In a move that reflects the growing emphasis on smart mining practices across Australia, a major open-cut coal operation has adopted BME’s cutting-edge AXXIS electronic initiation system to reduce machinery use and boost safety—without compromising blast performance.
Situated in a resource-rich region, the mine produces approximately seven million tonnes of coking coal each year. To meet demanding production targets, the mine had been employing standard cast blasting techniques across 40-metre bench heights, shifting more than three million cubic metres of overburden per blast using dragline-supported operations.
But geological complexities and the need to preserve the integrity of the coal seam forced the mine to rely heavily on auxiliary blasts and extensive dozer activity—a time-consuming and cost-intensive process.
Enter AXXIS: A Precision Solution
That’s where BME came in.
Tom Dermody, BME’s international technology and field services manager, explained the mine’s dilemma. “They wanted to eliminate the need for bulldozer push operations, which were not only consuming a lot of operating hours but also exposing crews to additional risk. They asked us to examine how AXXIS could help modernise their blasting strategy,” he said.
Compressed by jpeg-recompress
Rethinking the Blast Strategy
The challenge was clear: streamline operations without sacrificing safety or the effectiveness of overburden displacement. BME’s team stepped in with an integrated review of the site’s existing blast designs, placing a strong focus on burden movement and timing precision.
“Our approach was to adjust the blast design in a way that the auxiliary blast could do more than just break rock—it needed to strategically cast material toward the production face, effectively shielding the coal seam and eliminating the need for dozer work,” Dermody said.
Precision Timing Delivers Targeted Results
By harnessing the programmable flexibility of AXXIS, the team re-engineered initiation sequences and powder factors, fine-tuning each blast to control the direction and energy of material movement. The upgraded blasting method allowed for controlled muck pile formation, enhancing dragline productivity and minimizing coal loss.
“The key was our ability to precisely time each detonation using AXXIS. That level of accuracy simply isn’t possible with traditional non-electric systems,” Dermody noted. “It allowed us to execute throw-style blasts with remarkable control.”
Safer Blasts, Less Exposure
One of the major gains was in safety. Previously, dozer operations near highwalls had to be carried out under strict permit systems due to the inherent hazards. With the new blast design, the need for such risky post-blast activity was virtually eliminated.
“This wasn’t just about efficiency—it was a step change in safety,” said Dermody. “Reducing exposure to high-risk areas is a win for both the workforce and site productivity.”
Real Results That Speak Volumes
The results spoke for themselves. Not only did the mine record a drop in dozer operating hours, but the data also showed a measurable decline in potential coal loss. With fewer disruptions and smoother transitions between blasts, the site began to unlock significant cost and time savings.
“Compared to traditional methods, the revised approach was faster, safer, and ultimately cheaper. The return on investment was clear within just a few blast cycles,” Dermody added.
Smart Blasting: The Way Forward for Australian Mining
Beyond this single site, the success underscores a broader shift within Australia’s mining sector. Mines are increasingly leaning into digital and data-driven solutions to overcome long-standing operational challenges.
The AXXIS system, now in use at multiple mine sites around the globe, offers users real-time programmability, high detonator capacity, and millisecond accuracy. These features make it a go-to solution for operations aiming to reduce environmental impacts and increase ore recovery through targeted, efficient blasts.
Also Read: New World Resources Rockets 68% on Takeover Bid by Central Asia Metals
Setting a New Benchmark
“The beauty of electronic initiation is in its adaptability. Whether the goal is improved fragmentation, reduced vibration, or strategic throw direction, it allows for surgical-level precision,” said Dermody.
As Australia’s mining sector continues to evolve with an eye toward sustainability and tech innovation, the story of this coal mine’s transformation is likely to become a playbook for others.
“This is the direction the industry is headed,” Dermody said. “Smarter blasts, safer practices, and more value from every hole drilled.”
With AXXIS now embedded into its blasting operations, the coal mine is on a trajectory toward improved efficiency, reduced environmental footprint, and enhanced worker safety—all without sacrificing output.
