wirtgen surface mining manual. applications and planning guide · = can be cut economically in...
TRANSCRIPT
WIRTGEN Surface Mining Manual.
Applications and Planning Guide
WIR
TGE
N S
urfa
ce M
inin
g M
anua
l.
Ap
plic
atio
ns
and
Pla
nn
ing
Gu
ide
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
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 planningof the mining process, machine use, operationand maintenance.
Drilling Blasting Loading Crushing
11 l 12
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
8.4 Working methods, manoeuvring methods and times
Working zones of certain types and sizes are regu-larly encountered both in mining and in earthworks or construction in rock.
The following chapters describe the various methods highly recommended for the typical working zones, as well as the methods recom-mended for manoeuvring.
8.4.1 Working in a pit
Long and wide (> 4 times the bend radius) working zones in particular can be worked effectively using the method described here.
The deposit is worked by removing successive layers with the preset cutting depth.
Harvest mode / working in layers: the Surface Miner is cutting in bends here
Harvest mode / working in layers (schematic illustration)
4 5
6 7
8 9
9 8
7 6
5 4
3
3 5
7
94
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
107 l 108
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