Blasting News VOLUME 25 ISSUE 1 2016
IN THIS ISSUE •
Ensuring security of supply, AEL overcomes stormy conditions to supply AN between
continents
• 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 between continents 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 between continents. 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 between continents AEL has demonstrated the depth of its supply chain capability by delivering 5 000 tons of Ammonium Nitrate (AN) thousands
of
kilometres
between
continents, amid difficult conditions. This, according to Sean Slabbert, Commercial
Manager
for
Global
Ammonium Nitrate, was due to various supply
constraints
requiring
the
supply chain team to make alternative sourcing arrangements. Slabbert says once the most suitable source for quality AN was identified, the 5 000 ton shipment travelled a significant distance by rail before being loaded for deep sea travel. “We commend our supply chain team for ensuring that this product was delivered to its final destination despite a number of challenges encountered. The
shipment
weathered
stormy
winter seas to arrive in qualified AEL packaging at the destination,� says Slabbert. Imported product needs to meet a number of stringent quality, packaging
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Blasting News I First Quarter 2016
AEL REMOTE CAPABILITY
and logistics requirements. Shortly after
Slabbert concludes: “AEL is committed
the offloading of this shipment, the AEL
to giving our customers peace of mind
production team on site manufactured
and we believe a flexible supply chain
quality emulsion explosives.”
and consistent communication are two driving factors behind our ability to
“At the heart of AEL lies its customer-
deliver quality products and maintain
centric approach in providing explosives
security of supply.”
and mining solutions. AEL’s ammonium nitrate chain draws from as many as 16 qualified sources around the world,” says Slabbert.
Bagged Ammonium Nitrate product being loaded
Blasting News I First Quarter 2016
Bagged Ammonium Nitrate product
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AEL PARTNERSHIPS
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 makes 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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