Cutting, crushing and loading rock in a single operation.
The World of
Wirtgen Surface Miners
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Breaking new ground in the
mining of primary resources.
THE ECONOMICAL EXPLOITATION OF PRIMARY RESOURCES IN OPENCAST MINING IS
BECOMING INCREASINGLY DIFFICULT AS THE MINERAL CONTENT OF MANY DEPOSITS IS
DWINDLING DUE TO DIFFICULT GEOLOGICAL CONDITIONS. IN ROCK CONSTRUCTION,
MACHINES ARE REQUIRED FOR PRECISE LEVELLING OPERATIONS UNDER RESTRICTED
SPACE CONDITIONS. OUR PATENT REMEDY IN BOTH CASES IS MECHANICAL EXPLOITATION
BY MEANS OF SURFACE MINING. BEING THE INNOVATIVE LEADER IN THIS TECHNOLOGY,
WIRTGEN IS PASSIONATELY DRIVING THE DEVELOPMENT OF THIS ECONOMICAL AND
ENVIRONMENTALLY GENTLE PROCESS, USING ITS EXPERTISE TO SUCCESSFULLY MASTER
THE EVEN MORE DEMANDING CHALLENGES LYING AHEAD.
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CONTENTS
EFFICIENT AND ENVIRONMENTALLY COMPATIBLE MINING OF ROCK
67
FROM FUTURE VISION TO RECOGNIZED TECHNOLOGY
89
SURFACE MINERS IN DETAIL
10 11
OPERATING PRINCIPLE AND COMPONENTS
12 13
UNRIVALLED CUTTING TECHNOLOGY
14 15
HIGH-PERFORMANCE LOADING
16 17
EFFECTIVE OPERATING AND SAFETY CONCEPT
18 19
THE WORLDS LARGEST AND MOST COMPREHENSIVE MODEL RANGE
20 21
HIGHEST QUALITY FOR CONTINUOUS OPERATION
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WE ENSURE 24 / 7 OPERATION
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SUCCESSFUL MINING OPERATIONS IN ALL PARTS OF THE WORLD
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RESOURCE-EFFICIENT SURFACE MINING
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Efficient and environmentally
compatible mining of rock
WIRTGEN is global market leader in the manufacture of machines for cutting rock in opencast mining operations. WIRTGEN surface
miners cut primary resources such as coal,
gypsum, iron ore, salt, phosphate, bauxite,
limestone or granite, achieving high degrees
of purity in the process. They are increasingly
used as primary extraction equipment also in
newly opened-up opencast mines or extensions of existing opencast mine operations.
Surface miners are just one step in a whole
process chain but have a vital influence on the
entire process and in particular on the final
result. The following features are the hallmarks
of this innovative method:
SELECTIVE MINING
Surface miners extract primary resources in a
selective operation, achieving high degrees of
purity and maximizing exploitation of the deposits. Selective mining considerably reduces
equipment, labour and time requirements as
well as overburden volumes.
CUTTING, CRUSHING AND LOADING
IN A SINGLE OPERATION
BLASTING IS AVOIDED,
STABLE SURFACES ARE CREATED
The mining material is cut, crushed and, if required, loaded straight into trucks or dumpers
in a single operation, thus dispensing with
conventional primary crushing in an additional
work step. The surface mining process is much
more economical than standard drilling and
blasting methods with subsequent material
loading.
Strict environmental standards in terms of
noise and dust emissions make the vibration-free surface mining process attractive
in comparison to drilling and blasting. The
stable, precise and level surfaces produced
in mining, earthworks and rock operations
are suitable for immediate use as pavements,
slopes or tunnel floors.
Drilling
Blasting
Loading
The process is eminently suitable for
the selective mining
of various types of
minerals, such as
thin coal seams of
high quality.
Crushing
WIRTGEN surface
mining a single
operation instead
of four.
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From future vision
to recognized technology
1980
1983
The 3000SM prototype is successfully
used in coal mining.
The 1900SM is
mining gypsum in
South Africa.
1989
1989
WIRTGEN presents
prototypes of the
2600SM for use in
coal and limestone
mining.
An optimized model
of the largest surface
miner built to date,
the 4200SM, is produced even today.
1999
2000
WIRTGEN sets up
production of the
2500SM for special
operations in hard
rock.
The 2500 SM is of
modular design and
suitable for versatile
use in soft to medium-hard rock.
2009
2012
The optimized
4200SM is launched
in two designs for soft
rock and hard rock
mining.
WIRTGEN Pick Inspection (WPI) allows
measuring of the
degree of tool wear
and scheduling of
maintenance intervals.
1985
The 3500SM is in
operation in the USA,
cutting foundations
in hard limestone
material.
WIRTGEN DRIVES THE DEVELOPMENT OF
SURFACE MINING
Why dont we apply our expertise gained in
asphalt milling to the mining of hard rock? In the
mid 70s, this idea triggered the development of
a new, economically efficient opencast mining
method known as surface mining.
Cutting trenches, the
3700SM simultaneously produces gravel
material intended for
further use.
What followed was an unparalleled success
story, and it was headed by WIRTGEN as the
driving force behind it right from the start.
1980 marked the birth of the state-of-the-art
surface mining process WIRTGEN developed
a prototype based on road milling machines,
the 3000SM surface miner. Market entry was
accomplished in 1983 when the first machine, a
1900SM surface miner, was sold.
2001
In keeping with market requirements, we then
continued to develop ever larger machines for
ever higher performance rates.
1996
A modified method of
depositing the mining
material makes the
2100SM extremely efficient in coal mining.
2013
For the mining of soft
rock, the 2200SM3.8
is equipped with a
3.8m wide cutting
drum unit.
Surface miners in detail
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COUNTERWEIGHT
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DISCHARGE CONVEYOR
Movable counterweight for high machine stability and undisturbed operation along the edge of embankments.
Discharge conveyor including raising
and slewing function for direct loading onto a transport vehicle.
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POWER UNIT
WITH DIESEL ENGINE
Fuel-efficient, powerful diesel engine
paired with a heavy-duty mechanical
belt drive for high cutting performance.
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DRUM TOOLING
Extra-robust mining tools arranged
in a helical pattern for high cutting
performance, minimized tool wear
and extended durability.
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CUTTING DRUM
Mechanically driven, wear-resistant
cutting drum working in up-cutting
mode for efficient operation.
MINING MINERALS IN A SINGLE OPERATION
As the surface miner moves forward, a special cutting drum rotates against the direction of travel, cutting
layers of material from the rock formations and crushing it in the process. The primary conveyor picks up
the material in the drum housing and transports it towards the rear of the machine, where it is then accepted by the slewable and height-adjustable discharge conveyor. The discharge conveyor loads the material
into trucks or dumpers or discharges it to the side of the miner. The discharge height can be adjusted to
the height of the transport vehicles. The surface miner is driven via four steerable and height-adjustable
track units. An automatic levelling system ensures precise adherence to the cutting depth, thus enabling
even thin seams or layers to be mined selectively and with maximum accuracy.
SAFETY EQUIPMENT
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CABIN
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Comprehensive safety package ensuring
compliance with international mining
regulations.
Fully glazed and sound-insulated
comfort cabin including swivelling
function for productive working.
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WIRTGEN PICK INSPECTION
Automatic monitoring of the degree of
tool wear allows the tools to be replaced
economically at precisely the right time.
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ACCESS
Wide, hydraulically adjustable
access ladder for easy access to the
machine.
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TRACK UNITS
Separately steerable and height-adjustable track units for full manoeuvrability and precise cutting depth
adjustment in off-road operation.
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Operating principle
and components
INTELLIGENT CENTRAL-DRUM DESIGN
The technical centrepiece of the central-drum
design implemented in our surface miners
is the cylindrical cutting drum. Fitted with
replaceable carbide tools and mounted close
to the machines centre of gravity, the drum
guarantees maximum cutting performance
and precise cutting depths in the mining of
hard rock.
A powerful diesel engine combined with a
heavy-duty belt drive contributes to the machines rapid progress in hard rock.
Optimum transmission of power is ensured by
the highly efficient mechanical cutting drum
drive. Our miners are capable of selective
mining, and this valuable feature also enables
them to mine even thin coal seams or interburden with precision and economic efficiency.
The continuous, highly effective cutting operation guarantees an uninterrupted flow of
material. The production of both small-sized
material and a level, stable surface permits the
use of lightweight trucks in the mine operation.
1| Continuous mining
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2| Crushed aggregate
3| Direct loading
4| Precise cutting depth
5| Clean, level and stable
surface after cutting
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1| Clutch
2| Power belts
3| Planetary transmission
4| Diesel engine
5| Cutting drum
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Working direction
Drum drive design
with centrally
arranged cutting
drum.
The cutting drum
rotates against the
direction of travel
to allow cutting
from the bottom
upwards no vibrations incurred.
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WIRTGEN cutting
tools guarantee
maximum cutting
performance while
minimizing the cost
of wear.
Unrivalled cutting
technology
OUR FIELD OF CORE EXPERTISE
WIRTGEN cutting drums, toolholders and
cutting tools are tried-and-tested, proprietary
high-tech elements subject to a continuous
improvement process. For each application,
we are making every effort to optimize the
cutting performance while at the same time
maximizing the service life and minimizing
operating costs.
To achieve this goal, the cutting drum and
toolholder system are given a heavy-duty design tailored to performance requirements in
accordance with the type of rock to be mined,
rock hardness and material gradation. The un-
rivalled HT15 quick-change toolholder system
is the decisive element here. If required, the
cutting drums are additionally provided with
special wear protection equipment.
Yet another highlight is our optional
WIRTGEN Pick Inspection (WPI) feature: this
system identifies worn tools automatically by
means of an optical measuring process.
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1|The cut material
can also be deposited in a windrow
behind the cutting
drum.
2|WPI uses camera
laser sensors to
measure the degree
of cutting tool wear,
displaying the results on a separate
screen.
3 |Hydraulically operated cutting tool
extractors improve
productivity.
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High-performance loading
FLEXIBILITY GUARANTEED
WHATEVER THE JOB
WIRTGEN surface miners master material
loading with superior ease. Huge amounts
of mining material are loaded into transport
vehicles via a conveyor system. Needless to
say, however, that windrowing or discharging
the material to the side for stockpiling are
also part of the machines loading repertoire.
This high degree of flexibility is owed to the
height-adjustable and slewing discharge conveyor which can be adjusted precisely to any
given mining parameters. Surface miners are
designed as front or rear loaders, depending
on the model, but powerful and steady loading is a common feature of all miner models.
The miners powerful conveyor drive, continuously adjustable conveyor belt speed and
wide, steep-incline belts with extra high ribs
make sure that even large dump trucks are
loaded to full capacity regardless of the job to
be completed and even when mining minerals of high density, such as iron ore.
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1| The 2200SM is
a front loader, its
discharge conveyor
being mounted
at the front of the
machine.
2|The counterweight of the
2500SM rear loader provides stability
when discharging
the material to the
side of the miner.
3|The discharge
conveyor has a
slewing range of
90 degrees to the
left and right, thus
enabling direct
loading into trucks
or dumpers.
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Effective operating
and safety concept
his position on the ergonomically designed
operators platform so as to always have a
good view of the front track units and of the
conveyors discharge zone.
The cabins offer
perfect visibility and
ergonomic design.
The operator is in
full control of the
mining operation.
FULL FOCUS
ON PRODUCTIVITY
WIRTGEN surface miners can be operated
efficiently by one machine operator only. The
cutting operation, cutting depth control and
loading process are all carried out in a mostly
automated process. The operator can fully
focus on steering the track units, regulating
the miners advance speed and discharging
the mining material. To do so, he can choose
Numerous safety features ensure the safety
of machine operators and maintenance staff,
as well as compliance with stringent mining
regulations: vital ingredients of this concept
include a comprehensive lighting package,
non-slip walkways and accesses, standardized railings, readily accessible emergency
stop switches, wide-range cameras, FOPS or
ROPS/FOPS equipment, emergency exits and
fireproof cladding.
Strict safety regulations and machine
standards can be
complied with by
making the relevant
machine modifications.
The operator always
keeps an eye on the
loading operation.
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2200 SM
2200 SM 3.8
4200 SM (hard rock)
4200 SM (soft rock)
2500 SM
The worlds largest and most
comprehensive model range.
CHOICE BETWEEN TWO MINING METHODS
The surface miners from WIRTGEN cover the full performance range in mining, earthworks and
rock construction to up to 15 million tonnes of mining material per machine per year this is truly
unique! Whether a small quarry mining project in restricted space conditions or continuous operation in large-scale opencast mining: our range of machinery is the largest worldwide, offering
the ideal miner for every type of resource and overburden in most diverse operating conditions. In
addition, our surface miners can be tailored to accurately comply with specific application requirements and, as a standard feature, unconfined compressive strengths of up to 80 MPa.
WIRTGEN is also the only manufacturer worldwide offering customers two different mining methods. In line with requirements or to ensure maximum efficiency, the mining material can be deposited in a windrow or loaded onto waiting transport vehicles via a loading conveyor system.
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Highest quality
for continuous operation
WE MANUFACTURE PRODUCTS OFFERING
GENUINE VALUE
The way a machine is manufactured is the
key to a long and successful service life. That
is why, in view of the tough operating conditions that surface miners generally face,
robustness and quality must take pride of
place. In our production plant at the company
headquarters in Windhagen, our machines are
designed to be extremely robust. Combined
with production facilities developed in-house
and state-of-the-art processing technologies,
machines are built here for uncompromising
use in mining operations.
Our highly qualified and highly motivated staff
is yet another e
ssential asset when it comes
to ensuring the top quality of our machines.
Computer-aided manufacturing control and
the high degree of vertical integration ensure
first-class, consistent quality.
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1| Each cutting
drum is designed
in line with the
specific operating
conditions it is
intended for, using
state-of-the-art 3D
CAD technology.
2|Expert staff only
performs welding
work, for example,
on the drum housing shown here.
3|The cutting drum
is produced with
the greatest care.
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We ensure
24/7 operation
CUSTOMIZED SERVICE CONCEPTS
Surface miners are used as primary extraction
equipment and are typically operated on a
24-hour basis. To ensure maximum machine
availability, WIRTGEN offers a unique customer-specific service for large-scale projects: in
close cooperation between the German main
plant and the WIRTGEN GROUPs local subsidiary, WIRTGEN sets up additional service facilities in the immediate vicinity of the customers
site. Service centres ensure the professional
repair or overhaul of surface miners while
enabling a comprehensive parts inventory to
be stocked at the same time. Needless to say
that, as part of the efficient service concept,
highly qualified WIRTGEN GROUP specialist
staff is present at the service centre and in the
mine all the time to ensure optimum machine
support.
To ensure maximum machine utilization,
WIRTGEN offers a broad, ongoing training
programme at the mine, the service centre or
the German main plant.
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1|Cutting drums
and conveyor
systems are overhauled in our own
workshop set up
in the customers
immediate vicinity.
2|In cooperation
with our customer,
we make sure that
all of the required
spare parts are in
stock at the service
centre.
3|Numerous
WIRTGEN GROUP
service experts
offer just-in-time
support on site.
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Successful mining operations
in all parts of the world
CANADA
> Limestone
> Kimberlite
> Oil sands
> Salt
1 SM
2 SM
1 SM
1 SF
EUROPE
> Limestone 31 SM
> Oil shale
3 SM
> Salt
19 SF
> Pegmatite
1 SM
> Gypsum
3 SM
> Coal
5 SM
> Tuff
1 SM
> Copper
1 SM
USA
> Limestone 16 SM
> Coal
4 SM
> Gypsum
30 SM
> Dolomite
1 SM
> Sandstone 1 SM
LIBY
> Lim
MEXICO
> Limestone
> Gypsum
> Salt
MOROCCO
> Phosphate
2 SM
1 SM
2 SM
ALGERIA
> Limestone
> Phosphate
DOM. REPUBLIC
> Limestone 3 SM
SENEGAL
> Limestone
COSTA RICA
> Limestone
GUINEA
> Bauxite
3 SM
FRENCH GUYANA
> Limestone
1 SM
129
Coal
488
51
Iron Ore
184
SURFACE MINER
44
PERU
> Phosphate
BOLIVIA
> Salt
1 SM
BRAZIL
> Limestone
> Bauxite
2 SM
3 SM
2 SM
Limestone
APPLICATION BY ROCK TYPE
Gypsum
32
Salt
16 8 5 4 15
Bauxite
Phosphate
Others
Kimberlite
Granite
> Caliche
> Salt
1 SM
CHILE
1 SM
2 SM
2 SM
13 SM
8 SM
1 SM
RUSSIA
> Limestone 19 SM
> Kimberlite 1 SM
> Coal
3 SM
> Salt
1 SM
> Coal
UKRAINE
> Limestone 4 SM
> Gypsum
1 SM
LEBANON
> Limestone
YA
mestone 11 SM
EGYPT
> Gypsum
ISRAEL
> Phosphate
1 SM
SAUDI ARABIA
> Limestone
2 SM
> Phosphate
1 SM
YEMEN
> Limestone
KAZAKHSTAN
> Limestone 2 SM
> Coal
2 SM
1 SM
1 SM
> Limestone
1 SM
NIGERIA
> Limestone 14 SM
> Coal
2 SM
MONGOLIA
1 SM
INDIA
> Limestone
> Coal
UZBEKISTAN
> Phosphate
3 SM
> Gypsum
2 SM
> Limestone
1 SM
IRAN
> Gypsum
QATAR
8 SM
CHINA
> Limestone
> Caliche
> Coal
1 SM
1 SM
6 SM
THAILAND
> Shale
2 SM
> Limestone
> Granite
3 SM
41 SM
92 SM
PHILIPPINES
> Limestone
1 SM
INDONESIA
> Limestone 4 SM
> Coal
6 SM
BOTSWANA
> Clay stone
1 SM
> Salt
1 SM
MOZAMBIQUE
> Coal
1 SM
SOUTH AFRICA
> Kimberlite
1 SM
> Limestone
1 SM
> Coal
1 SM
> Gypsum
3 SM
AUSTRALIA
> Limestone
> Tuff
> Salt
> Iron ore
> Coal
2 SM
1 SM
4 SM
51 SM
6 SM
JAPAN
2 SM
5 SM
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MINIMIZED ENVIRONMENTAL IMPACT
We not only develop innovative machines of the highest quality. With our machine technology, we also constantly endeavour to keep environmental pollution as low as possible. A WIRTGEN surface miner is a perfect example of this philosophy: it impresses with its environmentally friendly technology as it cuts, crushes
and loads rock in a single operation. A tremendous advantage of selective mining is that the vibrationless
mining operation without drilling and blasting is accompanied by low levels of dust and noise. The low
environmental impact also permits maximum exploitation of the deposit right up to the edge of residential
areas. The selective mining of high-quality materials requires considerably less space than conventional
mining methods. Our fuel-efficient, intelligently controlled engines comply with the strictest exhaust emission standards.
>
>
>
>
>
WIRTGEN SURFACE MINING reduces four operating steps to one.
STATE-OF-THE-ART ENGINE TECHNOLOGY reduces exhaust and noise emissions.
ANTI-VIBRATION ENGINE SUPPORT reduces vibration and noise emissions.
STATE-OF-THE-ART MACHINE CONTROL reduces exhaust and noise emissions.
SOUNDPROOFING reduces noise emissions.
Resource-efficient
surface mining.
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WIRTGEN GmbH
Reinhard-Wirtgen-Str. 2 53578 Windhagen Germany
Phone: +49 (0)2645/131-0 Fax: +49 (0)2645/131-392
Internet: www.wirtgen.com E-Mail: [email protected]
Illustrations and texts are non-binding and may include customized fittings. Subject to technical changes.
Performance data depend on operational conditions. Nr. 2492003 EN-01/16 by WIRTGEN GmbH 2016. Printed in Germany.
