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ABSTRACT high den sity and water resistance of emulsions or slurries plus
the low cost of ANFO. The concept is very simple. ANFO is
ANFO has two major disadvantages as an explosive low density about 500,10 air, roughly 30% in the prills and 700,10 between the
and no water resistance. ANFO can be blended with more prills . The air in the prills provides the necessary sensitivity but
dense, water-resistant explosives to form " Heavy ANFO". the air between them is waste volume. If one fills this volume
The use of emulsion or slurry explosives as a matrix is an at- with a high density, waterproof product, the resultant mix will
tempt to correct deficiencies on the basic ANFO while main- ~e denser and more water resistant than ANFO and with very
taining cost effectiveness. little added cost. This basic concept was invented by B. Clay in
This paper will deal with four main topics. the 1970s and is covered by Canadian Patent No . I lIS 959.
1. Product description, general properties, strengths and The water resistance and/or den sity of the mix can be tailor ed
weaknesses. by changing the emulsion level. Because Heavy ANFO is
2. Technology of "Heavy ANFO" , the emulsion matrix con- relatively inexpensive while providing good in-hole densities
cept and the range of products. and water resistance, it can compete successfully against all
3. Relative performance and economics in various rock types. other bulk products. It competes against ANFO and Al l ANFO
4: Current status in Canada and worldwide, and the expecta- by allowing pattern expansion and reducing over-all costs
tions for future use. while it competes against emulsions and slurries on price.
Introduction Since Heavy ANFO first came on the market about ten years
a~o , it has found its way into a wide variety of applications.
ANFO has been in use for roughly three decades and remains
the explosive of choice where conditions are suitable. ANFO FIrst and foremost, it is a bulk explosive and the nearest thing
has not become the universal explosi ve - despite its un- to a univ~rsal product yet developed. It has become perhaps
doubted superiority in cost effectiveness - because it has the most Important bulk product in Australia and has made
serious flaws as an explosive. The most serious of these flaws major inroads in South Africa and the U.S.A. (where it
are the low density and absence of water resistance in ANFO. started) as well. In Canada, the harsher conditions (i.e. wetter
Low density implies a low concentration of explosive energy in and colder) and the availability of good, cost competitive
a borehole. The amount of energy available can be increased slurry technology has result ed in low market penetration so
by. adding an energetic material, generally aluminum, or by far, but Heavy ANFO is gaining momentum and appears likely
drilling more holes. Both solutions add considerably to the to become a major product in the future. The future also ap-
over-all costs. The absence of water resistance in ANFO is in- pears bright in other applications. In Australia, ICI has
herent and can only be overcome by changing the fundamental pioneered pneumatic loading of Heavy ANFO (about 10%
~ at ure of !he product. The history of research in the explo sives
emulsion) underground. The emul sion reduces blow back and
industry since the advent of ANFO is mainly the story of the raises in-hole densities. The strengths of Heavy ANFO will
varIOUS attempts to overcome one or both of ANFO' s short- result in increasing market share into the future, at least until
comings. somebody has a better idea.
Many technologies and products have been developed to
compete against ANFO, among them slurries, emulsion s and The Technology of Heavy AN FO
the so-called Dense ANFOs (ANFO with an extra nitroalkane
One of the advantages of Heavy ANFO is that the technology
liquid sensitizer). None of them was cost-competitive with AN-
is relatively simple. Actually, there are two separate technolo-
FO so their market penetration has been limited to wet holes or
gies. The first involve s the production of the matrix - the
specialized applications. The exception to this result is Heavy
name given the emulsion component. The second involves
ANFO. The aim here was to ha ve the best of both worlds, the
mixing and loading the final product. Everybody has their own
KeyWords: Technology, Heavy ANFO, Explosives , Blendmaster, idea how to. accomplish the first step; everybody does basically
C-I-L, Blasting . the same thing at the second. It is the matrix which imparts the
Paper reviewed and approved for publication by the Metal Mining Division of elM.
M TRIX
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FIGURE 3. Effect of matrtix level on density, critical diameter FIGURE 4. Sleep time vs % emulsion.
and minimum booster. .
ANFO is the matrix level. This has a profound effect on density, This is an area where a Blendmaster-type truck has a con-
strength, sensitivity, cohesiveness and water resistance. Table 1 siderable advantage over a standard Heavy ANFO truck.
shows how great these effects are. Much less controversial is the matter of sleep time in
As can be seen, there is very little energy to be gained above boreholes. In dry holes, the sleep time is equivalent to conven-
45070 matrix. This is because one is replacing a high weight tional products. In wet areas, the sleep time is dependent on
strength explosive (ANFO) with a lower weight strength the level of the water impermeable matrix. As has been de-
(because it contains water) emulsion while the increase in density scribed earlier, the matrix at lower to medium levels coast the
levels off. Depending on the density of the matrix, the max- prills. Even at 30% matrix, this is a very thin coating (about
imum density for Heavy ANFO will occur in the 45% to 55% 0.1 mm to 0.2 mm) and so does not provide much water resis-
range. This is because a partially emulsion impregnated prill is tance. By 40% matrix most of the air gaps are filled and the
denser than the surrounding matrix. prills are much better protected. About 40%, the matrix starts
The sensitivity falls off with increasing matrix level due to to push the prills apart and water resistance increases dramati-
the detonation wave being propagated mainly by the ANFO. cally. For levels above 50% to 55% matrix (doped emulsions),
The matrix is above its critical density and so acts more as an the product is essentially waterpoof. This data is outlined in
energetic fuel than an explosive. As the matrix level is increas- Figure 4.
ed, the ANFO is "diluted" with two main effects-a more
powerful initiator is needed and the critical diameter increases. Blasting Performance of Heavy ANFO
Both these effects are due to the greater difficulty in prop- Just as the physical properties of Heavy ANFO are critically
agating the detonation. A small booster will still initiate the dependent on the matrix level, so are the blasting propertie s
ANFO but the relatively insensitive matrix will tend to quench and economics. Heavy ANFO could be called the first univer-
detonation waves below a certain critical energy. The smaller sal bulk explosive. Due to the inate flexibility of the product
the diameter of the explosive column, the easier it is to quench and delivery systems, it can compete on cost and performance
the detonation. Thus the need for bigger holes and boosters with everything from ANFO to standard bulk slurries tor
for higher matrix levels. emulsions). Heavy ANFO is competitive because a tailor-made
The degree of cohesiveness is not critical in itself but it does product can be delivered to each borehole and because the
affect the packing efficiency of the Heavy ANFO which in matrix enhances the performance of the ANFO.
turn affects the density and water resistance . Air gaps outside Heavy ANFO is a mixture of a cheap (ANFO) and an expen-
the prills do not affect sensitivity but do lower density, so, sive (matrix) ingredient. Therefore, any combination will be
ideally, these gaps should be minimized. The higher the matrix more expensive than ANFO but cheaper than a bulk slurry or
level (and the more fluid the matrix), the better the packing emulsion. Heavy ANFO competes against ANFO because the
will be. This will optimize the products' performance. higher density allows more product to be loaded in the hole. In
The most controversial topic in Heavy ANFO is water resis- addition, it raises the detonation pressure. This combination
tance and, especially, loading through water. There has been allows the pattern to be pushed out, lowering drilling and
little solid evidence put forward 'by the proponents of this accessory costs. Even though there is more powder (and more
practice to indicate that loading through water will provide expensive powder) in each hole, there are fewer holes and the
reliable, consistent results. Most of the research that has been superior performance of the Heavy ANFO allows the over-all
carried out has been done by C-I-L and its sister companies costs to the mine to be lowered. For any matrix level used,
and has had largely negative results. Work continues because there will be a critical degree of pattern expansion above which
developing such a productlloading system would greatly ex- Heavy ANFO is cost competitive. A second approach is that
pand the possible applications for this product. Perhaps the Heavy ANFO will provide improved fragmentation over ANFO
most important point to keep in mind is that above approx- and the reduced processing costs for the mine may make the
imately 55% matrix, the product can be pumped and loaded use of Heavy ANFO cost effective without any (or only slight)
from the bottom of the hole. This provides a much more pattern expansion. The need at many mines for toe loading
reliable product in the hole with no increase in explosive costs. with All ANFO also increases the cost competitiveness of
Heavy ANFO.
TABLE 1'(1) The effect of matrix level on physical At the other end of the spectrum, Heavy ANFO competes
against bulk slurries or emulsions mostly on price. The water
properties resistance and explosive properties mayor may not be some-
% DenSI~ Critical Water what inferior to slurries or emulsions but Heavy ANFO is
Matrix(2) (g/cm RBS diameter Cohesiveness resistance
0 0.84 100 75mm None None
much cheaper. Generally the explosive performance desired
10 0.93 107 100mm None None can be obtained by varying the matrix level. Additionally, the
20 1.04 118 125mm Free Flowing Slight pattern could be brought in somewhat or the Heavy ANFO
30 1.15 128 125mm Somewhat cohesiv e Fair
40 1.28 140 150mm Cohesive Good aluminized while maintaining a cost advantage.
45 1.35 145 175mm COhesive Very Good
50 1.40 149 200mm Very cohes ive Excellent The key point for the customer to remember is that the
Notes: (1) Some of this data is presented graphically (Figs. 3, 4).
choice of explosive will affect the over-all costs to the mine.
(2) For the purposes of Ihls table, the emulsion Is considered 10 have an Too often in the past, an explosive was chosen solely on the
RWS of 80 and a dens ity of 1.40 g/cm 3 . basis of price. As analyses became more sophisticated, other
62 Volume80, No. 905
T p
V Mat ri x - - - -
1 umi nurn -------
... -.- - -... . .
Te mp e rat u r e
! Ma t r ix - - - -
Al u mi n um -------
FIGURE 5. Effect of aluminum and emulsion on explosion FIGURE 6. Effect of aluminum and emulsion on gas pressure
temperature and gas volume. and detonation pressure.
blasting costs (e.g. drilling, accessories, etc.) were included but fherefore, although the explosive energy is increased, the gas
this is still too simplistic. The blasting performance will also and detonation pressures (Fig. 6), which cause fragmentation,
affect downstream operations such as mucking and milling. and the gas volume (heave) do not increase at the same rate
The cost savings in these areas brought about by, for example, and, therefore, only limited, if any, pattern expansion would
improved fragmentation may dwarf the cost differentials in be possible. Adding matrix to ANFO has the opposite effect
the various explosives. These are numbers only the mine can - the explosion temperature decreases but the gas volume in-
determine and they will vary for each mine. Therefore, the creases. With the much greater increase of density both the
choice of explosives needs a much longer and deeper look than heave and fragmentation are much greater than for ANFO or
most operations take. There is a growing feeling that Heavy All ANFO, and considerable pattern expansion is possible .
ANFO will come out ahead in many instances when such an At the other end of the scale, the explosive properties of
analysis is made. Heavy ANFO compare very well with those of slurries and
Before going into relative costs more deeply, the relevant emulsions. Aluminized Heavy ANFOs have even more impressive
explosive properties of various product types should be properties. The product shown in Table 2 which has 40070
discussed. The important properties with regards to blasting matrix, plus 6% aluminum should be nearly the equal of
performance are the strength, detonation pressure and gas POWERGEL E (with 14% aluminum) at a considerably lower
pressure. These correlate to total energy available, fragmenta- cost. The numbers then tend to support the contention that
tion and heave respectively. Of course, they are interrelated, Heavy ANFO can compete across the board.
that is, if you don't break the rock, no amount of gas volume There is one important criterion which has not been discussed
will move the rock very far. The explosion temperature also yet and that is rock type. Everyone in the industry understands
affects fragmentation and heave. This is how aluminum that different rock types will break differently, but too often
works: by raising the explosion temperature the gas pressure is not enough consideration is given to optimizing blasting cost
increased (although the volume is decreased) and therefore effectiveness by careful selection of explosive s and pattern.
both the fragmentation and heave are increased. At equal The purpose of any explosive is first to break the rock into ac-
temperatures, the explosive with the higher gas volume will ceptably sized pieces, then to move it out to make mucking
provide better heave; the explosive with the higher VOD possible. All explosives partition their energy between the two
(Velocity of Detonation) and/or density will provide better functions. Those explosives with high brisance (shock energy)
fragmentation . Table 2 and Figures 5 and 6 provide data on are best for hard breaking rock, whereas most of this energy
some typical explosives . would be wasted in soft rock. Hydromex is the epitome of such
Figure 5 shows that adding aluminum to ANFO has the a product. On the other hand, soft rock calls for a low brisance
effect of increasing the explosion temperature but decreasing explosive such as ANFO. Most explosives have medium prop-
the available gas volume . The density is increased only slightly. erties so they can be used anywhere, if not at optimum effi-
ciency. Slurries fall into this category. Here it is necessary for
TABLE 2. Some explosive properties for typical the mine to determine the optimum pattern for cost effec-
products tiveness. The hardest rock can be, and in practice often is,
Density VOD broken by the lowest strength explosive if the pattern is small
Product RWS RBS (g/cm 3) (km/sec.) enough and the powder factor high enough to do the job. Only
ANFO 99 99 0.84 4.0 careful analysis of all the costs to the mine will reveal what the
6 % AI/ANFO 121 126 0.87 4.2 best option is.
10% AI/ANFO 134 142 0.89 4.4 Where does Heavy ANFO fit into the picture? Almost
20/80 HANFO 96 119 1.04 4.5 everywhere, as it turns out. Heavy ANFO is a mixture of a
30170 HANFO 94 130 1.15 4.5 high brisance component (the matrix) plus a low brisance com-
40/60 HANFO 92 140 1.28 4.5 ponent (the ANFO). As these components can be combined
50/50 HANFO 90 149 1.40 4.2 essentially in any ratio (at least on a Blendmaster type system),
40/54 HANFO 115 180 1.33 4.8 the blasting properties can be tailored to the rock type. In soft
+ 6% AI rock, a low emulsion level will suffice. As the rock becomes
70/30 Doped Emulsion 86 128 1.25 5.2 harder, the emulsion level can be increased to maintain blast-
Emulsion 80 119 1.25 5.6 ing performance. In the hardest rock, an aluminized Heavy
ANFO will do the job. Across the full range of rock types , the
POWERGEL A 82 122 1.25 4.5 higher density and VOD of Heavy ANFO compared to ANFO
POWERGEL C 112 167 1.25 4.7
will provide the enhanced performance necessary for cost ef-
POWERGEL E 131 195 1.25 4.9
fectiveness. The performance of Heavy ANFO is competitive
Appendix I demonstrates quite clearly that a cost savings of As a consequence of the cost savings to be realized and the
between 9.5% and 19% is achieved by using HANFO in satisfactory results of the test work conducted since January
replacement of ANFO + 10% AI ANFO, depending upon the 25 1985, we are replacing the use of all of the more costly pro-
ducts with Heavy ANFO. The only exception to this will be the
extent to which the burden and spacing are increased in a waste
use of slurries in wet blast holes which cannot be pumped dry.
pattern containing no caprock, In the case of a pattern con-
In addition, it may be possible to replace at least some of the
taining caprock, savings of 38% are made possible by the ANFO due to the fact that significantly wider burdens and
much lower cost of HANFO as compared to POC, even though spacings and longer collars are possible with Heavy ANFO.
the pattern is actually decreased by 0.5 m on both the burden This should result in comparable explosives-only costs with ap-
and spacing. preciably lower accessory and drilling costs.