-
shock wave efficiencies is difficult. Thus, achievement of a relation ing the joints spacing, the size of insitu blocks becomes more
in this case requires more researches. uniform. By releasing adequate gas particles, the blocks will
In Sungun Mine, there are several joint sets, which create liberate. Boulder formation is common in widely spaced jointed
uniform blocks. The explosive type used at the Sungun is ANFO, rock mass blasting [15]. Bhandari concluded that blasts in rock
which has high gas energy (EB) and produces high gas pressures. masses with parallel or perpendicular joints to bench face, leads
The gas particles passing the joints activate the elder joints and to a uniform fragmentation [15]. Certainly, BI may not be
then liberate the insitu blocks. In some sites at the Sungun Mine, completely proper to make a relation with uniformity; therefore,
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972 S. Gheibie et al. / International Journal of Rock Mechanics & Mining Sciences 46 (2009) 967–973
Table 5 model has the different prefactor of 0.073. But maybe it rises from
ROM size distribution of image processing and modified model at the Sungun for different geological aspects of blast sites.
validation.
On the other hand, KCO uses a parameter, b, which is called
Blast site X30 X50 X80 curve-undulation parameter. According to the KCO, b is the function
of Cunningham’s uniformity index, Xmax and X50. Xmax is defined as
M-1 the minimum of insitu block size, S or B. Equally, in newly proposed
Proposed model 18.5 27.3 45 model n0 as the modified uniformity index is adopted Cunningham’s
Image analysis 20 30 49
uniformity, n and BI as representative of rock mass. Interestingly,
M-2 BI and the insitu block size are related to each other. Therefore, it is
Proposed model 14.85 27.9 62.1
believed that it has a challenging concept in rock fragmentation size
Image analysis 16 30 65.5
distribution which was revealed in both the KCO and the newly
M-3
proposed model in this paper.
Proposed model 19.95 33.5 64.7
Image analysis 20.84 35 66.9
M-4
Proposed model 17.33 31.7 68 7. Conclusion
Image analysis 18.33 33 69.56
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