Blasting is widely used in civil and mining engineering projects, with the side effect of introducing damage to the remaining rock. The damage can be differentiated from the cracks in the remaining rock, which increases the concerns of safety and requirements for rock support. In situ study of crack development remains complicated and costly; therefore, small-scale blasting experiments are a viable alternative for a detailed investigation of the crack propagation behavior. To fill the gap, this study examined a small-scale blasting test by investigating the velocity of the cracks implementing the digital image correlation (DIC) technique and avoiding contact methods such as strain gauges. An ultra-high-speed camera (UHSC) was used to record the blasting test in a single blasthole rock-like sample with a PETN cord. The experimental design underwent calibration until achieving the configuration of the equipment while ensuring the safety distance. The developed experimental methodology was tested successfully capturing the crack behavior. The analysis outcomes showed that the raw UHSC data needed to be preprocessed to enhance the tracking of cracks with the DIC method. The findings of the DIC data analysis indicated a fluctuation in the propagation velocity along the cracks (889–1129 m/s), revealing that the proposed methodology positively contributes to the propagation behavior of using the DIC method to track the blast-induced cracks.

Sublevel caving (SLC) is a mass mining method based upon the utilization of gravity flow of blasted ore and caved waste rock. Production blasting has significant impact on the efficiency and productivity of SLC output, affecting material fragmentation, flow and recovery. Misfires could occur during blasting in SLC, which results in the loss of explosives and poor fragmentation. Usually, the blastholes are top-initiated with redundant lower primers set at + 25 ms as a precaution. If the top primers fail, the lower primers may initiate the explosive, which will induce out-of-sequence delays that can influence fragmentation and gravity flow. This work investigated the impact of misfires and out-of-sequence delays on fragmentation and gravity flow through numerical simulations using a coupled finite element and discrete element method. Different scenarios of misfires and out-of-sequence delays were studied, and the fragment size distribution was obtained to evaluate the blasting performance. The material flow behaviour was investigated to assess the gravity flow process. The results indicated that misfires significantly affect the fragmentation and the gravity flow process while the effects of out-of-sequence delays are not so significant for the investigated cases. 

The gravity flow behavior of blasted ore and caved waste in sublevel caving (SLC) mines is complex. The shape of fragmented ore and caved waste is identified as one of the principal factors influencing the gravity flow of ore. To investigate the effect of the particle shapes on the gravity flow, a code was developed to generate polyhedral fragments in different shapes and divide them into internal elements. Then these fragments were imported in the LS-DYNA code to generate SLC models containing blasted ore and caved waste and model the extraction process. To model the non-continuous loading process, the gravity flow was considered to be an intermittent process by setting a switcher at the extraction point. The flow behavior of ore from the numerical modeling is in agreement with the experimental results. The cumulative dilution of ore by waste is up to around 30%, which agrees with the results of the field survey.

Comminution is a major contributor to the production costs in a mining operation. There-fore, process optimization in comminution can significantly improve cost efficiency. The mine-to-mill concept can be utilized to optimize the comminution chain from blasting to grinding. In order to evaluate the mill performance of the ore from a specific location of the deposit, a direct link needs to be established between the mill performance and the place of origin in the mine. Today, technology enables the accurate positioning of drilling, loading, and dumping points in the mine, making the ore flow between loading and crushing more transparent. However, the material flow from the crusher to the mill is not yet fully understood and monitored. This paper presents the development of an ore transportation model, based on the virtual silo concept, between the crusher and the mill for Boliden’s Aitik mine in northern Sweden. The proposed model helps to establish a link between in situ ore location and mill performance. Two transportation time calculations are used, one based on mass balance, and one based on momentary values. Historical data are used to test the capabilities of the model and the results are compared with the transportation time calculated from the mean capacity values, commonly used in previous studies to connect mill parameters with in situ ore location. The comparison of the results show that the mean parameter-based values can be as much as 50% lower than the transportation times, even in normal operation. In the tested times, the transportation time based on momentary values systematically underestimated the cumulated times. The developed model will also serve as a starting point to analyze the effect of geotechnical parameters, in addition to drill and blast design, on the mill performance of the blasted ore.