Using low density explosives in Iron Ore applications
Document type: Case Study

Using Low Density Explosives
 In Iron Ore Applications

Project Summary
REDUCING THE OVERALL COST OF BLASTING AT
IRON ORE MINES
 ® ®
Dyno Nobel developed BlastLite and TITAN as cost effective
solutions for blasting weak to medium strength rock in Iron Ore
mines. The key to BlastLite lies in its ability to form a homogeneous
blend without the need to use an emulsion matrix as a binding
agent. The result is a low density explosive (LDE) of high
weight strength compared to existing LDE products, offering a
powder factor reduction compared to ANFO of around 25 per
cent in the process. These explosives are based on high ratios of emulsion to
 ammonium nitrate prill, which promote a physical barrier
TITAN BlastLite is based on a standard inhibited explosive
 between the prill and the reactive ground. formulation and has been developed as a solution for blasting
reactive ground. Customers are enjoying savings of up to 35% The challenge was to produce a low density product using
in explosives consumption. bulking agents and inhibited emulsion explosive that had both
 a low density and a resistance to reactive ground. Dyno Nobel
Both these products have the potential to significantly reduce
 built on its previous experience with emulsion blends for
powder factors and, therefore, the overall cost of blasting. reactive ground conditions to develop a new, low density
 reactive ground product.

uilt on its previous experience with emulsion blends for
powder factors and, therefore, the overall cost of blasting. reactive ground conditions to develop a new, low density
 reactive ground product. Background
 Technology Used
COST EFFECTIVE SOLUTIONS FOR BOTH NON-
REACTIVE AND REACTIVE GROUND RIGOROUS PROCEDURES FOR PRODUCT TESTING
A customer in the Pilbara wanted to reduce the overall cost of Dyno Nobel’s product protocol requires all products to be
blasting weak and/or highly fractured materials without blasted in pipes at the R&T test site prior to being fired in the
impacting on blast performance or production rates. Dyno ground. Velocity of Detonation (VoD) provided important
Nobel recognized that LDEs had the potential to satisfy their information on the performance of each explosive. A
requirement. Most LDEs that are available for non-reactive ShotTrack™ was used to measure VoD. ground are based on bulked-out versions of emulsion based High-speed video recording was employed to enhance post
explosives. The emulsion matrix is employed to make the blast analysis and the Modular Mining Dispatch system was
mixture sticky, which is necessary to minimize segregation of used to provide information on instantaneous dig rates. the explosive.

make the blast analysis and the Modular Mining Dispatch system was
mixture sticky, which is necessary to minimize segregation of used to provide information on instantaneous dig rates. the explosive. For the reactive ground solution, Isothermal and DTA tests
However, adding emulsion can off-set the benefit of lowering were used to measure the low temperature reactivity of
the density. The challenge was to produce a low-density mixtures of reactive ground and low density ammonium nitrate
product for use in non-reactive ground that also had a positive based explosives. The isothermal test, developed by Dyno
impact on costs. Nobel, is the closest representation to the actual conditions
Reactive ground conditions, on the other hand, require special, found in the field, where sulphide-containing ores are in
approved explosives that inhibit the reaction between the contact with ammonium nitrate based explosives. pyritic ground and ammonium nitrate.

Using Low Density Explosives
 In Iron Ore Applications

Large-scale field tests (bucket tests) were used to assess
ground reactivity with ANFO and low density ammonium nitrate
based explosives. A pH and oxidation/reduction potential
assessment of the reactive grounds was also undertaken.

Project Goals
ACHIEVING OVERALL COST REDUCTIONS AND
ENHANCED SAFETY LEVELS
The main project goals were to:
 1. Satisfy a customer’s need
 2. Reduce the overall cost of blasting
 3. Develop a product for non-reactive ground that is
 superior to existing LDEs in terms of performance and
 Savings in Blasting
 economics
 4. Develop a product that can achieve the safety of Both of these products are in full-time use at customer’s mine
 working with reactive ground conditions through the sites in Western Australia and are delivering significant savings
 development of explosive formulations best suited to over traditional products. the most reactive ground Blast Performance
 5. Develop a product that meets Dyno Nobel’s strict Low density explosives offer:
 safety criteria for blasting the most reactive materials.  Improved explosive distributions in the
  Blasthole (increased charge length from reduced
Value Added density), while maintaining low powder factors.  Increased charge length, without increasing powder
 factor, results in greater uniformity of fragmentation
ACHIEVING FINANCIAL AND NON-FINANCIAL
 and reduces the need for decking. BENEFITS
  There is a greater ability to compensate for drill
Safety and Productivity Gains pattern – ground mismatch – when the ground is
Dyno Nobel’s low density explosives enhance safe blasting easier to blast.

ere is a greater ability to compensate for drill
Safety and Productivity Gains pattern – ground mismatch – when the ground is
Dyno Nobel’s low density explosives enhance safe blasting easier to blast. practices in reactive ground conditions. Using the Dyno Nobel  As low density explosives produce less shock energy,
delivery system, products can be manufactured and delivered there is less damage to final walls when utilized in
as efficiently as ANFO direct to the blasthole. trim blasts. BlastLite reduced ammonium nitrate consumption by 45%  Blasting efficiency is enhanced through a reduction in
compared to an equivalent volume of ANFO. total quantity of explosive energy required to move
 less competent rock masses. TITAN BlastLite delivered a 45% reduction in ammonium
nitrate consumption compared to an equivalent volume of
TITAN 5050.

Disclaimer This case study is provided for informational purposes only. No representation or warranty is made or intended by DYNO NOBEL INC. /
DYNO NOBEL ASIA PACIFIC PTY LIMITED or its affiliates as to the applicability of any procedures to any particular situation or circumstance or as to
the completeness or accuracy of any information contained herein. User assumes sole responsibility for all results and consequences.

©2012 Dyno Nobel