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Underground bulk system enhances safety in mining

5th April 2013

By: Zandile Mavuso

Creamer Media Senior Deputy Editor: Features

  

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In its efforts to improve safety, commercial explosives manufacturer AEL Mining Services reports that it is at the full imple- mentation stage of its underground bulk systems (UBSes) developed specifically for the challenging deep-level gold mining sector.

AEL’s underground bulk system for narrow reef mining comprises three components, namely the bagged emulsions, a sensitising agent and a pumping mechanism.

“The current conversion at mines [involves] three days of a week [being] dedicated to the transportation of explosives to the face. However, with AEL’s newly developed UBS, time is saved by not having to close the shaft for explosives transportation, as this product is not classed as an explosive in transport mode, so more work can be done, which increases productivity,” AEL gold and uranium MD Johan Duvenhage says.

He adds that illegal mineworkers, especially in the Free State, pose a challenge for the com- pany, given the increased pilferage of explosives from the mines. “With the UBS, this cannot happen, given that the in-line mixer and gassing solution is controlled on surface and the product only becomes an explosive once it is mixed through the lance at the stope face underground,” explains Duvenhage.

Further, mines currently use extensive manual labour to transport explosives into areas where the product will be used, but with AEL’s UBS, mechanical transport into the workings can be used.

A further advantage of the system is that it reduces risk by minimising the exposure time of blasting crews during charging time by as much as 40%. In that way, AEL’s new system further enhances the safety aspects of the system used by the mine.

Portable Charging Unit
“We launched the portable charging unit (PCU) 010 pneumatic stope pump, which is a pumping mechanism that introduces an explosives-free mining environment, at the 2012 Electra Mining Africa expo. The pump converts chemicals into explosives at the blast site, eliminating the risk of transporting explosives down mine shafts, which, in turn, improves safety and mining logistics. Over time, it will also yield costs savings, which is a significant development for gold mining,” Duvenhage explains.

“[For the operation of the unit], the emulsion matrix and sensitiser produced by AEL are loaded into separate tanks in the pump, after which they are combined in the pumping action to form a sensitised explosive product. A static mixer at the end of the charging hose and lance ensures that the final product is well mixed, which produces an explosive of consistent quality to improve blast performance,” explains AEL underground bulk systems product manager Mark Cross.

“The PCU010 also has a built-in bursting disc as an additional safety feature to protect the emulsion matrix from overpressurisation. It has fewer working parts, compared with other products in the market, resulting in minimal spares being required and substantially reduced lead time for manufacturing and maintenance,” adds Cross.

He mentions that the PCU010 weighs just over 30 kg, is 1 054 mm long, 521 mm wide and 388 mm high, with a flow rate of 20 kg/min. The emulsion tank has a capacity of 15 kg and the sensitiser tank has a capacity of 2 kg. The unit includes a 5 m hose and a static mixer is available in various lengths. These dimensions make the AEL pump compact, easy-to-use and suit- able for small spaces in the narrow reef environment.


The company launched the Vivid range of Uni-Delay long-period shock-tube assemblies last year, which significantly improves the ability to identify potential cutoffs or misfires in the stope panel and muck pile given its bright colour.

AEL also has a specialised team of skilled and trained indi- viduals who assist mines with production challenges underground. This team assists in training mine personnel, ensuring safe, high-quality daily blasts by employing back-to-basics principles as well as the correct use and implementation of explosive products. “If we can get one worker to work ten times better, efficiency has increased by 10%. This is an initiative that we offer to all the mines with which we work,” says Duvenhage.

“AEL Mining Services believes in partnering with its customers to unearth wealth. Although the gold mining industry has been in decline for a number of years now, AEL’s commitment to this sector remains firm and we will continue to collaborate with stakeholders to provide mining solutions that deliver value,” concludes Duvenhage.

Edited by Megan van Wyngaardt
Creamer Media Contributing Editor Online

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