Open Cut Coal - Orica Mining Services Systems... · 2012-03-05 · 2 ORICA MINING SE RVICES OPEN CUT COAL 3 Blast Based Services Through our vast global experience in the open cut

September 2009

Open Cut Coal Products and Services

February 2012

At Orica, we recognise ‘The Power of Partnership’ and the value of building long-term relationships with our Customers. We are proud of our reputation for superior safety, environmental management, dependability, integrity and expertise, a reputation we aim to maintain.

Our Customers can have confidence that we will provide effective products and superior know-how to increase yield, improve productivity and reduce total process costs.

Contents

02 Research and Development

03 Blast Based Services

08 Delivery Systems

08 Bulk Systems

16 Electronic Blasting Systems

20 Initiating Systems

28 Packaged Explosives

OPEN CUT COAL 32 ORICA MINING SERVICES

Blast Based ServicesThrough our vast global experience in the open cut coal market, we understand that every coal mine has unique needs and value drivers. For this reason, we have created Blast Based Services.Blast Based Services is a suite of service based offerings that reinforce our commitment to supporting the productivity, growth, profitability and environmental outcomes of our Customers.

Our Blast Based Services capabilities include:

• a comprehensive range of survey, design, modelling and measurement tools;

• a series of blast improvement, compliance and quality services delivered by our Technical Services team;

• our Advanced Blast Based Services, which offer tailored solutions to deliver immediate results and also maximise downstream value generation in the mining process.

Technology& Tools

Survey

Design

Modelling

Measurement

QualityServices

Blast Quality Services

ROG™ Rock on Ground

Blast Training Courses

Quality Audits

Site Surveys

Blast Design & Management

Site Compliance & Risk Management

Industry Benchmarking

AdvancedSolutions

AVM™ Advanced Vibration Management

ABT™ Advanced Blast Technologies

Stratablast™

Sustainable Development

Technology& Tools

Survey

Design

Modelling

Measurement

QualityServices




Quality Audits

Site Surveys




AdvancedSolutions



Stratablast™


Technology& Tools

Survey

Design

Modelling

Measurement

QualityServices




Quality Audits

Site Surveys




AdvancedSolutions



Stratablast™


Research and Development Our aim is to develop innovative product and service solutions to improve mining efficiency. We do this by providing the right solution, first time, every time.Orica Mining Services is dedicated to the development of innovative product and service solutions that deliver safe and efficient blasting solutions to our Customers.

Our Global Technology Team is the driving force behind innovation in products and delivery services and blasting application and measurement. Orica Mining Services has a significant investment in technology which has led to many new and innovative technologies that now are used by our Customers throughout the world.

Orica Mining Services has seven Global Technical Centres around the world in Canada, USA, Australia, Germany, Sweden, South Africa and India. Orica Mining Services conducts R&D in ammonium nitrate, packaged and bulk explosives, explosives hazards, advanced delivery systems for explosives, Initiating systems (both non-electric and electronic) and advanced blasting and mining applications.

Orica Mining Services employs approximately 230 scientists and engineers around the world, researching, developing, supporting and maintaining our solutions for Customers.

Brownsburg

GyttorpTroisdorf

Capetown

Gomia

Kurri Kurri

Denver


QualityServices

Orica’s Technical Services Engineers understand the open cut coal market and the challenges you face. When you need technical support and training for better blasting outcomes, an Orica Technical Services Engineer is able to provide you the best advice and support available.

Our Technical Services team enable our Customers to achieve best practice standards by delivering a range of site tailored services:

• Blasting Courses – including Safe and Efficient Blasting, Explosives Awareness, Shotfirer training, Operator training, explosives and product training.

• Quality Blasting Audits and Risk Assessments – targeted at highlighting opportunities for cost efficiencies, safety and environmental improvements and blast optimisation

• Blast Design & Support – An experienced network of blasting professionals, providing assistance with designs, measurement or on bench support including the introduction of new bulk and initiation products.

• Site Compliance – Risk analysis, compliance monitoring, environmental planning and environmental impact assessments.

• Site Surveys & Industry Benchmarking – Comprehensive site process studies by experienced engineers on site to review blasting and mining operations and establish a base line for the identification of the best improvement/efficiency project opportunities. This can include the analysis of comparative blasting scenarios arising from proposed changes in product selection, blasting parameters, or mining/processing equipment selection.

For Customers in the Open Cut Coal market who are seeking to combine a number of quality services and truly optimise the drill & blast process, Orica offers the Rock on Ground™ service. Rock on Ground™ represents a complete rock extraction and delivery service, that delivers a reliable supply of rock at consistent sizing and ready to feed the haulage stage. Rock on Ground™ assures predictable cost, while enhancing your safety and environmental performance through tight process control, leading measurement tools and the highest on-bench standards.

Technology& Tools

Orica invests heavily in innovation. Over many years our advanced research and development program has allowed us to offer significant technical capabilities to drive greater value for our Customers.

The development of innovative products, delivery systems, applications and services assists our Customers to achieve optimum blasting results, cost effectively and safely. The suite of Technology & Tools offered within Blast Based Services is represented in four classes of technical capability:

• Surveying: Orica uses a range of measurement systems for borehole tracking, burden measurement and laser face surveying. These systems can be interfaced with existing blast management software.

• Design: Orica’s SHOTPlus® suite of software enable optimum blast design and analysis for open cut coal mines.

• Modelling: Orica has developed a wide range of modelling tools for the simulation of mine process, blast outcomes, cost optimisation and environmental performance.

• Measurement: Orica uses a range of measurement systems for the assessment of blast impacts such as rock movement, fragmentation, vibration and airblast as well as product performance and mine cycle time.

Blast Based Services continued


AdvancedSolutions

An Advanced Vibration Management™ solution offers blast design and execution supported by sophisticated measurement and statistical modelling techniques particularly appropriate to higher risk structures or specific geologies or where a higher degree of measurement/predictive reliability is required. Vibration or airblast information obtained from highly controlled test detonations is evaluated using the Monte Carlo simulation technique. The impact of proposed blast designs can be modelled and assessed to ensure appropriate corrective actions can be taken.

AVM also includes a web-based modelling service for our customers to use to continuously model their own designs using Orica’s Monte Carlo capability. For compliance monitoring, AVM offers a sophisticated web-based service that automatically records, processes and stores all vibration and airblast results from each blast, and alerts pre-selected representatives of the results of each blast. Blast environmental records need never be missed or lost again.

Advanced Blasting Technologies™ incorporates tailored services that produce highly specialised blast results. These can include blasting through multiple or dipping seams in a single event without risking coal seam integrity, cast blasting to a modelled profile that optimises digging performance, blasting against sensitive walls, testing for and managing safe loading procedures together with specifically formulated products for hot and/or reactive ground blasting.

Blast Based Services combine the best of Orica’s knowledge, experience, technology and tools to keep Customers on the leading edge of blasting developments while delivering outcomes of profitability, efficiency, safety, health and environment. At Orica, we believe in the Power of Partnership, two companies working together to achieve common goals.

AdvancedSolutions

Orica’s Advanced Blast Based Services reinforce our commitment to supporting the growth and profitability of our Customers through the introduction of services that can be tailored and adapted to meet the individual needs of each operation.

Innovation and excellence in unlocking tangible value are the hallmarks of our Advanced Blast Based Services. These advanced services are tailored for every site and have the potential to generate value for mine sites such as:

• Reduced unit mining costs through designs and on-bench standards that maximise the use of every unit of explosives energy

• Higher coal uncovery rates through improved blasting performance that delivers optimum fragmentation and dig rates

• More efficient coal uncovery through maximising throw, reduced dragline pad preparation time and minimising dragline re-handle or optimising dozer-push integration

• Increasing recovery by minimising coal loss while maximising blast performance

• Improving performance outcomes within environmental limits

• Reducing Greenhouse Gas intensities through advanced scenario modelling using Orica’s Value and Emissions calculator

Stratablast™ is one of the principal Blast Based Services offers that has the potential to bring about a revolution in current mining practice in open pit coalmines. Stratablast™ is a multiple layer blast that is drilled, loaded and fired in a single cycle; combining an overburden throw blast with at least one standup blast, the later usually being in a coal seam. Each layer has a unique blast timing design with interhole and interrow delays specific to each layer.

Blast Based Services continued


The Fortis™ System is a premium range of enhanced performance bulk explosives specifically designed for use in wet blasthole conditions. Utilising proprietary sensitising technology, the Fortis™ System is reliable in the most difficult blasting conditions and can be confidently used in open cut coal mining whenever you encounter wet blastholes.

The energy of the Fortis™ System can be tailored to suit specific applications by varying both density and formulation on site.

Key Benefits

• Energy can be tailored to match ground types

• Wet and dry blasting performance matching

• Reliable and consistent performance

• High delivery rates

• Products tailored to specific applications

The Fortan™ System is a range of high energy bulk explosives which deliver high heave energies enabling easier, faster overburden and waste removal. The heave energy also offers increased throw in coal overburden blasting.

Fragmentation of hard rock can also be improved by selecting the correct Fortan™ product, the result is uniform, predictable breakage.

The Fortan™ Series of products possesses higher energy and density than ANFO. Hence patterns can be expanded and overall drilling and blasting costs reduced.

Key Benefits

• Reliability in dry and dewatered blastholes

• Integrated product and delivery systems enabling accuracy, productivity and dependability of supply

• Ability to load at varying energies and densities

• Higher bulk strength when compared to ANFO enables pattern expansion

• High delivery rates

Delivery SystemsOrica’s bulk delivery systems are the result of over twenty years of research and development. They have evolved to be in a class of their own in terms of innovation, accuracy, flexibility and capacity. Our Mobile Manufacturing Units® (MMUs®) are designed to transport only raw materials directly to the bench, and mix directly into your blasthole. Flexible bin configurations allow the MMUs® to be optimised to the changing product requirements at each site, ensuring maximum load capacity, flexibility and productivity.

Our MMUs® – the Bulkmaster™, Flexmaster™ and new Megamaster™ are benchmark units with high loading capacities, flexible loading systems and highly mechanised in hole delivery systems. All of these features combining to ensure high productivity and efficient delivery on bench.

Bulk SystemsOrica is at the forefront with its Bulk Systems approach to mining explosives. Our integrated system of people, products, equipment and on the ground technical resources successfully operates in surface mines worldwide.

We have a proven track record in delivering benefits to our Customers across the total mining chain by tailoring our Bulk Systems to suit their particular needs. Through the application of innovative technology and worldwide experience, Orica can provide a solution that gives you the competitive edge.

ANFO is a free flowing (loose poured) mixture of porous prilled Ammonium Nitrate (Nitropril®) and Fuel Oil (FO), formulated to be oxygen balanced for use in dry blastholes. ANFO is suitable for most dry blasting applications. It is not applicable in ground containing reactive sulphides.

Key Benefits

• High productivity via Reload™ System

• Consistent high quality gives consistent blast performance


Coal

COAL SYSTEM

The Coal System is a range of bulk explosives designed specifically to meet the needs of the coal mining sector. The Coal System includes pumped, augered and variable density products which can all be delivered through the same mobile manufacturing unit, giving greater flexibility in product choice than has previously been available.

Key Benefits

• Cost effective blasting for coal mining

• Increased flexibility of product choice

• High delivery rates for all product systems

• Ability to load to 80 m deep blastholes

Hot & Reactive

ECLIPSE™ BULK PRODUCT SYSTEM

An inhibited range of bulk explosives products which when combined with site specific test methods and operating procedures, aimed to prevent uncontrolled reactions between explosives and reactive ground, resulting in safe blasting. The range is suitable for wet, dry and dewatered blastholes, and can be provided at a variety of energies and densities to target different levels of reactivity. The Eclipse™ range offers a cost-effective solution to blasting in mildly reactive ground via density and product selection linked to blast design. The Eclipse™ Plus range is designed for blasting in highly reactive ground.

Bulk Systems continued

The Flexigel™ System is a range of variable density bulk explosive products specifically developed to meet the needs of the mining industry. Flexigel™ can be used in both dry and dewatered blastholes and can be tailored to match variations in rock strength.

Key Benefits

• Ability to vary density and energy within the blasthole to match ground type

• Reduced environmental impact of blasting

• Applicable to dry and dewatered blastholes

• Reduced cost of blasting

• Compatible with Fortis™ and Fortan™ products

• Compatible with Orica Mobile Manufacturing Units®

A range of water resistant bulk explosive products specifically designed for use in dewatered blastholes. The ability to vary the density to match particular application needs enables Aquacharge™ to provide a cost-effective explosive system for dewatered blastholes.

Key Benefits

• Reliability in dewatered blastholes

• Cost-effective alternative to high density Fortan™

• Ability to load at varying energies and densities


Key Benefits

• Reliable blasting in dry, dewatered or wet blastholes

• Integrated product and delivery systems ensuring accuracy, productivity and dependability of supply

• Designed for minimum disruption on mining operations

• Significantly reduces fume from blasting operations when used in conjunction with good loading practices

EXTRA BULK PRODUCT SYSTEM

The Extra Product System has been specifically designed to meet more arduous blasting conditions in all open cut operations, where greater energy and longer blasthole sleep times than available with standard products is required.

The Extra System is suitable for dry, dewatered and wet holes over a range of energies and densities giving Customers greater product choice than has previously been available.

Key Benefits

• The most energetic bulk explosives available in the Orica range of products

• Increased sensitivity

• Increased sleep time

• Reliable performance in difficult blasting situations

• Energy can be tailored to match ground conditions

MARATHON BULK PRODUCT SYSTEM

Fortis™ Marathon is a premium bulk explosive product specifically designed for use in the most arduous wet blasthole applications where extended sleep time is critical. It can be confidently used where significant amounts of water are present. Fortis™ Marathon utilises advanced surface chemistry to achieve sleep times of up to 12 weeks in shallow small diameter blastholes.

Key Benefits

• Extended sleep time in small diameter holes

• Reliable performance in wet blastholes

• Energy can be tailored to match ground conditions

Bulk Systems continued

VULCAN™ BULK PRODUCT SYSTEM

Unique tailored bulk explosives products and initiation systems able to withstand temperatures of up to 150°C, and maintain high levels of performance in reactive ground.

The Vulcan™ System capability satisfies the critical safety requirements of mining in hot or hot and reactive conditions.

XTREME™ BULK PRODUCT SYSTEM

The Xtreme™ System comprises a range of bulk explosives specifically developed for blasting in temperatures of up to 100°C.

When combined with specialised initiation systems as well as Orica support through training and procedure development, the Xtreme™ System enables site blasting to be carried out in hot ground situations.

Key Benefits

• Safe solution to blasting in hot and/or reactive ground

• Ability to mine previously inaccessible areas

• Range of products formulated to match ground types with differing levels of reactivity and ground temperature

• Available in Fortis™, Fortan™, Aquacharge™ and Flexigel™ Bulk Product Systems

Challenging Conditions

CLEAR BULK PRODUCT SYSTEM

A range of bulk explosive products best suited to a Fume Risk Reduction strategy to assist customers with fume prone conditions. The Clear Bulk Product system provides an optimal solution when used in conjunction with loading, priming and assessment procedures developed in alignment with the AEISG code of practice for prevention and management for Blast Generated NOx gases in surface blasting.

14 ORICA MINING SERVICES OPEN CUT COAL 15

PRODUCT APPLICATION DENSITY (G/CC) RWS% RBS%* VOD (KM/S)

REC. MIN. BLASTHOLE DIAM.

(mm)

REC. MAX. BLASTHOLE DEPTH

(m)

REC. MAX. CHARGE LENGTH

(m) HOLE TYPE REC. MAX. SLEEP TIME GASSEDREACTIVE GROUND

ANFO Dry blasting applications 0.80 100 100 2.5–4.8 76 80 75 Dry 42 days No No

COAL

Fortan Coal 10111213

Increased bulk strength for dry holes in open cut coal mines 1.001.101.201.28

106111115118

132153172189

2.5–5.82.5–5.82.8–6.13.1–6.3

115115127150

80808080

75757575

DryDryDry

Dewatered

21 days No No

Aquacharge Coal Cost effective blasting for dewatered holes 1.20–1.25 111–116 166–173 4.0–6.3 120 80 45 Dry and dewatered 21 days Yes No

Fortis CoalCoal SCoal H

Reliable wet hole blasting in open cut coal mines 1.15–1.25 100–10697–103103–110

144–166139–161148–172

3.7–6.53.7–6.53.7–6.5

115 50 45 Dry, wet or dewatered 21 days Yes No

Flexigel Coal 506080100

Soft ground applications in open cut coal mines 0.500.600.801.00

45526679

28396699

2.5–3.62.5–3.72.5–3.93.7–4.1

250229100150

80808080

75757535

DryDryDry

Dry / dewatered

21 days No No

Fortis Deep Reliable wet hole blasting in deeper holes 1.25 114 178 4.5–6.5 250 70 65 Dry / wet 21 days Yes No

HOT AND REACTIVE GROUND

Fortan Eclipse 10111213

High bulk strength products for dry holes in mildly reactive environments 1.001.101.201.30

107112117121

134154175194

2.8–5.63.6–6.03.5–6.04.0–6.8

7676

102150

80 75 DryDryDry

Dewatered

12 hrs reactive ground21 days unreactive ground

No Yes

Aquacharge Eclipse Cost effective blasting for dewatered holes in mildly reactive environments 1.20–1.25 112–115 168–180 4.0–6.7 120 80 45 Dry or dewatered 12 hrs reactive ground21 days unreactive ground

Yes Yes

Fortis EclipseEclipse SEclipse H

Reliable wet hole blasting in mildly reactive environments 1.10–1.25 102–11298–108105–116

140–175135–169144–181

3.7–6.63.7–6.54.1–6.7

90 45 40 Dry, wet or dewatered 12 hrs reactive ground21 days unreactive ground

Yes Yes

Flexigel Eclipse 6080100

Soft ground applications in highly reactive environments 0.600.801.00

567084

4270

105

2.5–3.72.5–3.92.5–4.1

200100150

808080

757565

DryDry

Dewatered

12 hrs reactive ground 21 days unreactive ground

No Yes

Fortan Eclipse Plus 10111213

High bulk strength products for dry holes in highly reactive environments 1.001.101.201.30

108113118122

135155177198

2.8–5.63.2–6.13.5–6.53.8–6.9

7676

102150

80 75 DryDryDry

Dewatered


No Yes

Aquacharge Eclipse Plus Cost effective blasting for dewatered holes in highly reactive environments 1.201.25

113116

169181

4.0–6.54.0–6.7

120 80 45 Dry or dewatered 12 hrs reactive ground21 days unreactive ground

Yes Yes

Fortis Eclipse PlusEclipse Plus H

Reliable wet hole blasting in highly reactive environments 1.10–1.25 98–108100–110

135–169137–172

3.7–6.54.1–6.5

90 30 25 Dry, wet or dewatered 12 hrs reactive ground21 days unreactive ground

Yes Yes

Fortis VulcanVulcan Plus

Reliable blasting in hot, or hot and reactive ground with in-hole temperatures up to 150ºC

1.251.25

11281

175127

3.7–6.63.7–5.5

9090

4530

4025

Dry, wet or dewatered 8 hrs – 100ºC8 hrs – 150ºC

YesNo

Yes

Fortan Xtreme High bulk strength products for dry holes at in-hole temperatures up to 100ºC

1.20 118 177 2.8–6.5 102 80 75 Dry Up to 50ºC – 21 daysUp to 100ºC – 8 hrs

No No

Fortis Xtreme Reliable wet hole blasting for in-hole temperatures up to 100ºC 1.20 113 169 4.4–6.5 89 50 45 Dry, wet or dewatered Up to 50ºC – 21 daysUp to 100ºC – 8 hrs

Yes No

Xtreme Dry blasting applications for in-hole temperatures up to 100ºC 0.8 100 100 2.5–4.8 76 80 75 Dry Up to 50ºC – 21 daysUp to 100ºC – 8 hrs

No No

CHALLENGING

Aquacharge Clear To minimise fume generation in dewatered blastholes 1.20–1.25 113 –116 169 –181 4.0 –6.6 120 80 45 Dewatered 21 days Yes No

Aquacharge Clear i To minimise fume generation in mildly reactive ground. For use in dewatered blastholes

1.20–1.25 113–116 169–181 4.0 –6.6 120 80 45 Dewatered 12 hrs reactive ground21 days unreactive ground

Yes Yes

Flexigel Clear 80100

To minimise fume generation in soft ground applications 0.801.00

7084

70105

2.5 – 3.92.5 – 4.1

100150

8080

7550

Dry / dewateredDry / dewatered

21 days No No

Flexigel Clear i 80100

To minimise fume generation in soft ground applications in mildly reactive ground. For use in dry or dewatered blasthole applications

0.801.00

7084

70105

2.5– 3.92.5– 4.1

100150

8080

7550

Dry / dewateredDry / dewatered


No Yes

Fortis Clear S To minimise fume generation in dry, dewatered or wet blastholes 1.15–1.25 100–106 144–166 3.7–6.5 115 50 45 Dry, wet or dewatered 21 days Yes No

Fortis Clear i S To minimise fume generation in mildly reactive ground. For use in dry, dewatered or wet blastholes

1.15–1.25 100–106 144–166 3.7–6.5 115 50 45 Dry, wet or dewatered 12 hrs reactive ground21 days unreactive ground

Yes Yes

Aquacharge Extra Cost effective blasting with highest bulk strength for dewatered holes 1.20 – 1.25 116 – 119 174 – 186 4.0 – 6.5 120 80 45 Dry or dewatered 42 days Yes No

Fortan Extra 10111213

Highest bulk strength with longer sleep time 1.001.101.201.30

110116122128

137159183208

2.5–5.62.5–6.02.8–6.53.8–6.9

7676

102150

80 75 DryDryDry

Dewatered

42 days NoNoNoNo

NoNoNoNo

Fortis ExtraExtra H

Highest bulk strength, longer sleep time 1.10–1.25 110–120110–121

151–187151–189

4.1–6.74.1–6.7

64 45 40 Dry, wet or dewatered 42 days Yes No

Flexigel Control 456080100

Vibration and wall control in soft ground applications 0.450.600.801.00

49607487

284574

109

2.6 – 3.13.4 – 3.73.6 – 3.93.7 – 4.1

200200100150

80808080

75757530

DryDryDry

Dewatered

21 days No No

Fortis Marathon Longest sleep time, more robust, for the most challenging wet hole blasting 1.10 – 1.25 103 – 113 142 – 177 3.9 – 6.5 64–76 50 45 Dry, wet or dewatered 84 days Yes No

* Relative to ANFO @ density 0.8 g/cc

14 ORICA MINING SERVICES


Orica’s i-kon™ Digital Energy Control® System represents Orica’s most sophisticated blast initiation technology available. The extraordinary accuracy, flexibility and safety delivered by the i-kon™ System will allow you to optimise your blast designs like never before. The i-kon™ System is the result of Orica’s ongoing commitment to provide value-added products and services to our Customers that deliver real productivity improvements.

The i-kon™ System has four key integrated components; detonator, logger, blaster, software:

i-kon™ Detonator

The i-kon™ RX Detonator is recommended for use in surface mining applications where high bulk explosives loading rates, mechanical charging or abrasive stemming materials are likely to be encountered. The i-kon™ RX detonator is provided with a much tougher, more robust outer insulation than the standard i-kon™ wire, giving the RX unit superior performance in severe, abrasive mining conditions.

Technical Properties

Delay times Programmable from 0 ms to 15000 ms in 1 ms increments

Wire length (m) 10, 15, 20, 30, 40, 60, 80

Downline wire 0.6 mm steel

Wire tensile strength 25 kgf/250 N

i-kon™ Logger

The Logger is used on the bench as part of the hook-up process, checking the ID number and the status of each detonator. The Logger operates well below the no-fire voltage of the detonator ensuring inherently safe operation on the bench. The delay time for each detonator is stored against the ID number in the memory of the Logger for later programming by the Blaster.

Electronic Blasting SystemsElectronic Blasting Systems differ from electric and non-electric delay systems in that the delay time is controlled by a programmable integrated circuit, resulting in very precise timing. The accuracy and programmability of electronic detonators allows for blast timing to be tailored to the geometry, geology and unique requirements of any blasting operation to more effectively use explosives energy.

Key Benefits for coal blasting

• Improved blasting efficiency – the same results for reduced input cost

• Protection of coal and reduced coal loss

• Better productivity in truck and shovel operations

• Increased dragline productivity

• Better highwall control

• Ability to implement Stratablast™ and other novel blasting techniques

• Enhanced safety and security

• Reduced and simplified inventory

Our systems are easy to use, easy to program, and very safe. The detonators are identical in size and output to non-electric detonators. Every detonator has a unique, traceable ID number held on the chip, and printed on the attached tag. They are programmable in millisecond increments and have a high level of protection against accidental initiation by stray or induced currents and electrostatic discharges. The tough, all-weather hardware is intuitive and much liked by blasters.


The Uni tronic™ Electronic Blasting System is the result of the continuing development and evolution of Orica’s Electronic Blasting Systems product portfolio. Uni tronic™ will enable users who may have been unable to justify the adoption of electronic blasting technology to finally experience the benefits that Electronic Blasting Systems can deliver at an economical price point.

The Uni tronic™ System has five key components; detonator, scanner, network tester, blaster, software:

Uni tronic™ 500 Detonator


Delay times Fully programmable from 0 ms to 10,000 ms in 1 ms increments

Wire length (m) 6, 9, 15, 20, 25, 30, 37

Downline wire Copper-clad steel

Wire tensile strength 20 kgf/200 N

Uni tronic™ Scanner

The Scanner is used in surface blasting applications to passively and safely read the detonator ID from the barcode tag. The ID is associated with an assigned delay time in the scanner’s memory and later transferred to the Blaster. An auto-increment feature allows for very quick operations on the blast pattern.

Uni tronic™ Network Tester

The Network Tester is an inherently safe, hand-held testing device used to test for short circuits, open circuits, leakage and reverse polarity. Most problems can be discovered and corrected by this quick on-pattern testing of the wiring harness.

Uni tronic™ Blaster

The 300 Series Blaster tests, programs, arms and fires the detonators with full two-way communications.

The dedicated Blaster is the only means of initiating the Uni tronic™ 500 electronic detonator. When the scanner is docked into the Blaster’s docking station, the information held within it is transferred to the Blaster. At the designated time, blasting cables are attached to the box and the firing sequence is initiated.

i-kon™ Blaster

The Blaster is used to calibrate, program, arm and fire the i-kon™ detonators via the Loggers. Individual detonators and system integrity are fully verified and displayed to the user before the blast is fired, allowing confident blasting or trouble-shooting to be done.

There are two different Blasters for small and large blasts (Blaster 400 and Blaster 2400S). Two Blaster 2400S units can be synchronised together to fire 4800 detonators.

The i-kon™ Surface Remote Blasting System (SURBS) allow blasts to be fired remotely. The SURBS units can initiate blasts on the surface up to 2000 m away via a secure radio transmission.

The power of the i-kon™ System is SHOTPlus®-i, an in-house tool developed to provide a seamless front end to a mine’s design and production systems. By integrating directly with the i-kon™ Loggers the blast design process flows into the hook-up design, both speeding up and ensuring the integrity of the process.

SHOTPlus®-i can import survey data detailing blasthole coordinates and identifiers, geological boundaries, pit design information and critical design elements. This allows for more accurate initiation designs to be developed, seamlessly incorporating site based systems with Orica technologies. Data upload completes the process, with the ability to document and report the final blasting outcomes and explosive consumption.

Electronic Blasting Systems continued


Exel™ Connectadet™ Detonators

Exel™ Connectadet™ Detonators are colour coded signal tube based detonators designed to control the millisecond delay sequence from hole to hole, across the surface of a blast. The special design of Connectadet™ Detonators allows up to six outgoing signal tubes to be initiated. Exel™ Connectadet™ Detonators function as a surface relay system, which enables an unlimited number of blastholes to be fired in sequence. This allows large well-controlled blasts to be fired, producing better results more efficiently.


Signal tube Exel

Outer diameter 3 mm

Nominal tensile strength 45 kgf

Lengths (m) 3.6, 4.9, 6.1, 9, 12, 15, 18

Packaging

Lead length (m) Units per case Nominal gross weight (kg)

Coiled

3.6 180 10

4.9 160 11

6.1 140 10

F80

9 70 8

12 50 7

15 50 7

18 40 7

Initiating SystemsFeaturing the Cordtex™, Exel™ and Pentex™ ranges. Orica offers the widest range of Initiating Products to the market place.

Key Benefits

• High standards of safety

• Reliability of supply

• Consistent product and service performance

Products are produced and distributed throughout the region with world class manufacturing facilities located within Australia, Philippines, China and India.

Waxed Detonating Cord

The Cordtex™ Waxed Detonating Cord range consists of a continuous core of PETN powder encased by high strength textiles. This is covered by a seamless plastic jacket and overwrapped by an outer layer of textiles held in place by a special high temperature wax. Cordtex™ 3.6W is suited for use as a surface trunkline and is recommended where detonating cord downlines are required.

Detonating cord ColourNominal core load (g/m)

Length per spool(m)

Spools per case

Cordtex 3.6W Pink 2 black stripes 3.6 500 2

Plastic Detonating Cord

The Cordtex™ Plastic Detonating Cord range consists of a continuous core of PETN powder encased by high strength textiles. This is covered by a seamless plastic jacket.

Detonating cord ColourNominal core load (g/m)

Length per spool(m)

Spools per case

Cordtex 5P Green 5.0 500 2

Cordtex 10P Red 10.0 350 2


Exel™ Enduradet™ Detonators

Exel™ Enduradet™ Detonators are a series of highly durable, oil resistant millisecond non-electric delay detonators for use in harsh mining conditions. The special outer jacket of Exel™ Enduradet™ signal tube provides excellent protection against damage from impact, abrasion and of oil penetration making them an ideal in-hole initiating system for both long hole applications or where extended sleeptimes are required. Exel™ Enduradet™ detonators will directly initiate Pentex™ boosters and packaged explosives.


Signal tube Red Heavy Duty Exel

Outer diameter 3 mm


Lengths (m) 9, 12, 15, 18, 24, 30, 36, 45, 60, 80

Detonator #8* strength

Packaging

Lead length (m) Units per caseNominal gross weight (kg)†

Tangle free

F100 9 80 8

12 80 8

F80 15 50 7

18 40 7

24 35 9

Spool

Spool 30 36 11

36 36 12

45 36 14

60 16 9

80 16 11

† Gross weight varies according to the delay element.

Exel™ Trunkline Delay Detonators

Exel™ Trunkline Delay Detonators (TLDs) are non-electric delay detonators for surface initiation of signal tube or detonating cord downlines.


Signal tube Yellow Exel

Outer diameter 3 mm


Detonator #8* strength

Exel™ Bunchdet Detonator – Open Cut Mining

The Exel™ Bunchdet Detonator is a signal tube based surface connector system, designed to initiate detonating cord only, while providing equivalent timing to a conventional in-hole delay.


Signal tube Pink Exel

Outer diameter 3 mm


Standard delay 600 ms

Length (m) 0.76

Packaging

There are a total of 200 Bunchdet detonators per case. A case has dimensions 0.60 x 0.32 x 0.22 m and weighs 12 kg gross.

Exel™ Goldet™ Detonators

Exel™ Goldet™ Detonators are millisecond signal tube based detonators, combining a constant in-hole delay with a surface delay connector. They work as a single unit, simplifying blast design.



Outer diameter 3 mm


Lengths (m) 2.4, 3.6, 4.9, 6.1, 9, 12, 18, 24

Detonator in-hole #8* strength

Detonator surface Low strength

Packaging

Lead length (m) Units per case Nominal gross weight (kg)

Coiled

2.4 200 11

3.6 150 9

4.9 100 9

6.1 100 9

F80

9 70 8

12 50 8

18 40 7

24 35 8

Initiating Systems continued


Exel™ Lead In Lines

Exel™ Lead In Lines are long lead non-electric instantaneous detonators for remote initiation of blasts. Exel™ Lead In Lines consist of a non-electric detonator, a length of Exel™ signal tube, and a plastic connector. Exel™ Lead In Lines will directly initiate detonating cord or signal tube.



Outer diameter 3 mm


Lengths (m) 60, 150, 300

Nominal detonator delay 0 ms

Detonator #8 strength

Packaging

Lead length (m) Units per case Gross weight (kg)

60 16 9

150 8 9

300 3 8

Exel™ Connectaline™

Exel™ Connectaline™ is a reel-off signal tube system for initiation of blasts. Connectaline™ consists of a long length of Exel™ signal tube plus black end caps and clear splices. The signal tube is supplied on spools and closed at both ends. Connectaline™ enables long lead extension of Connectadet™ or Trunkline Delay (TLD) detonators to safely initiate blasts and to connect one blast to another.


Signal tube Exel

Outer diameter 3 mm


Minimum length on spool (m) 700

Tube colour Yellow, Pink or Red†

† Additional dark colours may be made available for specialist applications.

Packaging

Connectaline™ is supplied on spools which hold 700 m of tubing. A standard cardboard outer case contains 2 of these spools, packed into a sealed ‘barrier bag’. A case has dimensions 0.60 x 0.32 x 0.22 m and weighs 11 kg gross. There are 10 end caps and 10 splices, located inside a hollow cardboard tube, included in each case. The tube can be used to conveniently off-reel the tubing from the spools.

Exel™ Millisecond Detonators

Exel™ Millisecond Detonators are a series of high strength non-electric detonators with millisecond (MS) delay intervals between successive firing times. Exel™ MS Detonators provide a series of delay times suitable for Open Cut Coal mining. An ideal in-hole initiating system Exel™ MS Detonators will directly initiate Pentex™ boosters and packaged explosives.



Outer diameter 3 mm


Lengths (m) 3.6, 6.1, 9, 12, 15, 18, 24

Detonator 0 Delay 500 mg (#8 strength) Delays 1 – 30 790 mg (#8* strength)

Packaging

Lead length (m) Units per caseNominal gross weight (kg)†

Format

3.6 210 10 F100

6.1 150 9 F100

9 80 7.5 F100

12 80 8.0 F100

15 50 7.0 F80

18 40 6.5 F80

24 35 7.0 F80

† Gross weight varies according to the delay element.

Exel™ Millisecond Connectors

Exel™ Millisecond (MS) Connectors are signal tube based delay connectors designed to introduce accurate delays into surface detonating cord trunklines. Exel™ MS connectors operate in both directions to simplify hookup and permit layouts which provide multiple paths of initiation to each blasthole.



Outer diameter 3 mm


Total length (cm) 80

Detonator #8 strength

Packaging

A case contains 125 units of the same delay. The case dimensions are 0.60 x 0.32 x 0.22 m and a case weighs 9.0 kg gross.



Pentex™ PowerPlus™ P boosters are made from a high explosive composition cast into a cylindrical cardboard shell. Two longitudinal tunnels in the booster accommodate either a detonator or detonating cord. Pentex™ PowerPlus™ P boosters contain both Detlok™ and a PETN explosive bottle. Detlok™ securely holds the detonator in place during loading. The explosive bottle allows initiation by low charge weight detonating cords while delivering high velocities of detonation to maximise performance. Pentex™ boosters provide high energy initiating power for booster sensitive explosives.


Shell colour Orange

Nominal diameter 55 mm

Nominal length 120 mm

Nominal mass 400 g

Nominal density 1.7 g/cm3

Velocity of detonation 7.2 km/s

Nominal detonation pressure 22.0 GPa

Pentex™ PowerPlus™ 900 boosters are made from a high explosive composition cast into a cylindrical cardboard shell. Two longitudinal tunnels in the booster accommodate either a detonator or detonating cord. Pentex™ PowerPlus™ 900 boosters contain both Detlok™ and a PETN explosive bottle. Detlok™ securely holds the detonator in place during loading. The explosive bottle allows initiation by low charge weight detonating cords while delivering high velocities of detonation to maximise performance. Pentex™ boosters provide high energy initiating power for booster sensitive explosives.


Shell colour Red



Nominal mass 900 g





Pentex™ G boosters are made of a high explosive composition cast into a cardboard shell. Two longitudinal tunnels in the booster accommodate either a detonator or detonating cord. Pentex™ G boosters contain Detlok™. Detlok™ securely holds the detonator in place during loading, while still enabling safe removal of the detonator if required. Pentex™ boosters provide high energy initiating power for booster sensitive explosives.


Shell colour Pink



Nominal mass 110 g




Pentex™ H boosters are made of high explosive composition cast into a cardboard shell. Two longitudinal tunnels in the booster accommodate either a detonator or detonating cord. Pentex™ H boosters contain Detlok™. Detlok™ securely holds the detonator in place during loading, while still enabling safe removal of the detonator if required. Pentex™ boosters provide high energy initiating power for booster sensitive explosives.


Shell colour Green



Nominal mass 150 g





Senatel™ Pyromex™ is a water resistant packaged emulsion explosive specifically formulated to inhibit exothermic reaction which may occur in loaded blastholes in pyritic ore bodies. The combination of high detonation velocity, high energy and its robust nature makes Senatel™ Pyromex™ an ideal primer for the initiation of Fortis™ Vulcan™ and Simex™. Senatel™ Pyromex™ is packaged in white plastic film with an orange product logo. Standard dimensions are as follows:

Diameter (mm)Nominal length (mm)

Nominal mass (g)

50 200 500

Senatel Pyromex is made to order and may be available in other diameters.

Performance

Nominal density (g/cc) 1.16

Relative effective energy1 Relative weight strength Relative bulk strength– to ANFO @ 0.8 g/cc

105%

152%

Minimum velocity of detonation2 (km/s) 4.7

CO23 (kg/tne) 173

1 REE is the Effective Energy relative to ANFO at a density of 0.8 g/cc. ANFO has an effective energy of 2.30 MJ/kg. Energies quoted are based on ideal detonation calculations with a 100MPa cut-off pressure. Non-ideal detonation energies are also available on request. These take account of blasthole diameter, rock type and explosive reaction behaviour.

2 VOD will depend on application including explosive density, blasthole diameter, temperature and degree of con�nement. The minimum VOD range is based on uncon�ned test �ring data.

3 Carbon dioxide is the main greenhouse gas produced. The output is calculated assuming ideal detonation.

Packaged ExplosivesOrica Mining Services manufactures a range of packaged products for your open cut coal mining needs.

Packaged Senatel™ Powerfrag™ is a high strength, robust detonator sensitive emulsion explosive. The explosive is white in colour with a firm putty-like consistency. It is packaged in plastic film with wire end clips.

Senatel™ Powerfrag™ cartridges are packaged in white plastic film with a blue product logo, and wire end clips. Standard cartridge sizes are as follows:

Diameter (mm)Nominal length (mm)

Nominal mass (g)

32 200 185

32 700 640

45 400 750

55 300 830

65 300 1175

80 400 2275

Other sizes may be available on request.

Performance


Relative effective energy1

Relative weight strength Relative bulk strength– to ANFO @ 0.8 g/cc– to ANFO @ 0.95 g/cc

121%

183%139%

Minimum velocity of detonation2

(km/s) 3.4

CO23 (kg/tne) 184


2 VOD will depend on application including explosive density, blasthole diameter, temperature and degree of con�nement. The minimum VOD quoted is based on uncon�ned test �ring data.



Senatel™ Pyrosplit™ has been specifically designed for suitability in hot and reactive ground blasting. Senatel™ Pyrosplit™ incorporates ingredients to inhibit exothermic sulphide reactions, which have been known to occur between explosives and reactive ground. Senatel™ Pyrosplit™ is packaged in continuous film and double clipped every 400 mm. Senatel™ Pyrosplit™ packaging cases and film are white with a green product logo. Standard cartridge sizes are as follows:

Diameter (mm) Length (m) Case weight (kg)

32 30 25

Performance


Relative effective energy1 Relative weight strength Relative bulk strength– to ANFO @ 0.8 g/cc

104%

153%


CO23 (kg/tne) 168


2 VOD will depend on application including explosive density, blasthole diameter, temperature and degree of con�nement. The minimum VOD quoted is based on uncon�ned test �ring data and is in�uenced by the presence of detonating cord and emulsion in the product.


Packaged Explosives continued

Senatel™ Powersplit™ is designed for mining operations where a continuous length of decoupled explosive charge is required. Senatel™ Powersplit™ suits perimeter blasting applications such as smooth wall blasting, trimming and pre-splitting.

Senatel™ Powersplit™ is packaged in continuous film and double clipped every 400 mm. Senatel™ Powersplit™ packaging cases and film are white with a purple product logo. Standard cartridge sizes are as follows:

Diameter (mm) Length (m) Case weight (kg)

26 27 17

32 20 17

Performance


Relative effective energy1

Relative weight strength Relative bulk strength– to ANFO @ 0.8 g/cc

100%

147%


CO23 (kg/tne) 149

1 REE is the Effective Energy relative to ANFO at a density of 0.8 g/cc. ANFO has an effective energy of 2.30 MJ/kg. Energies quoted are based on ideal detonation calculations with a 100 MPa cut-off pressure. Non-ideal detonation energies are also available on request. These take account of blasthole diameter, rock type and explosive reaction behaviour.

2 VOD will depend on application including explosive density, blasthole diameter, temperature and degree of con�nement. The minimum VOD quoted is based on uncon�ned test �ring data and is in�uenced by the presence of detonating cord and emulsion in the product.


** Specialised hot ground blasting products to be used in conjunction with site specific blasting procedures. Donor units may not be compatible with hot/high temperature blasting applications. Contact your local Orica Representative prior to use.

All information contained in this brochure is as accurate and up-to-date as possible at the time of publication. Since Orica Group Companies cannot anticipate or control the conditions under which this information and its products may be used, each user should review the information in the specific context of the intended application. The Orica Group Companies will not be responsible for damages of any nature resulting from the use or reliance upon the information. No express or implied warranties are given other than those implied mandatory by law. Orica Australia Pty Ltd 004 117 828.

The word Orica, the Ring Device and the Orica mark are trademarks of Orica Group Companies. Advanced Vibration Management, Aquacharge, Bulkmaster, Connectadet, Connectaline, Cordtex, Detlok, Eclipse, Enduradet, Exel, Flexigel, Flexmaster, Fortan, Fortis, i-kon, Goldet, Megamaster, Mobile Manufacturing Units, Nitropril, Pentex, Powerfrag, PowerPlus, Powersplit, Pyromex, Pyrosplit, Reload, Rock on Ground, Senatel, SHOTPlus-i, Simex, Stratablast, Uni tronic, Vulcan and Xtreme are trademarks of Orica Explosives Technology Pty Ltd ACN 075 659 353, 1 Nicholson Street, East Melbourne, Victoria, Australia.

For contact information please visit our websitewww.oricaminingservices.com

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Open Cut Coal - Orica Mining Services Systems... · 2012-03-05 · 2 ORICA MINING SE RVICES OPEN CUT COAL 3 Blast Based Services Through our vast global experience in the open cut