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Minimization of Blast-Induced Hazards and Efficient Utilization of Blast Energy by Implementing a Novel Stemming Plug System for Eco-Friendly Blasting in Open Pit Mines

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Abstract

Stemming is an essential blast design parameter, and inadequate stemming length/materials impact directly, among others, rock fragmentation, backbreak, flyrock, and ground vibration. This study evaluated the impact of various stemming materials such as drill cuttings (fine cuttings), angular aggregates (3–7 mm size) and synthetic rubber-assisted stemming (rubber plug) on blast efficiency in surface mines. From the trial blasts, it was found that stemming plugs and angular stone chips of proper sizes (3–7 mm) were very much effective in holding the gas energy in the stemming column/blast hole and in reducing the generation of flyrock (in many trial blasts no flyrock was seen, only more throw of the material toward free face). After conducting the trial blasts near structures (50 m range), it was found that these changes increased minor ground vibration levels near a distance up to 50 m compared to normal drill cuttings due to the high gas pressure created by the plug. However, after 50 m, the vibration attenuation followed as normal blasting. The usage of the stemming plug helped in reducing the backbreak generation for the stability of the highwall, and it also reduced the fragmentation sizes up to 53%. Reduction in fragmentation sizes for the limestone mine, stone mine, and bauxite mine helped in reducing the crushing cost and loading cycle time. In multiple instances, the average backbreak and flyrock were reduced from 2.05 to 0.74 m and from 52.7 to 19.84 m, which showed 55.57% and 61.09% deduction, respectively.

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Acknowledgments

The author is indebted toward the excellent cooperation and support provided by the entire operational crew, staff and management of the mines during the field studies and data collection.

Funding

This research received external grants/funding from the F. No. 14/15/2015-Metal IV Ministry of Mines, India.

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Authors and Affiliations

  1. Department of Mining Engineering, Indian Institute of Technology (ISM), Dhanbad, India

    Bhanwar Singh Choudhary & Anurag Agrawal

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  1. Bhanwar Singh Choudhary
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Correspondence to Bhanwar Singh Choudhary.

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Choudhary, B.S., Agrawal, A. Minimization of Blast-Induced Hazards and Efficient Utilization of Blast Energy by Implementing a Novel Stemming Plug System for Eco-Friendly Blasting in Open Pit Mines. Nat Resour Res 31, 3393–3410 (2022). https://doi.org/10.1007/s11053-022-10126-8

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