Digital analysis of shovel dig time to optimize explosive usage vis-à-vis strata parameters

Efficient excavation in open-pit mining is critically dependent on the interplay between blast-induced rock fragmentation and the productivity of loading equipment. Traditional approaches often overlook the direct impact of explosive energy on shovel dig rates and overall operational efficiency. This study introduces a digital methodology using CyclePro™ software to analyze shovel cycle times and optimize explosive usage based on strata parameters. A total of 12 controlled blasts were conducted in identical geological conditions using varying explosive densities. Excavator productivity was assessed through video-based cycle time analysis, focusing on dig time, swing time, and dump time. The results revealed a clear correlation: higher explosive densities (1.15 gm/cc) led to improved fragmentation, faster dig rates (12.4 s), and higher productivity (519 Cu M/h), albeit at increased cost. Conversely, lower densities (0.6 gm/cc) reduced cost per cubic meter but compromised productivity and dig efficiency. These findings highlight a trade-off between cost and operational performance, suggesting that mid-range explosive densities offer an optimal balance. The study demonstrates the value of integrating digital analysis tools in blast design to enhance decision-making and cost-effectiveness in open-cast mining operations.