Professional Documents
Culture Documents
Preprint 11-091
IMPROVED FRAGMENTATION THROUGH DATA INTEGRATION
R. Owen, Freeport-McMoRan Copper & Gold Inc., Morenci, AZ
INTRODUCTION
An overwhelming amount of data can be collected around the
blasting process. This information can include blasting product,
pattern design, blast results, and routing. It is only when these data
sources are combined in a concise and accurate form that they are of
real use in determining the safety and economic implications of each
parameter. Two key technological aspects of blasting are drill fleet
management (DFM) and size fraction analysis (SFA). As these
technologies are integrated as near-real-time measurement and
QA/QC tools, the resolution and realization of blasting parameters is
significantly increased. The Freeport-McMoRan Morenci Mine has
integrated these technologies along with other existing database
structures to create a responsive and sustainable tool for
reconciliation, forecasting and parameter matching. This ability allows
Morenci to customize blast patterns to meet the criteria most critical to
each shot, whether the impact is influenced by routing and recovery,
equipment maintenance or safety concerns.
The SFA cameras are mounted to the bottom of the shovel cab
and are triggered to capture images only when the shovel is in dig
configuration. This is achieved by reading the shovel geometry and
control inputs to determine the shovels position relative to the bank.
By using this Smart Trigger, it is possible to significantly increase the
number of quality images taken by each camera. The cameras are
equipped with lighting sources that allow the images to be taken 24
hours a day.
The images are transferred to a folder where they are checked for
quality. Images that contain obscuration from dust or machinery are
discarded. Images that pass this quality control are then analyzed for
size fraction distribution and processed into a database. The database
names each image and captures the time it was taken. From this time
it is possible to determine the exact GPS point where the dipper was
located when the image was captured. This position is used to code
the images into the blasting block model for comparison to other
parameters.
The value add of the DFM does not stop at drilling accurate blast
patterns. The data flow from the system gives both operators and
engineers a suite of real-time and near-real-time tools for forecasting
and adjusting mining strategy. The DFM utilizes a web-based interface
The bulk explosive data stored in the system include total weight
of product loaded into the blasthole, the type of product used, the
depth of the blasthole, amount of stemming loaded and any measured
water levels in the blasthole. This information is stored for each
blasthole. By linking this data to the exact coordinates of each
blasthole, it is possible to model the kilocalories applied to the shot.
This information is stored on the blasthole in the database and coded
to the block model. The addition of blasthole depth and water level
can be used to track water infiltration and build water models to
forecast bulk explosive product selection and loading times.
Acceptance sampling on all blasting products is completed to verify
that product placement matches design and conforms to determined
standards. This brings confidence to the kilocalorie calculations and
reduces variation in the process. Any changes to product density and
mixing ratios can have a large impact on blasting performance and are
essential for quality control.
The bulk blasting product and ideal kilocalories are coded into the
block model. These values are similarly reported monthly but are
available on demand. These elements can be run through the mine
planning statistical suite to identify correlations between product,