SURFACE BULK EXPLOSIVES

Marketing Pack
2016 Version 1
Page 2 Surface Bulk Explosives I 2016
Surface Bulk Emulsions

AEL Mining Services Sales Offices

CONTENTS
Glossary of Abbreviations

Introduction

Bulk emulsions

Emulsion Offerings

Technical Properties

Compatibility Matrix

Product Comparison

Product Delivery

Product Testing & classification

Pioneering Achievements

Surface Bulk Explosives I 2016 Page 3

 AEL’s Surface Bulk Explosives range is of the best researched and developed formulations currently
in the market. All ranges of products have been optimised and developed to provide a fit-for-purpose
solution to surface mining blasting applications.

The use of recycled/used oil in the formulations has delivered an environmentally friendly range
of products whereby the stability and performance is not compromised, hence providing a unique
offering to our mining partners.

AEL’s highly skilled team, its vast range of products, equipment and technical resources have made
the company an acknowledged leader in the mining industry. In order to reliably and efficiently supply
its customers. AEL has strategically located sales offices, manufacturing sites and storage facilities
(both permanent and mobile) globally to ensure effective customer support.
AEL provides a full range of explosives and services to all our customers in both the African and
international markets. This includes a wide selection of specifically formulated emulsions to meet
site-specific requirements.

The AEL range of pumpable surface bulk emulsions offers cost efficient, flexible solutions ranging
from high energy, hot-hole, reactive ground to fume resistant variations. Within each variant family, a

SURFACE BULK water-resistant doped to heavy blended emulsion can be produced. These products provide scalable
energy levels to suit a variety of applications.

EXPLOSIVES
AEL offers a range of delivery options with a fleet of purpose-engineered vehicles to match its
customers’ specific bulk emulsion needs. AEL’s continuously expanding bulk emulsion technology,
demonstrates the company’s on-going commitment to research and development. These
developments continually adds to the convenience and flexibility of our products. AEL also backs up
these developments with on-site customer service.

Page 4 Surface Bulk Explosives I 2016

GLOSSARY OF ABBREVIATIONS MMN – mixed metal nitrates (such as calcium or sodium)

MMU – mobile manufacturing unit

AN – ammonium nitrate
RRS - rapid reloading system
ANA – ammonium nitrate prill, Anfo grade
RBS - relative bulk strength (% relative to Anfo, indexed to 100)
Anfo – ammonium nitrate fuel oil
RWS - relative weight strength (% relative to Anfo, indexed to 100)
CBEP – central bulk emulsion plant
S - surface
CN – calcium nitrate
SB – surface bulk (emulsion)
cP - centi Poise (a measure of viscosity)
SC - surface coal formulation
Eco – formulation of emulsion containing waste oil
SH - surface hot hole formulation
Hot holes – blast holes at temperatures above 40°C
SP - surface premium formulation for hard rock mining
IDE - ideal delivered energy
VOD – velocity of detonation (measured in meters per second)
MJ – Mega Joule (measure of explosives energy)

CONTACTS
Southern Africa - East London (T) +27 43 745 2169 Gauteng Quarry Services +27 11 606 3523 Johannesburg (T) +27 11 606 0000 Kimberley (T) +27 53 802 6352
Klerksdorp (T) +27 18 477 1062 Kuruman (T) +27 53 712 3035/2958 Kwa-Zulu Natal (T) +27 31 266 4303 Mankwe (T) +27 14 558 2800 Mokopane (T) +27 15 491 1373
Mogalakwena (T) +27 15 418 2189 Nelspruit (T) +27 13 747 2278 Northern Province +27 15 491 1328 O’Kiep (T) +27 27 713 8597 Rustenburg Bushveld (T) +27 14 594
9300 Steelpoort (T) +27 13 230 8020 Venetia Mine (T) +27 15 575 2335 Welkom (T) +27 57 217 1252 West Wits Sales (T) +27 18 788 3390 Witbank / Emalahleni (T)
+27 13 690 1242 Africa - Botswana +267 393 8133 DRC +243 995 366 257 Egypt +20 178 661 138 Ghana +233 302 762 633 Namibia +264 6440 3463 Tanzania +255
28250 2927 Zambia +260 966 90 945/9 Zimbabwe +263 429 16 315 International - Australia +61 459907745 Chile +56 2928 1300 Europe +27 82 553 9080 Indonesia
+62 21 7592 4498
Surface Bulk Explosives I 2016 Page 5
 AEL's Surface Bulk Explosives are
one of the best researched and
developed formulations currently
in the market. The Eco range of
products has been developed
to optimise blasting in surface
mining. Coupled with the use of
recycled oil in the formulation
has provided an environmentally
friendly range of products that
provide a unique offering.

With a solution to suit almost

every application – including
surface, massive operations and
quarries, AEL's highly skilled

INTRODUCTION
team, its vast range of products
and solutions, equipment and
technical resources have made the
company an acknowledged leader
by providing sector solutions in
South Africa, African regions and
the International business.
Introduction to Emulsion
An emulsion is a mixture, in which two immiscible substances like oil and water,
stay mixed together thanks to a third substance called an emulsifier. Emulsions are
formed by the emulsification of an oxidizer with a fuel phase. The oxidizer solution Safety Benefits
normally contains ammonium nitrate with a concentration greater than 80% by weight. AEL’s range of surface bulk emulsion is developed in a safe, non-explosive form and is
Sometimes other metal nitrate salts e.g. sodium, calcium and magnesium can also be only sensitised upon loading into the blast holes.
included in the oxidizer. Most emulsions will always have between 10% and 15% water
in the oxidizer solution. The fuel phase consists of a mineral oil and usually, a PIBSA- Storage
based surfactant. These emulsions are manufactured at temperature between 75°C AEL guarantees unsensitised emulsion in storage silos for a period of one month.
and 85°C and then allowed to cool before being used. Good shelf life can be expected if specific storage conditions are met.

For customers using the AEL surface bulk emulsions there are various benefits from a
safety perspective as well as being able to adopt a more “green” approach by including
used oils thanks to the use of a specifically formulated surfactant. Our emulsions are
formulated to be fit-for-purpose depending on storage requirements and application
needs.
Applications
Our surface bulk emulsions can be used across a wide variety of applications,
including quarrying, trenching, civils, mining, forestry and pre-splits and cater for all
geological conditions from softs to hard-rock mining.

Page 6 Surface Bulk Explosives I 2016

Features
• Water resistant
• Flexible solutions with scalable energies
• Use of recycled oil in our environmentally-friendly Eco range of emulsions
• Cost-efficient delivery in bulk
• Security – non-explosive transport of emulsions
• Emulsion manufactured on site or delivered via a reliable logistics network
• Suitable for holes ranging from 75mm to 300mm in diameter
Benefits
• Scalable energy – optimisation of blast performance partitioning, as well as
clearing (hauling) and downstream processing requirements
• On-site storage options – reduced turnaround time, transport costs and improved
blasting efficiency
• On-site manufacturing with the installation of AEL modular plants for heavy duty,
continuous operations
• Tried and tested logistics to ensure explosives delivery down the hole
• Wide variety of applications to suit specific needs from tunneling, civil works,
trenching, quarrying and pre-splits (fissures in rock) for all geological conditions
from softs to hard-rock mining
• Widest range of services available including down-the-hole (DTH), prime- loadtie-
and-shoot (PLTS) and rock-on-ground (ROG)
• Access to AEL’s wealth of expertise and knowledge gleaned over more than
100 years – from research and development, manufacturing, sales and mining
optimisation to full on-site partnerships
• Ability to take used oil at the customer sites for recycling and further use in
emulsion explosives
Surface Bulk Explosives I 2016
Currently AEL has three product ranges of emulsions in regular and eco variations:
• SB100 – virgin oil and AN-only emulsion, and SB100 Eco – Used/Recycled oil & AN
only
• S200 – virgin oil and AN/CN emulsion, and S200 Eco – Used/Recycled oil & AN/CN
• SB300 – virgin oil and AN/Urea emulsion, and SB300 Eco – Used/Recycled oil &
AN only
These emulsions can be pumped down the hole in one of three ways:
• Pure Emulsion – Pure emulsion is sensitised, charged and blasted
• Doped Emulsion – Emulsion is mixed with ammonium nitrate prill (ANA), then
sensitized and blasted
• Blended Emulsion – A mixture of Emulsion and Anfo. The Anfo which contains the
fuel oil sensitizes the emulsion during the charging process.
AEL has collaborated with a supplier to develop a surfactant which allows for a greater
used oil content to be incorporated in the fuel phase of the emulsions. One of the
benefits of eco emulsions is that the eco products gas more efficiently (smaller gas
bubbles) and therefore have better detonation properties and higher energy levels.
The shelf-life of all these base emulsions is 12 weeks from the date of manufacture,
including the time spent in storage silos. Furthermore, it is important to abide by the
legal storage requirements for the region. Sleep time should not exceed 3 weeks in
blast holes after sensitising.
Our emulsions need to be initiated with Pentolite primers that are suitable for the
respective hole diameter (see compatibility matrix). The use of detonating cord and/or
packaged explosives as primers is not recommended, except in consultation with the
AEL Mining Optimisation team.
AEL Surface Blends use Anfo to achieve an optimal oxygen-balance in the emulsion
for efficient delivery of heave energy during blasting. VODs vary based on the nature of
the blend used in the hole as well as the blast hole diameter.
Page 7
Emulsion offerings

AEL’s base emulsions are non-detonable, with the virgin oil emulsions
having a honey coloured appearance and the Eco emulsions being grey
or black in colour. Base emulsions (S100, S200, S300) are handled and Surface Bulk Emulsions
transported as an un-sensitised product to mines and/or operational
sites.
Virgin Oil or Eco (used oil) Variations
The product is charged into the blast holes when sensitised (with or
without ANA) or when blended with Anfo. The product’s water resistance
S100 / S100 Eco S200 / S200 Eco S300 / S300 Eco
is excellent, depending on the emulsion to Anfo ratio. The minimum
initiator required to reliably detonate the sensitised emulsion is a 150g Premium
Pentolite Primer. The typical in-hole density of AEL’s emulsion is 1.25g/ SP200 / SP200 Eco
cm³, but density varies with depth. Please contact your regional sales Hot Holes
office for finding the best product suited for your application. SH200 / SH200 Eco

Coal
The diagram to the right shows the various product options available
SC200 / SC200 Eco
to the market. The table on the technical properties gives a general
technical overview of the three main product ranges, as base emulsions. Reactive ground
S300 / S300 Eco

DOPED (mixed with ANA and sensitised) or BLEND (sensitised with Anfo)

DOPED BLEND
20%, 30% or 53% TAN 54%, 57%, 60%, 64% or 74% ANFO
Minimum hole diameter: 75-100mm Minimum hole diameter: 150-250mm
Water resistance is good @ 54%
Water resistance is poor @ 57%, 60%, 64% and 74%

Page 8 Surface Bulk Explosives I 2016

AEL supplies a world-class ammonium nitrate prill with excellent friability characteristics.

The surface bulk range, used in conjunction with our electronic delay initiating systems, can optimise the
mine’s loading, hauling and capital efficiencies by:

• Improving digging rates

• Reducing swing time on draglines
• Reducing bucket wear
• Reducing energy and diesel consumption
• Allowing for pro-active maintenance
• Improving truck fill factors
• Reducing tyre wear
• Influencing queuing time
• Increasing overall equipment efficiency
• Ultimately increasing the return on capital employed

Surface Bulk Explosives I 2016 Page 9

Technical Properties
PRODUCT NAME S100/S100ECO SH200ECO SC200ECO SP200ECO S300/S300ECO
Product Characteristic Ammonium Nitrate (AN) only Ammonium nitrate (AN)/calcium nitrate (CN) Emulsions Ammonium Nitrate/ Urea
emulsion Emulsion
Application Surface Mining – Open cast, Surface Mining – Open Surface Mining – Open cast Surface Mining – Open Pit Surface Mining – Open cast,
quarrying, open pit cast coal mining (hot hole coal mining and, quarries (Hard rock) reactive ground
conditions)
Density Base emulsion:1.30-1.34 Base emulsion:1.30-1.35
Sensitised emulsion:1.00-1.25 Sensitised emulsion:1.00-1.25
Ideal Delivered Energy 2.228 1.947 2.021 1.850 2.183
(MJ/kg at 100MPa)1
Relative Weight Strength 98 86 89 85 97
(% Anfo at 100MPa)1
Relative Bulk Strength 154 129 140 135 151
(% Anfo at 100MPa)1
Sleep time 3 weeks Not recommended due to 3 weeks 3 weeks Not recommended due to
safety requirements safety requirements
Viscosity 18000-22000cp at 60oC
VOD 3500-6000m/s 500-6000m/s 3500-6000m/s 3500-6000m/s 3500-6000m/s
Re-Pumpability 6 stages
Transport type Bulk – tankers. Rapid re-loaders and mobile manufacturing units

Note:
¹ The Relative Weight & Bulk Strengths are relative to ANFO (=100) at a density of 0,80 g/cm3. The figures have been determined using the VIXEN-I detonation code. For further information, please contact your local AEL
Mining Services office.

Compatibility Matrix - Surface Bulk Products

ACCEPTOR S100/ECO RANGE S200 ECO RANGE S300 RANGE
Diameter
140-215

250-311

140-215

250-311

140-215

250-311
76-127

76-127

76-127

Donors
150g Pentolite Primer • • •
250g Pentolite Primer • • •
400g Pentolite Primer • • • • • •

Page 10 Surface Bulk Explosives I 2016

Product Comparison
Product Application Density g/cm3 RBS (20MPa) RBS (100MPa) VOD (m/s) Operating Maximum Hole Minimum hole
Temperature depth diameter
S100 Eco Surface-Quarrying(softer rock) 1.25 133 154 3500-6000 Thermal 40m 75mm
S120 Eco Surface-Coal, open pit (harder rock) 20%TAN 146 167 stability to 80oC 100mm
S135 Eco Surface-Coal, open pit (hard rock) 35%TAN 156 178 100mm
SC200 Eco Surface-coal 1.25 121 140 3500-6000 Thermal 40m 75mm
SC220 Eco Surface-Coal, (harder rock) 20%TAN 136 155 stability to 80oC 75mm
SC235 Eco Surface-Coal, (hard rock) 35%TAN 148 169 100mm
SH200 Eco Surface-coal hot holes 1.25 114 129 3500-6000 Thermal 40m 75mm
SH220 Eco Surface-coal hot holes (harder rock) 128 144 stability to 75mm
20%ANA 280oC up to 8
hours
SH235 Eco Surface-coal hot holes (hard rock) 35%TAN 139 157 100mm
SP200 Eco Surface –quarrying, open pit 1.25 120 135 3500-6000 Thermal 40m 75mm
SP220 Eco Surface-quarrying, open pit (harder rock) 135 147 stability to 80oC 75mm
20%TAN
SP235 Eco Surface-quarrying, open pit (harder rock) 145 160 100mm
35%TAN
S300 Eco Surface-reactive ground 1.25 130 151 3500-6000 Thermal 40m 75mm
S335 Eco Surface-reactive ground (harder rock) 153 176 stability to 80oC 100mm
20%TAN
S350 Eco Surface-reactive ground (hard rock) 35%TAN 160 182 100mm

Note:
These operating temperature ranges are only for the emulsion and do not cover detonator and booster functionality

Surface Bulk Explosives I 2016 Page 11

Product Delivery

Product Delivery
In order for AEL to supply our customers with surface bulk emulsion, we have
developed a quality engineered delivery system comprising of manufacturing
plants, tankers and rapid re-loaders as well as state-of-the-art MMUs.

On-bench
The actual explosives are only manufactured on-bench by means of mobile
manufacturing units (MMUs). AEL’s 20 ton capacity MMUs translate to better
Rapid Reloader
utilisation of equipment due to not having to refill as often as the older generation
MMUs. These 20 ton MMUs also have superior pumping rates, which means more
holes can be charged with less equipment. MMU utilisation on the bench is further
optimised by AEL’s rapid re-loader system (RRS).

With the rapid re-loader, the MMU can be refilled on the bench and does not have
to waste time travelling to the silos to get refilled. The benefit to the customer
is that there is a greater utilisation of the MMU dedicated for a blast, resulting
Rapid Reloader
in being able to blast sooner, thereby shortening the mining cycle. MMUs can be
refilled on the bench either by a rapid re-loader (for prill), by a re-pump truck or
by tankers for emulsion.
Charging a bench
Currently AEL has an optimised fleet of tankers and MMUs to meet market
demand for ANA prill and emulsions. With flexible contracts and supplier
redundancy, AEL can easily accommodate growth in market demand for bulk
product.

Plants
Our emulsions are either made in high-volume permanent plants such as the
central bulk emulsion plant at Modderfontein or in modular fit-for-purpose plants
at the customer site, as found in Africa and Indonesia. Site-specific plants are
configured to meet the mine’s demand for emulsion product.
CBEP in Modderfontein Modular Indonesian Plant

Page 12 Surface Bulk Explosives I 2016

Product Delivery

Product Testing and Classification

Our product is tested according to a strict quality control regime at the point
of manufacture – at the bulk plants as well as at MMU level. This ensures our
customers are supplied with quality and reliable product. Daily bulk plant tests
include pH, viscosity and density tests. Prior to, and during charging, MMU
operators also test for sensitised product densities to ensure that the product
loaded into the blast holes is within specification.

Furthermore, all the raw materials supplied to AEL are checked in batches
according to the raw material specifications. AEL has a dedicated team of
quality assurance personnel that ensures each batch conforms to the required
Rapid Reloader
specification before releasing the raw material to the manufacturing plant.

AEL’s surface bulk emulsions have the following UN Classification:

Base Emulsion: Class 5.1, UN no. 3375, AMMONIUM NITRATE EMULSION

Charging a bench

Surface Bulk Explosives I 2016 Page 13

Pioneering Achievements

Hot-hole Blasting Re-active ground Blasting

Hot holes originate from burning coal exposed to oxygen. This phenomenon is found Re-active ground is found in similar locations where the ground (containing pyrites) reacts
in certain surface coal mining operations in South Africa, Australia and China. These with the ammonium nitrate causing a rapid rise in the emulsion temperature. Reactive
holes exist in coal surface mining sites which may have previously hosted underground ground conditions are as a result of a chemical reaction, not burning coal.
operations. A hot hole loading procedure has been developed in which holes below 40˚C are
considered safe to load. These “hot holes” pose a safety risk where blasting is concerned
due to blast holes having the potential to rapidly increase in temperature. Holes between
60˚C and 80˚C are considered hot and attempts are made to cool these holes down with
either water or Pyrocool™.

Hot Hole Monitor in use

Page 14 Surface Bulk Explosives I 2016

Pioneering Achievements

Hot-hole Monitor
AEL and Designs Unique have designed a system to continuously monitor the temperature at the
bottom of the hole or at the booster position. This unit is called a “Hot-hole monitor” and sounds
a continuous alarm when the temperature reaches 60˚C. The pitch of the alarm changes when
the temperature exceeds 80˚C, indicating that the hole is no longer safe and at this point the
responsible person should evacuate the bench.

The aim of the hot-hole monitor is to proactively detect and reduce the risks posed by hot holes,
especially in the coal mining industry. The hot-hole monitor is a temperature monitoring device
which makes use of an electronic thermocouple, connected to the booster or is lowered to the
bottom of the blast hole, in order to measure the temperature at that point. The length of the
probe wire is 30m.

The unit ensures continuous monitoring of loaded blast holes and provides early warning for
changes in the blasting conditions, which assists the blaster before and during operations.
This safety device will ensure that the blasting crew is aware of the condition in each blast hole
during the charging and tying of the blast. The product has been patented to AEL and has been
modified in design to make it disposable. It comes with a protective rip tag, which is connected to
the battery, and is guaranteed for approximately 8 hours of usage.

A Hot-hole monitor being used on-bench

Hot Hole Monitor
The temperature of these holes is monitored after cooling and blast holes are loaded only if the
temperature is cooled down below 60˚C. Detonator products are only stable up to 60˚C and can
spontaneously detonate at temperatures exceeding 60˚C.

The general procedure for charging and blasting hot-holes is to cool the holes above 60˚C with
water before charging and then to initiate the holes with detonating cord and boosters. In some
areas collar priming is also practiced. Holes that are hotter than 80˚C are abandoned and not
loaded.

Surface Bulk Explosives I 2016 Page 15

AEL Head Office
Tel: +27 11 606 0000
1 Platinum Drive, Longmeadow Business Estate North
Modderfontein, 1645
www.aelminingservices.com

Disclaimer
This publication does not necessarily reflect the views and opinions of AEL Mining Services Limited management. The copyright to this publication rests in AEL Mining Services Limited. Other product and corporate names used in this publication may be trademarks or registered trademarks
of other companies, and are used only for explanation and to the owner’s benefit, without intent to infringe. © AEL Mining Services Limited 2013