OFFICIAL INTEGRATION OF DIGITAL TECHNOLOGIES AND ADVANCED EXPLOSIVES FOR SAFETY, EFFICIENCY AND CONTROL IN ROCK BLASTING: EXPERIENCE FROM A SURFACE GOLD OPERATION *V. Barcelos1, D. Rocha2, B. Canesso1, M. Ramalho1, W. Vilas Boas1, J. Correia2, A. Oliveira2 1Technical Services, Orica, Brazil (*Presenting author: vitor.barcelos@orica.com) 2Drill and Blast, Equinox Gold, Brazil ABSTRACT The increasing complexity of surface mining operations demands solutions that integrate safety, efficiency, and sustainability. This paper presents the experience of a Brazilian gold operation that adopted digital technologies and advanced explosives to address three critical challenges: blasting near sensitive areas, cost optimization, and ore dilution control. The first initiative addressed one of the most critical challenges in surface mining: executing production blasts near sensitive infrastructure without compromising safety or operational continuity. The project required a rigorous approach to vibration and flyrock control, as the blasting area was located near administrative facilities and a water dam. To achieve this, the operation integrated electronic initiation systems with advanced timing precision, high-quality bulk explosives, and a suite of digital tools for planning, predictive vibration modeling, and real-time QA/QC monitoring. These measures ensured strict compliance with regulatory limits and eliminated risks to nearby structures, enabling the mine expansion without interruptions. This initiative avoided the relocation of critical infrastructure, resulting in an estimated cost saving of USD 1.6 million. The second initiative involved replacing the standard explosive with a higher-energy product, enabling wider drill patterns and lower powder factors without compromising fragmentation quality. Computational modeling supported design adjustments, ensuring predictable outcomes. After one year, the operation achieved an average pattern expansion of 13%, a reduction in powder factor of 17% for ore and 9% for waste, a 12% improvement in P80 fragmentation, and a 13% reduction in loading time. These improvements delivered annual direct savings of approximately USD 300,000 in drilling and blasting costs, alongside productivity gains. Finally, to mitigate metallurgical losses caused by dilution, a threedimensional blast movement modeling solution was implemented to define optimized diglayers and improve blend reliability. This practice reduced average dilution from 18.4% to 10.9%, generating an annual economic impact of approximately USD 840,000 in processing costs. The results demonstrate that integrating engineering practices, advanced explosives, and digital platforms for planning and control redefines standards in rock
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