mining applications

Hydraulic breakers in mining applications

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Atlas Copco hydraulic breakers in the quarry

In modern rock mining operations, each step in the process is subject to profitability analysis. Overall, hydraulic breakers are often the most economical and safest option.

One standard application is secondary reduction of oversize boulders in the rock pile. The use of hydraulic breakers here has made safety problems a thing of the past.

Selective mining with heavy-duty hydraulic breakers is a worthwhile consideration in many quarries, as it frequently allows improved material grades to be mined which bring higher sales revenue.

Using hydraulic breakers to remove the overburden allows the entire deposit to be utilized.

Environmental protection regulations and restrictions are prompting many quarry operators to look at alterna-tive mining methods. Rock mining companies all over the world have already enjoyed great success using heavy-duty hydraulic breakers for primary rock breaking as a substitute for blasting.

When you use Atlas Copco hydraulic breakers, you benefit from our many years of experience in assessing rock mining methods around the globe.

The illustration on the right shows the recommended assignment of hydraulic breakers to specific jobs.

Finally, there are no two identical quarries anywhere in the world, so whether the use of hydraulic breakers represents a viable alternative has to be analyzed on a case by case basis. We provide a questionnaire on the key data required.

The service we offer is rounded off by an individual estimate of operating costs for using hydraulic breakers to mine rock without blasting.

Our team would be pleased to provide advice and infor-mation on your personal requirements.

HB

700

0

HB

580

0

HB

420

0

HB

300

0

HB

250

0

HB

220

0

MB

170

0

MB

120

0

MB

100

0

MB

700

SB

450

SB

300

0

50

25

75

100

120

Carrier weight class (tons)

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Whenever blasted rock is too big to be handled by loading equipment or fed through the crusher, secondary reduction is required. Even with the most advance blasting tech-niques, it is inevitable that there will be oversize boulders, and these need to be broken as economically as possible.

Hydraulic breakers are particularly suitable for quarries where • loading is primarily done by wheel loaders • backhoe loaders are used• heavy-duty excavators with service weights upward of

150 t are in use• conditions make a high percentage of oversize boulders

inevitable• the rock to be loaded is very tough, or• secondary reduction work is sub-contracted.

Atlas Copco hydraulic breakers can be used to reduce boul-ders in the rock pile or on the primary crusher. Mounting the

Secondary reduction of oversize boulders with hydraulic breakers

secondary reduction breaker on a mobile carrier provides a flexible unit which can be used at several points in the quarry.

Breaking performance depends largely on the operator. The more experienced the operator, the higher the productivity. That’s why we always recommend using permanent staff members for this work.

In many cases, oversize boulders can be sold profitably for use in embankments, dry walls or as breakwater rocks. In suit-able rock types, hydraulic breakers can be used to create appropriate blocks.

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Secondary reduction performance figures

The characteristics of the rock – brittle or tough – have a major influence on reduction performance. Brittle rock types can be more easily broken by hydraulic breaker than tough types. For majority of secondary reduction applications, blunt tools have proven most effective. The table lists examples of rock types.

Selecting the most suitable Atlas Copco hydraulic breaker is based on the average volume of oversize boulders involved. It is important that a big enough breaker be selected, as reduc-tion performance is directly related to single blow energy. A high impact frequency is less important, as a higher blow rate will not result in the rock breaking if the single blow energy is insufficient.

On the other hand, reduction performance does not automati-cally increase with service weight. For example, a breaker which is twice as heavy as another will not necessarily deliver twice the reduction performance. One reason for this is that the breaking unit’s cycle times will lengthen as equipment size increases.

Please contact our applications advisors for more information on breaker selection.

Secondary reduction performance Examples of rock type

High Shell limestone, sandstone, slate, gneiss, marble

Average Limestone, dolomite, greywacke

Low Lava, porphyry, diabase, basalt, granite

Model Secondary reduction performance in t/hMB 1200 60 - 190

MB 1700 80 - �50

HB 2200 110 - ��0

HB 3000 1�0 - ��0

HB 4200 180 - 5�0

HB 7000 ��0 - 680

0

Non-binding guideline values t / h

100 �00 �00 �00 500 600 700

Oversize boulders

HB 5800 �00 - 610

The figures are based on performances achieved in practical operations.

HB 2500 1�0 - �50

The diagram shows guideline figures which can be achieved using hydraulic breakers for secondary reduction.

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Type of rock: basalt

Atlas Copco hydraulic breaker HB �000 Dust

Block size in m� 1-�

Average end size (mm) 600-800

Block breaking rate (tons/h) 180-��0

Secondary breaking examples

Type of rock: marble

Atlas Copco hydraulic breaker HB ��00 Dust

Block size in m� 1-�


Block breaking rate (tons/h) �90-�10

Type of rock: limestone

Atlas Copco hydraulic breaker HB 7000 Dust

Block size in m� �-6


Block breaking rate (tons/h) �00-500

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Selective mining

Selective mining allows different rock grades to be removed separately from an inhomogeneous deposit.

Deposits with high impurity levels and distinct fault zones can be very difficult to mine and result in raw materials of sharply differing grades. However, technical and economic require-ments call for a flow of material from the mine of largely consistent quality. Added to this is the need to obtain the maximum yield from a deposit. Systematic quality control is thus increasingly important for many rock mining operations.

Selective mining with a heavy-duty hydraulic breaker makes sense when:• special demands are made on mineral purity• higher product quality provides higher sales revenues • sharp fluctuations in raw material properties result in

higher processing costs• losses from mining must be minimized• special demands are made on the grain distribution of the

mined rock (e.g. to avoid excessive fines)

Selective mining and blastingIt is virtually impossible to selectively mine rock from dam-aged, fissured or complex seamed deposits by drilling and blasting. Drilling and loading costs are increased, and there is a significant risk of damage or injury from flyrock. Blasting mixes the rock grades together and makes it impossible to extract the higher value grades separately.

Breaker as flexible mining unitUsing hydraulic breakers as flexible mining units, deposits can be mined selectively regardless of the complexity or direction of the seams. Breakers are for more adaptable to operating conditions than rippers and cause a lower percent-age of fines than blasting.

Operations using breakers for selective mining frequently have the following characteristics:• Mining spread out over a wider area at

several points• Lower bench heights• Flexible mining units• Flexible organization

Integration in existing operationsHeavy-duty hydraulic breakers can also be used to great effect for selective mining in quarries using blasting or other methods, such as ripping. The hydraulic breaker is used to extract rock selectively from certain parts of the quarry, while conventional methods continue to be used to mine more straightforward deposits.

different rock grades in the deposit

mining unit

7

Removing overburden

overburden

deposit

mining unit

direction of mining

Before open pit deposits can be mined, the earth or clay overburden has to be removed. This is done continuously or in phases. The overburden is kept and reused subsequently for restoration.

Once the overburden has been removed, ramps and benches have to be built. As this work frequently takes place in the border areas of the mine, drilling and blasting involves considerable outlay. With no benches in place, it is very difficult for the drill rig to access the overburden, which can be several meters deep. Added to the loss of tools and drill rods in fissured deposits come the risks of injury and equipment damage from flyrock. In many cases, public roads and paths have to be closed, which can cause major problems on heavily used routes.

The costs of initial work impact the profitability of the over-all mining operation.

Using a heavy-duty hydraulic breaker, the costs of removing overburden can be reduced and the work carried out faster with more flexibility.

In many cases, the yield from a deposit can be increased because selective removal with a breaker allows materials to be extracted which would normally have been removed along with the overburden by conventional methods. Opening up mines without the use of explosives can also simplify approval procedures.

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Methods of mining without blastingRock quarries are long-term projects in which deposits are usually mined over several decades. These quarries are part of the landscape, and during operations residential develop-ments often expand up to the edges of the site.

The use of explosives to mine the rock then becomes a source of annoyance to residents, even though blasting techniques are being continuously optimized.

Mining methods without blasting are therefore becoming increasingly widespread. There are three basic methods:

• Ripping with hydraulic excavators and crawler rippers• Cutting with surface miners in medium-hard rock• Breaking with hydraulic breakers

Deliberations for changing to the use of hydraulic breakers for miningThe performance capacity and adaptability of heavy-duty hydraulic breakers make them an interesting and less con-troversial alternative for the mining of raw materials.

Possible reasons for switching mining methods:• Changes in the law• Environmental requirements• Safety considerations which make the use of

explosives difficult

Rock mining without blasting

• Avoiding restrictions to operations• Simplifying the renewal of mining

permits• Maintaining profitability• Increasing demands on product quality

A large number of conditions need to be investigated before a successful switch to mining with hydraulic breakers can be made.

On-site conditions, such as the type and structure of the surrounding rock, the materials to be mined and the volumes involved are just the tip of the iceberg.

Major factors in any changeover are the equipment, staff available and the mine layout.

Future requirements must also be taken into account, e.g. planned investments may need to be reconsidered. It is also better to restructure the quarry to smaller bench heights to provide optimum work-ing conditions for the breaker/carrier unit. And the issue of subsequent restoration must also be considered.

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Any comparison of blasting and the use of heavy-duty hydraulic breakers must take in all the relevant aspects. It is not enough to simply compare the costs of extracting the rock. The entire process from mining the rock – depending on the quarry layout – to saleable product must stand up to economic analysis.

But deliberations on switching methods involve even more aspects. Central topics include:

Enhancing productivity• by allowing continuous operations without interruptions

for blasting and clearing• by obtaining the optimal yield from the approved mining

volume• by reducing the load on the primary crusher, as preliminary

reduction is effected by the hydraulic breaker• by increasing the primary crusher throughput• by allowing more flexible planning

Minimizing costs• by reducing the security outlay required to store explosives • by downsizing or completely eliminating the primary crusher• by enabling the use of continuous conveying systems• by simplifying approval procedures with authorities

Improving quality• by reducing the amount of fines and thus increasing sales

revenue in cases where minimum grain sizes are specified• by reliably controlling grain size distribution• by allowing reproducible qualities• by allowing the selective mining of deposits

Reducing environmental pollution• by eliminating blasting emissions• by simplifying the mining of existing

resources• by simplifying the restoration of the site

upon closure• by protecting the surrounding rock

Summary:Rock mining with heavy-duty hydraulic breakers is not recommended in every case. For operations with an output of up to 600,000 tpy, feasibility studies should be carried out to show whether the use of heavy-duty hydraulic breakers repre-sent an economic alternative to blasting. Higher annual volumes may require addi-tional mining units.

It is important to include the entire pro-cess in these analyses, from mining to finished product.

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Mining rate (t/h)incl. servicing

Rock mining without blasting:Average mining rate

Deposit characteristics

un

suit

able

Min

ing

rat

e

Discontinuity spacing 1 m 0.4 m and less

Solid, compact rock formation fissured rock formation highly fissured rock formation

Breakdown by rock type

suit

able

Type a

Type b

Type c c

b

a

hig

hly

su

itab

le

Magmatic

Lava Granite

Diabase Basalt

Gabbro Syenite

Quartz porphyry

Metamorphic

Gneiss Phyllite

Slate Marble

Sedimentary

Platy limestone

Sandstone

Sedimentary

Limestone

Greywacke

Dolomite

360

240

180

140

120

100

90

HB 7000

t/h

220

140

100

80

70

60

HB 4200

t/h

170

120

90

70

60

50

HB 3000

t/h

280

190

140

110

90

80

HB 5800

t/h




un

suit

able

Min

ing

rat

e




suit

able

Type a

Type b

Type c c

b

a

hig

hly

su

itab

le

Magmatic

Lava Granite

Diabase Basalt

Gabbro Syenite

Quartz porphyry

Metamorphic

Gneiss Phyllite

Slate Marble

Sedimentary

Platy limestone

Sandstone

Sedimentary

Limestone

Greywacke

Dolomite

360

240

180

140

120

100

90

HB 7000

t/h

220

140

100

80

70

60

HB 4200

t/h

170

120

90

70

60

50

HB 3000

t/h

280

190

140

110

90

80

HB 5800

t/h

11




un

suit

able

Min

ing

rat

e




suit

able

Type a

Type b

Type c c

b

a

hig

hly

su

itab

le

Magmatic

Lava Granite

Diabase Basalt

Gabbro Syenite

Quartz porphyry

Metamorphic

Gneiss Phyllite

Slate Marble

Sedimentary

Platy limestone

Sandstone

Sedimentary

Limestone

Greywacke

Dolomite

360

240

180

140

120

100

90

HB 7000

t/h

220

140

100

80

70

60

HB 4200

t/h

170

120

90

70

60

50

HB 3000

t/h

280

190

140

110

90

80

HB 5800

t/h

1�

Rock mining without blasting – no two quarries are alike!

The diagram shows the correlation between mining rate and deposit characteristics. The rates that can be achieved vary from one application to the next.

Breaker productivity largely depends on• the discontinuity persistence of the deposit, and• the fracture characteristics of the rock

When assessing mining rates, the discontinuity persistence or bond strength of the rock is of greater significance than its compressive strength. It is not necessarily possible to draw conclusions about mining rate from the compressive strength of the rock.

In mines using blasting, it must be considered that the rock may be loosened by cracks resulting from blasting. For more information, please consult our applications specialists.

Example: HB 4200 in limestone, fissured deposit

1.Select rock – common rock types have been classified a , b or c depending on fracture characteristics. In this exam-ple, the limestone is class ( b ).

�.Highlight line b .�.Compare quarry face with photos – in

this example, the face which most resembles photo �.

�.Draw lines upward from the two corners of the photo until they intersect with the highlighted rock line.

5.Draw horizontal lines from each of these intersections as far as the performance data for the relevant breaker sizes at the right hand edge of the diagram.

6.The lines mark the upper and lower average productivity limits; in the case of the HB ��00, these are between 70 and 80 tons.




un

suit

able

Min

ing

rat

e




suit

able

Type a

Type b

Type c c

b

a

hig

hly

su

itab

le

Magmatic

Lava Granite

Diabase Basalt

Gabbro Syenite

Quartz porphyry

Metamorphic

Gneiss Phyllite

Slate Marble

Sedimentary

Platy limestone

Sandstone

Sedimentary

Limestone

Greywacke

Dolomite

360

240

180

140

120

100

90

HB 7000

t/h

220

140

100

80

70

60

HB 4200

t/h

170

120

90

70

60

50

HB 3000

t/h

280

190

140

110

90

80

HB 5800

t/h

3

4

5 6

2

1

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Productivity of hydraulic breakers

This brochure describes the use of Atlas Copco hydraulic breakers in mining applications:

• Secondary reduction (oversize boulders)• Selective mining• Removing overburden• Rock mining without blasting

The job descriptions and information on production perform-ance are intended to help you select a suitable breaker from our range.

The performance date provided is long term averages calculated from a wide variety of applications, not guaran-tees. The productivity and profitability of a hydraulic breaker always depends on the specific application.

The following factors exert a major influ-ence on hydraulic breaker efficiency:

• The rock/deposit type impacts decisively on productivity and wear.

• Operating conditions have a key effect on profitability.

• The influence of the carrier/breaker operator is often neglected in produc-tion figures. Skilled and experienced operators are needed to achieve satis-factory performances.

To find out more, contact your local Atlas Copco representative, who will consult the applications specialists at Atlas Copco to provide more detailed information for

your specific requirements.

Factors influencing productivity

Geology(rock anddeposit)

Mining unit(breaker and

carrier)

Conditions(operation, servicing,

organization)

Productivityof

hydraulicbreaker

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Job description:

Rock type: Limestone

Rock structure:Mainly homogeneous, only a few areas with tectonic faults

Particularities: Blasting prohibited in some areas of the deposit

Job Example 1

Solution:

Carrier: �� t, �� kW

Atlas Copco hydraulic breaker: HB ��00

Production data: 80 tph on average*

* incl. servicing time

Job Example 2

Job description:

Rock type: Limestone, very tough

Rock structure: Homogeneous deposit

Particularities: Legal reasons make cost of blasting too high

Solution:

Carrier: 68 t, �0� kW

Atlas Copco hydraulic breaker: HB 7000

Production data: 1�0 tph on average*


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Job description:

Rock type: Lava


Particularities: Blasting strictly prohibited

Job Example 3

Solution:

Carrier: �� t, 166 kW

Atlas Copco hydraulic breaker: HB �000

Production data: �5 tph on average*


Job Example 4

Job description:

Rock type: Shell limestone

Rock structure: Strong seaming

Particularities: Blasting prohibited

Solution:

Carrier: �� t, 17� kW


Production data: 1�0-180 tph on average*


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Job description:

Rock type: Orthogneiss

Rock structure: Deposit with strong tectonic faults


Job Example 5

Solution:

Carrier: 75 t, �� kW


Production data: ��0 tph on average*


Job Example 6

Job description:

Rock type: Diabase

Rock structure:Mainly homogeneous, only a few areas with tectonic faults

Particularities: None

Solution:

Carrier: 61 t, �9� kW




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Job description:

Rock type: Dolomite

Rock structure: Varying between homogeneous and areas with tectonic faults

Particularities: Selective mining difficult using conventional methods

Job Example 7

Solution:

Carrier: �5 t, ��7 kW




Job Example 8

Job description:


Rock structure:Varying between homogeneous and areas with tectonic faults


Solution:

Carrier: 77 t, �19 kW




�0

Job description:


Rock structure: Deposit with tectonic faults


Job Example 9

Solution:





Job Example 10

Job description:

Rock type: Limestone with iron content

Rock structure: Deposit with strong tectonic faults


Solution:

Carrier: 7� t, �17 kW




�1

Job description:


Rock structure: Varying between homogeneous and areas with tectonic faults


Job Example 11

Job Example 12

Job description:

Rock type: Reef limestone, extremely brittle


Particularities: Blasting strictly prohibited

Solution:

Carrier: 76 t, ��1 kW




Solution:

Carrier: 7� t, �17 kW




��

Job description:



Particularities: Blasting prohibited in some areas of the deposit

Job Example 13

Job Example 14

Job description:

Rock type: Porphyry

Rock structure: Deposit with tectonic faults


Solution:





Solution:

Carrier: 60 t, ��8 kW




��

Backed by decades of experience and equipped with the latest innovations, Atlas Copco hydraulic breakers meet your profitability requirements through features such as

• universal application• high durability• high performance• high availability• easy mainte-

nance• reduced

strain on carrier

Numerous sophisticated and proven details – as illustrated in this cross section of an HB ��00 – com-bine to make our hydraulic break-ers unbeatable and give you the edge you need.

High-tech for high profitability

1 Performance enhancement AutoControl optimizes ratio of impact energy to impact frequency. Energy recovery.

2 Ready for special applications Standard port for forced ventilation, e.g. for underwater jobs.

3 Easy maintenance Service opening provides direct access for routine maintenance; the percussion mecha-nism can be removed simply from the breaker box.

4 Constant impact energy Gas piston accumulator integrated in cylinder cover.

5 Automatic lubrication ContiLube® II mounted directly on the breaker box is simple to use and makes extremely economical use of lubricant.

6 Reduced strain on carrier Percussion mechanism suspended in pre-stressed elastic damping elements to prevent damage to carrier equipment.

7 Low noise emission levels No acoustic bridges between percussion mechanism and breaker box. All openings plugged.

8 Low-recoil action reduces strain on man and machine Long piston stroke for low recoil.

9 Optimum transfer of percussive energy Percussion piston and working tool have virtu-ally the same diameter.

10 Highly durable breaker box Wear-resistant materials used in high-stress zones.

11 Highly durable wear bushings DustProtector effectively prevents dust penetration.

12 Reliable working tools Precision matching of design, materials and heat treatment. In-house production!

13 Higher productivity StartSelect adapts the breaker to operating conditions.

1

2

3

4

5

6

7

8

9

12

10

11

13

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VibroSilenced systemAll MB and HB hydraulic breakers are fitted as standard with the efficient “VibroSilenced” noise and vibration damping system.

Elastic elements between percussion mechanism and guide system provide full acoustic insulation.

StartSelectThe “StartSelect” system allows the start-up and shut-off behavior of the breaker to be set in line with conditions.

“AutoStart” modefor jobs in unstable ground conditions, such as• secondary reduction of mined rock• working with the breaker in horizontal/

overhead position• size reduction of light concrete structures

“AutoStop” modefor jobs on firm ground, such as• trenching• bench leveling in the quarry• excavating foundations in rock• size reduction of heavy concrete

structures

AutoControlOptimal impact energy at maximum percussive performanceThe ratio of impact energy to impact rate is controlled to ensure maximum percussive performance at all times (percussive performance = impact energy x impact rate). Avoids blank firingReduces the load on both carrier and hydraulic breaker

AutoControl always starts in short-stroke mode – reduced energy for better tool positioningCentering effect facilitates handling

DustProtector II

DustProtector IIPrevents dust penetration on the hydraulic breaker

Reusable sleeve - can be reused several times when the wear bush-ing is replaced. Highly resistant to grease and mechanical loads

ContiLube® II

Advantages:• Mounted directly on the breaker box• Ports protected in breaker box• Quick and easy cartridge changing

without need for tools (screw cartridge)• Cartridges available worldwide• Cartridges are refillable• Compact design

• Patent protected

ContiLube® IIAutomatic lubrication unit mounted directly on the breaker

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Service you can depend on

Wherever the job, our service engineers and product spe-cialists are there to help you choose the right demolition tool, match carriers and attachments, make mechanical and hydraulic connections, as well as to provide on-site applications advice and servicing for your Atlas Copco products.The specialists from our author-ised distributors and service partners also receive regular training updates to ensure they can provide competent help in all areas – with advice, the full range of after-sales service, and the supply of genuine Atlas Copco spares, working tools and accessories, all in the quality you have come to know and expect. Only genuine Atlas Copco parts ensure that your Atlas Copco products maintain the highest levels of performance, availability and economy.

Your Atlas Copco service partner is never further away than the next telephone.

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With your help we can find out whether non-blasting methods are suitable for your mining operations.

QuestionnairePlease complete the attached questionnaire so that we can perform a feasibility assessment.The more details you can provide, the better!

Who evaluates the questionnaires and what comes next?The applications specialists at Atlas Copco will evaluate the questionnaire and give their recommendations. If hydraulic breakers are a viable option, you will be sent comprehensive information, e.g. attachment recommendations for your carrier, reference jobs, videos etc..

AC also stands for Application Counseling!

Example:

We assure you that all data will be treated in the strictest confidence.

Photos1.Take a photo of the quarry face�.Zoom in on one section of the face.

Important: The picture should include a person or object to give us an idea of the scale.

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www.atlascopco.com/cto

mining applications

Business

use of hydraulic breakers

heavyduty hydraulic

atlas copco hydraulic

secondary reduction

rock brittle

rock pile

blasted rock

secondary reduction