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MODELING FULL-SCALE BLAST HEAVE WITH THREE-DIMENSIONAL DISTINCT ELEMENTS AND PARALLEL PROCESSING 26 August 2015 Dale S. Preece, PhD, Senior Research Fellow and Manager Blasting Apps NA/EMEA Ayman Tawadrous, PhD, Consultant Stewart A. Silling, PhD, Distinguished Member of Technical Staff, Sandia National Labs Brandon Wheeler, Graduate Engineer

FRAGBLAST11

© Orica Limited Group 2

Outline • DMC-3D Computer Code Basics Parallel Processing Ore/Waste Separation and Dillution Similations Hundreds of Blastholes Millions of Particles Accurate Treatment of Delay Timing

• Quantifying Ore Waste and Dilution Overlay sphere array with Hexahedrons Sort Ore and Waste particles

• Conclusions


PREECE EQUATION

FUN = 𝑵𝑵𝑵𝑵𝑵𝑵𝑵𝑾𝑵𝑾𝑾


ORICA NA “MATRIX” COMPUTER LAB


3D SPHERE ROTATION & TRANSLATION


INTERACTION OF 3D SPHERES


DMC-3D - SPHERICAL PARTICLE INTERACTION


DMC-3D PARALLEL PROCESSING

150 Blastholes, 1,68 million three-dimensional spherical elements


BLASTHOLE DELAY TIMES ROW ON ROW DELAY TIMING

Note: Circles show area of influence instead of blasthole diameter


RECTANGULAR ORE BLOCK SINGLE POINT INITIATION - DISPLAY VELOCITY


RECTANGULAR ORE BLOCK SINGLE POINT INITIATION - DISPLAY ORE


DIAGONAL ORE POLYGON


DIAGONAL ORE BLOCK SINGLE POINT INITIATION - DISPLAY ORE


RECTANGULAR ORE POLYGON ORE/WASTE SEGREGATION TIMING

Two Point Initiation


BLASTHOLE DELAY TIMES RECTANGULAR ORE POLYGON – ORE/WASTE SEGREGATION TIMING



RECTANGULAR ORE BLOCK DUAL POINT INITIATION - DISPLAY VELOCITY


RECTANGULAR ORE BLOCK DUAL POINT INITIATION - DISPLAY ORE


DIAGONAL ORE POLYGON ORE/WASTE SEGREGATION TIMING

Two Point Initiation


BLASTHOLE DELAY TIMES DIAGONAL ORE POLYGON – ORE/WASTE SEGREGATION TIMING



DIAGONAL ORE BLOCK DUAL POINT INITIATION - DISPLAY VELOCITY


DIAGONAL ORE BLOCK DUAL POINT INITIATION - DISPLAY ORE

© Orica Limited Group

23

SINGLE-POINT VERSUS DUAL POINT INITIATION RECTANGULAR ORE BODY

Row-on-Row Timing

Ore Segregation Timing


SINGLE-POINT VERSUS DUAL POINT INITIATION DIAGONAL ORE BODY

Row-on-Row Timing

Ore Segregation Timing


DMC-3D COMPUTATION TIMES Single Processor Version CPU Efficiency = 1.81 CPUs/particle

Parallel Processor Version ( Beginning with a thorough efficiency study & improvem = > speedup = 24) Four Processors: Real Time Treated = 10 s Number of Particles = ~1.67 million CPU Time = 20 hours = 72,000 CPUs CPU Efficiency = 0.0431 CPUs/particle Speedup = 1.81/0.0431 = 42

© Orica Limited Group

1,679,534 spheres

248,561 hexahedrons

26

QUANTIFYING ORE WASTE AND DILUTION DIAGONAL ORE POLYGON

Create a hexahedron mesh occupying the same space as the displaced spheres

At initial and final times: • Sort spheres into hex’s • In each hex determine:

1. Total number of spheres 2. Total number of ore spheres


QUANTIFYING ORE WASTE AND DILUTION DIAGONAL ORE POLYGON

Geometry threshold plots of %ore Color for %ore

Geometry Threshold Plots of %waste Color for %Ore


QUANTIFYING ORE WASTE AND DILUTION ASSUMING NO POST-BLAST MOVEMENT OF ORE POLYGON

Ore Wasted = 22.9%



Segregation Delay Timing

Geometry threshold plot of %ore Color for %ore

Geometry threshold plot of %ore wasted Color for %ore

Ore Wasted = 2.9 %

Diagonal Ore Polygon





Ore Wasted = 30.2 %

Geometry threshold plot of %ore diluted Color for %ore

Ore Diluted = 25.7 %

Total Ore Loss = 30.2 + 25.7 = 55.9%

Row-on-Row Delay Timing

Rectangular Ore Polygon



Segregation Delay Timing

Rectangular Ore Polygon


Ore Wasted = 11.6%


Ore Diluted = 4.5%

Geometry threshold plot of %ore diluted Color for %ore

Total Ore Loss = 11.6 + 4.5 = 16.1%


CONCLUSIONS

3D Distinct Element Parallel Processor Modelling of Rock Movement is Becoming Available for Routine Use: 42 times faster than single processor version Must be run on a multi-processor server Sculpting of muck in mineral blasting Blast Designs for ore/waste segregation

substantially reduce ore waste and dilution Quantifying ore waste and/or dilution for

different delay timing patterns


FUTURE WORK

Run DMC-3D-Parallel on other common blasting patterns

and quantify ore waste and dilution Echelon V Patterns Perpendicular to Strike

Move the Ore Polygon after Blasting for processing ore waste and dilution

Run code on more complex ore polygons and quantify

ore waste and dilution The ore polygon algorithm can accomodate any

complexity Couple MBF (Multiple Blasthole Fragmentation) with

DMC-3D-Parallel

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