Mining explosives and blasting technology supplier BME’s modular emulsion manufacturing plants are addressing the extreme and remote conditions of the African mining sector, as they reduce exposure to the risk posed by transporting higher risk explosives products over long, hazardous and remote distances, says BME production and logistics GM Dirk Voogt.

Built into standard shipping containers, these on-site plants manufacture stable base emulsions from raw materials, significantly reducing supply chain risk and operational costs while allowing for fast installation at sites that are isolated or difficult to access.

The company offers flexible and scalable modular plants, with output capacities ranging from producing 20 t of emulsion in an eight-hour shift, to capacities of more than 40 t. These plants produce high-quality bulk emulsion explosives to match a mine’s explosives requirement.

Most of the raw materials used in the modular plants are classified as Class 5.1 oxidisers, thereby reducing overall transportation risk.

Unsensitised emulsions become true class 1.1 explosives only once chemically sensitised and pumped into a blast hole. Consequently, dedicated high-security magazine facilities on site are not required for the blasting material, clarifies Voogt.

Mining operations in regions such as West Africa, or in South Africa, often face disrupted supply lines, whereas on-site emulsions plants can provide a secure, continuous and independent supply of high-quality blasting explosives.

BME’s modular systems and emulsions are designed with sustainability in mind, including the ability to process used oil as a fuel agent, thereby supporting local circular economies, the responsible reuse of hazardous waste and helping mines meet their environmental, social and governance targets.

This innovative model directly addresses the distinct challenges of African mining operations, including those presented by remote locations, complex logistics, fluctuating demand, and rigorous safety and environmental standards.

The modular emulsion plants are designed to support full-service blasting contracts and integrate with BME’s comprehensive blasting ecosystem, adds Voogt.

The company has experience in deploying emulsion plants across operations in South Africa, Mali, Mauritania, Burkina Faso, Sierra Leone, the Democratic Republic of Congo and Angola.

Blasting Benefits

BME’s modular emulsion manufacturing plants significantly reduce civils work and site preparation requirements compared to traditional fixed or on-site-built emulsion facilities.

The plants are designed as self-supporting, containerised modules that can be installed on simplified foundations, such as compacted hardstands or basic concrete plinths, rather than extensive reinforced concrete structures and purpose-built buildings.

Additionally, utilities and services are connected through predefined interfaces, eliminating the need for complex underground services, extensive trenching or permanent infrastructure installations.

This approach, highlights Voogt, allows for site preparation activities to run in parallel with plant fabrication, significantly reducing overall project lead time and lowering construction risk – particularly at remote sites where civil construction resources, specialist contractors and quality-controlled materials can be limited.

In addition to reducing capital cost and schedule, the low civils footprint also allows for faster and simpler relocation should mine layouts or production requirements change over time.

“BME’s standardised modular plants have been designed to exceed international operational safety standards and represent the accumulation of more than 40 years of engineering development and design,” he concludes.