Safety is paramount in every responsible mining operation, yet certain geological conditions, such as reactive ground and hot-holes, pose significant challenges, particularly in the coal sector.
Edward Felix, Regional Manager of Surface South Africa at AECI Mining Explosives, highlights the company’s commitment to research and development, which has led to the creation of new surface emulsion technologies like the Powergel base emulsion range. These innovations not only enhance safety but also contribute to the sustainability of the industry.
Felix said: “AECI Mining Explosives is at the forefront of developing base emulsions for various applications. Our solutions are purpose-built and continuously improved to enhance product performance and decarbonise the value chain. These principles extend beyond emulsions to our entire surface product offering.”
Powergel X², part of the Powergel product range, is specifically designed for surface mining operations facing extreme blasting conditions. While most products cater to either reactive ground or hot-holes, Powergel X² addresses both simultaneously. This single-solution-technology not only improves safety but also reduces the need for maintaining large inventories, offering significant benefits to AECI’s customers dealing with a variety of extreme ground conditions.
Powergel X² is developed in a safe, non-explosive form as a base emulsion, sensitised upon loading into the blast holes from where it becomes an explosive after completion of a chemical process. Additional customer benefits include optimal shelf life, leading to better working capital and inventory management, as well as improved product ‘flowability’, which results in cleaner storage silos.
“Although coal mining is often perceived as environmentally harmful, it remains a crucial resource. AECI Mining is committed to helping customers and partners engage in responsible mining practices by developing technologies that ensure sustainability across the economy, industry, and environment. Our approach to continuous improvement drives us to keep advancing,” Felix states. “Recent advancements include emulsion technologies for extreme conditions, new booster technologies with non-explosive raw materials that reduce our carbon footprint, and improved electronic detonator technologies to minimise environmental impact.”
Taking the Powergel range a step further, AECI Mining has introduced an eco-variant of the product, which offers excellent water resistance and incorporates recycled oil within the emulsion. Over the past decade, since integrating used oils into its various Eco bulk emulsion formulations, AECI Mining Explosives has consumed more than 80 million litres of used oil and prevented approximately 55,000 tons of CO2e emissions from entering the atmosphere due to the properties within the chemistry.
Felix emphasizes that innovation is deeply embedded in AECI Mining Explosives’ DNA. As Africa’s first explosive manufacturer, the company has always prioritised explosives research and development to meet the needs of its customers operating in challenging mining conditions.
“Every product we develop at AECI Mining is designed with our customers and their specific applications in mind. Our goal is to meet customer needs responsibly by understanding and addressing the entire value chain,” he says. “While we initially developed the Powergel X² series to serve our Tier 1 customers in South Africa’s coal fields, addressing hot-hole and reactive ground conditions, we have expanded this success by creating a solution for extreme geothermal conditions in Papua New Guinea.”
The emulsion technology is now being used alongside AECI Mining’s specially designed delivery systems and hot-hole initiation systems. These technologies are not only tailored to meet the immediate challenges of extreme geothermal conditions but are also designed to sustain mining operations well into the future. By addressing both current and emerging needs, AECI Mining is ensuring that its innovations will continue to support the industry’s growth and adaptability in increasingly complex environments.
