Mining

Decomposed emulsion and water. (Image source: BME)

BME, a bulk mining explosive and blasting technology supplier, has found innovative solutions for an iron ore mine in South Africa that was struggling with a decline in blast performance

To support the customer, the Omnia company investigated a new mechanism for bulk emulsion breakdown. Publishing the results in the International Society for Explosives Engineers’ Journal of Explosives Engineering, experts from BME revealed an encounter with potential acidic sulphate soil (PASS) – sharing valuable insights for the mining sector globally. The article’s authors – BME global manager blasting science, Scott Scovira; BME general manager production & logistics, Dirk Voogt; and BME senior chemist, Quentin Steyl, noted that iron ore mines are not normally associated with reactive or acidic ground. Indeed, they conducted ground sample reactivity testing which confirmed that neither reactive ground nor acidic water was to blame.

What, then, caused the emulsion to break down; the same emulsion continued to be used by other customers around the country to normal effect? They conducted many tests, including the testing of a mixture of the straight gassed bulk emulsion plus mine blast hole water and blast cuttings – representing the total hold loading condition at the mine. These tests showed that this mixture created an environment in the blast hole leading to autocatalytic acid generation, with subsequent over-gassing and breaking down of the emulsion.

“A deeper investigation into the ground mineralisation revealed the presence of PASS, which is a new mechanism for bulk emulsion breakdown,” they noted. The condition was remarkably uncommon and was the first occasion that it had been observed in over 50 years of emulsion usage. Despite an extensive search of publicly available knowledge in this field, no-one had described PASS in the context of bulk emulsions. Research did reveal, however, that PASS can become an acid sulphate soil in the presence of a strong oxidizer.

“This conversion reaction results from the presence of reduced inorganic sulphur (RIS) in the soil,” they continued. “Actual acid sulphate soils (AASS) – soil materials that contain RIS – have undergone oxidation to produce acid; any pH drop indicates the soil’s potential to form sulphuric acid when it is disturbed and exposed to oxygen.”

In the absence of water, soil samples from the mine showed no reactivity with the straight gassed bulk emulsion. Some samples showed the potential to become reactive, and to start breaking up when a strong oxidiser was present. When a sodium nitrite-based gassing solution was used to sensitise the emulsion in contact with soil, a reaction began that impacted negatively on the emulsion matrix.

“To manage this challenge, we therefore investigated the difference between the effect of standard sodium nitrite and water solution, and an emulsified gassing agent (EGA),” they explained. “EGA is an emulsion which is incorporated more readily into the base emulsion – thus preventing contact between the gassing agent (a strong oxidiser) and the PASS.”

It was this homogenising of EGA into straight bulk emulsion which significantly inhibited PASS ground reactions with the emulsion – creating a product of very high viscosity which held its form. The resulting emulsion was found to reduce contact between the gassing agent and the PASS.

“These modifications to the bulk explosives system have provided a window of protection for the straight bulk emulsion against these site ground conditions,” they stated. “They have also enhanced resistance to product degradation by the action of dynamic water present at the mine site.”

Important performance improvements were achieved, with the increased dispersion of the gassing agent in the emulsion – as well as reduced bubble size in the gassing agent. Field measurements demonstrated that detonation velocity was increased – when compared to non-homogenised gassed bulk emulsion.

“As PASS has been only recently discovered as an emulsion decomposition mechanism, we expect there will be considerable learnings achieved in the future,” they concluded. “The focus will be on continuously improving the inhibition process against sulphate ground types – through chemical formulation and mechanical manipulation. We trust that our investigation and solutions will add valuable insights to blasting professionals and the global explosives engineering community.”

Recently, African Review sat down with experts from BME to learn how the company is incorporating ESG into its operations and product portfolio. Access the extended interview by clicking here.

With all the project’s core agreements requiring compliance with the highest ESG standards, Simandou also delivers a significant new source of high-grade iron ore that will strengthen the decarbonisation of the steel industry. (Image source: WFW)

Watson Farley & Williams (WFW) has announced that the US$15bn Simandou project, the largest greenfield integrated mine and infrastructure investment in Africa to date, has now completed, including the required Guinean and Chinese regulatory approvals

WFW, an international sector-focussed law firm, has been advising the Republic of Guinea through a multidisciplinary cross-border team. Whilst Simandou revolves around the exploitation of four world-class iron ore blocks in southern Guinea, the project goes beyond mining and includes the construction and operation of a 600+ km multi-use railway line connecting the blocks to a large, newly constructed state-of-the-art mineral port to export up to 120mn tonnes of iron internationally. This new rail and port infrastructure will act as a catalyst for transforming Guinea’s economic development, unlocking prosperity well beyond the Simandou corridor.

The closing was followed by the second anniversary celebration for Compagnie du Transguinéen (CTG), the joint venture consortium that will own and manage the Simandou rail and port infrastructure and is comprised of Guinea, Baowu Group, Simfer Jersey, and WCS. The signing of the first locomotive order to service the project was also celebrated.

“The strength and depth of our experience in our core sectors and ability to work seamlessly and collaboratively across our international network meant we were able to provide Guinea a truly global legal team to help it complete this historic project which represents a new era for the development of the African mining sector,” commented Alhassane Barry, Dubai projects partner, and London corporate partner and global mining & commodities sector co-head Jan Mellmann.

The KalPRO TireSight autonomous inspection station in action. (Image source: Kal Tire)

Autonomous tire inspections provided through KalPRO TireSight can bring numerous advantages to mining operations

A mining vehicle is only as effective as the wheels beneath it. Undetected tire faults can lead to critical failures and these, in turn, can lead to costly downtime or serious accidents that pose a threat to personnel safety. Effective tire inspections, therefore, are a vital component of any mine, serving to detect developing problems, extend vehicle tyre life and, ultimately, ensure effective operations are maintained.

It is no wonder then that leading tire management and supply partner, Kal Tire Mining Tire Group, has sought to maximise and refine this process – a pursuit that has led to the conception, design and now delivery of KalPRO TireSight. This autonomous tire inspection service integrates the thermal imaging camera and AI software of Pitcrew AI with Kal Tire’s TOMS (Tire & Operations Management System) in order to accelerate inspections and enhance vehicle productivity.

The solution from Kal Tire and Pitcrew AI takes the form of a thermal imaging camera station that is typically deployed next to a haul road or fuel bullet. Machinery operating on site passes the station (without halting), enabling images of the front and rear tires to be captured and assessed by Pitcrew AI software. Optimal images of the tires (from a higher position), the fact they are assessed in motion and not static (enabling numerous angles to be captured during rotation), and the use of advanced AI means that often unnoticed issues such as hot tires, tread damage and belt separation are more likely to be detected. Moreover, with work orders automated by TOMS and validated by condition monitoring experts, fleet planning teams can quickly make decisions to reduce risk and downtime.

Click here to read the full article – including the thoughts of Christian Erdelyi, manager mining technology solutions at Kal Tire – in the latest issue of African Review available now.

This solution offers a secure, stable, and high-performance primary connectivity network, crucial for engineering private networks or leveraging cloud-based applications. (Image source: Avanti Communications)

Avanti Communications, a leading multi-orbit provider of fully integrated connectivity services, has highlighted the crucial role satellite technology will play in the forthcoming digitalisation of Africa’s mining sector

The mining industry offers great promise for African nations in the years ahead having already underpinned the economies of many countries for a number of decades. Now, the critical mineral demand boom is enhancing global interest and offering the continent the chance to claim a leading position in the forthcoming energy transition.

In order to grasp this unprecedented opportunity, the sector must keep up with the modern technologies which offer the opportunity to maximise production and efficiency. According to Avanti, digitalisation will be a key facilitator of such innovative solutions and, going further, the use of satellite technology is therefore vital.

Mine Always On

It is with this understanding that Avanti has introduced its ‘Mine Always On’ solution, designed to ensure constant, undisrupted connectivity tailored to the unique demands of the mining industry. It brings about operational efficiencies and provides sustainable, reliable connectivity in remote mining locales.

Gamze Aydin, senior vice president sales and South Africa country manager at Avanti, commented, “Successfully charting this complex terrain heralds a new era of enhanced return on investment, operational efficiency, and sustainable practices in mining.”

Technologies such as this latest introduction by Avanti facilitate real-time communication and data exchange, vital for everything from enhancing safety to ensuring regulatory compliance. Moreover, the company has illustrated how the solution exemplifies its commitment to bolstering the mining sector’s digital transformation journey, focusing on cyber resilience and progress towards Net Zero goals.

“Satellite technology is an undisputed lifeline for mining,” said Aydin. “It will define new standards for improving efficiency, boosting safety, and addressing environmental compliance. It’s a transformative force, bringing vital technological advancements to legacy systems when it’s needed most.”