The Advantages of Recycled Oil in Blasting, a Refreshing Approach

Joseph Daly
Downer Blasting Services- Downer EDI Mining
X-Energy
Australia
Abstract
This is the detailed evaluation of the establishment and implementation of an oil recycle plant located
on site at Boggabri Mine NSW, (Australia); its production, its use and its value. Also discussed in detail
is the quality of the raw material produced, and the process and initial application of this raw material
generated as well as the analysis of such, as a component within bulk explosive as applied to the mining
industry as compiled during analysis. Laboratory analysis prior to field testing is also discussed
including independent external laboratory analysis as well as the environmental benefits and a business
case for recycled oil in blasting. This paper includes technical details of the product including densities,
velocity of detonation and other associated key performance indicators. The intention is to off-set the
amount of Distillate (Diesel) utilised as a component of bulk explosives, with a raw recycled oil and thus
reducing both the environmental carbon footprint as well as production costs with regard to introduced
petrochemical production and utilisation; an oil that is an existing recourse of controlled waste not only
difficult but expensive to otherwise dispose of, whilst keeping the entire process on-site. Though
recycled oil in blasting is not an entirely original idea, the key feature of this paper is the ability to
complete the entire process on-site.
Process
Working closely with strategic environmental firm X-Energy, a processing unit comprising of filters,
heating unit and centrifuge was located on site and when placed into production, was able to consume
100% of all waste oil produced through the workshops of the Mine. The trial unit had the following
specifications: (Ullrich 2006. p. 15 of 24)
Unit overall area:
2 m2 (21 feet2)
Unit overall weight: 150 Kg (330 pounds)
Process litres per min: 500 litres (132 US gal) per hour / 8 litres (2.1 US gal) per minute
Centrifuge speed:
10,000 rpm
Heater temp:
60 deg C (140 deg F)

Copyright 2014 International Society of Explosives Engineers

2014G - The Advantages of Recycled Oil in Blasting, a Refreshing Approach

1 of 12

Illustration1: Processing unit beside the mine workshops.

Illustration2: Centrifuge containing removed heavy sediment, metals, contaminants and foreign bodies.

Recycled Oil Fuel Laboratory Analysis

Blasting Laboratories
Samples of raw oil, as well as oil processed by our environmental partners from the mine workshops,
were sent to our laboratories in Qld, Australia. Here it was established that the product will physically
perform in a manner expected and have no ill effects on the existing raw materials contained within the
bulk explosives used at the mine.
Recycled Oil as a component in general
Oils with lower levels of refinement are typically black and extremely odorous due to carbon build up
from heating in previous uses. They can also contain traces of fine metals from internally grinding

Copyright 2014 International Society of Explosives Engineers

2014G - The Advantages of Recycled Oil in Blasting, a Refreshing Approach

2 of 12

engine components which may lead to increased sensitisation. Insoluble fine colloidal particles are also
known to de-stabilise emulsion explosives. Therefore, particular care must be taken in ensuring
compatibility with emulsion explosives.
Viscosity
Low ambient temperatures may cause these recycled oils to become too viscous for proper absorption by
ammonium nitrate (AN) prills and result in poor blast performance, safety hazards, and environmental
problems. To help quantify and resolve these issues, viscosity tests were conducted at ambient
temperatures, similar to those found in blasting areas. The raw oil and blended samples of recycled oil
used must be well stirred to put its carbon sediment in suspension. Laboratory analysis indicates that the
difference in viscosity is not enough to influence the performance of the blasting product of the blend.
Collection
Onsite collection must be made in a way that allows the mine site to easily store suitable volumes of
waste oil for further processing either on or off site. For those recycling methods that rely purely on
supply from the mine where the oil is intended for use, we need to ensure that adequate supply of waste
oil is available to fulfil the mines blasting needs. Otherwise, complications may arise in regards to
having to change from recycled blends back to straight diesel when supply is low. In light of this,
although a blend of 50% has been trialled and proved successful, at 50% the blasting operation would
expend the waste oil at a greater rate than it is being produced, therefore a balance of 30% for would
appear to suitable between waste oil being produced and processed oil in bulk explosives. Further
training and storage should also be made available to ensure that unwanted wastes such as brake fluids
etc are not mixed with engine oils for recycling.
Processing
Onsite processing provides one of the most cost efficient means of recycling over the long term as
transport cost are essentially eliminated. Although capital start-up costs associated with this method of
recycling are higher and these types of facilities are usually restricted to fairly simple processing such as
filtration, centrifuge, heat exchange, they still are more beneficial to offsite processing which have the
additional process of distillation which appears to not be of any benefit to the blasting product anyway.
Blending
Onsite blending can be beneficial if the processing is undertaken onsite as only the diesel portion of the
blend needs to be transported to site. However, this method as with processing requires capital start-up
costs and specialised training and personnel to oversee storage and blending of the oil and of the blended
product. If blending is undertaken at a processing site with access to diesel then there is little difference
in the price. This also eliminates the need for costly blending plants off site as the current diesel storage
facilities can be used for storage and blending of the oil. By using the fuel oil in a blasting compound,
transporting the waste oil is eliminated, the quantity of fuel oil needed for blasting is reduced, and
potentially toxic hydrocarbons in waste oil can be destroyed by the high blast temperature.

Copyright 2014 International Society of Explosives Engineers

2014G - The Advantages of Recycled Oil in Blasting, a Refreshing Approach

3 of 12

External Independent Laboratory Analysis

An external laboratory analysed samples of both raw waste oil direct from the mine workshops as well
as a sample of processed recycled oil. The main areas of interest with relation to the performance as a
component of bulk explosives are:
Metals
Moisture content
Micro Carbon Residue
Total Acid Number
Metals
The majority of metals tested were within the required parameters as set for the recycled oil project.
Testing was done in accordance with American Society for Testing and Materials. (ASTM 2012)
Moisture
Moisture will have an effect on the rate of oil absorption by prill. The laboratory analysis indicates the
final amount of water within the processed oil is approximately 0.4%. As production is utilising a
30/70% blend, this calculates to a moisture content of 0.07% total moisture content. The limit is 0.2%;
therefore the processed oil is within parameters.
Micro Carbon Residue
The idiosyncratic colour of the oil both before and after processing indicates immediately the presents of
suspended carbon, however, an excess of carbon can have an influential effect on the emulsion stability
and the general product performance. Though a slightly higher than expected level of carbon was
discovered, it did not result in any ill effect either in pre-trial lab analysis or production field trials.
Total Acid Number
The total acid number of a component in a bulk explosive should not be excessive as it may have an
undue effect on the gassing rates of a gassed emulsion product. The acid number was slightly higher
than the specification however, with regard to the higher amount of acid numbers; the % of gassing
agent has been increased in the formulation in gassed product to accommodate the gassing rate.
Oil Absorption Test
A batch of ANFO was prepared blending our environmental partners oil with diesel at 30:70 ratio. Prill
showed complete absorption of oil within 10 minutes of its introduction.

Copyright 2014 International Society of Explosives Engineers

2014G - The Advantages of Recycled Oil in Blasting, a Refreshing Approach

4 of 12

Illustration3: Sample of AN Prill with a 30% Recycled Oil absorption.

Water Resistance Test (Conductivity)

This test was undertaken to determine the water resistance of the product using conductivity readings.
An industry accepted fact is that AN is, by no means, resistant to water as it is extremely hygroscopic
(readily absorbs water). This test determines the quality of a bulk explosive with Ammonium Nitrate
emulsion (Heat 800) to create a Heavy ANFO, accepted industry wide to have water resistance
qualities due to the addition of a water resistant emulsion. Quality emulsion will have a lower
conductivity. If the emulsion breaks down, it will separate into a fuel phase and an AN (Ammonium
Nitrate)/CN (Calcium Nitrate) solution. The free hydrogen available in the solution, will allow current
transfer, thus measuring the conductivity of the product will indicate emulsion phase separation or break
down. Standard Distillate with emulsion will not readily break down and that bench mark of
conductivity has been established. This test will then determine the quality of the bulk explosive product
with the addition of recycled oil and measure its conductivity.
Water Resistance Test (Visual)
As outlined in the previous test, emulsion is utilized in the heavy ANFO bulk explosive product to aid
water resistance. An additional visual test was undertaken to determine if the addition of recycled oil
will have a detrimental effect on the bulk explosive product in direct relation to water resistance. A
sample of heavy ANFO (60% ANFO / 40% Emulsion) with ANFO component being 30% recycled oil
was slept under a colored indicator die/water. This sample was observed over time to determine if any
ingress of water was evident into the sample product. A side-by-side analysis was undertaken with a
standard distillate product of the same proportion.

Copyright 2014 International Society of Explosives Engineers

2014G - The Advantages of Recycled Oil in Blasting, a Refreshing Approach

5 of 12

Illustration 4: Water ingress testing over 22 days. Recycled oil, Standard Distillate

Lab Analysis Conclusion

Lower conductivity readings using Recycled oil in comparison to using diesel as only fuel indicate
products good resistance to water. The percentage of ammonium nitrate breakdown is greater using
diesel as the only fuel in the product. Photographic evidence indicates higher ingress of water using
diesel based fuel. The rate of oil absorption displayed by prill using Recycled oil/diesel blend was
comparable with using diesel as only fuel. In summary the Recycled Oil/Diesel blend provides higher
water resistance to the product compared to diesel as only fuel. Based on the test findings it is
recommended that the field trials using recycled oil in ANFO as well as 30% and 70% be conducted to
evaluate blast performance and monitor NOx emissions.
Blasting Research Firing Range
Additional testing was undertaken on the required detonators at the testing facility at Dalby QLD
Australia. Detonators were slept in the samples of oil and then fired on the range at both 2 weeks and 4
weeks to ensure no ill effects on the initiation system of the bulk product. No ill effects were noted with
the exception of some bloating of the rubber seal grommet.

Illustration 5: Detonators after sleeping in recycled oil, testing of detonators on range.

The deformation of rubber with regard to the detonators is of little consequence to the practical use of
the recycled oil as the detonators will already be in the booster at time of contact with oil and will in no
way hamper their practical operation. The mixing platform such as the MPU however will need to have
some seals retrofitted from rubber to biton or neoprene. These seals are around the flow meter and

Copyright 2014 International Society of Explosives Engineers

2014G - The Advantages of Recycled Oil in Blasting, a Refreshing Approach

6 of 12

process fuel pump. There would appear no other changes to the delivery system required after that apart
from calibration.
Recycled Oil Fuel Business and Environmental Case
The opportunity our Blasting Services has taken in short is to reprocess waste oil which in effect will
displace distillate used in bulk blasting explosives. In Australia we generate in excess of 200 million
liters (52.8 million gal US) of waste oil to be disposed of annually. This is a huge amount of controlled
waste to responsibly account for and dispose of in an environmentally responsible manner. Costs are
large as sites are charged for disposal, and as mining sites are rarely conveniently located near avenues
to dispose of the controlled waste, transport is another costly consideration added to the equation.
Existing methods for disposal are furnace and kiln firing which may have lower temperatures than an
explosive blast. According to a case study by Colin McKenna, (2001. pp. 2 of 4) explosive consumption
therefor has a lower environmental impact with fewer emissions.
The alternative is to reprocess the waste oil on the mine site and use it directly in bulk explosive. The
initial two benefits of this is firstly; to remove the disposal, transportation and processing stages of this
controlled waste and secondly; displace diesel brought on site to be used with the manufacture of bulk
explosives. This greatly reduces the mines overall carbon footprint on the environment and has a
significant effect to the financial bottom line. The aim is to develop the capability to reuse engine oil in
blasting products. In short, already paid for waste oils' are a much more cost effective product.
Although its not a total solution it is capable of partially offsetting the diesel usage in blasting.
Corporate aims are to make ourselves as valuable as possible to our clients. A belief that this can be
done and help provide to our clients the following:
Contract security
Differentiation
Environmental Credibility
Delivering sustainable value, not only in Blasting but in the Environment
Waste reduction delivering bottom line cost savings.
There is great value what can be extracted from waste oil. Waste is our fuel.
Other Benefits
Less waste production
Less transport required (fuel and waste)
Less community impact
More community environmental credibility
Adds to mining industry development
Demonstrates an innovations differentiator

Copyright 2014 International Society of Explosives Engineers

2014G - The Advantages of Recycled Oil in Blasting, a Refreshing Approach

7 of 12

Recycled Oil Fuel Field Analysis

The Oil
The Oil as processed on site is now in a clean form free of most water, solids, heavies and contaminants
that may prove detrimental to the bulk explosive or an explosive environment. The oil in its recycled
raw state has a density of 0.875 g/cc and is within the required density range. The oil is black in colour
and has little odour.
The Distillate
The distillate is of a Bio Diesel type. Further analysis is required to establish if its bio derivative has
any adverse effect on the product, however initial tests show there is little effect of the bio diesel versus
standard low sulphur diesel. The Bio-Diesel has a density of 0.84 g/cc.
The Oil/Distillate Blends
The Oil and Distillate is blended, mixed and stored in 1000 Litre (264 gal US) IBCs. A required density
of 30% at 0.85 g/cc and 50% of 0.86 g/cc is required. After agitating the IBCs prior to pumping into
MPUs the required densities were reached.
ANFO 30% Recycled Oil
This is a standard ANFO blend however at 30% of the fuel oil component being recycled oil. This
product proved to mix well and loaded as expected. Densities of the product averaged at 0.8004 g/cc.
CGAN was Yarra. The product performed well with good heave characteristics and no fume with a VoD
of ~ 4035 m/s.

Illustration 6: ANFO being loaded on the bench.

Copyright 2014 International Society of Explosives Engineers

2014G - The Advantages of Recycled Oil in Blasting, a Refreshing Approach

8 of 12

ANFO 50% Recycled Oil

The ANFO blend at 50% recycled oil proved to mix well and loaded as expected. Densities of the
product averaged to 0.793 g/cc across the holes loaded. The product performed well with a VoD or
approximately 4300 m/s.

Illustration 7: 50% Recycled Oil ANFO VoD of ~4300 ms

ThrowMAX 830 30% Recycled Oil

The ThrowMAX 830 product is a top loaded heavy ANFO at 70% ANFO and 30% emulsion however
30% of the fuel oil component being recycled oil. Physically the product appeared as expected with a
density of 1.16 g/cc (within specification).

Illustration 8: TM830 product manufactured and loaded.

The shot profile heave appeared to be uniform with that of the standard product indicating a similar
product performance. There was no trace of fume that could be attributed to the use of this product. A
consistent self-supporting velocity of ~4600m/s was recorded.

Copyright 2014 International Society of Explosives Engineers

2014G - The Advantages of Recycled Oil in Blasting, a Refreshing Approach

9 of 12

ThrowMAX 830 50% Recycled Oil

Physically the ThrowMAX 830 product at 50% recycled oil appeared as expected with a density of 1.16
g/cc (within specification). The product blended well with the emulsion indicating a successful
manufacture, with a similar consistency to the standard distillate blend. The VoD of the 50% recycled
oil TM830 was sufficient measured at approximately 4800 m/s. A power trough as expected allowed
visual observation down into the blasted strata exposing successful evidence of fragmentation. The
evidence of an even profile across the heave pile also indicated an even dispersal of energy across the
shot. No evidence of Fume of Fly-Rock was noted.

Illustration 9: TM830 (50%) product with a VoD of ~ 4800 m/s

AquaMAX 870 30% Recycled Oil

This Product is a pumped bottom loaded product consisting of 70% emulsion, 30% ANFO and gassing
agents. The manufacture was as expected and the product loaded on the shot was no different to that
expected with standard AM870; apart of course from the idiosyncratic colour.

Illustration 10: 30% recycled oil AquaMAX 870 and VoD of ~ 4381m/s

Copyright 2014 International Society of Explosives Engineers

2014G - The Advantages of Recycled Oil in Blasting, a Refreshing Approach

10 of 12

Physically the product appeared as expected with an initial density of 1.32 g/cc (within specification).
As this is a gassed product, the target density of 1.00 g/cc was set. Final density was reached in
approximately 50 minutes of an average of 1.03 g/cc (within specification).

Illustration 11: QA analysis and data gathering as the product gasses.

Gassing Rates

VM 8502 Gassing Rates AquaMAX 870

Loaded 16 May 2013
1.40
1.20

Density g/cc

1.00
Sample 1

0.80

Sample 2
0.60

Sample 3

0.40

Sample 4
Sample 5

0.20
0.00
0

10

20

30

40

50

60

Time minutes
Illustration 12: AM870 (30%) product manufactured and gassing to final density.

Copyright 2014 International Society of Explosives Engineers

2014G - The Advantages of Recycled Oil in Blasting, a Refreshing Approach

11 of 12

A cast allowed visual observation down into the blasted strata now spread over the lower bench
exposing successful evidence of fragmentation. The area of the shot blasted with the recycled AM870
(30%) appeared to have the same cast and fragmentation as the remainder of the shot loaded with
standard bulk explosive. An even profile across the heave pile also indicated a successful shot and an
even dispersal of energy across the shot comparing the trial product to the standard product. No
evidence of Fume, Fly-Rock or air blast was noted.
Conclusion - Recycled Oil Fuel Field Analysis
It has been standard practice for Australian mines to use 100% diesel with ammonium nitrate for mine
blasting. By utilising waste oil in the blasting process mining would save thousands of litres of diesel per
year on a 50:50 explosive fuel blend. This reduces the mines CO2 emissions by thousands of metric
tonnes per year; equivalent to the greenhouse emission of hundreds of passenger vehicles each year.
Less greenhouse emissions associated with transport of fuel, waste oil
Removal, waste oil refining, etc.
Does not produce more greenhouse gasses than diesel based blasting products
Financial benefits are clear, with the addition of possible future political benefits, we are now
well placed within the industry to best develop and implement these initiatives.
The project has proved a validity of concept utilising waste oil in blasting by processing it to ensure
minimal risk to bulk blasting product and process, thus reprocessing waste oil and displacing distillate.
The cost savings associated with completing the entire process from workshop to blast-hole without
leaving the mine site is clearly evident further reducing additional environmental effects and ensuring
ongoing profitability, and environmental credibility to not only the mine site in question but the industry
in general
Joseph Daly Senior Technical Engineer
References
Ullrich 2006. Westfalia Mineraloil Seperator Systems, Westfalia Separator, Mineraloil Systems GmbH
Werner-Habig-Strae 1 59302 Oelde (Germany). pp 15 of 24.
Colin McKenna 2001. ANFO Case Study Used Oil Waste or Resource, Shell Australia Limited
Melbourne Victoria 3000 (Australia). pp 2 of 4.
American Society for Testing and Materials, 2012, Various ASTM, ASTM International, West
Conshohocken, PA, USA, www.astm.org, viewed June 2013

Copyright 2014 International Society of Explosives Engineers

2014G - The Advantages of Recycled Oil in Blasting, a Refreshing Approach

12 of 12