QUARRY AND AGGREGATE

Transcription

1 QUARRY AND AGGREGATE

2 PROVEN MANUFACTURING FOR DECADES CONTENT Sandvik is a name that is familiar to quarry and extractive industry professionals across the world. And in Rammer, the company possesses a world leading and trusted brand that is reknowned for its ability to withstand harsh climates and hard rock applications. That reputation is based upon a proven manufacturing and quality control system and underlined by ISO certification and, where applicable, CE plates. When we talk about quarrying, the key issues are productivity, cost efficiency and end-product quality and to achieve those three targets by using safe, healthy and environmentally friendly methods. This guide is designed to provide general information about the use of Rammer products in quarry applications. We hope you find it useful. See you in the pit! Product Manager, Esa Sjönberg 2

3 SAFETY... 4 DEMANDING APPLICATION... 5 MAKING PROGRESS POSSIBLE... 6 WHY RAMMER?... 7 RAMMER QUARRY OFFERING... 8 RAMMER BOOMS OPTIMIZING THE INVESTMENT WIDE RANGE OF UNIQUE FEATURES SUMMARY CHART PRIMARY BREAKING SECONDARY BREAKING FIRST CLASS SERVICE AND SUPPORT RAMMER HAMMER SAFEGUARDS QUARRY PRODUCTION WHERE SECONDARY COMES FIRST RAMMER HAMMER BREACHES CASTLE

4 SAFETY IS A TOP PRIORITY IN EVERYTHING WE DO In the factory Safety is the primary consideration. Visitors are to consider and improve safety to help us achieve our aim of zero accidents. Products Safety is the driving force behind the development of all our new products. Our aim is to set the safety standard by making products that are safe to operate and maintain. Rammer operator and service training packages reinforce that message to ensure the safety of your entire workforce. Process Rammer products also improve the safety of the wider working site and its processes. For example, Rammer hammers can break oversize material, reducing loading and hauling and preventing blockages and bridging during the crushing process. Safety Your Advantage Injuries can impact upon an entire workforce and resulting in lost working days and a loss of production. A safe site is a productive site. Environment Rammer products are manufactured utilizing state-of-the-art, ISO standards technology that consumes the minimum electricity, and recycles cutting fluids and metal chips. Furthermore, when Rammer breakers reach the end of their useful working life, more than 90 percent of the metallic components can be recycled. 4

5 DEMANDING APPLICATION Having served quarry and aggregates industry customers for more than 30 years, we understand the specific challenges of this harsh and demanding application and have devised and developed products to meet those demands and make our customers more productive, more profitable and above all - safer. Rammer hammers have been developed in conjunction with quarry owners and operators across the world. As a result, they are tough, durable, reliable and offer the lowest possible owning and operating costs while delivering optimum production. And, if that s not enough, Rammer hammers are backed by a global Rammer dealer network that ensures optimum parts availability and profesional service with highly qualified personnel that are committed to minimize unplanned downtime and maximize production. 5

6 MAKING PROGRESS POSSIBLE High quality aggregates shape our future. They are a vital component in every new road, every new building, every new railway, bridge or man-made waterway. Quarry process Aggregate is normally produced by crushing the natural gravel or quarrying and crushing the solid rock. In these processes, hydraulic hammers play a pivotal role in primary and secondary breaking applications and in breaker boom installations. Constant material flow Extractive industries thrive on a constant material flow in which loading, hauling, crushing and breaking processes run continually at optimum levels. But that constant flow places specific demands upon the various elements of the quarry process and the equipment that facilitates those processes. Constant rock loading means no breaks in the material flow. Inconsistent loading causes slate shaped rocks (picture of process) that can break conveyor belts and causes blockages in the secondary crusher. Rammer breakers can: Prevent production blockages. Maintain a constant flow to the crushers Optimize the working process and minimize consumption of fuel and explosives. Inconsistent loading causes slate shaped rocks (picture of process) that can break conveyor belts and causes blockages in the secondary crusher. 6

7 WHY RAMMER? Since 1978 when the first hydraulic hammer was launched, quarry and hard rock applications have been a key focus area for Rammer and the brand is now recognized as the preferred choice among extractive industry professionals. And for good reason. They are compatible with a comprehensive range of carriers; are designed to withstand the rigors of primary and secondary breaking applications; and utilize Fixed Blow Energy (FBE) to maintain productivity whilst protecting the carrier. Rammer hammers are offered with durable Heavy Duty housings for maximum wear resistance; and wear parts are easy to replace. Other innovations include Ramlube, Ramona, Ramdata, VIDAT tie rods, Ramvalve and TS tool bushings. 7

8 RAMMER QUARRY OFFERING Rammer offering consist of comprehensive range of durable and highly productive large hammers for primary and secondary breaking applications. We also offers a wide range of breaker booms and a full line-up of smaller hammers that can be fitted to other boom installations. There are two key applications for a hammer in a quarry: 1. Primary breaking Hammer fitted to an excavator working directly in a bench. This is most commonly used where blasting is not allowed. 2. Secondary breaking, boulder breaking Three different ways of working can apply to secondary breaking in a Quarry 1) Hammer fitted to an excavator breaking boulders after blasting 2) Hammer fitted to an excavator reducing boulder size prior to crushing 3) Hammer fitted to a boom system to reduce boulder size prior to crushing 8

9 RAMMER HAMMERS READ MORE ABOUT RAMMER HAMMERS. Model Working weight, kg (lb) Impact rate, bpm, Long/Short stroke Operating pressure, bar (psi) Tool diameter, mm (in) Acceptable oil flow, l/min (gal/min) Carrier weight, allowed range, t (lb) (3880) ( ) 135 (5.31) ( ) ( ) ( ) / ( ) 142 (5.59) ( ) ( ) ( ) / ( ) 166 (6.54) ( ) ( ) (10470) ( ) 190 (7.48) ( ) ( ) (15432) ( ) 203 (7.99) ( ) ( ) 9

10 max. reach, m max. reach, m S G M XM L M L XL Z B 777 C D C D S MOBILE JAWS GRIZZLY GYRATORY RAMMER BOOMS MOBILE GYRATORY READ MORE ABOUT RAMMER BOOMS.

11 OPTIMIZING YOUR QUARRY INVESTMENT The two key factors concerning your quarry equipment investment: 1) Highest productivity 2) Minimizing owning and operating costs Soft Blow Sensor FBE (Fixed Blow Energy) Ramvalve (overflow protection) IBP (Idle Blow Protection) Upper buffer and side pads Heavy Duty housing PRODUCTIVITY RELIABILITY AND REDUCED O&O COSTS Wide range of tools availability Stroke Selector Ramdata II software VIDAT tie rods Stroke Selector Soft Blow Sensor Membrane type accumulator Ramlube I and Ramlube II (automatic greasing system) TS Bushing (Field replaceable insert bushing) With unrivaled power to weight ratio, Rammer hammers are designed to deliver the highest productivity levels in the industry while minimising owning and operating costs. This is achieved by using a wide range of unique Rammer features 11

12 WIDE RANGE OF UNIQUE FEATURES Ramlube (Different options) Rammer offers two types of automatic greasing systems for its Large Hammer Range: Ramlube I - Machine-mounted Ramlube II - Hammer-mounted to provide correct greasing levels, protect the tool and reduce owning and operating costs. VIDAT (Vibration Dampened Tie Rods) Vibration Dampened Tie Rods, spherical tie rod nuts and damper bushings ensures piston moves freely for longer, more productive working life. TS (Tool Saver) bushing Rammer Medium and Large hammers can be equipped with a field replaceable lower bushing insert that can be changed in less than 30 minutes. Wide tool selection See page 17. Heavy duty housing Fitted as standard, heavy duty housings feature a robust structure, minimum number of holes and plastic wear plates for optimum hammer protection. SBS (Soft Blow Sensor) Available on the Rammer 2577, Soft Blow Sensor (SBS) slows down the breaker and reduces power to minimise blank firing damage, making this model ideal for secondary breaking. Note: SBS, IBP or normal continuous working are options on the Rammer

13 IBP (Idle Blow Protection) Fitted as standard on all models from 2577 up (except 7013), Idle Blow Protection ensures the hammer cannot be operated until pressure is placed on tool. This eliminates tie rod stress, reduces oil overheating and protects against premature failures. Stroke selector Designed to protect the hammer and carrier, stroke selector allows operator to match hammer to material and application, delivering more frequent, softer blows in softer materials and fewer high impact blows in hard rock. Ramvalve More efficient than relief/check valves, Ramvalve detects overflow, prevents damage from system overload and protects against premature failure. Ramvalve is standard on models from 2577 up (except 7013). Membrane type accumulator Membrane-type accumulator eliminates nitrogen leakages, ensuring maximum piston acceleration and removing the need for time-consuming recharging. FBE (Fixed Blow Energy) A built-in pressure control valve maintains hydraulic pressure levels to ensure that every blow delivers the maximum power possible optimum productivity. Upper buffer and side pads The unique Rammer vibration absorption system consists of three buffers - one upper buffer and two side pads that prevent the transmission of vibration to protect both the breaker and the carrier s boom, stick and swing gears and to isolate the operator. Ramdata II The Ramdata II monitors vital functions including working hours, operating method and shift duration, using this information to help predict failures before they occur and schedule service and maintenance. 13

14 SUMMARY CHART S = Standard O = Optional N/A = Not Available Hammer model Fixed Blow Energy (FBE) S S S S S Better productivity Membrance Accumulator S S S S S Better productivity, hydraulics protection. Lower O&O costs Stroke Selector N/A S S S N/A Better productivity, less damages. Lower O&O costs Wide range of tools S S S S S Better productivity, less damages. Lower O&O costs Ramvalve (Overflow protection) S S S S N/A Hammer parts protection. Carrier protection. Lower O&O costs Idle Blow Protection (IBP) O S S S N/A Hammer parts protection. Carrier protection. Lower O&O costs Soft Blow Sensor (SBS) O N/A N/A N/A N/A Better productivity, less damages. Lower O&O costs TS Bushing O O O O O Hammer parts protection. Lower O&O costs Ramdata II S S S S S Possibility to increase productivity. Hammer protection. Lower O&O costs Ramlube I or II O O O O O Hammer parts protection. Lower O&O costs VIDAT Tie Rods S S S S S Hammer parts protection. Lower O&O costs Top buffer and Side pads S S S S S Hammer parts protection. Carrier protection. Lower O&O costs Heavy Duty Housing S S S S S Hammer parts protection. Lower O&O costs 14

15 PRIMARY BREAKING Productivity in primary breaking, maximum m³ per carrier hour, Rock formation: cracks <0,5 m and cracks <2,0 m m³ per carrier hour I II III IV V VI The figures are based on long term averages and are for comparison and evaluation purposes only. Productivity will vary depending on operator s skills, carrier and hammer setting and condition. Productivity can vary from one job to the next. Classification of Rock types are based mainly on material hardness and abrasiveness. Curves are showing maximum reachable productivities when rock discontinuity is less than 0,5 meter and less than 2,0 meter. With more homogeneous material productivity curves are lower level than these. If more consulting is needed please contact to your local Rammer representative. Rock type Mudstone (soft), Talc carbonate stone, Marl, Limestone Carbonate stone, Marble (tough), Dolomite, Shale (brittle) Black shale (alum), Phyllite, Schist, Blackschist (soft) Greywacke, Mudstone (hard), Gabbro, Basalt, Diabase, Diorite Gneiss, Biotite, Micaschist, Syenite, Andesite (hard), Granodiorite, Sandstone (soft), Gneiss, Pegmatite Conglomerate, Granite, Schist, Quartzite < 0,5 m < 2 m

16 SECONDARY BREAKING Productivity in Secondary breaking, Boulders per carrier hour, Rock types A and B Boulders per carrier hour The figures are based on long term averages and are for comparison and evaluation purposes only. Productivity will vary depending on operator s skills, carrier and hammer setting and condition. Productivity can vary from one job to the next. 0 0,5 1 1,5 2 2, Boulder size, m³ 0 ROCK A Limestone, Dolomite, Andesite, Slate ROCK B Granite, Gabbro, Diabase, Hard ores

17 FIRST CLASS SERVICE AND SUPPORT Hammer installation Installation inspection is an essential part of commissioning a new hammer, checking the compatibility of the hammer and carrier and ensuring that flows and pressures are adjusted correctly. Installation inspection together with correct operating methods guarantees reliable hammer operation. Trained service personnel Rammer products are renowned for quality, performance and reliability but when your hammer shows signs of natural wear, or the unexpected happens, our professional dealer service personnel are highly-trained, qualified and experienced which ensures that customers are never more than a phone call away from a Rammer hammer expert. Primary breaking Rammer standard chisel tool - For nonabrasive but tough rock or concrete - For material which has low or medium penetration rate Rammer limestone and concrete chisel - Very soft and easily breaking, nonabrasive rock or concrete - For rock which has high penetration rate Rammer moil point tool - Where chisels have excessive retaining pin groove wear - Soft and nonabrasive rock - General demolition of concrete Rammer hard rock chisel - Hard and abrasive rock with fractures - For application where drilling and blasting cannot be used - Materials with low penetration rate Rammer pyramid point tool - Soft, nonabrasive and tough rock and especially concrete - Materials requiring high penetration rate - Where chisels have excessive retaining pin groove wear Genuine parts and tools The Rammer global dealer network is the only place to access dedicated and experienced aftersales support. Genuine Rammer parts and tools availability is the best in class which keeps your hammer running at peak performance, ensuring downtime is reduced and enabling you to lower your operating and running costs. We offer a wide range of tools designed for various applications and materials. CHECKOUT MORE FROM OUR PARTS AND TOOLS BROCHURE. Secondary breaking and boom application Rammer blunt tool - Hard rock with low or medium abrasive ontent - Boulder breaking or concrete demolition - Application where tool wear rate is low Rammer super blunt tool - Hard and abrasive rock - Only for boulder breaking - Has Times more wear life than standard blunt in very abrasive applications - In non-abrasive applications life maybe shorter than standard blunt 17

18 RAMMER HAMMER SAFEGUARDS QUARRY PRODUCTION Quarrying giant Aggregate Industries is using a new Rammer 3288 hydraulic hammer supplied by local dealer Trojan Plant Equipment to maintain production levels and protect the primary crusher at its Back Lane Quarry in Lancashire. 18

19 Covering an area of 36 hectares and 80 metres deep at its lowest point, Aggregate Industries s Back Lane Quarry near Carnforth, Lancashire in the North West of England produces between 800,000 and one million tonnes of high grade limestone each year. Ranging in size from 225 mm to dust grades, the majority of that production is destined for the quarry s own asphalt plant where it is used to produce base and surface course materials. The quarry also supplies external customers across the north west and is a key source of road building materials in the region. Oversized Material On average, the company carries out one production blast per week, although this is sometimes supplemented by a second development blast designed to reveal more of the site s 40 million tonnes of reserves. Each production blast frees upwards of 30,000 tonnes of material from the 15 metre high quarry face that is loaded into three 60 tonne payload rigid dumptrucks for the 1,500 metre haul to the company s primary crusher. Through a combination of geology and the blasting techniques used, these blasts often produce a degree of oversized material that could cause damage to our primary crusher. These are cast to one side for further processing, explains assistant quarry manager Matthew Turner. But it is important that this additional breaking is done quickly and efficiently. While it s important to protect the primary crusher from oversized materials, it is equally important to keep the face clean and clear to safeguard production. According to Turner, that is why the secondary breaking task has been charged to a 2,350 kg Rammer 3288 hydraulic breaker supplied recently by local dealer Trojan Plant Equipment. We ve had Rammer hammers here on hire before and always found them to be highly productive and reliable, explains Turner. So when the time came to buy our own breaker, Rammer seemed like the obvious choice. Best Ever The Rammer 3288 benefits from a new operating principle that combines stroke length, blow energy and Rammer s proven idle blow protector. It is easily modified to allow breakers to be matched to individual carriers and applications, improving hydraulic efficiency and productivity and delivering massive impact energy and a high blow frequency for exceptional power-to-weight ratio. As with all new Rammer Large Range hammers, the 3288 features the VIDAT system, which provides improved reliability and lower operating costs. Mounted on a Komatsu PC340LC hydraulic excavator, the 2,350 kg is armed with a blunt tool that achieves excellent penetration and fracturing of the Back Lane Quarry s limestone, quickly reducing the product to a more manageable size and keeping the working face clear of debris. The Rammer hammer is a vital link in our production process. If it stops, production slows or stops altogether as we can t risk damaging the primary crusher or the tyres of the trucks, Turner asserts. Thankfully, the Rammer 3288 has proved to be every bit as reliable as we had hoped. And when we have encountered problems, the team at Trojan Plant Equipment have been responsive and knowledgeable and have got us back in action quickly. Turner s enthusiasm is echoed by veteran operator William Dennison. I have worked in the quarrying business for more than 40 years and, as far as I am concerned, Rammer means hammer. There is nothing else that even comes close, he concludes. I have used a lot of hydraulic breakers over the years, but the Rammer 3288 is simply the best I have ever seen. Rammer means hammer, thinks veteran operator William Dennison who has worked in the quarrying business for more than 40 years. 19

20 WHERE SECONDARY COMES FIRST A Rammer breaker has helped a New Zealand aggregates producer double its production in just four months. Dean 20 Hewlett from Digga NZ; Allan Parnwell, mechanic at Baldwin s; and Zak Reilly, the Rammer 2577 operator, soon to give the breaker its first run.

21 According to the Aggregate and Quarry Association, New Zealand uses 11 tonnes of aggregate per person per year in construction. Higgins Group-owned Baldwin s Aggregates Limited provides 160,000 tonnes of the sedimentary rock into the country s construction industry every year. Having recently procured another 80 hectares, Pokeno-based Baldwin s Aggregates has ensured it has the capacity to continue providing vast quantities of aggregate to the New Zealand market. Sheep to Stone Rewind 15 years and Baldwins Aggregate was just another sheep farm. Kerry Reilly, operations manager, stumbled upon it and started its transition from a greenfield site to the quarry that sits there today. From the beginning, Baldwin s Aggregates focused on producing a high quality product in an efficient manner, while respecting the environment and safety of the staff. Since 2002, Baldwins Aggregates has been working hard to ensure environmental sustainability. The company started a voluntary initiative to improve the quality of water that was discharged from the quarry, creating a wetlands to naturally filter the water. Reilly conceived the idea, however, he also praises the input of neighbouring dairy farmer, Peter Buckley. Buckley donated several hectares and put a lot of trust in what seemed like a wild idea at the time, Reilly says. Over the last 12 years Baldwin s has planted 15,000 indigenous trees and shrubs, with assistance from the Waikato Ecological Enhancement Trust. Those efforts were rewarded recently with Baldwins Aggregates taking home the Gold Mimico Environmental Excellence Award at the Quarry NZ Conference. The removal and relocation of overburden is another issue for all sedimentary quarries. Baldwin s found an innovative solution that would solve the problem from both an environmental and economic perspective. Incorporating the overburden into the wetlands was the logical solution with any excess placed into Baldwin s consented landfill site. This means no transportation on public roads and the landfill will provide good conditions for future forestry development. Hard Rock Baldwins Aggregates produces a very hard rock. After the initial explosion, the company is often left with large boulders that require secondary breaking before crushing. While most aspects of the quarry were running very smoothly, the company was struggling with its secondary breaking. Baldwin s trialled many different breakers, with little satisfaction. But the Rammer 2577 truly hit the bull seye. Four months since purchasing the Rammer 2577, Baldwin s could not be more pleased with how positively it is impacting production. Since getting the Rammer, rock breaking has doubled, says Reilly. The Rammer 2577 is also impressing with its auto selfgreasing to conquer the rock crazy operators. Reilly asserts that operators can often go numb and only focus on continually breaking boulders, causing premature wear on the breaker. Thankfully the Rammer breakers were made with this in mind. Baldwin s purchased the Breaker from Digga New Zealand which has just celebrated 10 years of continuous service as an authorised Rammer dealer. Kerry Reilly, operations manager of Higgin sowned Baldwin s and Cobus van Vuuren, Higgins Aggregates manager, celebrate their award success. 21

22 RAMMER HAMMER BREACHES CASTLE A new Rammer 3288 Hard Rock hammer is playing a pivotal role in the expansion and increased production of a unique UK granite quarry that is owned by Cornwall Council and operated by CORMAC Solutions Limited. Andy 22 Bartle - Quarry & Recycling Manager, Castle-an-Dinas Quarry Luke Harris - Sales Manager M & M Plant Ltd

23 Castle-an-Dinas Quarry in Penzance, Cornwall has taken delivery of a new Rammer 3288 Hard Rock hammer from local dealer M&M Plant Ltd. The new hammer modified to match the harsh and abrasive granite application replaces an existing Rammer G80 unit that will be refurbished before being pressed back into action. Driven by Demand Covering an area of almost 90 hectares, operating at a depth of 60 metres and producing over 100,000 tonnes per year, the Castle-an-Dinas Quarry is unusually owned by the local authority Cornwall Council and operated by their arms length company CORMAC Solutions Limited. Originally purchased to ensure that the council had a constant and reliable supply of fine grain granite for a variety of roadstone and concrete aggregate applications, the quarry has evolved to become a profit centre in its own right. As the biggest user of roadstone in the region, Cornwall Council was keen to safeguard its supply chain, says quarry and recycling manager Andy Bartle. But the operation has expanded to include increasing sales to third-party companies. In 2012, sales were split roughly 60:40 between the Council and external companies. Bartle says that the desire for sales production coupled with the need for a high-grade product drives every facet of the Castle-an-Dinas operation, from its strict environmental policies to the products and processes used to win the hard rock from the quarry face. We use drill and blast methods to extract the rock from the face with each blast dropping around 7,500 tonnes of material to the quarry floor. We blast as infrequently as possible to ensure that our neighbours aren t disturbed by noise and dust, Bartle explains. Oversized material is broken up by an excavator equipped with a hydraulic hammer and the material is then fed into a track-mounted mobile jaw crusher stationed at the face. After this initial processing, the material is hauled to the top of the quarry for further crushing and screening to produce the products that we and our external customers need. Great Partnership Bartle reports that the excavator and hydraulic hammer working at the face play a vital and pivotal role in the day-to-day running of the quarry. Our mobile jaw crusher obviously can t process oversized rock so the excavator and hammer are key to the smooth running of our operation, he explains. Until recently, this job was undertaken by our Caterpillar 336E excavator and a Rammer G80 hammer supplied by local dealer M&M Plant Ltd. But we have just upgraded the hammer to a new Rammer 3288 Hard Rock specifically modified for this application. That modification involved the addition of a heavy duty, hard rock body casing to help the 2,350 kg hammer withstand the rigours of a granite quarry. But, as Bartle reports, the Rammer hammer itself can also be adapted to the specific application. The Rammer 3288 uses a new operating principle that allows us to match the hammer to individual carriers and applications for improved efficiency and productivity, he adds. We have used this capability to full effect here at the Castle-an-Dinas Quarry and the Rammer 3288 is perfectly matched to our Caterpillar excavator. They are a great partnership and we are already seeing a marked increase in production levels. Long Term Reliability In addition to the productivity of the new Rammer 3288, Bartle says that the reliability and durability associated with the Rammer brand was a key consideration in his purchasing decision. We operated the Rammer G80 for 10 years and it rarely missed a beat. Even though it has been replaced, we are having it refurbished so it can act as a spare for when the new 3288 is out of action for scheduled maintenance, he says. The new hammer has a new sealing system and improved lubrication which will reduce our owning and operating costs. But the greatest benefit of the new hammer is that it is covered by Rammer s Lifetime Warranty. Rammer clearly has faith in the long term reliability of the hammer if they re willing to offer that. Rounding off what Bartle describes as a perfect partnership, the arrival of the new hammer means that Castle-an-Dinas Quarry will extend its working relationship with long-term supplier M&M Plant Ltd. Throughout the time we were running the Rammer G80, M&M Plant proved to be helpful and responsive. They are right on hand to provide the levels of service we expect, Andy Bartle concludes. As a local council contractor, we aim to support local businesses whenever it is practicable. The good news for CORMAC Solutions Limited is that our local dealer is excellent and the product they offer is the best in the business, so this was an easy decision to make. Mark Elliott - Excavator & Rammer 3288 Operator 23

24 Sandvik Mining and Construction Oy Taivalkatu 8, P.O.Box 165 FI Lahti, Finland Phone Int EN/11/2014/Ilme Printed in Markprint, Finland. Subject to change without notice. The Rammer name and logo are registered trademarks of Sandvik Mining and Construction Oy. 24