Ore crushing is a crucial phase in hard rock mining and mineral resource recovery, significantly focusing on optimizing the energy consumption balance between blasting and mechanical crushing. This study analyzed industrial test data from an iron mine to explore the relationship between parent rock size distribution characteristics and mechanical crushing energy sensitivity, providing a theoretical foundation for process optimization and energy efficiency improvement. Initially, the connection between the key parameters of the parent rock size distribution curve and crushing power consumption was investigated. Subsequently, the maximum block size under the screen(D75) was identified as a sensitive indicator for crushing power consumption through correlation analysis. Finally, a theoretical model based on shared blasting control was developed, utilizing an optimal parent rock size distribution curve, $R=1-\exp \left[-{\left(\frac{X}{282.1}\right)}^{1.69}\right]$ to control the block size. Field application of this model demonstrates a cost reduction of 17.63%, affirming its potential for enhancing energy management and cost efficiency in mining operations.

Efficient coordination between different processes is crucial in optimizing resource allocation and minimizing energy consumption during blasting operations in open-pit mines. To address these challenges, the theory of blasting sharing control is proposed, which integrates macroscopic ore fragmentation with mesoscopic damage analysis and introduces a novel ore damage model for the shoveling process. By optimizing inter-process connections and considering factors such as wear and depreciation, a comprehensive energy distribution model is developed across drilling, crushing, blasting, shoveling, and transportation processes. Evaluation and control indices are proposed for each process, leading to the establishment of a blasting sharing control model. The results demonstrate that the ore damage model reveals the multi-phase characteristics of rock blasting failure and effectively predicts the crushing energy consumption by regulating fragmentation levels. With a fitting accuracy exceeding 0.8, this model optimizes the crusher operations while reducing energy consumption. Using the blasting sharing control model enables calculation of the optimal solutions for blast parameter design while establishing an optimal comprehensive energy consumption formula under the constraint conditions, thus enabling the accurate adjustment of energy at each link and providing strong support for efficient, safe, and sustainable mine operations.

To investigate the effects of burden on rock crushing characteristics under lateral detonation of cylindrical charges, we analyzed the stress state at the free surface using the wave theory. Afterward, to simulate the cylindrical charge detonation, the physical experiment of lateral rock fragmentation was conducted using direct copper wire electro-explosion. The evolution process of surface crack network of the specimen was observed using ultra-high-speed camera technology. The impact of cylindrical charge detonation on rock properties was studied by combining the morphology, dimensions, and distribution characteristics of the blasting crater with different burdens. The results demonstrated that the burden is a crucial factor for controlling the fracture mode, morphology of failure zone, and fragment size during rock blasting. As the burden increased, the crack propagation velocity and density gradually decreased, while the range of crack network expanded, and the preferential propagation direction of cracks changed from transverse to circumferential. Furthermore, the experimental results indicated an increasing trend in the short axis of the fracture zone as the burden increased. Through analyzing the stress state at the free surface, the maximum tensile strain criterion was applied to justify this phenomenon. Finally, the relationship between fragment size and energy consumption was established. Our research findings provide a reference for optimizing the design of rock engineering blasting.