The mining industry plays a significant role in the extraction and processing of various ore materials (phosphate, copper, iron, gold, aggregates and others), contributing to industrial and economic development. Rock fragmentation is a fundamental operation and a complex element in mining activities influenced by multiple parameters, including geological and geometric factors, explosive load parameters, and others related to the details of the execution of the blasting plan. The effectiveness of blasting depends on factors such as the geological structure, volume, optimal size of rocks to be blasted, and compliance with safety conditions. To achieve desirable outcomes, it is crucial to make informed decisions regarding the types and quantities of explosives to be used, along with other principal parameters of drilling-blasting design. Continuous evaluation of rock fragmentation is essential for optimizing blasting plans by contributing to the improvement of the quality-price ratio under favorable environmental and safety conditions. This study aims to analyze and enhance the quality of rock fragmentation resulting from blasting activities in the Kef Lahmar-Setif limestone quarry (northeast Algeria), which is characterized by significant rock mass fracturing. This fracturing will be carefully analyzed in order to arrive at an accurate blasting plan for the structure of the studied rock massif. As the aim of the research is to optimize the blasting plan to generate maximum gas pressure and minimize shock pressure due to the existing fractures in the rock mass. in order to test this hypothesis, we conducted several blasting tests by modifying the charge rate of the explosives used (Anfomil and Marmanite III), while maintaining the same parameters in the blasting plan for each test. The goal was to achieve optimal fragmentation. The particle size of the blasted rock pile was analyzed using WipFrag software, which utilizes image analysis techniques.

In open-pit mining, optimizing blasting techniques is essential for enhancing both operational efficiency and achieving desired rock fragmentation, which directly impacts subsequent processes such as loading, hauling, and crushing. A well-designed drilling pattern and precise blasting plan are crucial for ensuring the effective distribution of block sizes. The technical and geometrical characterization of rock fragments plays a key role in improving blasting performance. This study focuses on enhancing fragmentation quality in the ENG Ain Touta limestone quarry, NE of Algeria, through the application of numerical modeling techniques. Current blasting outcomes were evaluated using WipFrag software to create particle size distribution curves, which revealed a significant proportion of oversized blocks, ranging between 21% and 25%. This highlights a critical need for modifications to the blasting plan. To address this, a revised plan was developed, incorporating an additional 20 kg of explosives per borehole. The predicted effects of this adjustment were modeled using the Kuz-Ram method, showing a 40% reduction in oversized blocks and a substantial improvement in rock fragmentation quality. The results underscore the effectiveness of integrating image analysis software and predictive modeling in refining blasting strategies. By mproving fragmentation, this approach can significantly boost mining operations’ efficiency, reduce the handling of oversized materials, and optimize the overall quarrying process. This study demonstrates the potential of numerical models and targeted adjustments in blasting plans to enhance productivity and cost-effectiveness in open-pit mining operations.

The Ouenza open-pit mine is one of Algeria’s major iron ore producers, where efficient blasting and fragmentation control are essential to maintaining stable, productive mining operations. The primary objective of this study is to quantitatively assess the agreement between predicted and measured rock fragmentation at the Ouenza open-pit mine. The research methodology includes a comprehensive analysis of blasting parameters. Field experiments used four blasts, all executed with the same blasting plans on the same working face to ensure comparability. The rock fragmentation was precisely measured and analyzed using the advanced image-processing software Wip-Frag to determine the particle-size distribution. The Kuz–Ram model predicted the fragment size distribution using the same blasting design implemented in the field, and the predicted fragmentation was quantitatively evaluated against Wip-Frag measurements using the coefficient of determination (R²), root mean square error (RMSE), and mean absolute error (MAE). The statistical evaluation yielded an R² of 0.9095, an RMSE of 9.71%, and an MAE of 6.54%, indicating good overall agreement between the predicted and measured fragmentation, despite noticeable deviations in the coarse-fragment size range. The observed discrepancies were mainly associated with potential inaccuracies in the field implementation of the designed blast pattern, limited compliance with blasting procedures, and the natural heterogeneity of the rock mass. The results show that comparing Wip-Frag measurements with Kuz–Ram predictions is an effective way to identify discrepancies between predicted and actual fragmentation and to determine the field factors driving these differences. These findings provide practical insights into blast implementation and fragmentation control under actual mining conditions.