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The effect of blast hole stemming length to

rockpile fragmentation at limestone quarries

Article in International Journal of Rock Mechanics and Mining Sciences July 2012
DOI: 10.1016/j.ijrmms.2012.04.005

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Title: The effect of blast hole stemming length to muckpile fragmentation

Article Type: Paper

Keywords: Key words: Stemming length, blasting, fragmentation, limestone,

Corresponding Author: Dr. H.T. Ozkahraman,

Corresponding Author's Institution: Suleyman Demirel University

First Author: H.T. Ozkahraman

Order of Authors: H.T. Ozkahraman; H. Cevizci, Dr.

Research Highlights

Research highlights
Two different stemming length of 3m and 4.5 m stemming length were
studied and compared with test blasting.
The analysis of measurements showed that large size boulder generation was increased
with increase in stemming length.
Better utilization of blast explosive energy is obtained with 3 m stemming length and
gave better-fragmented limestone.
Blasting efficiency is improved and blasting cost is reduced with 3 m stemming length
Finer fragmentation is obtained stemming length of three meter.
*Manuscript
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The effect of blast hole stemming length to muckpile fragmentation

H. Cevizci

H.T. Ozkahraman*

S.D.University, Engineering Faculty, Mining Engineering Department, Isparta

ABSTRACT

In this study, the effect of stemming length on muckpile size distribution is investigated.

Fourteen blasting rounds with 10 holes each are test blasted. In the first group of test eleven

blasting rounds were blasted where stemming length was 3 m long, and three groups of blast

rounds with stemming length of 4.5 m long were tested at limestone quarry of Konya cement

factory. In these test blasts average hole length were 11 m. long and diameter of holes were 89

mm. After the trial blasts muckpile size distribution were measured with standard compare

photo method. The analysis of measurements showed that large size boulder generation was

increased with increase in stemming length. For instance, +70 cm size fragments were

increased one and half times by increasing stemming length from 3 m to 4.5 m. It has proved

that the increase in high percentage of boulder formation means the cost of crushing, grinding

and hauling will be increased as well as increased time loss. Evaluating blast efficiency

resulted in important economical findings for cement sector.

Key words: Stemming length, blasting, fragmentation, limestone,

* Corresponding author +90 246 2111312 (Tel). + 90 246 237 08 59(fax)

E. Mail: tarik@mmf.sdu.edu.tr
1. Introduction

Drill cuttings are the most common stemming material used globally in open pits and

quarries, since it is most readily available in blast sites and it is cheap. Stemming blast hole

collar in surface mines with an inert material redirects blasting energy to the rock more

efficiently so, the energy is utilized more effectively in breaking rock. Cevizci (2010) studied

the effect of plaster stemming in quarry blasting and found plaster stemming was very efficient

in plugging the blast holes [1].

Fragmented limestone is used in cement production in great quantities and at building sector

as an aggregate in cement mortar [2]. The cheapest way to fragment limestone rock mass is by

blasting. Blasted limestone is send to crushers for size reduction. So producing fragments as

fine as possible reduces the work of crushers, thus the cost of breaking is reduced as well as the

cost of loading [3].

In the assessment of blasting result, rapid analysis of muckpile fragmentation is important.

So, meaningful conclusions can be drawn for blasting trials. And test blasts can be

meaningfully compared with each other, [4,5,6,7,8]. The estimation of fragmentation in blast

muckpiles by means of Standard photographs was first introduced by Van aswegen and

Cunningham [9]. The method was developed for the estimation of fragmentation in an

unknown muckpile Ozkahraman [2] used the method for critical evaluation of blast design

parameters. The Rosin-Rammler distribution equation is generally used as approximating the

size distribution of blast muckpiles in assessment and evaluation in measurement of

fragmentation. The Rosin-Rammler equation has two important parameters (K50 is the mean

size of the muckpile and n is the index of uniformity). By determining these two parameters the

size distribution can be found. The predictions of standard photograph method are found to be

accurate by Ozkahraman (2006), [2].

2. Method

The study is carried out at Konya Cement Co. limestone quarry. The quarry is located at in

Konya city, (Fig.1). Limeston quarrys view is on Fig.2. The quarry is on the Konya-Ankara

highway. There are houses and buildings around the quarry area (Fig.2), so only ten holes are

blasted at each round without any hazardous effect. Therefore, the amount of explosive is

reduced so no environmental damage would be occurred.

In the scope of study, fourteen blasting rounds with 10 holes each are test blasted. In the first

group of tests, eleven blasting rounds were blasted where stemming length was 3 m long, and

three groups of blast rounds with stemming length of 4.5 m long were tested at limestone

quarry of Konya cement factory. In these test blasts average hole length were 11 m. long and

diameter of holes were 89 mm. After the trial blasts, muckpile size distribution were measured

with standard compare photo method. The assessments were made on digital photos taken on

muckpiles generated as a result of blast trials. On these photographs, mean fragment size (K50)

and uniformity index (n) were determined by comparing with standard photographs [1].

The RosinRammler distribution equation is generally accepted as approximating the size

distribution of rock in blast muckpiles. The equation is as follows:

n
X
0.693
R K 50
=e
100

Where, R is the ratio of fragments larger than X in Eq. (3), and K50 is the mean size of the

muckpile fragments. This is also the screen size from which the 50 % of the muckpile passes, n

is the index of uniformity.

3. Results of Blasting Trials

Two groups of test blasts were studied. In the first group there were eleven rounds in the

second group there were three rounds.

3.1. First group of test rounds with drillcutting stemming length of 3 m

The results of size distribution of eleven test rounds are shown in Table 1 first column

(indicated as bold figures in Table 1). The size distribution of test round II is given below for a

sample calculation.

Fig. 3 shows a photograph of a muckpile identified as having an n equal to 1.25, with mean

fragment image size equal to 5mm, which are obtained by comparison on Standard photos. It is

easier to match uniformity index than mean fragment size. The size of the two ball images on

the muckpile photograph (Fig.3) are 2.2 and 2.8mm (the average is 2.5 mm), which

corresponds to 190mm which is the true size of balls. Reduction rate is therefore 190:2.5 or

76:1. The mean fragment image size was identified as 5 mm. Thus, the actual mean fragment

size is K50 = 76 x 5 = 380 mm and n = 1.25. Similarly, the size distributions of the ten test

rounds are shown in Table 1.

3.2. Second group of test rounds with 4.5 m drillcutting stemming

The results of size distribution of three test rounds are shown in Table 1 second column. The

size distribution of test round XIII is given below for a sample calculation.

Photograph of a muckpile identified as having an n equal to 0.75, with mean fragment image

size equal to 5mm is shown in Fig. 4. This photo is used for comparison with Standard photos.

The size of the two ball images on the muckpile photograph (Fig.4) are 2 and 1.4mm (the

average is 1.7 mm), which corresponds to 190mm which is the true size of balls. Reduction rate

is therefore 190:1.7 or 104.7:1. The mean fragment image size was identified as 5 mm. Thus,
the actual mean fragment size is K50 = 104.7 x 5 = 523.5 mm and n = 0.75. Similarly, the size

distributions of the other two test rounds are shown in Table 1.

4. Research Findings

Results of test blast trials at Konya are given in Table 1. The analysis of measurements

showed that large size boulder generation was increased with increase in stemming length.

Comparison of weight % retained for two groups of blast rounds (stemming length of 3 and 4.5

m) at Konya limestone quarry is shown in Table 2.

For instance, the amount of +150 cm size fragments were 2.01 percent at eleven test rounds

which had 3m stemming length, its increased to 18.93 percent at second group of three test

blasts where stemming length were 4.5 m., (Fig. 5). On the other hand, +70 cm size fragments

were increased one and half times by increasing stemming length from 3 m to 4.5 m., (Fig.6).

Therefore the blast efficiency is reduced by the increase of stemming length.

5. Conclusion

Stemming length should be chosen carefully. Because, the large size boulder formation is

increased rapidly by choosing the stemming length longer than necessary and blasting

efficiency will be reduced. It has proved that the increase in high percentage of boulder

formation means the cost of crushing, grinding and hauling will be increased as well as

increased time loss. Evaluating blast efficiency resulted in important economical findings for

cement sector.

Acknowledgement

Authors thank to Konya cement company for their support and Assoc. Prof. Dr. Hamdi

Akcakoca for his incouragement and help.

REFERENCES

[1] Cevizci H, 2010. In open pit blasting, the effect of stemming parameter to blasting

efficiency, Ph.D. Thesis, Isparta, 109 p.

[2] Ozkahraman H.T. Fragmentation assessment and design of blast pattern at Goltas

limestone quarry, Turkey. International Journal of Rock Mechanics& Mining Sciences 43

(2006) p. 628-633.

[3] Mac Kenzie A.S. Cost of explosives do you evaluate it properly? Mining Congress

Journal.American Mining Congress. 1966. p. 3241.

[4] Cunningham CVB. Fragmentation estimations and the KuzRam modelfour years on.

Proceedings of the second international symposium on rock fragmentation, Keystone, CO.

1987. p. 47587.

[5] Cunningham CVB. Keynote addressoptical fragmentation assessment, a technical

challenge. In: Franklin JA, Katsabanis T, editors. Proceedings of the Fragblast-5 workshop

on measurement of blast fragmentation, Montreal. Rotterdam: Balkema; 1996. p. 139.

[6] Latham JP, Kemeny J, Maerz N, Noy M, Schleifer J, Tose S. A blind comparison between

results of four image analysis systems using a photo-library of piles of sieved fragments.

Fragblast 2003;7(2):10532.

[7] Ozkahraman HT. Critical evaluation of blast design parameters for discontinuous rocks by

slab blasting. Ph.D. thesis, Middle East Technical University, Ankara, 1994.

[8] Kemeny J, Girdner K, Bobo T, Norton B. Improvements for fragmentation measurement by

digital imaging: accurate estimation of fines. In: Proceedings of the sixth international

symposium for rock fragmentation by blasting. South African Institude of Mining and

Metallurgy, Johannesburg. 1999. p. 10310.

[9] Van Aswegen H, Cunningham CVB. The estimation of fragmentation in blast muckpiles by

means of standard photographs. In: J.S.AF. vol.86(12). Republic of South Africa:Institute

of Mining and Metallurgy;1986. p. 469474.

Figure Captions

Fig. 1. Location of Konya Cement Co. limestone quarry

Fig. 2. A view of Konya Cement Co. limestone quarry

Fig.3. Muck pile used for measuring size distribution by standard photograph method in 3 m

stemming length, (Test round II).

Fig. 4. Muck pile used for measuring size distribution by standard photograph method in 4.5 m

stemming (Test round XIII).

Fig.5. Comparison of +150 cm size fraction in two groups of blast trials of stemming tests 3 m

and 4.5 m.

Fig.6. Comparison of +70 cm size fraction in two groups of blast trials of stemming tests 3 m

and 4.5 m.

Table Captions

Table 1. Weight % retained for two groups of blast tests (cumulative oversize) at Konya

cement factory limestone quarry.

Table 2. Comparison of weight % retained for two groups of blast rounds (stemming length of

3 and 4.5 m) at Konya limestone quarry

Table

Table 1. Weight % retained for two groups of blast tests (cumulative oversize) at Konya
cement factory limestone quarry
Stemming 3 4.5
length (m) FIRST GROUP TESTS SECOND
GROUP
Fragment
Size (cm) I II III IV V VI VII VIII IX X XI XII XIII XIV
300 0,0 0,0 0,5 0,3 0,0 0,0 0,0 0,0 0,1 0,0 0,0 4,2 4,9 9,7
200 0,3 0,2 3,0 1,9 0,0 0,0 0,4 0,0 0,7 0,3 0,3 9,7 10,9 17,8
150 1,3 1,2 7,2 5,2 0,0 0,3 1,7 0,1 2,4 1,4 1,3 15,2 16,7 24,9
100 5,4 6,9 17,4 14,0 0,7 2,9 6,5 2,0 8,4 5,8 5,4 24,9 26,7 35,9
70 13,0 18,0 29,4 25,2 5,7 10,4 14,7 8,1 17,6 13,7 13,0 34,5 36,4 45,6
50 23,2 32,5 41,7 37,4 17,7 22,6 25,5 19,2 28,9 24,1 23,2 43,8 45,6 54,4
40 31,1 42,7 49,6 45,5 28,9 32,5 33,5 28,7 37,1 32,0 31,1 49,7 51,5 59,7
30 41,7 55,2 59,1 55,4 44,7 45,6 44,0 41,9 47,5 42,6 41,7 56,9 58,6 66,0
20 55,8 69,9 70,5 67,4 64,5 62,3 57,9 59,2 60,9 56,6 55,8 66,0 67,4 73,6
15 64,6 77,9 76,9 74,4 75,2 71,9 66,3 69,4 68,9 65,3 64,6 71,5 72,8 78,1
10 74,7 86,0 83,9 82,1 85,6 82,0 76,1 80,2 78,0 75,2 74,7 78,1 79,1 83,3
5 86,4 93,9 91,6 90,6 94,7 92,0 87,2 91,1 88,3 86,7 86,4 86,3 87,0 89,7

Table 2. Comparison of weight % retained for two groups of blast rounds (stemming length of
3 and 4.5 m) at Konya limestone quarry

Fragment Average of Standard Average of three Standard

Size (cm) eleven tests Deviation tests Deviation
(3 m stemming) (4.5 m stemming)
300 0,08 0,16 6,27 2,44
200 0,65 0,90 12,80 3,57
150 2,01 2,13 18,93 4,26
100 6,85 4,74 29,17 4,82
70 15,35 6,68 38,83 4,85
50 26,91 7,16 47,93 4,63
40 35,70 6,79 53,63 4,35
30 47,22 6,04 60,50 3,95
20 61,89 5,24 69,00 3,30
15 70,49 4,80 74,13 2,85
10 79,86 4,15 80,17 2,25
5 89,90 2,91 87,67 1,47
Figure

Fig. 1. Location of Konya Cement Co. limestone quarry

Fig. 2. A view of Konya Cement Co. limestone quarry

Fig.3. Muck pile used for measuring size distribution by standard photograph method in 3 m
stemming length, (Test round II).

Fig. 4. Muck pile used for measuring size distribution by standard photograph method in 4.5
m stemming (Test round XIII).
 Comparison of +150 cm size fraction in two groups of blast trials

20,0 18,9

18,0
16,0
+150 cm size fraction,%

14,0

12,0
3 m stemming
10,0
4.5 m stemming
8,0

6,0
4,0
2,0
2,0

0,0

Fig.5. Comparison of +150 cm size fraction in two groups of blast trials of stemming tests
3 m and 4.5 m.

Comparison of +70 cm size fraction in two groups of blast trials

45,0
38,8
40,0

35,0
+70 cm size fraction,%

30,0

25,0 3 m stemming
20,0 4.5 m stemming
15,4
15,0

10,0

5,0

0,0

Fig.6. Comparison of +70 cm size fraction in two groups of blast trials of stemming tests 3 m
and 4.5 m.

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