EXPLOSIVES & BLASTING originated from.
“ The project has been ongoing for five years and will continue into its next phase,” he concluded.
Novel NOx removal
Hypex Bio is looking to remove NOx formation altogether with its products in what represents one of the most significant commercial blasting advancements since Alfred Nobel’ s invention of dynamite over 150 years ago.
The company launched its nitrate-free emulsion technology – a hydrogen peroxide explosive( HPE) solution for surface or underground blasting – into the mining market in 2021, saying that the solution solved a long-standing problem in the explosives space: the development of a nitrate-free emulsion explosive without NOx, nitrate leaching and crystallisation issues that matched the performance of standard nitrate-based explosives.
The product can be custom made to exhibit a wide range of viscosities and comes with or without a sticky texture, facilitating use in various applications. The emulsion is waterproof and can be used in wet applications and underwater, according to the company.
Hypex Bio’ s trialling shows that, in some cases, HPE technology can achieve the same results as the comparable
ammonium nitrate( AN) technology in terms of fragmentation, pull and wall control while reducing explosives use by up to 20 %.
In the last year, the company has made significant commercial strides with this product.
One of the notable advances is the opening of Sweden’ s first facility for manufacturing nitrate-free, climate-friendly explosives at the Kankberg mine, owned by Boliden.
This facility is proof that Hypex Bio’ s plant design is robust with industrial supply capabilities, the company says.
Thomas Gustavsson, CEO of Hypex Bio, said the company is currently engaged in dialogue with multiple regulatory entities across the globe as they work toward a shared consensus on a testing framework for its HPE solution. He explained:“ Our technology is so novel and distinct from the current standards that it’ s likely the discussion will ultimately need to be addressed at the UN level. In the meantime, we are collaborating with local authorities to ensure alignment with national regulations.”
He also said developments at the Garpenberg mine, also owned by Boliden, where the company has a much smaller HPE plant, were progressing well, with work having recently accelerated significantly. He added:“ We are now in a sensitive phase of the project, which limits the amount of detail
One of Hypex Bio’ s most recent notable advances is the opening of Sweden’ s first facility for manufacturing nitratefree, climate-friendly explosives at the Kankberg mine, owned by Boliden
I can share. However, we expect to have new technology available some time next year.”
This new technology, IM understands, could represent potential new applications outside of its existing underground mining methods. In addition, Hypex Bio has entered into a strategic collaboration with BME to establish a new HPE plant at BME’ s Nairn site. This facility will serve as a key production hub for the North American market, with commissioning targeted for the March quarter of 2026.
AECI innovations deliver safer, more sustainable mining at KPC
AECI Mining Explosives recently showcased the results of its revolutionary low ammonium nitrate( AN) emulsion technology and sustainable blasting innovations at Indonesia’ s largest coal mining operation during the IBES Annual Conference 2025. This milestone forms part of AECI’ s long-standing partnership with PT Kaltim Prima Coal( KPC), where the company has significantly enhanced blasting safety, efficiency and environmental sustainability, it says.
With over a decade of collaboration, KPC has served as a collaborative partner and proving ground for some of AECI’ s most significant breakthroughs in emulsion explosives. Central to these innovations is the development of a low-AN emulsion formulation, which reduces the AN content in the explosive matrix from over 70 % to between 66 % and 68 %. This advancement not only helps mitigate exposure to global AN price volatility but also significantly lowers the environmental footprint associated with explosive use through reduced greenhouse gas emissions and nitrate leaching risks.
Duncan Etwell, Vice President of Asia-Pacific at AECI, said:“ Optimising our formulations to lower AN content is part of our commitment to helping mines reduce costs without sacrificing safety or performance. This project at KPC demonstrates our ability to deliver tailored solutions based on customer needs and operating environments.”
Field trials at KPC confirmed that the reduced-AN emulsion
AECI’ s Eco emulsion formula supplied at KPC delivered comparable fragmentation, digging times and overall blast results to conventional formulations, the company says. Critically, the formulation enables more precise control of explosive energy output, aligning the energy release with specific blasting objectives. This targeted energy delivery not only optimises rock breakage efficiency but also reduces unnecessary energy input, supporting more sustainable blasting practices. Achieving this required precise rebalancing of the water phase and sensitiser mix, enabled by AECI’ s advanced polymeric emulsifier technology, to maintain both emulsion stability and energy output.
Another innovation from AECI’ s Indonesia operations is the integration of used oil into emulsion manufacturing. By replacing a portion of virgin fuel with waste oil, KPC has been able to reduce its environmental footprint while contributing to a circular economy. This initiative, now incorporated into AECI’ s global Eco range of emulsion products, safely uses recycled hydrocarbons without compromising explosive performance.
Etwell said:“ Our Eco emulsion technology enables customers to transform waste into value. By safely
incorporating used oil into our formulations, we help mines lower costs, reduce waste disposal issues and achieve their sustainability targets.”
AECI says its innovative, technically collaborative approach positions the company at the forefront of sustainable blasting solutions for the global mining sector.“ The successful trials at KPC underscore AECI’ s broader strategy of delivering responsible mining technologies worldwide, blending technical excellence with environmental stewardship,” it concluded.
International Mining | AUGUST 2025 47