WIRTGEN Surface Mining Manual.

Applications and Planning Guide

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Contents

1 The benefits and applications at a glance 9

1.1 Summary 10

1.2 Selective mining 13

1.3 Extracting and crushing material without blasting 14

1.4 Cutting trenches, surfaces and embankments with precision 15

1.5 Production of tunnel floors 16

1.6 Rehabilitation of haulroads 17

2 Which Surface Miner for which job? 19

2.1 Performance ranges of Surface Miners in easily crushable material 20

2.2 Assesment of rock cuttability 21

2.3 Which Surface Miner for which job? 22

3 The main technical data 31

4 Principle of operation and essential design features 37

4.1 Principle of operation 38

4.2 Machine design 41

4.3 Cutting depth control 44

4.4 Steering systems 47

5 WIRTGEN cutting technology 49

6 Cutting performance as a function of rock properties 61

7 Gradation 75

8 Planning aids for economic operation 80

8.1 Highly selective extraction 84

8.2 Machine dimensions, turning radii, discharge heights and distances, ambient conditions 85

8.2.1 Machine geometry 85

8.2.2 Cutting in a bend 85

8.2.3 Ambient temperatures 85

8.2.4 Working at higher altitudes 85

8.3 Effective performance as a function of the length of the working area 104

8.4 Working methods, manoeuvring methods and times 107

8.4.1 Working in a pit 107

8.4.2 Progressing in longitudinal direction of the opencast mine 111

8.4.2.1 Open cut operation 111

8.4.2.2 Trench construction 112

8.4.3 Progressing in transverse direction of the opencast mine 113

8.4.4 Working on benches 115

8.5 Methods and times for turning 117

8.5.1 Straightforward turning in wide working zone 117

8.5.2 Transverse cutting in front of slopes (turning radius) 119

8.5.3 Turning in working zones of medium width 121

8.5.4 Manoeuvring in narrow working zone 123

8.5.5 Turning times 125

8.6 Cutting of ramps 127

8.7 Transverse and longitudinal slopes 128

8.8 Mixing different grades 133

8.9 Selective extraction from inclined or steep seams 134

8.10 Cutting of embankments 136

8.11 Producing trenches 138

8.12 Tunnelling operations 140

8.12.1 Creating the tunnel floor 142

8.12.2 Cutting benches 144

9 Material loading 147

9.1 Choosing the loading system 148

9.2 Direct truck loading 151

9.3 Indirect loading 154

9.3.1 Sidecasting the material 154

9.3.2 Windrowing 155

9.4 Processing options depending on the various loading methods 158

10 Tips for practical use 162

10.1 Transport and assembly 164

10.2 Preparing the working zone 166

10.3 Working without damage to the machine 167

10.3.1 Cutting along the cutting edge 167

10.3.2 Driving in bends 167

10.3.3 Travelling over long distances 168

10.3.4 Cutting with reduced cutting drum width 168

10.3.5 Conveying capacity 168

10.4 Driving in difficult conditions 169

10.5 Adjustment and control of the cutting depth 170

10.5.1 Forms of adjustment for the rigid axle 172

10.5.2 Levelling surfaces 173

10.5.3 Removing layers of defined thickness 175

10.5.4 Selective mining and creation of defined surface profiles 177

10.5.5 Copying existing surface profiles 177

10.5.6 Final lane of a work section 178

10.5.7 Working on a tall embankment without edge protection 179

10.6 Optimizing cutting performance and grain size 180

10.7 Dust suppression 181

10.8 Effective supply of materials and maintenance 182

10.8.1 Fuel 182

10.8.2 Water 182

10.8.3 Maintenance 182

10.8.4 Tool changes 183

10.8.5 Communication 183

11 Job-site examples 185

Annex 195

Conversion tables 196

Rock testing methods 200

• Point Load Test 200

• RQD value 200

• Mohs hardness scale 201

• Seismic wave velocity 202

• Cuttability and rippability of rock 203

• Specific weights, bulking coefficients and Mohs hardness of selected types of rock 204

Glossary 205

WIRTGEN Surface Miner technology yields the following essential advantages:

> Mining without blasting> Simplified mining

> Better quality of the removed material due to highly selective mining processes (ROM = Run-of-Mine)

> Robust, clean cut edges and benches

1.1 Summary

Selective extraction of thin seams

Mining of rockwithout blasting

Bulk mining

Production of small grain sizes directly while mining the material

Production of stableembankments

Production ofdefined surfaces

Production and rehabilitation of roads

Mining and QuarryingEarthworks and construction

in rock, as well asroad construction

Surface MinersApplications

Main featuresHigh purity of the ore, simpler extraction and processing, lower price per tonne

Main featuresProduction of precise, stable, defined profiles in rock

10 l 11

Surface Miners cut, crush and load the material in a single operation with just one machine

1 |

2 |

3 |

4 |

5 |

1 | Continuous mining

2 | Crushed aggregate

3 | Direct loading

4 | Precise cutting depth

5 | Clean, level and stable surface after cutting

Surface Miners simplify the complex process of extracting and processing minerals. It is a produc-tion system that extracts, crushes and loads the material in a single operation.

Advantages:

> Higher system availability> Lower operating costs> Only one machine is needed for several work

steps; this simplifies coordination and planning of the mining process, machine use, operation and maintenance.

Drilling Blasting Loading Crushing

12 l 13

One of the most important features of the Surface Miners is their ability to work selectively. Thin seams interspersed with intermediate rock lay-

ers can be cut precisely and economically, for example.

1.2 Selective mining

Thin coal seams can be mined selectively with Surface Miners

Mining companies throughout the world are exploiting the advantages of WIRTGEN Surface Miner technology with its extremely precise control of the cutting depth to extract high-quality mined material (ROM) in coal mines, limestone mines, bauxite mines, phosphate mines and gypsum mines.

Selective mining with Surface Miners ensures that thin seams of high-grade minerals and overburden can be mined separately.

Advantages:

> Better quality of the cut material> Higher exploitation of the deposit> Improved overburden-to-mineral ratio> Less processing required

2.1 Performance ranges of Surface Miners in crushable material

The performance, tool wear and consequently the cost-efficient mode of operation of Surface Miners are decisively dependent on the mechanical prop-erties of the rock to be cut.In the following diagram, the performance ranges of the Surface Miners and cuttability of the vari-ous types of rock are plotted as a function of the unconfined compressive strength of the respective rock types.

The maximum cutting performances listed in the table “Performance ranges” apply for the respec-tive unconfined compressive strengths and for highly fissured, crushed materials. The actual performance achieved may differ considerably from the values listed here. Further details on cutting performance can be found in the diagrams in chapter 6. Please contact our specialists at WIRTGEN for an estimate of performance and operating costs.

Performance ranges of the Surface Miners

Cut

ting

per

form

ance

(bcm

per

ho

ur)

Unconfined compressive strength x 10 (MPa)

3,000

2,500

2,000

1,500

1,000

500

0

0 1 2 3 4 5 6 7 8 9 10 11 12

4200 SM

2200 SM 3.8 with windrowing

2500 SM 2200 SM

20 l 21

This general summary can be used to estimate the cuttability of a rock type. Queries concerning the cuttability of rock and the cutting performance to be expected with a Surface Miner should be

addressed to WIRTGEN, together with data and information on the type of native rock and the open-cast mine.

2.2 Assessment of rock cuttability

Met

amo

rphi

c

rock

Mag

mat

ic r

ock

Sed

imen

tary

ro

ck

= can be cut economically in mining operation

= cannot be cut at present

= can be cut in special applications and for earthworks as well as construction in rock

Quartzite

Serpentinite

Gneiss

Andalusite

Marble

Talc

Basalt

Basalt lava

Diabase

Granite

Tuffaceous rock

Tuff

Graywacke

Sandstone

Iron ore

Bauxite

Dolomite

Limestone, marlConglomerate, pudding stone

Clay schist

Phosphate

Gypsum

Salt rock

Bituminous coal

Lignite

MPaRock

Unconfined compressive strength

10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 270 280 290 300

120 t

120 t

Dimensions in mm

Dimensions in feet

15,0

00

16,0

00

17,0

00

14,0

00

15 12 9 6 3 0 3 6 9 12 1518212427303336394245485154

15 12 9 6 3 0 3 6 9 12 1518212427303336394245485154

24

27

30

21

18

15

12

9

6

3

0

24

27

30

21

18

15

12

9

6

3

0

13,0

00

12,0

00

11,0

00

10,0

00

9,00

0

8,00

0

7,00

0

6,00

0

1,000

0

2,000

3,000

4,000

5,000

6,000

7,000

8,000

9,000

10,000

1,000

0

2,000

3,000

4,000

5,000

6,000

7,000

8,000

9,000

10,000

5,00

0

4,00

0

3,00

0

2,00

0

1,00

0

0 1,00

0

2,00

0

3,00

0

4,00

0

5,00

0

15,0

00

16,0

00

17,0

00

14,0

00

13,0

00

12,0

00

11,0

00

10,0

00

9,00

0

8,00

0

7,00

0

6,00

0

5,00

0

4,00

0

3,00

0

2,00

0

1,00

0 0

1,00

0

2,00

0

3,00

0

4,00

0

5,00

0

Loading material onto trucks when working along embankment steeper than 54° (discharge conveyor slewed max. 45°)

94 l 95

Dimensions in mm

Dimensions in feet

15,0

00

16,0

00

14,0

00

15 12 9 6 3 0 3 6 9 12 1518212427303336394245485154

15 12 9 6 3 0 3 6 9 12 1518212427303336394245485154

24

27

30

21

18

15

12

9

6

3

0

24

27

30

21

18

15

12

9

6

3

0

13,0

00

12,0

00

11,0

00

10,0

00

9,00

0

8,00

0

7,00

0

6,00

0

1,000

0

2,000

3,000

4,000

5,000

6,000

7,000

8,000

9,000

10,000

1,000

0

2,000

3,000

4,000

5,000

6,000

7,000

8,000

9,000

10,000

5,00

0

4,00

0

3,00

0

2,00

0

1,00

0

0 1,00

0

2,00

0

3,00

0

4,00

0

5,00

0

15,0

00

16,0

00

14,0

00

13,0

00

12,0

00

11,0

00

10,0

00

9,00

0

8,00

0

7,00

0

6,00

0

5,00

0

4,00

0

3,00

0

2,00

0

1,00

0 0

1,00

0

2,00

0

3,00

0

4,00

0

5,00

0

Sidecasting material

Harvest mode / working in layers (schematic illustration)

4 5

6

7

8

9

9 8

7

6

5

4

3

3

5

7

9

4

6

8

1 2

3

10 11

12

13

14

15

16

1718

–8

m

–7

m

–6

m

–5

m

–4

m

–3

m

–2

m

–1

m

108 l 109

Cut 1

Cut 2

Cut 3

Cut 4

Turn

ing

w

itho

utcu

ttin

g

Cut 8

Cut

11

Cut

9

Cut 7

Cut 6

Cut 5

Cut

12

Cut

10

Removal with auxiliary units

Removal with auxiliary units

Removal with auxiliary units

Removal with auxiliary units

9.3 Indirect loading

Sidecasting means that a stockpile is produced by dumping the material removed in one or more cutting operations on a stockpile via the miner’s di-scharge conveyor. Depending on the slewing angle of the discharge conveyor, the material of between three to five adjacent cuts can be dumped on top of one another. Depending on the height of the resultant pile, the material can easily be picked up again by a front loader.

Advantage:When sidecasting the material, the Surface Miner can continue cutting regardless of whether a truck is available for loading.

2200 SM – Sidecasting

2200 SM – Sidecasting

9.3.1 Sidecasting

154 l 155

Surface Miner – windrowing mode

When working in windrowing mode, the cut material is deposited directly behind the machine without using the discharge conveyor system. This makes the cutting process independent of any loading processes (onto trucks). However, the material must subsequently be re-handled by a front loader.

9.3.2 Windrowing

2200 SM – windrowing mode