Improving Open-Pit Mining Efficiency: Economic and Operational Benefits of the Power Deck Method-A Case Study

This study introduces an innovative application of the Power Deck method to optimize drilling and blasting operations in open-pit mining, with a focus on the Nizar cement factory in Qom, Iran. Unlike traditional blasting techniques, this method strategically utilizes a controlled air gap at the end of each blast hole to enhance explosive energy distribution, thereby reducing excessive drilling and minimizing explosive consumption. Through five blast phases, optimal hole diameters (۷۶ mm and ۹۰ mm) were implemented while maintaining a standardized ۱-meter air gap, eliminating the need for additional drilling tests. The findings demonstrate a significant improvement in blasting efficiency, leading to a ۱۲.۵% reduction in specific charge and a ۹% decrease in specific drilling compared to conventional methods. Post-blast fragmentation analysis, validated using the F۵۰ index from Split-Desktop software, confirmed particle sizes ranging from ۱۰ to ۳۲ cm, aligning with predictions from the Kaz-Ram, Kaznetsov, and Swedifo models. Furthermore, the adoption of the Power Deck method resulted in a ۱,۴۴۸-ton increase in processed material over two months, minimizing crusher downtime due to oversized fragments. This study provides a novel, cost-effective approach to improving rock fragmentation, reducing blasting-related inefficiencies, and enhancing the overall economic performance of open-pit mining operations.

Keywords:

Drilling and blasting optimization , Power Deck method , Open-Pit Mining , Specific charge reduction , rock fragmentation