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
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.
