Drilling and blasting works and investigation of improvement opportunities in Yahyali-Karaçat (kayseri) open iron mine

Open-pit mining is one of the most widely used methods in modern mining practices. Among the key factors affecting the efficiency of production activities conducted through this method is the accurate determination of the physical and structural properties of the rocks. Characteristics such as hardness, fracturing, density, abrasiveness, and mineralogical composition directly influence various factors, from blasting design to production costs. Therefore, developing a blasting design suited to the rock properties in mining operations is critically important for both increasing efficiency and optimizing costs. One of the primary challenges in open-pit mining is the diversity of rock structures and determining blasting parameters suited to these structures. In this context, a detailed analysis of the physical and structural properties of rocks forms the initial step in creating an effective blasting design. A well-designed blasting plan not only ensures high efficiency but also contributes to maintaining slope stability in open pits and supporting reinforcement in underground mining. Furthermore, such designs minimize energy losses and reduce environmental impacts. This study evaluated the efficiency of existing blasting designs in the Karaçat open-pit mining operation and developed and implemented a more suitable blasting pattern. The rock types present in the study area include calc-schist, ankerite, limestone at ore contacts, and hematite, goethite, and siderite in the pit floor. The varying physical and mechanical properties of these rocks were taken into account during the blasting design process. Initially, a 3×3.5-meter pattern spacing was used; however, a transition to a 5×5-meter pattern spacing was made based on field conditions and rock characteristics to enhance blasting efficiency. As part of the study, the costs associated with the old and new blasting patterns were thoroughly compared, and economic benefits were evaluated. The initial findings demonstrated that wider pattern spacings allowed for reduced explosive use and fewer drilling operations. This resulted in significant cost reductions while also achieving more homogeneous fragmentation distribution post-blasting. Moreover, the alignment of the blasting design with rock properties reduced the environmental impact of vibrations generated during blasting. The data obtained offer significant insights into both efficiency improvement and cost advantages. This study underscores the importance of optimizing the blasting design process in open-pit mining to align with rock properties. The adaptability of such analyses to other mining sites further enhances the value of the study for the broader mining industry. In the future, similar studies conducted in different locations aim to develop new methods for blasting design processes.