Tag Archives: Omnia Group

BME formulates plan to tackle floc in blasting emulsion production

Omnia Group mining division company BME has been sharing its leading technical expertise at the 12th World Conference on Explosives and Blasting recently held in Dublin, Ireland, with a solution to eliminate ammonium nitrate (AN) coating agent residue – also called floc – during the production of emulsion causing a stir, it says.

Hosted by the European Federation of Explosives Engineers, the three-day conference drew over 500 delegates globally from among explosives users, manufacturers, drilling equipment operators, researchers and professionals involved in mining and construction.

Included in the Technical Development theme of the conference, the aforementioned paper was written and presented by Garfiansyah Rayes, Berbudi Utomo and Ngisomuddin of BME’s Indonesian office.

“We chose this topic because floc is a common challenge for emulsion producers in southern Asia, and compromises the performance of the final product,” Rayes, who is Technical Service Engineer at BME Indonesia, said. “The presence of floc within the oxidiser mixture poses significant risks to various aspects of our operations, including production, product quality, safety, environmental impact and customer satisfaction.”

For these reasons, the solution described in BME’s presentation raised considerable interest among conference delegates – as it could help to solve various related challenges, he noted. The methodology that the authors explain is not common in Southeast Asia in general, although it is well used in Europe and the US.

“The emulsion manufacturing process involves the blending of water, AN prill with coating agent, and other chemicals,” he explained. “In this process, a colloidal dispersion – or residual foam – forms on the surface of the melt tank, consisting of small particles, droplets and bubbles.”

If allowed to continue through the manufacturing process, the residual foam can affect final emulsion quality and performance – including reduced the value of velocity of detonation, according to BME Operations Manager, Ngisomuddin.

“To prevent this issue, the foam that accumulates on the surface of the transfer tank requires additional handling,” he said. “Previously, plant personnel had to manually skim off the residual foam, which raised safety concerns among customers. Furthermore, the collected foam must be treated as B3 hazardous waste by a licensed service provider to ensure responsible and legally compliant disposal. This process adds to the overall cost of emulsion production.”

To address the problem of floc, BME has developed a dispersal method that involves heating the AN coating agent residual to its melting point in the oxidiser tank. This causes the floc to dissolve into the oxidiser, resolving the issue of residue build-up.

“We tested how a plant could be re-engineered to eliminate floc generation during emulsion production, and researched two techniques,” Ngisomuddin said. “The technique we selected for implementation was melting with dispersal heat, followed by centrifugation.”

Rayes explained that, while dispersal heat is an effective technique for breaking down floc, it may not be sufficient to eliminate the residue. The melted floc may remain suspended in the emulsion and, if not removed, can potentially lead to issues in downstream processes.

“To overcome this condition, a high-speed centrifuge was used to separate the larger floc particles on the surface of the mixture,” he said. Through the process developed by BME, Rayes said that between 16-17 t of waste per year has been eliminated.

Tom Dermody, International Technology and Field Services Manager at BME, pointed out that the innovative solution to deal with floc in emulsion production was also strongly driven by BME’s environmental, social and governance commitment. With its strong in-house technical capability, the team aimed for ways to improve the product while making it safer to handle and reduce its potential impact on the environment.

“The result of this work is that our people are not exposed to hazardous gases, for instance, and we reduce the waste that the process produces,” he said. “We are pleased to be able to share these developments in the interests of supporting the progressive improvement of practices in the industry.”

BME recently finalised a joint venture agreement with Multi Nitrotama Kimia (MNK), Indonesia’s leading explosives producer. The two companies have already successfully partnered in a five-year contract for blasting services at a mine in Kalimantan, which has led to the commissioning of BME’s first mobile process units and emulsion plant outside of the African continent.

BME upgrades VIPERDET MS Series non-electric detonator range

BME, an Omnia Group company, has introduced an improved version of its non-electric detonator product range, the VIPERDET™ MS Series, into the quarrying and small-scale open-pit mining sector.

The VIPERDET MS Series boasts quality and reliability leveraged from automated production lines and a certified supply chain, it says.

“We have over the years invested considerably in our production technology, giving us automated processes that enhance safety, sustainability and efficiency to reliably deliver a world-class product,” Nishen Hariparsad, General Manager (Technology and Innovation) at BME, says. “Our systems harness robotics and artificial intelligence to ensure that we meet and exceed customer expectations with our non-electric detonators.”

Hariparsad highlighted that this high level of automation was a significant differentiator for the company, as most competitors relied on manual production lines. The result was that Omnia’s mining division was able to achieve consistency in detonator quality, enhanced production flexibility, less waste and reduced environmental impact. The company’s production facilities at Losberg and Dryden were also powered by renewable energy to prioritise sustainability and operational continuity.

“BME always strives to be at the forefront of technology and brings innovative and cutting-edge mining solutions that deliver best blasting and fragmentation outcomes,” Hariparsad said. “This has underpinned the launch of the VIPERDET MS Series – which includes downhole, trunkline and dual detonators. With its timing accuracy, flexibility and user-friendly design, we believe this range will offer great customer experience and deliver optimal blasting results.”

Dr Rakhi Pathak, BME’s Global Product Manager, noted that the design included a triple-layered shock tube designed to provide high tensile strength and prevent any damage during normal operating conditions.

“Made with high-strength material that is temperature resistant, the connectors are easy to use and quick to apply,” Dr Pathak said. “The connectors are also colour coded for ease of identification.”

She added that safety remains the utmost priority and so quality and manufacturing processes ensure that the product meets the highest industry safety standard.

Hariparsad explained that Omnia mining segment’s certified supply chain was crucial to achieving the standards for which it is known in the mining sector, including the quarrying sector where the VIPERDET MS Series is expected to find an important market.

“We have selected high quality raw materials and the latest manufacturing processes to guarantee exceptional quality in our VIPERDET MS Series detonators,” he said. “Each component goes through a series of rigorous tests to ensure it meets stringent industry standards.”

He noted that in-house manufacturing allows the company to closely manage its product quality, delivering reliability with high accuracy of delay timing.

BME enhances blasting control and monitoring with next-generation Xplolog release

Mining solutions specialist BME has released a new version of its Xplolog system for capturing and analysing data on blast holes and decks.

BME – part of Omnia’s mining segment – developed Xplolog as a powerful tool for mines to monitor their block progress in real time, providing the necessary data to track trends and continuously improve the quality of blasts, it says.

The focus in developing this next-generation Xplolog has been the detailed guidance by users, according to Christiaan Liebenberg, BME Product Manager Software Solutions. This has led to making the system more user friendly, scalable and streamlined with other BME digital solutions – while also benefiting from improved data security, the company says.

“We engaged our Xplolog users in a highly systematic way to inform us at every step of our upgrade process,” Liebenberg said. “After our first structured interviews with users, for instance, we developed mock-ups and wireframes that we could take back to the user group for further testing. This approach was even taken into the design and prototype stages, ensuring that the system was in many ways actually built by the users.”

With the design and application code built from the ground up, and with a new and upgraded database using Google’s Cloud Services, the performance of Xplolog has been enhanced. The capacity of the system can also be rapidly increased, allowing better scalability; customers can have a site set up within a matter of hours, according to BME.

Christiaan Liebenberg – BME Product Manager Software Solutions

“Security has been improved through a more robust login and registration process,” Liebenberg said. “There are different user access levels in the new version, giving customers more control over who can access information related to their role in the organisation.

“Users will appreciate how everything is centralised in this version of Xplolog, and how we have improved the workflow for third party blast design uploads in the system.”

The look and feel of Xplolog has been revised in line with the progressive standardising of design across BME’s Blast Alliance digital solutions. This makes users feel familiar with the BME offering, through increased brand identification and continuity of the customer experience with Blast Alliance, Liebenberg said.

“Another important aspect of our upgrade is that users can easily customise their dashboards, creating a personalised view of block information important to the user,” he said.

Customised reports can be created and saved, allowing users to return to that recurring daily, weekly or monthly report each week or month as required. A summary view of block data is visible to track progress at a quick glance for the user.

“We have also given users the ability to better visually track block progress, with the creative use of colours and iconography,” Liebenberg said.

The process of inputting data has been optimised by rationalising the number of steps or actions wherever possible. Importantly, Liebenberg pointed out that Xplolog’s integration with BME’s mobile manufacturing units (MMUs) has taken account of different regional preferences and conditions around the globe.

“The system also provides mines with a digital audit trail, so that they can track operator performance during the drilling and charging phases, as well as provide hole loading information per truck,” he said.

Xplolog is integrated with other BME offerings like its blast planning software Blastmap, and to third-party blast software.

Integrated with BME’s MMUs, Xplolog, BME says, allows the MMU operator to charge and top-up holes accurately from the source application, which will have the latest blast design updates loaded. The actual charged and top-up values from the MMU’s digital panel will automatically be sent back to Xplolog, which will make the data available on the cloud platform for review and analysis.

“Our new version of Xplolog continues to raise the bar in leveraging digital technology,” Liebenberg said. “Our software engineering team continues to add new features and implement continuous improvements as we receive feedback from users of the system in the field – to help mines operate more efficiently, cost-effectively and safely.”

These updates are released to all existing customers of Xplolog every quarter at no additional cost, according to BME.

Miners continue cost control focus amid demand uptick, BME’s Hennecke says

As BME gears up to showcase its explosives and blasting offering to a Mining Indaba crowd in Cape Town, South Africa, that is encouraged by the global energy sector’s appetite for minerals, the company’s Managing Director warns that the mining industry is still focused on reducing its cost base.

The demand for minerals – many of which can be sourced in Africa – is good news for the future of mining, and will no doubt be an important focus at this year’s Investing in Mining Indaba, which runs from February 6-9.

However, the pressure on mines is still all about low-cost production, Ralf Hennecke, Managing Director of Omnia Group company BME, warns. This year, BME will be exhibiting at the event to showcase its mining and explosive solutions, including its flagship AXXIS Titanium™ electronic initiation system.

Hennecke is bullish about the positive impact of the energy revolution on mining, as there is widespread expectation that volumes of battery-related commodities will need to ramp up considerably. Efforts to decarbonise the world economy are relying on energy technologies that are mineral-intensive, he explained.

“The average amount of minerals needed for a new unit of power generation capacity will grow by 50%, according to predictions by the International Energy Agency,” he said. “This is because solar photovoltaic plants, wind farms and electric vehicles generally require more minerals to build than their fossil fuel-based counterparts.”

The typical electric car, for instance, requires six times the mineral inputs of a conventional car, and a wind plant requires nine times more mineral resources than a gas-fired plant. This quickly translates into considerable demand growth in certain minerals.

“In terms of lithium, the largest consumers are now electric vehicles and battery storage applications,” he said. “It is expected that these applications will also be the largest consumer of nickel within less than 20 years.”

While this is good news for Africa, where many battery minerals will be sourced, the continent’s mining sector will always need to be globally competitive, BME says. This means efficiency across the mining value chain, rooted in on-mine productivity and safety.

“As an early-stage activity in the mining cycle, BME recognises the importance of blast design and execution in laying the groundwork for optimal operations,” Hennecke said. “Our technology developments including AXXIS™ and other digital innovations allow quality blasting that raises productivity in energy-intensive phases such as loading, hauling, crushing and milling.”

Only by optimising efficiencies can mines achieve a place in the lowest cost quartile of producers, which in turn enhances their commercial viability and makes them less reliant on commodity price cycles, BME says.

“Given the cyclical nature of the mining industry, Africa’s mineral producers can build a long-term future for the sector by remaining sustainable even through the dips in the cycle,” Hennecke said. “There is a depth of experience and technologies, developed right here on the continent, that can help put them in that advantageous position.”

The AXXIS Titanium system being showcased at Mining Indaba has been trialled and tested in various global mining destinations and conditions.

Blasting and explosives leader BME hits safety milestone with zero RCR

After five years of steadily implementing its Safety for Life brand, Omnia Group company BME says it has successfully achieved one of its key safety targets – a zero recordable case rate (RCR) – for the year ending January 2023.

“We consider our zero RCR over the preceding 12 months as a proud landmark to have reached, based on the positive safety culture that our Safety for Life initiative has fostered within the business,” Ramesh Dhoorgapersadh, General Manager for Safety, Health, Environment, Risk and Quality at BME, said.

The RCR is based on the number of safety incidents which resulted in treatment beyond first aid.

Dhoorgapersadh highlighted that BME’s achievement has its foundation not only in sound policies and systems, but in the committed and practical application of these principles every day.

“Companies’ systems and processes often look very good at face value, but these need to be effectively translated into action,” he said. “A RCR of zero does not happen overnight and requires constant reinforcement from the highest level before it forms part of the prevailing culture in the workplace.”

He explained that BME’s safety protocols were driven by a range of safety interventions. These included working on visual felt leadership, process safety, near-miss reporting, driver awareness programs and fatigue management.

BME Managing Director, Ralf Hennecke, re-emphasised the importance of ‘leading from the front’.

“Visual felt leadership has been vital in helping to embed the culture of safety in BME,” he said. “This means a daily commitment by senior executives to focus on how safety plans are being applied on site.”

He noted the corporate alignment of BME’s efforts with the Omnia Group’s vision of zero harm and positive impact through responsible business practices. These frameworks also aligned with the stringent standards of mining customers, many of whom are major global players.

Dhoorgapersadh said the zero RCR was not an end point in the safety journey. The challenge of safety, he explained, was to continue finding ways to improve – thereby steadily reducing any risk of incidents.

“In recent years, for instance, BME has placed growing focus on the medical wellness of our employees,” he said. “They often work under very stressful conditions – frequently out in the open or on the road. Our medical surveillance programme has become more intense, to ensure that their physical condition is optimal at all times.”

This intervention also included subcontractors, especially in the transport sector, to ensure that similar attention was paid to the health of all drivers. He said BME’s focus on safety extended beyond people to the natural environment as well. The effectiveness of safety protocols had also contributed to the occurrence of no chemical spillages that could have an environmental impact.

“We are very aware that, to sustain our enviable safety record, we need to be revisiting all aspects of our progress to look for ways to refresh our approach,” he said. “An important aspect of safety management is about doing the simple things better and better. In every task, you need to be identifying where the risks are – and find ways of preventing those risks from becoming reality.”

BME supports industry skills development with new graduate program

A two-year graduate program has been launched by Omnia-group company BME to, it says, address youth unemployment and skills shortages in an evolving mining industry.

The program targets various disciplines in engineering and science – including mining, chemistry and microbiology, as well as skills in the fields of safety, health, environment and quality assurance. This is part of the commitment by BME’s leadership to support skills development and the growth of young people within the mining industry. The initiative is also instrumental in attracting and retaining talent for the company, it said.

Announcing the initiative, BME Managing Director, Ralf Hennecke, said that many businesses in industry require work experience, and graduates are often overlooked as they do not have the necessary skills or the understanding of the work environment to fill the role.

“Coupled to this, some graduates consider the work environment to be daunting,” Hennecke said. “We, therefore, believe our role will be to ensure that each graduate on our program is provided with the opportunity to grow and develop and reach their full potential. It is vital that we invest in skills development of the next generation of people who will drive the mining industry in the future.”

BME has recruited 19 graduates and placed them at various underground and surface mining sites where the company is currently active. Some graduates have also been placed at BME’s Losberg emulsion plant and its AXXIS™ initiation system plant.

BME Human Resources Manager, Tebogo Seakamela, said: “In a country like South Africa, it is crucial to train graduates without prior work experience, and this is what BME aims to do. Skills development and bringing new entrants into the sector is critical in growing our economy and the mining sector, which is still one of the largest contributors to the country’s gross domestic product.”

She noted that BME prioritises the nurturing and development of young talent, highlighting that these graduates gain immeasurable knowledge and understanding of the real world of work while on the program, ultimately preparing them for the workplace.

“Due to their resilience, agility and bold characters, our graduates have remained committed to the program,” she said.

As a trend in the market, most locally trained graduates are also recruited into other countries after having completed a graduate program – including those around Africa. “This is commendable and a testament to the calibre of our South African mining graduates,” she said.

She highlighted that while the graduates were from various universities across the country, the majority were from Wits Mining Institute at the University of the Witwatersrand in Johannesburg.

The industry is also evolving in terms of minerals extraction, she said, noting that with the introduction of automated and artificial intelligence-based mining, the graduates will get first-hand experience of these technologies being used in the workplace.

“We are building the skills for the future, as well as ensuring that we cultivate a learning culture that encourages and enables critical thinking and innovation,” she noted. “At the same time, these graduates are offered diverse career path options.”

Mampe Mogale, a Mining Engineering Graduate currently based at a mining operation in the Northern Cape, noted that BME held a two-day induction for all its interns across various disciplines at the beginning of October.

“The aim was to familiarise us with the company structure, various disciplines and the people responsible for certain roles within the organisation,” Mogale said.

Clement Marilela, a Mechanical Engineering Graduate, explained that BME made his transition into the company as smooth as possible, informing the graduates about the organisation, while helping them realise the “incredible opportunity” they have been offered.

“It was great to be given the chance to interact with and learn from some of the organisations’ leaders as they shared their expertise and passion for the business,” Marilela said.

Hennecke concluded: “BME is proud to play its part in cultivating the future workforce, preparing them for the field of work. South African graduates are talented and, with on-site experience, can be gainfully employed.”

BME’s AXXIS Silver electronic initiation system passes the test in Lesotho

High in the mountain kingdom of Lesotho, explosives and blasting specialist BME recently achieved the first blast outside of South Africa with its new AXXIS Silver™ electronic initiation system.

BME, a member company of the JSE-listed Omnia Group, is assisting a diamond mine customer to conduct quality blasts in all weather. According to BME’s AXXIS™ Support Manager, Hennie du Preez, BME has been active on this mine since 2016. Located at an altitude of over 3,000 m, the operation frequently experiences snow and sub-zero temperatures.

“This means blasting under challenging conditions, including extreme cold, snow and ice,” du Preez said. “BME provides everything from the emulsion explosive to the detonation equipment, which all continues to function well under these conditions.”

The AXXIS Silver initiation system employed at the mine is a leaner version of BME’s flagship product AXXIS Titanium™. The company conducts the priming, logging and firing of the blasts, and ensures a regular supply of emulsions to the site.

“Among the benefits of AXXIS Silver is its thin, copper-cladded downline wire, which de-coils easily for use in small diameter holes – even when they are waterlogged,” Du Preez said. “Due to their robust quality, our electronic detonators were able to remain in the holes for two days before blasting, in temperatures below zero where the hole collars froze solid.”

Despite the conditions, there were no issue encountered with the wire or the connector. BME’s latest logger, the TDC 600, also performed as normal in these cold and wet conditions, with no signs of screen lagging. Its battery lasted the entire duration of the logging and the firing of the blast, according to the company.

“We kept our blasting boxes in the vehicle until blasting time, and they switched on without any problems,” du Preez said. “Neither did the cold conditions cause any sluggishness of the screens.”

He confirmed that firing the blast went ahead as planned, with smooth communication between the logger and the blasting boxes. In the final communication check, there was no instability detected.

“This was another confirmation of the resilience of our system in cold climates and freezing weather,” du Preez said. “We have had AXXIS successfully tested in the US for operating in temperatures below minus 40°C, in anticipation of growing business opportunities in the US and Canada.”

AXXIS Silver allows up to 1,800 holes to be detonated in a single blast, initiated from two blast boxes linked.

du Preez noted that mines are increasingly asking for larger blasts to reduce downtime from pit stoppages during blasting. BME is expecting to apply AXXIS Titanium at the Lesotho operation, which can raise the number of detonators in a single blast to 20,000 – or 20 blast boxes firing up to 1,000 detonators each.

An added benefit of the copper-cladded wire, du Preez said, is that the steel wire responds to a magnetic field. After a blast, this allows remnants of wire in the blasted material to be removed by magnetic separators on the conveyor belts before entering the crushing and milling phases. It, thus, prevents potential damage to comminution equipment and contamination of mined material.

BME has also been supplying various Lesotho mine with up to 500 t of emulsion explosive each month. This involves the monthly movement of over 15 tankers through steep mountain passes to keep them supplied with fresh emulsion.

Ralf Hennecke promoted to Managing Director at BME

Ralf Hennecke has been appointed as the Managing Director of BME, a division of the Omnia Group, with effect from December 1, 2021.

Hennecke started his career in 1987 at Rand Mines Limited and was employed at Johannesburg Consolidated Investments, following which he joined Omnia BME in 1995.

He has deep operational, marketing, sales, commercial and technical expertise, having been part of BME’s executive team for over 20 years and played a key role in BME’s recent global corporate development and strategy. In July 2021, Hennecke was promoted to the position of Managing Director for BME SADC.

BME, a leading manufacturer and supplier of explosives products, technology and blasting services to the mining sector, says it has a balanced presence in sectors that are essential to the sustainable use of the world’s finite resources and focuses on developing intellectual property to add value to the global mining sector.

Hennecke said: “It is an honour to accept this role, and with the support of my team, we are deeply committed to executing on BME’s growth plans across our global markets. We will achieve this through consistent product, technology and services delivery, close customer and stakeholder relationships and partnerships, whilst playing our part as a responsible and sustainable corporate citizen in the mining sector.”

The recent launch of AXXIS Titanium™, an advanced electronic blast detonation systems, will play a key role in driving growth, while the “Blast Alliance” approach will further entrench the division’s reputation as a collaborative partner, the company said.

Seelan Gobalsamy, CEO of the Omnia Group, said: “In line with Omnia’s growth strategy, it is vital to ensure that we have the leadership bench strength required to achieve our ambitions. It, thus, gives me great pleasure to welcome Ralf in his new role. Ralf’s wealth of experience and understanding of our group allows us to continue to execute on our growth strategy.”

BME brings technical blasting services online

Omnia Group company, BME, says it is now providing technical blasting services online, giving the industry access to experienced specialists through virtual consultations and solutions.

The service is an important part of BME’s recently upgraded website, according to the company’s Global Manager for Blasting Science, D Scott Scovira.

“Our online technical blasting service is provided not only by BME’s in-house technical staff, but it is also in association with other recognised third-party specialists in blasting, mining and construction,” Scovira said. “The initial online consultation to discuss and scope out a blasting project is at no charge, and the service is not limited to existing BME clients only.”

The range of services offered include blast fragmentation distribution prediction for surface greenfield sites, fragmentation distribution optimisation for supporting mine-to-mill initiatives at established surface and underground sites, and rock characterisation and specifications for blasting in hot or reactive ground. The team are also able to provide solutions related to highwall blast design and management, as well as novel and disruptive blast design and mining methods, it said.

BME launches Blast Alliance brand to encourage blasting technology collaboration

Blasting technology is moving mining towards a more sustainable future, with BME and its recent launch of the ‘Blast Alliance’ brand looking to add impetus to this evolution.

The Omnia Group company has announced that Blast Alliance will encompass its portfolio of digital innovations including its BLASTMAP™ planning software, BME Blasting guide app and XPLOLOG™ cloud data platform. Solutions such as AXXIS™ integration, custom development and training also fall under this brand.

“Our new Blast Alliance brand represents the company’s journey of digital innovation and the collaborative approach we take in this exciting process,” BME Managing Director, Joe Keenan, said. “We believe this collaboration must be holistic, so we partner in three arenas: internally to optimise our solutions; through direct engagement with our customers; and working with third-parties where the need is identified – to enhance outputs for customers.”

Keenan said by giving BME’s software and solutions portfolio its own brand and identity, it will assert a unique market position underpinned by the company’s spirit of enterprise and the highest levels of integrity.

Michelle Fedder, BME Manager: Marketing and Brand, emphasised that the step was part of enhancing BME’s reputation as a technology and innovation-orientated partner.

“Blast Alliance provides our software portfolio with its own values, character, essence and value proposition,” Fedder said. “From a marketing perspective, the brand assures our customers of collaborative, innovative and integrated digital and automated mining and blasting solutions – further enhancing their value chains.”

The portfolio will adapt and evolve with key solutions as needs are identified, applying BME’s growing depth of digital and technological expertise, according to BME Software Product Manager, Christiaan Liebenberg.

“We are delivering flexibility, fluidity and future-facing solutions to our customers,” Liebenberg said. “A key focus here is the integration of our technology with mine-wide platforms, as part of the drive to support mining’s ongoing productivity efforts. Our initiatives also leverage digital technology to allow greater availability of real-time data.”

Keenan said that the Blast Alliance brand underscored the company’s core objectives in its offering to customers. These include optimising productivity, efficiency and safety while minimising risk through predictability – as well as reducing costs, promoting data-driven and real-time decision making, and enhancing process optimisation.

“As the mining sector embraces more technology, it is likely to be increasingly viewed as a forward-looking contributor in the transition to a more sustainable economy,” he said. “Implementing digital communication infrastructure at mine level can also have positive spin-offs for local communities – potentially improving connectivity in remote areas as part of mining’s environmental, social and governance commitment.”