Statement of the Problem: The Need for Energy Efficiency Assessment in Blasting

In today’s mining and quarrying operations, energy efficiency remains one of the most pressing challenges. Blasting, being the first step in the comminution process, consumes a significant portion of total energy in mineral production. Yet, the true measure of blasting efficiency is not merely how rock is broken, but how well the resulting fragmentation supports downstream processes such as crushing and grinding.

A tool is therefore needed to assess and quantify the energy utilization in blasting, specifically through fragmentation analysis. By analyzing fragmented rock sizes in terms of percentage passing, engineers can evaluate how effectively a particular blast design converted explosive energy into rock breakage. Since controllable parameters such as burden, spacing, charge distribution, and initiation timing govern how explosive energy is distributed within the rock mass, understanding fragmentation helps determine how these parameters interact with uncontrollable factors like rock structure and discontinuities.

WipWare: The Global Ruler for Rock Size Assessment

WipWare Inc. is well known as the world leader in rock size measurement and fragmentation analysis. Known as the ruler for rock size assessment, WipWare provides innovative tools that quantify particle size distributions (PSD) from pre-blast through post-blast and into mineral processing stages, creating a continuous feedback loop for process optimization.

Pre-Blast Assessment with WipJoint

Understanding the geological conditions before blasting is crucial for predicting fragmentation outcomes. To bridge the gap between rock mass discontinuity and fragmentation potential, WipWare re-introduced WipJoint, a technology developed in 1990 by Dr. Norbert Maerz, Dr. John Franklin, and Dr. Tom Palangio.

WipJoint enables users to assess rock joint apparent spacing, apparent orientation, RQD and apparent in-situ block size from digital images of rock faces. This pre-blast information is invaluable for correlating structural conditions with post-blast fragmentation results. By analyzing joint characteristics, mining engineers can refine their blast design to ensure optimal energy distribution within the rock mass, thereby improving fragmentation and reducing energy waste in subsequent comminution stages.

Post-Blast Fragmentation Analysis with WipFrag

Once blasting is completed, WipFrag provides the most reliable and efficient means for evaluating fragmentation results. Using advanced image analysis, WipFrag calculates the particle size distribution (PSD) of fragmented rock piles and compares the results to target sizes such as the primary crusher’s gape.

This capability allows for quantitative comparison between different blast designs, helping to identify which parameters yield the best fragmentation for energy efficiency and crusher compatibility. With tools like specification envelopes and boulder detection, WipFrag makes it possible to assess whether the blast produced the desired material size and shape for downstream processes.

Material Assessment During Haulage with Reflex 6

Fragmentation control doesn’t stop at the muck pile. During haulage, WipWare Reflex 6 extends analysis to every truckload of material. Equipped with high-resolution cameras and an onboard computer, Reflex 6 captures real-time images of material in transit, either while loaded on the truck or when being dumped at the crusher hopper or stockpile.

This technology enables continuous monitoring of material quality from each blast bench, providing operators with valuable data on fragmentation size, shape, uniformity and ore type variation. The Reflex 6 system thus acts as vehicle load assessment platform, ensuring that no load goes unanalyzed.

Conveyor Belt Monitoring and Process Optimization with Solo 6

At the mineral processing stage, WipWare Solo 6 revolutionizes comminution monitoring. Installed over conveyor belts, Solo 6 continuously analyzes the size distribution of material feeding the crusher or exiting as product. This intelligent system provides live feedback to operators, empowering them to make real-time decisions for process optimization.

Solo 6 integrates seamlessly with existing process control systems such as Modbus TCP and OPC UA, allowing direct communication with plant control networks. This enables automatic crusher gap adjustment, SAG mill feed control, and load balancing, ensuring that the plant operates within optimal limits.

By maintaining consistent feed size and adjusting operational parameters accordingly, Solo 6 helps minimize bearing pressure, reduce liner wear, improve throughput, and enhance overall energy efficiency throughout the comminution circuit.

WipWare technology provides a fully integrated suite of solutions that cover every stage of the comminution chain, from pre-blast geological assessment (WipJoint), through post-blast fragmentation evaluation (WipFrag), haulage assessment (Reflex 6), and processing control (Solo 6). By quantifying and connecting each step, WipWare enables mines to measure, monitor, and optimize energy use across the entire operation. The result is smarter blasting, improved crusher efficiency, and a more sustainable approach to mineral processing, achieving the ultimate goal of energy-efficient comminution.

Mine-to-Crusher Application of WipWare Solutions: Case Study at dstgroup Quarry

This study presents the third phase of a three-part research series focused on optimizing the interface between blasting and primary crushing operations at dstgroup aggregate quarry in Portugal, using WipWare solutions. The central goal is to improve fragmentation outcomes to better align particle size distribution (PSD) with crusher requirements, thereby reducing energy consumption and enhancing operational efficiency.

Building on the baseline methodology developed in Part 1, which incorporated 3D bench modeling and borehole surveys to assess blast compatibility with crusher specifications, the study identified discrepancies between predicted and actual fragmentation results. Part 2 applied targeted adjustments, such as reducing subdrill depth and altering stemming material, achieving measurable improvements in D80, maximum fragment size, and overall blast efficiency. However, boulder formation persisted in certain blast rows, prompting further optimization.

In this phase, the team implemented remaining recommendations, including refined drill and blast patterns, increased stemming size (from D80 12 mm to 21 mm) and length (from 1.8 m to 2 m), improved drilling accuracy, and adjusted inter-hole timing. High-resolution drone imagery and point-by-point blast surveys were integrated into O-PitSurface simulations to evaluate blast performance. WipFrag software was utilized for detailed particle size analysis, enabling comparison of fragmentation outcomes before and after design modifications.

Results demonstrated significant gains: D50 decreased by 19%, D80 and D95 by 20% and 23%, respectively, and maximum particle size reduced by 3%, indicating better control over oversized material. Fragmentation efficiency improved by over 21%, and the uniformity index increased by 16%, reflecting more consistent and predictable PSD. Adjustments to stemming material and length enhanced energy confinement, minimizing premature blowout and promoting even energy distribution throughout the blast column.

Run-of-mine monitoring with the Reflex 6 system above the primary crusher provided real-time PSD analysis, confirming continuous improvement in fragmentation and crusher feed consistency. Over a six-month period, key size distribution metrics consistently trended downward, validating the effectiveness of iterative blast parameter adjustments and demonstrating the value of data-driven, integrated mine-to-crusher strategies.

In conclusion, the study illustrates how WipWare solutions, including WipFrag, Reflex 6, and O-PitSurface, enable quarry operations to optimize fragmentation, reduce oversize and fines, improve crusher compatibility, and enhance overall operational efficiency. The mine-to-crusher framework serves as a replicable model for energy-efficient, predictable, and high-performance blast-to-crusher integration.

Read Full paper here: Mine to Crusher Framework for Quarries

Welche Kantenerkennungsparameter (EDP) sollte ich verwenden?

Bei der Verwendung von WipFrag zum Analysieren von Misthaufen können Sie die folgenden Richtlinien verwenden:

Geldstrafen = Schieberegler nach rechts

Mittel = Schieberegler in der Mitte

Groß = Schieberegler nach links

Generally, you want to have accurate nets on the small- to medium-sized particles. Once you find a suitable net for this size of material you can manually edit the larger material. Using this method will help provide more accurate results. 

It’s also recommended that you try to keep a similar EDP for images of the same muck pile, or when trying to compare different muck piles.

If finer adjustments are required, you can activate the ‘Show Advanced Controls’ checkbox to access numeric inputs featuring a wider range of finer adjustments than the basic sliders provide.

WipWare Automated Photoanalysis Systems and EDP

In Delta, einer erweiterten Version der WipFrag-Software, die auf automatisierten Photoanalysesystemen von WipWare läuft, verwenden wir einen Prozess namens Best Fit EDP. Bei Online-Systemen wird dieser Vorgang in der Regel zum Zeitpunkt der Installation vor Ort durchgeführt. Es wird implementiert, indem ein Bild von typischem Material aufgenommen wird, nachdem alle Hardware- und Softwareeinstellungen abgeschlossen sind. Wir verfolgen so viele Partikel wie möglich manuell und führen dann die Best Fit EDP-Funktion aus. Die Software versucht dann, die manuelle Spur der Partikel mit den verfügbaren EDV-Einstellungen abzugleichen. Best Fit EDP gibt einen Satz numerischer Werte aus, die in die erweiterten EDP-Steuerelemente eingegeben werden. Diese Methode ist sehr genau und liefert unseren Online-Systemen gut geeignete Kantenerkennungsparameter. Es kommt selten vor, dass die EDV eines Online-Systems geändert werden muss, aber wenn dies der Fall ist, kann dies aus der Ferne von unserer Zentrale aus erfolgen.

Best Fit EDP was recently added to WipFrag software. Because of the time involved in editing an image to produce a good Best Fit EDP, this feature is most practical to reduce the amount of manual editing required if you are going to be analyzing many images (20, 30 or more) of the same material under the same conditions. For most users, where smaller batches tend to be analyzed at once, using the sliders to adjust the EDP is faster.

Within WipFrag, there is also a feature called Auto EDP which attempts to determine the edge detection parameters automatically. This feature works well if the particle size range is narrow.

Read more about WipFrag: https://wipware.com/products/wipfrag-image-analysis-software/

Sind Sie neu in der Photoanalyse-Technologie? Vielleicht haben Sie eine Installation und möchten andere Standorte untersuchen, um die Effizienz zu verbessern? Lesen Sie weiter hinter dem Sprung für einige der beliebtesten Standorte von WipWare.

Where would be an ideal location to install your technologies?

There are 5 main locations where photoanalysis technologies are installed, all of which have a similar theme of analyzing material after it has been reduced in size. I’ve listed a few (of the many) popular locations, from the mine to the mill:

Blast Fragmentation

Unlike conveyor belt technologies, blast fragmentation systems are providing particle sizing data that would otherwise be unquantifiable. As an example: When mine team is asked how they were determining blast performance, they responded with: “Well, we try to compare it just by looking at it”. By putting quantifiable values beside the material being dumped into the primary crusher, we eliminate any bias and baseline the blasting performance.

Now, think for a second how much cheaper it would be, if you could do most of your material breaking in the blasting phase: Reduced crusher needs, less maintenance on equipment, and significantly reduced energy costs to name a few of the benefits of optimizing blasting procedures.

Post-primary/Post-secondary crusher

 Either Jaw, Gyratory, or Cone, whatever type of crusher you use to break down your material, if it’s primary, secondary or tertiary crushing, you should be looking into evaluating the performance of those crushers, in order to a) maximize liner life, b) make crusher gap adjustments, c) change worn out liners before oversize contaminates your stockpile, d) improve overall crusher throughput.

See, most crusher maintenance schedules are based on a fixed timeline, when many variables can affect the lifetime of the liners. Think ore hardness, size, etc.

Wenn Sie zu einem früheren Blogbeitrag zurückkehren, können Sie diesen Teil Ihres Prozesses tatsächlich automatisieren, um maximale Effizienz zu erzielen.

Screen Breakages

Wenn Sie sofort Siebbruch- oder Verschleißindikatoren benötigen, können Photoanalysetechnologien übergroßes Material nach dem Sieben sehr gut erkennen. Hersteller von Zuschlagstoffen zum Beispiel sehen einen erheblichen Wert darin, Material außerhalb der Spezifikationen sofort nach der Identifizierung eines Siebfehlers zu identifizieren.

SAG Optimization

This is probably the location with the biggest potential return on investment, and is the most common first installation: Imagine controlling your stockpile blend based on continuous particle sizing information. Being able to optimize SAG feed can save an operation significant cost in a variety of areas.

Wissen Sie, wann Sie von den gröberen Seiten der Halde oder von der Mitte aus füttern müssen.

Want to read more about our conveyor analysis systems? Click here: https://wipware.com/products/solo-conveyor-analysis-system/

Looking for more information: See our Blast Fragment Optimization LinkedIn Page: https://www.linkedin.com/groups/12895040/

What happens to your blast fragmentation when you have excessive inter-row distance (burden)?

Introduction – Excessive Burden

According to Prasad et al. (2017), rock fragmentation size is a very important parameter for an economical point of view in any surface mining. Excessive inter-row distance, often referred to as an increased burden in blasting operations, can occur due to poor drilling operation (human factor, machine factor).

Applying Chapman–Jouguet (CJ) Condition:

The CJ condition holds approximately in detonation waves in high explosives. It states that the detonation propagates at a velocity at which the reacting gases just reach sonic velocity as the reaction ceases. In such case, excessive burden affects explosive energy distribution by diminishing the efficiency of the explosive shock wave travel, which impacts the creation of micro-cracks.

CJ Plane Theory

According to the CJ plane theory, an optimal burden ensures effective shock wave propagation and micro-crack formation, crucial for breaking rock.

With excessive burden, energy dissipates before adequately fracturing the rock, leading to poor fragmentation. This inefficient energy transfer disrupts the detonation process, reducing the effectiveness of the blast and resulting in larger, unbroken rock pieces.

Burden Distance Affects Rock Fragmentation

This article makes use of data from Prasad et al. (2017) to explain further the effect of burden increments from 2.5 to 3m. As shown by the regression line, the analysis revealed that the blast fragmentation size (D50 and D95) increases with more than 50% positive correlation.

This shows that, the larger the burden distance, the bigger the rock fragment generated from the blast. Having excessive burden with the same powder factor will definitely affect the fragmentation size and shape. To account for how your current burden is affecting your fragmentation, you should first assess your borehole condition before charging.

Furthermore, assess your blast results using image analysis software. WipFrag software is the most highly recommended blast assessment software, with a long history in addition to the latest technological innovation. The software offers significant advantages in assessing mine burden effects on fragmentation. Using the app on mobile phones allows for convenient, on-site analysis.

Deep Learning Capabilities

Deep learning capabilities save analysis time by quickly processing images. The boulder detection tool identifies oversized fragments, while the specification envelope helps correlate blast results with downstream primary crusher performance, ensuring optimal fragment sizes for efficient crushing and improved overall operational efficiency.

Follow for Part 3 – You can also find all three parts on Giant Miner’s Facebook page: https://www.facebook.com/GiantMiner

References

Prasad, S., Choudhary, B. S., & Mishra, A. K. (2017, August). Effect of stemming to burden ratio and powder factor on blast induced rock fragmentation–a case study. In IOP conference series: materials science and engineering (Vol. 225, No. 1, p. 012191). IOP Publishing.

Download WipFrag at https://wipware.com/get-wipfrag/

For Part 3 click here: https://wipware.com/effect-of-excessive-burden-distance-on-blasting-result/

Missed Part 1? Here you go: https://wipware.com/effect-of-excessive-burden-distance-on-blasting-result-part-1/

Excessive burden in blasting refers to having too much rock mass in front of the blast holes. This is relative to the designed blast parameters. The burden is the distance between a blast hole and the free face.

If this distance is too large, it can significantly impact the efficiency and effectiveness of the blasting operation. Here are some effects and consequences of excessive burden:

1. Incomplete Fragmentation:

When the blast design has too much burden distance between rows, the explosive energy may not be sufficient to break the rock effectively, leading to large, unbroken boulders or slabs.

2. Higher Vibration and Noise:

Relating ground vibration to this phenomenon, excessive burden can cause more energy to be transferred to the ground as vibrations, potentially causing damage to nearby structures and creating safety hazards (Blair & Armstrong, 2001).

On the other hand, inadequate burden can result in higher levels of air overpressure and noise, affecting the environment and nearby communities.

It’s worth noting that when there is excessive burden in blast design, the energy from the explosives is not used efficiently, leading to wasted explosive material and higher operational costs.

3. Flyrock Hazards:

Excessive burden can cause unpredictable flyrock, posing significant safety risks to workers and equipment.

4. Inefficient Loading and Hauling:

The resulting muckpile from an overburdened blast may have uneven fragmentation. This makes it harder to load and transport the material efficiently.

5. Incomplete Detonation and Misfires:

Excessive burden can cause incomplete detonation of explosives. This leads to misfires and the need for re-blasting, which adds to safety risks and costs.

Conclusion

In their paper for the 2nd World Conference on Explosives and Blasting Technique in 2003, Onederra and Esen stated that there is usually a discrete element of time that has elapsed from the time of explosive detonation to mass burden displacement. This time is designated as the minimum response time (Tmin) and is dependent on the burden mass, explosive and dynamic material response to the explosive stimulus. Generally, but not always, Tmin can be decreased by employing small burdens, using higher energetic explosives or a combination of both.

References

Blair, D. P., & Armstrong, L. W. (2001). The influence of burden on blast vibration. Fragblast, 5(1-2), 108-129.

Onederra, I., & Esen, S. (2003). Selection of inter-hole and inter-row timing for surface blasting—an approach based on burden relief analysis. In Proceedings of the 2nd world conference on explosives and blasting technique, Prague. Taylor & Francis (pp. 269-275).

Read more – Part 2: https://wipware.com/effect-of-excessive-burden-distance-on-blasting-result-part-2/

Download WipFrag at https://wipware.com/get-wipfrag/. Assess your blasting results, spot regions with poor fragmentation and trace back to your drill and blast design.

Visit Giant Miner’s Facebook page for more information about WipFrag 4 capabilities: https://www.facebook.com/GiantMiner

A Quick Summary on WipFrag version 4 and its New Features

Overview

Mining is the extraction of valuable materials called ore or sometimes industrial minerals from the earth crust, using appropriate technology with the aim to provide raw materials for industrial use.

The materials exist in massive form and must therefore be broken into handable size through blasting operation or other safe and productive ways. The use of explosive to break rock into smaller sizes had been adopted several years due to it well know advantages.

Image analysis had been proven as the way forward to enhancing blasting and improving downstream operation efficiency through accurate visualization. Image analysis is a technique use to evaluate blasting output and to monitor material flow during mineral processing.

WipFrag Image Analysis software is a powerful tool for analyzing particle size distribution (PSD) in digital images collected from various blast muck-pile, including fresh phase muckpiles after blasts, time series stockpile samples, and even drone or UAV images.

Features and Advantages

Let’s delve into its features and advantages:
1. Instant PSD Analysis: WipFrag 4 provides instant PSD analysis of the captured images. Whether you’re assessing post-blast muckpiles or analyzing stockpile samples, this software delivers accurate fragmentation data.

2. Auto-Scaling Capabilities: With auto-scaling capabilities, WipFrag 4 ensures precise measurements. It’s a cost-effective solution that saves time and resources.

3. Cross-Platform Compatibility: Seamlessly analyze images across multiple platforms, including iOS, Android, and Windows. Share results effortlessly and optimize blast performance.

4. BlastCast Blast Forecast Module: This module, included in the software, helps predict fragmentation when used alongside WipFrag particle size data. It’s a valuable tool for blast planning.

5. Deep Learning Edge Detection: This amazing tool will increase accuracy from our previous Simple edge detection and almost eliminate the need to manually edit your images.

6. Integration with WipWare Photoanalysis Systems: WipFrag 4 also controls sixth-generation WipWare Photoanalysis Systems. Monitor conveyor belts or heavy-duty vehicles in real time, providing continuous particle size data to your portable device 24/7.

WipFrag Software Options Available

WipFrag 4 offers flexible licensing options to suit different operational needs, whether you require continuous blast fragmentation analysis or occasional assessments. Here’s a quick overview of what’s available:

1. Annual Subscription

Ideal for operations requiring consistent fragmentation analysis, the annual subscription allows up to 10 simultaneous device activations per license. This is a cost-effective solution for teams working across multiple sites or needing frequent analysis.

2. Pay-Per-Use (PPU) Option

For users who need WipFrag on a project basis or for occasional assessments, the PPU image credit is a great option. This model offers flexibility, enabling you to pay only when you use the software without committing to an annual plan.

3. UAV/Orthomosaic Image Analysis:

This is included in the annual subscription with unlimited analyses for the year. If credits are preferred, a minimum of 3 credits is required to unlock the analysis results. Number of credits is determine by hectare.

4. MailFrag Single or UAV/Orthomosaic Image Analysis:

MailFrag is our online service when customers need a third party to analyze their images. Single image analysis is 3 credits and UAV/Orthomosaic image analysis is a minimum of 9 credits based on hectare. MailFrag is only available for use with credits. It is not included as an option with the annual subscription.

Which License is Right for You?

If you’re unsure which license best fits your needs, contact us to discuss your application and explore the best solution for your operation. Whether you need continuous monitoring or occasional analysis, WipFrag has an option that works for you!

Remember that credits can be transferred to other WipWare Account users. Additionally, UAV/orthomosaic images must be analyzed with the Windows version and be in GeoTIFF format.
In summary, WipFrag 4 offers a cost-effective and accurate solution for fragmentation analysis, making it an essential tool for professionals in various industries.

Multiple Language Options

WipFrag 4 has multiple language options available for our customers. The following nine languages are now available:

Englisch, Französisch, Spanisch, Deutsch, Portugiesisch, Russisch, Chinesisch, Italienisch und Hindi.

Um Ihre Spracheinstellung in WipFrag 4 zu ändern, folgen Sie bitte diesen Schritten:

Click on your Profile Icon

Klicken Sie auf die Schaltfläche Einstellungen

In Settings, click on Language to access the drop-down menu

Im Dropdown-Menü stehen 9 Sprachoptionen zur Verfügung

Weitere Informationen zu unserer WipFrag 4 Bildanalysesoftware finden Sie in unserem WipFrag-Seite.