1

TECHNICAL-ECONOMIC CONSIDERATIONS ON THE FEASIBILITY OF DEVELOPING bezvzryvnogo thin layer

SHAVAZSAYSKOGO CEMENT LIMESTONE DEPOSIT About JSC "Akhangarancement" WITH FIRM mining
machine WIRTGEN GmbH
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
TECHNICAL AND ECONOMIC WITH REVIEW 
 
 
" It is expedient to b APPLICATION DEVELOPMENT
bezvzryvnogo thin layer SHAVAZSAYSKOGO CEMENT
LIMESTONE DEPOSIT About JSC" Akhangarancement
"using a mining machine COMPANY GmbH WIRTGEN »
 
 
 
 
 
 
 
 
 
 
 
 
Head of Sales
Combine the Surface Miner ,
mining engineer,
Candidate of Technical Sciences,
Yu.B. Pankevich
 
Moscow, 20 11
 Content
 

INTRODUCTION ………………………………………………………………………….

I. BRIEF GEOLOGICAL CHARACTERISTICS OF THE SHAVAZSAY CEMENT

LIMESTONE DEPOSIT. THE CURRENT SITUATION OF MINING IN THE
QUARRY ...................................................

1.1. Brief geological characteristics of the Shavazsay cement limestone deposit ...             

1.2. The current situation of mining in the quarry ...................................................

3. GENERALIZATION OF THE WORLD EXPERIENCE IN OPERATING QUARRY

COMBINES OF THE COMPANY WIRTGEN GMBH IN CARBONATE
DEPOSITS. EVALUATION OF THE SCOPE OF THE NEW NON-EXPLOSIVE
THIN-LAYER MINING TECHNOLOGY .......................................................
3.1. General provisions …………………………………………………………………………

3.2. Experience in the application of thin-layer explosive-free mining technology

using Wirtgen Surface Miner combines ..........................................

3.3. Directions for the improvement of Wirtgen Surface Miner combines ……………………………………….

4. DETERMINATION OF PRODUCTIVITY AND QUANTITY OF EQUIPMENT WITH

THE NEW TECHNOLOGY ...................................................
 

5. CALCULATION OF ECONOMIC INDICATORS OF THE NEW

TECHNOLOGY ……………

IN S W O D
S ………………………………………………………………………………………………
….

                           
Introduction
 
This paper is a technical and economic considerations on the appropriateness of that
Wirtgen GmbH combines with mining of limestone cement Shavazsayskogo fields are
reserved raw materials About JSC "Akhangarancement".
              Open Joint Stock Company “Akhangarancement” is located in the Akhangaran
district of the Tashkent region in the Republic of Uzbekistan, 50 km southeast of the city of
Tashkent . Akhangarantsement OJSC is the second largest cement producer in the Republic
of Uzbekistan. The share of the domestic market is 27.9%. The company's products are
exported to neighboring countries of the Central Asian region to countries such as
Kazakhstan, Kyrgyzstan and Turkmenistan, Afghanistan.
Since 2006, from the moment the plant entered the EUROCEMENT group holding (the
Russian company owns 76% of the shares in Akhangarantsement OJSC), a new stage in the
revival of Akhangarantsement OJSC began. The company has developed a program for the
technical re-equipment of the enterprise in the period 2005-2009. The implementation of this
program will equip the enterprise with modern technological equipment, ensure the
production of high-quality products in a wide range and increase its exports. Currently, the
company produces an average of 1.74 million tons of cement per year.
 
The plant’s raw material base is the Karakhta limestone deposit, the active reserves of
which are being developed, and therefore, the decision of the Cabinet of Ministers of the
Republic provides for the reconstruction of the plant with the development of new sites,
including the Left-Bank section of the Shavazsaysky deposit, located 3-4 km from the
existing quarry.
However, working out of the plots and by traditional mining operations technology using
drilling and blasting loosening complicated by the presence along the western border of
residential buildings large settlement, resulting in a significant portion of proved reserves can
not be worked out. 
At the same time, due to rising prices for equipment, materials and services, production
costs rose sharply, and therefore the issues of reducing production costs are very relevant.
A significant proportion of the costs in the cost of limestone production are the costs of
drilling and blasting. The costs of primary and secondary crushing are quite high.
              All this predetermines the search for new non-traditional technologies.
Since the beginning of the 90s, when developing deposits of carbonate raw materials at
enterprises in Serbia, the USA, India and a number of other countries, there has been a
transition to a new mining technology using Wirtgen GmbH surface miner mining
combines. Combine harvesters are capable of conducting non-explosive thin-layer mining of
rock massifs and ensure high mining efficiency by combining the basic processes of mining.
The analysis of the results of operation and pilot works showed the following:
1. In conditions of carbonate deposits, it is possible, and in most cases, expedient, to
switch to blast-free rock development using Wirtgen Surface Miner combines .
2. By providing combines with thin-layer technology, the quality of raw materials is
improved, and the completeness of the extraction of minerals from the bowels is also
increased.
3. During development, the fractional composition of raw materials is ensured in the
faces, which does not require subsequent large and to a large extent average crushing.
4. Due to the abandonment of a number of processes traditional for mining (drilling,
well charging, blasting and crushing in the traditional form ):
 capital investments and operating costs are reduced,
 increased efficiency and reliability by reducing the number of operations and
the number of mechanisms,
 reduced need for production and maintenance personnel.
5. Safety is enhanced and the environmental impact of mining is reduced.
6. Due to the involvement of previously conserved reserves in the development, in some
cases, the completeness of exploration of proven reserves of the field increases .
 
In the preparation of this work, the following materials were used:
 1. Information from the mining development plan for limestone mining at
Akhangarancement JSC for 20 1 0 year. 
2. Generalization of operating experience of  Wirtgen G mbH Surface Miner mining
combines   in quarries for the extraction of cement raw materials. 
3. The results of pilot works on the introduction of Wirtgen Surface Miner combines in
Serbia, Russia, India and the USA.
4. Materials of Wirtgen GmbH regarding the application and cost parameters of Surface
Miner combines.
 
I. Brief geological characteristics of the Shavaz-Say cement
limestone deposit . The current mining situation in
the quarry.

1.1.           Brief geological characteristics of the Shavazsay cement limestone

deposit.
 
The Shavazsai limestone deposit is located in the Akhangaran district of the Tashkent
region of the Republic of Uzbekistan, 75 km southeast of the city of Tashkent and 10
km northeast of the city of Akhangaran.
The field is confined to the middle part of the Akhangaran valley and is located in the
right-bank part of the valley on the southern slope of the Chatkal ridge spurs. The relief of the
field has the character of an elevated ridge with asymmetric slopes - western , gentle,
coinciding with the angle of incidence of the useful stratum, and eastern steep. The absolute
elevation marks range from 720-860 m , and the relative elevations above the valley
reach 140 meters .
In the geological structure of the field, sedimentary rocks of the Paleogene, Neogene and
Quaternary ages take part.
The fall of the rocks is southwest. Angles of incidence vary between 5-16 .
In the composition of the limestone pack, four varieties are distinguished (bottom-up):
          Dolomitic sandy limestones of a grayish-white color, with a thickness from 0.4
to 7.4 m , averaging 3.0 meters ;
          Fine-crystalline marble-like limestones of light gray color, with a thickness of 1
to 10.5 meters , averaging  5.14 m ;
          Limestone, shell limestone, which is characterized by the presence of leaching
voids, the walls of which are made of sintered calcite. The thickness of the reservoir
varies from 1.2 to 8 m , averaging 3.74 m ;
          Detritus limestones are light gray to almost white. The limestone is dense, it easily
erodes during drilling, forming a slurry consisting of very small fragments of shells
and calcite. It should be noted that the contact between the last two differences of
limestone is fuzzy and is accompanied by a gradual transition from one variety to
another. The thickness of the detritus limestone formation varies from 1 to 9.3 m ,
averaging 4.07 meters .
The total thickness of a pack of limestone is on average about 16 meters , varying from
8.96 to 23 meters .
 
In terms of chemical composition, two varieties can be distinguished from a general pack
of limestone:
 The lower layer underlying the useful stratum is dolomitic limestones, which are
characterized by a low content of calcium oxide and an increased content of
magnesium oxide and silicon. For most samples, the content of calcium oxide ranges
from 23.7 to 40.1%, magnesium oxide from 0.8 to 16.4% and silica from 6.3 to 40.1%.
The second variety includes the upper three layers of limestone, which are
characterized by a uniform distribution of useful and harmful components in their
thickness. Thus, the content of calcium oxide ranges from 37.6 to 54.9%, magnesium
oxide from 0.1 to 6.2% and silica from 0.5 to 20.2%.
Marl and oyster clays, which are mainly distributed in the northwestern and central parts
of the deposit, lie over a pack of limestones. The thickness of the marl layer varies from 0.4
to 6.8 meters , averaging 3.03 m . Macroscopically, marl is difficult to distinguish from
detritus limestone. On marl clay layer occurs, an overflow of the first shells of oysters. The
thickness of the clay layer varies from 0.8 to 5.3 m .
Thus, the mineral resources at the Shavazsay deposit are represented by limestones, marl
and oyster clays and in terms of quality meet the requirements for raw materials for the
production of Portland cement.
There is no internal overburden in the productive mass. External overburden includes
sediments consisting of loess-like loams with fragments of limestone and pebble, as well as
partially marl rocks that were not included in the calculation of reserves due to substandard
thickness (less than 2 meters ) or increased (more than 1%) SO  content .
3 

The reserves of limestone and marl rocks approved by the State Reserves Committee of
the USSR in July 1974 in categories A + B + C  are: limestones - 36.47 million tons and,
1 

accordingly, marl rocks - 4.05 million tons.

 

1.2. The current mining situation in the quarry .

As mentioned above, the existing raw material base, the Karakhta deposit, is being
finalized, and therefore, the decision of the Cabinet of Ministers of the Republic of
Uzbekistan provides for the reconstruction of the Akhangaran plant with the development of
a new Shavazsai deposit of carbonate rocks, located 3-4 km from the quarry in operation.
In addition to increasing the range of transportation of raw materials, the difficulty of
developing a deposit lies in its proximity to the housing estate (Tut village). All this requires
the search for new non-traditional methods of open development.
The traditional mining technology mastered at the enterprise involves drilling and
blasting limestone, loading broken rock with EKG-5 excavators into dump trucks with a
lifting capacity of 40 tons and transporting raw materials to a crushing unit with an average
distance of about 2.2 km .
Further, after crushing limestone to a particle size of 25 mm , it is transported to a
distance of over 6 km by conveyor transport to a cement plant.
The conveyor line for the transportation of crushed limestone, connecting the Karakhta
quarry with a cement plant, began to operate in 1961. Its length is 6.3 km . Five KRU-350
conveyors with a rubber-cord tape were mounted along the highway, with lengths: two units
of 1000 m , two of 1250 m and one of 1850 m . A large crusher and two medium crushers
were installed near the quarry. The conveyor line is covered with a canopy of asbestos
cement slabs laid on a metal frame.
The KRU-350 conveyor belt with a productivity of 350 m  / h at a belt speed of 1.5 m / s
3 

has two drum drives with three squirrel-cage motors with a power of 85 kW
 each. Structurally, the conveyor link consists of an overpass, with a height from tape to the
base of 880 mm , which is laid on the planned surface of the subgrade.
The conveyor belt has a width of 1200 mm , reinforced with 120 steel cables with a
diameter of 4.2 mm . The total tensile strength of the tape 140 T.
Work schedule on a year-round career, 3 shifts of 8 hours. The annual production
capacity of the quarry is 2280 thousand tons, daily 6.300 tons.
 
 
Thus, the following features of mining conditions are characteristic of the field
under consideration, which determine the approach to justifying the most rational
mining equipment and technology:
- The upland character of the field, significant thickness and length of the useful
stratum;     
- drop in useful thickness at angles (5–16 );     
- when calculating reserves, off-balance reserves of marl are assigned with a mining
capacity of less than 2 m . The latter is predetermined by the parameters of the
applied mining technology,   and when applying the new technology of thin-
layer mining, they can be involved in mining, due to which the raw material
base can be expanded .     
 
 
 
 
3 . Generalization of the world experience in the operation
of Wirtgen GmbH open pit mining combines in carbonate
deposits. Evaluation of the scope of the new non-explosive
thin-layer mining technology

3.1. General Provisions
In the development of carbonate deposits, represented by rock and semi-rock, the
traditional is the drilling and blasting method of preparing rocks for excavation and loading
operations. Along with the primarily defined e stvami, blasting have several drawbacks, most
important of which yavl I by a significant danger of mining, both in seismicity, increased dust
- and gas evolution, and on the flight of the fragments. Simultaneously, the development
raznoprochnostnyh arrays, however are mostly represented deposits carb about adjusted to
room rock blasting low quality and high yield oversized, which leads to high of a spent
preparing the rock for excavation and loading work.
              The issues of purity and completeness of the extraction of minerals from the
bowels are also very important.
              The inability to provide conventional mining equipment recess thin layer leads to
what is currently considerable power (0.5- 3.0 m - s in and depending on the geological
conditions) interlayers with sharply lower quality or even waste rock included in useful
thickness.
At the same time, when mining a mineral, extraction without quality loss is impossible, as
a result of which, when using traditional technology, when calculating reserves, the potential
mineral is of the lowest grade or is generally considered substandard.
 An analysis of the latest achievements in the field of technology of explosive -
free and cross - bed mining of rock masses has allowed us to highlight new trends in the
development of mining technology.
Prospective generation technology began to be implemented in the mid 80s, when the
world came to the pits of the mining machine Surface Miner company the Wirtgen
GmbH ( Germany ), performing in-line design arrays rocks s GOVERNMENTAL rocks,
hara to ized by a compressive strength of 100-120 MPa (at the same time, there is
information on the mining of individual rock layers with a strength of up to 200 MPa).
The ability to develop an array of thin fibers (5-10 to 80 cm depending on the size
Harvester) up to 1 cm , with simultaneous loading of the rock mass particle size by 85-
95% and 50- 60 mm through the console discharge conveyor n about allows one not
only provide streaming of development, but also improve the quality etc. of happens
minerals by reducing clogging pores stripping of rows, to reduce losses to a minimum , as
well as reduce of and spending on crushing.
Unlike traditional slaughter where slope is the step at the new primary process of ology
using harvesting Surface Miner slaughter surface is horiz n tal or inclined area.
After the combine passes the working passage, a flat surface remains, ready for the
movement of vehicles, which dramatically reduces the need for additional funds for the
construction and maintenance of roads. Additionally, when loading a combine (compared to
the loading of the excavator) reduced impact loads against falling rock mass pieces to rolling
structure avtotranspo p ta.
              Analysis of the results of the first years of operation of enterprises, to
develop deposits of carbonate rocks on the technology of thin layers of blast-free recess
with that Wirtgen GmbH mining machines demonstrates the effectiveness of the new
primary process of ology.
              In quarries mining of limestone, dolomite, marl, and gypsum in Yugoslavia,
South Africa, Italy, Austria, India and the CIS along with the solution of environmental
problems (refusal of BSB allowed to master the areas of the field, located near the residential
etc. on the thinking of buildings and structures) reduced costs for mining and transport
operations, as well as crushing . At the same time, productivity and labor productivity were
increased 2–2.5 times .

3.2. Experience in applying thin-layer explosive-free mining technology

using Wirtgen Surface Miner combines
The traditional mining technology, which provides for the drilling and blasting preparation
of the rock mass for excavation and loading operations, is characterized by an increase in the
cost of mining operations, which is due to the constant increase in prices for fuel, materials
and services, as well as the deterioration of mining conditions.
One of the ways to reduce the costs of mining and transport is to switch to highly
profitable technologies using fundamentally new open-cast mining equipment that can
combine the basic processes of mining, such as drilling, blasting, loading, and a significant
part of the crushing process during operation.
One of these types of equipment is Wirtgen Surface Miner mining combines , which
perform milling of the array while loading and producing in the bottom face a piece of less
than 50 mm (about 80-90% of the total), which reduces the cost of mining and crushing.
The experience in the creation and practical work of open pit mines , which so far in the
amount of  340 units (of which 43 in 20 10 10 were transferred to consumers for
implementation at quarries and opencast mines, has now made it possible to implement the
concept of a new UNEXPLOSIVE mining of rock mass mining and civil engineering.
Wirtgen Surface Miner combines are designed to develop a wide range of rocks. The
considerable technical experience of using these combines in Japan (granites with strength
characteristics of 120-250 MPa), in the USA (up to 120 MPa), in Libya (80-140 MPa) and in
India testifies to the technical possibilities of working in rock massifs. Moreover, each time
the combine is created for specific mining and geological conditions.
Currently, about 80 units of mountain combines are used in quarries for the extraction of
cement raw materials and gypsum in 26 countries of the world. The greatest number -
3 5 harvester s different models used in India, where the three leading cement producing
companies: Ambu Cement, Madras Cement and India Cement in their enterprises using the
new blast-free technology of mining. Combines have been used since 1994 and to date, most
of them have worked from 8 to 12 years, after which new machines were purchased.
A number of cement plants and limestone, marl and gypsum mining plants in the USA use
26 Wirtgen combines . In the cement industry of Algeria and Nigeria, 10 combines of the
2500 SM model are used . In Russia, currently, 7 combines of the 2500 SM and 3-
2200 SM models are used in the extraction of raw materials for cement .
It should be noted that in Australia the development of the largest iron ore deposits are 20
miners 2500 SM , based on the results of the work, which
bought about 5 new x harvester s 4200 SM .
For the first time in the cement industry, a new mining technology  in Europe was
implemented at the limestone quarry of the Beochin cement plant (Yugoslavia)
The raw material base of the plant with a capacity of 1.6 million tons of cement per year
are limestone and marl deposits, which are operated by two quarries with a production
capacity of 0.9 and 1.4 million tons per year, respectively.
Limestone is represented by the horizontal fallow capacity of about 45 m and hara to ized
by the following strength properties: compressive strength of 23 to 74 MPa, a bulk density of
from 2.1 to 2.6 t / m  , 6-13% humidity. 
3 

The daily productivity of the quarry is 4300 tons with a two-shift operation mode. Before
moving to the new technology of preparing the rock for excavation osusches t vlyalas two
ripper-bulldozer units (RBA) power
410 hp, as well as by blasting. Used raw materials in dump gruzopode m NOSTA 40 m was
carried out two wheel loaders
Caterpillar 988S with a bucket capacity of 4 , 5 m  . Transportation and transportation
3 

distance is about 19 km .

Transition to the new technology was preceded by pilot projects that have provided
technical and operational parameters and the economic performance of the combine Surface
Miner model 1900 SM and justify it advisable h of the realization of the new technology.
Based on the results of the work performed, the following conclusions were made:
          The use of a mining combine for limestone mining made it possible to reduce
diesel consumption by 2 times and to significantly (more than three times) increase labor
productivity compared to the technology used .
          The need for large crushing is eliminated and the load on the secondary crushing
is sharply reduced .
          Working platforms and communications transport aligned on a career that, along
with the best use of duty truck (melkofra due to the insulating composition of the rock mass)
contributed to extending the life of the individual units and truck components and increase
the reliability of the movable sost and va.
     Providing material size 100% smaller than 80 mm it possible to consider switching
career to continuous transport means that at substantially w boiling high costs for road
transport (74% of the cost) are very important.
The following options were considered (table 1):
* The   loosening and bulldozer unit - a wheel loader - a mobile crusher - a mobile conveyor
in a quarry and a main conveyor to a cement plant;     
* Blasting - Wheel Loader - dump - semi-stationary crusher quarry on board and main
conveyor to cement the head of yes;     
* Harvester model 2600 SM (excavation and loading work and crushing) -avtosamosval -
transfer device on board a mine and to main conveyor of cement and water;     
 
Table 1. Data on operational costs compared alternatives pit mining technology to
develop limestone quarry B e quill
 
  Option 1 Option 2 Option 3
Loosening and stacking 0.361 - -
Blasting operations - 0.263 -
Secondary crushing 0.018 0.018 -
Additional stacks and of   0.051 -
Loading 0.224 0.224 0.472
Transportation 0,052 0.237 0.237
Splitting up 0.317 0.233 * 0,033
Total 0.972 1,026 0.742
Total 1.31 1.38 1.00
 
     including the cost of AC e crusher schenie
As a result of technical and economic comparison revealed the primarily indisputable e -
OPERATION third embodiment, the implementation of which production cost and
proces T ki 1 ton of limestone to be 31-38% lower than in the other and Rianta.
The performed work allowed the enterprise to purchase the 2600 SM combine and
completely switch to the new technology. Currently manufactures and telnost harvester of
600-650 t / h, at a time of loading dump c y zopodemnostyu 40 tons for about 3 minutes. The
speed of the working stroke of the combine is about 8 m / min. Consumption D of ATC 3
pcs. per 1000 tons. Diesel consumption is about 80 l / h.
Prolonged operation confirmed the projected economic
dormancy and exponent. Cost of production reduced by 25%. At a cement plant, the
costs of processing raw materials were reduced and at the same time the
productivity and productivity of the mill department were increased by a uniform and
uniform fractional composition of the raw materials. An array of thin layers of
development thereby reducing raw material moisture, which also led to the reduction in
energy e cally costs of the plant.
An interesting experience of implementing blast-free technology accumulated in the
cement industry in India, which currently Execu s zuetsya 35 combines the Wirtgen the
Surface Miner .
 Since 1995, the quarries of cement raw materials began to be used combine two 2100
SM and 1900 SM model, one, six more were introduced in 1995, out to about toryh five -
2100 SM and one - SM 2600, in 1997 and 1999. accordingly, four and two models 2100
SM. Since 2003, limestone quarries have begun to flow. Between 2000 and 2008, 14 combine
harvesters 2200 SM and two 2500 SM were purchased .
One of the quarries where the
1900 SM combine began to be used in February 1995 was the limestone quarry of Gujarat
Ambuja Cements.   
This company is one of the largest cement producers in India. The company's motto is to
eliminate environmental pollution. This is the only cement plant in India from pipes which no
emissions of smoke and n s Is.
Before the transition to the new blast-free technology limestone compressive strength of
25-40 MPa and a density of 1.8 t / m  extracted in the usual way using a drill of blasting. All
Z  

possible measures were implemented to protect neighboring villages and agricultural land

from the adverse effects of mining. This led to additional costs for drilling and blasting,
excessive secondary blasting and disruption of the continuity of the production process .
In February 1998, the model 1900 SM harvester worked out 12 thousand m-hours during
three-shift operation and mining.
At present, a productivity of 2000-2500 t / day has been achieved. The hourly capacity of
the combine is 100 - 125 t / h. The size of the extracted material is: up to 75 mm - 98% and
2% up to 150 mm. Cutter consumption 0.0015 pcs / t.
Diesel consumption 35 l / h.
After a year of successful operation of the above combine, Gujarat Ambuja Cements Ltd
in 1996 and 1998. acquired four more 2100 SM combines.
C and n relational 1996 and February 1998 the first 7091 are fulfilled m-hour, and the
second - 8412 m-hours, extraction screen respectively 1.315 and 1.59 million tonnes..
The last two combines, introduced in 1998, worked out 430-450 m-hours in February
and produced 65-73 thousand tons. The average productivity was about 160 tons /
hour. Cutter consumption was 0.0008 pcs / t.
Kankar on the limestone quarry of a cement company Pandalgudi Madras Cements plant
is used to m -Bains in 2100 SM.
Kankar mine limestone is mostly flat character and disintegrations of lozheno about 13
km from the cement plant. The thickness of the overburden is about 1 m. The thickness of the
limestone deposit is up to 1 m long.
Limestone deposits containing 74% CaCO  is used for the production of cement, in
3 

admixture with limestone with height of kim containing CaCO  . 3 

For limestone mining, the

Caterpillar 966 E wheel loader was initially used for excavation and loading. The
transportation of mined limestone was carried out by dump trucks. 80% of the rock deposit
was developed without the use of blasting, and only the hardest parts of working out did not
respond to the immersion wheel of Chick.
The use of this method created the following problems. The uneven size of the material
created a number of transportation problems. In operation, loader downloaded pieces with a
size of about 1 m. To remove this oversize needs and mo would often stop the belt conveyor,
thereby significantly decreasing the performance feed mat e rial.
As a result of the review, it was decided to use the 2100 SM combine 
, which began to operate in March 1995.
As of February 1998, the harvester produced 844.7 thousand tons and accumulated 5802
m-hours. The productivity of the combine reached 245 t / h, while the average for the entire
period was 144 t / h. The consumption of diesel fuel and cutters was 36 l / h and 0.004
pieces / t, respectively
.
The surface of the site after the next pass of the combine dries quickly after rain. Since
the rock is extracted in thin layers over a large area, mining is possible even during the rainy
season. Autopsy deposits can produ of drive poustupno in one direction, thereby providing a
quick Waters t water in case of rain and mining operations may be resumed much earlier than
with conventional mining with and tem.
                   After thoroughly exploring the possibilities of the new technology, Madras
Cements Limited specialists made the final decision in favor of Wirtgen Surface Miner
combines, for which they consistently during 1996-2001. put into operation combines of
models 2100 SM - 2 pcs., 2600SM (1 pcs.) and 2500SM (1 pcs.) for work in the quarries of
other cement plants of the company Pe n nadam , Pandalgudi and Alathiyur .
In March and November 1996, two 2100 SM combines were commissioned at
the limestone quarries of Pennadam at India Cements Limited
. N, p first of them on February 1998 3683 m-worked hours, the second - 3567 m-
hours. During this period, each of them produced 485-500 thousand tons, with a productivity
of 280-300 tons / hour. Cutters consumption amounted to 3 pcs. / 1000 tons.
Studying the experience of operating new equipment and technology in the limestone
quarries of India showed that Wirtgen Surface Miner combines provide excellent quality at a
reasonable cost. Of the known methods of conducting mining operations, combines to the
greatest extent meet the requirements of the environment and, in addition, are an excellent
tool for conducting selective development of complex structural mineral deposits. Sites of
mineral deposits located close to settlements, railway lines and roads are much better to use
with the help of combines.
Surface Miner combines have proven their performance in field development, providing
high productivity, no negative impact on the environment and a better economy. The number
of mountain cycle operations is declining, as is the number of equipment needed. This
facilitates the control of the production process, which is also accompanied by significant
labor savings.
The dimensions of the piece of rock obtained during the operation of the combine are
significantly smaller compared not only to traditional drilling and blasting operations, but also to
other mechanical methods, such as, for example, mechanical loosening.
       When milling rock with a strength of 10 - 60 MPa , a combine with a large unit capacity, for
example 2500 SM , has better performance compared to the models 2100 SM and 2200 SM ,
which is determined by the rear location of the discharge conveyor, in which the best transfer
of material from the milling drum to the unloading conveyor belt . In rocks with strength
characteristics of 60–100 MPa , the milling parameters of a combine of a larger size are better
because of its larger weight, as a result of which a higher specific load is provided per 1 mm of
the milled section. In this case, the greater weight of the machine contributes to a better
implementation of the working tool (cutters) in the array, and due to the higher traction, a
concentration of large dynamic forces is ensured.
  Company Ash Grove Cement to , is one of the largest US producers of cement. It
includes 9 cement plants with a total capacity of more than 7.8 million tons of cement per
year, as well as quarries for the extraction of aggregates in the USA and Canada and a lime
plant in pieces. Oregon.
Technical re-equipment of the quarry of Foreman marl , which is the raw material base
of the cement plant of the same name in pcs. Arkansas began in 2001.
The transition to the new non-explosive thin-layer mining technology
using Wirtgen 2500 SM combines has allowed a significant reduction in operating costs. The
processes of traditional mining operations, such as preparing the rock mass for loading, are
excluded, crushing volumes are reduced, the condition of career roads is improved, and it is
possible to form a drainage system in the best conditions. Upon transition to the combine
harvesting, mining operations resumed immediately after the rain stopped. Using a mining
combine, the surface of the working platform is not disturbed. A slight slope of the platform
towards the sump solves all the problems of drainage.
The harvester carries out four processes in one working pass: it mills the array, crushes
and loads the rock mass of a reduced size, which can be immediately implemented without
additional crushing. With the transition to new equipment, a significant (58%) reduction in
the need for fuel resources was noted.
In the initial period, the combine worked according to two schemes: the first - with
direct loading of dump trucks, the second - with side dumping into a pile, which was formed
when the combine worked out four lanes. Material was taken from the stack by scrapers. 
Each of these schemes had its advantages and disadvantages. So, in the first scheme,
the advantages are the absence of perekaskavatsii and the continuity of the required loading
cycle. At the same time, a wider platform is required to accommodate the dump truck during
the loading process. The second scheme is convenient for trenching and driving. The
harvester works continuously. There is no loss of time waiting for dump trucks. The
disadvantages include the need for re-excavation.
As a rolling stock, four TEREX TA- 40 articulated dump trucks with a lifting capacity
of 40 tons are used together with a combine , on which doors are used to increase the
capacity, which cover the tailgate. The average loading time is 1.85 minutes. 28-29 tons of
marl are placed in the dump truck. The working speed of the combine varies depending on
conditions from 4.6 to 13.7 m / min with a milling depth of 23 to 48 cm .
It was established that the parameters of the working platform (length and width), the
time for waiting and replacing the dump truck, as well as the time for the maneuvers of the
combine when leaving the face and entering the face affect the value of the combine
productivity.
Table 2 below shows the data on changes in combine harvester productivity for various
lengths of the working platform, as well as various values of the time spent on exchanging
dump trucks at the combine during their loading and combine maneuvers when changing the
face.
 
Table 2 . The influence of the parameters of the working platform, the time spent on
maneuvers and the exchange of dump trucks on the performance of the 2500 SM combine .
  Combine stroke length, m
150 210 300 450
Productivity at a time for replacement of dump trucks
of 44 sec. And time for maneuvers of 6 min. 510 534 554 570
Productivity at a time for replacement of dump trucks
of 30 sec. And time for maneuvers of 6 min. 550 580 600 620
Productivity at a time for replacement of dump trucks
of 30 sec. And time for maneuvers of 5 min. 565 590 610 628
 
An analysis of the data in Table 2 shows that the productivity of the
2500 SM combine with an increase in the stroke length from 150 to 450 meters increases by
10-15%. With a decrease in the time for replacing dump trucks by 14 seconds, productivity
increases by 7%, and a reduction of 1 minute in time for maneuvers of the combine,
productivity increases by 2%.  
 The 2500 SM harvester operates in straight lines according to a pattern with a turn at
the end of the stroke. The milling depth is 39-42 cm . Dump trucks during loading follow the
side of the combine, which carries out their loading by its conveyor.
 

 
Fig. 2. Harvester 2500 SM in combination with a dump truck with a lifting capacity of
40 tons.
 
Raw materials from the quarry are transported to a primary crusher located at the head
of the 2.5 km long conveyor system , which in turn transfers the material to a warehouse
located at a cement plant. But since the material from under the combine has a fineness of
less than 120 mm , the need for large crushing has disappeared.
The only reason for using the receiving section of coarse crushing is a certain
established flow.
Very little material is crushed in a secondary crusher. It is expected that if the distance
between the cutters on the milling drum of the combine is reduced, or the rotation speed of
the drum is changed by changing the pulleys, it is possible to obtain finer material. The
results of measurements of the fractional composition of marl are shown in table 3 .
Table 3 . The fractional composition of marl mined by the 2500 SM combine .
 
Fraction Size, The output of each fraction,% The same, cumulative
mm total,%
> 150 4.0 4.0
125-150 1,6 5 , 6
57-125 21.8 27 , 4
25-57 32.6 60 , 0
0-25 40,0 100.0
 
Ensuring positive results of the new technology allowed Ash Grove Cement in 2005 to
purchase another combine of the same model (Fig. 3).
 
  
Fig. 3. Two 2500 SM harvesters on marl mining in Foremen quarry
 
The cement plant operates continuously 24 hours a day. Limestone at the quarry is
mined 10 shifts per week or 80 hours per week. To equalize the peak loads in the limestone
supply, the plant has a seven-day storage warehouse. On a career, work is carried out in two
shifts the first three days a week and in one shift the remaining four days a week. Currently,
two combines provide productivity
up to 1200 tons per hour and 1750 thousand tons per year. Cutter consumption is 10-12
pcs. in Week. Costs average $ 0.91 per ton.
In 2005, the development of a new non-explosive thin-layer technology began at the
quarries of the cement plants of the Holding Company EUROCEMENT group . The
Dzhegutinsky quarry of Kavkazcement OJSC was accepted as the first object when two
combines of the 2200 SM model were purchased.
A third similar combine was commissioned in August 2006. From this moment,
a complete transition was made to the non-explosive production of limestone, with the
issuance of over 3.5 million tons per year by three model 2200 SM combines .
In connection with the growth of production volumes, as well as in connection with the
forthcoming expansion of cement production, it was decided to re-equip the Dzhegutinsky
quarry of Kavkazcement CJSC with more powerful equipment - 2500 SM model
combines . The first such combine was put into operation in March, the second - in August
2008.
Continuing the implementation of the technical re-equipment program, EUROCEMENT
group equipped the quarries of Lipetskcement and Pikalevsky cement plant with similar
combines.
With the commissioning of the 2500 SM combine in 2009 at the limestone quarry of the
Pikalevsky cement plant, five combines of this model are working at the quarries of the
EUROCEMENT group holding company.
As a result, in the middle of 2011, over 20 million tons were produced using the new
technology.

1
TECHNICAL-ECONOMIC CONSIDERATIONS ON THE FEASIBILITY OF DEVELOPING bezvzryvnogo thin layer
SHAVAZSAYSKOGO CEMENT LIMESTONE DEPOSIT About JSC "Akhangarancement" WITH FIRM mining
machine WIRTGEN GmbH
 Table 4 below shows the operational parameters of the work of combines in the quarries
of CJSC EUROCEMENT group.

1
TECHNICAL-ECONOMIC CONSIDERATIONS ON THE FEASIBILITY OF DEVELOPING bezvzryvnogo thin layer
SHAVAZSAYSKOGO CEMENT LIMESTONE DEPOSIT About JSC "Akhangarancement" WITH FIRM mining
machine WIRTGEN GmbH
 
 
Table 4 . Work parameters of combines 2200 SM and 2500 SM in quarries of CJSC
“EROCEMENT group”
  CJSC CJSC LIPETSKCEMENT CJSC
CAUCASEMENT "MIKHAILOVCEMENT"

2 2 00  2500 SM; N 2 2 00  2500 SM ; N 2500  2 2 00  2500 SM 2500 SM 

SM umber 24 SM umber 27 SM SM No. 13 No. 13
No.
13

Mine Small-block, thin-layer Limestones of light and light Large-block, multi-strength

ral limestone gray color, with a yellowish tint, limestone
resource medium strength, fissured,
medium and coarse-grained,
fine-grained.

The 35-70 40- 80 80-120

limit of
compressi
ve
strength,
MPa

Type W47 K W47 K W47 W47 K 19 WSM1 W47 K W47 K WSM19

of incisors 17; W47 17; W47 K K 17 7-42 17 19 W47 -42
  K 19 19 K 22
WSM22
W47 K
25 -42

Type NT6 NT6 NT6 NT6 NT14 NT6 NT6 NT14

of tool
holders

Milli 20-24 45-50 18-22 45-55 fifteen 40-25 25

ng depth,
cm

Cutte 1 1 2-3 0 , 25 0 , 30 3-4 13.8- 8-11.5

r 19.8
consumpti
on, pcs /
1000 tons

Tech 400-600 590-715 320- 480-540 145-300 305-420 180-300

nical 370
productivit
y, tons /
hour
 Oper 270-530 515-580 250- 360-400 140-280 200-320 145-300
ational 300
productivit
y, tons /
hour

Fracti              
onal
compositio
n,%

50 61 77 65 75.7 84  66 78.5   83.4  66.5

.5 92 64.8

+ 50- 26.9  17.7 15. 12.8  26.7 16.8   11.5  23,4

100 16.2 7 7 26.5

+100 12.1  17.3 8.6 3 1 7.3 4.7   5.1 8. 10.1

6.3 7

1
 
TECHNICAL AND ECONOMIC MESSAGE expressions on the appropriate use bezvzryvnogo thin layer DEVELOPMENT
SHAVAZSAYSKOGO DEPOSIT OF LIMESTONE CEMENT JSC "Akhangarancement" WITH FIRM mining
machine WIRTGEN GmbH
 

 
Fig. 4 . Work of the 2500 SM combine with a 45-ton dump truck at the limestone quarry of ZAO
Kavkazcement.
And the results of screening of the material obtained in the process of milling the rock
mass are interesting.
Within certain limits, by changing the operational parameters of the combine operation or
using a different configuration of the working tool for a particular array, the most rational
fractional composition can be achieved . 
At the Sokolsko-Sitovsky limestone quarry, which is the raw material base of CJSC
LIPETSKCEMENT in the process of milling the array with the 2500 SM combine model, in
 2010, studies were carried out to refine the operational parameters of the combine operation
and their influence on the output of various fractions.
Strength characteristics of rocks composing an array of 40-80 MPa. The work of the
combine on the development of large-block massif. The thickness of the milled layer is 40-
45 cm , the working speed is 5-6 m / min. Cutters with an insert of 22 mm. Drum type
NT14. The results are given in m ABLE 5 . Table 6 shows the results of the operation of the
combine with a changed size of the cutters (cutters with an insert of 17 mm were used) and a
lower milling speed.
           Table 5 . The output of various fractions of limestone during the operation of combine No.
13 on a large-block massif.
Fraction Fractions yield
Size, mm Weight kg Share% Progressive total%
5 50.9 13.9 13.9
5-20 93.0 25,4 39.3
20-40 82.9 22.7 62.0
40-150 121.7 33.3 95.3
150 17.1 4.7 100.0
  365.5 100.0  
 
  Table 6 . The output of various fractions of limestone during the operation of combine No. 13 on a
large-block massif.
 
Fraction Fractions yield
Size, mm Weight kg Share% Progressive total%
5 40.5 8.7 8.7
5-20 101.9 21.9 30.6
20-40 89.2 19.2 49.8
40 - 150 199.5 42.9 92.7
150 33.9 7.3 100
  465.0    
 
It is noteworthy that replacing the cutters with sharper ones allowed to increase the yield
of the +40 mm class from 33.3 to 42.9%.
 
The study of the results of operation of combines and pilot industrial operations in the world
showed:
1. In conditions of carbonate deposits, it is possible, and in most cases, expedient, to
switch to blast-free rock development using Wirtgen Surface Miner combines .
 Due to the abandonment of a number of traditional processes for mining
production, capital investments and operating costs are reduced;
 the mining planning process is simplified, efficiency and reliability are
improved by reducing the number of operations and the number of mechanisms,
and the need for spare parts is reduced;
  reduced need for production and maintenance personnel.
2. Lower transportation costs.
3. It provides the opportunity to start mining operations with a minimum
preparatory cycle.
4. Safety is enhanced and the environmental impact of mining is reduced.
5. The efficiency of the use of field reserves is increased, since production is possible
in areas where blasting is prohibited.
After analyzing the current state of mining and the materials presented, it is
proposed that the Shavazsay limestone deposit be mined using a fundamentally
new non-explosive mining technology using Surface Miner combines from Wirtgen
GmbH (Germany) equipped with a diesel engine. A possible standard size of the
equipment for field conditions is w tsya kilns e harvester s 2 2 00 SM and 2500 SM.   
 
 
 
 
 
 
 
 
Table 7 . Technical characteristics of mountain combines
Name of dormancy and exponent Unit Harvester Size
measuring 2200 SM 2500 SM
The maximum width of the strip mm 2200 2500
cut and Nia
Cutting depth mm 0-300 0-600
Milling drum diameter mm 1140 1400
Engine power kW / 671/910 783/1064
hp
Fuel consumption at full load l/h 168 191
Fuel consumption at 2/3 mo u NOSTA
l/h 112 128
Speed range m / 0-84 0-32
min
Speed range km / h 0-5.0 0-3.5
Machine Weight :      
- own kg 44500 98000
- working with dressing kg 50780 100500
Working capacity :      
- fuel tank l 1500 2400
- oil tank l 450 500
- tank for water l 5000 2800
Conveyor belt width mm 1100 1400
Consideration and justification of the rational size of the harvester in relation to the
development conditions of the Shavazsai deposit of carbonate rocks is carried
out below .
4. Determination of productivity and quantity of
equipment with new technology
 
The development of rock masses using Wirtgen Surface Miner combines has a number
of features:
                    Unlike traditional technology, the face is a horizontal or slightly sloping
platform;
                    The greatest productivity is achieved in the presence of a significant front of
work, when continuous continuous development of the array with a minimum number of
auxiliary operations and idle passes can be ensured.
The performance of the combine is determined by its working speed during milling,
multiplied by the cross section of the rock mass, formed by the width of the milling strip and
the thickness of the worked layer.
If the width of the milling strip, equal to the width of the working body, in most cases,
the value is constant, then the other two parameters are variables.
The size of the worked out layer can vary within the design capabilities of a particular
model, for example, for 2200 SM and 2500 SM, this value varies from a centimeter to 30
and 60 cm , respectively .
For specific arrays, the effective or optimal layer thickness depends on many factors that
can be grouped into two main groups: natural and technological.
The first can include: strength properties of the rocks that make up the massif, as well as
the state of the massif its fracturing, blockiness, abrasiveness, etc .; the second - requirements
for product quality, its fractional composition, as well as the type of work - cleaning the roof
or working out the sole of the mineral layer.
High-performance work in medium-strength rocks according to practice is performed
with a milling layer equal to about 75% of the maximum (structural) possible.
Another variable is the speed of the combine. Structurally, in all models of combines, the
use of a range of operating speeds in the range from 0 to 20 m / min is provided. The value of
the speed of the combine during milling is mainly limited by the resistance of the array to
mechanical development. In hard rocks, the speed can be 3-6 m / min, in medium -5-10 m /
min, in the lungs - 10-20 m / min. At the same time, the working speed of the combine to a
certain extent can affect the fractional composition of the rock mass, the higher the speed, the
greater the yield of large classes and vice versa, the lower the speed, the finer the fractional
composition.
It should also be noted that the effective layer thickness and the possible value of the
working speed, the values are, to a certain extent, interdependent and in specific arrays it is
advisable to optimize these parameters.
Technological schemes, the application of which depends on the parameters of the face
(work site), also affect the value of productivity. With a work front length of about 150 m, it
is advisable to use shuttle circuits with milling in one direction and reverse idle, carried out at
a transport speed (up to 50 m / min). In this case, the time to return back should be equal to or
less than the time to turn the combine at the end of the working stroke. This time according to
practice is 3.5-4 minutes. With a larger front of work, it is possible to use a scheme with a
turn of the combine and milling in the opposite direction.
For various technological schemes, the performance of Surface Miner combines is
determined as follows.
When the scheme of work with reverse idling (shuttle  , m  / h), the performance of the
3 

combine is determined by the formula:

                               ; 
       where:  -  milling depth;
                        - the width of the strip milling (working body);
        - utilization rate;
                            - average length of the working passage;
                            - the average length of the idle passage;
                         - the speed of the machine during milling;
                          - speed at idle (reverse) stroke;
         - the time during which the lowering and lifting of the drum to the bottom or from the
bottom to the start of movement (about 2 minutes );
                     - time for turning the combine for milling in the opposite direction.
When working with rotation and milling in the opposite direction, the  performance is
determined by the formula (m  / hour): 3 

When the flow scheme of work, the productivity is determined (m 3 / hour):

                 
Shift performance at 8 (12) -hour shift will be ( m 3 / cm ) :
                               
where: K 1 - coefficient taking into account the time spent on maintenance of machine units, 0.80;
K 2    - coefficient taking into account the time spent on inspection and replacement of incisors, 0.95;
K 3 - coefficient taking into account the loss of time when replacing and installing dump trucks
for loading - 0.90                                       
 
When calculating the annual productivity harvester assume that the necessary technical
service (TO-1, TO-2 and TO-3) in cross-sectional annual production time will occupy
35- 5 to 5 days. The world experience of using combines in the development of cement raw
materials allows for further calculations to select the operational parameters of the new thin-
layer mining technology.
 
An analysis of the development conditions of the Shavazsai limestone deposit, data from
the world experience in operating Wirtgen Surface Miner combines, made it possible to select
the operational parameters of the new mining technology, which are used in the calculation
below (table 8 ). Accepted schemes and the   work of the combine with rotation and milling
in the opposite direction . Block length 350 m. Turning time - 8 min.
Table 8 . Performance calculation for Surface Miner combines

The name of indicators unit of 2200 SM 2500 SM

measurement
Drum width m 2.2 2,5
Milling depth    
- maximum m 0.3 0 0.60
 - effective m 0.2 0 0.4 0
Milling speed m / min 5,0 4 , 0
Time utilization  
0.85 0.85
Harvester productivity :    
       
 Sentinel m  / h
3 
107 200
 The same for = 1.9 t / m 
3 t/h 203 380
 Interchangeable t / cm 1100 2 . 00 0
 Annual, with three-shift work    
schedule and 305 working days thousand tons / 10 00 1 . 8 3 0
year
 
Considering that the performance of Surface Miner combines during the blasting
development of rocks is largely determined by the specific mining conditions: the state of the
massif (fracture, size of the parts, structure), as well as the strength, toughness and
abrasiveness of the rocks that make up the massif, and these parameters are individual,
calculated productivity should to be specified.
Nevertheless, the experience accumulated in the country and abroad using similar
machines allows us to consider them real. Calculations show that for the implementation of
the annual program in the amount of 2.3 mln. Tons will require fleet of 3 harvesters 2200 SM
or two processor s model 2500 SM.
 
5. Calculation of economic indicators of the new
technology
 
When calculating the economic performance of Wirtgen Surface Miner combines in relation
to the development of cement raw materials, the following materials were used:
1. Summarizing the operating experience of Wirtgen Surface Miner mining combines in
the quarries of cement plants in the world.
2. The results of pilot work in the implementation of explosive thin-layer technology in
the quarries of cement plants in Serbia, the USA and India.
3. Wirtgen GmbH materials on the application and cost parameters
of Surface Miner combines .
 
For further calculations, the following operational and cost parameters were adopted:
For Model 2200 SM
 The number of hours of operation of three combines a year
is 11330 hours (one - 3777)
 Diesel fuel consumption - 7 0 l / h or 793 , 1 tons per year;
 The cost of the combine - 1 , 1 Mill. EUR ;
 Combine service life - 7 years;
 The cost of diesel fuel is 1.0 EUR ;
 The cost of lubricants and filters is 2 0 % of the cost of diesel fuel (according
to the company Wirtgen GmbH );
 Cutter consumption 3 pcs. per 1000 tons (according to the current quarries of
India and Caucasus cement) ;
  The cost of 1 cutter - 1 4 EUR ;
 The salary of the worker is 5 00 EURO per month (the composition of the
team is 2 people).
 
For Model 2500 SM
 The number of hours of operation of two combines per year - 6052 hours (one
- 3026)
 Diesel fuel consumption - 100 l / h or 6 05.2 tons per year;
 Combine cost - 2 , 2 Mill. Euro ;
 Combine service life - 10 years;
 The cost of diesel fuel - 1 , 0 Euro ;
 The cost of lubricants and filters is 2 0 % of the cost of diesel fuel (according
to the company Wirtgen GmbH );
 Cutter consumption 3 pcs. per 1000 tons (according to the current quarries of
India and Caucasus cement );
 The cost of 1 cutter - 1 4 Euro ;
 Salary of the worker 5 0 0 Euro per month (composition of the team 2 people).
 
Table 9 . Calculating the cost of 1 ton of limestone using blast-free thin-layer
technology of mining operations with the use of Combine the
Surface Miner company Wirtgen Model 2200 SM and 2 5 00 SM
 
Expenditures    For the whole volume, per 1 ton
EURO of limestone , EURO
  2 2 00 2500 SM 2 2 00 SM 2500 SM
SM
Accrued salary 201 . 6 00 67 . 2 00 0.0 88 0.02 9
Depreciation 4 71 . 9 00 44 0.000 0, 205 0, 1 9 1
Fuel 7 93 . 10 0 605 . 2 00 0, 345 0, 2 6 3
Lubricants and filters ( 20 % of diesel fuel) 1 58 . 6 2 0 121 .0 4 0 0.0 69 0,0 5 3
Repair costs ( 2 0% of depreciation) 94 . 38 0 88 .000 0.0 41 0,0 3 8
Cutter Consumption 96 .6 0 0 96 .6 0 0 0,042 0,042
Unaccounted for (5% of the above) 90 . 810 70 . 902 0.0 39 0.0 31
Total 1. 907 . 010 1.488.942 0, 829 0, 6 4 7
 
 
 
 
 
 
 
FINDINGS
 
The data obtained allow us to recommend the use of a new non-explosive
environmentally friendly mining technology using the Wirtgen GmbH model 2500 SM
combine, when mining reserves at the Shavazsai open pit of carbonate rocks of
Akhangarantsement JSC.