Tag Archives: AECI Mining Explosives

Surface emulsion innovations drive coal sector sustainability, AECI Mining says

Explosives and blasting, Mining consumables, Mining safety, Mining services, , , ,

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.

PT Kaltim Prima Coal feels the effects of AECI IntelliShot electronic blasting initiation system

Explosives and blasting, Mine operation news, Mineral project development, Mining equipment, Mining services, , , , , , , , , , , , ,

Having previously relied on conventional non-electric initiation systems, Indonesia-based PT Kaltim Prima Coal (KPC) has turned to AECI Mining Explosives’ IntelliShot® electronic blasting initiation system to improve the safety and efficiency of its operations.

Located close to Sangatta and Bengalon, East Kalimantan, Indonesia, KPC operates one of the largest open-pit mines in the world with coal resources of 9,275 Mt. The mine employs load and haul operations within its numerous pits, which are managed by two mining divisions: Mining Operation Division (MOD) and Contract Mining Division (CMD).

KPC commenced with coal production in 1992 and today moves approximately 500 million bank cubic metres of overburden per year, which allows the production of 60 Mt of coal. About 80% of the overburden requires drilling and blasting to enable efficient excavation, AECI says.

The mine has traditionally used conventional non-electric initiation within its CMD area, where AECI Mining Explosives Indonesia (AECI Indonesia) is contracted as the blasting services provider. This method required a lead-in-line to be run from the blast location to the firing position. In 2017, this method of initiation consumed approximately 650 m of lead-in-line per blast location, according to AECI.

High daily production targets set by KPC require multiple locations from where blasts could be initiated safely.

“Whilst this is possible within the strict safety parameters set by the mine, it sometimes requires some clever footwork, especially related to moving expensive capital equipment out of harm’s way,” AECI says. “This cumbersome method isn’t always the most efficient and often result in a loss of production time.”

AECI Indonesia, as the incumbent blasting services provider for KPC CMD since 2009, suggested IntelliShot, the company’s advanced electronic blasting initiation system.

IntelliShot has the capability to initiate one or more initiating systems wirelessly, known as remote firing. This application has the ability to generate much needed efficiencies by only using a short length of harness wire as opposed to the cost of a full lead-in-line when non-electric blast initiation is applied in the same application, the company says.

“Any new application of technology at the mine requires careful planning and demonstration of the ability to safely maintain improvement of these parameters,” it says. “The AECI Indonesia team embarked on a carefully controlled trial to test the applicability of the system and to ensure that KPC gets the full benefits.”

In addition to saving on costly lead-in lines, remote firing through the IntelliShot system offers additional safety benefits such as an advanced security system, the possibility to easily initiate the blast at larger and safer distances, allowance for the blaster to fire from locations that give greater visual security of the blast area during firing, and eliminating potential slap, snap and shoot that is possible with shock tube.

The introduction of remote firing at KPC was performed as a project and carried out in stages in the CMD area of KPC. Focused key performance indicator (KPI) targets agreed by the project team were carefully monitored on a daily basis to ensure the best possible outcome.

The project was conducted in the three CMD contractor pit areas at Sangatta and Bengalon under the management of KPC drill and blast department. AECI Indonesia successfully delivered multiple events of remote firing blasting in all areas. The team also complied with all safety and efficiency KPIs, AECI says.

The average usage of harness wire per remote firing event was around 100 m, compared with 650 m per blast of lead-in-line used in conventional blast initiation and has reduced the cost of blast initiation in KPC CMD by over 50%, AECI claims.

Yuli Prihartono, KPC Drill & Blast Manager, says: “Throughout the trial project of remote firing at CMD pits, AECI Mining Explosives has demonstrated its capability to deliver safe and efficient project to world class operations. Remote firing has successfully delivered quantifiable cost benefits for KPC. We expect AECI Mining Explosives to expand this initiative by introducing remote firing to all blast locations at CMD KPC.”