EXPLOSIVES & BLASTING downstream ,” Averett says . This is because secondary blasting and secondary treatment at the crusher are expensive .
The data from the Sandvik smart drill then goes through a rock hardness algorithm in the ΔE Preload application . An engineer or blaster can process this data in the back office , and it can be managed live if a pattern is still being drilled . It can also be turned into an automated process . The information is then sent to DynoLogix bulk truck loading system . The blaster and operator still have complete control in the field to make changes if needed . This allows direct communication between shot planning and hole loading .
“ The trucks have the ability to automatically retract the hose at the correct rate as the hole is being loaded ,” Averett says . “ This is another piece of the automation and ensures the energy is in the correct place in the borehole .”
There is now an electronic link rather than a manual link to what an operation is trying to do . “ That drives some really big benefits ,” Averett says . “ You have a higher level of confidence that what you asked to be loaded in your pattern is what actually happened . Or , if it ’ s different , you have a very good picture of what happened and why it ’ s different , and you can tie that back to the results .”
Operations can bring that data back into the preload plan to get visuals of what is happening , how well an operator hit its hole depths , what holes were loaded versus drilled , how well it did on weight , and more . The ΔE2 loading control shows all the different zones . This allows optimisation of the loading of that borehole based on what the data is telling an operator to do . They receive geologic information from the drill to allow a tighter fragmentation profile . Variable density holes can be custom loaded to also optimise fragmentation .
Averett concludes : “ If all these technologies are tied together , an operation can get a much better result on the bench , which drives downstream savings . The sum is greater than the whole of the parts .”
friendly emulsion , with one plant in operating in Norway and three more underway .
HPE has already shown it can achieve the same results from a productivity standpoint as the traditional AN solution , and Gustavsson is hoping to also prove out its economic competitiveness .
“ We have carried out quantification of cost in some instances , however , it is challenging to conduct a proper analysis since operations are still contaminated with AN residues ,” he said . “ Objective cost savings can be evaluated based on compartmentalised data , particularly in terms of savings in capital expenditure investments for nitrate cleaning plants and ventilation requirements .
“ Carbon intensity is relatively straightforward as environmental data from AN and HPE production is readily available , indicating up to a 90 % reduction in CO 2 emissions in regard to the oxidiser phase . This is a substantial saving , which aligns with the emission reduction roadmaps of the majority of mining houses .
“ In regard to cost of the product , as the supply volume for HPE increases , costs are likely to decrease and be comparable to AN emulsion , but this could take some time . Currently , due to smaller volumes , the cost is slightly higher , but it is expected that these costs will be significantly offset by savings in mitigation for nitrate , NOx and ammonia handling .”
Going lead-free
Speaking of removing contaminants from the blasting process , Austin Powder says it has developed lead-free primary explosive detonators for its clients that come ahead of regulators mandating the use of such an alternative .
The company started looking for a lead-free alternative to lead azide all the way back in 2007 at its detonator facility , Austin Star Detonator . The initial work was started by Morris Bannerman and Göran Jidestig .
“ Developing , testing and producing a new primary explosive is the biggest nightmare for any explosive / detonator maker ,” Jan Jidestig , Director of R & D and QC , said . “ It is a project that has taken us nearly 15 years . The new substance was designed by experienced chemists who worked collaboratively with the engineers to
Austin Powder says it has developed lead-free primary explosive detonators for its clients that come ahead of regulators mandating the use of such an alternative
design the production process . “ We couldn ’ t rush the process , and we had some dead ends and had to significantly change the product design , and even parts of the entire manufacturing process . But we did it .”
By 2016 , a pilot-scale reactor was designed , which could produce small-scale batches . This was then used to develop the method and to produce enough powder to perform a qualification test .
The first field test was carried out in 2018 with 8,500 detonators for Philipsburg in Pennsylvania , USA .
The first full-scale reaction was completed on April 5 , 2019 , with production of the new component starting in late 2020 , with over 93,000 detonators shipped to the field for trials .
In 2022 , a total of 2.6 million detonators were shipped and used throughout Mexico and USA . To date , the company has shipped over 6 million caps with lead-free primary detonators .
Jidestig added : “ The lead-free primary detonators have met all our specifications during testing and in production ; it ’ s pretty much a drop in replacement for lead azide .”
Otta Greben , Global Director of Detonator Products for Austin Powder , concluded : “ There is a rule for any explosive makers – don ’ t change it if it works . But the world is changing , and our approach to safety and health within our production is changing . Here we have internal and external contributors to drive the change . We also have requirements from regulators ( you must ) and our own decision to improve production hygiene and safety ( you should ). However , we proactively made the decision to develop lead-free detonators way in advance .”
IM
AUGUST 2023 | International Mining 59