Research Progress and Prospects on Energy Consumption Flow in Ore Crushing of Open-pit Metal Mines
XU Zhenyang, LIU Xin, GUO Lianjun, CHAI Qingping, HUANG Mingjian,
2026, 55(9):
13-25.
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The pivotal systemic engineering issue in ore production is controlling energy consumption across the full
process,from blasting through mechanical crushing and grinding.To address the paramount need for collaborative efficiency im
provement in large open-pit metal mines,and based on a review and synthesis of research progress in China and abroad,together with the authors′decade of research on multi-process coupling in large mines,this paper proposes energy-flow transfer in ore
fragmentation within open-pit metal mines as a central concept.Its aim is to address fragmentation in mining processes,achieve
full-process energy optimization,and guarantee a stable supply of ore with consistent quality.Accordingly,this paper reviews re
search progress in several areas,including energy-consumption modeling for rock fragmentation based on intelligent perception
during drilling,three-dimensional information extraction of blasting fragmentation,the use of spatial distribution features of blas
ting fragmentation to guide loading and ore blending,coupled control of ore crushing efficiency based on differences in blasta
bility,and the developmental characteristics of blasting vibration energy.The results show that:① A rock fragmentation energy
model constructed from field drilling parameters,combined with energy-time density indices along with efficiency evaluation
functions,can effectively characterize rock-mass properties and provide a foundation for the rational regulation of energy con
sumption among blasting,crushing,and grinding processes.② Through integrating three-dimensional laser scanning,3D Gauss
ian splatting,and machine-learning algorithms,blasting fragmentation is able to be characterized from two-dimensional images
to three-dimensional shape features and volume calculations,providing key data support for crushing energy-consumption calcu
lation and crusher parameter refinement.③ Based on an adaptive layered model of the muckpile,improved path-planning algo
rithms,and a multi-goal intelligent ore-blending system,a refined operational chain has been established that links the spatial
distribution of fragmentation,loading-path optimization,and coordinated ore blending across multiple mining areas,thereby ef
fectively supporting improvements in loading efficiency and stability of ore quality.④ The matching of explosives and rock
based on blastability zoning,together with coupled control of crushing efficiency that accounts for fragmentation characteristics,
can improve the utilization efficiency of explosive energy and reduce full-process energy consumption.⑤ Blasting vibration en
ergy indicators are sensitive to the structural response of the rock mass,enabling blasting vibration,traditionally regarded as an
adverse effect,to be transformed into an effective auxiliary means for inferring rock-mass information in the area to be blasted.
Building on this,the paper further discusses key research directions for the field during the 15th Five-Year Plan period and be
yond.Future research ought to focus on the construction of integrated terrain-geology-grade models and refined blastability zon
ing,intelligent matching of explosives and rock based on blastability zoning and on-site mixed charging technologies,full
process coupled control of ore crushing efficiency based on differences in blastability,and characterization of rock-mass struc
ture and damage features using blasting vibration energy indicators.These efforts are expected to add to a systematic solution for
full-process energy optimization and stable ore-quality supply,thereby supplying theoretical foundations and technical support
for green,efficient,and intelligent mining in large open-pit mines