Transforming mining operations: The revolutionary impact of WebGen? Wireless Blasting Technology.

Welcome to the first 2025 edition of Blasting and Beyond. This year, we're thrilled to bring you a series of special Orica Insights editions, showcasing exclusive interviews with our subject matter experts from across the globe.

WebGen? Wireless Blasting Technology – How it’s proving to be a game-changer?

Orica’s commitment to technology and innovation in delivering solutions that are safe in challenging mining conditions has been the underlying premise for our electronic blasting systems. In 2017, Orica launched the world’s first fully wireless initiating system, WebGen? which has significantly pushed the boundaries of blasting technology. Today, the WebGen? wireless initiating system is proving to be a game changer for mining operations, providing a safer and more efficient approach to blasting. It offers significant improvements in safety, efficiency, cost, reliability, flexibility and performance compared to traditional wired blasting methods.

In this edition of Blasting and Beyond, we spoke with Adam Aubin, Head of Technical Solutions for North America, about the advantages of the WebGen? wireless initiating system over traditional wired blasting methods with a focus on two recent case studies in metal extraction at the Sierrita Mine, in the US and New Afton Mine in Canada. With over a decade of experience in explosives and blast engineering, Adam has played a key role in successfully introducing WebGen? to customers across North America and abroad. With a seasoned technical mind paired with extensive global operational experience, he is well aware of the challenges our customers encounter in their day-to-day operations and is committed to offering solutions that prioritise safety and deliver bottom line results.

What advantages does WebGen? wireless initiating system offer over traditional wired blasting methods??

The mining industry constantly seeks innovative solutions to improve safety, efficiency, and cost-effectiveness. WebGen? is one such groundbreaking technology that offers significant advantages over traditional wired initiation systems in delivering the solutions our customers are seeking.

In terms of safety, WebGen? eliminates the need for miners to re-enter blast areas to connect wired detonators, thereby reducing the risk of exposure to hazardous conditions and unplanned initiation. In contrast, traditional methods require re-entry, increasing the risk of accidents and exposure to dangerous environments.

The efficiency gains using WebGen? are significant. Wireless initiation allows for faster stemming placement and eliminates the time-consuming tie-in process, making the blast ready to fire immediately after stemming. This enhances the overall speed and efficiency of the blasting process. Traditional methods, however, involve additional time for connecting wires and ensuring secure connections, which can delay blasting operations.

Cost efficiencies is a key driver for our customers, by minimising the need for extensive wiring and re-entry procedures, WebGen? significantly reduces development costs. For instance, at New Afton Mine, the use of WebGen? resulted in estimated development cost savings of over CAD$1 million across 18 undercut drives. Traditional methods incur higher costs due to extensive wiring, additional safety measures, and potential delays caused by re-entry procedures.

WebGen? also offers key advantages in terms of reliability and flexibility for operations. The low-frequency magnetic induction signals used to initiate primers, eliminates the risk of unplanned initiation in challenging conditions, such as lightning strikes and other external factors. In contrast, wired systems are more susceptible to such risks, posing safety hazards and potential delays.

WebGen? enables innovative blast designs that are not feasible with wired systems, such as adjacent slot blasts charged together but fired separately. This flexibility allows for more efficient and effective blasting strategies. Traditional methods are limited by the need for wired connections, restricting the flexibility and efficiency of blast designs.

Overall, WebGen? is demonstrating improved recovery and dilution results, as well as substantial enhancements in safety, scheduling, and cost reduction. For example, at Sierrita Mine, the technology increased tonnage output and cost efficiency. Traditional methods may result in lower recovery and higher dilution due to the limitations and risks associated with wired connections.

Case study: Sierrita Mine optimising operations through WebGen?

At the Sierrita Mine, a surface copper mine in the United States, we had the opportunity to showcase how the WebGen? wireless initiating system can optimise operations and enhance efficiency. The mine was interested in the innovative ways WebGen? could overcome traditional mining challenges such as blast delays, congestion between personnel and equipment, and issues during the storm season, such as cut-offs, leakage, heavy rain, and production delays due to lightning risks.

Download the full case study: Sierrita Mine, increasing efficiency and safety through wireless blasting technology.

We initiated an exploratory phase at the Sierrita Mine, looking for efficiencies across their operation. One application demonstrated was eliminating/reduction in blast delays. Lightning exclusion zone reductions were also identified as a potential future opportunity. By mitigating lightning risks on a loaded pattern, WebGen? enables the preloading of multiple benches during storm seasons without the need for physical products on the bench. This approach aimed to reduce or eliminate exclusion zones and evacuation plans related to lightning.

The benefits of WebGen? for lightning risk reduction

WebGen? offers several key benefits, including enhanced control and flexibility. It allows for blasting according to optimal conditions rather than being constrained by traditional mining cycles. WebGen? eliminates issues such as leakage, cut-offs, wire or crimp problems, and physical attachments to the surface. This technology enables different treatment of loaded patterns, allowing them to serve as haul roads, temporary storage, or crossovers. It also facilitates quicker planning and adaptation, reducing congestion and exclusion issues, and enabling the development of a substantial loaded inventory. Hot loading becomes easier, allowing continuous equipment use. WebGen? defines efficiency by eliminating the tie-in cycle, enabling new loading and blasting practices, and integrating blasting activities seamlessly into mining operations.

The implementation of WebGen? technology significantly streamlined the blasting process. Preloading and timing were completed ahead of time, reducing the loading cycle and minimising the time personnel spent in high-risk environments. Recent blasts demonstrated the ability to preload safely and efficiently, optimising operations through larger, less frequent blasts. This approach improved performance, reduced downtime, and increased output, transforming the scheduling of the entire operation.

The successful implementation of WebGen? at Sierrita Mine demonstrated the potential of this technology, marking a fundamental redesign of blasting possibilities. The collaboration with Sierrita and Southwest Energy was key in showcasing a successful proof of concept and increasing the complexity of blasts over time. It highlighted the safety, performance, and reliability of WebGen?, setting a precedent for what can be achieved in blast design and initiation.

Case Study: New Afton safer undercutting, block-cutting and improved savings with WebGen?

New Afton Mine is an underground copper and gold mine in British Columbia in Canada, that uses the block caving mining method, which has presented several challenges, particularly with the conventional slot blasting method. The mine faced significant re-entry challenges on their undercut level due to the limited stand-off between initiation slots. The geometric constraints required the second slot to be drilled offset into waste material, increasing dilution and exposure to compromised ground. Additionally, the stand-off slot necessitated an extra 15 meters of lateral development.

Download the full case study: New Afton Mine, WebGen enables safer undercutting in block caving operations

The Picrite zone at New Afton Mine is particularly challenging due to its weak ground conditions, making stabilisation difficult. To address these challenges, New Afton implemented a new blast design using WebGen? technology. This innovative approach eliminated the need for re-entry, wire management, and physical connections to the blast holes. Both slots were designed and executed adjacent to one another, allowing them to be drilled in ore, thereby eliminating waste, non-profitable rework, and re-entry into fractured, compromised ground.

To protect primers from overbreak in the new slot design, standard WebGen? design stand-offs, loading practices, and specific plugging methods were employed. Orica and New Afton conducted an in-field test and QA/QC profile to determine the standard collar length and expected overbreak, tailoring the design accordingly.

The new method significantly impacted re-entry risks, recovery, and dilution. It eliminated all re-entry risks as both slots were drilled and loaded in a single campaign, and dilution was significantly reduced because both raises were drilled in ore. The estimated development cost savings from using WebGen? at New Afton were calculated to be over $1 million CAD per year.

New Afton envisions potential applications for WebGen? in their ring firing operations to eliminate re-entry and conceptual future use in some stoping activities. Multi-lift drawbell blasting with WebGen? offers the potential to completely eliminate the undercut drive, thereby reducing development costs, ground support costs, and overall operating expenses substantially. Given the increasing depth, complexity, and stress of mines, accelerating the process of bringing more stopes and caves online and completing them ahead of schedule is a primary focus.

What potential do you think the WebGen? wireless initiating system has for the future of mining operations?

The potential of the WebGen? wireless initiating system for future mining operations is substantial and continually evolving. Since its inception in 2016, initially targeting cave mining, WebGen? has expanded its applications across various mining sectors, including civil tunnelling and niche blasting. The system has been integrated into some of the most advanced mines globally, enhancing and optimising operations in ways previously deemed impossible.

WebGen? has revolutionised mining methods, making novel techniques commonplace and significantly improving safety and productivity. Initially, the focus was on recovery; however, as mines have become deeper, more complex, and more seismically active, the emphasis has shifted to speed of resource access and operational efficiency. The ability to design mines around preloading, eliminating the need for access or re-entry, and simplifying ore waste separation has become paramount. WebGen? facilitates continuous loading operations, eliminates exclusion zones, and removes the necessity for top sill development in up-hole mining.

Furthermore, the wireless system is a cornerstone of fully automated drill and blast environments, a key focus for the entire industry. By integrating innovations such as WebGen? with Avatel? the world’s first automated development charging system, and the interconnectivity of Orica’s Digital Solutions, mine sites can extract more value from their operations while simultaneously addressing critical safety, productivity and sustainability concerns.

The future of mining with WebGen? is limited only by imagination, offering unprecedented opportunities for innovation and efficiency.

Want to optimise your site with WebGen??

Learn how WebGen? can enhance your site's safety and operations. Reach out to us today through our contact form.