Manual English

Wirtgen Surface Mining Manual Edition 2002

This manual outlines the production and operating capabilities of the versatile Wirtgen Surface Miners. Here we collected a lot of information to help with the selection of an appropriate Wirtgen Surface Miner meeting your specific requirements for your jobs in hand. The given data represent an average of our current experience based on a variety of applications. However, However, depending on the specific application, given technical data are subject to change. Since production and consumption data are based on these values, this manual should be used for preliminary estimates and comparative purposes only. Due to the fact that applications may vary considerably, especially regarding rock properties and working conditions, we suggest that you contact a Wirtgen sales subsidiary or a Wirtgen dealer if you require specific information regarding your project. Based on detailed material, deposit and site conditions, your local Wirtgen representative, in co-operation with Wirtgen GmbH’s Mining Division, will be pleased to provide you with more accurate data for your specific project. Wirtgen shall have no liability for damages, consequential or otherwise, arising from the use of this manual or any part thereof.

Wirtgen GmbH Mining Division Hohner Strasse 2 53578 Windhagen Germany Phon one e: +49-264 +49-2645-13 5-131-36 1-368 8 Fax: + 49 49 -2 - 2645 -1 -131 - 24 242 E-Ma EMail il:: mi mini ning ng@w @wir irtg tgen en.de .de

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CONTENS Page 1. THE BENE BENEFITS FITS AND APPLI APPLICA CATIONS TIONS AT A GLANCE ........ ................ ................ ................ ................. ................. ................ .......... 6 Main applic applications ations for Wirtge Wirtgen n Surfac Surface e Mine Miners rs ....... ................ ................. ................ ................ ................ ................. ................. ........... ... 8 Selective Select ive Minin Mining g ........ ................ ................ ................ ................ ................. ................. ................ ................ ................ ................. ................. ................ ................ ........ 8 Material Mater ial exploi exploitatio tation n and crush crushing ing witho without ut blast blasting ing ........ ................ ................ ................. ................. ................ ................ ........... ... 9 Precise Preci se cutting of tren trenches, ches, surfaces surfaces and slopes ................. ......................... ................. ................. ................ ................ .............. ...... 10 Haulroad Haulr oad reha rehabilita bilitation.. tion.......... ................. ................. ................ ................ ................ ................. ................. ................ ................ ................ ................. .............. ..... 11 2. PHYSICAL PHYSICAL ROCK PROPERT PROPERTIES IES ......... ................. ................ ................ ................ ................. ................. ................ ................ ................ ............... ....... 12 3.THE MAIN TECHN TECHNICAL ICAL DA DAT TA ........ ................ ................ ................ ................. ................. ................ ................ ................ ................. ................. ........... ... 13 4. MAJOR DESIGN FEA FEATURES TURES OF WIRTGEN SURF SURFACE ACE MINERS MINERS..................... ......................................... .................... 15 5. OPERA OPERATION TION METHODS ........ ................ ................ ................ ................ ................. ................. ................ ................ ................ ................. ................. ............ .... 18 Harvesting Harve sting meth method od ........ ................ ................ ................ ................ ................. ................. ................ ................ ................ ................. ................. ................ ............. ..... 18 4

Block operatio operation n with ramp ramp cutting cutting ....... ................ ................. ................ ................ ................ ................. ................. ................ ................ ............. ..... Ramps ........ ................ ................ ................ ................. ................. ................ ................ ................ ................. ................. ................ ................ ................ ................. ............... ...... Open cut ........ ................. ................. ................ ................ ................ ................. ................. ................ ................ ................ ................. ................. ................ ................. ........... .. Speciall operat Specia operations ions ....... ................ ................. ................ ................ ................ ................. ................. ................ ................ ................ ................. ................. ............. ..... Selective Select ive mining mining of inclined inclined seams seams ........ ................. ................. ................ ................ ................ ................. ................. ................ ................ ........... ... Blending Blend ing material material while while cutting cutting on a ramp ramp ........ ................ ................ ................ ................ ................. ................. ................ ................ .......... Cutting Cutti ng the bench bench and floor floor in a tunnel tunnel ........ ................ ................ ................ ................ ................. ................. ................ ................ .............. ...... Cutting Cutti ng steep steep highwall highwall slopes slopes ........ ................. ................. ................ ................ ................ ................. ................. ................ ................ ................ ........... ... Operating Operat ing condit conditions ions ........ ................ ................. ................. ................ ................ ................ ................. ................. ................ ................ ................ ................. ......... Turning radius ........ ................ ................ ................. ................. ................ ................ ................ ................. ................. ................ ................ ................ ................. ............ ... Cutting Cutti ng and travelli travelling ng on inclinati inclinations ons ........ ................ ................ ................. ................. ................ ................ ................ ................ ................. ......... Geometrical Geomet rical facto factors rs ......... ................. ................ ................ ................ ................. ................. ................ ................ ................ ................. ................. ................ .......... ..

19 20 21 22 22 23 23 24 25 25 25 26

6. LOADING LOADING OPTIONS ........ ................. ................. ................ ................ ................ ................. ................. ................ ................ ................ ................. ................. .......... Directt loading ........ Direc ................. ................. ................ ................ ................ ................. ................. ................ ................ ................ ................. ................. ................ ........... ... Front loader ......... ................. ................ ................ ................ ................. ................. ................ ................ ................ ................. ................. ................ ................. .............. ..... Rear loader ........ ................. ................. ................ ................ ................ ................. ................. ................ ................ ................ ................. ................. ................ ............... ....... Smooth loading loading of trucks with fine material material ................... ............................ ................. ................ ................ ................ ................. ............ ... Truck excha exchange nge ......... ................. ................ ................ ................ ................. ................. ................ ................ ................ ................. ................. ................ ................ ........ Advanced truck exchange................................... exchange............ ............................................. ............................................ ........................................... ..................... Considered Consi dered truck size ........ ................ ................ ................ ................. ................. ................ ................ ................ ................. ................. ................ ................ ........ Indirect Indir ect loadin loading............. g..................... ................. ................. ................ ................ ................ ................. ................. ................ ................ ................ ................. .............. ..... Sidecasting Sideca sting of the mater material ial ........ ................. ................. ................ ................ ................ ................. ................. ................ ................ ................ ................ ........ Windrow Windr ow ........ ................. ................. ................ ................ ................ ................. ................. ................ ................ ................ ................ ................. ................. ................. ............ ...

27 28 28 28 29 29 29 30 30 30 31

7. CUTTIN CUTTING G TECHN TECHNOLOGY OLOGY ........ ................ ................. ................. ................ ................ ................ ................. ................. ................ ................ ................ .......... .. Cutting Cutti ng tools ........ ................ ................. ................. ................ ................ ................ ................ ................. ................. ................ ................ ................ ................. .............. ..... Cutting Cutti ng toolho toolholder lder ......... ................. ................ ................ ................ ................. ................. ................ ................ ................ ................. ................. ................ ............. ..... Characteris Chara cteristics tics of different different cutting tool types ........ ................. ................. ................ ................ ................ ................. ................. ............ ....

32 33 34 35

8. TECHN TECHNICAL ICAL DA DAT TA AND DIME DIMENSION NSIONS S ........ ................ ................ ................. ................. ................ ................ ................ ................ ............... ....... Surface Surfac e Miner Miner 2200 SM ........ ................. ................. ................ ................ ................ ................. ................. ................ ................ ................ ................. ............ ... Surface Surfac e Miner Miner 2500 SM ........ ................. ................. ................ ................ ................ ................. ................. ................ ................ ................ ................. ............ ... Surface Surfac e Miner Miner 3700 SM ........ ................. ................. ................ ................ ................ ................. ................. ................ ................ ................ ................. ............ ... Surface Surfac e Miner Miner 4200 SM ........ ................. ................. ................ ................ ................ ................. ................. ................ ................ ................ ................. ............ ... Dinting Dintin g Mach Machine ine 2600 SM ........ ................ ................ ................. ................. ................ ................ ................ ................. ................. ................ ................ .......... ..

36 36 38 40 42 44

9. PRODUCTION PRODUCTION ESTIMATE ESTIMATE ........ ................. ................. ................ ................ ................ ................. ................. ................ ................ ................ ................ ........ Surface Surfac e Mine Minerr 2200 SM ........ ................ ................ ................ ................. ................. ................ ................ ................ ................. ................. ................ ............. ..... Surface Surfac e Miner 2500 SM ........ ................ ................ ................. ................. ................ ................ ................ ................. ................. ................ ................ ............. ..... Surface Surfac e Miner Miner 3700 SM ........ ................. ................. ................ ................ ................ ................. ................. ................ ................ ................ ................. ............ ... Surface Surfac e Miner 4200 SM ........ ................ ................ ................. ................. ................ ................ ................ ................. ................. ................ ................ ............. ..... Comments Comme nts on the charts ......... ................. ................ ................ ................ ................ ................. ................. ................ ................ ................ ................. ........... ..

46 46 47 48 49 50 5

1.

The Th e ben benef efit its s and and ap appl plic icat atio ions ns at a gla glanc nce e

The main advantages of the Wirtgen Surface Miner technology are: • Mining without blasting • Simplified mining technology • Enhanced quality of ROM (Run Off Mine) product by highly selective mining • Stable, clean surfaces and benches

Wirtgen Surface Miners Possible uses

Uses in the mining sector

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Uses in earthmoving and construction

Selective mining from thin seams of useful mineral

Production of stable embankments

Mining rock without blasting

Production of defined surfaces

Producing small particle sizes during the mining process

Production and rehabilitation of traffic routes

Main features

Main features

High purity of the useful mineral, high cutting performance, low price per tonne

Production of precise, stable and defined profiles in rock

The benefits and applications at a glance

Continuous cutting Crushed aggregate

Precise cutting depth

Direct loading

Clean, level and stable surface

Wirtgen Wirtge n Surface Miner Miner cut, crush and load material material in one operat operation ion with only one machine.

These jobs are no longer required: Cleaning, levelling and bolder splitting Drilling

Blasting

Loading

Crushing

Wirtgen Surface Miners

The complex hard rock mining system is replaced by only one machine.

Advantages: • Improved overall availability of the system • Reduced operating cost • Several working steps are realized by only one machine, leading to easier coordination and process planning during planning, dispatching and maintenance The benefits and applications at a glance

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Main applications for Wirtgen Surface Miners Selective Mining One of the most important characteristics of the Wirtgen Surface Miners is their ability to work highly selective. Thin, disturbed seams, for example, can be mined precisely and economically.

Is possible when using Wirtgen Surface Miners: Selective mining of thin coal seams.

Mine operators world-wide use the benefits of the Wirtgen Surface Miner technology with its very precise cutting depth control for the production of high quality ROM material in coal, phosphate and gypsum mines. Selective mining with Wirtgen Surface Miners ensures that even thin seams of valuable minerals and overburden can be mined separately.

Advantages: • Enhanced ROM-quality • Improved exploitation of the deposit • Reduced stripping ratio • Reduced processing after mining required

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Material exploitation and crushing without blasting All over the world, mine operators and construction companies use the advantages advantages of Wirtgen Surface Miners in numerous mine operations.

Is possible when using Wirtgen Surface Miners: Mining without blasting in the vicinity of buildings, electrical wires etc.

• Drilling and blasting is not necessary - No vibrations - No fly rock • Reduced noise and dust development • Production of small particle sizes directly during the mining process - Cut material can directly be used as gravel - Primary crushing stage can be omitted - Gentle loading of trucks due to size of the cut material - The material can be conveyed without further crushing. • One Wirtgen Surface Miner replaces equipment for drilling, blasting, loading and auxiliary works i.e. boulder splitting.

Advantages: • Low investment costs in comparison to the range of equipment necessary for conventional mining • Low operating costs due to less equipment and less personnel • Several working steps are realized by only one machine, leading to easier coordination and process planning during planning, dispatching and maintenance • Improved exploitation of the deposit • Improved safety


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Precise cutting of trenches, surfaces and slopes Construction companies benefit from technical features of Wirtgen Surface Miners for precise cutting of: • Trenches • Tunnel floors • Slopes • Surface profiles in limestone, granite and other medium hard to hard minerals.

Is possible when using Wirtgen Surface Miners: Cutting limestone for a water deposit.

Is possible when using Wirtgen Surface Miners: Lowering Loweri ng tunnel floors ...

... for modern railway systems with improved capacity. capacity.

Advantages: • No blasting required • Cutting of steep and stable surfaces and embankments (better exploitation) • Precise cutting of designed profiles (slopes, surfaces) • Production of small particle sizes directly during the cutting process. The granulometry of the cut material renders it suitable to be used as gravel. 10


Haulroad rehabilitat rehabilitation ion Wirtgen Surface Miners can be used to maintain the surface of existing haulroads in virgin rock in opencast mines or in underground mines. Wheel ruts, floor heaves because of rock throws, but also other hard, not rippable spots can be eliminated or smoothened.

Haulroads in an opencast mine

Haulroads in an underground mine

Advantages: • Higher overall travel speed for haulage vehicles due to better road surfaces • Reduced wear and tear of tires, mechanical and structural elements • Less fuel consumption • Improved safety The benefits and applications at a glance

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2.

Physical ro rock pr properties

The performance, the cutting tool consumption and the economic operation of Wirtgen Surface Miners is significantly affected by the mechanical properties of the rock to be cut. The main properties of rock affecting the cutting performance are: • Uniaxial compressive strength [MPa] and tensile strength [MPa] • Abrasivity • Structure of the rock (i.e. number and distance and direction of fractures) In general, Wirtgen Surface Miners are capable of cutting rock with a hardness of between 10-80 MPa. Under certain circumstances (e.g. highly fractured material) even harder material can be cut economically economically.. Please consult Wirtgen’s Mining Division to determine the cuttability of rock with a Wirtgen Surface Miner based on the available information concerning the rock and the mine.

soft

hard

very hard

2200 SM

750 t/h

2500 SM

1.550 t/h

220 t/h

65 t/h

3700 SM

2,550 t/h

365 t/h

100 t/h

4200 SM

3,400 t/h

0

300 t/h

20

475 t/h

40

60

80

MPa

Performance data of Wirtgen Surface Miners for rock with different hardness.

Based on material density (bank) of: • 1,3 t/m3 for a compressive strength of approx. 10 MPa • 2,5 t/m3 for a compressive strength of 50-80 MPa The performance data given are guideline values only. Rock with a higher uniaxial compressive strength than stated can be cut under certain circumstances. The actual performance depends amongst other factors also on the structure of the rock. Please consult Wirtgen’s Mining Division for further information. 12

Physical rock properties

3.

The main technical data 2200 SM Cutting width: Cutting depth: Engine: Weight: Cutting drum drive: Number of tracks: Track drive system:

2.20 m 0.35 m 811 PS 51.0 t mechanical 4 hydraulic

2500 SM Cutting width: Cutting depth: Engine: Weight: Cutting drum drive: Number of tracks: Track drive system:

2.50 m 0.60 m 1,065 PS 103.0 t mechanical 4 hydraulic


The main technical data


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Dinting Machine 2600 Cutting width: Cutting depth: Engine: Weight: Number of wheels: Cutting drum drive: Wheel drive:

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2.60 m 0.20 m 326 PS 29.0 t 4 hydraulic hydraulic

The main technical data

4.

Major design features Site illumination

Operator’s cab

Drive unit with Diesel engine

Boom counterweight

Slewing ring Site illumination

Discharge boom, slewable and adjustable in height

Crawler track, steered and adjustable in height

Crawler track, adjustable in height Scraper blade with primary conveyor Cutting drum, mechanically driven

Principle design of a Wirtgen Surface Miner.

A range of technical design features ensures ensures that Wirtgen Surface Miners are are up for their job. The Wirtgen Surface Miners are machines made for an efficient, continuous mining operation. They are equipped with 4-track crawlers with infinitely variable speed. During driving, a rotating cutting drum, equipped with tungsten carbide bits, cuts the material and crushes it down to a size suitable for belt conveyors. The cutting drum operates in upward direction. The cutting tools, mounted to the drum in form of a helix, propel the material towards the center of the drum. There the material is loaded via the primary belt conveyor to the discharge belt conveyor. The main design features are: • Diesel engine The Wirtgen Surface Miners are all diesel powered. The engine’ engine’s s power is transmitted via a robust belt drive to the drum, ensuring an effective power transmission. Moreover, Moreover, other systems (e.g. track and belt drive) are hydraulically driven.

Major design features

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• Central cutting drum with mechanical drive The cutting drum is located in the center of the machine, between the four crawler tracks. It is located close to the center of gravity. The entire machine weight and installed power can thus be converted into cutting force. This allows cutting of harder materials with good results and ensures at the same time stability of the machine.

Drive concept with central cutting drum

The cutting drum speed can be varied by interchanging the belt pulleys. The usual range of drum speeds, which can be realized with these changings vary from 60 to 100 r.p.m. The belt pulleys are tensioned automatically by a hydraulic cylinder. This is an energyeffective, low maintenance system, minimizing operating and maintenance costs.

Adjustment of drum rotation speed

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• Automatic adjustment of cutting depth The cutting depth is regulated by an automatic levelling system mounted to the machine. The pre-selected cutting depth is maintained either automatically or can be adjusted manually. manually. The control system can be connected with: • Cable sensors scanning the distance to a reference plate sliding on the surface. Milling depth controlled by scanning the height (e.g. with a cable sensor)

Milling depth controlled via a slope sensor

• Non-contact ultrasonic sensors measuring the distance to the side plate or the surface. • Automatic control of transversal slope: The machine is equipped with a slope sensor to control transversal slope of the cutting surface. It can be used to create defined slopes, for water drainages for example, on the cutting surface.

Control unit 3 sensors left

• Multiplex sensors working with three sensors on one or both sides of the machine, thus levelling uneven surfaces in longitudinal and transversal direction.

Slope control

3 sensors right

• Laser sensors working with a transmitter and receiver.

Control unit

In practice operation, a depth tolerance in the range of ± 0.5 cm can can be achieved. achieved.


Precise control of cutting depth with a laser.

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5.

Operating me methods

Harvesting mode – slice method In the harvesting mode, the Wirtgen Surface Miner operates on an even field and continuously cuts the material. The cutting process can thus be continued also during driving a curve with the machine. A

1

– 8 m – 8

2

– 7 m

– 5 m

– 6 m

– 4 m

– 3 m

– 2 m

–1 m

°

3 4 5 6 7 8 9 10 11 12 3

5 4

7 6

13

9

14

8

15 16 17 18 9 8 7 6 5 4 3

A Harvesting / slice method – (schematic)

The mining area is developed by cutting slice by slice. Fo r each slice the cutting depth only needs to be set once on the Wirtgen Surface Miner. Miner.

Harvesting / slice method: Here the Surface Miner cuts while driving a curve.

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Operating methods

Block operation with ramp cutting Wirtgen Surface Miners can be integrated into existing mines and quarries using conventional drilling and blasting operations in benches. They are able to continue to work on the existing benches, using the block method.

A B

A = Block height height B = Block width

Block Method

While cutting the block down to its planned level, the Wirtgen Surface Miner also cuts its own ramp. After completing the cut of the first block, the next block can be started adjacent to the first one. Since turning on narrow benches is difficult and time consuming, two alter native operations can be recommended: a.

Turn urnin ing g the the mach machin ine e on an an appr approp opria riate te are area a outs outside ide the the ram ramp p (thi (this s area area can can be be mine mined d later together with the bench by means of the Wirtgen Surface Miner).

b.

Reverse the machine after finishing one cut and reposition the Surface Miner at the adjacent cut.

A Wirtgen Surface Miner (on the right edge of the ph oto) cutting his own ramp.

Operating methods

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Ramps Typical ramps have a gradient of approx. 10-15% in order to allow trucks to traffic them loaded in upward direction. A Wirtgen Surface Miner is able to cut its own ramp. These ramps can be made cutting upwards or downwards. In the graphic shown below, cutting a ramp in upward direction is explained. When cutting in a downward direction, the process is vice-versa. In this case the cutting depth has to increase from 0 to the maximum cutting depth.

2 m Working width

-0.2

2m

Working direction

A -0.4

-0.2

0.2 m

B -0.4 0.11 m -0.6 -0.6

Example for cutting a ramp (working direction upwards) 1. The Wirtgen Surface Miner cuts the first slice. Once the Miner reaches the red line A it is gradually decreasing the cutting depth within the next two meters. Therefore less material is being cut. The resulitng ramp has a gradient of 10 %. 2. When the Miner is cutting the second cut, the Miner slowly cuts itself out of the cut until the red line, once it reaches the green line B. Here the cutting depth shall be zero. At the red line, the cutting drum should not be able to cut any material because the drum should be above the cutting surface. This process will continue slice by slice until the final length of the ramp has been achieved.

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Operating methods

Operation in an open cut

Operation in an open cut

Depending on the length and the width of the open cut the Wirtgen Surface Miner can be either turned at the end of each cutting path or driven rearwards to start the next cut on the same side of the area as the previous one.

1

2 9

3 10

17

4 11

18 25

5 12

19 26

6 13

20 27

7 14

21 28

8 15

22 29

16 23

30

24 31

32

Cutting sequence of a Wirtgen Surface Miner in an open cut.

Operating methods

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Special operations The design (position of the cutting drum in the middle of the machine) and the working characteristics (continuous cutting, precise cutting depth control, cutting even and stable surfaces) surface s) of a Wirtgen Surface Miner allow to work in various conditions, conditions, thus providing technical technical solutions for many demanding tasks in mining. • Selective mining of inclined seams Depending on the degree of inclination of the seams different working methods are possible:

Block 2

Block 1

Slightly inclined seams can be cut in blocks as shown in the adjacent drawing. When cutting at the boundary between coal and waste, a certain degree of dilution of the material has to be considered.

Slightly inclined seams

Cutting very steep seams or pockets of paymaterial can be mined as shown on the adjacent drawing.

Steeply inclined multiple seams

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Operating methods

• Blending material while cutting on a ramp

Blending material while cutting on a ramp.

Irregular deposits often require the blending of material in order to maintain quality standards – either for the following process or for the production of market-oriented mineral blends. Horizontally variations of the deposit can be blended with Wirtgen Surface Miners directly during cutting. The machine cuts continuously on a ramp, thus mining through all layers and homogenizing the material. Subsequently the requirements for mixing plants are minimized.

• Cutting the bench and floor in a tunnel

Surface Miner lowering the bech of a tunnel ...

... directly loading the cut material onto a train.

Wirtgen Surface Miners can effectively work in congested workspace like tunnels, to cut benches and floors precisely according to the required profiles in a minimum amount of time. The cut material fits very good to be used as gravel. Operating methods

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• Cutting steep highwall slopes Wirtgen Surface Miners can produce steep highwall slopes. Generally, Wirtgen Surface Miner Generally, achieve achie ve a slope angle angle of 60° in normal normal operation. Under certain circumstances even higher angles have been achieved. Please consult Wirtgen’ Wirtgen’s s Mining Division for specifications.

Cutting steep highwall slopes

Cutting steep highwall slopes

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Operating methods

Operating conditions Cutting in edges and curves, turning, turning radius For sharp turns, the cutting drum has to be lifted in order to acheive a small turning radius. However, the machine can also turn while the cutting drum is still in operation. As a rule of However, thumb the turning, the turning radius is: • 12 x cutting width (when cutting harder rock, the cutting depth has to be reduced) The radii which can be achieved depend – amongst other factors – on the material to be cut and the actual depth of the cut. Generally, they can only be determined precisely during the first operations in a deposit. So it i t is possible to acheive smaller or larger radii in practice.

Cutting and travelling on inclinations The following table contains the operation limits for lateral and longitudinal inclinations.

Type of Surface Miner

Normal operation Transversal inclination Longitudinal inclination (*)

2200 SM 2500 SM

8% 8%

20 % 20 %

3700 SM

8%

20 %

4200 SM Dinting machine 2600

8% 5%

20 %

*)

Althou Alth ough gh the these se inc incli lina nati tion ons s are are poss possib ible le und under er norm normal al oper operat atin ing g condi conditi tion ons s with with reg regar ard d to stability, stability, the cutting performance of the machine will be reduced when longitudinal inclinations exceed 5°. The reduction of cutting performance for even steeper inclinations depends on the inclination itself and the material to be cut.

Please contact Wirtgen’s Mining Division for further details.

Operating methods

25

Geometrical factors Length of working area The productivity of a Wirtgen Surface Miner depends on the length of the available working area. Longer cuts will enhance the productivity, productivity, because only a smaller amount of time is spent is in manouvering from one cut to the next. The for ward speed (and therefore travel time for a given cutting length) furthermore depends from a number of factors: • cutting depth • material hardness and structure • type of machine and installed engine power Therefore, the graph below only can show the general relation between effective production and cutting field length.

n o i t c u d o r P e v i t c e f f E

Cutting field length Cutting field length vs. effective production

In standard applications, the appropriate minimum cutting field length should be in the range of: • 100 m (hard material, low forward speed) • 300 m (softer material, high forward speed)

26

Operating methods

6.

Loading options

The Wirtgen Surface Miner range offers the following loading and material handling options:

Loading options

Direct truck loading

Indirect loading

front loading

rear loading

2200 SM

2500 SM 3700 SM 4200 SM

windrow

sidecast

Comparison of the differen differentt loading methods: ADVANT ADV ANTAGES AGES Direct Loading

No re-handling of material required

DISADVANT DISADV ANTAGES AGES Larger working area required for truck manoeuvering Production affected by truck exchange time Belt wear

Sidecasting

Windrow

Blending of materia materials ls in the mine

Restricted to 3-5 cuts wide on each side of the mine stockpile

Stockpile of material in the mine

Belt wear

No waiting for trucks, independent operation

Material has to be re-handled Material prone to absorb water when lying on the ground

No waiting for trucks

Large working area required

No belt wear / higher availability

Material has to be re-handled either by loader or scraper

Higher production rates than conveyor loading

Material prone to absorb water when lying on the ground

Coarser material Better selectivity on steep inclined seams

Loading options

27

Direct loading Direct loading onto trucks One of the main characteristics of the Wirtgen Surface Miners is their ability to load the cut material directly onto trucks. Depending on the machine type, Wirtgen Surface Miners are designed either as front loading or rear loading machines. Front loading The 2200 SM is a typical front loader, with the discharge conveyor mounted in front of the machine. The conveyor can be slewed of the right and the left and the height is adjustable. Depending on the truck size, these machines load the trucks either from behind (see photo on the left) or from the side (see photo on the right). The Surface Miner’s operator has a direct view on the truck.

Front loader – loading from behind

Front loader – loading from the side

Rear loading Other models, such as the 2500 SM, 3700 SM and the 4200 SM are rear loaders, with the discharge conveyor mounted in the rear of the machine. The conveyor can be slewed of the right and the left and the height is adjustable. The weight of the conveyor is balanced by a counterweight. To To ensure safety when cutting steep benches the counterweight can be lifted. The Surface Miner’s operator has direct visual contact to the truck because he may slew his seat to the right or left hand side.

Rear loader 2600 SM loading from the side (machine type replaced by the new 2500 SM)

28

Rear loader 4200 SM loading from the side

Loading options

Smooth loading of trucks with fine material In all cases, the fine gradation of the material cut by a Wirtgen Surface Miner ensures a smooth, continuous and complete loading of the truck body body.. The loading characteristics allow flexibility when choosing a suitable truck size. For example, under certain circumstances trucks with aluminium truck body and enhanced payload can be used.

Smooth loading of a 27 t truck with aluminium truck body and enhanced payload.

Truck exchange To enhance productivity and to minimize waiting time for the Wirtgen Surface Miner an empty truck should be waiting beside the machine just before the presently loaded truck is completely filled. The normal truck exchange times are between 15-30 seconds, depending on the type of the Wirtgen Surface Miner and the size o f the truck. The exchange times are also affected by the available area for manoeuvering of the trucks and the driver’ dri ver’s s experience.

Advanced truck exchange For Wirtgen Surface Miners with a front loading system the empty truck positions itself parallel to the presently loaded truck. The loading of the second truck starts by simple swinging of the conveyor only. Stopping the cutting process is not required. The following sequence shows a perfect truck exchange while the Surface Miner continuously goes on with cutting.

Truc ruck k no. no. 1 is is being being loa loaded, ded, tru truck ck no. no. 2 is posi position tioning. ing.

Loading options

The Surface Surface Miner Miner slews slews its conveyor conveyor to truck truck no. 2, truck no. 1 drives to further processing of the material.

29

Recommended truck size The recommended truck size for a Wirtgen Surface Miner depends on the foll owing factors: • The conveyor boom’s discharge height determines the maximum loading height of the truck (see sketches in chapter 8). This is based on the assumption that the Wirtgen Surface Miner and the truck are on the same (cut) level without any relative inclination. • The cutting performance of the Wirtgen Surface Miner in a given material. To reach an economic truck loading and transportation cycle the truck size should be selected such that loading times of 2 to 6 minutes are achieved.

Indirect loading • Sidecasting of the material Sidecasting the material means that a stockpile is built by dumping the material from different cuts via the conveyor on one pile. Depending on the slewing angle of the conveyor, conveyor, up to 3 to 5 adjacent cuts can be dumped on top of each other. other. Due to the height of the formed stockpile, the material can easily be reloaded with a front-end loader.

2200 SM – sidecast mode

Advantage: The cutting operation of the Wirtgen Surface Miner using sidecasting is independent from the truck loading operation.

2500 SM – sidecast mode

30

Loading options

Windrowing In windrowing mode the cut material is directly discharged behind the machine without using a conveyor. conveyor. Therefore the cutting operation is independent from the truck loading operation, but the material has to be re-handled with a front-end loader.

Wirtgen Su Surface Mi Miner – windrow op operation

Wirtgen Su Surface Mi Miner – windrow op operation

Wirtgen Surface Miner windrow operation

Reloading windrow material

For many applications, the higher productivity in the windrow operation in comparison to direct loading, over-compensates for the additional cost for the re-handling of the material (e.g. wheel loader). In addition, no belt wear and no operating cost for the conveyor will arise when working in the windrowing mode.

Loading options

31

7.

Cutting technology

The cutting technology is Wirtgen’s core competence. We continuously improve our technology to enhance even further: • Maximum cutting performance • Maximum lifetime of cutting tools • Minimum operating cost • Control of granulometry of cut material

Wirtgen cutting drum 2200 SM

Wirtgen cutting drum 3700 SM

The cutting performance of a Wirtgen Surface Miner is significantly affected by the following machine parameters: • Type of cutting tool • Type of cutting tool holder • Number of cutting tools on the drum (spacing) • Angle of attack of the tools • Rotation speed of cutting drum • Cutting depth • Advance speed of the machine

Wide tool spacing

32

Narrow tool spacing

Cutting technology

Cutting tools The selection of the appropriate cutting tool is essential for g ood cutting performance and for the lifetime of the cutting tool itself. Wirtgen GmbH’s GmbH’s standard delivery range of cutting tools for mining comprises the tools shown below. belo w. Moreover, Moreover, for special applications, Wirtgen can provide additional tools, too. Please consult Wirtgen’s Mining Division for further information.

W 47 K12

W 47 K13

W 47 K15

Ø 12 Ø 15

Ø 13

2 2

4 2

8 2 0 0 1

W 47 K17

W 47 K19 Ø 17.5

Ø 25

0 3 7 7

7 7

W 47 K25 Ø 19

5 . 8 2

Cutting technology

7 7

0 4 7 7

7 7

33

Cutting drum for a Wirtgen Surface Miner 4200 SM.

Cutting toolholders One of the features of Wirtgen cutting drums is the type of toolholders used. Which type of toolholders is chosen depends on the application the drum shall be used for. The “point attack tools” themselves are fixed in the toolholders, each of them exactly positioned on the drum. The tools are stuck into a bushing and are fixed by means of a retainer ring so that they keep their position relatively to the holder holder,, but still are able to rotate during the cutting process. Worn out tools can be taken away by simple loosening of the retainer ring and fixing a new tool.

Wirtgen toolholder type HT 6 in bushing form, here equipped with a typical mining point attack tool. The tool is fixed against falling out by means of a retainer ring, but still is able to rotate.

34

Cutting technology

The toolholders are subject to high stress, especially when cutting hard materials, because irregular rock formations may lead to enormous peak loads on the single toolholders. Here the heavy duty design of the bushing-type toolholders ensures long lifetime. Special systems take care of the exact positioning of the toolholders. In consequence worn out toolholders can be replaced by new ones easily. Another special feature bases on the the fact that only the worn out tools respectively toolholders have to replaced, not the complete set. This has an extremely positive effect on the costs arising while working with the Wirtgen Surface Miners.

Characteristics of different cutting tool types

12 mm

25 mm

Small diameter of tungsten carbide:

Large diameter tungsten carbide:

• Low lifetime • Good penetration • High cutting performance • Coarse gradation (*)

• Long lifetime • Poor penetration • Low cutting performance • Fine gradation (*)

(*)

In gen genera eral, l, the gra gradat dation ion of the cut mat materi erial al dep depend ends s prim primari arily ly on the mat materi erial al har hardne dness ss and structure. Tool Tool spacing, the type of tools on the drum and other machine factors have only a secondary effect on gradation.

Cutting technology

35

8.

Technical data and dimensions

Wirtgen Surface Miner 2200 SM – Technical data Surface Miner 2200 SM mm Cutting width max. 1 mm Cutting depth* Cutting drum Spacing mm Number of tools Drum diameter with tools mm Drum inclination, max. ° Engine Manufacturer Type Cooling No. of cylinders Output kW / HP / PS Engine speed min-1 Displacement cm3 1 Fuel consumption: / 1 load l/h Fuel consumption: 2 / 3 load l/h Speed/gradeability Travel speed m / min (km/h) Theoretical gradeability % Ground clearance mm 2 Weights* Front axle load, full tanks daN (kg) Rear axle load, full tanks daN (kg) Own weight daN (kg) 3 Operating weight, CE* daN (kg) Operating weight, full tanks daN (kg) Tracks Front tracks (L (L x W x H) mm Rear tracks (L x W x H) mm Tank capacities Fuel tank l Hydraulic fluid tank l Water tank l V Elektrical system Conveyor system Belt width 1st belt (loading belt) mm nd Belt width 2 belt (discharge belt) mm Theoretical conveying capacity m3 /h Shipping dimensions / Weight Weights* s*2 Dimensions of machine (L x W x H) mm Dimensions of discharge conveyor (L x W x H) mm Upper part of operator’s cab (L x W x H) mm Weight of machine daN (kg) Weight of discharge conveyor daN (kg) Weight of upper part of operator’s cab daN (kg)

2,200 0 – 350 38 76 1,140 5 Caterpillar 3412E Water 12 596.5 / 800 / 811 2,100 27,000 150 100 0 – 84 (0 – 5) 90 370 25,430 25,350 44,500 47,730 50,780 2.200 x 370 x 790 2.200 x 370 x 790 1,500 450 5,000 24 1,100 1,100 668 9,600 x 2,750 x 3,000 8,600 x 1,600 x 1,200 2,600 x 2,900 x 1,500 41,700 1,800 1,000

* 1 = The maximum milling depth may deviate from the value indicated, due to tolerances and wear. * 2 = All weights refer to b asic machine without any additional equipment. * 3 = Weight of machine with half-full water tank, half-full fuel tank, driver (75 kg) and to ols.

36


Wirtgen Surface Miner 2200 SM – Dimensions Dimensions in mm

9600

0 0 8 * 4 0 0 0 3

0 0 0 3

1400

2600

1100

3200 5800

16100 16800*

° 5 4

0 0 0 5 0 0 7 2 1 2 2 2

0 6 5 1

0 9 1

5 0 1

0 0 2 5 R

0 8 6 1

0 6 3

° 5 5

* = Low-loader transportation transportation dimensions


37

Wirtgen Surface Miner 2500 SM – Technical data Surface Miner 2500 SM mm Cutting width, max. mm Cutting depth *1 Cutting drum Number of cutting tools on drum Cutting drum diameter with tools mm Drum inclination max. ° Engine Manufacturer Type Cooling Number of cylinders Output kW / HP / PS Engine speed min-1 Displacement cm3 Fuel consumption, 1 / 1 load l/h 2 Fuel consumption, / 3 load l/h Speed/gradeability Operating speed m / mi n Travel speed km/h Theor. gradeability % Max. transverse gradient % 2 Weights * Front axle load, full tanks daN (kg) Rear axle load, full tanks daN (kg) Own weight daN (kg) 3 Operating weight, CE* daN (kg) Operating weight, full tanks daN (kg) Crawler tracks Front crawlers (L (L x W x H) mm Rear crawlers (L x W x H) mm Tank capacities Fuel tank l Hydraulic fluid tank l Water tank l Electrical system Control V Lighting V Conveyor system Width of primary belt (Loading belt) mm Width of secondary belt (Discharge belt) mm Theoretical discharge belt capacity m3 /h Shipping weights/Weights *2 1st module (L x W x H) mm 2nd module (L x W x H) mm st Weight 1 module daN (kg) nd Weight 2 module daN (kg)

2,500 0 – 600 Depends on application 1,400 4 Cummins QST 30 Water 12 783 / 1,050 / 1,065 2,100 30,500 191.5 127.6 0 – 25 0 – 3.9 20 8 39,200 63,800 98,000 100,500 103,000 2,920 x 400 x 970 2,920 x 400 x 970 2,400 500 2,800 24 24 1,400 1,400 1,100 12,800 x 3,470 x 3,300 15,700 x 2,750 x 3,400 76,600 21,400

* 1 = The maximum cutting d epth may deviate from the value indicated, due to tolerances and wear. wear. * 2 = All weights refer to b asic machine without additional equipment. * 3 = Weight of machine with half-full water tank, half-full fuel tank, driver (75 kg) and to ols.

38



22700

0 0 5 7 – 0 0 3 4

5 3 9 4

1 1 3 0 0

2920 5195

3545

0 7 9

8740

0 0 5 8 R

° 0 9

0 0 9 1

0 0 7 4 0 8 4 0 1 3 4

° 9 3


39

Wirtgen Surface Miner 3700 SM – Technical data Surface Miner 3700 SM Cutting drum

Cutting width max.

mm

3,700

Cutting Cutti ng depth *

mm

0 – 600

Cutting drum diameter with tools

mm

1,400

1

Number of cutting tools on drum

Depending on machine application

Engine Make

Cummins

Type

KTA 50

Cooling

Water

No. of cylinders Output

16 kW/HP/PS

1,194 / 1,600 / 1,623

Fuel consumption: 1 / 1 load

l/h

284


l/h

189

Speed /gradeability Operating speed

m/min

0 – 20

Travel speed

km/h

0 – 2.5

Gradeability

%

20

Max. transverse gradient

%

8

Weights Wei ghts / load loads s *2 Front axle load

daN (kg)

59,000

Rear axle load

daN (kg)

98,000

Own weight

daN (kg)

157,000

Operating weight, full tanks

daN (kg)

176,000

Crawler tracks Front crawlers (L x W x H)

mm

3,880 x 500 x 1,200

Rear cr crawlers (L x W x H)

mm

3,880 x 500 x 1,200

Tank capacities Fuel tank

l

2,900

Hydraulic fluid tank

l

800

Water tank

l

15,000

Control

V

24

Lighting

V

220

Electrical system

Spotlights

10 x 400 W each

Conveyor system Width of primary belt

mm

1,800

Length of primary belt

mm

7,000

Width of discharge belt

mm

1,800

Length of discharge belt

mm

12,000

m3 /h

2,400

Theoretical discharge belt capacity

* = The maximum cutting d epth may deviate from the value indicated, due to tolerances and wear. wear. * 2 = All weights refer to b asic machine without additional equipment. 1

40



0 0 0 7 . x a m / 0 0 3 4 . n i m

0 0 2 8

3550

5375 8925 25330

R 1 6 2 5 0

0 0 0 0 4 5 2 2

0 0 5

3832 º 0 9

0 7 4 2

º 9 0

4 5 º 5 0 0


41

Wirtgen Surface Miner 4200 SM – Technical data Surface Miner 4200 SM Cutting drum Cutting width max.

mm

4.200

Cutting depth* 1

mm

0 – 800

Cutting drum diameter with tools

mm

1.860

Number of cutting tools on drum

Depending on machine application

Engine Make

Cummins

Type

KTA 50

Cooling

Water

Number of cylinders Output

16 kW/HP/PS

1.194 / 1.600 / 1.623

Fuel consumption, 1 / 1 load

l/h

284

Fuel consumption, 2 / 3 load

l/h

189

Speed/Gradeability Operating speed

m/min

0 – 20

Travel speed

km/h

0 – 2,5

Gradeability

%

20

Max. transverse gradient

%

8

Weights * 2 Front axle load, full tanks

daN (kg)

73.600

Rear axle load, full tanks

daN (kg)

117.800

Own weight

daN (kg)

172.400


daN (kg)

191.400

Crawler tracks Front crawlers (L x W x H)

mm

3.880 x 500 x 1.200

Rear crawlers (L x W x H)

mm

3.880 x 700 x 1.200


l

2.900


l

800

Water tank

l

15.000

Control

V

24

Lighting

V

220

Electrical system

Spotlights

10 à 400 W

Conveyor system Width of primary belt

mm

1.800

Length of primary belt

mm

7.000

Width of discharge belt

mm

1.800

Length of discharge belt

mm

15.000

m3 /h

2.400

Theoretical discharge belt capacity

* 1 = The maximum cutting d epth may deviate from the value indicated, due to tolerances and wear. wear. * 2 = All weights refer to b asic machine without any additional equipment.

42



0 0 5 8 . x a m / 0 7 0 5 . n i m

0 0 2 8

3550

5375 8925 28000

R 1 6 2 5 0

0 0 0 5 4 5 2 2

0 0 7

3832 º 0 9

0 0 5 2

º 9 0

4 5 º 5 0 0


43

Wirtgen Dinting Machine 2600 – Technical data Dinting Machine 2600 Cutting width max.

mm

2,600

Cutting depth*1

mm

0 – 200

Spacing

mm

15

Number of tools

mm

855

Cutting drum

Drum diameter with tools Drum inclination, max.

212 °

5

Engine Manufacturer

Deutz

Type

BF 12 L 413 FW

Cooling

Air

No. of cylinders

12

Output

kW/HP/PS

240 / 321/ 326

Engine speed

min-1

2,300

Displacement

cm3

19,144


l/h

71.2


l/h

51.7

Speed/gradeability Working gear (1 st gear) Travel gear (2nd gear)

m/min

0 – 36

km/h

0 – 20

Theor. gradeability (1st gear)

%

35

Theor. gradeability (2nd gear)

%

12

Ground clearance

%

8

Weights/loads* 2 Weights/loads* Front axle load

daN (kg)

15,000

Rear axle load

daN (kg)

13,000

Own weight

daN (kg)

28,000


daN (kg)

29,000

Tyre size, front

mm

Ø 1,200

Tyre size, rear

mm

Ø 1,200

Tyres


l

1,000


l

435

V

24

Elektrical system Shipping dimensions Machine (L x W x H)

mm

8,790 x 3,000 x 1,700

* 1 = The maximum milling depth may deviate from the value indicated, due to tolerances and wear. * 2 = All weights refer to b asic machine without any additional equipment.

44


Wirtgen Dinting Machine 2600 – Dimensions Dimensions in mm

8790 8550 120

120

0 0 7 1

750

3950

1850

2000

5800

0 0 7 2


0 0 0 3

45

9.

Production estimate

Production range (cutting performance) of the Wirtgen Surface Miner 2200 SM 700 Windrowing max. Conveyor loading max. Conveyor loading min.

600

500

) h / 3 m b ( e c n a m r o f r e p g n i t t u C

400

300

200

100

10

Note:

46

20

30

40

50

60

70

80

90 100 110 120

UCS (MPa)

Material with a hardness > 50 MPa can only be cut only under certain conditions. Production estimate

Production range (cutting performance) of the Wirtgen Surface Miner 2500 SM 1400 Conveyor loading max. Conveyor loading min.

1200

1000 ) h / 3 m b ( e c n a m r o f r e p g n i t t u C

800

600

400

200

10

Note:

20

30

40

50

60

70

80

90 100 110 120

UCS (MPa)

Material with a hardness > 80 MPa can only be cut under certain conditions.

Production estimate

47

Production range (cutting performance) of the Wirtgen Surface Miner 3700 SM 2000 Conveyor loading max.

1800

Conveyor loading min.

1600

1400 ) h / 3 m 1200 b ( e c n a m r 1000 o f r e p g n i t 800 t u C

600

400

200

10

Note:

48

20

30

40

50

60

70

80

90 100 110 120

UCS (MPa)

Material with a hardness >80 MPa can only be cut under certain conditions. Production estimate

Production range (cutting performance) of the Wirtgen Surface Miner 4200 SM 3000 Conveyor loading max. Conveyor loading min.

2500

2000 ) h / 3 m b ( e c n a m r 1500 o f r e p g n i t t u C

1000

500

10

Note:

20

30

40

50

60

70

80

90 100 110 120

UCS (MPa)

Material with a hardness > 60 MPa can only be cut under certain conditions.

Production estimate

49

Comments to the charts The figures in the production charts are based on cutting performance without downtimes for manoeuvering the machine etc. They are based on 100 % efficiency (e.g. sufficient number of trucks). Drums with a tool spacing of 35-50 mm are considered for materials with a compressive strength (UCS) of 25-80 MPa. Materials with UCS values > 80 MPa are only to be cut under certain circumstances (fractured material). For materials with a UCS < 25 MPa, cutting drums with 90 mm tool spacing are considered. The maximum curves represent operation under ideal conditions only. only. The assumptions are: weathered rock, horizontally laminated or heavily fractured rock (fractures in different directions with max. 5 cm distance). The minimum curve represents cutting performance in solid rock or benches with only little amount of fractures (distance of fractures 0.5-1 m). For the 2200 SM (front loading machine), the cutting performance depends on the loading method (conveyor or windrow method). Please see section “loading methods”. Because of the large variety of possible influences the charts can only be used for preliminary estimates and forecasts. More detailed estimates estimates have to be based based on specific information such such as rock properties, deposit and site information. Please consult Wirtgen’s Mining Division for further information. Wirtgen GmbH shall have no liability for damages, consequential or otherwise, arising from the use of the production analysis or any part of thereof.

50

Production estimate

y n a m r e G n i d e t n i r P 1 0 0 2 H b m G n e g t r i W y b © 1 0 / 9 0 N E 2 1 5 2 . o N

Wirtge Wirt gen n Gm GmbH bH · Ho Hohn hner er St Stra rass sse e2 53578 Windhagen · Germany Phone: Phon e: +49 (0 (0)) 26 26 45 45 /13 /131-0 1-0 Fax: + 49 49 (0) 26 45 / 13 131 -2 -242 Internet: www www.wirtgen .wirtgen.com .com

– . s n o i t i d n o c l a n o i t a r e p o n o d n e p e d a t a d e c n a m r o f r e P . s e g n a h c l a c i n h c e t o t t c e j b u S . n o i t a g i l b o t u o h t i w e r a s n o i t a r t s u l l I

Manual English

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