Energy- and Cost-Oriented Management of Rock Fragmentation Quality in Borehole Blasting Using a Shock Adiabat-Based Crushing Zone Model

Efficient blasting design is increasingly regarded not only as a geomechanical problem but also as a managerial challenge related to energy use, fragmentation quality, downstream comminution costs, and environmental performance. This study develops a shock-adiabat-based analytical model for predicting the radius of the crushing zone around borehole explosive charges and demonstrates its applicability as a decision support tool for energy- and cost-oriented blasting management. The model integrates shock wave propagation parameters, particle velocity behind the shock front, and the physical and mechanical properties of limestone, sandstone, and granite. The calculated crushing zone radiation was compared with a previously developed analytical model based on borehole pressure and validated using finite element simulations in SolidWorks Simulation. The discrepancy between the proposed shock adiabat model and the reference analytical solution did not exceed 6%, while the difference between analytical estimates and numerical simulations remained below 5%. The results show that borehole diameter, compressive strength, and explosive–rock interface pressure significantly affect the crushing zone radius and, consequently, the volume of rock effectively fragmented during blasting. A scenario-based assessment further indicates that improved prediction and management of the crushing zone may reduce downstream crushing and grinding energy demand by approximately 10–20%, generating potential cost savings and indirect CO2 emission reductions. The proposed method therefore supports the management of blasting energy efficiency, fragmentation quality, operational costs, and sustainability performance in mineral extraction systems.