Quarry - Orica Mining Services · PDF fileQUARRY 1 At Orica, we recognise ‘The Power of Partnership’ and the value of building long-term relationships with our Customers. We are

Quarry Products and Services

August 2011

QUARRY 1

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, and we aim to maintain and enhance that reputation.

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

09 Bulk Systems

11 Electronic Blasting Systems

13 Initiating Systems

17 Packaged Explosives

QUARRY 32 ORICA QUARRY SERVICES

Blast Based ServicesThrough our vast global experience in quarry operations, we understand that every quarry has unique needs and value drivers. For this reason, we developed 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;

• compliance and quality services delivered by our Technical Services team;

• Advanced Blast Based Services, which offer tailored solutions to deliver immediate results and also maximise downstream value generation in quarry operations.

Technology& Tools

Survey

Design

Modelling

Measurement

QualityServices

Blast Quality Services

Blast Training Courses

Quality Audits

Site Surveys

Blast Design & Management

Site Compliance & Risk Management

Industry Benchmarking

Environmental

AdvancedSolutions

ROG™ Rock on Ground

AVM™ Advanced Vibration Management

R2S™ Rock to Speci�cation

ABT™ Advanced Blast Technologies

Sustainable Development

Research and Development Our aim is to develop innovative product and service solutions to improve mining, quarrying and construction efficiency. We do this by providing the right solution, first time, every time.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 quarry 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 professional advice and support.

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 specifically designed for the Quarry Market.

• 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 quarry operations and establish a base line for identifying 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 processing equipment selection.

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, 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 quarry operations.

• Modelling: Orica has developed a wide range of modelling tools for the simulation of quarry 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, flyrock and airblast as well as product performance and cycle time.

Blast Based Services continued


AdvancedSolutions

For Customers in the quarry 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 consistent, reliable supply of rock through quality inputs. Rock on Ground™ assures predictable cost to a specified site, while enhancing your safety and environmental performance through tight process control, measurement tools and high on-bench standards.

An Advanced Vibration Management™ solution offers blast design and execution supported by sophisticated measurement and statistical modelling techniques particularly appropriate to higher risk structures, specific geologies or where an elevated 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 tailored wall control blasting, or specialised blast designs where holes are designed and loaded to individual specifications to manage blasting effects in close proximity 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 are designed to deliver:

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

• Risk assessment, design, management and execution of blasts in close proximity to sensitive structures.

• Reduced unit cost through the most cost-effective blasting of caprock zones.

• Optimising crushing and screening throughput by blasting to specific fragmentation specifications.

• Improving performance outcomes, and maximising blast sizes within allowable vibration and air overpressure limits.

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

Rock 2 Spec™ draws on Orica Mining Services expertise in novel design of blast parameters, leading edge visioning systems and data base management services aimed to deliver tailored fragmentation benefits to Customers. It provides Customers with a service that aims to deliver agreed relative improvements in the fragmentation of blasted material (e.g. reduction of fines or minimisation of cap rock oversize).

Blast Based Services continued


The Centra™ Bulk System is a range of high energy, water resistant, pumped emulsion blends designed for small diameter use in quarrying blasting applications. Manufactured and delivered with precise control, the high on bench productivity of the Centra™ Bulk System means faster delivery and turn around of shots.

The Centra™ Gold Bulk System is a range of high energy, water resistant pumped emulsion blends. Centra™ Gold is a chemically sensitised, variable density product. The Centra™ Gold Bulk System complements the Centra™ Extend dry hole product range.

Key Benefits

• Centra™ Gold is manufactured and delivered with precise control at a rate to enhance your productivity compared to traditional quarry blasting

• Centra™ Gold is an energetic explosive with proven reliability in difficult blasting applications

• The increased energy of Centra™ Gold GT enables pattern expansion resulting in reduced drilling and quarrying costs

• Centra™ Gold GT maximises energy and promotes muckpile movement

• Centra™ Gold ES delivers lower charge weights with reduced energy for sensitive blasting applications

• Centra™ Gold ES can be used to reduce energy in situations where burden designed for Centra™ Gold products are not realised in the field, resulting in under-burdened blast holes

• Centra™ Gold provides fully coupled explosive charges to maximise blasting outcomes

• The high on bench productivity of the Centra™ Gold range means faster delivery and turnaround of shots

• OH&S issues around the handling and storage of packaged products is eliminated

Centra™ Extend is one of the leading products in Orica Quarry Service’s bulk product range, specifically designed for quarry and construction blasting applications in dry conditions. Centra™ Extend is a dry hole bulk explosive performance matched to Centra™ Gold.

Key Benefits

• Reliability in difficult conditions gives consistent performance

• Less labour intensive than traditional quarry methods resulting in reduced costs

• Increased pattern size lowers cost of drilling

• Performance matched means on the day you can choose wet or dry, or a combination of both

• Increased energy enables greater pattern expansion

Bulk Systems

Orica’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® (MMU®) 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 MMU® fleet for the quarry market consists of Quarrymasters™ and Handimasters™. These units can be combined with trailers to deliver in excess of 20 tonnes in a single load. Delivery of product through Orica’s twin hose loading system means even the largest load is delivered quickly and efficiently.

Delivery Systems


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 Quarry blasting

• Vibration control

• Improved blasting efficiency

• Enhanced safety and security

• Reduced and simplified inventory

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

Technical Properties

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

Units per case 120, 90, 60, 55, 40, 35, 30

Downline wire Conductor is copper-clad steel for tensile strength

Wire tensile strength 25 kgf / 200 N load

Product ApplicationDensity

(g / cc)RWS% RBS%

VOD

(km / s)

Rec. Min.

Blasthole

Diam.

Rec. Max.

Blasthole

Depth

Rec. Max.

Charge

Length

Hole

Type

Rec. Max.

Sleep

Time

Gassed Re-active

Centra GoldGold ESGold GT

Designed specifically for use in wet blastholes

1.201.101.20

11299

115

168136172

4.5 – 6.44.1 – 5.84.4 – 6.5

767676

252525

202020

Dry or Wet

Dry or Wet

Dry or Wet

21 days Yes No

Centra Extend Dry hole bulk explosive

1.10 114 157 3.5 – 6.05 89 25 20 Dry 21 days Yes No

Centra Eclipse Designed for mildly reactive ground

1.10 – 1.25 102 – 112 140 – 175 3.7 – 6.6 90 30 25 Dry, wet or dewatered

21 days Yes Yes

Centra™ Eclipse™ Bulk System has been designed specifically to provide explosive performance characteristics best suited to the requirements of Australian quarries with mildly reactive ground. Specific densities can be selected to match desired blast performance criteria. It can be used in wet, dry or dewatered blastholes. Product selection should be made on the basis of the results of Orica laboratory testing.

Key Benefits

• Ability to blast safely in mildly reactive sulphide deposits

• Energy can be tailored to match ground conditions

• Ability to blast in dry, wet or dewatered blastholes

Bulk Systems continued


Initiating SystemsFeaturing the Exel™, Pentex™ and Cordtex™ 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.

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 quarrying operations. An ideal in-hole initiating system Exel™ MS Detonators will directly initiate Pentex™ boosters and packaged explosives.


Signal tube Pink Exel

Outer diameter 3 mm

Nominal tensile strength 45 kgf

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.

Uni tronic™ Scanner 120

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™ 500 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™ 310 Blast Box

The 310 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.

Uni tronic™ 310 Remote Firing System allows users to initiate Uni tronic™ and non-electric blasts conveniently and remotely from a chosen point-of-safety, well away from any safety hazard or blast effects.

A programmable Dongle is required to convey the remote box serial number and one-time code to the control box at the point-of-safety. Until this Smart Dongle is docked in the control box, and the code is activated, the remote box cannot power up or program any detonators.

Electronic Blasting Systems continued


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™ 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


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 Systems continued


Packaged ExplosivesOrica Quarry Services manufactures a range of packaged products for the Quarry Industry.

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™ is packaged in white plastic film, colour highlighted in blue. 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

Nominal density (g / cc) 1.21

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

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 confinement. The minimum VOD quoted is based on unconfined test firing data.

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

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 diameter 34 mm

Nominal length 120 mm

Nominal mass 150 g

Nominal density 1.7 g / cm³

Velocity of detonation 7.2 km / s

Nominal detonation pressure 22.0 GPa

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

Initiating Systems continued

18 ORICA QUARRY SERVICES

Senatel™ Powersplit™ is designed for quarrying 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 colour highlighted in purple. Standard cartridge sizes are as follows:

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

26 27 17

32 20 17

Performance

Nominal density (g / cc) 1.18

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

100%

147%

Minimum velocity of detonation2 (km / s) 6.5

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 confinement. The minimum VOD quoted is based on unconfined test firing data and is influenced by the presence of detonating cord and emulsion in the product.

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

Packaged Explosives continued

** 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, Centra, Connectadet, Cordtex, Detlock, Eclipse, Exel, Goldet, Handimaster, Mobile Manufacturing Unit, Pentex, Powerfrag, PowerPlus, Powersplit, Quarrymaster, Rock on Ground, Rock 2 Spec, Senatel, SHOTPlus‑i and Uni tronic 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 website www.oricaminingservices.com

Documents

Quarry - Orica Mining Services · PDF fileQUARRY 1 At Orica, we recognise ‘The Power of Partnership’ and the value of building long-term relationships with our Customers. We are