Blasting News Q1 2016

Blasting News VOLUME 25 ISSUE 1 2016

IN THIS ISSUE •

Ensuring security of supply, AEL overcomes stormy conditions to supply AN Down Under

• Simon Tose celebrated as SAIMM fellow • AEL’s eco emulsion range developed to optimise surface mining using recycled oils

Printed on 100% eco friendly paper

Editor’s Note Welcome to the first issue of Blasting News for 2016.

Focused and determined to add value to our customers’ operations and the communities where we operate, in this issue we share some of our contributions to the industry

CONTENTS

during the first quarter.

We introduce you to another member of our Executive Committee, Thinus Bierman, Executive - International

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AEL CAPTAINS OF INDUSTRY: Meet Thinus Bierman

4 AEL KNOWLEDGE-SHARING: AEL overcomes stormy conditions to supply Ammonium Nitrate Down Under 6 AEL PARTNERSHIPS: Simon Tose celebrated as SAIMM fellow 7 AEL THOUGHT LEADERSHIP: Explosives Today 14 12 AEL PAYING IT FORWARD: The AECI Community Education and Development Trust invests in communities 14 AEL CASE STUDY: AEL’s eco emulsion range developed to optimise surface mining using recycled oil

Business.

To showcase our global capability, we share our success story of overcoming stormy conditions to supply Ammonium Nitrate Down Under.

Creating valuable partnerships with industry bodies helps further our knowledge-transfer process. We proudly announce our very own industry stalwart, Simon Tose’s appointment as SAIMM Fellow.

Looking forward, we inform you of our participation at the Institute of Quarrying (IOQ) Conference where we will demonstrate our support to the mining market.

Remaining close to our hearts are our CSI initiatives which uplift communities where we operate globally. In our Paying it Forward section, we share AECI’s drive to help combat recent water shortages in rural areas across South Africa.

Finally, in our Case Study section, we highlight our eco emulsion range developed to optimise surface mining using recycled oil.

To subscribe to Blasting News please visit our website www.aelminingservices.com and fill in the subscription form located under the Publications tab in the News & Media portal.

Enjoy the read!

Eubulus Contact Details: Eubulus Pillay - Editor Tel: +27 11 606 0313 eubulus.pillay@aelms.com www.aelminingservices.com Cover image: Kenecott Copper Mine

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 First Quarter 2016

CAPTAINS OF INDUSTRY

Meet Thinus Bierman Executive: International Business Role: Responsible for sustaining the International business and continuing to establish AEL’s business footprint within Middle East, Africa, Latin America and Asia Pacific regions.

Professional background: Began his tenure at AEL over 25 years ago. He holds a Witwatersrand School of Mines NHD Mining and Metallurgy certificate and a MDP Business Administration and Management qualification.

Blasting News I First Quarter 2016

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AEL REMOTE CAPABILITY

Ensuring security of supply, AEL overcomes stormy conditions to supply AN down under AEL has demonstrated the depth of its supply chain capability by delivering 5 000 tons of Ammonium Nitrate (AN) thousands of kilometres from central Russia to the east coast of Australia, amid difficult conditions.

This, according to Slabbert, was due to various supply constraints. AECI Australia regularly sources AN from the Ukraine however in this instance, the supply chain team had to make alternative sourcing arrangements.

Slabbert says once the most suitable source for quality AN was identified in central Russia, the 5 000 ton shipment travelled 4 500 km on the Trans-Siberian railway to the port of Nakhodka in east Russia, where it was shipped to Australia’s east coast.

“We commend our supply chain team for ensuring that this product was delivered to Australia despite a number of challenges encountered.

The shipment weathered stormy winter seas to arrive in qualified AEL packaging at Port Alma, Queensland, Australia in early January,” says Slabbert.

“Australian authorities have the highest standards for imported product and require suppliers to meet a number of stringent quality, packaging and logistics requirements. Shortly after the offloading of this shipment, the AEL production team at Bajool manufactured quality emulsion explosives.”

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Blasting News I First Quarter 2016

AEL REMOTE CAPABILITY

In February 2015, AEL’s holding company AECI announced that it had signed a five-year agreement with Thiess, the world's largest mining contractor, signalling AECI's entry in to Australia. As part of the agreement, AEL provides explosives, initiating systems and technical services to Thiess in Australia.

qualified sources around the world,” says Slabbert.

Slabbert concludes: “AEL is committed to giving our customers peace of mind and we believe a flexible supply chain and consistent communication are two driving factors behind our ability to deliver quality products and maintain security of supply.”

“At the heart of AEL lies its customercentric approach in providing explosives and mining solutions. AEL’s ammonium nitrate chain draws from as many as 16

Bagged Ammonium Nitrate product being loaded

Blasting News I First Quarter 2016

Bagged Ammonium Nitrate product

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AEL THOUGHT LEADER

Simon Tose Celebrated as SAIMM Fellow

Simon Tose, Global Mining Optimisation Manager at AEL, has been accepted as a Fellow of the South African Institute of Mining and Metallurgy (SAIMM).

This is the latest honour bestowed upon Tose, a highly regarded industry expert, following his election as a board member of the Institute of Quarrying (IOQ) in April 2015.

Tose thanked the SAIMM for the recognition of his work within the mining sector over the last 30 years and said he would take the opportunity to give back to the industry, especially with the youth.

“I see my role now as developing and empowering the next generation of professionals who are passionate about mining and I want to get them involved in taking the industry to the next level,” says Tose.

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“The SAIMM is the perfect forum for this because it provides a platform where you can share ideas and get input from a variety of industry experts in order to find solutions to some of the challenges facing the mining sector.”

Tose says he plans to run a blasting workshop this year, which will include the involvement of university students, in order to provide insights and expertise around the developments within the blasting processes.

Furthermore, he assisted his colleagues with their involvement in major mining events this year, including the SAIMM’s symposium on automation in mining in February and the Diamonds Still Sparkling 2016 Conference in Botswana in March.

In order to be accepted as a Fellow of the SAIMM, a person has to meet certain criteria. These include being over the age of 35 years, demonstrating contributions to the industry and actively participating in educational initiatives such as conferences and symposia. In addition to these criteria, a person has to be nominated by at least two SAIMM Fellows and then undergo an evaluation by the Institute to determine whether the nominee meets the requirements.

Tose has published several groundbreaking papers and has represented AEL at several international key symposia, conferences and colloquiums over the years, including the hosting of a workshop at the 41st Annual Conference on Explosives and Blasting Technique in New Orleans, USA, in February 2015.

Blasting News I First Quarter 2016

EXPLOSIVES TODAY Series 4 I No 14

BLAST GENERATED GASSES IN SURFACE BLASTING

By Ken Meiring

The group of gases known as Oxides of Nitrogen or NOx, of which the most common are nitric oxide (NO) and nitrogen dioxide (NO2), are often found as by-products in the postblast gases of ammonium nitrate-based explosives.

Together, these gases are loosely referred to as “NOx”.

(primarily

Nitric oxide is invisible, but nitrogen

NOx emissions, very few quantitative

dioxide ranges from yellow to dark

studies have been done under realistic

red depending on the concentration

field conditions.

power

generation

and

may arise.

motor vehicles) and natural sources.

In the absence of a single general

However blasting produces a sudden

cause or general solution, it should be

localised

with

understood that, given the complexity

potentially high concentrations of

of the problem and the inherent

NOx. Such gas emissions pose a

variability in the blasting environment,

health risk if people are exposed to

NOx events may still occur even after

them before the plumes can dissipate.

prevention and mitigating actions

Despite a long history of blast-related

have been put in place.

release

of

gases

Causes of fumes from blasts •

and size of the gas cloud. These gases

Emulsion formulation deficient in

The underlying causes of high NOx

oil content, or rich in ammonium

are fuel-deficiency in the explosive

nitrate content (oxygen rich/

NOx from blasting constitutes only

or detonation reactions that do not

positive)

a small proportion of the total NOx

continue to completion. There are

emissions

many ways in which these conditions

are toxic.

from

human

activities

Blasting News I First Quarter 2016

•

Poor

diesel

absorption

by

ammonium nitrate prill 7

Nitrogen dioxide ranges from yellow to dark red depending on the concentration and size of the gas cloud

• •

Excessive fines in ammonium

Common links between major

nitrate

events

Water ingress in products as the product exceeds sleep time limits

•

free face) •

Area to be blasted

•

The geological structure and rock strength of the area to be blasted

There is no one decisive factor that

•

Critical density of the product

will ensure the generation of NOx

•

The pattern dimensions

•

Poor hose handling practices (top

within the blast process

•

The product available

There are some common links

•

The amount of explosives required

loading products into holes)

•

•

Critical diameter for the product

that increase the likelihood of

•

Presence of dynamic water

NOx fumes within any blast. These

•

Weather conditions

•

Direct contact with incompatible

include:

•

Blasthole conditions

is

•

Sleeping of blast

manufactured and loaded that

•

Timing

chemical products •

Product

-- Any

desensitisation

by

pressure •

There

are

certain and

geological,

blast

design

conditions in which high levels of

Matching the ground conditions to

emulsion and gassing agents)

the Powder Factor •

product)

observed.

•

specifications (AN prill, AN -- Dynamic water (regardless of

post blast fume are consistently

•

that

is outside the optimal product

confinement

•

product

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Several major fume events have been found to have had a powder

-- Excessive sleep time ground

factor that was significantly higher

confinement (including stemming)

conditions (cavities, hardness,

than the powder factor required for

Ground condition such as presence

excessively weathered)

the ground conditions

Lack

of

proper

product

-- Unfavourable

•

of cavities/cracked ground

Disturbed ground due to back

Bringing it together…

This is often the result of: -- A lack of understanding of the ground conditions

break from a previous blast •

to blast the area (Powder Factor)

-- Changing the product selection

Dynamic effects when blasting

The engineering phase should consider

in such conditions are believed

at least the following aspects of any

to influence some fundamental

blast:

explosive design properties. These

•

The blast outcomes

techniques/blast patterns/drill

impacts are not well understood.

•

The method of blast relief (vertical/

data

to reduce costs -- Inappropriate

drilling

Blasting News I First Quarter 2016

Fume Classification (AEISG)

LEVEL

TYPICAL APPEARANCE

LEVEL 0 No NOx gas LEVEL 1 Slight NOx gas 1A Localised 1B Medium 1C Extensive LEVEL 2 Minor yellow / orange gas 2A Localised 2B Medium 2C Extensive LEVEL 3 Orange gas 3A Localised 3B Medium 3C Extensive LEVEL 4 Orange / red gas 4A Localised 4B Medium 4C Extensive LEVEL 5 Red / purple gas 5A Localised 5B Medium 5C Extensive

Blasting News I First Quarter 2016

9

-- Areas of any blast, that are

mud into the product column (rain

over blasted are much more likely to produce a major fume

event) •

There

relief as opposed to other designs •

was

no

definitive

The use of deck loading where a product selection has been

event than areas of the blast

geotechnical

to

changed from a low density

pattern that are not as heavily

either the condition of the rock

product (ANFO) to a higher density

loaded

within the explosives loading

product

area (voids, cavities, fracture and

emulsion)

An example…

data

relating

faults) or the rock strength •

•

(Doped

or

Blended

Consider the development of

The area was identified to be

blast parameters for particular

During one such blast/fume event,

comprised of wet clays and the

geological domains in mine sites

the root cause was attributed to the

compression

following:

materials in this area was low

Other steps that can be taken

•

There was not definitive geological

with a reasonable powder factor

to minimise Nox exposures on

technical data available relating

which could be estimated to

sites…

to either the condition of the rock

be in the range of 0.3 to 0.45.

or the rock strength

The application of the designed

Ensure that the mine site has:

The designed powder factor was

energy

•

listed as 0.53, but from historical

factor) to an area of soft/ wet

neighbouring

data a reasonable powder factor

clay resulted in the generation

blasting activities

for previous blasts was in the

of NOx and CO fumes through a

range of between 0.3 and 0.45

loss of confinement and product

A product change changed the

decoupling

•

•

strength

levels

(0.67

of

the

powder

•

This is an actual energy rating increase

of 47.5% increase

applied to the same ground conditions •

This was combined with a vertical displacement of relief/loss of

•

If you do what you always did, you’ll get what you always got…

Recommendations

A fume monitoring programme Physical control barriers such as blast

guard

positioning

and

communication •

A process to estimate potential travel and spread of fumes prior to the firing of the shot

•

A process to sample blasting activities on site to establish base

•

Revise the use of standard pattern sizes during the wet season

A second example…

of

the use of suitable gas monitors,

confinement and product column decoupling

communities

for the neighbouring mine sites

powder factor to 0.61 •

A suitable process to notify

•

line data (fume reporting) •

Engage a lower powder factor for the areas of mine sites

A

suitable

plume

modelling/

tracking process •

A suitable risk management for

During a second blast/fume event,

where the geological structure is

Blast Controlling (including fume

the root cause was attributed to the

predominantly of a softer rock/

management)

following:

clay structure

•

Incomplete combustion reaction, due to the ingress of water or

10

•

•

A suitable document detailing

Engage a free face blasting to

obligations of persons performing

provide the appropriate burden

the role of blast controller (in

Blasting News I First Quarter 2016

NOx from blasting constitutes only a small proportion of the total NOx emissions

•

regards to fume management)

including tracking of the fume

Assessment and implementation

cloud pathway

of a minimum blast exclusion •

•

•

A reviewing site procedure for

A site specific proforma letter to

the toxic gases on site and a

zone

the treating physician to assist in

supporting procedure for the

A system to ensure that all

the diagnosis of a person exposed

management of post blast (NOx)

persons involved in a blast as

to oxides of nitrogen fumes (NOx)

fume

either

Blast

controllers/Blast

•

exclusion zones/marker locations

•

A pre-shift meeting document

Guards are deemed as competent

that includes a particular section

persons in regards to the roles on

relating blast information which

site

includes proposed firing time,

Has a process to video all blasts

blast location, expected blast

to

results and control measures and

capture

any

fume

event

Acknowledgements • Downer EDI Limited: Reducing the risk of NOx fume exposure during Blasting (presentation) • AEISG (Australian Explosives Industry and Safety Group): Code of Practice - Prevention And Management Of Blast Generated NOx Gases In Surface Blasting Edition 2, August 2011 Disclaimer: Any advice and/or recommendation 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.

Blasting News I First Quarter 2016

11

The AECI Community Education and Development Trust investing in the development of communities aboard with programmes such as The “Water for Tomorrow” Environmental Programme.

Every day, millions of women and children in developing countries are forced to rely on traditional methods of water collection that consume excessive amounts of energy and time. It is estimated that globally, women and children spend 140 million hours collecting fresh water every day.

One innovation “The Hippo Water Roller” offers an immediate and appropriate response to the issues surrounding water access and security. Designed in Africa for Africa, the 90 litre Hippo Water Roller enables women, children and the elderly to collect 5 times more water than a single bucket by simply rolling it along the ground.

During 2015 the AECI Community Education and Development Trust invested in the sustainable development of vulnerable communities in South Africa through education, skills development and a focus on the environment. Over 5 124 beneficiaries were impacted by these investments and over 7 organizations across 7 provinces in South Africa.

The Trust has partnered with Hippo Roller to provide education and training on water conservation including the provision of hippo rollers to various rural communities surrounding the mining areas in which we operate.

Following the 2015 programmes, the Trust continued its commitment to supporting the sustainable development of vulnerable communities in South Africa

whilst

addressing

key

socio-economic

development issues facing the country. During the This

was

achieved

through

key

partnerships

and

collaborations with stakeholders in AECI’s areas of

first quarter of 2016 AECI addressed the critical water shortage in Limpopo and Mpumalanga.

operation. Various organisations across the country came

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Blasting News I First Quarter 2016

The handover of thousands of litres of water at Maokeng Primary School in Modimolle, Limpopo

On 10 February, AECI supported the Hippo Water Roller Project and handed 200 Hippo Water Rollers (90l) to residents of the Likasi village near Witbank, South Africa.

AEL Mining Services, a subsidiary of AECI facilitated the handover.

On 4 March AECI delivered over 62 000 litres of water to Modimolle, Limpopo in conjunction with Operation Hydrate, the NGO which has brought water relief to droughtaffected areas across South Africa. AECI was honoured to be part of the Operation Hydrate initiative.

Images show the handover of thousands of litres of water at Maokeng Primary School in Modimolle, Limpopo, an area which has been severely affected by the country’s drought.

Thank you Operation Hydrate Initiative SA!

Blasting News I First Quarter 2016

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AEL’s ECO EMULSION RANGE DEVELOPED TO OPTIMISE SURFACE MINING USING RECYCLED OIL CASE STUDY

SITE PROFILE PT Kaltim Prima Coal (KPC) is a coal mining company located in the region Sangatta and Bengalon, East Kalimantan, Indonesia. Exploiting an area 90,938Ha, KPC operate one of the largest open-pit mining in the world with coal resources and reserves totalling 9,275 billion tonnes. The mining method applied is strip mining of multi pits with truck and shovel operation, which are managed by mining divisions, Mining Operation Division (MOD) and Contract Mining Division (CMD).

BACKGROUND KPC coal production has been increased since the beginning of the operation in 1992. The average of KPC overburden removal in the last 5 years, had reached up to 500 million BCM per year. Coal production target for 2015 is 60 million which equals to 540 million BCM of overburden removal.

About 80% of overburden requires drilling and blasting while the excavation is done with trucks and backhoe/shovels. The maintenance carried out on heavy equipment produces about 10 – 11 million litres of used oil per year (2010 – 2014). Before 2011, used oil in explosives was in ANFO mixing only while the rest was shipped to a licensed waste processor.

KPC overburden removal (2010 – 2014)

BUSINESS CHALLENGES The requirement on bulk explosives at KPC is in the range of 100,000 tons per year. Approximately, 55% of that requirement is supplied by AEL at CMD operation in the form of emulsion-based explosives.

KPC had identified fuel and explosives consumption as two of the main operating costs. Therefore, KPC have been actively looking for more efficient and safe blasting processes through improvement, especially saving on diesel for emulsion manufacturing. Currently, KPC has permit to utilise used oil to replace diesel up to 80% in formulation following SNI 7642:2010 (SNI, Standar Nasional Indonesia).

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Blasting News I First Quarter 2016

SOLUTIONS

CASE STUDY

AEL’s range of Surface Bulk Explosives is amongst the best researched and developed in the market; in Indonesia PT AEL has pioneered the use of used oil in emulsion manufacturing.

In order to fulfil KPC’s expectations in the use of used oil to manufacture emulsion, AEL introduced S335 Eco, a product suitable for reactive ground environments with the existing benefits of Bulk emulsions such as safety, easy handling and water resistance. The eco range has been specifically developed to optimise surface mining using recycled oils in the formulation.

AEL then make use of specialised technology to ensure the used oil based bulk emulsion explosives is of equal quality as any virgin fuel product, with emulsifiers custom-made for each level of used oil. The recent development on emulsifiers enables AEL to replace diesel up to 80%.

Sample of S335 Eco on the bench

In January 2011, AEL started trials at KPC with 10% replacement of virgin oil and has been ramping up until the current 80%.

OUTCOME The performance of the bulk explosives has been stable with all levels of used oil and monitored regularly on bench by conducting quarterly VOD tests. The product, S335 Eco, has performed within its specification with good blast performance since the introduction of used oil.

Since used oil has been utilised in emulsion manufacturing, the volume of saving in diesel during 2011 – 2014 was about 6 million litres or 1.5 million litres per year.

CONTACT Simon Tose Global Mining Optimisation Manager +27 11 606 0000 simon.tose@ aelminingservices.com Used oil utilisation (2011 – 2014)

CUSTOMER ACKNOWLEDGMENT “Utilisation of used oil in the mixture of explosives to replace diesel oil delivered great benefits for KPC. S335 eco using 80% of used oil have met KPC’s expectations to reduce blasting costs without reducing the quality and helping to reduce waste oil management cost.”

Aris Hermawanto, KPC Technical D&B Superintendent

Blasting News I First Quarter 2016

AEL MINING SERVICES 1 Platinum Drive, Longmeadow Business Estate North, Modderfontein, 1645, South Africa www.aelminingservices.com

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