Innovative Initiation System- Digital Detonator

Dr. A. K. Mishra
Faculty, Department of Mining Engineering, Indian School of Mines, Dhanbad- 826 004

Keywords: Blasting; Initiation System; Electronic Detonator; fly Rock; Noise; Controlled Blasting.

ABSTRACT:
Ever growing demand of mineral is forcing mine management to seek out and adopt technologies in order to
produce mineral economically and efficiently. Today, many mine operators use the latest explosives, equip-
ment, designs, and evaluation tools in an effort to ensure every kilogram of explosives being utilized to its
fullest potential. Globally mine operators are using few hundred tonnes of bulk explosives in each round with
variation of hole depths 35 m to 50 m and hole diameter from 259 – 310 mm. An accurate controlled se-
quence of blast detonation is a fundamental design parameter having a major direct impact on overall blast
performance. Since it is also necessary to maintain ground vibration levels within permitted limits, the mining
engineer usually prefers to have an initiating system, which should help in reduction of vibration levels along
with the capability of improving rock fragmentation, particularly keeping the environmental aspects in the
mind. As most of the Indian surface coal mines are reaching close to habitat, importance of time accuracy of
initiators are becoming more important for the mine operators as little scatter of the order of 5%~10% can
cause severe ground vibration and fragmentation problems. The need of time accuracy resulted in introduc-
tion of electronic detonators in the field of blasting applications. This paper discusses the features and bene-
fits of comparatively new electronic detonator system in the mining field.

1 INTRODCTION detonator. It has been observed by many researchers

Increased demand of mineral has compelled mineral
industry to adopt mega projects with large size of
blasts and higher capacity equipments. Hence, usage
of large amount of explosives in the mines near town
area has become a regular feature and it has in-
creased public environmental consciousness. This
has called for much greater control over blast in-
duced ground vibrations, noise and fly rock. In
search of better technology and enhancement of pro-
ductivity every mine operator is trying to adopt the
latest technology available globally. Every research
and development effort has been put by the explo-
sive and initiation system manufacturers to provide
the best to the excavation industry and to a large ex-
tent they have succeeded as well. One specific tech-
nology in initiating systems that has been under de-
velopment for several years, by several
manufacturers, and is beginning to be tested and
used increasingly in the industry is the electronic
that proper initiating system and precision of delay
time in detonators offer great advantages in control-
ling ground vibrations, fly rock, noise and improving
fragmentation.
The technology of electronic detonators is becoming
more and more advanced and being used popularly
in production blasts. This is the fitting time for blast-
ing engineers to fully explore the potential offered
by electronic detonators. While electronic detonators
are perfectly suited for controlled blasting in open
pit mines, they also offer great flexibility to under-
ground production blasts. In the underground blast-
ing, creation of sufficient void or free face is influ-
enced by having proper delay time. In underground
blasts, delay time may not be properly used if there
is not enough void/free face. In case of underground
mining applications, detonators are required to have
long delays and high precision for obtaining consid-
erable amount of void/free face. Here, electronic
detonators offer clear advantages over pyrotechnic
detonators as the accuracy is about 1 ms and delay
timings up to about 6 s can be achieved, [1].
2 IMPORTANCE OF INITIATION SYSTEMS
IN BLASTING
Blasting is usually the first step in any mining proc-
ess and its results influence the efficiency of down
stream processes to varying degrees. Blast results
are considered good when they ensure good digging
and loading operations while maintaining the safety
and environmental standards. Initiator is a term that
is used in the explosive industry to describe any de-
vice that may be used to start a detonation in explo-
sive. Detonation is the process of propagation of a
shock wave through an explosive, which is accom-
panied by a chemical reaction that furnishes energy
to maintain the shock wave propagation in a stable
manner. The devices that initiate high explosives are
called detonators and devices that start burning or
deflagration are called squibs or igniters. It is as-
sumed that the holes have been laid out and drilled
in the designed pattern and the objective of initiators
is to communicate with the holes so that it may en-
sure:
• The sequence in which the holes (or portions
of the hole) should fire,
• The time delay between holes, rows or decks,
and ,
• The energy required to begin the detonation
process,
It has been emphasized that precisely controlled re-
lease of explosive energy in a sequence of blast
holes yield better fragmentation. Hence, an accurate
control is necessary over the blast detonation se-
quence to bring direct impact on over all blast per-
formance. Any variation in hole detonation timing
results in that hole being fired prior to or after its
nominal firing time due to which holes could poten-
tially detonate totally out of sequence causing im-
proper relationships that can have adverse impacts
on the performance of a blast. The results of these
impacts have been briefed as following:
• Poor rock fragmentation
• Large amounts of oversize
• High ground vibration levels
• High air blast levels
• Fly rock incidents
• High downstream process costs
The optimum delay pattern lies within the range of
burden response time that allow good fragmentation
and displacement of each burden without the pres-
ence of cutoffs. The delay interval required for op-
timum fragmentation varies with the type of rock,
burden distances and type of explosive being fired.
The best fragmentation is achieved when each
charge is given sufficient time to break its quota of
burden from the rock mass before the next charge
detonates. Hence, the initiation systems today re-
quired to set off many charges in many separate
blast holes in a predetermined time delay pattern
which is designed to provide optimal fragmentation
and a minimum of ground vibration and fly rock.
Currently, either detonating cord with cord relays or
shock tube initiation system with trunk line delays or
electric delay detonators are used to provide proper
delay between holes or rows for proper control over
fragmentation, ground vibration, noise, back break
and fly rocks. All these systems are pyrotechnic
based which provides scattering in firing from the
designated time delay. This has called for develop-
ment of a system with precision in time delay and
with the efforts of scientists in the beginning of 20th
century electronic detonators evolved.
3 ELECTRONIC DETONATORS
At the beginning of the 20th century, a combination
of primary and secondary explosives began to be
used in detonators. During the last part of this cen-
tury, significant progress in detonator technology
has made it possible to transfer the ignition energy to
the detonator in a variety of ways via electric wires
and fuse heads, or via the NONEL tube. Pyrotechnic
delay elements with a wide span of high-precision
burning rates have been developed in 1950s with the
introduction of short-delay or millisecond-delay
blasting with 25 ms intervals which was a major
break thorough for controlling the rock blasting
process that made possible to minimize ground vi-
brations and fly rock while simultaneously improv-
ing the fragmentation. Drifting and tunnelling de-
mands half-second interval times and today the use
of high precision delays up to 6 second is in practice.
The scatter with pyrotechnic delay charges can be
held to within 1.5 to 2.5% of the nominal delay time
for short delays. The scatter in firing times has de-
creased with the successive introduction of more and
more refined detonator systems in the past (Figure
1). Over the years the manufacturers of pyrotechnic
delays have invested in manufacturing, process, and
chemical improvements in order to achieve the high
level of precision and accuracy.
Even though the improvements have been made sig-
nificantly, the most precise pyrotechnic delay com-
positions in a detonator are influenced by the follow-
ing problems causing scattering in time, [2]:
• The detonator delay compositions can shift
over time due to the chemistry of fuel and
oxidizers in the mix
• The variation in the burning rate of delay
element
 • The temperature and moisture condition at
time of use or storage may affect delay per-
formance
• The humidity and storage conditions may af-
fect performance
Cap scattering of pyrotechnic based detonators
called for launching of electronic detonator technol-
ogy to replace the conventional pyrotechnic delay
elements for having better blasting results in terms
of fragmentation with vibration control. The elec-
tronic detonator has basically integrated circuits that
produce precise timing in microseconds rather than
in milliseconds, as it is the case with pyrotechnic de-
lays, PERSSON ET AL, [3]. The electronic detonators
have been manufactured by the various manufactur-
ers in different trade names as given below:
• Daveytronic® digital blasting system
• Deltadet II ™ system (Delta cap initiators)
• SDI Electronic ignition module
• Hotshot
• i-kon™ digital energy control system (Orica
Explosives)
• UNI Tronic ™ Electronic Blasting System
[Sasol Mining Initiators Africa (Pty) Ltd.,
SA]
• SMARTDET ®, ELECTRODET® (African
Explosives Ltd.)
• Digidet® (Dyno Nobel)
pical s A typical section of an electronic detonator is shown
a. Safety fuse
b. Ordinary / Electric detonators
c. Second-interval detonators
d. Short delay detonators
e. High precision caps
f. Electronic detonators
3.1 Electronic detonator – design aspects
The electronic detonator system has three closely
interacting main components, namely, the detonator,
logger and the blasting machine, which are neces-
sary for the proper functioning of the system.
Detonator
All the electronic detonators utilize stored electrical
energy inside the detonator as a means of providing
the time delay and initiation energy. But the other
initiating systems utilize pyrotechnic energy as a
means of delay and initiation. Although construction
may not appear to be significantly different, there is
a very basic design difference between an electronic
detonator and the other two (shock tube and elec-
tric). The igniter in the electronic design is posi-
tioned below the delay (timing) module, whereas
both the shock tube detonator and the electric deto-
nator utilize the igniter ahead of the delay module
(shock tube functions as the igniter in the shock tube
device), which can be seen in figure 2. The elec-
tronic detonator design also differs from the other
two with the use of some type of stored (electrical)
energy device, typically a capacitor, in the delay
module(s).
in the figure 3. In principle, the detonator consists of
an electronic delay unit in combination with an in-
stantaneous detonator. An integrated circuit on a mi-
crochip constitutes the heart of the detonator. The
microchip circuitry includes an oscillator for timing,
memory for retaining its programmed delay, and
communication functions to receive and deliver digi-
tal messages to and from the control equipment. The
detonator has a capacitor, which can store sufficient
energy to run the microchip independent of external
power for 8 seconds and also to separate circuits on
the input side (toward the lead-in wires) in order to
protect against various forms of electric overload.
The chip itself also has internal safety circuits in the
inputs. The fuse head for initiating the primary
charge is specially developed to provide a short ini-
tiation time with a minimum of time scatter.
The detonator has the similar dimensions of a con-
ventional electric detonator with two wires, which
are usually marked with delay numbers between 1
and 250. These period numbers do not indicate the
delay time but only the order in which the detonators
will go off. Each detonator has its own time refer-
ence, but the final delay time is determined through
interaction between the detonator and the blasting
machine only immediately before initiation.
Logger
The logger is used to communicate with the detona-
tors during the hookup. It operates usually at an in-
herently safe voltage, the logger recognizes and
checks each detonator as it is clipped onto the har-
ness wire. The required delay time for each detona-
tor is entered and written into logger memory. This
information is stored in non-volatile memory (hard
memory) of the logger and used to program each
detonator only during the firing sequence. At any
stage the logger can be used to check the hook-up
and get the response from every detonator, KAY, [4].
Blasting machine
The blasting machine constitutes the central unit of
the initiation system. This machine communicates to
each detonator in turn via the logger. The unit is ba-
sically microcomputer controlled and its mode of
operation can be altered with various control pro-
grams that gives part of the flexibility of the system.
A panel with lamp indicates the current status and
gives proceed signal when the round is ready to be
fired. If any errors occur, they are immediately indi-
cated on the panel and the machine resets the sys-
tem. The ready signal for firing is given only after
receiving the satisfied operation status from the sys-
tem.
The delay timing allocation is made by the unique
coded signals exclusively coming form the blasting
machine to eliminate the possibility of error and also
to reduce the risk of any unintentional initiation
coming from other energy sources.
Mode of operation
The preparatory work for a blasting operation in-
cludes determining the delay time for each blast hole
in the round and charging the holes with detonators
of suitably chosen period numbers. The blasting ma-
chine’s time memory is then programmed with the
necessary time information adapted to the period
numbers chosen. This can be carried out by logger,
which is connected to the blasting machine.
Connection
An outline of a round using this system is shown in
figure 4. The detonators in the round are connected
in parallel rather than in series with arbitrary polar-
ity. The parallel connection is made if a faulty deto-
nator is registered, the blast can still proceed, as the
circuit will not be affected by the fault, WORSEY and
LAWSON, [5]. The parallel connection is done by
connecting each detonator to a two-wire bus cable
via a terminal block, using pliers. It is not necessary
to strip the lead wires or the bus cable before con-
necting. If an error occurs, this is automatically de-
tected by the pliers. Finally, the bus cable is con-
nected to the blasting machine via terminal box and
a firing cable.
Electronic detonator systems can first be grouped
into two basic categories:
• Factory Programmed Systems
• Field Programmed Systems
Factory Programmed Systems, in most cases,
have a fairly close resemblance to the conventional
hardware and components found with standard elec-
tric detonators. In some cases, the user may even
have a difficult time differentiating a wired elec-
tronic detonator from a wired electric detonator.
Even though these units may not appear to be differ-
ent, electronic detonators generally cannot be fired
or shot using conventional blasting machines or fir-
ing devices. Each system will have a unique firing
code or communication protocol, used to fire the
detonators in the blast.
Factory Programmed Systems can be further
grouped into specific types or styles. There are elec-
trically wired systems, where each manufacturer has
a specific wiring style or methodology, and a factory
programmed system that utilizes shock tube tech-
nology to energize an electronic timing circuit
within the detonator. Factory programmed systems
utilize "fixed" delay holes which are generally
loaded and hooked up in the same manner as stan-
dard electric or shock tube systems. Depending on
the manufacturer, some type of surface connector
may be utilized for ease of wiring, or maintenance of
correct electrical polarity.
Field Programmed Systems utilize electronic tech-
nology to program delay times "on the bench". Each
system is manufactured with unique system architec-
tures, styles, hardware and communication protocol.
There are no fixed delay times associated with these
detonators. These systems rely on direct
communication with the detonator (either prior to
loading, after loading, or just prior to firing) for the
proper delay time and subsequent blast design. In
general, these systems will utilize some type of elec-
tronic memory, which allows them to be repro-
grammed at any time up until the fire command is
given.
3.2 Characteristics of Electronic Detonators
The characteristics or important features of an
electronic detonator include:
• The detonator initially has no initiation en-
ergy of its own.
• The detonators can be programmable from 1
to 8000 milliseconds in one-millisecond in-
crements.
• The detonator cannot be made to detonate
without a unique activation code.
• The detonator receives its initiation energy
and activation code from the blasting ma-
chine.
• The detonator is equipped with over-voltage
protection.
• The short delay time between two adjacent
period numbers (equal to the shortest interval
time) is 1 ms.
• The long delay time is 6.25 seconds.
• A detonator with a lower period numbers
cannot be closer to each other in delay time
than the difference in their numbers. (For ex-
ample, the interval time between No.10 and
No.20 must be at least 10 ms)
• The maximum number of detonators con-
nected to each blasting machine is about
1600, KAY, [4].
• In comparison to shock tube initiation sys-
tems, the electronic detonators scatter per-
centage varies around 0.01 percent for any
programmed delay period, where as the
shock tube initiation systems has the scatter
percentage variation of 3.5 to 5.5 percent,
GROBLER, [6].
• The system has full two-way communication
between detonators and control equipments.
3.3 Benefits of Electronic Detonators
It has been found that electronic detonators offer the
following advantages:
• Inherent safety - with built in protection from
static electricity, stray currents, radio fre-
quency and high voltage.
• Electronic detonators can be programmed to
fire at any time from 0 ms to 8000 ms in
steps of 1 ms, which makes it possible to se-
lect the best delay time between holes and
rows to suit the particular characteristics of
each blast, rather than having to choose from
set numbers such as 17 ms or 25 ms.
• A factory-programmed security code unique
to the operator that will provide more secu-
rity and prevent unauthorized use.
• Interactive facilities with full two way com-
munication ability – as well as being pro-
grammed and armed by the system for
checking the status of the detonator and mak-
ing a circuit check before firing.
• The reduced delay and accuracy of the elec-
tronic detonators result in improving the
fragmentation in surface mining with a re-
duction in the upper size classes (oversized
material) and the fines, which in turn slash
down the power consumption significantly in
the primary and secondary crushers as well
as total throughput, BOSMAN ET AL, [7].
• Electronic detonators improve face advance
and provide safe working environment as it
reduces the over break in tunnelling.
• The possibility of having a presplit effect in
the blasts if delay timing between holes using
the shock tube initiation system below 11 ms
can be over come with the availability of
short delay electronic detonators GROBLER,
[6].
 • Reduced stock management – as electronic
detonators are programmable, only one type
of detonator is required to be stored in the
magazine.
• The absolute accuracy of electronic detona-
tors ensures each blast hole fires exactly
when it is supposed to fire. All mines, which
have used electronic detonator, have wit-
nessed 10% or more relative improvement in
casting.
• By selection of proper delay timings, blast
vibration energy can be channeled such that
predominant energy falls into higher fre-
quency range and so it offers a tool for vibra-
tion control and frequency channeling
BHUSHAN [8].
• The flexibility of selecting the timing of
holes offers blast designer to create separate
muckpile of different grades to get ore and
waste separation by re-establishing relief at
any stage of progression of blast.
3.4 Reasons for poor popularity of electronic
detonators among the users
It has been observed that the following factors are
contributing towards the less popularity of electronic
detonator among the users in the global, BRACE [9].
• Lack of understanding of the negative impli-
cations of pyrotechnic scatter.
• Perception that they are over-priced.
• Budget-controlled management systems.
• Disbelief in reported successes.
• Perceptions that the benefits of electronic
systems are limited to some applications
only.
• Archaic regulations having the effect of en-
trenching outdated technologies.
• Poor reliability, robustness, set against a very
high price premium.
• Poor marketing, spelling out of benefits, de-
livery, support, etc.
• Difficulties and cost in gaining approvals.
• Bad estimates of market potential.
• Unexpected competitive reactions.
• Poor timing of introduction and rapid market
changes after introduction.
• Inadequate quality control of a bad product.
• Wrong estimates of production costs.
• Poor market testing (price and performance)
and improper channels of distribution.
3.5 Applications of digital detonators in India
The electronic initiation system has been launched in
India by Indian Explosives Limited, a wholly owned
subsidiary of Orica, Australia. It has been used at
Zawar mines of HZL, Jayant and Dudhichua mines
of NCL and West Bokaro Colliery of TISCO.
The digital detonators have globally found their ap-
plications in the following areas:
• Improving contour blasting and decreasing
the need for the rock support,
• Minimising ground vibrations,
• Reducing damage to mine infrastructure and
nuisance to society,
• It is used regularly for production blasting in
strip mining of coal and casting of overbur-
den, open pit mining of copper, massive min-
ing of diamond and zinc, stone quarries, nar-
row reef mining of gold and platinum, and in
development of under ground excavations,
• Optimizing the rock fragmentation in under-
ground and surface mine blasts,
• The electronic detonators are preferred where
large sized blasts can be fired at risky loca-
tions, and have their delay sequencing opti-
mized to maximize fragmentation and mini-
mize other environmental hazards.
3.6 Precautions while using Electronic Detonators
The blasting personnel should adopt the following
precautions while handling the electronic detonators
in the field.
• It is always necessary to follow manufac-
turer’s warning and instructions, especially
hook-up procedures and safety precautions.
• The electronic detonators must be fired with
the equipment and procedures recommended
by the manufacturer.
• The integrity of the detonator system must be
verified prior to initiation of a blast.
• The firing circuit should be completely kept
insulated from ground or other conductors.
• The wires, connectors and coupling devices
as specified by the manufacturer should be
used.
• A minimum of 30 minutes should be suffi-
ciently given before returning to a blast site
after aborting a blast unless the manufacturer
provides other specific instructions.
• The blast area should be cleared of person-
nel, vehicles and equipment prior to hooking
up to the firing device or blast controller.
• The detonator leads, coupling devices and
connectors should be fully protected until
ready to test or fire the blast.
• The wire ends, connectors and fittings must
be kept clean and free from dirt or contami-
nation prior to connection.
• It is always necessary to follow manufac-
turer’s instructions for system hook-up of
electronic detonators.
• The manufacturer’s recommended practices
to protect electronic detonators from elec-
tromagnetic, radio frequency, or other elec-
trical interference sources should be strictly
followed in the field.
• The electronic detonator wires, connectors,
coupling devices, shock tube or other com-
ponents should be protected from mechanical
abuse and damage.
• The blaster should ensure that he has control
over the blast site throughout the program-
ming, system charging, firing and detonation
of the blast
• The extreme care should be maintained when
programming delay times in the field to en-
sure correct blast designs as an incorrect pro-
gramming can result in misfires, fly rock, ex-
cessive air blast and vibration.
• The electronic detonators and electric deto-
nators should not be kept in the same blast,
even if the same manufacturer makes them,
unless the manufacturer approves such use.
• The electronic detonators of different types
and/or versions in the same blast, even if the
same manufacturer makes them, unless the
manufacturer approves such use.
• The test equipment and blasting machines
designed for electric detonators should not be
used with electronic detonators.
• The equipment or electronic detonators that
appear to be damaged or poorly maintained
should be prohibited from use in the field.
• The blasting machines, testers, or instru-
ments with electronic detonators that are not
specifically designed for the system should
not be used.
• The attempt to cut and splice leads should
not be made unless specifically recom-
mended by the manufacturer.
• The final hook-up to firing device or blast
controller should not be made until all per-
sonnel are clear of the blast area and they
must be withdrawn to a safe location.
• The blast holes in open work near electric
power lines should not be charged unless the
firing lines and detonator wires are secured
or are too short to reach the electric power
lines.
• The handling or use of electronic detonators
during the approach and progress of an elec-
trical storm must be strictly prohibited.
• The electronic detonator systems outside the
manufacturer’s specified operational tem-
perature and pressure ranges should never be
used.
• Under no circumstances, the testing or pro-
gramming of an electronic detonator in a
booster, cartridge or other explosive compo-
nent (Primer Assembly) should be done
unless it has been charged in the blast hole.
• The electronic detonator should not be kept
in hand while it is being tested or pro-
grammed.
4 CONCLUSION
Blasting is an integral part of mining, tunneling and
construction industry. Apart from the performance,
the blasting should also satisfy the requirements of
environmental thresholds set by regulatory organiza-
tions in terms of reduction in ground vibration, air
blast etc. With the efforts of many researchers and
scientists at last a flexible and accurate initiation
system is available with blasting engineer. It has
been observed that the electronic delay detonators
improve the blasting performance for both open pit
and under ground operations. The accuracy, preci-
sion, flexibility and methodology of electronic deto-
nators offer enhanced safety and improved produc-
tivity. The improved productivity is in the form of
fragmentation control, extraction of blast geometries
and preservation of the integrity of the in-situ rock
mass. It has also found acceptance in underground
tunneling, with outstanding improvements in both
advance and back break, and has been delivering
unique ore recovery and productivity benefits in
massive mining. Continuous improvement is a nec-
essary part of blasting to maximize crusher through-
put, minimize waste and lower the total cost of pro-
duction. Here, the flexible programming capability
of electronic detonator system allows for the devel-
opment of new initiation sequences to provide new
solutions to the mining and construction industry.
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