Manufacturer of packaged explo- sives African Explosives Limited (AEL) Zambia reports that, since the completion of the construction of its bulk emulsions manufacturing plant, production levels have ramped up significantly.

The plant, based at international mining company Equinox Mineral’s Lumwana copper mine, in Zambia, has reached 50% of planned capacity and should meet planned output well before year-end, says AEL Zambia MD Thinus Bierman.

The commissioning of the mine took place in April and was attended by Zambia’s President Rupiah Banda, local dignitaries, the board of Equinox Minerals, government officials and employees of Lumwana and the AEL group, as well as subcontractors.

Bierman says: “The commissioning of the mine officially heralded the start of the largest single investment in Zambia and the largest copper mine in Africa. The contract with Lumwana also fits in well with the company’s long-term objectives. The company aims to further establish AEL’s position as the market leader in Zambia, Central Africa and Africa.”

Having an additional large manufacturing facility in the country reduces supply risk to its overall customer base and the increased volume output assists in maintaining the cost base. He explains: “As a supplier of blast- ing solutions, our future is tightly linked to the mining industry. Having a broader supply base makes AEL less vulnerable.”

AEL Zambia, a member of the inter- national AEL Mining Services group, has been involved in discussions with Lumwana copper mine since early 2005 and completed the construction and commissioning of the bulk emulsions manufacturing plant, in January 2009. All bulk explosives supplied to Lumwana copper mine, since the end of January 2009, have been manufactured at the facility.

The company was granted a ten-year agreement for explosives services and supply. Bierman says that AEL made a capital investment on the customer’s site by establishing a manufacturing, storage and supply facility that it will have sufficient capacity to supply Lumwana’s current and future explosives requirements.

The bulk explosives demand is forecast to peak at about 3 000 t/m, as the mine ramps up to full production.
It has also commissioned mobile manu- facturing units to provide on-bench explosives supply. Mining and explosives engineers provide blasting advice and the service is further supported by the main product manufacturing and assembly facility close to Mufulira.

The bulk emulsions plant at Lumwana is a modular plant, manufactured by AEL South Africa and assembled on site. The facility also provides an alternative production and buffer stock facility in Zambia, assisting in managing risk-of- supply concerns.

“The company’s emulsions plant at the mine is an example of how the AEL group can provide a world-class facility with a full range of customised products and services at strategic sites in remote locations around the world,” says Bierman.

He says that the company experienced the normal start-up problems with the logistics supply chain of raw materials mainly from South Africa. “AEL and AEL Zambia, however, have extensive experience in setting up and starting up new operations and this kept challenges to a minimum,” he adds.

The company has also employed the majority of its staff from the Lumwana area and, together with skilled and experienced personnel from the facility at Mufulira, ensured maximum skills transfer in a short period.

AEL Zambia has taken delivery of the first two of the three of the new-gene- ration AEL 20T mobile manufacturing units, for Lumwana mine, which are used to deliver bulk explosives directly into the blast holes at the mine.
Meanwhile, the opening of the mine completed a process that started, for Equinox Minerals, over 13 years ago and included a diverse range of disciplines, such as exploration, feasibility studies, raising of finance, planning, construction and commissioning.

At the opening ceremony, Banda praised Equinox Minerals for the perseverance and commitment shown to the Lumwana project, despite the current economic climate.
“AEL Zambia was chosen for its ability to meet high production requirements for the Lumwana project, as well as being able to provide a modern bulk emulsions plant and accessory storage facility, specifically based at the Lumwana mine,” says Lumwana mine manager Jon Yelland.
He adds that AEL’s competitive cost structure and experienced and professional management team were important criteria in the selection process. These factors, as well as AEL’s previous record in operations within Africa and the support and operation team at Mufulira and at Modderfontein, in South Africa, were the reasons that AEL Zambia was selected to be part of the Lumwana project moving into the future.
The Lumwana project’s increased- efficiency development plan is based on processing 20-million tons a year of ore to produce copper concentrate for ship- ment to local smelters. Life-of-mine is estimated at 37 years and production will average at 156 000 t/y of copper metal, with over 172 000 t/y being produced during the initial six-year period.
The mining group is exploring a number of options for expansion. One of these is increased throughput of the current process plant and this could increase demand for further bulk explosives.