{"id":11486,"date":"2025-12-04T18:30:05","date_gmt":"2025-12-04T18:30:05","guid":{"rendered":"https:\/\/northamericanmining.com\/?p=11486"},"modified":"2025-12-04T18:30:07","modified_gmt":"2025-12-04T18:30:07","slug":"green-vibrations-rethinking-drill-and-blast-for-a-cleaner-future","status":"publish","type":"post","link":"https:\/\/northamericanmining.com\/index.php\/2025\/12\/04\/green-vibrations-rethinking-drill-and-blast-for-a-cleaner-future\/","title":{"rendered":"Green vibrations: rethinking drill and blast for a cleaner future"},"content":{"rendered":"\n

Innovation in surface drill and blast operations is delivering measurable improvements in environmental performance, operational efficiency, community impact, and personnel safety.<\/strong><\/em><\/p>\n\n\n\n

by Jonathan Rowland<\/em><\/p>\n\n\n

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\"Adjustments
Adjustments to drill-and-blast practices can deliver improvements that cascade throughout the entire value stream.
Photo: Dyno Nobel<\/em>
<\/figcaption><\/figure>\n<\/div>\n\n\n

As the mining industry intensifies its focus on sustainability, surface drill and blast practices are undergoing a shift. Once viewed primarily through the lens of productivity and cost-efficiency, innovation is helping to reimagine these operations as significant levers for reducing environmental impact, enhancing safety, and supporting long-term operational resilience. North American Mining<\/em> asked several leading suppliers of drilling equipment and blasting solutions how they were supporting this evolution.<\/p>\n\n\n\n

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\"Electronic
Electronic detonators, such as Dyno Nobel\u2019s DigiShot Plus XR initiator, offer greater control over fragmentation and vibration.<\/em><\/figcaption><\/figure>\n<\/div>\n\n\n\n
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\"Epiroc\u2019s
Epiroc\u2019s Common Automation Panel is a single ergonomic station that enables remote control of multiple surface rigs.<\/em><\/figcaption><\/figure>\n<\/div>\n<\/div>\n\n\n\n

DYNO NOBEL: THE POWER OF PRECISION<\/strong>
Blasting presents an excellent opportunity to develop more environmentally friendly practices, Mike Kotraba, Dyno Nobel\u2019s general manager of Advanced Solutions, told North American Mining<\/em>, noting that the success of sustainability initiatives in surface mining is reliant on the ability to execute blast plans as designed. \u201cExplosive products designed for precision and accuracy enable operations to fine-tune their blasting practices, minimizing environmental impacts,\u201d he explained.<\/p>\n\n\n\n

According to Kotraba, the company\u2019s DIFFERENTIAL ENERGY technology was developed with that precision in mind: \u201cBy varying the density of TITAN bulk emulsion throughout the borehole, it ensures each rock segment receives the explosive energy needed for optimal fragmentation. Meanwhile, our Delta E2 preload software utilizes data from drills, alongside other sources that characterize rock properties, to target the ideal placement of energy. Blast plans are then sent directly to the loading equipment to ensure each hole is loaded as designed.\u201d<\/p>\n\n\n\n

By placing the energy exactly where it is needed, it is \u201ceasier to minimize flyrock and NOx emissions,\u201d continued the Dyno Nobel expert. \u201cIn addition, because TITAN bulk emulsion is viscous, it tends to stay in the hole rather than migrating into cracks and voids; it also minimizes groundwater contamination by displacing the water in the borehole, so dewatering is not required.\u201d<\/p>\n\n\n\n

In one example, a gold mine in Australia switched from an ammonium nitrate\/emulsion blend to TITAN bulk emulsion and DIFFERENTIAL ENERGY technology. \u201cThey reduced their greenhouse gas emissions by 7%, improved truck fill factors by 13%, and eliminated post-blast NOx emissions,\u201d said Kotraba.<\/p>\n\n\n\n

Electronic detonators are another innovation that provides the precision necessary for sustainability in mining. \u201cBy enabling millisecond timing accuracy, they offer unmatched flexibility in any environment,\u201d Kotraba explained. \u201cMeanwhile, their precision provides operations with greater control over fragmentation and vibration, thereby reducing the negative environmental impacts and effects on nearby communities.\u201d<\/p>\n\n\n\n

Sustainability From Drill to Mill and Seam to Stone<\/strong>
Kotraba also highlighted the company\u2019s Drill to Mill and Seam to Stone processes, which focus on adjusting drill-and-blast practices to improve outcomes that cascade throughout the entire value stream. These processes rely on the DynoConsult team of drill-and-blast experts, who partner with operations to baseline current practices, establish best practices, identify areas for improvement, implement changes, and sustain results in the long term. \u201cAs optimized material moves downstream through the remaining mining processes and processing circuit, it is not just monetary value that compounds; sustainability benefits compound as well,\u201d explained Kotraba, with the impact felt in both load-and-haul operations and downstream to the mill.<\/p>\n\n\n\n

For example, precise energy placement, millisecond timing accuracy, and well-crafted blast designs optimize fragmentation, resulting in:<\/p>\n\n\n\n

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  • Improved excavator and truck fill factors;<\/li>\n\n\n\n
  • Shorter loading times, allowing for the movement of more tons per shift;<\/li>\n\n\n\n
  • Lower carbon emissions from heavy equipment as they become more efficient; and<\/li>\n\n\n\n
  • Reduced wear and tear on equipment, increasing its longevity and reducing the carbon footprint associated with equipment manufacturing.<\/li>\n<\/ul>\n\n\n\n

    Meanwhile, at the crusher and the mill, optimized rock fragmentation enables improved throughput and reduced power requirements. The lifespan of wear items such as mantles and liners is also extended.<\/p>\n\n\n\n

    The Drill to Mill and Seam to Stone processes \u201cillustrate what is possible when operations combine the right products with the right blast design and execute it with precision,\u201d concluded Kotraba. \u201cThe sustainability benefits reach beyond the bench to compound throughout the entire value chain.\u201d<\/p>\n\n\n

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    \"Incorporating
    Incorporating electrification and automation reduces a drill rig\u2019s environmental impact while removing operators from hazards. Pictured: Epiroc\u2019s SmartROC D65 battery electric (left) and Pit Viper 271 XC fully electric drill rigs (right).<\/em><\/figcaption><\/figure>\n<\/div>\n\n\n

    EPIROC: AUTOMATING AND ELECTRIFYING DRILL RIGS
    <\/strong>Two items high on Epiroc\u2019s agenda are minimizing environmental impact, which encompasses decarbonization and electrification solutions, and enhancing operational safety by removing humans from hazardous situations through automation. \u201cBy 2030, we have committed to halving absolute CO\u2082 emissions across our operations, transport, and from customers\u2019 use of our products,\u201d said Matthew Inge, Business Line Manager \u2013 Surface Drills, Automation & Digital. \u201cWe are committed to offering a full range of emission-free products, while striving to tackle social, operational, and environmental challenges and significantly reducing work-related injuries.\u201d<\/p>\n\n\n\n

    For example, the company\u2019s Live Work Elimination (LWE) product portfolio integrates technology, change management, and safety culture to prevent operators from being exposed to harm. \u201cIt focuses on extending equipment lifespan to reduce maintenance risks, utilizing remote diagnostics to minimize onsite intervention, and advancing automation and equipment design to enable remote task execution in hazardous environments,\u201d explained Inge.<\/p>\n\n\n\n

    To support a cleaner environment, Epiroc is advancing its shift toward electrification with innovative battery-electric drilling solutions, said Ron Hankins, Business Line Manager \u2013 Surface & Exploration Drilling Equipment, who pointed to the SmartROC D65 battery-electric rig as a \u201csignificant step toward zero-emission drilling, replacing traditional diesel engines with electric powertrains to eliminate direct CO\u2082 emissions, reduce noise pollution, and improve energy efficiency.\u201d According to Hankins, electric motors also offer better torque control, lower maintenance needs, and less downtime. At the same time, the rig\u2019s simplified hydraulic system uses 80 fewer gallons of oil while reducing the risk of leaks and contamination.<\/p>\n\n\n\n

    As mining equipment becomes more battery and electric-driven, \u201cautomation is also revolutionizing operations by enhancing safety, efficiency, and precision,\u201d added Hankins. \u201cAutonomous rigs, such as the SmartROC D65, operate without an onboard operator. Monitored remotely from a centralized control center, they enable 24\/7 operation while keeping personnel out of hazardous environments. They can perform tasks such as tramming, handling drill rods, and drilling blast holes entirely independently, with GPS integration ensuring consistent drilling, improving fragmentation, and reducing the need for secondary blasting.\u201d<\/p>\n\n\n\n

    Similarly, the electric-driven Pit Viper 271 XC E marks \u201canother milestone in Epiroc\u2019s electrification journey,\u201d said Hankins. \u201cBy eliminating fuel consumption and exhaust emissions, it significantly reduces the environmental impact of drilling operations, while advanced automation allows similar remote operation as the SmartROC D65, improving operational safety and efficiency.\u201d Operational gains include a 34% increase in drilling capacity and the ability for one operator to oversee multiple rigs. Additionally, \u201cby eliminating human variability, the system maintains consistent performance, resulting in higher productivity and more reliable results.\u201d The full Pit Viper lineup is now available in electric versions.<\/p>\n\n\n\n

    Sitting alongside autonomous rigs, the company\u2019s Common Automation Panel is a single ergonomic station that enables remote control of multiple surface rigs. \u201cDesigned for safety, efficiency, and operator comfort, CAP supports mixed-fleet operations with seamless rig switching, scalable architecture, and standardized components that reduce training, maintenance, and spare-parts costs,\u201d Inge explained. \u201cIts intuitive touchscreen and joystick interface improve usability, while centralized control enhances situational awareness, operator well-being, and alignment with ESG goals.\u201d<\/p>\n\n\n\n

    By integrating emission-free equipment, remote and autonomous operations, and advanced safety systems, Epiroc is \u201csignificantly reducing the environmental and human impact of drilling and blasting,\u201d concluded the two experts, \u201cdemonstrating how purposeful innovation can drive meaningful progress toward a safer, more sustainable mining industry.\u201d<\/p>\n\n\n

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    \"Orica\u2019s
    Orica\u2019s FRAGTrack automated fragmentation analysis system, enabled with high-precision georeferencing capability, provides particle size distribution down to the blast and blasthole level.<\/em><\/figcaption><\/figure>\n<\/div>\n\n\n

    ORICA: INNOVATING FOR IMPACT<\/strong>
    Orica is combining chemistry, digital tools, and real-world mining expertise to minimize the impact of drilling and blasting while enhancing field results, focusing on technological innovation. \u201cIt is not just about breaking rock anymore; it is about how that rock is broken, what happens next, and what impact is left behind,\u201d explained Adam Aubin, principal manager at Orica Technical Solutions North America. This philosophy is evident in several recent innovations.<\/p>\n\n\n\n

    According to Aubin, the company\u2019s 4D bulk system enables real-time energy customization, allowing operators to match explosive energy to specific geological conditions. This precision enhances fragmentation and wall control while reducing overall explosives consumption by optimizing energy use in each blast hole. \u201cThe result is lower environmental impact \u2013 less vibration, fume, and nitrate leaching \u2013 and improved cost efficiency, making it an intelligent and sustainable solution for modern surface mining,\u201d Aubin concluded.<\/p>\n\n\n\n

    Another example is Fortis Protect, a bulk explosive engineered to address the environmental concerns over nitrate leaching that have recently gained attention across surface mining operations. \u201cNitrates can wash out of waste dumps over time, leaching into surrounding soil and water,\u201d explained Aubin. \u201cFortis Protect is designed to minimize this risk right from the start, with a formulation that limits nitrate loss during and after the blast. Our approach also includes a broader nitrate management framework. This three-step strategy begins by mapping how nitrates behave on a mine site, comparing current practices to industry best practices, and recommending changes to reduce environmental exposure. It is a methodical, data-backed approach to solving a problem many mines know they have but are not always sure how to fix.\u201d<\/p>\n\n\n\n

    A final product innovation is the company\u2019s WebGen wireless initiating system, which gives operations the flexibility to maintain sleeping shots by firing on demand, ensuring minimal disruptions to nearby environments. \u201cThe secret lies in the absence of wires or signal tubes on the surface, ensuring the product is secure in the blasthole once loaded,\u201d explained Aubin. \u201cWebGen thus enables a reduction in the number of blasting events by merging multiple blasts and firing in one event. Meanwhile, flyrock and dust can be controlled by providing an extra layer of material, such as clay, steel, or rubber mesh, as an additional mitigation measure. Irrigation by water trucks can also help suppress dust.\u201d<\/p>\n\n\n\n

    Digital tools bring precision and accountability<\/strong>
    Orica Digital Solutions\u2019 BlastIQ integrated solutions provide \u201cquality control throughout the drill and blast process, delivering cost savings and superior blast outcomes,\u201d David Reyes, senior manager, Orica Americas, told North American Mining. \u201cThese applications allow customers to design blasts to match performance objectives and present insights to enable continuous blast optimization.\u201d Seamlessly integrated applications include:<\/p>\n\n\n\n

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    • SHOTPlus blast design and modeling software. \u201cFeaturing charging and initiation design tools, superior visualization, and blast analysis functionality, the application also facilitates compliance, improves productivity, and reduces the overall cost of drill and blast operations,\u201d said Reyes.<\/li>\n\n\n\n
    • BlastIQ Mobile, which allows remote access to blast designs and hole conditions, integrating the engineering office with the bench.<\/li>\n\n\n\n
    • BlastIQ Insights for tracking of key performance indicators and comprehensive digitized library storage per blast.<\/li>\n<\/ul>\n\n\n\n

      Reyes also highlighted the company\u2019s vibration and airblast automated monitoring solution. \u201cENVIROTrack can natively integrate with BlastIQ, SHOTPlus, and our environmental modeling tools to provide an end-to-end vibration management ecosystem,\u201d said the senior manager. \u201cData is also made available through our cloud-hosted API for customer use in their own third-party systems.\u201d<\/p>\n\n\n\n

      Finally, on the digital side, Orica Digital Solutions\u2019 FRAGTrack machine vision systems automatically capture and analyze near real-time fragmentation data to help engineers fine-tune their blast designs. \u201cBetter fragmentation means smoother processing, less wear on crushers, and more energy-efficient operations overall, as we reduce energy intensity by enabling an increase of processed tons with the same amount of diesel, electricity, and water,\u201d explained Reyes.<\/p>\n\n\n\n

      Recycling waste oil into an emulsion<\/strong>
      Aubin concluded with a mention of the company\u2019s Cyclo solution, which reuses one of the mine\u2019s most overlooked waste streams: used oil. \u201cInstead of being treated as a disposal problem, Cyclo recycles used oil, after it has been properly treated, to be incorporated into emulsion production for bulk explosives,\u201d he explained. \u201cMines cut waste and disposal costs while also reducing reliance on raw materials for explosive manufacturing.\u201d<\/p>\n","protected":false},"excerpt":{"rendered":"

      Innovation in surface drill and blast operations is delivering measurable improvements in environmental performance, operational efficiency, community impact, and personnel safety. by Jonathan Rowland As the mining industry intensifies its focus on sustainability, surface drill and blast practices are undergoing a shift. Once viewed primarily through the lens of productivity and cost-efficiency, innovation is helping to reimagine these operations as…<\/p>\n","protected":false},"author":8,"featured_media":11487,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"om_disable_all_campaigns":false,"_monsterinsights_skip_tracking":false,"_monsterinsights_sitenote_active":false,"_monsterinsights_sitenote_note":"","_monsterinsights_sitenote_category":0,"_themeisle_gutenberg_block_has_review":false,"_jetpack_newsletter_access":"","_jetpack_dont_email_post_to_subs":false,"_jetpack_newsletter_tier_id":0,"_jetpack_memberships_contains_paywalled_content":false,"_jetpack_feature_clip_id":0,"_jetpack_memberships_contains_paid_content":false,"footnotes":"","jetpack_publicize_message":"","jetpack_publicize_feature_enabled":true,"jetpack_social_post_already_shared":false,"jetpack_social_options":{"image_generator_settings":{"template":"highway","default_image_id":0,"font":"","enabled":false},"version":2},"jetpack_post_was_ever_published":false},"categories":[4],"tags":[4211,4212,1155,1152,942,21],"coauthors":[1635],"class_list":["post-11486","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-features","tag-advanced-solutions","tag-battery-electric-drilling-solutions","tag-blast-operations","tag-decarbonization","tag-dyno-nobel","tag-surface-mining"],"aioseo_notices":[],"aioseo_head":"\n\t\t\n\t\n\t\n\t\n\t\n\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t\n\t\t