Blasting and Chemicals
Alleviating supply chain complexities in modern mining
Inflation has been a significant concern for the mining industry, and mining companies have had to take measures to mitigate its impact while feeling pressure to upgrade processes to reduce environmental harm. This has pushed the industry, especially service providers, to delve deeper into R&D, seeking technological advancements to both enhance production efficiency and reduce environmental impact. Meanwhile, supply chain disruptions of cyanide, flocculant, antiscalants and ammonia, all necessary to process minerals or fabricate explosives to extract minerals, have added an extra layer of complexity. According to Brady Greifzu, Solenis' global corporate sales executive, these factors have not been compensated for by corresponding surges in mineral commodity costs. "The recent global supply chain crisis and inflation have not been matched by similar increases in mineral commodity prices, creating a gap for mine operators to fill. Thus, to enhance profitability, many operators have turned to Solenis to help reduce reagent costs and boost throughput and recovery," he explained.
To help its clients prevent disruptions and determine the exact dosage of a product, Solenis has developed Solenis Cloud, an online performance monitoring automation and data analytics platform paired with a set of sensors that can be customized based on the application and customer needs: "We have automation programs that use parameters like pH, flow rate, and ore body chemistry in real-time algorithms to determine the dosage of a product. When paired together with our online inventory, the demand can help in projecting usage. This allows us to forecast when a tank needs to be refilled and coordinate with the supply chain for timely and optimal delivery service," stated Nick Morrison, mining applications manager at Solenis.
Cyanco is another company that has witnessed an increase in the cost of essential raw materials, particularly ammonia and natural gas, which are vital for sodium cyanide production. Like Solenis, Cyanco offers its vendor-managed inventory (VMI) to control cyanide dosing precisely, set specific targets, and receive continuous feedback to tackle rising costs and assist its customers. "Having an online analyzer with real-time feedback is especially relevant in milling operations where cyanide is added at the front end of the circuit to extract raw materials. By closely monitoring and controlling cyanide dosing at the beginning of the milling process, customers can reduce the need for detox reagents at the end, leading to additional, significant cost savings," explained Steve Cochrane, US sales manager at Cyanco.
Looking for a greener blasting
The choice and usage of chemicals are intricately linked to the efficiency of explosives. "Chemical crushing achieved through explosives has long been recognized as more efficient than mechanical crushing involving steel, such as crushers and grinders. By optimizing chemical crushing through blasting, mill operations, which are significant cost drivers for the mine, can function more efficiently," explained Braden Lusk, America's president at Dyno Nobel.
But how can a mining company optimize blasting? Investing time in understanding the expected outcomes through the integration of new technology enables companies to achieve a targeted fragmentation. "Once the expected outcome is clear, we can effectively fine-tune our blasts, considering both cost and performance factors to ultimately provide the mine with precisely what it requires," elaborated Lusk.
Dyno Nobel is focusing on manufacturing ammonia to produce ammonium nitrate. "A strategic move considering the volatility of the ammonium nitrate and ammonia market in recent years," Lusk stated.
ESG compliance is prompting mining companies to ask their service providers for more eco-friendly products and services. As such, Dyno Nobel is also working on carbon dioxide sequestration at ammonia plants and nitrogen abatement projects across various facilities to provide customers with lower-carbon products.
While the market share of the blasting segment may be controlled by a few major global companies, the Western United States presents opportunities for other companies looking to enter the market. Such is the case of the South African BME. The blasting company, currently focused on Canada as it works on establishing a manufacturing and distribution facility in Sudbury, Ontario, has a modest footprint in the US but aims to expand its presence. "The US remains a strategic market for the company, and we plan to evolve our offering in this region as we have in other international markets," commented Scott Scovira, global manager blasting science at BME.
Like Dyno Nobel, BME has been actively developing "greener" explosives and emulsions through partnerships. One such collaboration is with the Swedish company Hypex Bio, which commercializes hydrogen peroxide explosives. According to Scovira, these products demonstrate a 90% lower carbon footprint during manufacturing compared to standard nitrate products: "Hydrogen peroxide explosives stand out due to their inherent lack of nitrates, a key contaminant in mine water known to impact aquatic ecosystems and wildlife," explained Scovira.
Article header image by Dimitri Melkin at Adobe Stock