The blasting operation considerably influences the overall productivity of opencast mines, especially when blasting results in oversized fragments that impact the operations ranging from excavation to milling. In this work, a numerical analysis of blasting performance was implemented to optimize the blasting parameters and improve the fragmentation of the hard rock in a copper open pit mine site in Brazil. In this paper, the methodology comprised data collection, 3D numerical model construction for blasting optimization using Blo-Up software, calibration with historical data, and predictive analysis, including testing two different blast designs. With the objective of achieving a desired P80 size of the blasting fragmentation, the results indicate an optimized calibrated model with an overall error equal to 4.0% using a Swebrec distribution fitted to the model data. The optimal P80 size of the resulting muckpile was equivalent to ~0.53 m for the hard rock copper fragments, which was close to the desired P80 size.

Rock blasting with explosives is the first stage of rock fragmentation and plays a key role in the results of the mining chain. Fragmentation optimization is achieved by considering the energy efficiency of the explosive, the optimal distribution of explosive energy in the rocky mass, and the programmed and controlled release of explosive energy during blasting. The quality of fragmentation is usually performed using tools that estimate the sizes of fragments via the analysis of two- or three-dimensional images. This article presents a study of the rock fragmentation optimization of very compact itabirites, based on four blasting tests, performed in a different way from the conventional blasting design. The fragmentation analysis was performed using the PortaMetricsTM tool, and compared with the Kuznetsov and Rosin–Rammler particle size distribution model, to compare the reliability of this tool. Finally, the mine productivity after blasting was estimated from the particle size distribution obtained in the tests. The model presented idealistic results considering the technical parameters used in the equations. However, the PortaMetricsTM tool suggests good performance for the preliminary evaluation of blast design.

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Innovation has an important role in improving the productivity, safety and sustainability of mining operations. Historically, ore transport was done by diesel trucks, but with the commitment to reduce CO2 emissions and increase mine safety, mining companies have invested in innovative, more sustainable ore transport technologies. The innovative truckless system, with the intensive use of belt conveyors to transport the ore from the mine to the processing plant, represents a huge project and capital investment. However, operation costs are lower when considering the decrease of fuel use and also maintenance expenses. This paper presents an economic analysis of a mine-to-crusher model to estimate and minimize the operating expenses of an open-pit iron mine located in northern Brazil. The activities at this truckless mine consist of drilling and blasting, loading and primary crushing. In this study, the calibration of the mine-to-crusher model was based on rock fragmentation from the blasting phase. The costs of each mine operation phase were estimated for an optimum 80% passing size (P80). The calibration was conducted with the values of technical and economic parameters in 2019. By considering the structural lithologies of canga and jaspillites, we concluded that the P80 value that minimizes costs might be in the range from 0.31 to 0.34 m.