An Integrated Approach Towards Meeting Tomorrow’s Challenges

In what has become a rapidly evolving industry, the importance of future-proofing mining should not be underestimated. However, it should be understood that future-proofing means a whole lot more than simply staying ahead of the game.

According to Stuart Miller, executive vice president: mining at AECI, true future-proofing is about reshaping the industry to meet tomorrow’s challenges head-on.

“Our integrated approach across explosives, mining chemicals, and water solutions ensures that we are not only solving today’s operational hurdles, but also anticipating future demands,” he says.

“From precision blasting technologies to advanced water management systems, AECI’s innovations are engineered to enhance safety, drive operational efficiency and support responsible environmental practices across the mining value chain.”

AECI clearly takes an active role in “future-proofing” the mining industry, particularly in Africa, as the company offers solutions that address evolving challenges and opportunities.

Research and development

This includes leveraging its research and development (R&D) capabilities to deliver customised solutions, promote sustainable practices, and embrace cutting-edge technologies. The company is also focused on developing a resilient ecosystem and fostering a shared vision for a more sustainable future.

“R&D is at the core of AECI’s future-ready strategy. With more than a century of innovation behind us, our commitment to research continues to drive breakthrough solutions for complex mining environments.

“We invest in developing advanced technologies that deliver measurable impact – like the IntelliShot® X electronic detonator, for precision blasting in extreme conditions, and the Sengen 900 flotation reagents, for improved mineral recovery and sustainability. Each solution is backed by robust scientific research and close collaboration with customers to ensure relevance and effectiveness,” he notes.

Miller says at AECI Mining, the business is embracing Industry 4.0 through the introduction of automation in its IntelliShot electronic detonator assembly line.

“The new state-of-the-art line incorporates two laser soldering robots, purpose-built to enhance both quality control and throughput efficiency. This technology reduces manual intervention in critical soldering processes, ensuring consistency, precision, and traceability.

“It also supports our safety and [environmental, social and governance] commitments, by minimising human exposure to hazardous operations, while also boosting productivity to meet growing global demand.”

Recent innovations

Miller states that sustainability is embedded in every aspect of AECI’s innovation pipeline. These technologies are specifically designed to lower environmental impact – from reducing fuel consumption and emissions, to
conserving water.

“For example, our vertical emulsion drop system improves underground logistics while significantly decreasing Scope 3 emissions. Similarly, our flotation reagents are formulated to reduce water usage and enhance recovery efficiency. And in water management, we help customers convert waste into value, aligning operational goals with long-term environmental stewardship.

“We have, in fact, developed quite a range of exciting innovations, [including] our S300 Volcano technology, which is engineered specifically for extreme volcanic mining conditions.”

Another solution is the PowerBoost™, which is a high-temperature booster designed for blast holes exceeding 89mm, and able to withstand temperatures of up to 200°C, while the Emulsion Vertical Drop System is a record-setting 980m drop, which enhances underground efficiency and reduces environmental impact.

“IntelliShot® X, on the other hand, is our next-generation detonator technology that delivers unmatched blasting accuracy, while the Sengen 900 series of flotation reagents provide cost-effective, high-performance solutions for complex ore bodies, with sustainability benefits.

“Finally, we also provide integrated water solutions, which are focused on retreatment and safe discharge of process waste streams, enabling value recovery and environmental compliance.”

Critical collaboration

Collaboration is key to delivering future-fit solutions, continues Miller, explaining that AECI works closely with customers across Africa and the rest of the globe, to co-create technologies that directly address their site-specific challenges.

“This customer-centric approach – supported by our deep technical expertise – ensures that we are not only responsive, but proactive in driving change. We believe that meaningful partnerships with our customers unlock the best solutions, which tend to be tailored to specific site conditions, operational challenges, and long-term goals,” he says.

“Our team works closely with mining operations to understand their unique needs, then applies deep technical expertise to develop fit-for-purpose technologies. For example, in Papua New Guinea, our work on the Lihir project led to the development of the breakthrough S300 Volcano emulsion, designed to perform reliably in extreme volcanic environments.”

Similarly, AECI’s support of the Kamoa project in the Democratic Republic of the Congo has driven advanced underground emulsion applications, which enhance productivity and safety in deep, high-pressure mining conditions. These collaborations are proof of AECI’s commitment to delivering custom innovation where it matters most.

For Miller, the message is clear: AECI is committed to shaping a resilient and responsible future for mining.

“Through relentless innovation, deep technical partnerships, and a focus on sustainable value creation, we’re enabling mines to operate smarter, safer, and greener. We’re not just delivering products – we’re delivering future-proof technologies that align with the global shift towards more sustainable and efficient mining practices.

“Furthermore, our teams span disciplines across mining engineering, chemistry, digital technology, and environmental science, allowing us to approach challenges from multiple angles and deliver holistic, future-forward solutions.

“It’s this blend of technical excellence and practical know-how that enables us to consistently deliver value and stay ahead in a rapidly evolving mining landscape,” he says.