CASTINGSSTEEL CONSTRUCTIONSCRUSHERS AND CRUSHING SETS Reliability of the future

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ABOUT US

INDEXAbout us ............................................... 2

Castings .............................................. 4

Steel constructions ............................. 8

Crushers and crushing sets ................. 12

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The current offer of the company includes the following categories of products and services: mining machinery, conveyor belts, crushers, steel structures, castings, an-chors, flotation machinery, shaft equipment, servicing, repairs and maintenance.

For many years, KGHM ZANAM has been a major supplier of mining machinery and equipment for KGHM Polska Miedź S.A. mines and plants. It also provides

equipment and services to other underground mines in Poland - salt, zinc and lead mines.

KGHM ZANAM also sells products to foreign customers: Russia, Kazakhstan and Germany. Company products are also present in France, Estonia, Uzbekistan, Turkey and Pakistan and the international distribution network is con-stantly expanding.

KGHM ZANAM S.A. is one of the largest Polish producers of machinery and equipmentfor the mining sector. The company also manufactures equipment used in han-dling systems, transportation units, stone mining and openpit mining. In addition, KGHM ZANAM is also a major producer of steel and iron castings

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CASTINGS

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Regular offer of KGHM ZANAM Foundry includes cast steel and cast iron castings, produced in a number of pro-duct groups:

• castings for jaw crushers, cone crushers, impact and hammer crushers,

• castings for mills used in the processing of metal ores, industrial minerals, coal and lignite (linings, armour pla-tes, perforated plates, vents, feed material accessories, pin caps, beaters, shields, etc.),

• castings for teeth and links for track chains of excava-tors and loaders,

• castings for mining backfill accessories (pipes, elbows, tees),

• components of heavy equipment (joints, brake housin-gs, hubs),

• castings of anode plates and chill moulds,

• castings for haulage vehicles and conveyors,

• other castings as specified by the customer.

KGHM ZANAM Foundry completes orders for many indu-stry branches, such as: rock handling, mining,metallur-gy,chemicals, energy, machines, transport, railway.

Production profile includes approx. 2 000 product items manufactured annually and made of approx. 50 types of cast steel and cast iron and with weight ranging from 5 kg to 5 tons. This extensive range of manufactured products enables us to meet the needs, demands and requirements every customer including small individual businesses. The foundry operates necessary production facilities and tools enabling us to complete complex orders at every sta-ge of the production process:

• preparing a process design,

• manufacturing or adapting foundry models,

• casting,

• heat treatment,

• machining,

• testing of the finished product.

The foundry implemented an integrated quality ma-nagement system in accordance with ISO 9001:2009, ISO 14001:2005, PN-N-18001: 2004. Experienced person-nel, modern equipment and certificates guarantee high quality of our products.

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CAST STEEL CASTINGS

The foundry specializes in manufacturing cast steel castings according to national and European standards. It also pro-duces cast steel items according to its own specifications. The foundry offer includes different types of structural carbon steel castings, structural alloy steel and cast steel for quenching and tempering and for saturation with high-strength and increased abrasion resistance. A large part of production includes high-manganese abrasionresistant steel of high quality that ensures a long service life of the spare parts for machines used in mining industry.

Our wide range of products includes items made of:

• structural carbon cast steel,

• structural alloy cast steel,

• cast steel for quenching and tempering and for saturation with high-strength and increased abrasion resistance, pro-duced according to national and European standards,

• heat resistant cast steel.

We also produce alloys with chemical composition and properties defined according to individual customer demands.

All castings are subject to heat treatment processes carried out in a modern, fully automated furnaces (standardization, annealing, solutioninig, quenching and tempering, etc.).

Cast steel castings are produced in a wide range of weights, depending on the size and type of moulding.

• small and medium production series using moulding machines - from 5 to 100 kg,

• production of individual moulds by manual forming - from 15 to 4 500 kg.

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CAST IRON CASTINGS

The production offer of the foundry includes castings made of grey cast iron and ductile cast iron, produced according to national and European standards. Technology of producing cast iron in electric arc furnaces provides a high-quality metal with the required chemical composition, properties and structure, to meet the requirements of the most deman-ding customers.

The production offer includes castings made of:

• grey cast iron,

• ductile cast iron,

• alloy cast iron.

Cast iron castings may be subject to heat treatment processes, depending on the requirements and needs of the customer.

Depending on the size and type of moulding series, the weight range of castings made of cast iron is as follows:

• small and medium production series using moulding machines - from 3 kg to 60 kg for grey cast iron and ductile cast iron,

• production of individual moulds by manual forming - from 10 kg to 5 000 kg for grey cast iron and from 10 kg to 1 500 kg for ductile cast iron.

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STEEL CONSTRUCTIONS

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KGHM ZANAM S.A. Is a well-known and experienced manufacturer of large-scale welded steel constructions. ExperiencedEmployees, technological potential, granted approvals and certifications guarantee high quality of our constructions.

Our products are covered by a service agreement. We operate our own, modern design office.

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Type Sheets SectionsThickness [mm] Width [mm] Length [mm] Width [mm] Height [mm] Length [mm]

Open shot blastingmachine -PP8R 5 - 50 up to 2500 up to 12000 up to 2500 up to 500 up to 12000

Shot blastchamber

Length [mm] Width [mm]14000 5000

1.3. Plastic formingBending on bending brake.

Guillotine cutting of shaped profiles and sheets with thickness up to 25 mm.

Gas cutting.

Straightening of parts and metal plates.

1.2. Cutting Saws.

1. PRE-TREATMENT1.1. Cleaning

TYPEDimensions of cut material

Diagonal cutRound Square

Band-saw STG440DGH / 620.460DGM ɸ 440 440 ± 60o

0L 400A / 0L 400 ɸ 400 400

Shaping slots Max. sheetsize

Max. rodsize

Gap betweenstands

Lengthof stands

Universal NU 25Aangles

180x180x18

25 Round 65Square 55

180x120x18tees 140x15

flat bars 160x28

Guillotine NG 13 13x3000 3200 600ScTP 25 25x3150 3250 630

Name Type Thickness range Max. cutting length Max. cutting width Additional accessoriesCORTA DP 5000 0-100/200 6.000 4.000 Plasma torch, cutting thickness 0,5-12mmOMNICUT 5000 0-100/200 6.000 4.000 n/a

Type Nominal pressure[t] Slider pitch Table width

[mm]Gap between

columnsDepth stop pitch

mm/sEdge PS 650/55 650 515 320 4500 2000

Type Nominal pressure[t] Slider pitch Slider-table

distance Table dimensions Body clearance

Eccentric PMS –160A 160 140 580 1140x760 840Hydraulic PMM300HD 600 500 700 2500x4000

Type Nominal pressure[t] Slider pitch Spacing of supports Height of supports Min. bending radius

Boxer PB-200 200 260 330-1200 340 ɸ130-1000, ɸ100-560

Folding sheets.

TypeDimensions of rolled sheet Diameter range of

rolled sheetsDiameter of the

upper rollSpacing of lower

rollersThicknes Width

PS 460 30 3000 Min. 700 460 adjustable

2. WELDING2.1. Welding methods Arc welding methods • Manual metal arc welding (MMA), • Semi-automatic, metal inert gas/metal active gas welding (MIG/MAG), Tungsten inert gas welding (TIG), • Submerged arc welding.We offer welding of the following materials: • carbon steel, • low-alloy steels with high durability and resistance to abrasion, • highalloy steels, stainless and acid-resistant.Removing welding stresses by: • heat treatment, • vibratory stress relief.Established welding methods according to PN - EN 288-3: • SLV inspection unit, Berlin • UDT inspection unit – WPQR No. 32/111/O1-02 • TÜV inspection unit.

2.2. Available weld tests:Non-destructive: • visual tests (VT), penetrant tests (PT), • magnetic-particle tests (MT), • ultrasonic tests (UT).

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3. MACHININGMachining on vertical milling machines, universal and conventional, CNC and planner mills.

TypeDistance

of spindlefrom the table

Working surfaceof the table

Max. table travelTable turnLongitudinally Crosswise Vertically

Horizontal FWA-41 0 - 450 410x1900 1070 360 440 45°Vertical FYA-41 0 – 510 410x1900 1070 370 360

CNC FXR 40CJ2 0 – 465 400-1400 1030 320 460 45°

Type Spindleextension

Max. table travel Tablesurface

Slidertravel

Max. distance of spindle face from the

table

Max. diameter

Transverse Longitudinal drilling boring

B440A M30P-7116 200 400 710 800x400 270 630 25 50

Type Sliderpitch

Max. table travelTable

surfaceSlider shift

Max. holder distance from the

table

Max. travel of the slide

Vertically Horizontally Horizontally Vertically

LONGITUDINAL M30P-7116 6200 1400x6000 300 1500 1730 1400

SLOTTING MACHINE HOV-25A 250 450 560 Ø 500 525 15-5357M-450 400 650 800 Ø 800 725 700

TypeDistanceof spindle

from the table

Distanceof spindle faces

Millinglength

Clearancebetween stands

Working surfaceof the table Spindle vertical travel

Longitudinal 6Γ 610 25-1130 750-1250 3200 1460 1000x3150 250

Machining on conventional drilling-milling machines with a rotary table and spindle diameter up to 160 mm, equipped with electronicposition readings.

Machining on conventional and CNC lathes.

Machining on vertical lathes.

TypeMax. diameter Spindle

diameterSpindle

extension

Table travel Tablesurface

Height of the spindle axis Spindle slotBoring Facing Transverse Longitudinal Above

the tableOver

the bedWH-80 450 80 710 1250 1250 1000x1090 0-940 5W-100 560 900 100 900 1600 1250 1250x1250 0-1120 6HWCa-110 600 1000 110 850 1200 1550 1200x1400 800-2350 6AD-115 600 1200 115 700 1600 2000 1400x1600 0-1500 6ADP-115 600 1000 115 700 2000 3500 1600x1800 850-2850 ISO 50BFP 160/2 1000 1000 160 1250 6710 500 2000x2000 1900 ISO 50

TypeMax. turning diameter Thread pitch range Max.

turninglength

Spindle swing

Centreheight

SlotOver the

bedOver

the slide Metric Inch Spindle Tailstock

LIGHT TUD-40 400 225 1-88 88-1 zw/” 750-2000 56 6TUD-50 500 325 1-88 88-1 zw/” 750-2000 56 6

MEDIUM TR 70 B 680 420 1-120 60-1/2 zw/” 1500-2000 80 335 8 6TR 70 bis 800 460 1-120 30-1/4 zw/” 3000 95 400 8 6

HEAVY

TRA 90 900 570 0,5-15 60-2 zw/” 4000 105 435 120 6TRA 100 1000 680 0,5-15 60-2 zw/” 6000 105 490

165 1000 650 1-120 28-1/4 zw/” 2800 90 500 8 5TCG 160 1600 1290 1-192 30-1/8 zw/” 4000 105 800 110 70

NUMERICALLYCONTROLLED

TZD-63NMN-630TUR-50N

630630520

450380280

1-88 1-88150020002000

10571,5

11580

55

LB 3000 OKUMA 580 470 Full within

the range 900 91(62 interception) JIS A2-8 intercep-

tion

Type Max. turningdiameter

Workpieceheight

Table diameter

Travel of vertical slide Travel of side slideVertically Horizontally Vertically Horizontally

1516 1600 1000 1400 700 950 1000 630SK-40A 4300 2500 3700 1400 2415 1250SKIQ8-CNC 1000 765 800 630 625

4. ANTI-CORROSIVE PROTECTION4.1. PaintingPainting of machinery, welded structures and components in cabin-dryer with dimensions 6 x 16 x 5 [m].Painting using hydrodynamic and pneumatic methods with one-component and two-component paints.

4.2. Galvanizing with Zing methodThis is used to provide an independent protective coating for various steel structures (e.g. bridge structures, road safety barriers, containers, towers, masts, silos, chassis of heavy equipment, construction machinery, wagons, culverts, and others).

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CRUSHERS AND CRUSHING SETS

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JAW CRUSHER SETS:ZKDSh 130/75, ZKDS 130/75, ZKMSh 100/55, KDSn 130/75, KMS 100/55E, KWS 40/20

IMPACT CRUSHER SETS:ZKDU 120/130, ZKMU 100/110, ZKMUh 100/110, KKL 50GE (mining version), KKL 50E (surface version), KKL 100E, KDU 120/130E

APPLICATIONJaw crusher sets are designed for crushing materials with compressive strength up to 300 MPa, such as: construc-tion waste, basalt, granite, amfibolit, gneiss, quartzite, li-mestone, dolomite, etc.

Impact crusher sets are designed for crushing used for crushing mineral materials and construction waste of high and medium hardness, susceptible to impact crushing e.g. granite, dolomite, limestone. Impact crushers may be also used for recycling waste materials generated during road

and building construction, such as concrete, rubble from demolition, asphalt, etc. The resulting aggregate has a high cubicity.

KGHM ZANAM offers crushing sets in different design versions (self-propelled, sliding, fixed) and compilations (optional: magnetic separator, sprinkler system, automatic lubrication system, etc.) designed to individual customer needs.

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TECHNICAL SPECIFICATIONSOF JAW CRUSHERS

TECHNICAL SPECIFICATIONSOF IMPACT CRUSHERS

Capacity[m3/h]

Maximumsize of fedmaterial

[mm]

Gapadjustment

range[mm]

Combustionenginepower

Weight[Mg] Notes

ZKDS 130/75 up to 110 700 40–155 294 kW at2100 rpm 52 Self-propelled crushing set with classic drive of

the crushing module.

ZKDSh 130/75 up to 110 700 40–155 224 kW at1600 rpm 45

Self-propelled crushing set with hydrostatic drive of the crushing module, adapted for automatic (unattended) operation.

ZKMSh 100/55 up to 70 500 40–105 224 kW at

1600 rpm 29,5Self-propelled crushing set with hydrostatic drive of the crushing module, adapted for automatic (unattended) operation.

KDSn 130/75 up to 110 700 40–155 - 31,5 Movable jaw set with electric drive of all assemblies. Supply voltage 400 V.

KMS 100/55E up to 70 500 40–105 - 22,5 Stationary crushing set with electric drive of all assemblies. Supply voltage 400 V.

KWS 40/20 up to 50 900 100-220 - 39 Stationary jaw crusher with electric drive. Supply voltage 400 V/ electric motor 132 kW.

Crushing efficiency depends on the type of crushed material and the dimensions of the fed material.

Crushing efficiency depends on the type of crushed material and the dimensions of the fed material.

Capacity[m3/h]

Maximumsize of fedmaterial

[mm]

Crushingdegree

Combustionenginepower

Weight[Mg] Notes

ZKDU 120/130 up to 110 700 1:10–1:50 294 kW at2100 rpm 45 Self-propelled crushing set with classic drive of

the crushing module (hydrodynamic coupling).

ZKMU 100/110 up to 70 500 1:10–1:50 224 kW at

2000 rpm 31 Self-propelled crushing set with classic drive of the crushing module (hydrodynamic coupling).

ZKMUh 100/110 up to 70 500 1:10–1:50 224 kW at

1600 rpm 31Self-propelled crushing set classic drive of the crushing module, adapted for automatic (unattended) operation.

KKL 50GE/ KKL 50E up to 50 500 1:10–1:50 - 21

Container set with electric drive for all modules. Supply voltage 500 V (for mining version - GE) or 400 V (for surface version - E).

KKL 100E up to 70 500 1:10–1:50 - 28 Container set with electric drive for all assemblies. Supply voltage 400 V.

KDU 120/130E up to 110 500 1:10–1:50 - 26Movable crushing set with electric drive of all assemblies. Supply voltage 400 V/ electric motor 132 kW.

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WWW.KGHMZANAM.COM

marketing@kghmzanam.com

KGHM ZANAM S.A.ul. Kopalniana 7, 59-101 Polkowice, Poland

Public Relationstel. +48 76 84 70 893

Marketing and Exporttel. +48 76 84 70 823

Sales Officetel. +48 76 84 70 820

Officetel. +48 76 84 70 905 fax. +48 76 84 71 100 sekretariat@kghmzanam.com