DIFFERENTIAL ENERGY™ IN IRON ORE

PROJECT SUMMARY

In March 2020 Dyno Nobel Chile carried out four test blasts with the DIFFERENTIAL ENERGY System (hereinafter ∆E) in an Iron Mine. We call ∆E a system (Image 1), because it is a combination of the TITAN® ∆E line of bulk explosives in addition to the exclusive technology of DYNOBULK® trucks that include the software and hardware necessary to implement ∆E.

Image 1

Prior to the start of the tests, a set of samples from different areas of the mine (that were presumed to be reactive) were sent to Dyno Nobel’s R&D laboratory in Salt Lake City, Utah. The objective of sending these samples consisted of verifying, through the methodology established in the Australian Explosives Industry Safety Group (AEISG), the compatibility of Dyno Nobel´s inhibited explosive (TITAN 5000∆E) with the samples from the mine. Results came back negative for reaction, thus enabling the use of TITAN 5000∆E on those sectors.

Blastings were configured under the current D&B standards used at the mine, i.e. drilling and initiation sequence were not altered during the process.

The results confirmed benefits in:• Safety. Due to the loading efficiency of the trucks,

the exposure times of the blasting crew are reduced in loading holes subjecalling rocks and/or falling to different mine levels.

• Immediate cost reduction. In addition to the savings generated by the reduction of the direct powder factor (6.5%), a better distribution of the explosive allowed elimination and reduction of the use of double priming and decking from the standard configurations,

PROCESS DEVELOPMENT

Using the ∆E System, with the TITAN® 5000 emulsion (inhibited) and the exclusive technology incorporated in the DYNOBULK trucks, it was possible to precisely implement in each blast up to three (3) segments of different densities inside each blasthole, optimizing the use of the explosive resource without altering current results (Image 2).

DIFFERENTIAL ENERGY™ SYSTEM

optimizing the operation times and directly impacting the cost of the explosive between approximately 3% and 8%.

• Inventory optimization. Given the wide range of densities that can be achieved with the ∆E system, a single product is available for a wider range of applications, thus eliminating the complications associated with having more than one type of emulsion in the explosives plant.

Image 2

Within the main objectives established for each blast the team defined:

• Maintain or reduce direct theoretical powder factor.• Maintain or reduce the current fragmentation results.• Demonstrate the versatility of the ∆E system to

achieve a better powder distribution in the explosive column.

• Contribute to the reduction of the carbon footprint of each blast event by eliminating the consumption of fuel oil in the explosive.

As seen in the holes configuration on image 2 (loading proposal of the first test blast), the distribution of the segments can be varied and is not limited to having high densities exclusively on the bottom of the hole.

One of the unique advantages of the ∆E system is that the effective loading rate (800 kilos per minute) is not affected by the presence of water. It is for this reason that ∆E was used interchangeably in holes with water and dry holes. In dry holes, the hose was lowered to the depth of the stem (from the collar) and for holes with water, the hose was lowered to the bottom of the hole.

RESULTS

• There were no increases in the temperature of the holes loaded with ∆E in any of the stages of the process (attributable to exothermic reaction of the product and the rock).

• The gasification curve is steep within the first 5 minutes. Cup density is reached approximately within 10 minutes. The total gasification process takes between 5 to 10 minutes.

• During the density control of the segments, the results were within the parameters specified for ∆E and were consistent with the values indicated on the design. Image 3, Density control from two different segments.

• The homogeneity, viscosity, and critical diameter characteristics of ∆E contribute to eliminate the emission of nitrous gases in wet hole conditions and/or the presence of fractures. Nitrous gases were not

Image 3

observed in any of the test blasts carried out during this process.

• The velocity of detonation records obtained in the control holes showed the inflections of the density changes and are within the expected ranges for ∆E in the tested diameters. Charts 1 and 2 correspond to measurements in 97/8”. Graphs 3 and 4 Correspond to diameters of 97/8” and 8” respectively.

DIFFERENTIAL ENERGY™ IN IRON ORE

• The system reports showed that, in each blast, the effective loading time of a hole was approximately 40 seconds; this effective loading rate was recorded for both dry and wet holes.

• Using the Differential Energy technology (all test blasts), the powder factor was reduced approximately

• 6.5% (compared to the current standard). Image 4, blast result in mineral. Image 5, DYNOBULK in operation.

• Given the versatility of the system, it was possible to eliminate and reduce the double priming and double decking used in the current mine standard. It was estimated that the total removal of the additional prime (within the explosive column) in test blasts 1 and 2 reduced the cost of the explosive by approximately 8%. It was estimated that the partial removal of the additional priming in test blasts 3 and 4 reduced the explosive cost by approximately 3% and 5%.

• Due to the short time of the test period and the objectives set to the trial, the density range of the designed and proposed segments at each blast with ∆E was restricted at its upper limit to match the customer’s current densities and direct powder factor (using the same parameter settings of BxS).

• Dyno Nobel considers that, based on the results obtained, there is a clear potential for new stages of optimization where, modifications to the BxS parameters are sought which will generate greater benefits and savings. Image 6, Dyno Nobel Chile Team involved in the tests.

DIFFERENTIAL ENERGY™ IN IRON ORE

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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. ©2020 Dyno Nobel