AEL Blasting News - third quarter

Blasting News VOLUME 25 ISSUE 3 2016

IN THIS ISSUE • Fuel costs halved, postponed blasts eliminated with AEL’s unique Vertical Drop offer in Zimbabwe • Chemical energy provides the right formula for accuracy and efficiency in mining operations • A closer look at intelliBlast™ - AEL’s total value proposition

Printed on 100% eco friendly paper

Editor’s Note Welcome to the third issue of Blasting News for 2016. This bumper issue focuses on AEL’s vast industry knowledge spanning over 100 years and revolutionary technologies, which ensure our

CONTENTS

continued leadership in providing sector solutions for customers’ operations globally.

In this issue, under our AEL Thought Leadership banner, we take

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SPECIALIST SPEAK by Simon Tose

4

AEL DELIVERY SYSTEMS: Fuel costs halved, postponed blasts eliminated with AEL’s unique Vertical Drop offer in Zimbabwe

6

AEL ENERGY EFFICIENCY: Chemical energy provides the right formula for accuracy and efficiency in mining operations

a closer look at our 3rd AEL Blasting Masterclass (see pages 1226) which takes the lead in offering customers blasting science intelligence and technology of the future. Having established itself as a premier industry event offering in-depth insight and cutting edge solutions for customers in the underground and surface mining sectors, this year’s conference, themed Simplexity* hosted a large number of local and international delegates.

The AEL Blasting Masterclass, comprised insightful case studies presented by subject experts and AEL key customers.

Complementing the conference session, a dynamic exhibition

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AEL THOUGHT LEADERSHIP: EXPLOSIVES TODAY 16

showcased AEL’s vast suite of products with special emphasis on AEL’s latest innovations i.e. the new generation, revolutionary portable charging unit PCU011 and the intelligent electronics

12 AEL VALUE ADD: A closer look at intelliBlast™ AEL’s total value proposition 14 AEL CUTTING EDGE INNOVATIONS: AEL is proud to announce the launch of two trailblazing innovations 16 AEL DIFFERENTIATED PRODUCTS AND SERVICES: Adaptable Underground, Surface and Electronics product and service offerings

system, intellishotTM engineered to increase cost saving, enhance safety and deliver value.

One of the key events at the conference was the unpacking of our value proposition branded intelliBlastTM. intelliBlastTM is a holistic approach to helping our customers on their unique journey to optimal blast outcomes through our differentiated products and services. We share a breakdown of the building blocks of intelliBlastTM in our Value Add section. We also take you through a case study to further showcase our value proposition.

Join us on this journey to explore our targeted approach in

22 AEL CASE STUDY: ViewShot™, delivering beyond expectations

optimising our customers’ operations.

Enjoy your read! *Simplexity is a process which combines the complexity of endless hours of analysis, design, testing, technological innovation and expertise to create a product that allows the most simple, yet effective usability for the end user.

Eubulus Pillay Cover image: Coal mine, coal on the palm

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

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 Third Quarter 2016

SPECIALIST SPEAK

Specialist Speak

by Simon Tose, Global Mining Optimisation Manager

explosives controlling the fragmentation. Yet chat to the mine rescue teams and we hear why this product should be finding a home in the dynamite museum.

Unlike the shock tube systems that have replaced it, the capped fuse burns with an open flame, a hazard in our wood A pile of mining industry magazines on my desk as I returned from a blasting accident investigation framed my first technical editorial, at the root of which is the word; KNOWLEDGE. The dictionary defines the word as; facts, information, and skills acquired through experience or education; the theoretical or practical understanding of a subject.

The Mining Industry Human Resources Council has recently said that about 40% of the resource extraction industry’s workforce worldwide is at least 50 years old and one third of them are expected to retire by 2022. In South Africa, according to the government, we lose more than half of new technical mining graduates to other sectors of the economy, in their first 5 years of employment. This figure increases to around 70% within 10 years of employment.

The impact of the current mining industry downturn has only accelerated this situation.

An article on the import, supply and local assembly of capped fuse and igniter cord, a query from an appointed blaster

support underground environment. A misfired fuse exposes the core to possible sources of friction and re-ignition; people have lost their lives to an unplanned detonation as a result of such a fuse smouldering underneath the broken muckpile.

Our appointed blaster phoned to query why there was a problem with using a capped fuse to initiate the primary blast on surface. Taking a scenario from the AEL Blasting Competency programme; a blaster lighting the fuse and getting stuck in mud on the way to the position of safety.

We engaged in a series of thoughts, ideas and discussion, termed continued professional development. At the end, the blaster realised that other initiation methods were more appropriate, as lighting a fuse meant that the control over the blast had been lost whilst the fuse burned, to abort would not have been possible.

Whilst we will share the learning from the blast investigation in a future Blasting News,

and the accident investigation highlighted the gap between

statistically the people involved will have left

what we teach in the classroom and the need to find a more

the industry in the next 5 years. The challenge

practical way to share life experiences we gain over a career in the industry.

to those of us involved in blast training is how do we secure that life learning experience

Capped fuse and igniter cord, the backbone of blasting in gold reefs, has served the mining industry well. In our text books it talks to the ease of use and the sequential firing, the mass of

Blasting News I Third Quarter 2016

and emotion to prevent the sequence of events occurring again?

3

AEL DELIVERY SYSTEMS

Fuel costs halved, postponed blasts eliminated with AEL’s unique Vertical Drop offer in Zimbabwe

A model of AEL’s Vertical Drop System

AEL Mining Services has successfully

AEL is a subsidiary, is focused on

fast becoming the globally accepted

demonstrated that it can reduce its

delivering

solutions

best practice for the delivery of

customers’ operational cost of blasting

to the mining industry during what

emulsion to underground operations

underground significantly, by making

has been a challenging economic

by transporting these products safely

use of the Vertical Drop emulsion

environment over the past few years.

through a reticulation system of piping

cost-effective

delivery system, which has a short payback period.

to an access point adjacent to the “Projects such as the installation

workings.

and operation of the Vertical Drop This is according to Ashworth Chiringa,

emulsion delivery system are all about

Chiringa says this infrastructure is a

Regional Mining Engineer at AEL

adding value to the customer through

perfect example of AEL’s innovative

Zimbabwe, who says mines are looking

equipment and blast efficiencies, which

approach and he highlights the benefits

to their suppliers to solve operational

result in operational cost savings

that the Vertical Drop has provided to

challenges to remain competitive, such

and increased levels of output,” says

a platinum mine in Zimbabwe, which

as drastically reducing equipment costs

Chiringa.

has a production rate of 1.8 million

and eliminating operational downtime.

The JSE-listed AECI Group, of which

4

tons per annum. Chiringa’s case study The Vertical Drop delivery system is

on the mine was named as one of the

Blasting News I Third Quarter 2016

AEL DELIVERY SYSTEMS

top-three presentations at AEL’s 2016

total annual savings equivalent to

because it reduces interface time with

Workshop for Explosive Engineers and

15% of the annual explosives cost as

explosives which are manufactured

Technical Representatives (WEETR), in

the result of significant reductions in

at the working face during charging.

Johannesburg, South Africa.

fuel consumption and maintenance, in

Security is also improved through the

addition to increased productivity.

streamlined delivery channels with

The case study revealed the increase

seamless inventory control, reducing

in production and rapid advance of

“The total daily travelling distance

underground workings at the mine in

for Mobile Charging Units has been

recent years had increased the distance

dramatically decreased from 200 km to

Chiringa says the client thanked AEL

between the working faces and surface

70km, which equates to a reduction of

for its commitment to making these

mounted storage facility for UG100

nearly 50% in annual fuel consumption

achievements possible.

emulsion and the sensitiser, meaning

for these vehicles. Furthermore, we

transportation was a long, expensive

expect the Vertical Drop to ensure

He concludes, “The data on the

process.

there will be zero postponed blasts, a

efficiencies provided by the Vertical

the risk of explosives theft.

challenge which saw the mine losing

Drop delivery system speaks for itself

Within an 18 month period, AEL

about 800 production tons daily last

as an example of finding innovative

equipped

solutions to our customers’ needs.

the

year due to emulsion or sensitiser

Vertical Drop delivery system at the

and

commissioned

shortages. We calculate the increase

mine. Tracking and reporting back on

in productivity that arises as a result

While it is clear this infrastructure can

the benefits and cost savings to the

of zero postponed blasts to be worth

deliver real value to a single mine,

mine on a monthly basis is currently in

R10.5 million annually,” Chiringa says.

mining houses can realise greater

progress.

benefits by rolling out these systems The

Based on the data, the mine will realise

Vertical

significant

Drop safety

also

provides

across their portfolios.”

enhancements

The total daily travelling distance for Mobile Charging Units has been dramatically decreased from 200 km to 70km, which equates to a reduction of nearly 50% in annual fuel consumption for these vehicles

Blasting News I Third Quarter 2016

5

AEL ENERGY EFFICIENCY

Chemical energy provides the right formula for accuracy and efficiency in mining operations

AEL's on bench capability

Making

operations

cost

Manager at AEL Mining Services says

group in South Africa, focuses on mining

effective, sustainable and productive

the use of chemical energy in mining

solutions, one of the AECI growth

is what any supplier to the mining

operations is often under utilised

pillars. AECI has been successful in

industry aims to achieve, especially

as mechanical energy appears to

maintaining explosive volumes through

during a commodity down cycle. While

be cheaper at face value. However,

strong client relationships within as

earthmoving

AEL.

and

efficient,

mining

chemical energy offers several benefits

machinery is critical to mines, the use

surface

in each step from mine to mill and can

of chemical energy is a key approach to

decrease expenditure and increase

“The use of chemical energy in mining

driving operational efficiencies.

production if used effectively.

processes has led to higher rates

Simon

AEL, a member of the JSE-listed AECI

of efficiency through its ability to

6

Tose,

Mining

Optimisation

refine factors such as fragmentation

Blasting News I Third Quarter 2016

AEL ENERGY EFFICIENCY

and rockthrow, reducing reliance on

footprint. Implementing alternate ways

it only becomes an explosive once it is

machinery which is capital intensive

into mining processes which help save,

sensitised.

and heavy on maintenance costs,” adds

reuse and recycle energy and oil will

Tose.

cut costs further but also contribute positively to the environment.

“It is important for us as an industry to be responsive to change. We need

There is still a need for mechanical

to be innovative and sensitive to our

energy for certain procedures on-site,

AEL's Surface Bulk Emulsions is one

surroundings. By doing so we will

such as draining and ventilating mine

of the best researched and developed

be able to produce optimised blasts

shafts, hauling up and processing

formulations currently in the market.

which not only save us time and money

ores and blasthole drilling. However,

The Eco range of products has been

but

implementing

developed to optimise blast results

sustainability and improving the way

delivering

mining is conducted throughout the

alongside

chemical

these

energy

processes

offers

value

throughout

the

more control over the blast and the

surface mining sector. Eco emulsions

environment,

making

incorporates used oil in the fuel phase

significantly

more

the

process

efficient

and

also

focus

on

environmental

world,” concludes Tose.

as a non-detonable emulsion because

productive.

According to Tose, another significant benefit of employing chemical energy on mining sites is the ability to control rock throw distances and rock fragmentation with great accuracy

Chemical energy offers several benefits in each step from mine to mill and can decrease expenditure and increase production if used effectively

while optimising transport and load capacity. Tose says that even a onesecond improvement to transport or load speed has the potential to increase operational

efficiencies

drastically

by allowing more ore to be processed every day, while simultaneously saving on mechanical costs, without any operational restructuring.

“Ironically, we have noticed instances where mines have cut costs on chemical energy only to later end up spending more money than they reduced on new earthmoving equipment. This is because their machines could no longer handle the larger rock fragmentation, which is a direct result of lower spending on blasting,” says Tose.

With the emphasis on conservation and making mining processes sustainable, chemical energy also becomes a key imperative to reducing a mine’s carbon AEL's eco range of emulsions

Blasting News I Third Quarter 2016

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AEL INTERNATIONAL

EXPLOSIVES TODAY Series 4 I No 16

BLASTHOLE DRILLING AND INITIATION PATTERNS IN SURFACE BLASTING Part 2 By Ken Meiring – Manager Blast Optimisation The layout of the drill holes, burden and spacing and ratio between them has an important effect on blasting results. In the previous Explosives Today, Blasthole Drilling and Initiation patterns in surface blasting, Part 1, the importance of the effect on blasting results due to the layout of drill holes, burden and spacing and ratio was discussed. It was shown how blasthole initiation patterns can control the overall performance of production blasts by optimising the degree of timing interaction between adjacent blastholes and rows of blastholes.

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The concept of chevron timing was described and how to achieve the desired timing contours by altering the intra-row and inter-row delays. It also explained what the effect on the fragmentation and muck pile profile could be.

In this issue the importance of how by changing the timing, the burden and spacing, one can influence both fragmentation and muck pile profile.

Various timing configurations will be shown to demonstrate these effects.

In order to achieve optimum fracturing the correct interaction between individual holes must be such that the crack formation for each hole results in the rock mass being fragmented into correctly sized particles rather than large unbroken blocks.

Optimum fracturing is therefore obtained by ensuring that each blasthole fires independently, but such that the interaction between adjacent holes (and adjacent rows) results in the desired fragmentation while ensuring heave and the desired muck pile profile.

This can be achieved in two ways; • •

Initiate each blasthole in sequence Arrange that simultaneously initiated blastholes are far enough apart to prevent mutual interaction between their stress fields. In practice, it has become necessary to initiate blastholes individually in sequence, especially where shock tube and electronic detonators are in use and this can be achieved.

Shock tube has been successfully used in surface open pit, quarrying and Blasting News I Third Quarter 2016

AEL THOUGHT LEADERSHIP

open cast blasting to achieve control of sequential firing, heave and movement of the muck pile. However electronic initiation has become the best method to achieve the best of both fragmentation and heave requirements and to address the environmental impact of blasting on nearby communities using single hole firing.

The benefit of using the correct timing method by means of employing the chevron or half chevron (echelon) configurations is reduced apparent burdens due to the effect of the timing in conjunction with a staggered pattern (figure 1). This will mean that a pattern can be expanded slightly, resulting in a lower powder factor and reduced drilling whilst maintaining fragmentation.

Figure 1 Squared and staggered V2-cut chevron patterns

Timing contours In timing, it is important to understand the significance of timing contours, i.e. imaginary lines indicating when holes are firing at the same delay. The contour lines when drawn will give an indication of the alignment of the holes firing at the same delay and thus the perpendicular direction of movement of the rock.

Figure 2 Square drill pattern with 25 v 42ms timing

Assuming a square pattern has been drilled and timing has been allocated as 25ms intra-row and 42ms inter-row as shown in figure 2, this will result in contours as shown in figure 3. For example, there is no 42ms delay on the intra-row axis, but the contour indicates where it would have been. Similarly, there is no 50ms delay on the inter-row axis, but the contour line shows where the delay would have been.

This also helps to identify the chevron being used, to ensure the correct effect is realised. So depending on what the blasting requirement is, the contours can be adjusted by changing the inter-

Blasting News I Third Quarter 2016

Figure 3 Timing contours for 25 vs 42ms timing

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AEL THOUGHT LEADERSHIP

row and intra-row delays.

Timing configurations The blasting requirements may include; fragmentation, muck pile profile, cast percentage, looseness of the muck pile for digging, to name a few. These can all be achieved through specific timing configurations loosely referred to as;

Figure 4 Line blasting

Figure 5 Muck pile profile (Line blasting)

1. Line blasting – row by row (also known as cast blasting) 2. Shallow ‘V’ blasting 3. Deep ‘V” blasting 4. Box cut blasting 1. Line blasting

Figure 6 Shallow ‘V’

As shown in figure 4, the timing applied results in rows being blasted at 25ms intervals. The rock movement will be perpendicular to the contour lines; •

• • •

Produces lowest muck pile height, suitable for a dragline or for dozing (figure 5) Muck pile thrown furthest Broken rock very loose and easy to dig Requires highest powder factor to get good fragmentation

Figure 7 Muck pile profile (shallow ‘V’)

2. Shallow ‘V’ blasting • Changing the inter-row delay to 75ms and the intra-row delay to 25ms the contour shape moves from a flat line to a shallow V and the change in the rock movement means that the rock will be thrown more to the centre than towards the front of the pattern; •

•

10 10

Muck pile is slightly more heaped than the line blast, suited to a wheeled front-end loader Fragmentation is slightly better due to the higher inter-action between rock particles during heaving

Digging will be slightly tighter than with the dragline •

3. Deep ‘V’ blasting By adjusting the delays, to 17ms interrow and 67ms intra-row, as shown, changes the angle of the timing contours substantially. Movement of the rock is even more towards the centre, resulting in a well heaved muck pile which is above the level of the bench; •

Produces

highest

muck

pile

• •

height, suited to a hydraulic shovel or back hoe Muck pile will produce highest heave and it will always be above the bench Muck pile will be thrown the least Broken rock could be very tight and difficult to dig, but will generally achieve the best fragmentation due to the increased level of interaction between particles during heaving

4. Box Cut blasting Box Cut blasting (also known as drop

Blasting News I Third Quarter 2016 Blasting News I Third Quarter 2016

AEL THOUGHT LEADERSHIP

on the timing methods of old, where detonating cord and detonating relays or fixed shock tube delays were the norm.

Figure 8 Deep ‘V’

Figure 9 Muck pile profile (Deep ‘V’)

While these were very effective, electronic detonators with their range of delays between 0ms and 20,000ms in 1ms increments, allows for much more effective blasting in that the blaster can now plan his blast to achieve the fragmentation, heave and muck pile profile required by the operation requirements, without the constraints of fixed delay periods.

AEL Mining Services Explosive Engineers based at the regional offices are available to help and advise on this subject and the use of electronic detonators to achieve all controlled blasting scenarios.

Figure 10 Box Cut

Figure 11 Muck pile profile (Box Cut)

cut blasting) is used where there is no free face to blast to, other than the surface of the bench. As a result the potential for flyrock is high due to the potential for choking of the rock movement during heaving. It may also require a higher powder factor to allow for the breaking out of the initial holes in the cut area;

•

•

single hole firing (figure 10) Muck pile high with minimal forward displacement of material (figure 11) Produces good fragmentation, but a high potential for flyrock and requires more stemming than usual

Conclusion •

The contours can be offset by using more than one delay, which will assist with preventing too many holes firing at the same delay, however optimised timing with electronics will allow for

Blasting News I Third Quarter 2016 Blasting News I Third Quarter 2016

The timing methods shown in this issue are very basic and are just the tip of the iceberg regarding what can be achieved through innovative timing.

To some extent, the industry still relies

References: This document is a new addition to the Explosives Today series. This document should be read with BLASTHOLE DRILLING AND INITIATION PATTERNS IN SURFACE BLASTING Part 1, and replaces all previous Explosives Today on this subject including Series 2. No 12: June 1978 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: 1.1warrant 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.

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AEL VALUE ADD

A closer look at intelliBlast™ AEL’s total value proposition

by Wayne Du Chenne, Executive Director: Southern Africa

AEL prides itself in partnering with customers on their journey toward optimal blast outcomes. We have always looked for ways in which to innovate so that we not only supply products and services, but add real value to our customers’ operations and establish long-lasting partnerships.

We understand that our customers across the world are facing tough times with challenging economic conditions. Now, more than ever, they need us. Our customers come to AEL because we have always been innovative, flexible and able to meet the challenges they are dealing with.

This is where intelliBlast™ comes in.

It is our total value proposition that demonstrates to our customers that we are perfectly positioned to deploy into their operations seamlessly,

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through our innovative and agile products and services. Through intelliBlast™, we highlight to our customers that our approach can help them improve their balance sheet and pursue cash preservation, which is imperative in the current economic climate. It is about being able to do more, with less.

As we all know, when you use energy correctly at the source you can eliminate many inefficiencies in the value chain, reducing operating costs and improving productivity and output.

The intelliBlast™ approach is not new to AEL, over 100 years of being the market leader in Africa has brought us to this point where we can bring our holistic approach to our customers across the world.

What is new, however, is our ability

to demonstrate our flexible and customisable capabilities in a simplistic manner.

At AEL, we are already configured in the intelliBlast™ mould of seeking out improved outcomes for our customers with each and every blast. This means that our ability to partner with customers is a matter of ‘switch on’, providing rapid time to market.

This ability to rapidly deploy, combined with our flexibility, allow us to provide a range of offerings to our clients, from customer applied energy through to a complete optimal energy solution.

This means that we can meet the unique needs of our customers by tailoring our solutions to effectively and efficiently rise above the challenges they face. Whether it is simply

Blasting News I Third Quarter 2016

AEL VALUE ADD

What is intelliBlast™? intelliBlast™ is a holistic and flexible approach to help customers on their unique journey to optimal blast outcomes.

This approach can help customers improve their balance sheet and pursue cash preservation, which is imperative in the current economic climate.

Optimal blast outcomes reduce inefficiencies and operating costs and improve productivity and output. intelliBlast™ is the culmination of over 100 years as a market leader in Africa and is what differentiates us from our competitors.

Our flexibility allows us to provide a range of offerings to our clients, from customer applied energy through to complete optimal energy solutions.

Pictorial representation of AEL’s Value Proposition

providing them with the products and services they need to perform their own blast or full integration into their daily operations with planning, execution, measurement and tracking, intelliBlast™ has a solution for every requirement.

In the figure above, you can see the desired outcomes of intelliBlast™ in the silver blocks. Optimised mining conditions, safely optimised blast outcomes and efficiencies, skills enhancement and environmental sustainability are the overall values that we want to deliver to our customers.

The red blocks, meanwhile, are our enablers. These are the ways in which we will reach our outcomes, through differentiated products, adaptable delivery systems and services, blast

Blasting News I Third Quarter 2016

consulting and predictive software.

Each of the outcomes and enablers is then supported by ‘heroes’, the products and services that combine to make our successes a possibility.

The heroes are also supported by proof points which highlight the added values each one can provide to our customers.

Everything that we do through intelliBlast™ revolves around what we call ‘simplexity’. Simplexity is a process which combines the complexity of endless hours of analysis, design, testing, technological innovation and expertise to create a product that allows the most simple, yet effective, usability for the end user.

employee at AEL puts into their work means we are able to make extremely complex processes simple for our customers. At the same time, we want our customers to have peace of mind knowing that the ‘simple’ products and services we provide have been through rigorous testing and development, and are the result of a century of expertise and innovation.

At the heart of it, intelliBlast™ is the culmination of the passion and dedication our employees put into their careers each and every day. For this, we thank all employees and look forward to sharing more information about this approach so that everyone can become an intelliBlast™ ambassador and help our customers thrive.

IntelliBlast™ achieves simplexity because the dedication each and every

13

AEL CUTTING EDGE INNOVATIONS

AEL is proud to announce the launch of two trail-blazing innovations

INTRODUCING… intellishot

TM

THE INTELLIGENT CHOICE

The IntelliShot® system developed in conjunction with our technology partner DetNetTM, is the latest addition to AEL’s Electronic Initiating System product suite. This advanced blasting systems is easy-to-use, ensuring the best blast, on time, every time.

Unique Features •

Fast and simple “tag by plan” deployment methodology

•

An automatic check to ensure that the correct number of detonators are connected per channel

•

Monitoring of detonator energy is performed up to the point of blasting

•

Detection and testing of detonators automatically takes place when connected to the intellishotTM Commander

•

Detonator programming speed is 7 times faster than existing systems

•

User friendly interface enabled via a wireless interface between the intellishotTM Commander and the multi-purpose CE4 Tagger

•

GPS location stored in the detonator and CE4 Tagger simplifies on-bench fault finding

These unique features ensure that complex blasts are easily deployed and

The complete intellishotTM System

fired successfully on time.

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Blasting News I Third Quarter 2016

AEL CUTTING EDGE INNOVATIONS

INTRODUCING THE PCU011...

THE NEXT GENERATION PORTABLE CHARGING UNIT AEL provides portable charging units (PCU’s) for charging in narrow reef mining environments. The pumps have been specifically designed to deliver the UG100 and UG200 non-sticky range of AEL’s bulk explosives products in conjunction with a sensitiser in stoping.

The lightweight PCU011 is a robust and reliable portable charging unit designed to specifically work in narrow working spaces where heavy equipment is difficult to manage.

The pump is available for low compressed air pressure environments as found in typical narrow reef stopes.

Used for charging bulk emulsion in underground narrow reef environments, the focus area for the PCU011 is narrow reef stoping. However, the pump can be utilised in development, including boxholes and travelling ways. The pump is used in conjunction with AEL’s pre-packed bulk emulsion and bottled sensitiser. This allows the customer to enjoy the advantages of an emulsion explosive even though one is limited to the current infrastructure of a conventional mine.

Benefits •

Lightweight and portable

•

Robust and reliable

•

Allows the application of emulsion explosives in a narrow reef environment

•

Suitable for application of emulsion explosives in short, small diameter holes of any inclination (Eliminating the necessity to use packaged explosives)

•

The PCU011 in operation

No longer a requirement for a primer in short blast-holes

Blasting News I Third Quarter 2016

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AEL DIFFERENTIATED PRODUCTS AND SERVICES

Adaptable Underground, Surface and Electronics product and service offerings Underground Capability Being an international leader and innovator in commercial explosives and blasting solutions, AEL has continuously demonstrated its understanding of the industry’s needs and challenges, as well as the importance of extracting valuable minerals from the earth responsibly. To that end, AEL strives to optimise your mining operations by bringing you a “state-of-the-art” suite of products, delivery systems and equipment to meet the challenges of your underground mining environment, with key emphasis on safety.

Underground Bulk Emulsion While widely accepted as the industry standard underground mining, new emulsion formulations continuously being developed in conjunction with continued enhancements of the associated pumping delivery systems.

for are the and

Classification Underground bulk emulsion explosives consist of a base emulsion and a sensitiser, which are classified as nondetonable and non-explosive, respectively.

Appearance The base emulsion is a honey coloured mixture of an oxidiser within an oil matrix.

When a surfactant is introduced and sufficient mechanical energy is created the oxidiser and oil blend together to form a base emulsion. The sensitiser is an aqueous or emulsified liquid, which, when added to the base emulsion and mixed/ sheared, creates an explosive in the blast-hole.

Benefits • Improved safety • Ease of use • Less labour intensive • Improved logistics • Easier adherence to explosives legislation • Improved Fragmentation • Faster charging time

16 16

Features • High safety standards • High strength • High VOD • Water resistance • Low fume emissions Bulk, Bagged, Hybrid emulsion charging systems AEL has launched the Bagged, Bulk and Hybrid emulsion charging systems as a replacement for packaged explosives in the Narrow Reef and Trackless Mining environments, introducing “Explosive free” mining and the innovative “Vertical Drop” to pipe emulsion underground.

The systems were developed to meet the needs of the highly regulated mining industry, where safety is a key priority.

The emulsion-based product is not an explosive until it is pumped into the hole during charging and offers a high level of security and control never experienced before.

Emulsion Delivery Systems Bulk System Application Conventional or trackless mining at any depth.

Description Bulk emulsion is delivered to the surface silo(s). MCU’s are either filled from these silos on surface or alternatively, cassettes are filled for transport underground. These cassettes then deliver emulsion either to a secondary storage silo or to the MCU in the workings. The cassettes are then returned to surface for re-filling.

This can be conducted for all AEL underground emulsions.

Benefits • Shrunken explosive footprint • Bulk storage of emulsion • Cassettes reduce the travelling distance for MCU’s • No more explosive transport underground • Non-explosive environment

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AEL DIFFERENTIATED PRODUCTS AND SERVICES

• • • •

Potential for primer-less blasting (depending on product) Reduced product inventory Cost-effective alternative to packaged explosive Easier adherence to explosive legislation

Bagged System Application Conventional Narrow reef mining at any depth.

Description Pre-packed bagged emulsion is delivered to the customer. It is stored on surface and sent underground in material cars and stored adjacent to the workings. The emulsion is used in conjunction with PCU’s.

Benefits • Shrunken explosive footprint • Bulk storage of emulsion • Cap-sensitive product for primer-less blasting • Non-explosive environment • No more explosive transport in shaft and underground • Reduced product inventory • Cost-effective alternative to packaged explosive • Easier adherence to explosive legislation Hybrid System Application Conventional Narrow reef and trackless mines.

Description Conventional, trackless mines or mines with a combination of both trackless and conventional narrow reef mining can make use of a delivery of bulk emulsion by means of a “Vertical Drop” delivery system. The “Vertical Drop” can be either from surface or from a sub-level and allows you to deliver emulsion close to the current workings.

Vertical Drop Emulsion Delivery System “AEL, has pioneered the world’s first, “Vertical Drop” emulsion delivery system”.

through pipes installed in a borehole from surface. This will enable large scale implementation of emulsion explosives in underground mining.

How does Vertical Drop assist the customer?

Vertical Drop does away with the constraints of explosive deliveries at fixed times, strict shaft and tramming schedules and the delivering of explosive products requiring strict legal control of a large inventory of explosive products.

The “Vertical Drop” emulsion delivery system has been developed to assist miners in their “Trackless Mining” by shrinking their explosive footprint, eradicating the need for bulk emulsion at silos and surface magazines.

Out with the old, no more….

• Silos at the shaft to store bulk emulsion • Surface magazines to store a multitude of explosives and their accessories In with the new, an innovation for the customer.

An underground bulk emulsion delivery system that offers: • Significant safety enhancement and universal logistics efficiency by reducing the flow of explosives in main arteries to the mine • Seamless inventory control • High level of security and control of products • Reduced interface with explosives which is manufactured at the working face during charging • Reduced risk of explosive theft due to the streamlined delivery channel • Charging units no longer required to refill on surface • Significant saving in maintenance, fuel and asset wear on equipment used for charging • Time and labour resources drastically reduced due to direct delivery of product into the workplace • Silos and associated surface infrastructure no longer required • Bulk emulsion deliveries at any time

What is “Vertical Drop”?

It is a bulk emulsion delivery system that delivers the base emulsion and sensitiser required directly to a storage facility, in close proximity to the underground production areas

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AEL DIFFERENTIATED PRODUCTS AND SERVICES

AEL delivery systems

Surface Offerings

substances like oil and water, stay mixed together thanks to a third substance called an emulsifier. Emulsions are formed by the emulsification of an oxidizer with a fuel phase.

AEL’s Surface Bulk Explosives are one of the best researched and developed formulations currently in the market. The Eco

These emulsions are manufactured at temperature between

range of products has been developed to optimise blasting

75°C and 85°C and then allowed to cool before being used.

in surface mining. Coupled with the use of recycled oil in the

For customers using the AEL surface bulk emulsions there

formulation has provided an environmentally friendly range

are various benefits from a safety perspective as well as

of products that provide a unique offering.

being able to adopt a more “green” approach by including used oils. Our emulsions are formulated to be fit-for-

With a solution to suit almost every application – including

purpose depending on storage requirements and application

surface, massive operations and quarries, AEL’s highly

needs.

skilled team, its vast range of products and solutions, equipment and technical resources have made the company

Safety Benefits

an acknowledged leader by providing sector solutions in

AEL’s range of surface bulk emulsion is developed in a safe,

South Africa, African regions and the International business.

non-explosive form and is only sensitised upon loading into the blast holes. Storage AEL guarantees unsensitised

Introduction to Emulsion

emulsion in storage silos for a period of one month. Good shelf life can be expected if specific storage conditions are

An emulsion is a mixture, in which two immiscible 18

met.

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AEL DIFFERENTIATED PRODUCTS AND SERVICES

Applications

Currently AEL has three product ranges of emulsions in

Our surface bulk emulsions can be used across a wide

regular and eco variations (used oil):

variety of applications, including quarrying, trenching, civils,

•

SB100 and SB100 Eco

mining, forestry and pre-splits and cater for all geological

•

S200 and S200 Eco

conditions from softs to hard-rock mining.

•

SB300 and SB300 Eco

Features

These emulsions can be pumped down the hole in one of

•

Water resistant

three ways:

•

Flexible solutions with scalable energies

•

•

Use of recycled oil in our environmentally-friendly Eco range of emulsions

Pure Emulsion – Pure emulsion is sensitised, charged and blasted

•

Doped Emulsion – Emulsion is mixed with ammonium

•

Cost-efficient delivery in bulk

•

Security – non-explosive transport of emulsions

•

Emulsion manufactured on site or delivered via a

The Anfo which contains the fuel oil sensitises the

reliable logistics network

emulsion during the charging process.

•

nitrate prill (ANA), then sensitised and blasted •

Blended Emulsion – A mixture of Emulsion and Anfo.

Suitable for holes ranging from 75mm to 300mm in diameter

One of the benefits of eco emulsions is that the eco products gas more efficiently (smaller gas bubbles) and therefore

Benefits •

Scalable energy – optimisation of blast performance partitioning,

• •

have better detonation properties and higher energy levels. as

well

as

clearing

(hauling)

and

The shelf-life of all these base emulsions is 12 weeks from

downstream processing requirements

the date of manufacture, including the time spent in storage

On-site storage options – reduced turnaround time,

silos. Furthermore, it is important to abide by the legal

transport costs and improved blasting efficiency

storage requirements for the region. Sleep time should not

On-site manufacturing with the installation of AEL

exceed 3 weeks in blast holes after sensitising.

modular plants for heavy duty, continuous operations • •

Tried and tested logistics to ensure explosives delivery

Our emulsions need to be initiated with Pentolite primers

down the hole

that are suitable for the respective hole diameter. The use

Wide variety of applications to suit specific needs from

of detonating cord and/or packaged explosives as primers

tunneling, civil works, trenching, quarrying and pre-

is not recommended, except in consultation with the AEL

splits (fissures in rock) for all geological conditions

Mining Optimisation team.

from softs to hard-rock mining •

•

Widest range of services available including down-the-

AEL Surface Blends use Anfo to achieve an optimal oxygen-

hole (DTH), prime- load, tie and shoot (PLTS) and rock-

balance in the emulsion for efficient heave energy during

on-ground (ROG)

blasting. VODs vary based on the nature of the blend used in

Access to AEL’s wealth of expertise and knowledge

the hole as well as the blast hole diameter.

gleaned over more than 100 years – from research and development, manufacturing, sales and mining optimisation to full on-site partnerships •

Ability to take used oil at the customer sites for recycling and further use in emulsion explosives

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AEL DIFFERENTIATED PRODUCTS AND SERVICES

Electronics Technology AEL is recognised as a world leader in the development and manufacture of electronic detonators. Through our joint venture with high-tech electronic initiating systems developer, DetNetTM, AEL has been at the forefront of pioneering this exciting technology, which is set to revolutionise the future of mining, for many years. Safety is a core value within AEL and the design of its systems ensures that they are inherently safe. This means that our electronic detonators are highly resistant to accidental initiation from static, stray currents, induced current, and over voltage from lightning. Safety keys ensure that the detonators are only initiated by authorized persons using encrypted codes. The robustness of AEL’s electronic detonator systems makes them suitable for use in the toughest tunneling, shaft sinking, underground stoping, quarrying and open cast mining environments. There is a wide range of systems to suit the various applications and AEL’s trained sales engineers can assist in selecting the system that suits each customer’s particular application.

Our range of systems: DigiShot™ DigiShot™ is an easy-to-use, reliable, electronic initiating system for use primarily in smaller blasting operations that demand accurate timing. Examples include environmentally sensitive operations such as quarrying, tunneling operations

AEL Electronics in use on bench system has been improved over several years of continuous use and offers a truly reliable and robust connection mechanism.

The BlastWeb™ The BlastWeb™ electronic initiation system is designed for underground environments where there is a requirement for ease-of-use, limited user interaction and centralised blasting. The BlastWeb™ electronic initiation system is

and smaller civil blasts.

capable of initiating specific AEL electronic detonators. The

The DigiShot™ electronic initiation system represents an

initiate underground shock tube rounds. The system is

innovative advance in technology which enables users to achieve the accurate timing benefits of electronic initiation systems with robust all-weather downlines and surface connectors. As an added benefit, the ability to blast wirelessly

main requirement is filled by NetShock™ which is used to deployed internationally with a solid performance track record.

NetShock™

has now been included in this system.

NetShockTM is a purpose designed device that links the cost

DigiShot™ Plus

electronic centralised blasting systems without the need to

DigiShot™ Plus is the Flagship system in Electronic Detonators. It is an easy-to-use, reliable, electronic initiating system with remote firing capability and can be extended to fire very large blasts. The user can link several systems together through an RF link to fire multiple large benches in a synchronised or offset manner. The detonator connector

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benefits of traditional shock tube systems with those of switch to electronic detonators.

CE4 Tagger The CE4 Tagger is an upgraded replacement for the existing V8 electronic delay detonator tagging device. It provides the user with several updated features and is housed in an improved robust casing that stands up well to the harsh user

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AEL DIFFERENTIATED PRODUCTS AND SERVICES

environment. The power management system has been

level of security. The GeoShot™ system delivers reliable

improved giving extended battery life. The upgraded LCD

initiation with accurate shot-point data in the challenging

display is easier to read and can display more information

conditions that are often encountered in geophysical

at once. The touch pad has been upgraded from a flat pad to

exploration.

raised silicon buttons with backlighting, providing improved tactile feedback to the user when inputting information

GeoShot™ control equipment, namely a Tagger and Seismic

especially when wearing gloves. A vibration user feedback

Interface Unit (SIU) is designed to meet the specific needs

has been added along with a variable tone audio speaker

of seismic customers and is compatible with most seismic

which improves user error communications vastly. The

firing equipment in use today.

IP rating has been improved to the point that it can be immersed under 1m of water and remains fully functional

ViewShot™

afterwards. GPS capability has been added as well as other

ViewShot™ is a software package designed for interfacing

features useful to blasting personnel. The CE4 Tagger is

blast designs with DigiShot™ and DigiShotTM Plus firing

loaded with the appropriate software for the product being

equipment. It provides the user with the ability to design

used so that the user interface between different products

complex and detailed blast designs and interrogate the

remains familiar.

timing design before the blast takes place. When using ViewShot™ the blast timing does not have to be uploaded

GeoShot™

manually which saves time. The user can apply the timing

GeoShot™ seismic electronic initiation system (under

design to the detonators right up to the point where it

development) is an electronic solution to our seismic

becomes necessary to blast. This means that last minute

customers who need highly accurate timing, quick

changes to the timing can be done without the need to re-visit

deployment, safe and robust detonator downline wires.

the detonators deployed in the blast area. The ViewShot™

GeoShot™ detonators are only able to communicate and

blast design software package allows blasting plans to be

be initiated by GeoShot™ control equipment due to the

designed and simulated on a computer that can be directly

electronic circuitry containing system- specific, coded,

downloaded into the control equipment. This enables the

encrypted signals which provide users with an additional

user to save substantial time during the blasting process.

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VIEWSHOT™, DELIVERING BEYOND EXPECTATIONS CASE STUDY

BUSINESS CHALLENGE ViewShot™ is primarily used to do blast delay designs. Due to the flexibility of the electronic initiating systems, it was inevitable that there would be a request from a customer who required us to stretch this particular software beyond its conventional operating limits. This particular customer is an open cast platinum operation situated in the North West province of South Africa.

The customer provided six perimeter hole coordinates that defined the perimeter of the blast area. The instruction was that a blast design had to be generated from the information provided in Figure 1.

Figure 1 - Blast perimeter co-ordinates

Figure 2 - Initial planned design

Drilled pattern including channel allocations for DigiShot™ Plus

Dual Diamond cut chevrons designed for the blast

Animated feature allowing for blast simulation

This request presented an interesting opportunity to explore the capabilities of the ViewShot™ design tools. The customer required control of the spill over material while minimising the backbreak on the High wall. The ruler tool found in ViewShot™ was used to measure the bench to determine the dimensions of the intended blast area. A staggered hole design was created for this blast using the customer’s design requirement.

Once the dimension of the blast was determined, it became a simple task of calculating the number of holes required based on the calculated burden and spacing measurement. The mine accepted and approved the design shown in Figure 2 allowing for the blast pattern to be drilled and completed 7 days later.

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Blasting News I Third Quarter 2016

CASE STUDY

CONTACT Ashlin Pillay Field Technician +27 11 606 0000 ashlin.pillay@ aelminingservices.com

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

A comparison of the designed and actual drilled patterns revealed that there were two rows of drilled holes missing. The perimeter holes were picked up by the survey department when the material in front of the new blast bench was not cleaned out. On completion of the loading process and subsequent inspection it was determined that there were two rows missing from the intended design as a result of excessive back break, thus allowing for additional material excavation from the previous blast. This did not delay the drilling process as bench preparations had commenced.

The charging was done over a three day period with no delays. The pre-split was shifted into the main bench by 1.5 m while the last line on the blast was squared off as per requirement by the mine. Due to missing holes and a ragged free face the customer decided to drill additional holes on the first row to ensure proper burden relief shown in the figure above.

The ViewShot™ programme enables the user to allocate the different channels of the Control Equipment which is represented by the different hole group colours on the design above. This technique assists in harnessing and possible fault diagnostics if required. It also assists the designer to ensure that the allocation of the number of holes and surface wire length falls within the system parameters. To reduce the spillage of material, two diamond cut chevrons were proposed to obtain the required results by confining the cast. In this particular blast the two chevrons also generated a secondary pulverisation of the material resulting in the uniformity of material distribution through the muckpile which improves digging and loading rates.

The blast delay design was optimised by the responsible AEL representative according to scientific calculations and their pre-knowledge of the ground behaviour and environmental conditions.

SOLUTION By implementing a thorough analysis of operations, AEL identified that precision blasting and the correct use of energy has the potential to reduce the full cycle of a dragline by one second by throwing the rock 1 m closer to its destination.

While these figures may appear nominal, operators know that if you multiply these efficiencies throughout the day and across several mines, even the slightest of improvements can optimise man hours and reduce costs significantly.

OUTCOME The AEL support team on site had highlighted the benefits of electronic initiation systems, blended emulsion and accurate blast design while also reducing the powder factor from previous designs of 1.1 to 0.9 for the AEL blast.

The customer expressed satisfaction regarding the blast fragmentation achieved while stating that there was an improved bucket fill factor as a result of the uniformity in material distribution on the muckpile which contributed positively to cleaning time and productivity.

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