The Swebrec Function - Blast Fragmentation...
The Swebrec Function - Blast Fragmentation...
function further;
plugs right into the Kuz-Ram model and removes two of its drawbacks, the poor predictive
capacity in the fines range and the upper limit cut-off to block sizes,
reduces the JKMRCs one-family description of crusher breakage functions based on the
t
10
concept to a minimum and
establishes a new family of natural breakage characteristic (NBC) functions with a realistic
shape that connects blast fragmentation and mechanical comminution and offers new
insight into the working of the Steiners OCS sub-circuits of mechanical comminution.
It is suggested that the extended Kuz-Ram model, with the Swebrec
function
When analysing the data of the Less Fines project
16
, it was realised that the following
fragment size distribution does a very good job of fitting sieved fragmentation data
20
. The
transformation
P(x) = 1/[1+f(x)] with f(x
max
) = 0, f(x
50
) = 1 (2a)
ensures that x
max
and x
50
are fixed points on the curve and a suitable choice for f(x) is
f(x) = [ln(x
max
/x)/ln(x
max
/x
50
)]
b
. (2b)
Like the Rosin-Rammler function it uses the median or 50 % passing value x
50
as the central
parameter but it also introduces an upper limit to the fragment size, x
max
. The third parameter
b is a curve undulation parameter. Unlike the Rosin-Rammler or the CZM/TCM functions the
asymptotic properties of f(x) for small fragments is logarithmic, not a simple power of x.
Figure 9 shows sieved data from a 500 ton bench blast with 51-mm blast-holes on a 1,82,2
m pattern and a specific charge of about 0,55 kg/m
3
. At the Brarp
17,18
dimensional stone
quarry, 7 single row test rounds with constant specific charge and an accurate EPD inter-hole
delay of 25 ms were shot. The hole diameters ranged from 38-76 mm. The muckpiles were
sieved in three steps, all of the 25-500 mm material and quartered lab-samples 0,063-22,4
mm. Figure 9 shows round 4. The 1000-mm value is a boulder counting estimate.
The Swebrec function fit is excellent in the range 0,5-500 mm. The average goodness of fit is
r
2
= 0,9970,001 (meanstd deviation). The parameter statistics became x
50
= 49070 mm,
x
max
= 1720440 mm and b=2,460,45, see Table 1. (So high an x
50
-value would probably
Finn Ouchterlony: The Swebrec function, blast fragmentation, the Kuz-Ram etc 5
give hard digging in an aggregate quarry but this was a 500 ton test blast). The corresponding
Rosin-Rammler fits have a goodness of fit of about 0,98 and the curves start to deviate from
the data already for 20 mm fragments.
Interestingly, the coarse fractions seem to contain information about the fines. Using the +90
mm data and fitting a Rosin-Rammler function gives entirely different results than fitting the
Swebrec function, Figure 10. The filled symbols denote the data used for the fitting. For a
typical Swedish aggregate quarry with marketing problems for 4 mm material e.g., the
Rosin-Rammler fit to the +90 mm material predicts 0,3-0,4 % of fines, the Swebrec function
predicts 2 %, which is much closer to the actually measured value 2,5 %.
The Swebrec and Rosin-Rammler curves run very close for fragment sizes around x
50
.
Equating the slopes at x
50
makes it possible to compare the parameter values
n
equiv
b/[2ln2ln(x
max
/x
50
)]. (3)
Furthermore the Swebrec function has an inflection point in logP versus logx space at
x/x
max
= (x
50
/x
max
)
(b-1)
1/b
or x/x
50
= (x
50
/x
max
)
(b-1)
1/b
-1
(4)
When b 1, the inflection point tends to x = x
max
. For increasing values it moves towards x
= x
50
, which is reached when b = 2. When b increases further, the inflection point moves to
smaller values of x and then moves back towards x = x
50
. The inflection point and hence the
undulating character of the Swebrec function is always there and this makes it possible to pick
up the fines behaviour already from the coarse fractions data.
Start instead with a sieved sample with fragments in the range 1-22,4 mm from Brarp round
4. This data set was obtained after quartering of the 25 mm fraction from an Extec sizer,
which sieved all 200 mm material. If we know the percentage of the 22,4 mm fraction and
make the guess that x
max
B = 1800 mm because the rock is massive then a curve fit with the
Swebrec function yields the result in Figure 11. The filled symbols again denote the data used
for the fitting.
Finn Ouchterlony: The Swebrec function, blast fragmentation, the Kuz-Ram etc 6
The curve runs remarkably well through the missing coarse fraction data and provides an
excellent estimate of x
50
. It seems that limited portions of the fragment size distribution
contain relatively accurate information about the missing mass fractions.
Taking samples from a crusher product stream where the percentage of say 22,4 mm fines is
better known than in a muckpile and using the closed-side setting and fragments shape to
estimate x
max
is another example of where missing mass fractions might be successfully
determined. Figure 12 gives an example from a granite quarry where the fines percentage was
known to be 18-20 % and the largest crushed pieces were 250-300 mm.
The final dip in the Brarp round 4 fragment size distribution in the 500 micron range in
Figure 9 may be taken care of by adding a second term to f(x) in the Swebrec function
f(x) = a[ln(x
max
/x)/ln(x
max
/x
50
)]
b
+ (1-a)[(x
max
/x-1)/(x
max
/x
50
-1)]
c
. (5)
See Figure 13. This extended Swebrec function has 5 parameters and is able to fit most
fragment size distributions with extreme accuracy.
The Swebrec function has been fitted to hundreds of sets of sieved blasting, crushing and
grinding data from a large number of sources
20
, e.g.
Brarp full-scale and model blasts
17,18
Less Fines project model blasts on 5 types of limestone and an amphibolite
16
Norwegian model and full scale bench blasts in different rocks with different explosives
25
Bench blast samples before and after crushing of gneiss and dolerite
Blasting of iron ore oversize
South African reef and quarry blasts
US bench blasts in dolomite
Blasting of magnetite concrete models
Blasting of layered mortar models
10
Feed and product streams from gyratory, cone and impact crushing of andesite
Product stream samples from roller crushing of limestone
Single particle roll mill crushing
Ball mill grinding of limestone
Finn Ouchterlony: The Swebrec function, blast fragmentation, the Kuz-Ram etc 7
HECT (high energy crushing test) crushing of seven rock types
Drill cuttings from the Christmas mine
Two examples of crusher product size distributions are shown in Figures 14 and 15. For
nearly all these sets of sieved data, the 3-parameter Swebrec function gives a better fit that the
Rosin-Rammler function.
The experience
20
is that good to excellent fits to different kinds of fragmentation data is
obtained with correlation coefficients of usually r
2
= 0,995 or better over a range of fragment
sizes of 2-3 orders of magnitude. This range is at least one order of magnitude larger than
what the Rosin-Rammler function covers.
Of the three parameters the central median measure, i.e. the size of 50 % passing x
50
shows
the most stable behaviour. The maximum fragment size x
max
will be physically related to the
block size in-situ in blasting but as a fitting parameter it varies quite much. On the other hand
in crushing, it is more or less given by the closed-side setting. Fixing the value of x
max
hardly
changes the goodness of fit or the value of x
50
at all and the value of b comparatively little,
see Table 2.
The parameter b normally accepts values in the range 1-4. Only in special cases, like model
blasting near the critical burden, does the fitting give a value of b < 1. When the sieved
fragmentation curve becomes Rosin-Rammler like, both b and x
max
tend to drift during the
fitting procedure and can become unnaturally large. This tendency may be suppressed by
choosing a pair of coupled b and x
max
values that are related through the expression (3) for
n
equiv
. In these cases the value of n
equiv
tends to vary less than the b-value. Otherwise, in the
majority of cases b is more constant than n
equiv
.
Many times b is quite constant for a given material even when the fragmentation conditions
do change. A couple of data sets show however that b also depends on the explosive used, see
Table 3, on the charge concentration and on the size of blast (model scale or full-scale e.g.).
There is thus no basis for considering b as a material property or as depending only on the
specimen geometry as the Kuz-Ram model suggest be the case for the uniformity index n.
Finn Ouchterlony: The Swebrec function, blast fragmentation, the Kuz-Ram etc 8
The Swebrec function is an improvement over the CZM and the TCM models too. Both
JKMRC models show linear behaviour in the fines range in log-log space where a vast
majority of the data sets are clearly non-linear. The Swebrec function doesnt rest on an
assumption of the origin of the blasting fines that has been disproved by tests.
The extended Swebrec function with 5 parameters shows capacity of reproducing sieved
fragmentation curves all the way into the super fines range, x < 0,1 mm and also of
reproducing laboratory ball mill grinding data, Figure 16.
It could thus be said that the Swebrec function gives the fragment size distributions from
blasting and crushing a common form.
The crusher breakage and NBC connections
A comparison of Figure 8 and the presented size distributions from blasting and crushing
shows that the general curve-forms look alike. Some mass passing versus non-dimensional
fragment size data for crusher and AG/SAG mill breakage functions from the JKMRC
19
were
matched against the non-dimensional version of the Swebrec function
P() = 1/{1+[ln()/ln(
50
)]
b
} with = x/t and
max
= 1. (6)
One example from the data sets behind Figures 7 and 8 is given in Figure 17. In fact the
whole t
10
family of crusher curves of Table 6:1
19
may be reduced to the following equation
t
n
= 100/{1+ (100/t
10
1)[log(n)]
b(
t
10)
}. (7)
Here n is the size reduction ratio. When n = 10 e.g., log(n) = 1 and (7) reduces to the straight
line t
n
= t
10
as it should. An approximate expression for b(t
10
) was obtained from the data
fitting
20
b = 1,616+0,02735 t
10
, (8)
Finn Ouchterlony: The Swebrec function, blast fragmentation, the Kuz-Ram etc 9
and the results are plotted in Figure 18. The full lines were obtained using (8), the dashed
ones for n = 2 and 75 using the value b = 2,174 valid for t
10
= 20 %. It is seen that the
variations in the b-value do make a difference. The data are well represented by the isolines,
differing by at most 3-4 %.
Excellent fits were also obtained to the data in Tables 4:7 and 4:9
19
. This is an indication that
the whole set of spline functions used to describe the breakage functions could be replaced by
two simple equations, (7) and one like (8).
The connection with the NBC theory rests on an observation of the asymptotic behaviour of
the Swebrec function. The parallel shift property in logP versus logx space reduces to the
statement that P(x)/P(x) = constant, independent of some parameter that describes the shift.
This is not met by the Swebrec function itself but the behaviour when x 0,
P(x) 1/f(x) yields P(x)/P(x) -f(x)/f(x) = b/[xln(x
max
/x)],
which is independent of x
50
. To retain the meaning of x
max
as the maximum allowable and x
50
as the median fragment size, make the substitutions x
max
x
c
and x
50
x
max
. Now x
c
denotes
a characteristic size value for the distribution, which lies outside the acceptable range of x-
values, 0 - x
max
.
Then the following function has NBC properties
P
NBC
(x) = [ln(x
c
/x
max
)/ln(x
c
/x)]
b
with x
50
= x
max
/(x
c
/x
max
)
2
1/b
-1
. (9)
It describes a set of parallel shifted curves when the value of x
max
is changed but x
c
and b are
kept constant. P
NBC
(x) is always concave upwards when x < x
max
, which is the behaviour of
the OCS sub-circuit curves in Figure 3 except in the super fines range.
The simplest description of an OCS sub-circuit is a sharp sieve that lets the fines bypass the
comminution chamber, which in turn processes the coarse material retained by the sieve.
When the derivative of P
NBC
(x) is used to describe the breakage function of the chamber, the
following results emerge
for the combined product stream
20
Finn Ouchterlony: The Swebrec function, blast fragmentation, the Kuz-Ram etc 10
1. If the entire feed stream passes the chamber, then the product stream has NBC properties
irrespective of the feed stream properties.
2. If parts of the feed stream bypass chamber then if the bypass stream has NBC properties
then so does the combined product stream.
Otherwise the combined product stream doesnt have NBC properties.
This has a direct bearing on the interpretation of Figures 3 and 5. As long as the size reduction
ratio in an OCS sub-circuit is large enough to make the bypass flow have NBC properties,
then the product stream has NBC properties no matter what the size distribution of the
processed part looked like beforehand.
The fragment size distributions for OCS crushed or milled rock and rock models blasted with
different levels of specific charge look pretty much the same in the 20 mm range in Figure 5.
Hence we may conclude that if the NBC curve from mechanical comminution indeed is
material specific, then the model blasting tests produce material specific results too in that
range. The relation between the blasting curve and the NBC curve is
P(x) = 1/[1+1/P
NBC
(x)]. (10)
Similarly (10) contains a potential correspondence between the OCS sub-circuits and the
JKMRC crusher models.
The Kuz-Ram connection
In connection with the Kuz-Ram model, (3) offers the possibility of simply replacing the
original Rosin-Rammler function in (1) with the Swebrec function of (2a-b). Thus we arrive at
an extended Kuz-Ram model (or KCO model, see below) based on the following prediction
formulas
P(x) = 1/{1+[ln(x
max
/x)/ln(x
max
/x
50
)]
b
}
x
50
= g(n)AQ
1/6
(115/s
ANFO
)
19/30
/q
0,8
with g(n) = 1 or (ln2)
1/n
/(1+1/n)
Finn Ouchterlony: The Swebrec function, blast fragmentation, the Kuz-Ram etc 11
b = [2ln2ln(x
max
/x
50
)]n =
= 2ln2ln(x
max
/x
50
)(2,2-0,014B/
h
)(1-SD/B)[(1+S/B)/2][|L
b
-L
c
|/L
tot
+0,1]
0,1
(L
tot
/H)
x
max
= min(in-situ block size, S or B). (11a-d)
Here
x
50
= median or size of 50 % passing in cm!
Q = charge weight per hole (kg)
q = specific charge (kg/m
3
)
s
ANFO
= explosives weight strength relative to ANFO (%)
B = blast-hole burden (m)
S = spacing (m)
h
= drill-hole diameter (m)
L
b
= length of bottom charge (m)
L
c
= length of column charge (m)
L
tot
= total charge length, possibly above grade level (m)
H = bench height or hole depth (m)
SD = standard deviation of drilling accuracy (m).
The factor g(n) = (ln2)
1/n
/(1+1/n) essentially shifts the fragment size distribution to smaller
values of x
50
or to predicting more fines
4
. For expedience call the original Kuz-Ram model
with g(n) added the shifted Kuz-Ram model. The shifting factor g(n) could be incorporated
into the extended model too, if experience proves that this is an advantage.
Further the rock mass factor A is given by
A = 0,06(RMD+JF+RDI+HF) where (11e)
RMD = Rock mass description = 10 (powdery/friable), JF (if vertical joints)
or 50 (massive)
JF = Joint Factor = JPS + JPA = Joint Plane Spacing + Joint Plane Angle
JPS = 10 (average joint spacing S
J
< 0,1 m), 20 (0,1 m-oversize x
O
) or 50 (> oversize)
Finn Ouchterlony: The Swebrec function, blast fragmentation, the Kuz-Ram etc 12
JPA = 20 (dip out of face), 30 (strike
function has three parameters and gives good to excellent fits to different
kinds of fragmentation data with correlation coefficients of least r
2
= 0,995 or better over a
range of fragment sizes of 2-3 orders of magnitude. Hundreds of sets of sieved data from
crushing and blasting have been analysed with excellent results.
Finn Ouchterlony: The Swebrec function, blast fragmentation, the Kuz-Ram etc 14
The inherent curvature of sieved fragment size distributions is captured by the Swebrec
function. Using coarse fractions data to extrapolate into the fines range has the potential of
giving accurate fines predictions. Similarly using samples of fine material from a muckpile or
crusher products on a belt and an estimate of x
max
has the potential to give accurate estimates
of the coarser fractions.
The extended Swebrec
function so
successful? The 3-parameter Swebrec
/
g
]
Hengl CP NK Type R
NK Type S NK Type K NK Type F
Finn Ouchterlony: The Swebrec function, blast fragmentation, the Kuz-Ram etc 23
Figure 5: Comparison of fragmentation curves from OCS comminution in Figure 3 and
model-scale blasts on same amphibolite
16
.
Figure 6: Comparison of fragmentation curves from model- and full-scale blasts of Brarp
granitic gneiss
18
.
g p
0,1
1,0
10,0
100,0
0,01 0,1 1 10 100
Screen size [mm]
P
a
s
s
i
n
g
[
%
]
BIT 2B (190/4)
BIT 66 (190/4)
BIT 3 (190/5)
BIT 79 (190/5)
BIT 2A (240/5)
BIT 21 (240/5)
BIT 8 (290/5)
BIT 78 (290/5)
BIT 73A (100/5)
BIT 73B (100/5)
Comminution
Curves
BIT 2B (190/4)
BIT 66 (190/4)
BIT 3 (190/5)
BIT 79 (190/5)
BIT 2A (240/5)
BIT 21 (240/5)
BIT 8 (290/5)
BIT 78 (290/5)
BIT 73A (100/5)
BIT 73B (100/5)
Comminution
Curves
Blasting
C
o
m
m
i
n
u
t
i
o
n
0,1
1
10
100
0,01 0,1 1 10 100 1000
Screensize (mm)
P
a
s
s
i
n
g
(
%
)
Blast 1 51 mm
Blast 2 51/76 mm
Blast 3 76 mm
Blast 4 51 mm
Blast 5 38 mm
Blast 6 64 mm
Blast 7 76mm
BA 1-2 (192/5)
BA 10-1 (102/5)
BA 10-2 (102/5)
BA 2-1 (192/5)
BA 2-2 (192/5)
BA 9 (289/5)
BA1-1 (242/5)
180g/t
210g/t
214g/t
202g/t
210g/t
Fullscale Blasts:
Model Blasts:
specific charge
full scale blasts
Finn Ouchterlony: The Swebrec function, blast fragmentation, the Kuz-Ram etc 24
Figure 7: Family of breakage functions for crusher based on the t
10
concept
19
.
Figure 8: Fragment size distributions extracted from the family of breakage functions in
Figure 7.
0 20 40 60 80 100
Breakage index t
10
, %
0
20
40
60
80
100
t
n
, % passing
t
4
t
2
t
10
t
25
t
50
t
75
0.001 0.01 0.1 1
inverse size reduction ratio 1/n
0.1
1
10
100
Mass passing, %
t
10
= 10 %
t
10
= 20 %
t
10
= 30 %
Finn Ouchterlony: The Swebrec function, blast fragmentation, the Kuz-Ram etc 25
Figure 9: Fragment size distribution for Brarp round 4 with best fit Swebrec function
20
.
Data range 0,5-500 mm. Curve fit parameters: x
50
= 459 mm, x
max
= 1497 mm and
b = 2,238 (Table 1). x = 1000 mm is based on oversize counting, not a sieved value.
Figure 10: Comparison of Swebrec and Rosin-Rammler fits to coarse fraction data +90 mm
and extrapolation to fines range.
0.02 0.2 2 20 200 2000
Mesh size, mm
0.1
1
10
M
a
s
s
p
a
s
s
i
n
g
,
%
0.1
1
10
-1
0.5
2
-1
0.5
2
R
e
s
i
d
u
a
l
s
Finn Ouchterlony: The Swebrec function, blast fragmentation, the Kuz-Ram etc 26
Figure 11: Using Brarp sample data in range 1-22,4 mm plus estimate of x
max
to make
Swebrec prediction of x
50
and coarse fractions.
0.05 0.5 5 50 500
Mesh size, mm
0.1
1
10
M
a
s
s
p
a
s
s
i
n
g
,
%
0.1
1
10
-0.1
0.2
-0.1
0.2
R
e
s
i
d
u
a
l
s
Figure 12: Using 0,5-22,4 mm fraction data from jaw crusher sample of granite plus closed-
side setting estimate of x
max
300 mm to predict missing fractions. Curve fit
parameters: x
50
= 77 mm and b = 2,33.
0.1 1 10 100 1000
Mesh size, mm
0.1
1
10
100
Mass passing, %
Swebrec function: x
50
= 460 mm
x
max
= 1800 mm and b = 2,41
x
50
50
x
max
= B
Finn Ouchterlony: The Swebrec function, blast fragmentation, the Kuz-Ram etc 27
Figure 13: Brarp round 4 data with best fit extended Swebrec function
20
. Data range 0,075-
500 mm. Curve fit parameters: x
50
= 459 mm, x
max
= 1480 mm, b = 2,224, a =
0,99999812 and c = 2,0. r
2
= 0,9976. Note magnitude of prefactor (1-a) in (3).
Figure 14: Fragment size distribution for gyratory crusher product 2 (CSS = 1,5) of
andesite with Swebrec fit
20
. Data range 0,425-63 mm. Curve fit parameters: x
50
= 35,6 mm, x
max
= 68 mm and b = 1,531. r
2
= 0,9961.
0.02 0.2 2 20 200 2000
Mesh size, mm
0.1
1
10
M
a
s
s
p
a
s
s
i
n
g
,
%
0.1
1
10
-1
0.5
2
-1
0.5
2
R
e
s
i
d
u
a
l
s
0.1 1 10 100
Mesh size, mm
1
10
M
a
s
s
p
a
s
s
i
n
g
,
%
1
10
-1
3
-1
3
R
e
s
i
d
u
a
l
s
Finn Ouchterlony: The Swebrec function, blast fragmentation, the Kuz-Ram etc 28
Figure 15: Fragment size distribution for belt sample 2-04 of Nordkalk limestone
20
.
Swebrec function fit with fixed x
max
= 315 mm. Data range 0,25-300 mm.
Parameters: x
50
= 48,8 mm and b = 2,451. r
2
= 0,9994 (Table 2).
Figure 16: Laboratory ball mill data for limestone after 6 min grinding with extended
Swebrec function fit
20
. Data range 0,063-3,36 mm. Curve fit parameters: x
50
=
1,00 mm, x
max
= 3,36 mm, b = 1,010, a = 0,9911 and c = 1,753. r
2
= 0,9995.
0.05 0.5 5 50 500
Mesh size, mm
0.1
1
10
M
a
s
s
p
a
s
s
i
n
g
,
%
0.1
1
10
-0.5
1
-0.5
1
R
e
s
i
d
u
a
l
s
0.05 0.5 5
Mesh size, mm
10
M
a
s
s
p
a
s
s
i
n
g
,
%
10
-0.5
0.25
-0.5
0.25
R
e
s
i
d
u
a
l
s
Finn Ouchterlony: The Swebrec function, blast fragmentation, the Kuz-Ram etc 29
Figure 17: JKMRC breakage function for crusher
19
at t
10
= 30 %, with Swebrec function
20
.
Data range 0,025-1. Curve fit parameters:
50
= 0,197,
max
= 1,0 and b = 2,431.
r
2
= 0,9985.
Figure 18: Mass passing isolines for constant degrees of size reduction, plotted as function of
the breakage index t
10
. Full lines denote predictions by (5) and (6).
0.01 0.1 1
Size fraction
1
10
M
a
s
s
p
a
s
s
i
n
g
,
%
1
10
-2
1
-2
1
R
e
s
i
d
u
a
l
s
0 10 20 30 40 50
Breakage index t
10
, %
0
20
40
60
80
100
t
n
, % passing
t
10
t
2
t
4
t
25
t
50
t
75
b = 1,616+0,02735
.
t
10
b = 2,174
Finn Ouchterlony: The Swebrec function, blast fragmentation, the Kuz-Ram etc 30
Figure 19: Comparison of three model predictions of the fragment size distribution of the
Brarp round 4 muckpile with actual data in logP versus logx space.
Figure 20: Comparison of three model predictions of the fragment size distribution of the
Brarp round 4 muckpile with actual data in P versus logx space.
0.1 1 10 100 1000
Mesh size, mm
0.1
1
10
100
Mass passing, %
extended Kuz-Ram or KCO model:
x
50
= 448 mm, x
max
= 2000 mm and b = 2,43
x
50
50
Kuz-Ram model:
x
50
= 448 mm and n = 1,17
shifted
Kuz-Ram
0 1 1 10 100 1000
0
20
40
60
80
100
Mass passing, %
extended Kuz-Ram
or KCO model
50
Kuz-Ram
model
shifted
Kuz-Ram