Document Type : Case Study

Authors

1 Department of Mining Engineering, Higher Education Complex of Zarand, Shahid Bahonar University of Kerman, Kerman, Iran

2 Shahid Bahonar University of Kerman

3 The Robert M. Buchan Department of Mining, Queen’s University, Kingston, Ontario, Canada

10.22044/jme.2026.17439.3463

Abstract

Effective blast design is crucial for downstream comminution efficiency. However, modeling its impact on size-based production remains challenging due to complex, non-linear rock–fragmentation interactions. This study developed an integrated mine-to-mill framework using optimized Artificial Neural Networks (ANNs) to predict total and size-fractioned production (0–40 mm, 40–80 mm) from blasting parameters at the Sar-Asiab Limestone Complex, Iran. The dataset comprises 55 real industrial observations after preprocessing. Two optimization algorithms, Genetic Algorithm (GA) and Particle Swarm Optimization (PSO), were employed to enhance ANN performance. The PSO-optimized ANN demonstrated significantly superior generalization, achieving a testing RMSE of 1341.8 (vs. 1549.5 for GA), an MAE of 1108.9 (vs. 1260.4), and an R² of 0.9487 (vs. 0.8937). Sensitivity-based feature importance analysis quantified the dominant predictors: explosive quantity (Emulite) contributed 18.4%, the number of boosters 14.9%, and key geometric parameters (mean hole depth, diameter, and spacing) collectively accounted for over 41%. In contrast, initiation system variables such as cortex length showed high linear correlation (r = –0.91) but minimal predictive importance (1.5%). These results underscore that explosive energy and its distribution, not just initiation configuration, are the primary drivers of size-based output. This data-driven framework provides a practical tool for aligning blast design with processing needs, directly supporting energy reduction and production stability in open-pit mining.

Keywords

Main Subjects

[1]. Eloranta, J. W. (1997). Efficiency of blasting vs. crushing and grinding. In Proceedings of the 23rd Conference on Explosives and Blasting Technique, Las Vegas, USA.
[2]. Kahriman, A. (2004). Influence of blasting on the energy consumption of crushing and grinding operations. International Journal of Rock Mechanics and Mining Sciences, 41, 787–796.
[3]. Oluokun, O., & Pub, A. (2025). Energy efficiency in mining operations: Policy and technological innovations. International Journal of Multidisciplinary Research and Growth Evaluation, 5, 994–1008.
[4]. Bilgin, N., Tuncdemir, H., & Demircin, M. A. (2016). Effects of blasting on crushing and grinding efficiency in a limestone quarry. Tunnelling and Underground Space Technology, 51, 295–305.
[5]. Kanchibotla, S. S., Valery, W., & Morrell, S. (1999). Modelling fines in blast fragmentation and its impact on crushing and grinding. In Proceedings of Explo '99 Conference, Kalgoorlie, Australia.
[6]. Zaman, U., Qamar, Zhao, Y., Zaman, S., Batool, K., & Nasir, R. (2024). Energy efficiency and environmental consciousness in the minerals industry amidst digital transition. Resources Policy, 91, 104851.
[7]. Drechsler, M., & Skinner, W. (2023). Commercialisation pathway for low-energy wet/dry gyratory rolls crusher comminution technology. Minerals Engineering, 204, 108419.
[8]. Workman, L., & Eloranta, J. (2003). The effects of blasting on crushing and grinding efficiency and energy consumption. In Proceedings of the Annual Conference on Explosives and Blasting Technique.
[9]. Eloranta, J. W. (1995). The efficiency of blasting versus crushing and grinding. In Proceedings of the International Conference on Mining.
[10]. Zaman, U., Qamar, Zhao, Y., Zaman, S., Batool, K., & Nasir, R. (2024). Energy efficiency and environmental consciousness in the minerals industry amidst digital transition. Resources Policy, 91, 104851.
[11]. Drechsler, M., & Skinner, W. (2023). Commercialisation pathway for low-energy wet/dry gyratory rolls crusher comminution technology. Minerals Engineering, 204, 108419.
[12]. Monjezi, M., Dehghani, H., & Bahrami, A. (2008). Prediction of rock fragmentation due to blasting using multiple regression analysis. Journal of Mining and Environment, 4, 23–30.
[13]. Eloranta, J. W. (1995). The efficiency of blasting versus crushing and grinding. In Proceedings of the International Conference on Mining.
[14]. Monjezi, M., Dehghani, H., & Bahrami, A. (2008). Prediction of rock fragmentation due to blasting using multiple regression analysis. Journal of Mining and Environment, 4, 23–30.
[15]. Bahrami, A., Monjezi, M., Goshtasbi, K., & Ghazvinian, A. (2011). Prediction of rock fragmentation due to blasting using artificial neural networks. Engineering with Computers, 27, 177–181.
[16]. Al-Bakri, A. Y., & Sazid, M. (2021). Application of artificial neural network (ANN) for prediction and optimization of blast-induced impacts. Mining, 1(3), 315-334.
[17]. Basu, J. K., Bhattacharyya, D., & Kim, T. H. (2010). Use of artificial neural network in pattern recognition. International journal of software engineering and its applications, 4(2).
[18]. Guo, H., Nguyen, H., Vu, D. A., & Bui, X. N. (2021). Forecasting mining capital cost for open-pit mining projects based on artificial neural network approach. Resources Policy, 74, 101474.
[19]. Abd Elwahab, A., Topal, E., & Jang, H. (2023). Review of machine learning application in mine blasting. Arabian Journal of Geosciences, 16, 133.
[20]. Charbonneau, P. (2002). An introduction to genetic algorithms for numerical optimization. NCAR Technical Note, 74, 4-13.
[21]. Xing, L. N., Chen, Y. W., & Cai, H. P. (2006). An intelligent genetic algorithm designed for global optimization of multi-minima functions. Applied Mathematics and Computation, 178(2), 355-371.
[22]. Zhang, C., Shao, H., & Li, Y. (2000). Particle swarm optimisation for evolving artificial neural network. In Proceedings of the 2000 IEEE International Conference on Systems, Man, and Cybernetics, Vol. 4, pp. 2487-2490.
[23]. Saubi, O., Jamisola Jr., R.S., Suglo, R.S., & Matsebe, O. (2025). Optimisation of blast-induced rock fragmentation using hybrid artificial intelligence methods at Orapa Diamond Mine (Botswana). Journal of Mining Institute, 275, 179–195.
[24]. Gholami, A. R., & Khoshdast, H. (2025). Intelligent estimation of selectivity index and metallurgical responses of coal bioflotation using artificial neural networks. Energy Sources, Part A: Recovery, Utilization and Environmental Effects, 47, 3713–3731.
[25]. Gebretsadik, A., Kumar, R., Fissha, Y., Kide, Y., Okada, N., Ikeda, H., Mishra, A.K., Armaghani, D.J., Ohtomo, Y., & Kawamura, Y. (2024). Enhancing rock fragmentation assessment in mine blasting through machine learning algorithms: a practical approach. Discover Applied Sciences, 6(5), 1-12.
[26]. Bai, R., Zhang, P., Zhang, Z., Sun, X., Fei, H., Bao, S., Hu, G., & Li, W. (2023). Optimization of blasting parameters and prediction of vibration effects in open pit mines based on deep neural networks. Alexandria Engineering Journal, 70, 261-271.
[27]. Shields, L., Silva, J., Calnan, J., Maldonado, E., & Agioutantis, Z. (2025). Integrating underground blast fragmentation modeling for sustainable mine-to-mill optimization: a focus on blast fragmentation and energy efficiency in comminution circuits. Rock Mechanics and Rock Engineering, 58, 4497–4508.
[28]. Guo, J., Zhao, Z., Zhao, P., & Chen, J. (2024). Prediction and optimization of open-pit mine blasting based on intelligent algorithms. Applied Sciences, 14(13), 5609.
[29]. Bisoyi, S. K., & Pal, B. K. (2022). Optimization of blasting parameters in opencast mines using firefly algorithm and deep neural networks. Sādhanā, 47, 172.
[30]. Ronkin, M. V., Akimova, E. N., & Misilov, V. E. (2023). Review of deep learning approaches in solving rock fragmentation problems. AIMS Mathematics, 8(10), 23900–23940.
[31]. Huan, B., Li, X., Wang, J., & Hu, T. (2025). An interpretable deep learning model for the accurate prediction of mean fragmentation size in blasting operations. Scientific Reports, 15(1), 11234.
[32]. Nielsen, K., & Kristiansen, J. (2020). Blasting–crushing–grinding: Optimisation of an integrated comminution system. In Mine-to-Mill Optimization, CRC Press.
[33]. Valery, W., Duffy, K. A., Jankovic, A., Valle, R., Tabosa, E., & Yelkin, I. (2016). Complete optimisation from mine-to-mill to maximise profitability. In Proceedings of AusIMM Conference.
[34]. Linardatos, P., Papastefanopoulos, V., & Kotsiantis, S. (2021). Explainable AI: A review of machine learning interpretability methods. Entropy, 23, 18.
[35]. Min, J., Song, X., Zheng, S., King, C. B., Deng, X., & Hong, Y. (2024). Applied statistics in the era of artificial intelligence: A review and vision. arXiv preprint, arXiv:2412.10331.
[36]. Zhu, J., Jiang, Z., & Feng, L. (2022). Improved neural network for wastewater treatment processes. Chemosphere, 308, 136116.
[37]. Assis, A., Dantas, J., & Andrade, E. (2025). The performance–interpretability trade-off: A comparative study of machine learning models. Journal of Reliable Intelligent Environments, 11, 1.
[38]. Khoshdast, H. (2019). Practical problems in froth flotation. Hormozgan University Press, Tehran, Iran.
[39]. Gharaei, R. S., Gholami, A., Khoshdast, H., & Biglari, H. (2024). A multi-method machine learning framework for simulating power dynamics in an iron ore cone crusher plant. Mineral Processing and Extractive Metallurgy Review, 1–16.
[40]. Hall, M. A. (1999). Correlation-based feature selection for machine learning. PhD Thesis, University of Waikato, New Zealand.
[41]. Gholami, A., Khoshdast, H., & Hassanzadeh, A. (2021). Hybrid genetic and artificial bee colony algorithms for modeling wastewater bio-treatment processes. Journal of Environmental Management, 299, 113666.
[42]. Khoshdast, H., Gholami, A. R., Hassanzadeh, A., Niedoba, T., & Surowiak, A. (2021). Advanced simulation of chromium removal from wastewater using hybrid neural networks. Materials, 14, 2880.
[43]. Eskandar, H., Heydari, E., Hasanipanah, M., Jalil Masir, M., & Mahmodi Derakhsh, A. (2018). Feasibility of particle swarm optimization and multiple regression for the prediction of an environmental issue of mine blasting. Engineering Computations, 35(1), 363-376.
[44]. Nazari, S., Gholami, A., Khoshdast, H., Li, J., He, Y., & Hassanzadeh, A. (2023). Advanced simulation of quartz flotation using historical data and deep learning methods. Minerals, 13, 128.
[45]. Jarkani, S. A., Khoshdast, H., Shariat, E., & Sam, A. (2014). Modeling the effects of mechanical parameters on hydrodynamic behavior of vertical current classifiers. International Journal of Mining Science and Technology, 24, 123–127.
[46]. Khoshdast, H. (2019). Practical problems in froth flotation. Hormozgan University Press, Tehran, Iran.