0000cdse

Hydraulic breakers in
mining applications

2
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. The ability to mine the entire seam is
a further advantage.
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. You can read several examples in this brochure.
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.
When you use Atlas Copco hydraulic breakers, you benefit
from our many years of experience in assessing rock mining
methods around the globe.
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 information on your per-
sonal requirements.

3
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.
Factors influencing
productivity
Geology
(rock and
deposit)
Mining unit
(breaker and
carrier)
Conditions
(operation, servicing,
organization)
Productivity
of
hydraulic
breaker
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.
Atlas Copco accepts no lia-
bility for damage, consequential
damage or other claims arising
from information contained in
this brochure or parts thereof.

4
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 4200 – com-
bine to make our
hydraulic breakers
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 pre-
vent 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.
1
2
3
4
5
6
7
8
9
12
10
11
13

5
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.
StartSelect
The “StartSelect” system allows the
start-up and shut-off behavior of the
breaker to be set in line with conditions.
“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
AutoControl
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 (per-
cussive performance = impact energy x impact rate).
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
DustProtector II
DustProtector II
Prevents 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®
II
Automatic
lubrication
unit mounted
directly on the
breaker

6
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
150t 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.
Small: MB on the primary crusher Big: HB 7000 breaking boulders

7
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 auto-
matically increase with service weight. For example, a
breaker which is twice as heavy as another will not neces-
sarily 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 informa-
tion on breaker selection.
HB 3000
Model Secondary reduction performance in t/h
MB 1200 60 - 190
MB 1700 80 - 250
HB 2200 110 - 330
HB 3000 140 - 420
HB 4200 180 - 540
HB 7000 230 - 680
0
Non-binding guideline values t / h
100 200 300 400 500 600 700
Oversize boulders
HB 5800 200 - 610
Secondary reduction
performance figures
The diagram shows guideline figures which can be achieved using hydraulic breakers for secondary reduction.
The figures are based on performances achieved in practical operations.
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
Secondary reduction performance Examples of rock type
High Shell limestone, sandstone, slate, gneiss, marble
Average Limestone, dolomite, greywacke
Low Lava, porphyry, diabase, basalt, granite
types. For majority of secondary reduction
applications, blunt tools have proven most
effective. The table lists examples of rock
types.

8
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
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 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 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.
different rock grades
in the deposit
several
working faces
mining unit

9
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.
HB 7000 in clearing operations

10
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 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 mining
The 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.
This page: Quarry layouts old and new
Next page: Primary breaking with continuous conveying system

11
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.

12
Rock mining without blasting:
Average mining rate
Depo
unsuitable
Discontinuity spacing 1 m
Solid, compact rock formation fissured ro
Breakdown by rock type
Type a
Type b
Type c
Magmatic
Lava Granite
Diabase Basalt
Gabbro Syenite
Quartz porphyry
Metamorphic
Gneiss Phyllite
Slate Marble
Sedimentary
Platy limestone
Sandstone
Sedimentary
Limestone
Greywacke
Dolomite
Average mining rate
unsuitable
Discontinuity spacing 1 m
Solid, compact rock formation
Type a
Type b
Type c
Magmatic
Lava Granite
Diabase Basalt
Gabbro Syenite
Quartz porphyry
Metamorphic
Gneiss Phyllite
Slate Marble
Sedimentary
Platy limestone
Sandstone
Sedimentary
Limestone
Greywacke
Dolomite

13
Mining rate (t/h)
incl. servicing
Deposit characteristics
Mining
rate
0.4 m and less
fissured rock formation highly fissured rock formation
suitable
c
b
a
highly
suitable
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

14
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 ).
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.
Mining rate (t/h)
incl. servicing
Average mining rate
Deposit characteristics
unsuitable
Mining
rate
Discontinuity spacing 1 m 0.4 m and less
Solid, compact rock formation fissured rock formation highly fissured rock formation
suitable
Type a
Type b
Type c
c
b
a
highly
suitable
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

15
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: 44 t, 224 kW
Atlas Copco hydraulic breaker: HB 4200
Production data: 180 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:

16
Job description:
Rock type: Lava
Particularities: Blasting strictly prohibited
Job Example 3
Solution:
Job Example 4
Job description:
Rock type: Shell limestone
Rock structure: Strong seaming
Particularities: Blasting prohibited
Solution:

17
Job description:
Rock type: Orthogneiss
Rock structure: Deposit with strong tectonic faults
Job Example 5
Solution:
Job Example 6
Job description:
Rock type: Diabase
Rock structure:
Mainly homogeneous, only a few areas
with tectonic faults
Particularities: None
Solution:

18
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:
Job Example 8
Job description:
Rock structure:
Varying between homogeneous and
areas with tectonic faults
Solution:

19
Job description:
Rock type: Granite
Job Example 9
Solution:
Job Example 10
Job description:
Rock type: Limestone with iron content
Solution:

20
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:
Solution:

21
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:

22
With your help we can find out whether non-blasting
methods are suitable for your mining operations.
Questionnaire
Please 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.
Photos
1.Take a photo of the quarry face
2.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.

23
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��
��

KS
AC0106
gb2-2.2004
PMI
3390
0513
01
Elanders
Gummessons
2004
03
Subject
to
technical
modifications
.
www.atlascopco.com

0000cdse

Recommended

Recommended

More Related Content

What's hot

What's hot (16)

Similar to 0000cdse

Similar to 0000cdse (20)

Recently uploaded

Recently uploaded (20)

0000cdse