Reducing the Risk of NOx Fume Exposure during Blasting

Major Fume Events

Recently, Downer EDI Blasting services has had some success in reducing the generation of NOx fume from open cut blasting activities. 60 blasts that were reported to have generated fume within the scope of Downer Blastings Qld Many of these have been thoroughly investigated to determine the root cause

Causes of fume from blasts

9 Emulsion formulation deficient in oil content or rich in ammonium nitrate content (Oxygen rich). 9 Poor diesel absorption by ammonium nitrate prill. 9 Water ingress in products as the product exceeds sleep time limits. 9 Critical density of product. 9 Poor hose handling practices (top loading product into blast holes).

Causes of fume from blasts

9 Critical diameter for product. 9 Product desensitisation by pressure. 9 Ground conditions such as presence of cavities / cracked ground. 9 Presence of dynamic water. 9 Lack of proper product confinement (including proper stemming) 9 Direct contact of incompatible chemical compounds

Common links between major events

There is no one decisive factor that will ensure the generation of NOx within the blast process. There was however some common links that increased the likelihood of NOx fume within any blast. These included: Any product that is manufactured and loaded that is outside the optimal product specifications (AN prill, AN Emulsions and gassing agents) Dynamic water (regardless of product) Excessive sleep time Unfavourable ground conditions (cavities, hardness)

Bringing it together.
The engineering phase should consider (at least), the following aspects of the any blast: The blast outcomes The method of blast relief (vertical / free face) Area to be blasted The geological structure and rock strength of the area to be blasted The pattern dimensions The product available The amount of explosives required to blast the area (P/F) Water content Blasthole conditions Time / weather Timing

Matching the ground conditions to the Powder factor

Several of the major fume events have been found to have a powder factor that was significantly higher than required for the ground conditions. This is often the result of: A lack of understanding of the ground conditions Changing the product selection Inappropriate drilling techniques / blast patterns / drill data Areas of any blast, that are over blasted are much more likely to produce a major fume event than areas of the blast pattern that are not as heavily loaded.

An example
During one blast / fume event, the root cause was attributed to the following: There was no definitive geotechnical data available relating to either the condition of the rock or the rock strength. The designed powder factor was listed as 0.53, but from historical data, a reasonable powder factor was in the range of 0.3 to 0.45. A product change product the powder factor to 0.61 This is an actual energy rating increase of 47.5% increase applied to the same ground area This was combined with a vertical displacement relief / loss of confinement and product column decoupling.

An second example
During a second blast / fume event, the root cause was attributed to the following: Incomplete combustion reaction and due to the ingress of water or mud into the product column. (rain event) There was no definitive geotechnical data relating to either the condition of the rock within the explosives loading area (voids, cavities, fractures and faults) or the rock strength. The area was identified to be composed of wet clays and the compression strength of the material in this area is low with a reasonable powder factor could be estimated to be in the range of 0.3 to 0.45. The application of a designed energy levels (0.68 powder factor) to an area of soft / wet clays has resulted in the generation of NOx and carbon mono-oxide fumes through a loss of confinement and product column decoupling.

If you do what you always did, youll get what you always got...
DBS has recommended to the relevant sites that: Revise the use of standard pattern sizes during the wet part of the year. Engage a lower powder factor for areas of mine sites where the geological structure is predominately of a soft rock / clay structure. In areas where the geological structure is predominately of a soft rock / clay structure minimise the sleep times Engage a free face blasting to provide the appropriate burden relief as opposed to other designs The use of deck loading where a product selection has changed from Anfo to Heavy Anfo. Consider the development of blast parameters for particular parts of mine sites.

The Result???

Very encouraging with a decrease in both frequency and intensity of NOx fume event from the same areas of the same mine sites that has seen significant fume events previously Fume events are still a concern but the reduction in risk to all personnel on site(s), through the management of some key blast engineering aspects, is providing a safer work place for all.

Other steps taken to minimize NOx exposures on sites

Ensure that the mine site has: A suitable process to notify neighbours of blasting activities A fume monitoring programs for the neighbouring mine sites are in place Hard controls barriers such as the use of suitable gas monitors, blast guard positioning and communication A process that enables the estimation of the travel and spread of a credible fume event prior to the firing of the shot (e.g:- GPS compass and wind meter) A process to sample blasting activities on site to establish base line data (fume reporting) A suitable plume modelling / tracking process.

Other steps taken to minimize NOx exposures

Ensure that the mine site has: A suitable risk assessment for Blast Controlling (including fume management) A suitable document detailing obligations of persons performing the role of Blast Controller (in regards to fume management) Assessed and implemented a minimum blast exclusion zone Ensure that all persons involved in a blast as either Blast Controllers / Blast Guards and / or Shotfirers are deemed as competent persons in regards to their role on site.

Other steps taken to minimize NOx exposures

Ensure that the mine site has: A process to video all blasts to capture any fume event including tracking of the fume cloud pathway. A site specific proforma letter to the treating physician to assist in diagnosis of persons exposed to oxides of nitrogen (NOx) A pre-shift meeting document that includes a particular section relating blasting information including proposed firing time, blast location, expected blast affects and control measures, and exclusion zones / marker locations Reviewed the site procedure for Toxic Gasses on site and include a supporting procedure for the Management of Post Blast (NOx) Fume.

The aim of this presentation was simply to share our experiences with all of you! Thank You Questions?