total cost optimization for contour blasting in the appalachia region

105 Pages·2016·4.76 MB·English

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Theses and Dissertations--Mining Engineering Mining Engineering
2015
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Brett Christopher Jackson
University of Kentucky, [email protected]
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Jackson, Brett Christopher, "TOTAL COST OPTIMIZATION FOR CONTOUR BLASTING IN THE APPALACHIA
REGION" (2015). Theses and Dissertations--Mining Engineering. 20.
https://uknowledge.uky.edu/mng_etds/20
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The document mentioned above has been reviewed and accepted by the student’s advisor, on
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Brett Christopher Jackson, Student
Dr. Braden T. Lusk, Major Professor
Dr. Braden T. Lusk, Director of Graduate Studies
Title Page
TOTAL COST OPTIMIZATION FOR CONTOUR BLASTING IN THE
APPALACHIA REGION

THESIS

A thesis submitted in partial fulfillment of the requirements for the degree of Master of
Science in Mining Engineering in the College of Engineering at the University of
Kentucky

By:

Brett Christopher Jackson

Lexington, Kentucky

Director: Dr. Braden T. Lusk, Professor of Mining Engineering

Lexington, Kentucky

2015

Copyright © Brett Christopher Jackson 2015
ABSTRACT OF THESIS

TOTAL COST OPTIMIZATION FOR CONTOUR BLASTING IN THE
APPALACHIA REGION

Abstract

This thesis recounts the study of contour blasting practices in the Appalachia coal region.
Contour blasting practices vary widely and problems are often encountered. Several
different sites were visited and contour blasting practices at each were studied. Based on
the information gathered, a comprehensive plan was developed for blasting operations to
follow and then was tested and compared to an example of blasting practices without use
of the plan. The blasting practices were compared by examining monthly production
rates as well as a time study to measure the efficiency a contour blast could be loaded and
hauled away and a cost per cubic yard of material determined. The plan was found to be
successful in keeping safety while increasing profitability. However, the plan will need
to be backed and understood by management in order to achieve the same success.

KEYWORDS: Contour Blasting, Control Blasting, Blast Optimization, Drill and Blast,
Total Cost Optimization

Brett Christopher Jackson

6/25/2015
TOTAL COST OPTIMIZATION FOR CONTOUR BLASTING IN THE
APPALACHIA REGION

By:

Brett Christopher Jackson

Dr, Braden Lusk
Director of Thesis
Director of Graduate Studies

Dr. Kyle A. Perry
Assistant Professor

Dr. Jhon Silva-Castro
Assistant Professor
Acknowledgements
The following thesis benefited from the help of many people. First, I would like
to thank Dr. Braden Lusk, my thesis chair, for all his help, guidance, and support
throughout the process. I would also like to thank Josh Calnan and the rest of the
University of Kentucky Explosives Research team for the help and assistance they
provided when it was needed. Also in need of thanks are Dr. Kyle Perry and Dr. Jhon
Silva-Castro for their time to sit on my Thesis Committee. Everyone provide insight and
suggestions that gave guidance to improve the final product.
In addition to the technical support I received from those above, I also benefitted
from important support and encouragement from my family and friends. My parents,
Brett and Marybeth, were always providing love and support not only for this thesis, but

my entire college education from the beginning. All my friends from back home in the
Chicagoland area also provided me constant inspiration and support, believing in my
efforts to complete this endeavor. I also could not have done it without the support I
received from all my fraternity brothers in Triangle Fraternity. They were always there
to provide supportive and positive words throughout the process.

iii
Table of Contents

Acknowledgements ............................................................................................................ iii
List of Tables ..................................................................................................................... vi
List of Figures ................................................................................................................... vii
Chapter 1: Introduction ....................................................................................................... 1
Chapter 2: Review of Literature ......................................................................................... 4
2.1 Background ............................................................................................................... 4
2.2 Blast Design and Cost ............................................................................................... 4
2.3 Fragmentation ........................................................................................................... 6
2.4 Drilling ...................................................................................................................... 8
2.5 Detonators ................................................................................................................. 9

2.6 Presplits ................................................................................................................... 11
2.7 Preparing Blast Plans .............................................................................................. 11
2.8 Accidents................................................................................................................. 13
Chapter 3: Methodology ................................................................................................... 15
3.1 Evaluation of Current Practices .............................................................................. 15
3.2 Mine 1 ..................................................................................................................... 15
3.3 Mine 2 ..................................................................................................................... 17
3.4 Mine 3 ..................................................................................................................... 18
3.5 Mine 4 ..................................................................................................................... 20
3.6 Mine 5 ..................................................................................................................... 23
3.7 Mine 6 ..................................................................................................................... 26
3.8 Mine 7 ..................................................................................................................... 28
iv
3.9 Comparison ............................................................................................................. 32
Chapter 4: Proposed Plan .................................................................................................. 34
Chapter 5: Expected Results ............................................................................................. 55
5.1 Overview ................................................................................................................. 55
5.2 Fragmentation ......................................................................................................... 55
5.3 Drill and Blast Cost ................................................................................................. 56
5.4 Excavation and Haulage ......................................................................................... 57
5.5 Reclamation ............................................................................................................ 58
5.6 Profitability ............................................................................................................. 59
Chapter 6: Discussion ....................................................................................................... 61
6.1 Kuz-Ram ................................................................................................................. 61
6.2 Loader Time Study ................................................................................................. 68
6.3 Total Cost ................................................................................................................ 70

6.4 Drilling Accuracy.................................................................................................... 74
6.5 Flyrock .................................................................................................................... 74
6.6 Workplace Culture .................................................................................................. 76
Chapter 7: Summary ......................................................................................................... 78
Chapter 8: Conclusions ..................................................................................................... 82
Appendix A ....................................................................................................................... 85
References ......................................................................................................................... 91
VITA ................................................................................................................................. 94

v
List of Tables
Table 5.1: Drill and blast cost comparison of standard vs. optimized pattern .................. 57
Table 5.2: Load and haul comparison of standard vs optimized pattern .......................... 58
Table 6.1: Kuz-Ram results comparison ........................................................................... 67
Table 6.2: Drill and blast cost comparison per cubic yard ............................................... 71
Table 6.3: Truck fill factor ................................................................................................ 72
Table 6.4: Excavation cost comparison ............................................................................ 72
Table 6.5: Cost savings based on number of trucks utilized............................................. 73

Note: Tables between pages 36-64 do not follow the same table formatting pattern.
Pages 36-64 are from a different document that has been inserted into the text as a

necessary component.

vi
List of Figures
Figure 2.1: Costs based on fragmentation (Neale, 2010) .................................................... 5
Figure 2.2: Drilling and blasting cost effect on total cost (Kate, 1998).............................. 6
Figure 2.3: Particle size effect on bucket fill factor (Neale, 2010) ..................................... 7
Figure 2.4: Excessive wear due to oversize material (Neale, 2010) ................................... 7
Figure 2.5: Blast plan example ......................................................................................... 12
Figure 3.1: Typical pattern and timing sequence for Mine 1 ............................................ 16
Figure 3.2: Typical pattern and timing sequence for Mine 2 ............................................ 17
Figure 3.3: Typical pattern and timing sequence for Mine 3 ............................................ 19
Figure 3.4: Geologic conditions at Mine 3. Note highly jointed rock with additional blast
induced cracking ............................................................................................................... 19
Figure 3.5: Presplit at Mine 3 ........................................................................................... 20
Figure 3.6: Outside-row-first timing at Mine 4 ................................................................ 21
Figure 3.7: Echelon timing pattern at Mine 4 ................................................................... 21
Figure 3.8: Highly jointed and fractured geologic conditions at Mine 4 .......................... 22
Figure 3.9: Little jointing and fractured geologic conditions at Mine 4 ........................... 23
Figure 3.10: Back rows zig-zag timing at Mine 5 ............................................................ 24
Figure 3.11: Typical geological conditions and highwall at Mine 5 ................................ 25
Figure 3.12: Shot material in foreground and highwall in background at Mine 5 ............ 25
Figure 3.13: Typical pattern and timing sequence for Mine 6 .......................................... 27
Figure 3.14: Typical geologic conditions at Mine 6 ......................................................... 28
Figure 3.15: Typical pattern and timing sequence at Mine 7 ........................................... 29
Figure 3.16: Geological conditions at Mine 7 .................................................................. 30
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