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Hydraulic breakers
in mining applications
Atlas Copco hydraulic breakers in the quarry
Carrier weight class (tons)

HB 7

000

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.
120

75

0



MB 7
00

MB 1
200

MB 1
000

MB 1
SB 3

00

50

Our team would be pleased to provide advice and information on your personal requirements.

Stationary
boom

25

SB 4

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

700

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.

HB 2
500

50
HB 2
200

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

HB 3

000

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

800
200
HB 4

Environmental protection regulations and restrictions
are prompting many quarry operators to look at alternative 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.

Secondary reduction

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

HB 5

100

Selective  overburden

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.

Primary rock breaking

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.
Secondary reduction of oversize
boulders with hydraulic breakers
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 techniques, 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.

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 suitable rock types, hydraulic breakers can be
used to create appropriate blocks.

Atlas Copco hydraulic breakers can be used to reduce boulders in the rock pile or on the primary crusher. Mounting the
Secondary reduction performance figures

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

Model		Secondary reduction performance in t/h
MB 1200

  60 - 190

MB 1700

  80 - 250

HB 2200

Oversize boulders

  110 - 330

HB 2500

  120 - 350

HB 3000

  140 - 420

HB 4200

  180 - 540

HB 5800

  200 - 610

HB 7000

  230 - 680
0

100

200

300

400

Non-binding guideline values

The figures are based on performances achieved in practical operations.
Secondary reduction performance

Examples of rock type

High

Shell limestone, sandstone, slate, gneiss, marble

Average

Limestone, dolomite, greywacke

Low

Lava, porphyry, diabase, basalt, granite

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 reduction 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 automatically 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.


500

600

700
t / h
Secondary breaking examples

Type of rock: basalt
Atlas Copco hydraulic breaker

HB 3000 Dust

Block size in m3

1-4

Average end size (mm)

600-800

Block breaking rate (tons/h)

180-220

Type of rock: marble
Atlas Copco hydraulic breaker

HB 2200 Dust

Block size in m3

1-2

Average end size (mm)

600-800

Block breaking rate (tons/h)

290-310

Type of rock: limestone
Atlas Copco hydraulic breaker

HB 7000 Dust

Block size in m3

2-6

Average end size (mm)

600-800

Block breaking rate (tons/h)

400-500
Selective mining
different rock grades
in the deposit

mining unit

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 requirements 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 blasting
It is virtually impossible to selectively mine rock from damaged, 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 unit
Using 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 percentage 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 operations
Heavy-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.
Removing overburden
direction of mining

overburden

mining unit

deposit

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 overall 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.
Rock mining without blasting

Methods of mining without blasting
Rock 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 developments often expand up to the edges of the site.

•	Avoiding restrictions to operations
•	Simplifying the renewal of mining
permits
•	Maintaining profitability
•	Increasing demands on product quality

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

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

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 mining
The performance capacity and adaptability of heavy-duty
hydraulic breakers make them an interesting and less controversial 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



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 working conditions for the breaker/carrier unit.
And the issue of subsequent restoration
must also be considered.
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 represent an economic alternative to blasting.
Higher annual volumes may require additional mining units.

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.

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

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
Rock mining blasting:
Rock mining withoutwithout blasting:
Average mining rate
Average mining rate

Phyllite

Slate Marble

Marble

Slate

unsuitable

Metamorphic
Metamorphic
Gneiss Phyllite
Gneiss

unsuitable

Breakdown by
Breakdown by rock type rock type

Type a

Type a

Type b

Type b

Granite Type c

Type c

Sedimentary
Sedimentary
Platy
Platy limestone limestone
Sandstone
Sandstone

Sedimentary
Sedimentary
Limestone
Limestone
Greywacke
Greywacke
Dolomite Dolomite

MagmaticMagmatic
Lava Granite
Lava
Diabase Diabase
Basalt
Gabbro Gabbro
Syenite

Basalt
Syenite

Quartz
Quartz porphyry porphyry

Depo

Solid, compact rock formation
Solid, compact rock formation

10

Discontinuity spacing
Discontinuity spacing
1m

fissured ro
1m
Mining rate (t/h)
incl. servicing
HB 7000

HB 5800

HB 4200

HB 3000

t/h

t/h

280

220

170

240

190

140

120

180

140

100

90

140

110

80

70

120

90

70

60

100

80

60

50

Mining rate

highly suitable

t/h

360
suitable

t/h

a

b

c

90

Deposit characteristics

fissured rock formation

highly fissured rock formation
0.4 m and less

11
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 example, the limestone is class ( b ).
2.Highlight line b .
3.Compare quarry face with photos – in
this example, the face which most
resembles photo 3.
4.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 4200, these are between
70 and 80 tons.

Rock mining without blasting:
Average mining rate

Mining rate (t/h)
incl. servicing
HB 7000

Breakdown by rock type

HB 5800

HB 4200

HB 3000

t/h

Phyllite

Slate

220

170

190

140

120

180

140

100

90

140

110

80

70

120

90

70

60

100

80

60

50

highly suitable

unsuitable

Gneiss

280

240

Metamorphic

t/h

360
suitable

t/h

t/h

Marble

Type a
Sedimentary
Platy limestone
Mining rate

Sandstone

Sedimentary

a

Limestone

2

Type b

Greywacke

1

Dolomite

b

5

Magmatic
Lava

Granite

Diabase

Basalt

Gabbro

c

Type c

Syenite

4

90

Quartz porphyry
Deposit characteristics

3
Solid, compact rock formation
Discontinuity spacing

12

fissured rock formation
1m

highly fissured rock formation
0.4 m and less

6
Productivity of
hydraulic breakers
This brochure describes the use of Atlas Copco hydraulic
breakers in mining applications:

The following factors exert a major influence on hydraulic breaker efficiency:

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

•	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 production figures. Skilled and experienced
operators are needed to achieve satisfactory performances.

The job descriptions and information on production performance 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 guarantees. The productivity and profitability of a hydraulic breaker
always depends on the specific application.

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 and
deposit)

Productivity
of
hydraulic
breaker

Mining unit
(breaker and
carrier)

Conditions
(operation, servicing,
organization)

13
14
15
Job Example 1

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

Solution:
Carrier:

44 t, 224 kW

Atlas Copco hydraulic breaker:

HB 4200

Production data:

80 tph on average*

* incl. servicing time

Job Example 2

Job description:
Rock type:
Rock structure:

Carrier:

68 t, 302 kW

Atlas Copco hydraulic breaker:

HB 7000

Production data:

120 tph on average*

* incl. servicing time

16

Homogeneous deposit

Particularities:

Solution:

Limestone, very tough

Legal reasons make cost of blasting too high
Job Example 3

Job description:
Rock type:

Lava

Rock structure:

Homogeneous deposit

Particularities:

Blasting strictly prohibited

Solution:
Carrier:

34 t, 166 kW

Atlas Copco hydraulic breaker:

HB 3000

Production data:

45 tph on average*

* incl. servicing time

Job Example 4

Job description:
Rock type:

Shell limestone

Rock structure:

Strong seaming

Particularities:

Blasting prohibited

Solution:
Carrier:

42 t, 173 kW

Atlas Copco hydraulic breaker:

HB 4200

Production data:

140-180 tph on average*

* incl. servicing time

17
Job Example 5

Job description:
Rock type:

Orthogneiss

Rock structure:

Deposit with strong tectonic faults

Particularities:

Blasting prohibited

Solution:
Carrier:

75 t, 324 kW

Atlas Copco hydraulic breaker:

HB 7000

Production data:

230 tph on average*

* incl. servicing time

Job Example 6

Job description:
Rock type:
Rock structure:

Carrier:

61 t, 294 kW

Atlas Copco hydraulic breaker:

HB 7000

Production data:

100 tph on average*

* incl. servicing time

18

Mainly homogeneous, only a few areas 	
with tectonic faults

Particularities:

Solution:

Diabase

None
Job Example 7

Job description:
Rock type:

Dolomite

Rock structure:

Varying between homogeneous and areas with tectonic faults

Particularities:

Selective mining difficult using conventional methods

Solution:
Carrier:

45 t, 227 kW

Atlas Copco hydraulic breaker:

HB 4200

Production data:

120 tph on average*

* incl. servicing time

Job Example 8

Job description:
Rock type:

Limestone

Rock structure:

Varying between homogeneous and
areas with tectonic faults

Particularities:

Blasting prohibited

Solution:
Carrier:

77 t, 319 kW

Atlas Copco hydraulic breaker:

HB 7000

Production data:

160 tph on average*

* incl. servicing time

19
Job Example 9

Job description:
Rock type:

Limestone

Rock structure:

Deposit with tectonic faults

Particularities:

None

Solution:
Carrier:

68 t, 287 kW

Atlas Copco hydraulic breaker:

HB 5800

Production data:

200 tph on average*

* incl. servicing time

Job Example 10

Job description:
Rock type:
Rock structure:

Carrier:

74 t, 317 kW

Atlas Copco hydraulic breaker:

HB 7000

Production data:

300 tph on average*

* incl. servicing time

20

Deposit with strong tectonic faults

Particularities:

Solution:

Limestone with iron content

None
Job Example 11

Job description:
Rock type:

Limestone

Rock structure:

Varying between homogeneous and areas with tectonic faults

Particularities:

None

Solution:
Carrier:

74 t, 317 kW

Atlas Copco hydraulic breaker:

HB 7000

Production data:

190 tph on average*

* incl. servicing time

Job Example 12

Job description:
Rock type:

Reef limestone, extremely brittle

Rock structure:

Homogeneous deposit

Particularities:

Blasting strictly prohibited

Solution:
Carrier:

76 t, 331 kW

Atlas Copco hydraulic breaker:

HB 7000

Production data:

300 tph on average*

* incl. servicing time

21
Job Example 13

Job description:
Rock type:

Limestone

Rock structure:

Homogeneous deposit

Particularities:

Blasting prohibited in some areas of the deposit

Solution:
Carrier:

60 t, 328 kW

Atlas Copco hydraulic breaker:

HB 5800

Production data:

140 tph on average*

* incl. servicing time

Job Example 14

Job description:
Rock type:
Rock structure:

Carrier:

80 t, 319 kW

Atlas Copco hydraulic breaker:

HB 7000

Production data:

150 tph on average*

* incl. servicing time

22

Deposit with tectonic faults

Particularities:

Solution:

Porphyry

Blasting prohibited
High-tech for high profitability

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

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 maintenance
•	reduced
strain on
carrier
Numerous
sophisticated
and proven
details – as
illustrated in
this cross
section of an
HB 4200 – combine to make our
hydraulic breakers unbeatable
and give you the
edge you need.

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

1
3
4
6
5

13
7

8
9
10

11

12

  3	 Easy maintenance
Service opening provides direct access for
routine maintenance; the percussion mechanism 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 prestressed 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 virtually 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.

23
DustProtector II

ContiLube® II

DustProtector II
Prevents dust
penetration on
the hydraulic
breaker

ContiLube ® II
Automatic
lubrication
unit mounted
directly on the
breaker

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

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

AutoControl

StartSelect

Optimal impact energy at maximum percussive
performance
The ratio of impact energy to impact rate is controlled to
ensure maximum percussive performance at all times
(percussive performance = impact energy x impact rate).

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

Avoids blank firing
Reduces the load on both carrier and hydraulic breaker
AutoControl always starts in short-stroke mode – reduced
energy for better tool positioning
Centering effect facilitates handling

VibroSilenced system
All 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.
24

“AutoStart” mode
for 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” mode
for jobs on firm ground, such as
•	trenching
•	bench leveling in the quarry
•	excavating foundations in rock
•	size reduction of heavy concrete
structures
Service you can depend on

Wherever the job, our service engineers and product specialists 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 authorised 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.

25
AC also stands for Application Counseling!

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

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

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

Photos
1.Take a photo of the quarry face
2.Zoom in on one section of the face.

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..

Example:

26

Important: The picture should include a
person or object to give us an idea of the
scale.
27
www.atlascopco.com/cto

3390 0513 01

© 2006, Atlas Copco Construction Tools GmbH, Essen, Germany.

Subject to technical modifications.

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Mining applications

  • 2. Atlas Copco hydraulic breakers in the quarry Carrier weight class (tons) HB 7 000 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. 120 75 0 MB 7 00 MB 1 200 MB 1 000 MB 1 SB 3 00 50 Our team would be pleased to provide advice and information on your personal requirements. Stationary boom 25 SB 4 The service we offer is rounded off by an individual estimate of operating costs for using hydraulic breakers to mine rock without blasting. 700 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. HB 2 500 50 HB 2 200 The illustration on the right shows the recommended assignment of hydraulic breakers to specific jobs. HB 3 000 When you use Atlas Copco hydraulic breakers, you benefit from our many years of experience in assessing rock mining methods around the globe. 800 200 HB 4 Environmental protection regulations and restrictions are prompting many quarry operators to look at alternative 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. Secondary reduction Using hydraulic breakers to remove the overburden allows the entire deposit to be utilized. HB 5 100 Selective overburden 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. Primary rock breaking 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.
  • 3. Secondary reduction of oversize boulders with hydraulic breakers 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 techniques, 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. 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 suitable rock types, hydraulic breakers can be used to create appropriate blocks. Atlas Copco hydraulic breakers can be used to reduce boulders in the rock pile or on the primary crusher. Mounting the
  • 4. Secondary reduction performance figures The diagram shows guideline figures which can be achieved using hydraulic breakers for secondary reduction. Model Secondary reduction performance in t/h MB 1200   60 - 190 MB 1700   80 - 250 HB 2200 Oversize boulders   110 - 330 HB 2500   120 - 350 HB 3000   140 - 420 HB 4200   180 - 540 HB 5800   200 - 610 HB 7000   230 - 680 0 100 200 300 400 Non-binding guideline values The figures are based on performances achieved in practical operations. Secondary reduction performance Examples of rock type High Shell limestone, sandstone, slate, gneiss, marble Average Limestone, dolomite, greywacke Low Lava, porphyry, diabase, basalt, granite 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 reduction 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 automatically 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. 500 600 700 t / h
  • 5. Secondary breaking examples Type of rock: basalt Atlas Copco hydraulic breaker HB 3000 Dust Block size in m3 1-4 Average end size (mm) 600-800 Block breaking rate (tons/h) 180-220 Type of rock: marble Atlas Copco hydraulic breaker HB 2200 Dust Block size in m3 1-2 Average end size (mm) 600-800 Block breaking rate (tons/h) 290-310 Type of rock: limestone Atlas Copco hydraulic breaker HB 7000 Dust Block size in m3 2-6 Average end size (mm) 600-800 Block breaking rate (tons/h) 400-500
  • 6. Selective mining different rock grades in the deposit mining unit 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 requirements 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 blasting It is virtually impossible to selectively mine rock from damaged, 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 unit Using 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 percentage 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 operations Heavy-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.
  • 7. Removing overburden direction of mining overburden mining unit deposit 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 overall 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.
  • 8. Rock mining without blasting Methods of mining without blasting Rock 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 developments often expand up to the edges of the site. • Avoiding restrictions to operations • Simplifying the renewal of mining permits • Maintaining profitability • Increasing demands on product quality The use of explosives to mine the rock then becomes a source of annoyance to residents, even though blasting techniques are being continuously optimized. A large number of conditions need to be investigated before a successful switch to mining with hydraulic breakers can be made. 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 mining The performance capacity and adaptability of heavy-duty hydraulic breakers make them an interesting and less controversial 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 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 working conditions for the breaker/carrier unit. And the issue of subsequent restoration must also be considered.
  • 9. 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 represent an economic alternative to blasting. Higher annual volumes may require additional mining units. 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. It is important to include the entire process in these analyses, from mining to finished product. 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
  • 10. Rock mining blasting: Rock mining withoutwithout blasting: Average mining rate Average mining rate Phyllite Slate Marble Marble Slate unsuitable Metamorphic Metamorphic Gneiss Phyllite Gneiss unsuitable Breakdown by Breakdown by rock type rock type Type a Type a Type b Type b Granite Type c Type c Sedimentary Sedimentary Platy Platy limestone limestone Sandstone Sandstone Sedimentary Sedimentary Limestone Limestone Greywacke Greywacke Dolomite Dolomite MagmaticMagmatic Lava Granite Lava Diabase Diabase Basalt Gabbro Gabbro Syenite Basalt Syenite Quartz Quartz porphyry porphyry Depo Solid, compact rock formation Solid, compact rock formation 10 Discontinuity spacing Discontinuity spacing 1m fissured ro 1m
  • 11. Mining rate (t/h) incl. servicing HB 7000 HB 5800 HB 4200 HB 3000 t/h t/h 280 220 170 240 190 140 120 180 140 100 90 140 110 80 70 120 90 70 60 100 80 60 50 Mining rate highly suitable t/h 360 suitable t/h a b c 90 Deposit characteristics fissured rock formation highly fissured rock formation 0.4 m and less 11
  • 12. 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 example, the limestone is class ( b ). 2.Highlight line b . 3.Compare quarry face with photos – in this example, the face which most resembles photo 3. 4.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 4200, these are between 70 and 80 tons. Rock mining without blasting: Average mining rate Mining rate (t/h) incl. servicing HB 7000 Breakdown by rock type HB 5800 HB 4200 HB 3000 t/h Phyllite Slate 220 170 190 140 120 180 140 100 90 140 110 80 70 120 90 70 60 100 80 60 50 highly suitable unsuitable Gneiss 280 240 Metamorphic t/h 360 suitable t/h t/h Marble Type a Sedimentary Platy limestone Mining rate Sandstone Sedimentary a Limestone 2 Type b Greywacke 1 Dolomite b 5 Magmatic Lava Granite Diabase Basalt Gabbro c Type c Syenite 4 90 Quartz porphyry Deposit characteristics 3 Solid, compact rock formation Discontinuity spacing 12 fissured rock formation 1m highly fissured rock formation 0.4 m and less 6
  • 13. Productivity of hydraulic breakers This brochure describes the use of Atlas Copco hydraulic breakers in mining applications: The following factors exert a major influence on hydraulic breaker efficiency: • Secondary reduction (oversize boulders) • Selective mining • Removing overburden • Rock mining without blasting • 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 production figures. Skilled and experienced operators are needed to achieve satisfactory performances. The job descriptions and information on production performance 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 guarantees. The productivity and profitability of a hydraulic breaker always depends on the specific application. 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 and deposit) Productivity of hydraulic breaker Mining unit (breaker and carrier) Conditions (operation, servicing, organization) 13
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  • 16. Job Example 1 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 Solution: Carrier: 44 t, 224 kW Atlas Copco hydraulic breaker: HB 4200 Production data: 80 tph on average* * incl. servicing time Job Example 2 Job description: Rock type: Rock structure: Carrier: 68 t, 302 kW Atlas Copco hydraulic breaker: HB 7000 Production data: 120 tph on average* * incl. servicing time 16 Homogeneous deposit Particularities: Solution: Limestone, very tough Legal reasons make cost of blasting too high
  • 17. Job Example 3 Job description: Rock type: Lava Rock structure: Homogeneous deposit Particularities: Blasting strictly prohibited Solution: Carrier: 34 t, 166 kW Atlas Copco hydraulic breaker: HB 3000 Production data: 45 tph on average* * incl. servicing time Job Example 4 Job description: Rock type: Shell limestone Rock structure: Strong seaming Particularities: Blasting prohibited Solution: Carrier: 42 t, 173 kW Atlas Copco hydraulic breaker: HB 4200 Production data: 140-180 tph on average* * incl. servicing time 17
  • 18. Job Example 5 Job description: Rock type: Orthogneiss Rock structure: Deposit with strong tectonic faults Particularities: Blasting prohibited Solution: Carrier: 75 t, 324 kW Atlas Copco hydraulic breaker: HB 7000 Production data: 230 tph on average* * incl. servicing time Job Example 6 Job description: Rock type: Rock structure: Carrier: 61 t, 294 kW Atlas Copco hydraulic breaker: HB 7000 Production data: 100 tph on average* * incl. servicing time 18 Mainly homogeneous, only a few areas with tectonic faults Particularities: Solution: Diabase None
  • 19. Job Example 7 Job description: Rock type: Dolomite Rock structure: Varying between homogeneous and areas with tectonic faults Particularities: Selective mining difficult using conventional methods Solution: Carrier: 45 t, 227 kW Atlas Copco hydraulic breaker: HB 4200 Production data: 120 tph on average* * incl. servicing time Job Example 8 Job description: Rock type: Limestone Rock structure: Varying between homogeneous and areas with tectonic faults Particularities: Blasting prohibited Solution: Carrier: 77 t, 319 kW Atlas Copco hydraulic breaker: HB 7000 Production data: 160 tph on average* * incl. servicing time 19
  • 20. Job Example 9 Job description: Rock type: Limestone Rock structure: Deposit with tectonic faults Particularities: None Solution: Carrier: 68 t, 287 kW Atlas Copco hydraulic breaker: HB 5800 Production data: 200 tph on average* * incl. servicing time Job Example 10 Job description: Rock type: Rock structure: Carrier: 74 t, 317 kW Atlas Copco hydraulic breaker: HB 7000 Production data: 300 tph on average* * incl. servicing time 20 Deposit with strong tectonic faults Particularities: Solution: Limestone with iron content None
  • 21. Job Example 11 Job description: Rock type: Limestone Rock structure: Varying between homogeneous and areas with tectonic faults Particularities: None Solution: Carrier: 74 t, 317 kW Atlas Copco hydraulic breaker: HB 7000 Production data: 190 tph on average* * incl. servicing time Job Example 12 Job description: Rock type: Reef limestone, extremely brittle Rock structure: Homogeneous deposit Particularities: Blasting strictly prohibited Solution: Carrier: 76 t, 331 kW Atlas Copco hydraulic breaker: HB 7000 Production data: 300 tph on average* * incl. servicing time 21
  • 22. Job Example 13 Job description: Rock type: Limestone Rock structure: Homogeneous deposit Particularities: Blasting prohibited in some areas of the deposit Solution: Carrier: 60 t, 328 kW Atlas Copco hydraulic breaker: HB 5800 Production data: 140 tph on average* * incl. servicing time Job Example 14 Job description: Rock type: Rock structure: Carrier: 80 t, 319 kW Atlas Copco hydraulic breaker: HB 7000 Production data: 150 tph on average* * incl. servicing time 22 Deposit with tectonic faults Particularities: Solution: Porphyry Blasting prohibited
  • 23. High-tech for high profitability   1 Performance enhancement AutoControl optimizes ratio of impact energy to impact frequency. Energy recovery. 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 maintenance • reduced strain on carrier Numerous sophisticated and proven details – as illustrated in this cross section of an HB 4200 – combine to make our hydraulic breakers unbeatable and give you the edge you need.   2 Ready for special applications Standard port for forced ventilation, e.g. for underwater jobs. 2 1 3 4 6 5 13 7 8 9 10 11 12   3 Easy maintenance Service opening provides direct access for routine maintenance; the percussion mechanism 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 prestressed 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 virtually 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. 23
  • 24. DustProtector II ContiLube® II DustProtector II Prevents dust penetration on the hydraulic breaker ContiLube ® II Automatic lubrication unit mounted directly on the breaker Reusable sleeve - can be reused several times when the wear bushing is replaced. Highly resistant to grease and mechanical loads 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 AutoControl StartSelect Optimal impact energy at maximum percussive performance The ratio of impact energy to impact rate is controlled to ensure maximum percussive performance at all times (percussive performance = impact energy x impact rate). The “StartSelect” system allows the start-up and shut-off behavior of the breaker to be set in line with conditions. Avoids blank firing Reduces the load on both carrier and hydraulic breaker AutoControl always starts in short-stroke mode – reduced energy for better tool positioning Centering effect facilitates handling VibroSilenced system All 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. 24 “AutoStart” mode for 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” mode for jobs on firm ground, such as • trenching • bench leveling in the quarry • excavating foundations in rock • size reduction of heavy concrete structures
  • 25. Service you can depend on Wherever the job, our service engineers and product specialists 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 authorised 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. 25
  • 26. AC also stands for Application Counseling! With your help we can find out whether non-blasting methods are suitable for your mining operations. We assure you that all data will be treated in the strictest confidence. Questionnaire Please complete the attached questionnaire so that we can perform a feasibility assessment. The more details you can provide, the better! Photos 1.Take a photo of the quarry face 2.Zoom in on one section of the face. 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.. Example: 26 Important: The picture should include a person or object to give us an idea of the scale.
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  • 28. www.atlascopco.com/cto 3390 0513 01 © 2006, Atlas Copco Construction Tools GmbH, Essen, Germany. Subject to technical modifications.