How much can better fragmentation measurement contribute to mining and quarrying performance?
For decades, researchers and industrial operators have used WipFrag to evaluate blast results, investigate material handling challenges, and understand how particle size influences downstream operations.
In 1999, WipWare’s Tom Palangio and Dr. Norbert Maerz presented Case Studies Using the WipFrag Image Analysis System at the sixth International Symposium for Rock Fragmentation by Blasting (FRAGBLAST 6) in Johannesburg, South Africa.
Their paper summarized seven applications of image-based fragmentation measurement, drawing on field studies conducted during the 1990s. The examples remain valuable today because they demonstrate how quantitative measurements helped operators evaluate problems that had previously been difficult to investigate consistently.
The following review highlights the research findings and the practical lessons that can be drawn from them.
1. Selbaie Mine — Understanding the Cost of Fragmentation
Joutel, Quebec, Canada
During the mid-1990s, Selbaie Mine used WipFrag to evaluate explosive performance and investigate how blast fragmentation affected other mining costs.
The research examined relationships between particle size and several operating variables, including:
- Energy consumption during crushing.
- Loading rates and haul truck payloads.
- Secondary blasting requirements.
- Maintenance and material handling costs.
By quantifying fragmentation, the operation could begin evaluating the cost implications of different blast results rather than relying on visual assessments alone.
Key finding: Fragmentation measurements can help establish relationships between blast performance and costs throughout the mining process.
2. INCO Coleman Mine — Improving Fragmentation While Expanding Blast Patterns
Sudbury, Ontario, Canada
A 1994 study at INCO’s Coleman Mine demonstrated that tighter blast patterns do not necessarily produce better fragmentation.
The original blast pattern measured 5 × 10 ft (approximately 1.5 × 3.0 m), producing a characteristic fragment size (Xc) of 617 mm and substantial oversize requiring secondary blasting.
After reviewing the WipFrag results, the operation progressively expanded the blast pattern.
At 6 × 10 ft, the characteristic size decreased to 509 mm. Further expansion to 7 × 10 ft reduced it to 318 mm, with oversize largely eliminated.
The researchers reported a 40% expansion in the blast pattern and cost savings of up to 80% in the studied blasting application.
These results illustrated how excessive confinement and blast-design conditions could produce an unexpectedly broad distribution containing both oversize and fines.
Key finding: Measured fragmentation results can challenge assumptions about blast design and help identify opportunities to improve performance while reducing costs.
3. Highland Valley Copper — Connecting Fragmentation and Mill Performance
Logan Lake, British Columbia, Canada
Highland Valley Copper investigated how run-of-mine ore properties influenced grinding performance.
The research considered both ore hardness and particle size, tracking material through the mine’s crushing, conveying, and stockpile network to the grinding circuits.
Camera-based WipFrag measurements helped characterize material size distributions, while the mine’s dispatch and modelling systems supported the tracking of ore properties.
The researchers identified differences in the particle size distributions feeding the grinding lines, including variability associated with stockpile segregation.
These observations helped operators evaluate stockpile feeder adjustments and better understand the relationship between mill feed characteristics and throughput.
Key finding: Connecting fragmentation measurements with material tracking and processing data can help explain variations in grinding performance and support more consistent mill feed.
4. Benchmark Materials Quarry — Evaluating Detonator Timing
Ogdensburg, New York, USA
Bartley and Trousselle investigated the effects of detonator timing accuracy during blasting trials conducted at Benchmark Materials Quarry in 1997.
The study compared blast performance using programmable digital detonators, with WipFrag providing quantitative measurements of fragmentation size and uniformity.
The researchers reported improved fragmentation and lower vibration levels associated with high-accuracy detonators.
WipFrag provided a practical way to assess changes in the resulting particle size distribution and compare blast outcomes.
Key finding: Quantitative fragmentation measurements can provide evidence for evaluating the effects of initiation systems and timing adjustments.
5. Lafarge Exshaw — Improving Crusher Throughput and Power Consumption
Exshaw, Alberta, Canada
At Lafarge’s Exshaw operation, a fragmentation study investigated how blasting practices influenced downstream mechanical performance and energy consumption.
Researchers evaluated several factors, including blasthole deviation, subdrilling, blast design, and fragmentation uniformity.
A revised blast design using 102 mm blastholes produced finer and more consistent fragmentation.
The study reported:
- 16% improvement in crusher throughput.
- 30% reduction in crusher power consumption.
- Reduced mechanical downtime and improved loading conditions.
The research also identified improvements related to vibration and final wall damage.
Key finding: Improving blast fragmentation can support better crusher performance, but evaluating the benefit requires measurements across both blasting and processing.
6. Barkley and Carter — Evaluating Optical Fragmentation Measurement
Research on optical sizing methods
Barkley and Carter investigated the suitability of optical methods for assessing rock fragmentation.
Their research considered the limitations of traditional sizing methods and the challenges of obtaining representative measurements from blasted material.
They concluded that WipFrag, when applied carefully, could provide useful information for blast modelling, equipment selection, mining methods, and economic evaluation.
The study also highlighted the importance of sampling frequency and material variability.
This distinction remains important: collecting more images does not automatically guarantee better results. Image quality, scale, surface visibility, and representative sampling must all be considered.
Key finding: Optical fragmentation measurement can be a practical alternative or complement to physical sampling, provided the measurement method is appropriate for the application.
7. Panama Canal — Fragmentation Assessment Under Challenging Conditions
Panama
Research documented during the 1990s described the use of WipFrag to evaluate fragmentation and stemming consistency in blasting associated with Panama Canal expansion works.
The project presented challenging conditions, including complex geology, water saturation, marine traffic, and demanding construction schedules.
Fragmentation measurements helped engineers assess blast results and evaluate changes to blasting procedures.
Key finding: Image-based fragmentation analysis can provide practical measurement data in environments where conventional sampling is difficult, provided suitable imaging and sampling conditions can be established.
What These Studies Demonstrate
Although the technologies and operating practices described in these studies date to the 1990s, several lessons remain relevant.
First, blast fragmentation affects more than the immediate results of blasting. Particle size and distribution can influence loading, haulage, crushing, grinding, and material handling.
Second, measurements are most useful when they support a specific operational decision. Whether the objective is evaluating a blast pattern, comparing detonators, or investigating mill feed variability, the measurement should help answer a practical question.
Finally, fragmentation data becomes more valuable when it can be compared with other operating information. Relationships between particle size, energy consumption, throughput, and equipment performance are rarely established through fragmentation measurements alone.
Modern WipWare technologies continue to support these objectives through WipFrag for on-demand analysis, Reflex for automated vehicle-load measurements, and Solo for continuous conveyor monitoring.
For a broader explanation of where these measurements can support decisions throughout mining and mineral processing, see From Blast to Mill: Using Fragmentation Data to Improve Mining Performance.
For more information about the geological and blast-design factors influencing fragmentation, see Understanding Rock Blasting and Fragmentation.
Continuing the Research
The applications described in these early studies helped establish the foundation for subsequent developments in automated fragmentation monitoring and industrial process control.
Explore WipWare Case Studies: Fragmentation and Process Monitoring for additional research spanning conveyor analysis, SAG mill optimization, crusher performance, UAV fragmentation assessment, and integrated blast-to-crusher measurement.
References
Principal source
Palangio, T. C., & Maerz, N. H. (1999). Case studies using the WipFrag image analysis system. Proceedings of the Sixth International Symposium for Rock Fragmentation by Blasting (FRAGBLAST 6), Johannesburg, South Africa, pp. 117–120.
Selected underlying studies
Simkus, R., & Dance, A. (1998). Tracking hardness and size: Measuring and monitoring ROM ore properties at Highland Valley Copper. Proceedings of the Mine to Mill 1998 Conference, pp. 113–119.
Bartley, D. A., & Trousselle, R. (1998). Daveytronic, digital detonator testing in a vibration sensitive environment. Proceedings of the 24th Annual Conference on Explosives and Blasting Technique, pp. 247–261.
Elliott, R., Ethier, R., & Levaque, J. (1999). Lafarge Exshaw finer fragmentation study. Proceedings of the 25th Annual Conference on Explosives and Blasting Technique, Vol. II, pp. 333–354.
Barkley, T., & Carter, R. (1999). Evaluation of optical sizing methods. Proceedings of the 25th Annual Conference on Explosives and Blasting Technique, pp. 305–324.
Historical results reflect the conditions and methodologies reported in their respective studies and should not be interpreted as guaranteed performance improvements for other operations.
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