Chemicals and mining explosives company AECI unveiled trinitrotoluene- (TNT-) and pentaerythritol tetranitrate- (PETN-) free booster technology at the European Federation of Explosives conference, held in Kraków, Poland, in September.

Against a backdrop of tightening supply chains and rising safety expectations, the company says the supply of TNT, a cornerstone of traditional booster formulations, has become increasingly constrained.

AECI explains that production of TNT is concentrated in regions such as China and Russia, noting that geopolitical instability has placed commercial users in competition with defence sectors.

Beyond supply, TNT and PETN carry inherent risks in handling, storage and transportation.

The company says the mining industry, long reliant on such materials, has thus been compelled to re-examine its dependence on volatile global supply chains.

AECI Mining Explosives GM for mining explosives South Africa Ritzema Nel says engineers and scientists at AECI developed a two-component booster that contains no TNT or PETN.

The system uses mostly local, inert materials that only become sensitive in their final combined state.

AECI notes that benefits include non-explosive inputs that lower the probability of accidental detonation during shipping or storage and, by avoiding UN Class 1 classification, logistics are easier and less costly across air, road and sea.

Additionally, local sourcing reduces carbon emissions associated with importing explosives, aligning with stricter climate regulations and environmental, social and governance (ESG) commitments.

Moreover, on-site or near-site manufacturing opens pathways for local enterprise development and job creation.

“By moving away from TNT and PETN, we’re reducing operational risk and opening the door to more sustainable and resilient supply chains,” says Nel.

AECI notes that developing an alternative was only part of the challenge. Proving its reliability under field conditions was equally critical.

At a coal producer’s South African opencast mines, blast hole temperatures can reach 120 °C, an environment in which conventional TNT-based boosters soften or degrade.

AECI says the new booster incorporates a thermally resilient shell that maintains structural integrity in hot-hole applications.

The company notes that laboratory testing was followed by extensive field trials where more than 84 000 units were tested across African sites before full-scale commercial rollout.

Since adoption, the company says, over 1.8-million boosters have been safely fired without incident.

Operational crews also reported strong acceptance of the design, noting practical features such as easy detonator placement and adaptability in varied blast configurations, AECI adds.

Nel says the innovation arrives at a critical time for global mining.

“Supply chain disruptions, decarbonisation targets and heightened ESG scrutiny are reshaping procurement and operational practices.

“By reducing reliance on restricted imported inputs and aligning with climate reporting frameworks, the TNT-free booster demonstrates how explosives technology can evolve in step with these broader pressures.

“Importantly, localised manufacturing not only improves flexibility and security of supply but also creates measurable socioeconomic benefits through job creation and supplier development.”

While explosives have historically been viewed through a narrow technical lens, AECI says the case presented in Kraków shows how rethinking their composition can have far-reaching effects.

From reducing insurance premiums tied to risk exposure, to easing compliance burdens and lowering emissions, the company says the booster design now intersects directly with issues of competitiveness and sustainability.

“The interest we’ve seen reinforces that precision, safety and measurable return on investment are universal priorities in mining.”