Blasting News - June 2015

Blasting News VOLUME 24 ISSUE 2 2015

IN THIS ISSUE • AEL’s record blast at Sukari Gold Mine in Egypt • Simon Tose leading the way through Mining Optimisation • Unveiling of revolutionary non-detonable rock breaking device

Printed on 100% eco friendly paper

Editor’s Note

CONTENTS 3

AEL Captains of Industry: AEL welcomes Managing Director, Edwin Ludick

4

AEL Knowledge-transfer: Simon Tose leading the way through Mining Optimisation

5

AEL Innovation: Unveiling of revolutionary non-detonable rock breaking device

6

AEL Pay it Forward – AEL and Venetia mine join hands to support a future mining engineer

7

AEL Thought Leadership – Explosives Today 12: Narrow Reef Stope Blasting

12 AEL Showcase: WEETR 2015 14 AEL Africa: Getting to know AEL North East Africa 15 AEL Africa: Record blast at Sukari Gold mine in Egypt 16 AEL forthcoming events

Cover image: Underground Salt Mine, Praid

AEL has over a century of expertise and knowledge in developing ground-breaking and innovative blasting solutions that are designed to add value to our customers. Innovation is key to ensure we remain relevant to the market we serve. This customer centric approach fuels our drive to keep our finger on the pulse of future trends. Armed with this knowledge, we constantly update and improve our existing product portfolio and couple this with our fraternity of renowned AEL experts to better serve the needs of our customers.

AEL CAPTAINS OF INDUSTRY

In this issue we show how we deliver on our commitment to produce at least two trail-blazing innovations per year in the quest to help our customers optimise their operations. The AEL Innovation section presents the launch of InstaStem, a technologically-advanced range of non-detonating, selfstemming rock breaking cartridges.

AEL welcomes Managing Director, Edwin Ludick

Under our Thought Leadership banner, we offer you the 12th issue of our successful series of our technically-driven customer publication, Explosives Today, which focusses on “Narrow Reef Stope Blasting”.

In our AEL Showcase, read about the success of our internal WEETR (Workshop for Explosives Engineers and Technical Representatives), an open forum where our subject experts share learnings through case studies, with their colleagues.

This workshop empowers our technicians and engineers with knowledge that enables them to better serve the market.

In our AEL Africa section, we share news of another one of our successes where a new record blast was achieved at Sukari Gold Mine in Egypt.

AECI announced the appointment of Edwin

The AEL Pay it Forward section sheds light on AEL’s goal to maintain its status as a responsible corporate citizen, through targeted CSI initiatives that enhance the lives of communities where we operate.

from 24 July 2015.

In line with our mission to meticulously apply our learning in developing appropriate technology and helping the mining industry use our energy confidently, we invite you to attend AEL’s Blasting Masterclass 2015 on 30 September, which is hosted annually for our customers in the underground and surface markets. This year’s event takes place in Johannesburg, South Africa.

Manager in 1991, was appointed to its Executive

To receive the latest news from the AEL world, we invite you to subscribe to Blasting News by visiting our website www.aelminingservices.com and clicking the Publications tab. Also follow the AEL conversation on our social media sites such as Twitter, LinkedIn, Facebook and YouTube.

cluster and as Chairman of several others. He

Contact Details: Eubulus Pillay - Blasting News Editor I Tel: +27 11 606 0313 I Fax: +27 11 605 0000 I eubulus.pillay@aelms.com I www. aelminingservices.com

We wish him every success in his new role.

Ludick as Managing Director of AEL effective

Edwin joined Chemserve as a Human Resources Committee in 2008 and to its Board in January 2010. He joined AECI’s Executive Committee later in 2010. Edwin has served as Managing Director at four companies in the specialty chemicals is currently also a member of the Specialty Chemicals Executive Committee. He has a BCom (Hons) degree from UNISA.

Disclaimer This publication does not necessarily reflect the views and opinions of AEL Mining Services Limited management. The copyright to this publication rests in AEL Mining Services Limited. Other product and corporate names used in this publication may be trademarks or registered trademarks of other companies, and are used only for explanation and to the owner’s benefit, without intent to infringe.

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Blasting News I Second Quarter 2015

Blasting News I Second Quarter 2015

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AEL KNOWLEDGE TRANSFER

AEL INNOVATION

Simon Tose making strides at IOQ

AEL unveils revolutionary nondetonable rock breaking device

and reactive grounds”, which detailed

“FRAGBLAST 10” held during 24 –

how AEL has tested and developed

29 November 2012. The Fragblast

ways to ensure safety and ease-of-

Symposia represent the most

selection of explosives and initiating

important events in disseminating the

systems in situations where a specific

latest advances in the science and

additional hazard may exist.

technology of rock fragmentation by blasting and other related means.

Tose has represented AEL at

Simon Tose

Simon Tose, AEL’s Global Mining Optimisation Manager, was elected

several international key symposia,

Tose and one of his colleagues,

conferences and colloquiums over the

AEL’s Blasting Science Manager,

years, the most recent of which was

Sandy Etchells will be participating

the hosting of a workshop at the 41st

in the Sub level caving workshop:

Annual Conference on Explosives and

Technical Developments in Breakage,

Blasting Technique in New Orleans,

Fragmentation, Flow and Recovery

USA, in February this year.

in Sub Level Caving (SLC) at the Fragblast 11 Conference from 24-26

as a board member of the Institute of Quarrying (IOQ).

This was confirmed following the IOQ’s AGM on 16 April, before the start of the institute’s annual conference, which brought together 260 registered industry delegates this year.

Tose’s workshop focused on “Highwall

August in Sydney, Australia. They will

Control” providing insight for blasters

look at the design and optimisation

into the basics around “safe” highwall

of the blasting in a sub-level caving

control at the conference, which was

application, and focus on the AEL

hosted by the International Society for

product offerings such as Ring

Explosives Engineers and attracted

software, electronics, sticky emulsion,

more than 1 400 delegates from

and expertise in other massive mining

around the world.

operations, to enable this.

Another one of his visits was to New

Congratulations to Simon Tose on

Delhi, India where he attended the

being a motivational leader who is

10th International Symposium on

a driving force to the team enabling

Rock Fragmentation by Blasting

them to craft future innovation!

Tose, a well-respected and highlyaccomplished industry stalwart, has published several ground-breaking papers including “A scientific perspective of blasting in hot holes

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Blasting News I Second Quarter 2015

AEL recently unveiled its latest offering to the market, InstaStem, a technologically-advanced range of non-detonating, self-stemming rock breaking cartridges, at the Institute of Quarrying conference and exhibition in Somerset West on 16 April.

At the the conference, which brings together over 200 industry delegates from around the world, AEL’s Account Manager for South East Cluster Northern Region, Velly Mngomezulu, presented the revolutionary benefits to safety and uninterrupted operations which InstaStem Cartridges provide.

“InstaStem Cartridges produce no shockwaves which means these products are safe and ideal for use in vibration-sensitive areas.

Furthermore, the non-detonating nature of this range of products ensure safer operations because they provide no over-break detonation damage in the tunnel ceiling or floor,” says Mngomezulu.

which are quickly diluted even in low-venitlation areas and there is a minimal gas re-entry time of about 15 minutes,” notes Mngomezulu.

As there is no stemming or required change of existing drilling patterns, these products provide “drop-andgo” ease-of-use and do not impact on support infrastructure. Therefore, there is no interruption or down time caused to the quarry or mine because there is no need to remove equipment or staff.

Re-entry period of 15min after the blast

Mngomezulu says the range is also extremely efficient and competitive with traditional explosive products.

InstaStem is also highly accurate, delivering no overbreak in the visible barrels left behind after the blast, coupled with a reduction of commodity loss in fines and dust.

Ensures consistency in fragmentation size

With these products there is no risk of auto-ignition and they have a shelflife of 18 months. By South African legislation, InstaStem cartridges do not require transportation by an explosive truck for quantities less than 250kg because they are classified as UN:0323 cartridges, power device, Class 1.4S. “InstaStem operations are also suitable in areas of low-ventilation as the blasts emit only harmless gasses

Blasting News I Second Quarter 2015

The range of InstaStem Cartridges

Enables continuous production without clearing the area

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AEL THOUGHT LEADERSHIP

AEL Paying it forward

AEL and Venetia Mine join hands to support a future mining engineer

AEL THOUGHT LEADERSHIP Explosives Today Series 4 I No 12

AEL in partnership with De Beers

500GB external hard drive with case,

to adopt and support this school

Venetia Mine, rewarded a top learner,

Vodacom 3G modem plus 200mb

as part of the De Beers Employee

Mashudu Ndondeni Masindi from

data for 12months and a notebook

Volunteer Programme where they aim

Musina High School in Nancefield, with

backpack).

to motivate learners and offer them

a state-of-the-art laptop for achieving

career guidance.

exceptional results in his matric

The gift was awarded by Kelebogile

examinations.

Sibanda (Senior Commercial Manager)

This worthy cause is an indication

and Gloria Lekalakala (Senior Ore

of De Beers’ and AEL’s commitment

Mashudu received distinctions in

Processing Manager) with the school’s

to investing in the communities

Mathematics, Life Science, Physical

principal Mr Abraham Legavha in

where they operate. The nurturing

Science, Geography and Life

attendance.

and motivation of youth to focus on

Orientation. Unfortunately Mashudu

education will ensure that they make

was not present at the Excellence

their mark as contributors to the

Awards as he was already at University

economy in the future.

where he has enrolled to study Mining

Narrow Reef Stope Blasting Henk Esterhuizen – Explosives Engineer

Engineering.

INTRODUCTION

His proud mother Mrs Masindi

The subject will be dealt with under

LENGTH OF HOLE LEFT UNCHARGED

the following headings:

(pictured above right) received the laptop package (which included an HP Notebook, MS Office Home & Student suite, Kaspersky Internet Security

The awards were hosted by both

2015, wireless mouse, Skype headset,

senior managers who have chosen

If blasting in stopes is to be efficient,

• Length of hole left uncharged;

Basically, the length of hole left

certain basic principles must be

• Angle of holes in relation to stope

uncharged is governed by the burden

observed. At times these principles

face;

placed on the hole. Explosives tend to

tend to be overlooked therefore we

• Effect of out-of-sequence shots;

break to the nearest free face and that

take this opportunity to stress what

• Decreasing the shattering effect

portion of the charge which is closer

we consider to be the more important

around a borehole;

facets of efficient and economic stope

• Hanging-wall control.

to the collar than to the free face will therefore crater out towards the collar.

blasting.

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Blasting News I Second Quarter 2015

Blasting News I Second Quarter 2015

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AEL THOUGHT LEADERSHIP

EFFECT OF OUT-OF-SEQUENCE

out, without significantly reducing

SHOTS

Figure 1a: Overcharge hole showing probable overbreak

• A bump on the face which is not only detrimental to face scraping but which can also

advance or throwing rock into back areas.

Out-of-sequence shots are due

cause the initiator to be cut by

either to the absence of timing

flyrock from the next blast.

When using shock tube initiation

between holes or to the occurrence

systems drilling at 90° has become

of misfires, which will automatically

condition which is progressively

the norm and is necessary to

cause succeeding holes to fire

exaggerated the longer the

prevent damage to the support and

out-of-sequence. It is important to

mistimed hole.

to capitalise on the increased throw

assess the effect of out-of-sequence

that shock tube systems provide.

shots on the stoping operation and

However, it must be remembered

the following points are worthy of

that if the burden is stretched too far,

consideration.

• Creation of bad hanging wall

• Serious damage to support and scatter barricades.

• The cutting off of adjacent holes which can also be a cause of misfires.

even shock tube blasting will result in The burden, hole depth and angle at

• Less than optimum burden

which holes are drilled into the face,

being used because of fear

It is equally important not to drill

all influence the degree of out-of-

of the occurrence of out-of-

at angles smaller than 70° where

sequence firing that can be tolerated.

sequence shots.

angled drilling is still required.

For example, where short (1m)

sockets and uneven face advance.

AEL THOUGHT LEADERSHIP

this angle helped the hole to break

holes are drilled at a comparatively shallow angle into the face, under

with a one metre hole, the effect

relatively easy breaking conditions,

on advance at various angles is as

a misfire or out-of-sequence shot

The following modifications have

follows:

need not necessarily have serious

resulted in better hanging wall

consequences, disregarding, of

control where, for various reasons,

Loss of advance per metre drilled (cm)

course, the safety aspect.

normal stope blasting practice has

90o

0

On the other hand, where holes are

80o

2

1m in length and drilled virtually

70o

6

straight into the face, drilling

60o

13

accuracy becomes very important

less than 90° into the face and

50o

23

and, depending on such factors as

careful attention paid to drilling

stope width and stress conditions

accuracy.

Angle Figure 2a: Correctly Charged Hole

Overcharged holes produce no

and blast barricades.

ANGLE OF HOLES IN RELATION TO

significant improvements in breaking

In general, the recommendation in

STOPE FACE

efficiency, either from the aspect

charging holes is to ensure that the

of increased burden or that of

uncharged portion of the hole is at

Prior to the introduction of shock

decreased socket length. In fact, they

least equal to the burden. Experience

tube (when using capped fuse

only result in excessive airblast which

has shown that a charge length of

and igniter cord), in most mining

is prone to cause excessive flyrock,

two-thirds of the length of the hole is

conditions a 70o horizontal drilling

aggravating damage to the support

adequate.

angle minimised sockets because

HANGING WALL CONTROL

Fig 3.1 Assuming full length breaking

proven unsuccessful in maintaining

of the rock, the presence of out-ofsequence shots can result in:

stoping width.

• Use of short holes, angled at not

• Reduction of explosives charge per unit length in top holes by the use of smaller diameter

• A lapse of ten holes and possibly

cartridged explosives, lightly

more before the full face

compacted but well stemmed

advance is once more attained.

with proper stemming material.

Figure 3c: Breaking effect when drilling angled holes 8

Blasting News I Second Quarter 2015

Blasting News I Second Quarter 2015

9

AEL THOUGHT LEADERSHIP

AEL THOUGHT LEADERSHIP

The advantage of this technique is that the throw of rock is towards the footwall, therefore damage to the hanging wall is reduced. The first bottom connector is connected to the first top hole and second bottom hole shocks. These connectors are then connected in pairs to the next two shock tubes and repeated in the same sequence.

Figure 5a: Reverse timing for bad hanging wall conditions

With this method, it is important to

Figure 3a: Breaking effect of angled holes (capped fuse)

ensure that bottom holes are not overburdened, i.e., that they are able to break to full depth, otherwise this would adversely affect the free breaking potential of the top holes and thereby possibly result in damage to the hanging wall.

Figure 5b: Throw of the rock is towards the footwall

The above measures should result in better hanging wall control. However, they are considered complementary

regional offices are available to help

Explosives Today issues on this

to accurate drilling and good mining

and advise on underground stope

subject including Series 2. No 7

practice, in particular the provision of

blasting scenarios.

March 1977.

strong support as close to the working face as possible.

Figure 3b: Breaking effect of angled holes (Shock Tube)

This document is a new addition to the Explosives Today series.

AEL Explosive Engineers based at the Besides there being a direct

25%. This not only compensates

reduction in the mass of

for drilling inaccuracy but also

explosives used, the reduced

minimises the chances of “tight”

hanging, a further modification

explosives to rock coupling

holes occurring as these can be

can be introduced where holes

will result in less shock being

an important cause of hanging

are drilled in pairs with bottom

transmitted to the hanging wall.

wall damage. This again

holes timed to fire before the

• In cases of really bad hanging

emphasizes the importance

top holes (Reverse Timing).

wall conditions, a reduction

of cutting down, by whatever

See figure 5a and b which

of the normal burden by up to

means, the amount of shock

show a layout for achieving this

This document replaces all previous

transmitted to the hanging wall.

• Under extreme conditions of bad

Disclaimer: Any advice and/or recommendations given by AEL Mining Services Limited (“AEL”) in this publication, is given by AEL in good faith in order to provide assistance to the reader. AEL does not however: 1.1 warrant the correctness of its advice and/or recommendations; 1.2 warrant that particular results or effects will be achieved if AEL’s advice and/or recommendations are implemented; 1.3 accept liability for any losses or damages that may be suffered, as a result of a party acting, or failing to act, on the advice and/or recommendations given by AEL; 1.4 accept liability for any acts or omissions of its employees, representatives and/or agents, whether negligent or otherwise.

Copyright: All copyright that subsists in this publication together with any and all diagrams and annexures contained herein, which shall include all and/or any ideas, plans, models and/or intellectual property contained in this document vests in AEL. Any unauthorised reproduction, adaptation, alteration, translation, publication, distribution or dissemination (including, but not limited to, broadcasting and causing the work to be transmitted in a diffusion service) of the whole or any part of this document in any manner, form or medium including, but not limited to, electronic, oral, aural, visual and tactile media) whatsoever, will constitute an act of copyright infringement in terms of the Copyright Act No.98 of 1978 and will render the transgressor liable to civil action and may in certain circumstances render the transgressor liable to criminal prosecution. This document remains the intellectual property of AEL. Intellectual Property: all ideas, concepts, know-how and designs forming part of this publication belong to AEL, save for where it is clearly indicated to the contrary.

objective.

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Blasting News I Second Quarter 2015

Blasting News I Second Quarter 2015

11

AEL SHOWCASE WEETR (Workshop for Explosives Engineers and Technical Representatives) 2015 Looking toward the future with electronic blasting systems Electronic products were the hot

automation and autonomous mining,

topic at the 2015 Workshop for

Smit told delegates.

Explosive Engineers and Technical Representatives (WEETR), which took

Christo Peltz, product manager at

place between 24 and 25 June at the

AEL, then detailed the stringent

Velmoré Hotel Estate in Pretoria.

testing processes that AEL’s electronic detonators must undergo in order to

Kicking off the event, which saw AEL

meet the highest of standards. These

delegates from across the globe

detonators must still be functional

convene for two days of fascinating

even after major stress testing,

presentations, Executive Director:

including surviving 1 750 direct impact

Technology, Liesel de Villiers outlined

hits, being dropped from a 5 metre

the company’s ambitious plans to sell

height in various orientations and

4 million electronic units by 2017.

withstanding temperatures ranging from -20°C to 80°C.

She said that this means both new and existing customers will need to be

Peltz also told the fascinated audience

converted to electronic systems, which

how these detonators have been

will be aided by improvements to AEL’s

tested to withstand lightning strikes,

current options in addition to new

not only in order to fail-to-safe but

products which will be revealed in the

to also remain functional after a hit.

near future.

This is achieved because the design of

Delegates at the WEETR exhibition

these detonators allows energy to be Johann Smit, Director of Marketing at

channelled out to ensure the current

DetNet, AEL's electronic technology

never reaches sensitive electronic

enabler, explored some of these

components.

innovations, including the 4G chip which is expected to go on trial later

Over the two days, the attendees at

this year.

WEETR engaged with each other to learn from their colleagues, including

The improvements to electronics will

case study presentations of how

see the integration of data to enable

AEL’s products and services are being

real-time analysis and optimisation

received globally.

decisions with a future focus on

12

The delegates learned about the

These presentations gave insight into

mining house an advantage in an

The conference also demonstrated

implementation of electronics in

the successes and challenges global

extremely competitive market.

that by working closely with one

Australia from Sean Rodger and Bruce

markets are having and how AEL is

Lee, vibration and air-blast monitoring

assisting to overcome these for clients.

in Botswana with Tshepo Modise,

another and being supported by WEETR 2015 proved a great success by

cutting-edge technology and expertise,

imparting knowledge about how AEL

AEL is perfectly positioned to reach

explaining precise drilling for precise

For example, Tsoriyo’s presentation

is constantly innovating ways to save

the goal of selling 4 million electronic

timing in Indonesia with Carlos Paz

estimated that by implementing

the customer time and money, while

units by 2017.

and the application of a centralised

a Vertical Drop system one mine

simultaneously keeping processes safe

blasting system in Zimbabwe with

could reduce transport times of their

and efficient.

Vincent Tsoriyo.

explosives by up to 80%, giving the

Blasting News I Second Quarter 2015

Blasting News I Second Quarter 2015

13

AEL AFRICA

AEL AFRICA

Getting to know AEL North East Africa The North East Africa region extends from Tanzania to Egypt and includes countries such as Tanzania, Ethiopia, Egypt, Eritrea, Sudan and Kenya amongst others.

AEL’s record blast at Sukari Gold Mine in Egypt

Contributor Haytham Mohammed, Site Manager, Sukari Gold Mine, AEL Egypt

On 25 March 2015, Sukari Gold Mine

collaborated to ensure the charging

in Egypt recorded a milestone when

operation was successful and hassle-

they fired the largest shot ever blasted

free.

AEL has a track record of helping its customers to unearth wealth

since blasting operations began more

in the region with legal entities and bulk manufacturing facilities in

than 6 years ago in February 2009.

operational hubs are supported by a network of well-established global supply chains that provide customers with access to the full range of AEL

AEL worked with our Blasting Crew to achieve such a record, they

Open Pit Mine Manager, Hitham

were consistent, they displayed

Okasha, said” I’d like to take the

perseverance and will to succeed,

671 double-primed twenty one metre

opportunity to thank AEL for the new

there were some minor problems

deep blast holes were charged with

record and achievement.

but everything was under control.

both Tanzania since 1998 and in Egypt since 2009, as well as bulk manufacturing facilities in Ethiopia since 2002. These strategically placed

fragmentation of rocks and no fumes.

products whilst relieving them of all the onerous legal aspects associated

246.22 tons of bulk explosives over 2

with the shipping, transport and storage of Class 1 and 5 products.

shifts. Just over one million tons of

AEL worked to a world standard over

important player in such a significant

rock were blasted in this single shot.

the course of two days to set a new

day at Sukari“.

Sukari and AEL teams on bench,

record mine site, 223 tons of Emulsion

with the support of the maintenance

charged into 679 holes to blast One

AEL was very proud to be part of the

and plant teams back at the AEL site

Million Tons in one shot with good

occasion.

AEL offers the latest value adding blasting technologies, products and solutions to enhance and optimise safety, productivity and cost effectiveness at operations in the mining, quarrying and construction industries. Trained resources complement the in country value add

Thanks a lot for being such an

capabilities.

AELs focus is on delivering measurable customer value through Key Performance Objectives that meet customers’ site specific requirements in terms of production capability, infrastructure and a range of blasting services. Strong safety and environmental policies are aligned with global best practices.

AEL will continue to look for opportunities to partner and develop new projects throughout the North East Africa Region. For further information, please contact our Divisional Director North East Africa, Des Decina.

Des.Decina@aelms.com

Photograph courtesy of Graeme Cox, Open Pit Drill and Blast Superintendent

Work: +20 128 559 6004 Mobile: +27 82 788 9052

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Blasting News I Second Quarter 2015

Blasting News I Second Quarter 2015

15

AEL FORTHCOMING EVENTS AEL Blasting Masterclass: 30 September 2015

24-26 August

26 – 28 August

26-28 August

14-17 September

AEL under the umbrella of AECI Mining Solutions and in partnership with Thiess will be participating in the Fragblast 11 Conference in Sydney, Australia. Sean Rodger, Business Support Manager: Asia Pacific and Nigel Convey, Divisional Director: Australia will be in attendance.

AEL will host its annual SHEQ (Safety, Health, Environment and Quality) Conference at Thaba Ya Batswana. The conference is a platform for AEL SHEQ personnel to adopt world class practices and to learn about the management and reporting of safety, health, environment and quality issues.

AEL’s Divisional Director Southern Africa North Cluster, Platinum & Chrome, Hendrik Jansen Van Rensburg and team will be positioning AEL’s products and services to the market at the annual Mine Safe Conference at Emperor’s Palace. A range of AEL’s products will be showcased including electronics and surface offerings.

AEL under the auspices of AECI Mining Solutions will be participating in the Exposibram Conference in Belo Horizante, Brazil. Alois Kwenda, Business Development Manager: Latin America and Central Africa will be representing AEL.

AEL Your Global Explosives Partner

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