In an era where operational margins are won or lost in the blast outcome, Eureka Mine has moved beyond traditional pyrotechnic constraints to better blasting. By transitioning from legacy shock tube systems to AECI’s flagship electronic initiation platforms, Intellishot®, the operation is not just blasting, it is taking full control of the blasting outcome.
Located in Guruve, Zimbabwe, Eureka Mine is a cornerstone of the nation’s gold production. Operated by Dallaglio Investments (a subsidiary of Padenga Holdings), the mine utilises the contractor mining model on drilling, blasting, loading, and hauling services. While this model offers flexibility, it requires high-level of technical blasting integration to ensure that every blast yields into the downstream mine performance.
Historically, Eureka Mine faced several technical bottlenecks common in legacy systems. Poor fragmentation and inconsistent perimeter control were leading to high secondary breakage costs. Furthermore, the limitations of shock tube timing meant an inability to blast larger benches, resulting in a high frequency of blasts, averaging ten per month, reducing the mine equipment utilisation index.
From a safety perspective, the open-flame initiation system posed a fatal risk which modern mining engineering seeks to eliminate.
The transition to AECI’s IntelliShot® system began strategically in controlled (buffer blasting) and ore blasting before a full rollout on all blasting activities. The technology allows for up to 16,000 programmable detonators per blast, with delays ranging from 0 to 20,000 ms, which enhances the Drilling and Blasting Engineers’ control over a design blast.
This millisecond-accurate timing allows for single-hole firing and complex blasthole sequencing that is not possible with pyrotechnic systems. “Precision equals performance,” notes the AECI Explosives Engineer, Kudzai Kondo. “Optimised muck pile profiles, vibration control, and cast accuracy are the direct results of the adoption of the new technology on precise and accurate blast timing.”
The adoption of the AECI’s Electronic Initiation Systems (EIS) has yielded operational benefits into the mine value chain. By optimising blast designs, Eureka Mine has achieved the following:
- Blast Size Scale-Up: Blast sizes have increased from an average 30,000 bcm to a staggering 110,000 bcm.
- Reduced Blast Frequency: Blast frequency has reduced from ten (10) to an average of six (6) per month, increasing the mine equipment utilisation index.
- Fragmentation Excellence: Fragmentation performance rose from 95% to a consistent average of 97% per ore bench, increasing the crusher performance from 302 tph to an average of 331 tph.
- Wall Stability: Final wall berm retention ratings rose from an average of 79% to an average of 85%, allowing for an optimised pit shell design, which increases the life of the mine.
Michael Zvaraya, the Mining Manager at Eureka Mine, emphasises this results-oriented approach: “We have seen the benefits off the new system on our value chain from blasting of benches to the processing of the blasted rock. This system has been a key enabler during our production ramp-up period to ensure we optimise on all the key mining indices.”
The new system required a comprehensive training conducted by AECI Mining to Eureka Mine and Mining Contractor technical and operational teams to ensure there is transference of knowledge as part of the Management of Change (MOC).
“AECI has been pivotal in our drilling and blasting optimisation strategies” says Senior Mining Engineer, Desmond Chawira. “They have been with us from the trial phase into the full rollout phase, providing 24/7 technical assistance on complex blasting operations.”
From a safety standpoint, the ability to initiate blasts remotely from up to 3 km away from the blast has enhanced control on fatal risk management over explosives. “Intellishot significantly reduces personnel exposure to the effects of the blast,” says Taurai Mudzimuirema, AECI Site Manager.
Ryan Masona, Drilling and Blasting Superintendent, adds: “The system is safe, simple to use, and easy to understand even in challenging situations.”
The success at Eureka Mine serves as a blueprint for the Zimbabwean mining sector. Moshen Jena, Regional Manager for AECI, concludes: “The future belongs to those organisations that embrace technology. We are proud to partner with Eureka Mine to unearth wealth. Our electronic blasting systems have gained widespread application in both underground and surface operations across Zimbabwe and the world over.”
Through the pillars of Precision, Safety, and Efficiency, Eureka Mine and AECI are proving that intelligent blasting is no longer a luxury, it is a prerequisite for the modern, high-performance mine.
