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Exploration Fundamentals of Drilling - Rock Destruction During the Drilling Process

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4Issue 02 | 2009

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ExplorationIntroduction It is imperative to conduct exposure, in order to determine the type, composition, as well as the location of deposits and in order to establish a sound basis for the qualitative and quantitative assessment of a deposit. Direct exposure is com-posed of both natural, as well as artificial exposure. An exposure, which is an integral component of field tests, allows for inspection of the bedrock, as well as for taking soil and rock samples. Thereby there is a distinction between loose rock (soil) and hard rock (rock), as well as the genesis of rocks, in order to separately maintain the sequence, density and location of individual layers. With the taken samples the type, petrographic composition, composition of grains, the status and the consistency of the different layers can be determined. Moreover the samples are further analyzed and appraised in laboratories with the help of soil- and rockmechanical examinations. An integral part of the exploration work consists of the chemical analysis of the samples, in order to determine the raw material content and the distribution of quality.

There is a need to differentiate between exploration digs, exploration pits, exploration tunnels and drillings, as direct exposure types. Different types of probings are counted as indirect subsoil exposures. It is necessary that all exposures have to be exactly levelled and explicitly marked according to their location and shoulder height. In order to do so, a reliable site plan with all investigation points has to be developed. The water resources law requires that, in case an exposure is done near the ground water, the relevant office of the environment has to be informed and can issue certain requirements, which then need to be observed. As an example it can require the sealing of the exploration dig exposures in such way, that it has no adverse effect on the ground water.After a short description of prospecting trenches the basics of drilling technology are illustrated in the report on hand, due to their special relevance for exploration of mineral deposits.

Exploration DigThe establishment of prospecting trenches is usually

the most favourable exploration method. Particularly if the development extends to a low depth. On a stable soil mostly excavators are applied to prepare exploration digs, in order to examine the composition of the surface layer or to check the expected situation. With common excava-tor types the depth reaches up to approximately 4 m. It is possible to reach depths of up to 8 m with an elongation of the grappler, as well as with a circular grabber. However, in view of the ground water, in case the possibility of re-aching ground water is existent, no exploration dig should be established.

The preparation of exploration digs has the advantage, that the course of the layers can better be seen than in the case of drillings. Compared to drillings, the samples in exploration digscan be freely selected by hand by size and direction.

However, while digging trenches it has to be seen that the excavated material is not temporarily stored too close to the groove or the excavator has to be removed from the edge while reviewing the trench, so that gliding off of the material is prevented. In trench depths of more than 1.25 m support measures have to be taken.(1)

(1)For example, the DIN 4124 is the appropriate framework for such measures in Germany

Photo 1 : Example for prospecting pit in Mexico

by Univ.-Prof. Dr.-Ing. habil. H. Tudeshki ; Dipl.-Ing. Thomas HardebuschSurface Mining and International Mining | TU Clausthal | Germany

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The risk of accidents without support mea-sures is higher, the bigger the diameter of the surface cut, the more the layout deviates form the form of a circle, the more inhomogeneous the excavated material is, the more leak water is encountered, and the lower the fine fraction is.

Exploration tunnels are similar to exploration digs, although they are mainly applied in tunnel construction. They provide initial information on the characteristics and composition of a moun-tain, before the tunnel construction is started in large cross-section. Compared to the usual subsoil exposure, the emphasis is mostly on the determination of information on clefts, areas of layers, flow conditions, natural stress condi-tions and solubility, rather than on the extrac-tion of samples.

Explorations of near-surface deposits, parti-cularly in mountainous and hilly regions, explo-ration drifts are headed. Compared to usual surface cuts exploration works are primarily focussed on the determination of information related to shape and direction, especially of veined deposits, as well as joints, stratification, water content, natural stress condition and solubility.

In order to explore surface-near groundwater-free deposits with unconsolidated rock as overburden in regions with re-latively smooth topography, sometimes exploration shafts are sunk using a lower diameter. These building can also be used as starting point for exploration tunnels or drifts when the ore body was achieved. Generally, exploration shafts are sunk with simple equipment, particularly in regions with low labor costs. In layered and lenticular deposits prospecting trenches are build as perpendicular as possible to the assumed strike of the beds. If the overburden layers very thick, so that a pros-pecting trench can not be used, or it is intended to follow the deposit to depth, an exploration shaft is sunk. An exploration

shaft can reach a depth of approxi-mately 30 m in unconsolidated and dry soil conditions, in stable rock considerably lower. When sinking the exploration shaft the most small diameter should be used. Hitting the groundwater table manual work nor-mally must be stopped.

In deposits with thick overburden layers exploration drifts are prefer-red, unless the terrain allows, i.e. in a valley. Furthermore, prospecting trenches starting from a shaft or drift works are common for enhanced ex-ploration activities. In order to safe expenditures during prospecting/trenching, the cross sections of these exploration buildings are kept as low as possible.

Photo 2 : Example for prospecting pit in Mexico

Photo 3: Example for prospecting pit in Iran - temporary construction

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EDUCATION


DrillingsVarious drilling methods are applied in exploration of

deposits. Usually during exploration the aim is to achieve a borehole with continuous coring, so that the complete pro-file can be viewed and photographed, provided that no drill core loss occurs. Another advantage of boreholes is that many samples can be obtained for further classifications. It is also possible to take special samples, which allow for advanced laboratory tests for chemical and physical ana-lysis. A borehole is done according to the principle of a dy-namic penetration coring with the help of various sampling tools (scoop, single core barrel, core catcher) and various rotational core drilling methods (air flush, water flush, wi-thout mud; double or triple core barrel, hose coring, cable core barrel). Hereby the influence of the core drilling me-thod determines the quality of the samples. As an example the exploration drillings in loose rock are protected by pipe installation. The cost for the conduct of a drilling method mainly depend on the geometrical dimensions of the plan-ned drilling and the size of the drilling tools, respectively.

In order to understand the importance of drilling tech-niques in connection with the extraction of mineral com-modities, particularly in the area of exploration, drilling and blasting, as well as dewatering, a detailed technical exa-mination of the drilling technique is needed. Therefore the next chapter of this article deals with this task.

Fundamentals of Drilling - Rock Destruction During the Drilling ProcessDefinition of Drilling:

Drilling is characterized by penetration of the tool into the material to be drilled, either by removing damaged mate-rial through the mouth of bore, or by pushing the material into the material surrounding the drilling tool.

In both cases a long, mostly round hole is produced. Based on the type of application of energy, the mode of operation of the drilling tool is divided into:

blowing,•

hammering,•

rotating and hammering,•

or rotating•

With the blowing impact high destruction energy is in-duced, along with a low hammering frequency, while the drill-head is completely relieved between the single impul-ses. The rotary drilling produces a high, axial and cons-tantly sustained pressure. In hammer-type drilling, an ad-ditional low destruction energy overlies the low, constant primary pressure, along with a high hammering frequency (see pic. 1-3).

The elementary processes effective during drilling are outlined in picture 2.

Pic. 1: Load type: 1 blowing, 2 rotary, 3 hammering [1]

Photo 4: Example for prospecting pit in Iran - topview of pit

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EDUCATION


In connection with the form of the impacting elements, the elementary processes allow to derive the functioning of the drilling tool in the respective drilling procedures:

Hammering drilling•

Splitting, notching, pushing, crushing•

Rotary drilling•

Cutting, chipping, grating, grinding•

The common feature of all drillings is the fact that the drill head is rotating. In purely rotational drillings the rotati-on leads to the actual removal process of the bored mate-rial from the surrounding material.

In hammering drilling, the rotation serves various goals. Firstly, in following operations, the drilling head is moved by a small, defined angle of rotation, which leads to the fact that a new, fresh contact surface emerges, and con-sequently the share of the unproductive after-crushing of already removed material is lowered.

Secondly this rotation is done without a lifting of the drill-head from the borehole base, but rather with a cons-tant and relatively high bit load, so that an additional chip-ping effect is achieved during drilling.

Removal of rock at the bottom of the borehole

The removal of the rock at the bottom of the borehole is done in connection with the drilling procedure, the drilling tool and its impacting elements, through the formation of a crater or through the generation of radial flutes, ruts or furrows.

The size of the crater or furrow to be generated depends, among others, on the brittle fracture and plastic characte-ristics of the material to be drilled.

Generally it can be said that, the bigger the formation of achieved cavity is with comparable energy effort, the higher is the economic progress in drilling.

The geometrics of a blade can be described by wedge angel, clearance angle and chip angle and are outlined in picture 3.

Hammer-drilling – pressing/crushing (crater- formation)

In hammer-drilling, an exclusively vertical application of force into the material to be drilled leads to a pressing/shattering mode of operation, which creates a crater (Pic-ture 4). The process comprises of four stages.

Beginning of the strain: Through an increased strain 1. of a blade, which is in contact with the rock, the com-pression stress in the rock below the contact surface increases.Formation of a rock wedge: The compression strength 2. of the rock is exceeded. A wedge consisting of ultrafi-ne stone-dust is formed.Crater-shaped Breaking: With increasing compression 3. load the wedge is compressed in a way, that the sheer in the rock exceeds its shear strength.After the crater formation: The rock material loosens 4. along the generated cracks in the surrounding rocks.

a = wedge angle of the blade, F = bit load, A = Thrust Pic. 2: Elementary processes during drilling [1] Pic. 3: Angle descriptions of a cutting unit [1]

a clearance angle

b wedge angle

g chip angle

Rotation

Bit load / impact

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Hammering drilling - chipping

During hammering drilling a removal of the rock done through chipping, where the drill head is rotatingly trans-positioned, while having constant contact with the bore-hole bottom. The demolition of rock is done on a small scale directly at the blade, as well as through introduction of compression load into the mountains, which lead to the removal of the sheared cuttings. At the same time, smaller remnant chippings are formed along the shear plane, which can be carried out together with the main chippings.

Rotary drilling – cutting, grating, chipping

The cutting, grating or chipping mode of operation of the cutting elements is achieved with the usage of bits with hard edges in relatively well drillable material.

Rotational drilling- pressing/ crushing and splitting/furrowing

The pressing/crushing destruction of rock occurs in very hard material, which normally can only be drilled with the application of diamonds and with the usage of a very high bit load.

Contrary to the cutting, grating or chipping tools, the penetration depth of the drilling tools in the pressing/crushing destruction of rocks is very small and no chip is produced by the blade during the circular motion. Bene-ath the diamond a small-scale, strong compression of the material is achieved through the high bit load, which leads to enormous compression stress. Through the rotation of the bit the loaded area of the bore hole bottom is again de-compressed, so that a chip is formed behind the diamond, whose thickness of depth corresponds to the maximum compression stress.

The cycle of the rock destruction by a diamond tool is portrayed in picture 7.

Based on the type of material and type of the diamond bit, in front of the diamond small primary chips are also formed in the direction of the movement. However, the loo-sened material behind the diamond constitute the major part and are called secondary chips.

Rotary drilling with rotary bits – digging/grating

During rotating drilling in soft material, the roller bits are equipped with long teeth. At the same time the geometry of the rotary bits, in this case, is characterized by a big

Pic. 4: shammering demolition of material – crater formation [1]

h Penetration depth

b wedge angle

1 Blade

2 bore hole bottom

3 crushed material

4 crack formation

5 main chip

Pic. 6:Effect of a rotary drilling tool cutting, grating, chipping [1]

Pic. 8: Formation of chips by a diamond tool [16]

Pic. 7: Demolition of rock through a diamond tool [1]

Pic. 5: Chipping destruction of material [1]

1 Bit with inserted cutting element (e.g. PDC bit)

2 Bore hole bottom

3 immediate rock destruction

4 Sheared cuttings

5 Small remnant chippings

6 penetration depth

(thickness of chips)

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EDUCATION


offset, i.e. displacement of revolving axis. Therefore the cutting units do not neatly roll on the bore hole bottom, but produce a leverage force during their rotation. Therefore the rock destruction through this type of rotary bit is called digging/grating.

In picture 9 this process is portrayed in picture. In this case it is assumed that a rinsing fluid is used, which weighs on the bore hole bottom as a hydrostatic force Pm, and as such causes a pseudo-plastic characteristic of the rock.

Rotary drilling with rotary bits – pressing/crushing

When rotary bits are used in hard material, the rolls are equipped with short, round cutting elements. These nipp-les are not intended to penetrate the material, but should, under the stress of the high drilling bit load, produce high compression stress in the material. The rotary bit with nipples has no or very low off-set, so that a good, low-wear rolling movement on the bore hole bottom is achieved.

The processes below the nipples are similar to the pro-cesses of crater formation in the hammering demolition of rock.

Destruction of rock – Summary

The destruction of rock during drilling is highly depen-dent on the material to be drilled and the type of the tools. In given geological conditions it is possible to optimize the process of drilling, only by the correct selection of the

Drilling method,•

Type of drilling tool and •

Parameters of drilling.•

Wrongly chosen drilling methods and tools lead to a bad drilling result, which is characterized by low progress in drilling, high wear-out, and consequently high costs of dril-ling. Furthermore there is a danger of wrong interpretation of the drillability of the mountain. As a result, the drilling in-struments for further drillings are wrongly chosen and the uneconomical drilling operation is continued.

It is therefore recommended that a specialist is consul-ted for the selection suitable drilling systems and the con-secutive execution of test drillings.

Drillability of RocksBackground

Definition Drillability:Drillability is the size of the (drilling)-resistance, which the material to be drilled has towards the penetration of the drilling tool.Contrary to the usual assumption, the hardness of rocks, which can be determined with the hardness scale after MOHS, has a subordinate significance. This is due to the fact, that the combination of the following rock parame-ters determines the drill ability.

Thereby the following resistances are differentiated:Active drilling resistance: Wear-out due to abrasiven-1. ess of the material to be drilledPassive drilling resistance: mechanical resistance to 2. penetration (Single-axial compressive resistance)

The drilling resistance is influenced by the following rock characteristics:

Single-axial compressive resistance • sD

Shearing strength • tS

Single-axial tensile strength • sZ

Concentration of abrasive minerals•

Hardness and grain size of rock forming minerals and •binding material

Other parameters, e.g. crevasse formation, stratifica-•tion, faulted zone, ...

Pic. 9: digging/grating rock destruction of the rotary bit [1]

Pic. 10: pressing/crushing rock destruction of a rotary bit [1]

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EDUCATION


Besides the concentration of abrasive minerals, the grain size of the quartz crystals, as well as the tensile ad-hesive strength of the mineral bond are responsible for the wear-out.

The classification of rocks is often done by the rock hardness. This is because the definition says that a brea-kage in a solid body occurs, when the local tensions ex-ceed the strength of the material. Thereby, however, the type of stress is of significant importance. In picture 11 the connection between the various strengths is roughly portrayed. Reference value is the single-axial compressi-ve strength, since it can be determined relatively easy and accurately:

Tensile adhesive strength: • sZ = 0,10 . sD

Shearing strength : • sS = 0,25 . sD

Compressive strength (as reference value): • sD = 1,00 . sD

Penetration strength: • sE = (10 bis 20) . sD

The compressive strength of rocks often has a broad scope. This results from fluctuations in the mineralogical composition, as well as from changes in the original rock through outside influences. Picture 12 depicts the com-pressive strength for selected rocks in the possible sco-pe.

A carry-over of compressive strengths to the drillability can be done with the help of the classification of exploitati-on of Kögler-Scheidig, which is based on empirical values and connects the economical application areas of cutting elements with the compressive strengths. (Picture 13)

Experiments can be conducted to determine the drilling of rocks. The Drilling Rate Index DRI, which was developed by R. Lien in 1961, is introduced as example.

In order to determine the DRI, two separate experiments are needed.

S20-Value (Swedish Stamp Test): Drop hammer •experiment for the indirect determination of the rock resistance in crushing and cracking

SJ-Value (Determination of the Sievers-J-•index): Small drill experiment for the indirect determination of the penetration resistance)

The results of both tests are recorded in a diagram and allow for determination of the DRI.

Pic. 11: Approximate correlation of strengths of rocks

Abb. 12: Druckfestigkeiten ausgewählter Gesteine, nach [12]

Pic. 13: Classification of Exploitation after Kögler-Scheidig [1]

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The experiment to determine the S20-Value starts with the crushing of a defined rock sample by a drop weight of 14 kg, which is dropped from a height of 25 cm on a rock sample. Subsequently a sifting on three screen cloths in undertaken, and the passage through the sieve with a mesh size of 11.2 mm is determined in percentages. At least 3 to 4 experiments are needed to achieve statistically secured results. (Picture 14).

For the small drill experiment, a defined rock sample is clamped in a bracket.

The vertically slideable bracket is preloaded with a weight of 20 kg, so that a constant vertical bit load is ge-nerated on the drill beneath the sample. The SJ-Value re-sults from the depth of the drill hole in the rock sample in 1/10 mm, which is achieved after 200 rotations. In order to achieve statistically secured results, up to eight experi-ments have to be conducted (Picture 15)

Subsequently both test results can be recorded in a diagram. As an example a S20-value of approximately 70,

in combination with a SJ-Value of 100 has been assumed, which lead to a DRI of around 70 and 82 respectively (Pic-ture 16). Generally it can be said that with the reduction of the DRI, the drillability is reduced.

The following list provides indications for the classifi-cation of the drillability of various rocks, by means of the Drilling Rate Index [4]:

Gabbro 30...65•

Granite 30...80•

Graywacke 25...65•

Conglomerate 25...75•

Copper ore 30...90•

Pegmatite 40...80•

Quarzite 25...80•

Sandstone 15...90•

Tuff 30...80•

The wide scope of the values results from the high num-ber of different varieties, which can be found in rocks. This can be seen, for example, in the comparison of the sco-pe of the single-axial compressive strength in picture 12. A comparison of compressive strength and DRI has been done on the basis of 80 tests on different rock samples. Excerpts from that are depicted in the following diagrams.

Pic. 14: Experiment to determine the S20-Value [4]

Pic. 15: Experiment to determine the SJ-Value [4]

Pic. 16: Diagram to determine the DRI [4]

Pic. 17: Relation between single-axial compression strength and DRI for selected rocks. [4]

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EDUCATION


It is evident, that the drillability of Limestone, Marble or Calcerous shale cannot be derived from the single-axial compression strength. At an almost constant compressi-on strength of around 100 MPa, the drillability index DRI of limestone reaches from 50 to 80. The right-side diagram shows that the drillability of quartzite, limestone or silts-tone is highly dependant on the compression strength. As mentioned already in chapter 10, a corresponding test program to determine the attainable drilling performance is sensible.

Drilling progressBackground

The attainable drilling progress is influenced by a num-ber of parameters, which are listed in the following sec-tion. Some of these parameters can be influenced by the operator, others are given.

Mountain characteristics•

Drilling equipment•

Mechanical factors•

Hydraulik/pneumatic factors of the mud system•

Handling of th drilling unit•

Performance of the drilling unit•

External conditions•

The mountain characteristics cannot be influenced and are composed of the following parameters:

Hardness and abrasiveness•

Ensile and compression strength•

Mountain characteristics (plastic/refractory)•

Drillability•

Fissure/lamination•

Physical characteristics, e.g.•

Porosity, permeability•

Fluid content•

Mountain temperature•

The drilling equipment is composed of mechanical com-ponents and the mud system. Both are closely interlinked and must therefore be coordinated.

The mechanical factors of the drilling equipment are composed of the following points:

Tool pressure and rotation speed•

Type of tool and diameter•

Rock destruction (grating- digging, pressing-crushing, •combined)

Geometrics of cutting elements•

Type, size and direction of direction of mud flow•

Status of tools•

The mechanical factors are all adjustable to the require-ments of the drilling task. However, the diameter of the tool is one exception, as it usually is preset by the subsequent use of the drilling.

The mud system is completely adjustable to the given mountain characteristics and consists of the following pa-rameters:

Mud flow characteristics•

Type of mud (hydraulic/pneumatic)•

Density, solids content•

Viscosity, flow limit•

Filtration characteristics•

Rate, pressure and speed of mud flow •

Loss of pressure in connecting rods•

Pressures in bore hole bases•

The handling of the drilling unit is mainly based on the efficiency of the relevant personnel, which depends on the qualifications and experience of staff, as well as on their sense of responsibility and motivation. Influencing the efficiency of the personnel is therefore possible in some areas.

The outer conditions are determined by the geographi-cal position and the accessibility to the needed infrastruc-ture, as well as by weather and climate. In addition the spatial circumstances, which are relevant in above ground and underground applications, pose special demands on the selection and application of the entire drilling system.

Determining the drilling parameters through the Drill-OFF-Test

Being an indicator for performance, the drilling progress is usually measured in centimeters per minute or meters per hour. The calculation of costs of a drilling project are often done on the basis of the assumed drilling perfor-mance and the related time needed for a given length of drilling.

After selection of the appropriate drilling system, the drilling progress can decisively be influenced through ap-propriate adjustments of the influencing parameters. The

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EDUCATION


most important adjustments are related to the load of the drilling tool through drilling bit load and rotary speed, as well as through the hydraulic parameters of the mud sys-tem.

The Drill-Off-Test is used to determine the maximum dril-ling progress, while tuning the drilling bit load and rotary speed of tools. If it becomes known that a longer route of alike or like-drillable mountains is on the drilling agenda, this possibility can be explored.

In order to carry out the Drill-Off-Test, the threshold va-lues of press-on and rotary speed of the used bit need to be known from manufacturer’s data. For a maximum load, a maximum rotary speed has to be chosen.

After that a minimum press-on value, which should be above the threshold value of the mountain for the penet-ration of cutting tools, has to be determined. The basis is usually a 10- or 20- fold of the single-axial compression strength of the mountain. Originating from the maximum rotary speed, 3 to 5 rotary speeds are to be fixed, in in-tervals of 10 to 20 rotations per minute. Based on these basic adjustments, individual tests can be carried out and a working sheet can be completed. The course of the Drill-Off-Test is highlighted in the following:

After a short warm-up time, the bit is loaded with the combi-•nation of the firstly selected rotary speed and the selected maximum press-on.

With a fixed break, the bit load is drilled off in steps of 20 kN. •The time needed for the drilling off of the bit load in each 20 kN is determined in seconds with a stopwatch and regis-tered in a table. The first test series ends, when the minimal drilling bit-load is obtained.

The same procedure is followed with the next-higher rotary •speed.

With the help of the time values of the table, a diagram is •prepared, which contains one graph per rotary speed. The best combination of rotary speed and drilling bit load can be seen at the lowest point of this graph.

One example for a Drill-OFF-Test is shown in the follo-wing section. A roller cone bit with a diameter of 6 inch (152 mm) is applied. Maxim values for drilling bit load and drilling rotary speed are:

120 kN bei 80 rotations/min•

60 kN bei 160 rotations/min•

Based on these values, the span of the drilling bit load was chosen from 100 kN to 68 kN. The rotary speed areas to be examined are 140 rotations per min, 110 rotations per minute and 80 rotary per minute. The results of the three

test series are registered in table 1 and graphically as-sessed in picture 18.

Through the Drill-OFF-Test a maximum drilling progress could be determined for a bait load of approx. 86-90 kN, at a rotary speed of 80 rotations per minutes.

Pic. 18: Drill-Off-Test, graphical analysis

Drilling proof in kN

rotatation speed in Rotation/min

von bis 140 110 80

100 98 15 14 1198 96 14 13 896 94 12 11 794 92 11 10 692 90 10 8 590 88 9 7 488 86 10 7 486 84 12 7 684 82 13 10 782 80 15 12 880 78 16 13 1078 76 18 14 1276 74 19 15 1374 72 20 17 1572 70 21 19 1670 68 21 19 16

Tab. 1: Drill-Off-Test, work-sheet

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Pic. 20:Drilling progress of a diamond bit, in relation to the drilling bit load and

rotary speed [1]

Examples

The achievable drilling progress for a drag bit and a dia-mond bit under certain conditions are presented below as examples:

Picture 19 shows the drilling performance of a drag bit in a rock with a compression strength of around 75 Mpa. With an increasing rotary speed at constant bit load in each case, an exponential array of curves is obtained, which show the maximum drilling progress at the highest point. The dashed line connects the maxima and as such demonstrates a characteristic curve for the optimal appli-cation of the bit.

The drilling progress whi-le applying a diamond bit is presented in picture 20. Through the logarithmic scaling of the coordina-te axis, straight lines result from the constant drilling bit load. For the diamond bit the drilling progress has a linear increase at a constant dril-ling bit load with increasing rotary speed, i.e. the drilling progress is doubled with the doubling of the rotary speed.

Components of a Drilling PlantThe most important components of a drilling plant are

introduced in this chapter. Since the applied technique is highly dependant on the drilling method, for now only ge-neral explanations are possible. In later chapters that deal with detailed introduction of the drilling methods and their application, specific characteristics are further explained.

A drilling plant generally consists of the following main components:

Support frame with energy supply•

Drill truck/tower•

Drilling motor•

Drill string•

Drilling tools•

Mud system •

mud types•

In the following subchapters these components are briefly introduced.

Support frames for drilling plants

The support frames for drilling plants mainly serve the mobility of the entire system. Drills are usually self-pro-pelled, and as such they need to have their own drive unit. Wheel-tired, as well as chain driven carriages with the operating power of almost exclusively diesel engines, are

employed. Drilling plants wit-hout their own drive unit, which are assembled on trailer carria-ges or on sledges, are restric-tedly mobile.

For wheel-tired machines, mostly large-scale produc-tion lorries are used as basic units. Instead of box or dropsi-de chassis, the actual drilling components are installed on the rear. Special designs with wheeled undercarriages are more seldom (see picture 21). Drilling equipment with tires is of advantage for an application in longer routes, as it reaches higher speed and has lower carriage costs. A lorry has the additional advantage of road-going.

While the wheel-tired drilling plant is applied more in geo-technique and in special found-

Pic. 19: Drilling progress of a drag bit, depending on the drilling bit load and rotary speed[1]

Rock with a com-pression strength of approx. 75 MPa

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ation, chain-run carrier vehicles are also applied in the producing industry. The main advantage of the chain-driven vehicles is the higher traction and the lower sensitivity towards mechanical strains. The operating power is provided by diesel mo-tors, but is mostly used by hydraulic components for the vehicle operation. Rubber and steel chains are used. Depending on the area of application and the tool class, the chain vehicles are equipped with an operator’s cab or a radio control.

Pic. 21:wheel tired, driven drilling plants [14], [7]

Pic. 22:Wheel-tired drilling plant without own drive mechanism [7], [13]

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A further distinctive feature of chain-driven drilling plants is the arrangement and flexibility of the drill truck and the tower. The pictures on the left side show drilling equipment, where the drill trucks are closely installed on the support frame, and can only be adjusted in their inclination. In the drilling equipment shown in the right-side pictures, the drill trucks are ins-talled on a flexible arm, so that the lateral inclination can be varied. Furthermore, drill trucks in many drilling appliances, are fold-away for the transport. The reduction of the height and thereby the lowering of the center of gravity, enables the moving of the machines.

Pic. 23:chain-driven, small drilling plants without an operator’s cab [7], [5]

Pic. 24:chain-driven drilling rigs with operator’s cab [15], [9]

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Drill truck / tower

In each drilling process, the directed feeding of the bore rods is needed. Apart form this directed feeding, more or less large forces have to be applied, in order to press the drilling bit with sufficient bit load to the borehole bottom. In return, the drill string has to be pulled again, after reaching the desired drilling depth. This task can be solved in vari-ous ways. Established systems are:

Shafts•

Hydraulic cylinders•

Drag link conveyor chain•

Exceptions are rotary drills, which are used for great drilling depths. In this case the drill string hangs on a hoist system in the tower, and the bit load is generated with the own weight of the bore rods, with the help of specific drill-collars.

Drill string

The composition of the drill string is highly dependant on the drilling method. The components and their arran-gements are therefore dealt with in the technical chapters dealing with the drilling method.

Tasks of the drill string, however, are the same in any •case:

Transfer of the drilling energy to the bit•

Carrier of the drilling tool•

Creating a connection between the surface and the •bore hole bottom for the assembly and dismantling of the drilling tool

Separation of the fresh drilling mud to the drilling tool •and the bore hole bottom to the surface

Support to the bore hole wall•

•

Drilling tools/drilling bit

The drilling tools and their selection criteria with rela-tion to their rock-destructing effects were already briefly discussed in chapter 0. The current chapter will go into details of various bit types.

Generally, the following bit types are used:

Rotary Drilling:Drag bit1. Roller bit2. PDC-bit3. Diamond bit4. (Rotational) hammering drilling5. Core bits for top hammer6. Core bits for down-the-hole-hammer7.

1. Drag bitFIn purely rotational drilling, drag bits are used for soft rocks. The ring-shaped base body can be equipped with 2 to 4 blades. The number of blades increases with the hard-ness of the rock.Based on the drillability of the rock and the bore hole dia-meter, the drag bits are designed as so-called staged bits. This means that they do not have a continuous blade, but each wing is set with several single blades, which are ar-ranged in a cascade. In addition, the cutting elements can be equipped with hard metal in form of welded-on layers or embedded platelets, to increase the running life with abra-sive material. Exceptions are bits, which are characterized by waved wings and are inserted into clay.

2. Roller bitRoller drilling bits are offered in numerous varieties. They are differentiated by their construction characteristics:

Diameter of the bit•

Type of the cutting elements•

Tooth depth, tooth angle, tooth form, tooth distance •and number of teeth in row

Type of the wear-protection of the tooth:•

Arrangement and form of the teeth/nipples•

Measures for the caliber accuracy•

Arrangement of the mud flow•

Size of the journal angle•

Size of the off-set•

Type of bearing, bearing seal and lubrication•

Pic. 25: Drag bit [7], [11]

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Generally three-roller bits are applied. The basic com-position of a Roller bit is portrayed in picture 26.

Due to their comparatively complex mechanism, roller bits are only available from a diameter of above approx. 100 mm.

The biggest diameters reach several meters, however these bits vary considerably from the three-roller bits in terms of number and arrangement of rolls on the bit base body, as well as in terms of the drilling method, the air lift method.

Beside the diameter, the type of the cutting tool is a fundamental differentiating factor. Milled tooth bits have milled rolls, whose teeth are furnished with a hard-metal

plating. This bit type is more used with soft rocks. Insert tooth bits are characterized through the fact, that the cut-ting tools are embedded into the roll base body as bolts (nipples). The insert tooth chisels are applied with hard rocks. Both bit types are portrayed in picture 28.

The more difficult the drilling of a rock is, the shorter the selected teeth have to be. In rocks of a compression strength of approximately 120 MPa and above, only roller bits can be applied.

Further structural differences arise from the geometric arrangement of the rolls on the base body. The rolling cha-racteristics of the bit are determined by the journal ang-le and the offset of the roller axes, thereby achieving an adjustment to the rock to be drilled. A big bearing angle, in connection with a low off-set leads to a rolling motion, in which the cones demolish the hard rock in a pressing-crushing way. In the geometrically reverse case, the teeth work in soft rock in a digging-chipping way (picture 29).

The main field of application of the roller bit is deep dril-ling technology and the well sinking. Here they are exclusi-vely applied in connection with fluid rinsing media, which,

Pic. 26: construction of a roller bit [1]

Pic. 27: Roller bit with high diameter [16]

Pic. 28: Roller bits [16]

Pic. 29: Bearing axis displacement in a roller bit [1]

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among others, ensure a good cleaning of the bore hole, while at the same time ensuring good cooling of the bit.

A further field of application are large caliber blast hole drillings in deposits with a diameter of up to 400 mm, where the compressed air is applied as a flushing medium. The cooling of the bit and the transporting of the drilling cut-tings can be regulated by the speed of the entrained air in the annulus collector. The maximum mud speed is limited by the erosive effects of the drilling fluid, which is loaded with drilling cuttings, bit and rods. Therefore, in practice, the flow rate and volume compression of the compressors is adjusted in a way, that the rate of ascent reaches 30 to 40 m/s.

3. PDC-bitPDC is an abbreviation of „polycrystalline diamond

compact“ and therefore describes a bit, which is equipped with polycrystalline diamonds as cutting elements.

The surface of PDC-bits is covered with blades that are occupied with a layer of synthetic diamonds. A diamond layer with a thickness of 0.5 mm is located on a hard me-tal plate (tungsten carbide) of about 2.5 mm strength. The diameter of the cutting element is around 10 mm to 25 mm. This unit is captured on a fit bolt, which is fastened in the base body of the bit.

A special design of the PDC-bit are the TSP-bits, who-se cutting elements consist of artificial diamonds, that are formed as cuboids and prisms. TSP is the abbreviation for „thermally stable polycrystalline“.

PDC-bits loosen rocks with a chipping effect, and are therefore applied in softer rocks. Together with the drill

motor, most of the PDC-boring meters are sunk in homoge-neous, non-abrasive rocks like lime-stone, salt, anhydrite and areas of the range of mottled sandstones.

Aside from the full face bit, coring bits are also designed as PDC-bits.

4. Diamond core bitsDiamond core bits are produced in two versions:

Surface-set diamond core bits•

Impregnated diamond core bits•

In surface-set diamond bits, the diamonds are arran-ged on the front and lateral surface, in a matrix, following a certain pattern. They are called SS – surface set. The wear-off of the diamonds always leads to a sharp cutting edge, until the time that they do not protrude the base body of the bit. Diamonds with a grain size of 4 to 100 stones/carat are used.

Pic. 30:PDC-cutting elements [18]

Pic. 31:Application of PDC [17]

Pic. 33: PDC-full face bit [10]

Pic. 34: Core bits with TSP-applications and PDC applications [18]

Pic. 32:TSP-cutting elements [18]

Pic. 35: Surface-set diamond bits [16]

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Diamond- full face bits were developed for an applica-tion in the deep drilling technology. In comparison with the operating conditions in mining, particularly because of the lower depth of the drillings, drilling tools have to ful-fill different requirements. Table 2 shows the differences between the used diamonds and their geometric general conditions.

Impregnated diamond bits are characterized by a matrix, in which the fine-grained diamond slivers are sintered up to a certain depth. The diamonds and the hard metal matrix wear off during drilling. In this process single embedded diamonds fall out of the matrix and new ones are exposed. Therefore, in order to achieve an optimal application, the targeted wear-off of the matrix has to be aligned with the rock which is to be drilled. In case the matrix is too soft, it is destroyed too quickly and the diamonds fall off, before they are worn out. If a matrix is too hard, the exposure of new diamonds is prevented and the drilling progress reduced. Diamonds used have small grain sizes of 100 - 500 stones/carat, in extreme cases even up to 1000 stones/carat.

The fields of application of the two types of diamond bits vary and are described in the following:

Surface-set diamond bitsThese are used in almost similar rocks which are mo-

nolithical, with little cracks, and are used in soft, medium hard and hard rocks.

Argillites, lime stones, marble, dolomite, sandstone •and lime sand brick

Metamorphic and crystalline rocks like siderite, gab-•bro, basalt, porphyry, granite, gneiss or pegmatite.

Impregnated diamond bits:These are used in poorly drillable rocks.

Conglomerates, coarse-grained conglomeratic •sandstones

Hard fractional, fragmented rocks•

Very hard, abrasive rocks•

e.g. monolithical ferrousquartzite•

Decision criteria for the selection of bits

The selection of an appropriate bit depends on many ba-sic conditions. Usually the aim is to select the most cost-effective tool.

Based on the combination of the process- and the tool data and the expected performance of the bit, a pre-selec-tion can be done. Afterwards, in connection with the eco-nomical data, the most cost-effective bit can be selected (Picture 38).

Mud systems and types

Since the mud systems and types differ considerably in various drilling methods, this aspect is dealt with in detail in later chapters. Following is a description of the classical hydraulic mud system of a rotary drilling plant as an intro-

Pic. 36: Geometry of the applied diamonds [16]

a = Diameter of grains

s = depth of penetration = 1/30 a

b = pressing surface = 10 s

Bonding = 2/3 a

Exposure = 1/3 a

Diamond Crude oil coal mining

Diameter D [mm] 2 - 5 1 - 2Stone per carat [st/ct] 15 - 1 100 - 15

Depth of embedding E [mm] 1,3 - 1,83,3 - 4,4

0,67 - 0,881,3 - 0,67

Exposure e [mm] 0,25 - 0,670,67 - 1,7

0,13 - 0,330,25 - 0,67

Depth of penetration p [mm] 0,025 0,025Contact-area F [mm] 0,16 - 0,40 0,08 - 0,16Pressure per Stone P [kg] 3 - 6 2 - 4

Tab. 2: Comparison of application areas for surface-set diamond bits

Pic. 37:Diamonds in the matrix of an impregnated diamond bit [10]

Pic. 38: Flowchart for the selection of bit [1]

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duction.One or several horizontal, double-acting duplex- piston

pumps, or single-acting Triplex-piston pumps (2) draw in the mud from a container (1) and pump it first into a con-nection system (3, 4, 5) and then through the hollow drill string (6, 7, 8) to the drilling tool (9).

The mud enters the open bore hole at the bit (9) and rises upwards in the annular space between the drill string and the bore hole wall. Above ground the mud is done through

the drilling

Cooling and lubrication of the work items, •which heavily heat up as a result of the me-chanical work at the bore hole bottom

Reinforcing the unstable rocks at the bore •hole wall

Isolating the horizons to be drilled through, •through creation of a protection layer

Keeping the drillings in balance, in case of •the interruption of the mud circulation

Generating a counter pressure against the •intrusion of gas, oil water or similar deposit contents from the drilled through formations

Transfer of the hydraulic energy to the ore •hole bottom, in order to operate the motors of the bore hole bottom or as hydraulic ener-gy for the cleaning of the bore hole bottom

In order to tackle these tasks, a high number of various mud types are used, which range from ga-seous, over water and oil-basic muds, up to muds with diverse additives.A main criterion for charac-terizing mud is its density, since this influences the bore hole stability through the created hydro-static pressure in the bore hole. A higher weight is usually reached through the addition of barium sulphate.

One other important and often used additive is bentonite, which undertakes various tasks. Ben-tonites are clays, which are swellable due to their high content of Montmorillonite, and as such they generate thixotrope gels. This suspension stabili-zing effect happens, when the circulation is stop-ped, for example in the case that the bore rods are fed or expanded. The drilling fluid coagulates and the solids in the fluid are kept in balance. Through the prevention of sedimentation, the stucking of the bore rod is counteracted. At the same time a so-called mud cake is generated at the bore hole wall, which prevents the influx of ground water

into the bore hole, as well as preventing loss of water from the mud into the mountain. Furthermore bentonite has fric-tion reducing characteristics.

The following table 3 shows a selection of different mud

types, based on a density scale.

Pic. 39: Rotary flush drill [1]

a cleaning system for solids, consisting of sieves (12), Cy-clones and centrifuges, so that they are redirected to the vacuum container as solid-free as possible.

Based on the type of the bedrock to be drilled and on the applied drill method, as well on the goal of the drilling, the following tasks have to be tackled:

Removal of all drilling particles produced by the bit •from the bore hole bottom

Discharge of drillings through the annular space of •

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Literature[1] WIRTH Maschinen- und Bohrgeräte – Fabrik GmbH: Bohtechni-

sches Handbuch, Ausgabe 2002.[2] Arnold, Werner: Flachbohrtechnik Deutscher Verlag für Grund-

stoffindustrie, 1993.[3] DIN Taschenbuch 272:Bohrtechnik, Beuth Verlag, 1999.[4] Sandvik Tamrock Corp.: Rock Excavation Handbook, Sandvik

Tamrock Corp., 1999.[5] Sandvik BPI: Firmeninformation.[6] Ernst-Georg Fengler: Grundlagen der Horizontalbohrtechnik,

Schriftenreihe aus dem Institut für Rohrleitungsbau an der Fach-hochschule Oldenburg, Band Nr. 13, Vulkan-Verlag, 1998.

[7] Nordmeyer GmbH & Co. KG: www.nordmeyer.de[8] WIRTH Maschinen- und Bohrgeräte – Fabrik GmbH:

www.wirth-europe.de[9] Atlas Copco MCT GmbH: www.atlascopco.com[10] Schlumberger Limited: www.slb.com[11] Palmer Industries Inc.: www.palmerbit.com[12] Caterpillar Inc.: Caterpillar Performance Handbook, Edition 33,

2002.[13] Diedrich Drill Inc.: www.diedrichdrill.com[14] BAT Bohr- und Anlagentechnik GmbH: Firmeninformation.[15] Harnischfeger Corporation, P&H Mining Equipment:

www.phmining.com[16] Institut für Bergbau, TU Clausthal: Bilderdatenbank.[17] Sandia National Laboratories: www.sandia.gov[18] Dimatec Inc.: www.dimatec.com[19] Ernst-Ulrich Reuther: Einführung in den Bergbau, Verlag Glückauf

GmbH, 1982

Mud density in kg/l Spülungsart Type of mud

0 bis 0,83

LuftSpülnebel

Airflush fog

Stabiler Schaum Stable foamSchaum unter DruckBelüftete Spülung

Foam under pressureVentilated mud

0,83 bis 1,0 Ölspülung Oil mud

1,0 bis 1,2KlarwasserspülungBetonitspülungGelförmige Wasserspülung

Mud with clear waterMud with benotiteGelatinous water-mud

1,2 Salzwasserspülung Saltwater mud1,2 bis 1,25 Wasserspülung mit Naturton Water-mud with natural clayab 1,33 Beginn der beschwerten Spülungen Start of the weighted mudca. 1,44 Gesättigte CaCl2-Spülung Saturated CaCl2-mud1,44 bis 2,4 Beschwerte Spülung (Schwerspat) Weighted mud (barium sulfate)

Tab. 3: Mud types, Classification based on density after [1]

Univ.-Prof. Dr.-Ing. habil. Hossein H. Tudeshki studied from 1977 to 1980 at the Mining Col-lege of Shahrud (Iran); following several years of work in the mining industry, he completed his mining study at the RWTH Aachen in 1989. Since 1992 he was Chief Engineer at the Insti-tute for Surface Mining (Bergbaukunde III) of the RWTH Aachen, mainly active in the field of open cast mining and drilling technique. He did his doctor degree in 1993 and qualified as a university lecture in 1997. In 1998 the Venia Legendi was awarded to him be the RWTH Aachen for the field “Rock and Earth Open Pit Mining”. In Novem-ber 2001 he was appointed as Professor for Surface Mining and International Mining at Clausthal University of Technology.

[email protected] | [email protected] www.bergbau.tu-clausthal.de

http://www.bergbau.tu-clausthal.de

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Traces of the sand:In each grain of sand is a piece of Earth. Its diversity is reflec-ted for example in the myriad of architectural applications. Today sand is one of the main raw material ever.

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Blastings in a German City –Experiences, Optimization and Emission Protection for example the Rheinkalk Corporation

For over 100 years, limestone has been mined in quarries in the Limeworks Dornap of the Rheinkalk Corporation. The quarries are separated by railroads and roads, and are surrounded by housing construction. Every yearl, approximately 1.5 million tons of limestone are mined through drilling

and blasting. The observance of immission protection guidelines is of highest priority for the location. In this article, measures that allow for secure and acceptable blasting and are in accordance with the rules, are being introduced. Hereby the goal is an agreeable cooperation between quarry and neigh-borhood.

IntroductionThe Rheinkalk Corporation operates limestone

quarries and lime works in ten locations in Germa-ny, with its domicile in Wuelfrath. The cooperation belongs to the Belgian Lhoist Group, the biggest global lime producer.

Besides Wuelfrath, the lime work Dornap in Wuppertal is the other of the two establishments of the group. The mining of limestone and the produc-tion of lime in the NIEDERBERGISCH ES KALKRE-VIER both have a very long tradition, which can be traced back to the late middle ages.

Since the year 1887, limestone has been indus-trially mined and burned to lime in Dornap. This lime was economically freighted to the steelworks at the Ruhr by railroad. Due to these favourable factors, i.e. deposit, railroad and manpower, this important lime location emerged in the surround-ings of Wuppertal.

The plant Dornap is located at the western border of the city of Wuppertal, directly at the border of the Mettman district. The firing operation was shut down and relocated to the Flandersbach factory in the year 1999. Since then only unfired grainings are produced in the Dornap factory, and the proportion of grainings, which is chemically fireab-le, is transported to Flandersbach with lorries, in order to continue to optimally use the high-value deposit.

The raw material base of the Dornap factory is the Gru-iten-Dornap reef limestone, that is explored in four quarri-es, because of the houses and traffic lines. The quarries are connected by tunnels. The location is characterized by a high density of traffic routes and a dense housing const-ruction, which sometimes are directly bordering the quar-ries (picture 1).

by Dipl.-Ing. Uwe StichlingDepartment of Environmental Protection and Approvals | Rheinkalkwerk Corporation Wülfrath | Germany

Today only the Hahnefurth and Vossbeck quarries are in operation. The central primary crusher is still located in Hanielsfeld quarry, and the former quarry Schickenberg serves as sedimentation tank for the stone tailings and classification. The Vossbeck quarry has been transitionally used as sedimentation tank since the end of the 1960ies, and has not been mined for approximately 20 years.

However, in the Hahnenfurth and Vossbeck quarries, considerable limestone deposits are present, and further lateral and vertical expansions of the Hahnenfurth quarry to the south are planned. Currently extraction is only done in Vossbeck quarry, since work in the Hahnenfurth quar-ry is suspended because of the planned expansion. The available central Devonian limestone is extracted in the classical way with drilling and blasting. Bore hole drillings,

Pic. 1: Areal picture

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as well as large diameter borehole blastings are carried out. (picture 2).

The tests for an explosive-free mining have shown that loosening by cracking by a hydraulic excavator or with a hydraulic hammer cannot be carried out economic-ally. The yearly amount produced is appro-ximately 1.5 million tH. Work is done six days a week, whereas no blastings are done on Saturdays. On other days at least one blas-ting is carried out. The comparatively small blastings of an average of 5 to 10,000 tons are done because of the qualitative de-mands from the rock pile and the proximity to housing construction. The rock piles are loaded with wheel excavators with a bu-cket size of 6 to 7 m³, and are transported with 50-t trucks to the central primary crus-her in the former Hanielsfeld quarry

.

Local Conditions for Blastings

The general conditions of blastings in the Dornap site are pretty bad. The location is characterized by a number of factors, which impede blas-tings, making them impossible at times.

The Vossbeck quarry is surrounded by housing const-ruction from three sides. The country road L 74 takes cour-se west of the quarry, the federal road takes course south. The distance of the permitted quarry border to the nearest housing construction sometimes is only 100 m airline dis-tance (Pic. 3).

In December 1996, the Vossbeck quarry was approved by the Duesseldorf local government, which was in char-ge at that time. In that document the lateral excavation border and the maximum excavation depth of +60 sea level were specified. From approximately +145 sea level there is a need to go below the ground water level in this location and to sumps the quarry.

Due to the high proximity to housing construction, a ground motion forecast was done at that time.(1) In that forecast limits for loading were established based on ex-pert opinion, which initially stood at a maximum of 48 kg/ stage of ignition time. This limitation lead to a forecast of ground motion values, which did not exceed the DIN 4150 reference value (5). In that forecast a conventional ignition with electrical time fuses of 20 ms was assumed, where-by a classification of the column load through temporary edgingand different ignition times was already foreseen. Borehole blastings, as well as large-diameter boreholes

were anticipated. Loose ANC- explosives, PATRONIERT, gelatinous explosives, and - if needed- a detonating cord were used. Due to the comparatively small loadings, a merge vehicle was not applied (Picture 4).

Pic. 2: Mining in Vossbeck quarry

Pic. 3: Aerial photograph of the Vossbeck quarry

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The authorization included a condition to continuously monitor the blastings at selected locations of immission. Therefore seven permanent measu-ring stations were established and are since in operation. A permanent measuring station consists of a ca-librated measuring apparatus for commotions, which registers the in-coming oscillations and the respec-tive frequencies at the foundations and in all three directions.

In addition, the measurement re-sults are verified through a measu-ring point according to § 26 Bim-SchG. Thereby measurements are conforming to standards, both in the foundation, as well as is the first full storey.

Resumption of BlastingsIn 1976 the deferred Vossbeck quarry was put into ope-

ration again with these parameters regarding blasting. Frequent complaints about ground motions were received; however, they did not jeopardize the operation of the quar-ry. Unfortunately in October 2004 a blasting accident oc-curred, in which rocks were catapulted over a distance of 700 m into a settlement. This fortunately only lead to dama-ge of property, and no person was injured. Consecutively the Vossbeck quarry was shut down by a public authority for three months. Despite consultation with several tech-

nical experts it was not possible to completely clarify the reason for the blasting accident.

Today it is assumed that unnoticed residues of explo-sives from a previous blasting lead to an overcharge and as such to the catapulting of the rocks. One fact suppor-ting this assumption is that the blasting was intended to blast old quarry walls and merge them into a new wall. Blasting mistakes or human failure could not be verified (Picture 5).

The resuming of work in the Vossbeck quarry was bound to additional, tightened requirements – like set standards for the proportion of lateral distance, a detailed wall-expo-sure, a detailed documentation of blasting arrangements, a temporary ban of large diameter borehole blastings, and most of all a ban to use loose ANC- explosives. How-ever, the ban on loose ANC explosives could be eased in the sense that ANC explosives could be inserted into a plastic hose in the borehole. The plastic hose prohibits an

uncontrolled run off of the loose explosive in possibly available clefts, which could lead to a dangerous accumu-lation of explosives in the mountains (Picture 6)

Since then the ANC explosive is only applied in plastic hoses, therefore the application of explosives is a big pro-blem. A complicating factor is the fact that the excavation is done under the +145 bed in ground water, and therefore the drill holes are full of water. One blasting optimization has led to the fact, that ignition is done alternately non-

Pic. 4: Filling of a blasting site in Vossbeck quarry

Pic. 5: blasting accident

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electric or electronic. Furthermore the load per ignition time stage needs to be reduced in case blastings get ne-arer to housing construction. Blasting plants with loads of less than 10 kg per ignition time stage were dismissed, and the blasting result was poor, as expected (Pic. 7).

Optimization with regard to blasting: Considering the above conditions, it is obvious that an economic mining is impossible. Therefore several attempts have been made to optimize the process, in collaboration with an expert for ground motion, Dipl.-Ing. Josef Hell-mann, as well as with the supplier of explosives and electric match. The goal of all optimizations was an economical blasting with maximum blasting results, while adhering to immision control and legal require-ments.

A further requirement, which was added later, was the compliance with approximately 60% of the refe-rence value from the table of DIN 4150, part 3 (5). This table states the allowable reference values for vari-ous building types at the foundation and in the upper full storey.

The transfer factor between foundation and the highest floor level could be empirically determined at around 3 to 5 from many measurements in Dornap and Falndersbach

(1,3). Otherwise keeping the threshold value for the highest floor level cannot be assured (Table 1).

In table 2, measures and blasting parameters that have been changed (optimized), are presented. Not all measu-res have shown a noticeable and definite effect. A drastic reduction of commotions could not be observed. However, certain stabilization in adherence to the standard value of 2.0 to 3.0 mm/s was seen.

The relatively high ground water table, which also is across the strike – which means to the north and to the south – and which steeply ascends to its unaffected level, has a highly negative influence, since it very well relays the commotions.

Monitoring of Commotions and Management of Complaints

The surrounding population was already highly sensi-tized before the blasting accident, since due to the 20-year break in operation emissions from blastings were virtually unknown. Compared to the conditions in Wuppertal, the Ki-cherfeld settlement can be called a particularly quiet living area. Aggravating circumstances are that, due to the natu-

Pic. 6: Application of ANC explosives in plastic hoses

Pic. 7: Blasting result at low load

Tab. 1: Maximally allowed commotion values in buildings

Line Type of Building

Reference values for the oscillation speed vi [mm/s]

FoundationFrequency

Highest floor level, horizontal

1 to 10 Hz 10 to 50 Hz

50 to 100 Hz*

all frequencies

1Commercially used, industrial and other similar buildings

20 20 bis 40 40 bis 50 40

2Residential and other similar buildings

5 5 bis 15 15 bis 20 15

3

Buildings, which are particu-larly sensitive to commotions or for example are under monument protection and do not fall under line 1 and 2

3 3 bis 8 8 bis 10 8

* In frequencies of more than 100 Hz, minimum reference values of 100 Hz can be used

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ral fluctuation, the former worker’s village has turned into a normal residential district , which is not highly connected to the location (picture 8).

The sensitized general public lead to the establishment of a comprehensive commotion monitoring and a system for management of complaints. Both measures aim at de-termining robust data over a long period, in order to use this basis to arrive to an expert opinion, which is court-proof. Furthermore data lead to transparency and to a cer-tain extent to trust. After all both measures lead to self-monitoring, with the aim of running an operation, which observes collateral clauses and is compliant with the ob-tained authorizations.

Before resuming the blastings in the Vossbeck quarry, initially an area-wide registration of the situation of buil-dings was done in all buildings which were potentially af-fected by the commotions. Thereby the current status of

the building was captured in an inspection and documen-ted in a report. Both the owner and the ordering party re-ceived a copy of the report. In case of damage, the report can be used as a basis for further assessment of the buil-ding, and if need be, it can be used as evidence in a court. Altogether around 100 buildings were captured. Since the conduct of this exercise, several records of buildings have been made. No causal damage could be ascertained up to now, and claims could successfully be averted.

A further essential point is an adequate network of com-motion measuring stations. In selected buildings, commo-tion measuring stations which are according to standards were set up permanently for continuous measurement. The analysis is usually done on a monthly basis, but it is coordinated with the owner. A remote transmission with a modem, which is not very expensive and quite helpful at sensitive points, is also possible. With this, the blasting-beneficiary is in a position to retrieve the result immedia-tely after a blasting, which can be taken into consideration during planning of the next blasting site.

Picture 9 shows such a commotion measuring instru-ment, which nowadays is used in Rheinkalk Company by default.

Despite these measures, the complaints about commo-tions or the blasting noise are very frequent. The emissions are carefully observed by the population, and any peculia-rity is immediately relayed to the regulating authority.

It is obvious that these complaints need to be dealt with. Since the beginning of 2008, Rheinkalk has integrated com-plaint management into the existing QM-system, which is to a large extent formalized and automatized. The affec-ted circle of people, the plant manager, master craftsman, blasting-beneficiary, and the appointee for immission pro-tection are automatically informed about complaints ente-red into the system and requested to take action.

Based on our experience the affected persons, as well as the persons complaining are relatively constant and straightforward. Even in case of citizen’s initiatives, the number of contact persons to be dealt with is low. A con-stant contact with these people is extremely important. However, it should be noted that personal human relations are very time consuming and require high personal dedi-cation.Pic. 8:

Residential settlement Wuppertal-Kirchenfeld

Pic. 9: Commotion measuring instrument of ZEB

Tab. 2: Scope of Optimization

Arrangements/Optimization actual situation

Various height of wall between 10 and 20 m 15 m

Standards between 3,5 and 4,5 m 3,5 m

Lateral distance between 2,5 and 4,0 m 3,0 m

1- to 4-row blastings 2-Reihen

Graining of the final edging 5 - 22 mm

Height of the temporary edging between 1, 5 and 2,5 m 1,5 m

Bore hole diameter from 95 to 115 mm 105 - 115 mm

Primary ignition upper and lower cloumn load upper

Load per ignition time stage from 10 to 50 kg approx 35 kg

Number of ignition time stages in the borehole from 1 to 3 maximal 2

Delay from borehole to borehole 24 ms

Delay 2. Row of boreholes 16 ms

Delay in borehole 24 ms

Application of different explosives X

Blasting signals with fixed signal-horn X

Conduct of open councils X

Regular dialogue with the residents X

Exact determination of location of the blastings X

Documentation of the blasting plants X

Remote inquiry measuring station X

30Issue 02 | 2009



of electric match and explosives, as well as a competent blasting expert, since the establishment is not in a posi-tion to deal with this task, neither technically, nor human resource-wise.

Literature

Rheinkalk GmbH, Wülfrath. Interne Unterlagen1. Orica Germany GmbH, Dortmund.f2. Dipl.-Ing. Josef Hellmann, Dortmund.3. Westspreng GmbH, Finnentrop-Fretter.4. Deutsches Institut für Normung: DIN 4150 - Erschütterung im 5. Bauwesen, Teil 1 bis 3. Berlin: Beuth Verlag, 1999.

Experience from Almost Ten Years of Blastings

It is almost 10 years now that limestone is being mined through drilling and blasting in Vossbeck quarry. During this time, extensive organizational, informative and blas-ting optimations were implemented.

The following experiences can be recorded:

An individual choice of the delay interval to the extent pos-•sible verifiably causes a reduction of the blasting emission and a better blasting result (rock pile).

In the case of a divided column load it cannot be clearly veri-•fied, which initiation (from above or below) has an influence on the blasting emission. However it should be noted that the initiation away from the housing construction reduces com-motions related to the blastings.

The proximity to the ground water is clearly a very negative •factor and causes considerable and far transmissions. An ef-fective and preparatory dewatering of mountains leads to a significant improvement.

A registration of the status of buildings that is done in advan-•ce, leads to trust and legal security, and unjustified claims can be lawfully rejected.

A representative registration of the blasting commotions, ac-•cording to norms, is essential to prove an operation, which is according to authorizations.

A structured registration and processing of complaints from •inhabitants leads to objectivity, transparency and trust, in line with a continuous improvement.

ConclusionThe conduct of blastings is not easy, particularly in a

German city, and the acceptance threshold of the inhabi-tants lowers day by day. The conduct of blastings and their optimization in the Vossbeck quarry by Rheinkalk company has shown that such blastings are still possible, despite difficult surrounding conditions.

However, these measures can only be economically conducted with constant and highest technical efforts and know-how, as well as with continuous training of the staff involved in the blasting. In certain frameworks it is essen-tial to take accompanying measures, such as monitoring of buildings and commotions. In such optimization proces-ses it is also essential to have the support of the suppliers

Dipl.-Ing. Uwe [email protected] | www.rheinkalk.de

http://www.rheinkalk.de

31Issue 02 | 2009



ContiTech Conveyor Belt Group | Phone +49 5551 [email protected]

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32Issue 02 | 2009



Application of vertical drilling systems with automatic control, in drilling projects with the highest demands on accuracy

Due to the increasing depths in exploration and site development of deposits in international mi-ning , automatic directional drilling systems are being applied more often. This article introduces two completed projects, in which the function and operation of these systems is explained.

With increasing depths, the exploration and site deve-lopment of deposits in the international mining requires the increased application of reliably working automatic-cont-rol directional drilling systems. Hereby, the fields of appli-cation of these systems span the entire spectrum of the drilling technique in mining – from freezing borehole, over vents, up to pilot drillings for Raise Boring. In the following section two completed projects are introduced, in which the function and handling of these systems , which define the state of the technology, is explained:

Drilling of freezing boreholes with a diameter of 8 ½ up t ao •final depth of 650 m, in a given target window with a diameter of 0.3 m for a shaft sinking project in Poland.

Drilling of a pilot hole with a diameter of 13 ¾“ up to a depth •of 865 m in a given target window with a diameter of 0.3 m for a following raise drilling in the Canadian gold mining.

These self-controlled systems stand out from the con-ventional directional drilling technique, due to the possib-le combinations of these systems – originally developed for specific applications- with the diverse available bore strings and plants in the highly varying geology in the dif-ferent areas of mining, at a consistent and reliable mode of operation.

Setup and functioning of theMICON -RVDS

In a drill string the so-called Rotary Vertical Drilling Sys-tem (RVDS) is installed directly behind the roller bit. The MICON-RVDS consists of two 1.5 m long components (Pic-ture 1).

by Dipl.-Ing. Kai SchwarzburgManaging Director of MICON Drilling GmbH | Nienhagen | Germany

The lower component carries the steering ribs, as well as the control logic and the electronic measuring equip-ment on a cover, which does not rotate. The power sup-plies, data transfer and the hydraulic tank are located in the upper component.

During the drilling, the existing inclination value is conti-nuously measured and compared with the required values. In case the measured values deviate from the required va-lues, i.e. in case the tool deviates from the plumb line, the steering ribs are activated and counteract the build-up of the inclination. The ongoing measured inclination values are transformed into signals and communicated from the lower component to the upper component, in order to transfer the values above ground. At the same time the data are internally stored, along with other relevant data like rinse flow, bore hole temperature and steering status.

Incoming signals are transferred from the upper compo-nent with the help of the so-called positive-pulse-technolo-gy to surface. Furthermore, the upper component contains a turbine and a hydraulic tank. The turbine is powered by the rinse flow and is connected to an electric generator and the hydraulic pumps. The running turbine produces both the needed electrical energy for the internal power supply, as well as the hydraulic pressure for operation of the steering ribs. In the hydraulic tank the hydraulic oil is

Pic. 1: Sectional view of the MICON-RVDS

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stored, to make up for smaller leakages.Based on the intended use, the RVDS is either delivered

in separate components or is completely assembled – for the application in raise-bore-machines it is typically as-sembled in 1.5 m long components, for the application in rotary drilling plants it is generally completely assembled over a length of 3 m. Matched according to the drilling dia-meters, various RVDS are applied.

The common RVDS diameters are:

7 ¾“,•

10“ and•

12 • 7/8“

With matching steering ribs in drilling diameters. Establis-hed drilling diameters are:

8 ½“,•

9 ½“,•

12 ¼“,•

13 ¾“,•

15“ and•

17 ½“.•

The systems are adapted for deviating diameters.

Fields of ApplicationThe RVDS are almost exclusively applied in

areas, where highest demands are made on ac-curacy, with regard to course of drilling and target window.

The drilling diameter of 8 ½ , for example, is an established diameter for freezing bore holes. Here a small target window is to be met with a concur-rently straight course of the drilling, from the star-ting point of the boring site to the final depth.

The drilling diameters of 12 ¼“, 13 ¾“ and 15“ are common diameters in raise boring. Here again the requirements are the same as with freezing bore holes., i.e. a drill course that is as straight as possible, from starting point to the final depth in a small target window. Irrespective of the drilling diameter, the achievable accuracy with the RVDS with regard to drilling length lie in ranges of one tenth of percent – in the past 15 years of applicati-on, average accuracies of 0.25 m in a length of 500 m have been achieved (Table 1).

Further application areas to be mentioned are gas tank drillings, as well as gas venting drillings and drillings for supply lines in mining. The drilling

RVDS Drilled distance by continent Average deviation

7 ¾” (8 ½” – 9 7/8” holes) 18,739 m Europe 0.05 %- Asia -- Australia -- Africa -- North America -- South America -

Total 18,739 m Worldwide 0.05 %

9 ½“ (12 ¼“ – 13 ¾“ holes) 7,948 m Europe 0.13 %3,879 m Asia 0.23 %1,738 m Australia 0.08 %753 m Africa 0.23 %

1,010 m North America 0.10 %- South America -


10“ (12 ¼“ – 13 ¾ holes) 1,290 m Europe 0.04 %1,104 m Asia 0.04%573 m Australia 0.10 %

- Africa -835 m North America 0.08 %

- South America -Total 3,802 m Worldwide 0.06 %

12 7/8“ (15“ – 17 ½“ holes) 3,056 m Europe 0.05 %- Asia -

3,315 m Australia 0.07 %3,818 m Africa 0.06 %2,062 m North America 0.21 %1,399 m South America 0.34 %


Total all RVDS-Sizes 53,460 m Worldwide 0.09 %

diameters in these applications deviate from the above-mentioned diameters by 16“ and 17 ½“, respectively.

RVDS Application in freezing boreholes in Lagoszow, Poland

In order to sink a hauling shaft in Lagoszow, Poland, it was necessary to first stabilize the mountain through free-zing boreholes (picture 2). For this reason a total of 36 dril-lings were done with the 7 ¾“ x 8 ½“-RVDS, alternately in 430 and 650 m.

Up to a depth of 430 m, the Bottom Hole Assembly (BHA) consisted of an IADC 1-1-7 and 1-1-8 roller bit, respectively, the 7 ¾“ x 8 ½“-RVDS, an undersized stabilizer behind the RVDS, 6 ½“-drill collars and 5“-API bore rods.

Tab. 1: RVDS-field results from 1993 to 2008 (153 projects

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Due to the fact that the rock was harder from a depth of 430 m up to the final depth, the deeper drillings were done with a IADC 4-3-7 roller bit, but with the same BHA. In ad-dition, three surveillance drillings were done in a depth of 650 and 850 m, outside of the actual freezing circle (picture 3)

.

Pic. 2: Arrangement of the freezing boreholes in Lagoszow, Poland, comparing drilling results of conventional methods with RVDS application

Pic. 3: Picture of the RVDS on rigfloor

During the entire project two parallel drilling plants were used. An average gross drilling progress of 3.6m/h was achieved over the period of the project. The net dril-ling progress was higher as the gross drilling progress by a factor of approx. 2. Altogether 18,000 m of freezing boreho-les and 2,100 m of surveillance drillings were done. All drillings ran through the entire drilling length within a “target cy-linder”, with a diameter of 0.3 m. inclusi-ve of the drilling diameter of 0.2 (picture 4).

RDVS- Application in a pilot drilling for subsequent raise boring in Rouyn,Canada

A 13 ¾“-Pilot hole was drilled in the Canadian Rouyn, for the consecutive raising of an air shaft. The drilling was done with a final depth of 865 m in a target window of 0.3 m. The BHA from beginning to final depth consisted of a IADC 5-1-7 roller bit, the 10“ x 13 ¾“-RVDS, a hole opener behind the RVDS, three 12 7/8“ x 10 ½“ DI 22 Raise Bore Rods, an undersized stabilizer and consecutive 12 7/8“ x 10 ½“ DI 22 Raise Bore Rods (Picture 5).

No deviation (dogleg) could be measured over the en-tire drilling length, i.e. the straight drilling could be used without restrictions for the RAISE in the planned diameter of 4.5m. The usual drilling progress of 1.5 m/h in raise bo-ring was not exceeded at any time, the RVDS was changed when the worn out bit was changed; for this, altogether two roundtrips were necessary on a drilling length of 865 m (Picture 6).

Pic. 5: Installation of RVDS in RBM Robbins 85 R

Pic. 4: View of the drilling plants in Lagoszow, Poland

http://www.micon-drilling.de

35Issue 02 | 2009



Future ProspectsThe following RVDS developments are currently planned

or to be concluded soon. The development of a 3-D-tool is planned, which is a system that can be programmed to drill into any given direction in space. The development of the RVDS for the drilling with air lift method will be concluded in April/Mai 2009. Along with that, the EM-datatransfer will also be finalized in May/June 2009, as well as the bi-di-rectional communication with the RVDS, which will allow a communication and a „reprogramming“ during the dril-ling.

In future the application of self-controlled systems is foreseeable. This is on one hand related to the fact, that increasing complexity of upcoming projects require new solutions, on the other hand the mere availability of the-se systems allows planning and implementing of projects, which although planned 5 years ago, at that time were only implementable with high efforts. As examples only the re-cently concluded raise borings in mining on a final depth of over 1,000 m, starting from already existing drifts, as well as freezing boreholes with highest requirements to course and accuracy are mentioned here.

Pic. 6: Breakthrough RVDS in Rouyn, Canada

Dipl.-Ing. Kai [email protected] | www.micon-drilling.de

MICON Mining and Construction Products GmbH & Co. KG

Im Nordfeld 1429336 Nienhagen | Germany

Tel.: +49 (0)5144 - 4936 0Fax:+49 (0)5144 - 4936 20

Internet: www.micon-drilling.de

http://www.micon-drilling.de

36Issue 02 | 2009



Puscherstr. 9 90411 Nuremberg, Germany

Tel.: +49 (0) 911 5 40 14 0 Fax: +49 (0) 911 5 40 14 99

Innovative and E�cient Solutionsfor challenging tasks in extraction, surface mining and surface forming.

T1255 Terrain Leveler

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Vermeer has transcribed its long-standing experience in the area of rock mills into its new surface mill.The T1255 is characterized by protected tech-nology, intelligent design, excellent produc-tion and system stability. Meanwhile the Terrain Leveler can process an area of up to 3.7 m width and 61 cm depth in one single run.

The machine has been designed to ablate all kinds of rocks, gypsum, coal and other ma-terial (e.g. concrete). This is done using a big, hydrostatically steered milling drum, which ablates the rock in a more efficient way and with a higher cutting depth.The result: More coarse material with a low proportion of fine fraction.

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37Issue 02 | 2009



New drill rig generation brings decisive innovations to conventional

tunnelling technology

Decisive innovations in the development of the new drill rig generation have led to a leap in performance in conventional tunnelling technology which was considered impossible up until now. One essential factor besides the high penetration

rate is the improved precision of the kinematics. This allows critical cost-savings in concreting work and subsequent profile corrections. At the same time, customer requirements such as probe drilling, recording of drilling parameters, profile control and communications technology were implemented in this new generation of drill rigs.

by Dipl.-Ing. Karl-Heinz Wennmohs,Senior Project Director, Global Strategic Customers,

Atlas Copco MCT GmbH, Essen

Decisive progress in drilling technology has been achie-ved in recent years through the development of powerful rock drills and modern control systems. The first steps were taken in conjunction with existing, proven techno-logy. Starting with building site configurations (some of them risky) and attempts to mechanise the drilling work, a standardised drill rig technology was developed in the subsequent years which is still relevant to the fundamental thinking. The initial parameters were the pure penetration rate and the resulting gross penetration rate as the total performance of the drill rig. Accuracy and precision were initially not of great significance as high-performance ex-cavation speed evolved. A phase of reflection occurred after the first projects had “run up against a brick wall” due to the inaccuracy of the profile and the resulting costs. Such an example will be explained later, at the same time showing the high costs that overbreak can cause.

Initially, the preference was to integrate the most po-werful hydraulic rock drills available at the time into the development stages for the drill rigs. In doing so, the com-ponents belonging to the “drill rig” system were frequently adapted to the rock drill capacities now available. These figures were essentially characterised by the rise in the

impact energy of hydraulic rock drills over the years and broke through a “power barrier” with the 30 kW rock drills for this range of applications (that technology has already been reported in these pages).

The designers accomplished the leap into a new era of percussive drilling technology by installing this tech-nology on a suitable platform through the development of new systems for the components essential to the drilling process. Besides the rock drills, numerous subassemblies within the drill rig were also modified – indeed, some rede-veloped. This led to the possibility of combining drilling and blasting operations being recognised at an early date and incorporated into the driving process.

The penetration rate has undergone an impressive evo-lution over the past 100 years. We can see from Fig. 1 that starting with a pneumatic rock drill around 1907 with a pe-netration rate of 3 – 5 drill metres (Bm) per hour and ope-rator, 100 years later a gross penetration rate of 450 Bm/h per operator is possible. Parallel to these developments, blasting technology – thanks to improved explosives and detonator systems – has kept pace with the constantly growing demands – thanks to drilling technology.

38Issue 02 | 2009



Crucial further developments in boomsBoom technology began with the simple rotary booms,

which moved the entire boom via a rotation system. The parallel positioning of the feed was initially achieved with mechanical scissors which, however, allowed only limited movement options, especially with respect to the lateral pivoting movements of the feed. Then the first booms that could move in the X-Y axis – albeit with separate cylinder systems for the two axes – were developed. The parallel positioning of the feed was accomplished hydraulically, partly with the help of pilot cylinders. The first boom that operated without splitting the movements into the X-Y coordinates was developed in early 1980. This made it possible to realise the diversity of movement of a boom in straight-line movements in space. Repositioning times bet-ween holes were cut and at the same time these new hyd-raulic kinematics systems could increase the accuracy of the drilling process with an improved parallel positioning in space. This boom technology was used for various boom sizes – corresponding to the desired range of applications, e.g. for use in mines with relatively small cross-sections, and the large types for tunnelling with correspondingly lar-ger cross-sections and reaches. Between 1980 and 2008, more than 4000 of this type were built for tunnelling.

The arrival of the latest rock drill generation – 30 kW power class – and the demands of the market for a further increase in the gross penetration rate, greater accuracy and the desire for additional com-ponents, inspired the development of a new gene-ration of booms. These were intended to meet all demands and represent the latest stage of develop-ment.

The BUT 45 boom series is the result of these many years of development and testing.

New to this configuration and design are the double rotation systems for the feed movements in space. And with almost unlimited movement options for the feed position, the appeal of this system is the high accuracy of the parallel guiding. This techni-cal solution makes it possible to omit cylinders and hinges in this area. The feed position can be moved through ±190° in the driving direction and by ±135° about the pivoting axis (Fig. 2).

An increase in the penetration rate generally means faster tunnelling overall. The new boom is characterised by approx. 50% faster movements compared to its prede-cessor (Fig. 3).

The elasticity of the boom has been reduced by 50% in this newly developed model. That enables a positioning and repetition accuracy of max. ±10 cm at full extension or over a cross-section of about 130 m². But the optimum design of the boom also means approx. 30% more weight can be carried, e.g. a rod carousel for probe drilling can now be attached.

The requirements of the new rock drill class with 30 kW (or higher) have been satisfied, the new boom can now

Fig. 1: Developments in penetration rates from 1905 to 2008

Fig. 2: BUT 45 feed movements with double rotation head

39Issue 02 | 2009



brace the feed against the rock with a maximum force of 25 kN. This is important for the driving and anchor position. This bracing force ensures a secure drilling position and is the prerequisite for precise drilling.

The new generation of drill rigsThe software necessary for operations was updated

and adapted to the new methods upon the launch of the 30 kW hydraulic rock drill and the new BUT 45 boom.

Particular attention was given to the motion sequences for the boom movements because the faster repositioning speeds are controlled in a better way for the machine, i.e. with optimised acceleration and deceleration values. The control technology for rock drill and feed was updated to match the new hardware options. The result is almost per-fect control of the drilling process in the most diverse geo-logical formations for blast, bolting and long holes.

Drill rigs for the most diverse requirements are built with this new technology – from the one-boom type to the most powerful models with four booms plus service platform (Fig. 4).

This series can be deployed in cross-sections from 6 to 206 m². The gross penetration rates feasible range from 120

to 450 Bm/h (Tab. 1).The gradeability of the rigs is 1:4 for the one- to three-

boom drill rigs, but this does depend on the condition of the tunnel floor. The gradeability of the four-boom version, which weighs about 50 t, is 1:5.

The much more powerful rock drills require a powerpack unit with 95 kW electrical output for the hydraulic supply to each boom. For the three- and four-boom rigs that means an installed power of 285 – 380 kW plus additional equip-ment. These drill rigs are therefore preferably operated with a 1000 V electrical supply.

Spacious operator cabins are standard practice these

Cross-section Gross penetration rate

1-boom 6 to 70 m² 120 Bm/h2-boom 8 to 112 m² 220 Bm/h3-boom 20 to 206 m² 320 Bm/h4-boom 20 to 153 m² 450 Bm/h

1 Hole diameter 45 – 64 mm; granite 200 Mpa.

Tab. 1: Parameters of the new 30 kW hydraulic rock drill with new boom BUT 451.

Fig. 3: The Atlas Copco range of drill rigs

for tunnelling.

Fig. 4: New drill rig generation BH XE 3 C.

40Issue 02 | 2009



days. The cabin can be raised on the three- and four-boom rigs. The noise level during drilling should not exceed 80 dB(A).

By the end of 2007 this gene-ration of drill rigs had been able to cut the drilling time within one excavation phase by more than 50% compared to 1973. Compa-red to all other processes during an excavation phase, this incre-ase was by far the greatest (Fig. 5).

Options for requirements in tunnelling technologyService platform

The current technical safety requirements and the larger cross-sections now possible with the new drill rig series made it necessary to upgrade the service platforms. Special features are an FOPS-tes-ted, folding protective roof and a pivoting option for the platform (Fig. 6).

Extension rod carousel

The newly developed BUT 45 boom generation meant that for the first time it was now possible to equip an Atlas Copco drill rig with an optional rod carousel for the extension drilling during tunnelling work.

It was necessary to develop this system in order to comply with the technical safety requirements for tunnelling in Scandinavia. The aim was to avoid the need for any workers to be on the service plat-

Fig. 5: Time required per metre of tunnel and operation for a

tunnel segment – a comparison of the years

1973, 1998 and 2007.

Fig. 6: Service platform with folding protective roof.

Fig. 7: Rod carousel for the BUT 45m boom.

41Issue 02 | 2009



form to change the rods during extension drilling. All the operations for extension drilling have to be controlled from the operator’s cabin.

Probe drilling for rock surveys or grouting work are re-garded as everyday operations when tunnelling in hard rock.

Grouting work requires holes to be drilled 20 – 30 m long with diameters of 64 – 76 mm.

The newly developed rod carousel “RHS E” (Rod Hand-ling System E) can be fitted to feeds with a drilling rod length of 6.3 m (Fig. 7). The carousel is loaded with eight 3.05 m rods with fixed sockets. Two rod carousels – cont-rolled from the operator’s cabin – are installed on a three-boom drill rig.

Automation levels

The new developments in the control system allow users to operate the drill rig with three different levels of automation.

ABC BASICIn the “ABC BASIC” version only the inclination angle of the feed in space is shown on the display. All the move-ments of the booms and the drilling itself are performed manually. Neither drill plans nor the position of the drill rig in the drilling position are loaded into the system.

ABC REGULARIn the “ABC REGULAR” version the drill rig is set up in the drilling position via the laser coordinates of the tun-nel. The operator can call up drill plans on the display. The operator’s task is to move the boom manually so that it coincides with the computerised drill plan. All drilling data is recorded and can be called up later as required.

ABC TOTALThe “ABC TOTAL” version provides the user with a fully

automatic drilling system. After positioning the drill rig in the laser, every boom drills its predetermined holes in the desired sequence according to the programming of the drill plan (Fig. 8). In this mode the drill rig operator performs only a supervisory function. Very helpful is the possibility of being able to intervene in the automatic mode of any boom at any time and switch the system to “ABC REGU-LAR” mode for this boom with manual control.

This might be the case, for instance, for a certain hole or group of holes. Afterwards, the system can be switched

back to the fully auto-matic “ABC TOTAL” mode when required

Tunnel Manager Software für die Planung

An important prere-quisite for the plan-ning and evaluation of drilling data is the software available. The development of the “Tunnel Mana-ger Software” (TMS) for this new series of drill rigs was therefo-re an important step. The software can be used to draw the tunnel profiles requi-red and also design special profiles. Drill plans are produced according to the tech-nical drilling and blas-ting parameters and

Fig. 8: Evaluation with the Tunnel Manager Software.

42Issue 02 | 2009



transmitted to the drill rig. All the drilling data recorded can be evaluated with this software or printed out in the form of logs (Fig. 9).

Recording and transmitting data according to international standards

The experience gained in large mines with a number of different rigs formed the starting point for finding a suitable data standard. In order that all rigs can be integrated into a mine’s network, an international data exchange standard was drawn up. This standard – “IREDES” (International Rock Excavation Exchange Standard) – has been adopted by Atlas Copco and other manufacturers and incorporated into the rig technology.

Recording and evaluating the drilling parameters by means of “MWD”

“The way ahead looks black!” This German mining ex-pression reveals the uncertainty about evaluating the rock and its geology. In recent years there have been numerous attempts to obtain data from the rock through probe drilling and the use of suitable sen-sors and software.

The rod carousel now available on the new ge-neration of drill rigs and the possibility of using op-timised software for recording and evaluating the drilling data mean that users now have completely new possibilities at their disposal.

The abbreviation “MWD” stands for “Measu-re While Drilling”, a technique that in conjunction with the new drill rigs records a whole range of data during the drilling operation:

Penetration rate [m/min].•

Hydraulic percussion pressure [bar].•

Hydraulic feed pressure [bar].•

Hydraulic damping pressure (hydraulic damper in •rock drill) [bar].

Rotation speed of drilling rod [U/min].•

Hydraulic rotation pressure [bar].•

Water flow rate [l/min].•

Water pressure [bar].•

All of this data is recorded during the drilling operation, but simply recording the data provides only limited infor-mation about the in situ rock conditions (Fig. 10).

Only with the help of suitable software – included in TMS – is it possible to analyse the drilling with different recording parameters. The result is that it is possible to lo-calise structures, changes of rock strata and voids.

Fig. 9: Probe drilling and evaluation of “MWD” data with the Tunnel Manager Software.

Fig. 10: Probe drilling and recording with the “MWD” system – eight parameters.

43Issue 02 | 2009



If these evaluations are required frequently in a mine or long tunnel project, the values determined, e.g. penetra-tion rates and rotation pressure, can be assigned to cer-tain geological formations in the software. The information from the drilling means that “surprises” can be reduced to a minimum. Any measures necessary can be initiated in good time. The additional costs frequently caused by ab-rupt geological changes can be avoided or reduced.

Scanning the tunnel profile

Checking the quality of the excavation produced is al-ways extremely important, especially in the case of multi-ple lining systems. The additional costs for an inaccurate excavation profile can cause a project to slip into the red. It is well known that rectifying underbreak is an expensive operation, but the cost of sprayed concrete in the case of overbreak can also lead to serious additional costs when an entire project is affected. With a modern road or rail tunnel the cost of overbreak can certainly reach 30 – 50 €/cm per metre of tunnel depending on the cross-section.

For all those involved with tunnelling it is therefore es-sential to check the section just completed before procee-ding to the next one (Fig. 11).

The Atlas Copco “Profiler”, which can be mounted on a drill rig as an option, enables the section just completed to be recorded while carrying out the drilling for the next sec-tion. As the scanner is part of the drill rig electronics, it re-quires no adjustment and the recordings can be compared

with the given target profiles in the drill rig. Measures can be initiated immediately in the case of critical deviations.

The scanning procedure takes about five minutes for a 65 m² excavated profile. The result is shown on a separa-te display and afterwards can be processed by the TMS. Sprayed concrete thicknesses can be measured exactly by scanning the profile before and after application.

Network/Internet interface for data exchange

The new generation of drill rigs is fitted with an interface that can exchange data with an existing data network or, if available, via WLAN.

Information from the drill rig can be called up by any PC connected to the network or, if required, data, e.g. a new drill plan, can be sent to the drill rig.

This allows maintenance and service work to be plan-ned, but also malfunctions to be analysed and rectified as necessary.

Fig. 11: Checking the profile with the “Profiler”.

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Drilling and blasting as one activityDrilling and blasting operations are being increasingly regarded as contiguous operations in heavy-duty driving.

Drilling and blasting in parallel is not yet possible for safety reasons, but the drilling and blasting operations can be net-worked. The first moves in this direction were made in Scandinavia in the 1980s, and involved ANFO systems being fitted to the drill rigs.

This possibility was taken up again when emulsion explosives were introduced, resulting in the coupling of drilling and blasting systems.

The new generation of drill rigs can be prepared for the use of emulsion explosives by providing so-called docking points for the blasting vehicle on the back of the drill rig. Two or three charging systems are routed through the drill rig – two on the floor and one on the charging platform, which is also fitted with automatic hose retraction as well. Automatic hose retraction enables the right quanti-ty of explosive to be pumped into the hole at a cons-tant flow rate but variable retraction rate (Fig. 12).

This technology enables profiles to be blasted with greater accuracy. The stress on the in situ rock/void can therefore be reduced to a minimum.

OutlookThe new generation of drill rigs sets new stan-

dards in conventional tunnelling with respect to safety, speed, accuracy and economy. This is an important step towards increasing the competitiven-ess compared to mechanical tunnelling methods. Conventional rock excavation by means of drilling and blasting still represents the most cost-effective solution. The flexibility of conventional tunnelling cannot be beaten by any other method.

Options available such as a rod carousel for me-chanised probe drilling, profile measuring equip-ment on the drill rig, evaluation software and the link to computer networks plus the coupling of drilling and blasting operations opens up new possibilities for this method of tunnelling (Fig. 13).

Fig. 12: Drilling and blasting as one activity – docking the

pumping vehicle onto the drill rig.

Fig. 13: View from the control cabin of the XE 3C heavy-duty drill rig.

45Issue 02 | 2009



Dipl.-Ing. Karl-Heinz Wenmohs studied at the Technical University „Georg Ag-ricola“ in Bochum, Germany. His job at Atlas Copco, he started in 1970 and since he has been operated versatile in this company. His activity covers the tasks of a sales advisory engineer in the field of coal mining and on the duties of a Project Engineer in the field of tunnel and mining. As project engineer for Atlas Copco, he was responsible for the tunnel extension of the motorway Hanover-Würzburg (120 km tunneling). In other international Atlas Copco projects, he worked in China (Er-tan Hepp) and South Africa (Lesotho Highlands Water Project). In addition, he is in function of CMT-business director for Germany as well as senior officials including the neighboring countries of Aust-ria and Switzerland. Furthermore, he is a member of the GSC Group for civil engineering and cement producer, internationally known as a „Senior Project Director Global Selected Customers“ with the task of close contacts between the main building and cement com-panies, as well as to establish existing clients and clientcenters to assist them in the coordination of international projects.

| [email protected] | | wwww.atlascopco.com |

Atlas Copco MCT gmbhLangemarckstr. 3545141 Essen | GermanyTel.: +49 (0)201 - 2177 0 eMail: [email protected]: www.atlascopco.de

www.ADVANCED-MINING.com

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http://www.atlascopco.com

46Issue 02 | 2009

NEWS & REPORTS


Focussing on starscreen technique, the German Company Backers Maschinenbau GmbH has been producing starscreens for the processing of mineral and organic materials for the past 17 years. Due to its long-standing experience in this area, particularly its practical experience with the user,

the Backers engineers have managed to continuously expand their product range and to update their know-how to the state-of-the-art, i.e. to the latest stand in research and development.

Perfected Starscreen Technique with Self-Cleaning Appliance

The starscreen technique encompasses both two-frac-tion, as well as three-fraction starscreens and screening machines. Two-fraction starscreens can screen oversize particles and fine grains, whereby alternatively grids and vibrationgrid can be integrated as complementary equip-ment. The material to be screened is fed into the hopper of the respective screen type. Based on the material, it is possible to additionally insert a dosing screw, so that the material can be fed into the starscreen in a more batched way. The screening process starts on the starscreen, whereby the screen stars rotate in one direction and loo-sen the material. The fine screening material falls beneath the stars on a collecting conveyor, which pushes aside the material to a fine grain belt. The oversize particles are conveyed to the end of the starscreen and carried to an oversize particle belt, which conveys the over-sized particles to the back. The optimum sizes that are screened out correspond to 6/8 - 80 mm

The three-fraction starscreen machines can screen out the oversize particles, medium grains and fine grain from the input material. In this technique grids and vibrationgrid can also be alternatively integrated as complements. Along the lines of the two-fraction-screening technique, the material is placed into the respective hopper of the

screen type. Consecutively the material is first delivered to the wide-mesh screen, in order to loosen the adhesive material for the fine screen. The medium-/fine grain is delivered in batches to the lower belt, from where it is delivered again flatly and in

batches to the second star screen. There the fine and me-dium grains are delivered according to the principle of the two-fraction star screen. The optimum size to be screened out is also 6/8 – 80 mm.

Recently the three-fraction starscreens have been equipped with a new cleaning appliance, which consi-derably improves the screen performance. The cleaning system is assembled above the starscreen aggregates. Hereby the distance between the screen stars and the cle-aning system is big enough to ensure an unrestrained flow of material during the screening process. Based on the version of the system the cleaning can be operated either electrically or hydraulically.

The cleaning can be started either automatically or ma-nually over a defined time period, with a specified pressu-re, e.g. 140 bar. The cleaning combs, which are used in this process, clean the areas between the screen stars and screen finger. Based on each application case, the clea-ning system can be individually adapted to the division of the screenstar aggregate. The cleaning system starts at

Fig. 1: Two-fraction-starscreen

Fig. 2: Three-fraction-starscreen

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NEWS & REPORTS


the time when the feeding stops. Before the actual clea-ning starts, the screen deck is run free in a few seconds, so that the material is removed from the area to be cle-aned. The cleaning is done by lowering the screen combs onto the running screen deck. The cleaning of the residue of materials is done with a light pressure on the screen finger. This material is again laterally fed into the screening process over the hub area. The hubs are cleaned through consecutive relocation of the screen combs for one shaft position. The final cleaning of the entire cleaning unit is done during the runback of the unit into its original positi-on, in opposite direction of rotation of the starscreen.

All procedural steps of the Backer-starscreen tech-nique are coordinated in detail and therefore achieve high screening performances. Generally the screening tech-nique is applied for screening of grain fractions of 8 to 80 mm. Hereby an economical screening is done, according to the „Becker Principle“ , which is coarse screening be-fore fine screening (three fraction screening). In the first screening stage the coarse grain is accurately separated and distributed. The undersized particles reach the second screening stage (fine screening) free from coarse grain and impurities. Apart form the advantage of a thorough cleaning of the medium grains, the further advantage of the three-fraction principle is that the screening flow of the material is increased, thereby increasing the turnover of the material. This is accompanied by a reduction of costs through the minimum strain of the screen stars and the se-condary equipment, like for example feeding equipment. Due to their various models and compact measurements, the Backers-starscreen technique is flexibly applicable in

many materials and thus starscreens from Backer are con-venient for both mineral, as well as for organic material.Material with an edge length of over 250 mm is separated in advance with a bar screen.

Backers produced both mobile two-fraction-, as well as three-fraction starscreens. Based on the application of the star, the mobile three-fraction screens first screen the coarse grained particles between 35 and 80 mm. Following the coarse screening, the screening of the fine fraction is done. This procedure has the following advantages:

Reduction of wear-out: The coarse screen deck is equipped •with stronger screen shaft and bigger stars. This minimizes the wear-off.

Higher screening performance: The screening performance •of the coarse screen deck with a width of 1.2 m is up to 300 tons per hour.

Better preparation of material: The fine material, which is •being delivered to the fine screen deck, has already been loosened by the coarse screen deck. Therefore the feeding of material and delivering is more even.

The screenings, which are delivered from the coarse screen to the fine screen deck, are batched, loosened and flatly fed with the help of a quickly running conveyor belt. This process increases the screening performance and mi-nimizes the existence of long pieces of material in the fine screening fraction during the second screening stage.

As an example the screening performance can reach up to 200 tons per day for the screening of material with an edge length of 18 mm. If all process steps are carefully coordinated, this technique will optimally work. Besides the flow of material, the drive, deflector, other factors, as well as ease of maintenance are of significant importance. With the CANBUS-control it is possible for one person to completely operate the screening machine with radio-control from a wheel loader or excavator.

The Backers three-fraction screen 3-mtb is particularly suited to screen cohesive components.

The Backers company has used a new cleaning app-liance in its three-fraction screens. With this appliance, for example, loamy soil can be separated from rocks of a grain size of 18 mm, as well as humid compost with a good screening performance and little wear-off. In case the fine screen deck does not run properly (rough-running) due to adhesion of cohesive material, the feeding of the hopper

The new starscreen 3-mtb from Backers.

Fig. 3: cleaningsystem - on top cleaning

Fig. 5: automatic or manual cleaning connection

Fig. 4: cleaningsystem

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is stopped and the cleaning appliance cleans the screen deck between the stars on the hub, as well as in the po-ckets of the screenstars. A few seconds later the scree-ning process is restarted.

The product range of Backers is extensive and compri-ses of wheel-, crawler-mounted-, whell-crawler-mounted combinated- mobile starscreens, as well as static screen aggregates and plants. Besides the standard screen width of 1.2 meters, an oversize of 1.8 meters is also offered. For coarser pre-separation, grids or vibration grid are offered as optional upgrades for all available starscreen models. A further innovation is the new rotor blade of Backers, which can be applied as pre-separator.

The development and production is done in an appli-cation- and customer- oriented way in the production site Twist in Germany. Here, mobile and semi-mobile two- and three fraction starscreen machines are produced. Fur-thermore, for the stationary plant construction, individual starscreen solutions and aggregates are developed pro-ject-specificly.

Fig. 6 & 7: Rotorblade of Backers

Backers Maschinenbau GmbHAuf dem Bült 42

49767 Twist | GermanyTel.: +49 (0)5936 - 9367 0 | Fax:+49 (0)5936 - 9367 20

eMail: [email protected] Internet: www.backers.de

http://www.advanced-mining.com

http://www.backers.de


49Issue 02 | 2009

NEWS & REPORTS


Sandvik Mining and Construction’s MB750 Bolter Miners (previously with the designation ABM 30) were ranked number one and two in the 2008 South African board and pillar coal production statistics.

The best performing board and pillar section was Tavistock Colliery’s section 4, producing 1,249 Mio. tons of ROM coal between Ja-nuary and December 2008. The production machine being used at the facility is an MB750 Sandvik Bolter Miner, cutting a 3.4-meter-high and 6.6-meter-wide opening in a single pass, in combination with two shut-tle cars. The second Bolter Miner section at Tavistock also produced more than 1 Mio. tons. The mine is ope-rating in a Fulco shift sys-tem – seven days a week, 24 hours a day – stopping for one shift per week to perform maintenance.

In addition to the ex-ceptional performance de-monstrated at Tavistock, two Sandvik Bolter Miners at Syferfontein Colliery also produced in excess of 1.2 Mio. tons each during the same period, cutting

a 4.5-meter-high and 6.6-meter-wide opening. These machines are used in com-bination with a continuous haulage system. Syferfon-tein operates a two-shift system, five days per week. The third shift is scheduled for maintenance.

These Bolter Miners with record-breaking perfor-mance are regularly main-tained and monitored by Sandvik Mining and Cons-truction service engineers as part of service contracts. A total of 34 machines are currently operating under service contracts to gua-rantee top performance at all times.

Sandvik Bolter Miners:Top ranked in South African Coal Production

The Sandvik Bolter Miner MB700 series is designed for rapid entry roadway development and coal production in

board and pillar operation.

Sandvik Mining and Constructionfurther more information:

[email protected] [email protected]

Internet: www.sandvik.com


50Issue 02 | 2009

NEWS & REPORTS


Great Product Range from GriessheimWith 190 staff, the Griessheim factory is the biggest factory in the internationally active Strohmaier Group. Altogether

the family business, which was established in the sixties, has around 300 employees in four other sites, south of the Baden region, the bordering Elsass, and since the end of the nineties also in the region around Sarajewo, the Bosnian capital. In addition to mineral material and aggregates from high quality sand and gravel, Strohmaier delivers ready-mix concrete from its five concrete factories. The range of finished products of the brands “Grissheimer Betonwaren“ and “Betonia“ encom-passes concrete rocks for planes and roads, designs in GaLaBau, as well as products for structural and civil engineering for aquifer systems or for formwork applications.

This palette is completed by studwork material (concretes, cement mortars, pavements) as silo and bagged cargo. In Baden, Strohmaier delivers its raw and construction material into the Freiburg/Basel area with its own fleet of vehicles – a nearby loading terminal at the Rhein river allows for further reaching mass transports of high quality grainings. The concre-te rock range, which is being produced with often complex mechanical finishing treatment in three fully automated lines, is being marketed in Germany, as well as well into the surrounding foreign countries.

Dumpers at the Center of the Transport ChainThe above-mentioned reveals that the internal transport in the Griessheim fac-

tory is considerable. Altogether, three crusher lines process the crude gravel into numerous intermediate and end products, which circulate through a batcher on a conveyor belt in the factory, for defined material mixes or as base material for the production of concrete. A major part of the products, however, has been „driven“ for years by four articulated 25-ton dump trucks.

Approximately half of the daily dumper transports are allotted to raw material from the studwork and the filling of the covering, which is in layers of 40 to 60 cm. The remaining rides - for storing intermediate and end products- between the altogether four silo roads in the factory and the external storage, which is close

Performance Giant on a Slender FootSince 1970, the Strohmaier group in Griss-heim in the South-Baden region near Neu-enburg has been mining high-quality sand and gravel. Their extensive product range and the close link to other Strohmaier companies in the region have turned the operation into a strong production site with around 4000 tons of alpine moraine material as daily output. The wet and dry mining operation on an area of approximately 25 ha, nume-rous refinement stages, as well as the affiliated production lines, require a powerful internal transport organization, in which articulated dump trucks with narrow overall width are applied.

Bell B25DN in Internal Transport

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NEWS & REPORTS


to 700 meters away, are done by vehicles, which were ma-nufactured from 1992 to 2003. In this way around 40% of the daily output of more than 4000 tons is moved off from the product silos, although the narrow passages are designed for much smaller street dumpers. Here, the requirements are defined by the passage with measurements of 2,95 m x 3,40 m in the neighboring Steinenstadt factory, where, if needed, a vehicle is being sent for a short-term capacity increase.

The narrow serial overall width of the old vehicles at 2.75m, which is specific for the manufacturer, is barely up to the requirements of Grissheim. In the currently upco-ming stage-wise renewal of the existing fleet of dumpers, the management was confronted with the problem that in the large-scale production of the leading manufacturers, none of the 25 –ton vehicles remotely reached the requi-red maximum measurements in width and height. It is only Bell equipment that offers - ex factory- the desired eco-nomical solution, without expensive project-specific modifications, while maintaining the loading capacity and 6x6-typical all-round characteristics of the serial production basic unit: The new special edition Bell B25DN with a normal overall width of 2,60 m and the LowCab-low cabin (Overall height: 3,25 meter). The date for the test was quickly set with the res-ponsible regional salesman Michael Welte – and in early March the slen-der Bell completed a test week under Griessheim production conditions.

Performance without Concessions

Compared to the trail of the 2.88m of the standard vehicle, it is only at second glance that the narrow trail of the Bell B25DN can be detec-ted. This is due to the identical EM-standard tires 23.5R25 and the un-changed B25D-motor coach with the Bell-LowCab-cabin (- 200 mm height), which ensures generous space for the driver, something which is typical for Bell. The differences are more articulate in the completely renewed hollow bu-cket. Thanks to the minor elevation of the platform gates, but extended body at only 2,510 mm overall width, it offers the same loading capacity than the standard bucket. The revised design, which also includes a hatch that is atta-ched to the inside and correspondingly is narrow shaped, ensures a narrow-gauge optimized load center, which lar-gely absorbs the inevitable deficits in driving, loading and tilting. The unchanged Bell-carriage with oil shock absor-bers in the front and Tri-Link-supported tandem swing in

the back also has a share in this. Here only the axis has been shortened to the new gauge.The modular construction group concept also encompas-ses the fuel efficient drive-train with 205-kW-Mercedes-Benz-Turbodiesel and ZF-Ecomat-six-gear- automation, the Retarder-supported brake system with high safety margins, as well as the Bell- control and operation moni-toring, with links to the satellite-supported Fleetm@tic-ma-nagement of trucks, which were specifically developed for the application of dumpers. This proximity to large-scale production makes the special edition quickly available with the German Bell- supplier Eisenach and ensures eco-nomical investment costs. Both points clearly favour the Bell-solution to complicated remodeling exercises.

Passed the Practice-TestThis has also been the clear sum-

mary of the Strohmaier-decision makers in Griessheim. Under pro-duction conditions the Bell B25DN harmonized well with the availab-le 4- to 5 m³-loading devices and convinced with its superior driving performance on the approximately 1,200 m (studwork) to over 3,000m (filling material) tours. On its trou-ble-free passage through the silo, the vehicle even took high loads of highly running grains, even without the attached hatch, and thus it en-tirely fulfilled the main requirement of the factory.

Meanwhile the Bell B25DN revealed a highly economic-al consumption – the mean daily consumption amounted to only 9.2 liters/hour. Just to compare: the old vehicles with equal performance, which have been in operation in Griss-heim for 32,000 hours, have an average consumption of 12 liter/hour.


52Issue 02 | 2009

NEWS & REPORTS


Bell equipment presented its newest developments in the articulated dump truck technology. Apart from impro-vements in the safety, workplace convenience and pro-ductivity, which will be brought about with the revision of the current D-series, there were two new models, which emphasized the claim of the company to develop innovati-ve 6x6 concepts along actual costumer demands.

The world-wide first 45-ton articulated Bell B45D (Actual load: 41,0 t; bucket size: 25,0 m³ (SAE 2:1) aroused high in-terest in mining and earth-moving experts. With its definite market start Bell now opens a new performance category between the common 40-ton and the 50-ton-6x6, whereas the Bell flagship product B50D is still replacing the stan-dards of the industry. According to Bell, the most important advantages of the B45D are high contingency and stability reserves, even under the hardest operation conditions, as well as loading and transport performances, which are ex-actly tailored to the given practice specifications.

As a second premiere Bell presented the B25DN in nar-row overall width for internal transports and public road-going in markets with respective guidelines. On the basis of the successful Bell B25D, it is in fact the only serial dumper of the narrow construction classification, which corresponds to all required authorizations and economical demands of the extraction industry. Presented as an eye catcher at the Bell booth, the 25-ton truck which was only 2.6 m wide and in its “Low-Cab-Version” only 3.2m high, emphasized the practical and economical advantages of the Bell-Concept of small-series, along customer-specific requirements.

Bell Equipment Germany GmbHWilly-Brandt-Str. 4-636304 Alsfeld | GermanyTel.: +49 (0)6631 - 9113 0 | Fax:+49 (0)6631 - 9113 13eMail: [email protected] Internet: www.bellequipment.de

Defy the Crisis!This has been the slogan of Bell equipment in the Intermat 2009

“For us this is the most successful Intermat up to now!” This surprising summa-ry was given already at halftime of the interna-tional exhibition of con-struction machines by Claude Boulet, managing director of Bell in Fran-ce, Paris. This statement contains a high amount of optimism for the coming months, although it first of all re-flects the ultimate positioning of Bell equipment as one of the leading suppliers of articulated dump trucks in France and other European markets, a little more than ten years after the opening of the first branch office. “Like all other manufacturers we had a difficult start into the year 2009 and consequently we did not have much expectation from the exhibition. In reality, however, we have registered a lasting and strong costumer attraction and are particularly happy about very concrete projects with short- and long-term demand for implementation”. This is the assessment of Claude Boulet of the promising outlook of the French market.

The Bell-chairman Gary Bell gave a more complex ap-praisal of the international situation: “The low number of British and Iberian visitors to the exhibition clearly shows the very difficult circumstances in these regions. At the same time we are more optimistic regarding the European market, as well as for major parts of our worldwide activi-ties. Being real dump truck specialists, we are not affected too much by the broad uncertainty, which currently has reached almost all construction sectors, and therefore we can fully concentrate on our segment. In addition our glo-bal activities do not only rely on the big developed markets, which currently suffer most from the crisis. “Our strong engagement in the so-called emerging markets makes the difference”, Gary Bell explains.


53Issue 02 | 2009

NEWS & REPORTS


Laser scanner ILRIS 3D-HD sets new standards for 3D-Modelling

Terrestrial Laser scanners (TLS) are often applied in mining, architecture

and plant documentation. They quickly lead to exact and reliable results, both in the inner and outer areas. Thanks to high economic efficiency and productivity, the newly developed laser scanner ILRIS 3D-HD from Optech sets new standards in accuracy, speed and mobility.

Geo-konzept receives Award for its Planning of Blastings!

The German Quarry Professional Association (StBG) is characterized by particularly innovative manufacturers, who for example increase security in blastings or signifi-cantly improve operation cycles. This award is not granted every year to manufacturers, but only in case outstanding innovations justify the prize. This year it was awarded to the Geo-konzept company for their planning of blastings. The company stands for exact measuring, quick planning and reliable control of large diameter borehole blastings. The applied technologies range from high-precision ter-restrial laser scanning through planning and control soft-ware to bore hole measuring and integration of GPS data. The Producer Prize 2009 of the StBG is awarded for the integration of all operating cycles, the planning and control to blasting in a software. The basis for the award was the new development of the laser scanner ILRIS 3D-HD, which presents new standards in 3D-Modelling.

Such terrestrial laser scanners (TLS) are mainly applied in mining, architec-ture or in documentation of plants and are used both in inner and outer areas. A telling argument of this technique is its economic efficiency, with which higher productivity can be reached. The new laser scanner ILRIS

3D-HD from Optech sets standards for accuracy, speed and mobility. The new device is highly mobile, as well as extremely robust and has been available since April 2009.

Due to its quick, exact and mobile functioning, the tech-nique of the ILRIS 3D-HD fulfills highest expectations to exact 3D_Modellings. Compared to conventio-nal methods, the new la-ser scanner leads to much quicker and more accurate 3D-modelling results in dif-ferent areas of application. Currently, the ILRIS 3D-HD is used for 3D-modellings, geo-monitoring, plant- and inventory documentation, respectively. In this regard “HD” stands for “high den-sity” and assures high point density, which is connected to a high accuracy in mea-surement in a short time.

An advantage of the new scanning technique of the ILRIS 3D-HD, which is worth noting, is the speed and accuracy. The improved laser and the newly developed electronics offer various modes for scanning, so that compared to the conventional technique, four times quicker results or twice as accurate results can be achieved, as required.

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NEWS & REPORTS


The “Rapid Survey” mode is comparable to the common scanning methods; however it has a critical time advan-tage. Thanks to a real 10kHz- repetition rate, the ILRIS 3D-HD works four times quicker, so that results of conventio-nal quality can be obtained in one quarter of the time.

The “High Precision” mode, however, meets highest demands of accuracy. The scanner works with the com-mercially available repetition rate of 2.5 kHz, but doubles the accuracy of measurement. Hereby the scanner scores with unrivalled and low angle resolution (13 µrad) and the best ray expansion worldwide (150 µrad). The high distance accuracy (up to 3 mm) doubles the accuracy of 7 mm hitherto prevailing. The result: Twice as high quality in achieved in the usual scanning time.

Integration of mobility and efficient software package

The ILRIS 3D-HD laser scanner is highly integrated, extremely compact and portable. All components lie well protected under the robust outer casing. Therefore the scanner can cope with the hardest demands and is fully trail worthy.

Under the resistant casing there is also a digital color camera. This makes correct information of colors pos-sible for your 3D-models. ILRIS 3D-HD further offers the possibility to attach an external camera of your choice for even higher quality. A further advantage is the fact, that the scanner can be operated with a pocket-PC, so that no Laptop needs to be taken along.

In spite of the compact design for the increase of mobili-ty, the ILRIS 3D-HD has an unbeatable operating distance. A dynamic operating distance of 3m to 1,800m is unequalled in the market. This offers the opportunity of working in dan-gerous areas, like for example in observation of glaciers, and to always keep a secure distance. Furthermore, laser

of the ILRIS-series are unlimited safe for eyes in all ran-ges!

The efficient software packages can easily be handled and still offer possibilities, which meet highest require-ments. For example the current workflows for measuring and geo-referencing are already fully integrated and allow clearly more effective operation.

The already known options of the ILRIS-family for the expansion of the system are also taken into consideration in the innovation ILRIS-3D-HD:

“PanTilt“ - for scans over 360°•

“Enhanced Range“ - for scans up to 1800 m•

“Motion Compensation“ - ffor highly accurate scans in mo-•tion. As an example in ships, for the measurement of coast lines or for quick and efficient plant documentation from a driving car

Participating company

The geo-konzept Company was established in 1992 and is a reliable partner in measurement, planning and control of large diameter bore hole blastings. The applied techno-logies reach from highly accurate terrestrial laser scan-ning through adapted planning software to processing of geo-referenced data. The application of the bore hole probes and high expertise in application of GPS-systems perfects the picture. Further business areas are the appli-cation of precise GPS in the agriculture, remote sensing (multi-spectral aerial photographing and assessment), mobile GIS, as well as provision of services and software development..

Optech Inc from Canada is the world market leader for development, manufacturing and support of high-quality laser supported monitoring instruments. The company offers systems for the laser measurement for end-users, air-supported systems for cartography, 3D-modelling, mine control, industrial plant documentation and space travelt.

geo-konzept GmbHGut Wittenfeld

85111 Adelsberg | GermanyTel.: +49 (0)8424 - 8989 0 | Fax:+49 (0)8424 - 8989 80

eMail: [email protected] Internet: www.geo-konzept.de

Optech Incorporated300 Interchange WayVaughan, Ontario | Canada, L4K 5Z8Tel.: +49 1 905 660 0808 | Fax:+49 1 905 660 0829Internet: www.optech.ca

http://www.geo-konzept.de

http://www.optech.ca

55Issue 02 | 2009

NEWS & REPORTS


Pfreundt presents the new dumperscale DW-3 for articulated dumptrucks on theglobal-market!

The manufacturer Pfreundt plans, develops and distributes mobile weighing systems including software and data sys-tems to the global markets of the production-, disposal- and recycling-industry. Their products are characterized by good quality, high value and high reliability. These properties are the result of continuous development that is necessary to meet the growing demands of markets and customers all over the world.

The new dumperscale DW-3 for articulated dumpers has a pioneering and market-oriented character. Their use ena-bles cost savings while increasing efficiency. Based on the customer-focused research and development work, the company Pfreundt succeeded to present a dumperscale for articulated dumpers on the markets, which already check the loaded material during the loading-period. The new DW-3 dumperscale measures the material weight in the bed du-ring loading already, using two measuring sensors at the rear axle. The weighing electro-nics display the exact weight to the driver in the cabin. In addition, two bright LED lights (red/yellow/green) signal the loading status on the outside of the machine. This optimally utilises the capacity and prevents overloading, saving time and reducing costs.

Optimal use of capacity!

Bright LED lights on the outside of the Dumpers shows the current loading

conditions.

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Precise weight control for optimum vehicle utilization

With its universal measuring principle, the DW-3 is suited for virtually all articulated dumpers and can also be retro-fitted. Thus it represents a good opportunity to redu-ce working expenses while increasing the working speed and cost-efficiency.

Because of the customer-oriented advices the new dumperscale DW-3 promise to be an enrichment of the production-, disposal- and recycling-industry markets. It also shows, that continuous education and training of staff reflects high quality standards..

PFREUNDT GmbHRamsdorfer Straße 10

46354 Südlohn | GermanyTel.: +49 (0)2862 - 9807 0 | Fax:+49 (0)2862 - 9807 99

eMail:[email protected]: www.pfreundt.de

www.ADVANCED-MINING.comwww.ADVANCED-MINING.com

http://www.pfreundt.de

57Issue 02 | 2009

NEWS & REPORTS


www.ADVANCED-MINING.comwww.ADVANCED-MINING.com

ADVERTISEMENT



58Issue 02 | 2009

NEWS & REPORTS


Caterpillar Releases MineStar™ FleetCommander 3.0

Featuring Software Enhancements and New On-Board Display

Caterpillar announces the release of FleetCommander 3.0, which includes software and hardware upgrades that expand capabilities for improving day-to-day mine site operations. MineStar™ FleetCommander is a comprehen-sive surface mine monitoring and control system that uses technology to improve productivity and lower costs. Real-time interaction with mobile field equipment allows mine managers to improve machine utilization, manage opera-tors, track material movement and monitor production in near real-time.

FleetCommander has proven its value in mines worldwi-de. Operations that switched from manual control to Fleet-Commander typically have experienced a 10 to 15 percent productivity improvement. One mine im-plemented FleetCommander for managing its shift change process and gained 15 truck loads per shovel each shift. MineStar FleetCommander 3.0 builds on proven results and delivers an additional 5 percent productivity improvement compared to previous versions.

Software enhancementsThe FleetCommander core truck assignment

engine has undergone significant enhancements. Key improvements are closer integration with the mine model and optimization of the assignment algorithm. With these enhancements, mining ope-rations are seeing even greater productivity im-provements when they allow the system to assign

trucks automatically with no restrictions. Letting the as-signment engine run automatically also allows mine cont-rollers to focus on other operational needs.

The new blending functionality included in the assign-ment module enables the mine controller to specify the type and quality of materials delivered to the dump, stock-pile or processing plant. FleetCommander 3.0 assigns trucks based on the specified ore and productivity targets. The new feature is fully integrated with production plan-ning and key performance indicator (KPI) summaries.

The MineStar Fleet Commander Touch Screen Displayprovides equipment operators with an on-board

computer that serves as a navigation system.

http://www.cat.com

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To enhance tire management, the controller can set a maximum TKPH/TMPH for an individual truck or a class of trucks. The feature is integrated with KPI summaries to allow complete tire management performance re-views.

New software also supports decision making by evaluating “what if” impacts of making changes to the production plan during the current shift. The software helps controllers make decisions that optimize mine productivity.

The new embedded dashboard enables mine control-lers in the office to view shift-based and real-time KPI and production variance information. Graphics such as gauges, histograms and trend lines promote easy inter-pretation of data.

The upgraded site editor and computer-aided-design capabilities eliminate the need for an external mine site design program. New features enhance the ability to create and maintain accurate digital site representa-tions.

On-board hardware enhancementsNew FleetCommander hardware includes an up-

graded on-board display that is easier to read due to 18 percent more viewing area and higher resolution. The easy-to-use touch screen enables operators to input information without memorizing keypad functions.

The upgraded system now supports standard wire-less protocols, such as 802.11 and other IP wireless in-frastructures. The expanded capabilities enable Fleet-Commander 3.0 to work with industry standard wireless communications networks, giving operations the oppor-tunity to choose and implement infrastructure based on their site needs.

The new system is scaleable. For example, a mine can start with hardware for machine tracking and sub-sequently can upgrade the FleetCommander software for machine scheduling and assignment.

The same hardware is used across all equipment types equipped with FleetCommander. Standardizing components reduces service parts inventory and dec-reases the burden on technicians. Additionally, the dis-play and GPS receiver are now separate, which allows more cost effective repair of components.

Looking toward autonomous miningMineStar FleetCommander is a key building-block

technology in the development of a Cat® equipped au-tonomous mine. A key element is the FleetCommander 3.0 assignment engine, which provides closer integra-tion with the digital mine site model. Additionally, al-gorithm optimization and software improvements are targeted to future management of the Cat Autonomous Haulage System and Autonomous Drill System.

Caterpillar Inc.Internet: www.cat.com

Functionality to manage mine personnelin the daily mining environment.

http://www.cat.com

60Issue 02 | 2009

NEWS & REPORTS


Dennis Gillson & Sons Ltd is using an Extec C-12+ mobile jaw crusher and an X38SBS mobile cone to create a high quality aggregate from the waste from the decorativestone production process.

A West Yorkshire-based decorative stone producer is using a pair of Extec crushers to turn a waste product into a revenue stream

A pair of Extec crushers is helping a family-owned decorative stone producer maximise the profitability from its process by effectively converting a waste pro-duct into a valuable, high-quality aggregate. Keighley-based Dennis Gillson & Sons Ltd has employed an Extec C-12+ mobile jaw crusher and an Extec X38SBS mobile cone to process overburden, fines and waste material derived from the decorative stone production process.

Family Business Although there has been an active quarry on the site

for several hundred years, the 7.0 hectare Naylor Hill Quarry has been in the Gillson family since the family-owned business was formed some 70 years ago by Dennis Gillson Snr, grandfather of current managing director, Darrell Gillson.

Following family tradition, the company quarries de-corative sandstone, for flagstones, and architectural finishing features such as lintels, sawn heads, sills, jambs, steps and copings and edging plus finished complicated masoned material, such as quoins, sawn pavings and fire places.

The quarry is on two levels and extends down to a depth of approximately 25 metres at its deepest point. This new, lower level is made up of a hard mill (grit) stone while the upper level of the workings comprises fine grain ashlar sandstone overlaid with around 9.0 metres of overburden which, until recently, was viewed as a waste material.

Rock is extracted at the site using a hydraulic ex-cavator equipped with a hydraulic hammer as blasting causes too much damage to the valuable stone. Blocks of up to 5.0 tonnes are taken into the saw mill and cut into flags or blocks before being finished by hand to give a natural texture.

Best on the Market Dennis Gillson reports that the Extec crushers were

purchased to deal with the overburden from the upper le-vel of the quarry and to utilise the waste from the cutting and finishing process. “We pride ourselves on the quality of our finished stone products so we have traditionally seen the overburden purely as a waste,” he says. “But with the purchase of the Extec machines, we are now using that same material, together with the waste from the finishing processes, to produce a valuable commodity.

The Extec C-12+ is fed by a Cat 365BL hydraulic excava-tor in mass excavation configuration. The crusher is fitted with grizzlies that remove the fines prior to crushing to help maintain the quality and consistency of the end product. With its jaws set t to >90 mm, the C-12+ feeds directly into the X38SBS cone which in turn produces a 38 mm prima-ry aggregate product. The output from the track-mounted mobile Extec cone is also screened to produce a wide variety of other fractions 10, 6, and 4 mm together with a sand product. Gillson says that the combination of Extec machines will easily produce a throughput of more than 200 tonnes/hour but says that he is more interested in qua-lity than quantity.

“We purchased the Extec units because, in my opinion, they’re simply the best machines on the market. They are really well built and have lots of excellent features such as the self-lubricating system,” Gillson concludes. “What is a real boon is the ability to change the size of the product so easily. In fact the systems on the two crushers are so well automated that I can just set them up to produce the required products and simply load in the rock at one end and watch a perfect product come out the other, without the need for additional help.”

Extec Screens & Crushers LtdHearthcote Road | Swadlincote

DE11 9DU | United KingdomTel.: +44 (0)1283 - 212121 | Fax:+44 (0)1283 - 217342

eMail: [email protected]: www.extecscreens.com

61Issue 02 | 2009

NEWS & REPORTS


New John Deere Graders Offer Unrivaled Choice, Productivity

John Deere

872G Motor Grader from John DeereMOLINE, Illinois (2009) - John Deere has been a compa-

ny of firsts, introducing the industry‘s first articulated mo-tor grader and the first dual path hydrostatic front-wheel drive system. Now the tradition continues: John Deere has revolutionized motor graders with its new G-Series, offe-ring users a choice of console-mounted industry standard controls or armrest-mounted industry standard fingertip controls, as well as features like cross-slope control, auto-matic differential lock and a rearview camera.

„With the G-Series, it‘s not ‚one size fits all‘ – you‘re free to choose the control style that makes you the most com-fortable and productive,“ said Kent Stickler, product mar-keting manager for motor graders, John Deere Construc-tion & Forestry. „And every grader has a steering wheel, no matter which control pattern you pick.“

Using extensive customer input and the successful D-Series as a platform, Deere is introducing six G-Series mo-dels, ranging from 185 to 275 net hp, each engineered for increased productivity, reliability, durability, serviceability and low daily operating costs.

Choices for EveryoneWith its G-Series graders, Deere is offering the industry

unequalled choices. In controls, choose from the console-mounted low-effort industry standard control pattern or intuitive and easy-to-use armrest-mounted industry stan-dard fingertip controls. If an operator specifies the finger-tip controls, he‘ll still have a choice between using lever

steering or the ever-present steering wheel. Either way, G-Series controls provide a smooth, predictable response and plenty of power whether the application calls for hea-vy blading or fine grading.

There‘s also a choice of ground-engaging tools. G-Series graders are available with a front- or mid-mount scarifier, or a rear ripper/scarifier. „Owners and operators can pick the tool configuration that‘s best for the jobs they do,“ Stickler said. „We recognize everyone has different needs.“

Ultimate Productivity:The Grade Pro Package

For road builders, larger site prep contractors and coun-ties with many road miles to maintain, the G-Series‘ Grade Pro package offers a suite of productivity-enhancing fea-tures for high-production grading. Grade Pro models have industry-standard pattern fingertip controls, located on the armrest. They offer lever steering and the steering wheel for operators who prefer traditional steering. With the push of a button, operators can engage return-to-straight, bringing the rear frame back to center. Exclusive cross slo-pe control allows operators to select a desired slope and maintain it with just one blade lift lever. Slope control tech-nology can assist less experienced operators.

„With the Grade Pro package, Deere makes it easier to do your best work,“ Stickler said. „When you combine smooth ergonomically correct controls, cross slope and return-to-straight, you have a machine with unmatched comfort and control. These are the controls that all blade


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NEWS & REPORTS


operators prefer – there‘s no need to re-learn how to run this motor grader.“

All John Deere G-Series Grade Pro units are grade-con-trol ready. These machines can accept Trimble® or Top-con® grade control systems, whichever manufacturer the customer prefers. All automatic grade control buttons and controls are integrated into the control levers.

A rear camera system with radar object detection is an available option and a high/wide-back air-suspension hea-ted seat completes the package.

All G-Series graders also have keyless start with mul-tiple security codes, enabling owners to control who has access to the grader. JDLink Ultimate is also standard equipment.

Engine and TransmissionJohn Deere PowerTech Plus™ 9.0-liter high torque Tier

3 engines provide best-in-class lugging and best-in-class low RPM power, with standard variable horsepower. Cou-pled with the heavy-duty Deere transmission with EBS (Event Based Shifting) transmission software, operators will not only enjoy plenty of power to get the job done but will also experience extraordinary smoothness. The rear axles feature automatic differential lock. The hydraulic clutch-style differential lock can be engaged on the go.

Three of the six new G-Series models have six-wheel drive rather than tandem drive, enabling them to power through the toughest cuts with power flowing to all wheels. As a result, operators enjoy increased traction and a 30-percent increase in tractive effort. Six-wheel-drive units also have a precision mode for ultra-low speed opera-tions and steering compensation to help pull the machine

through a turn. These models are the 672G, 772G and 872G. All G-Series machines have programmable auto-shutdown for fuel savings.

ServiceabilityJohn Deere believes that easy-to-service machines

are important to increased uptime and low daily operating costs. That‘s why each G-Series motor grader has been engineered with a convenient transmission, hydraulic and differential filter bank for fast access. There‘s also ground level fueling and a swing-out cool-on-demand automatic reversing fan standard on every model.

„If you work in a dusty environment or one prone to de-bris, the standard auto reversing fan is going to save you time and maintenance costs,“ Stickler said. „The entire cooling package folds out for easy cleanout.“

John Deere‘s NeverGrease™ pin joints mean a 56-per-cent reduction in greasing, leading to more time and mo-ney savings.

„NeverGrease joints will last longer,“ Stickler said. „And the tighter joints will also improve the accuracy of your blade work.“

The multi-function LCD color monitor lets the operator continuously track vital machine readings and tempera-tures. Other items shown include diagnostics system ana-lysis and the view from the optional rear camera. Additi-onal G-Series enhancements include increased blade lift height, increased circle throat clearance and a large ta-pered roller bearing in the articulation joint. A Balderson-style front lift group has been added to make it easier to attach snow equipment.

Deere & Company (NYSE: DE) is the world‘s leading provider of advanced products and services for agricultural and forestry and a major provider of advanced products and services for construction, lawn and turf care, landscaping and irrigation. John Deere also provides financial services worldwide and manufactures and markets engines used in heavy equipment. Since it was founded in 1837, the company has extended its heritage of integrity, quality, commitment and innovation around the globe. John Deere Construction & Forestry produces more than 120 machine models and distributes its construction, forestry and worksite products through a network of more than 1,300 dealer locations worldwide.

Deere & CompanyOne John Deere PlaceMoline IL 61265-8098 | USAInternet: www.deere.com


63Issue 02 | 2009

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High output and flexible!Kleemann together with Wirtgen France will showcase their mobile impact crushers MOBIREX MR 130 Z and MOBIREX MR 100 Z.

Kleemann Gmbh

The two plants combine a sophisticated and functional machine design with robust construction and economical operation - simultaneously producing extremely high outputs. Apart from this, the plants

can manufacture a defined fraction in a single operation thanks to the optimal and generous dimensi-ons of the screen.

The sophisticated features of the MOBIREX MR 100 Z and MOBIREX MR 130 Z are impressive. To achieve optimal loading, the feeding units consist of feed hoppers made from wear-resistant steel, whose walls can be folded hy-draulically for transport, and vibrating feeders, which are powered through frequency-controlled electric motors. Large double-deck heavy-duty screens, which vibrate in-dependently, are subsequently attached to ensure effec-tive screening of the feed materials. In addition, the mate-rial, which is now already in the required fraction, is routed around the crusher via the by-pass directly onto the vibra-ting discharge chutes. This increases not only the quality of the end product, but also the efficiency of the crusher. The vibrating discharge chutes themselves are fitted with wear-resistant steel (Hardox) and transport the material evenly and gently onto the large discharge conveyors. The

wear at the discharge conveyors is considerably reduced, thus increasing the overall availability of the plants. Be-cause of their particularly tough and robust design, the two crushing plants from the SHB series are also used.

With its simple transport, short set-up times and high output for its comparatively light weight, the MOBIREX MR 100 Z is an extremely impressive plant.

Kleemann MOBIREX MR130ZFlexible use and extremely efficient: Up to 400 t/h feed capacity, very well suited for limestone or recycling purposes.

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Together with its efficient drive, the plant makes very economical crushing possible, even for smaller amounts.

The feed opening of the MOBIREX MR 130 Z crusher measures 1,300 mm x 900 mm, thus allowing feed capaci-ties of up to 400 t/h. Overall, one of the most appreciated

features of the MOBIREX MR 130 Z is its flexible applicati-on. With its hydraulically driven impact crusher, the plant can work with limestone, reinforced concrete, brick and asphalt to produce top-quality final fractions.

Kleemann GmbH is a member company of the Wirtgen Group, an expanding and international group of companies doing business in the construction equipment industry. The group includes the four well-known brands Wirtgen, Vögele, Hamm and Kleemann with their headquarters in Germany and local production sites in the United States of America, China and Brazil. Worldwide customer support is provided by 55 own sales and service companies.

Kleemann MOBIREX MR100ZEconomical crushing even for smaller amounts. With its simple transport and simultaneously high outputs, the MOBIREX MR 100 Z is a truly impressive plant.

Kleemann GmbHMark Hezinger

Hildebrandstr. 1873035 Göppingen | Germany

Tel.: +49 (0) 7161 20 62 09Fax: +49 (0) 7161 20 61 00

eMail: [email protected] Internet: www.kleemann.info

WEITERE INFORMATIONEN UND KONTAKT:

http://www.kleemann.info

65Issue 02 | 2009

NEWS & REPORTS


With its Generation 6 crawler excavators Liebherr achieves new levels of performance, economy,

operator convenience and reliability. The new series of machines set new standards for crawler excavators in the 21 to 28 tonne category.

New series of crawler excavators launched from LIEBHERR

There are three of these new-generation crawler excavator mo-dels: the R 906 with a service weight of 21.7 - 23.3 tonnes,the R

916 Litronic (23.7 - 26.4 tonnes) and the R 926 Litronic (25.7 - 27.1 tonnes), the figures depending in each case on the machine’s

equipment specification. Each of the three new models is powered by a Liebherr four-cylinder construction-machi-

nery diesel engine. Outputs are 105 kW (143 hp) for the R 906 Litronic, 115 kW (157 hp) for the R 916 Litronic

and 130 kW (177 hp) for the R 926 Litronic. These Liebherr engines comply with internationally valid

exhaust emission limits (stage IIIA/tier 3). Engine management with CAN bus system integration

keeps engine speeds more constant and thus optimises fuel consumption and makes more

efficient use of the available power.

The Liebherr R 916 Litronic, the new series of crawler excavators.

lIebherr

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In response to differing market requi-rements and customers’ wishes, each of the three new crawler excavator models is available in either a ‘Classic’ or an ‘Advanced’ version. The ‘Classic’ Gene-ration 6 versions are intended for typical earthmoving tasks; the ‘Advanced’ ver-sions are equipped with an even higher level of innovative Liebherr technologies and are thus high-performance ‘full op-tion’ products, suitable for all kinds of tasks. In addition to earthmoving, their very high performance offers customers valuable benefits in mining, embankment construction, industrial applications or on demolition sites.

The large number of hydraulic con-sumers on modern hydraulic excava-tors, often with three or more in use at the same time or partially synchronised, calls for the installation of technically mature, high-quality systems. All Gene-ration 6 crawler excavators are therefo-re equipped with the “Positive Control” hydraulic system, which is a new deve-lopment, and the corresponding control-system logic.

Two independent hydraulic circuits make it possible to energise components in the most efficient manner. In particular when movements have to be superimposed, the necessary volume-tric flow can be made available quickly enough, with optimal use of the available energy. Maxi-mum individual movement speeds are obtained by adding the pump circuits together.

The Liebherr “Positive Control” hydraulic system thus enhances performance when ex-cavator movements have to be superimposed, for instance when grading and during travel eit-her straight ahead or in a curve. The Advanced version’s higher operating pressure also increa-ses tractive effort as well as tearout and break-out power.




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Early this year, Möbius Bau AG commissioned another P 995 Litronic Liebherr mega excavator in Bremerhaven. The pontoon-mounted excavator weighs roughly 360 tonnes and is installed upon the stilt-mounted pontoon MP 40. General Director Werner Möbius launched the ship during a short ceremony. The expansion of the fleet puts Möbius in an excellent position to tackle the new challenges posed by hydraulic engineering, in parti-cular in Northern Europe. The MP 40 is an entirely new design of stilt-mounted pontoon. It is 60 m long, 18 m wide and has a height of 4 m. The P 995 Litronic installed upon it is the second mega-machine of its kind in Möbius‘ fleet. Another P 995 Litronic has already been proving its mettle as an economic and particularly powerful loading machine for hydraulic engineering since 2004.

As a first trial run, the new machine is to be employed in the planned Jade-Weser-Port in Wihelmshaven. This hydraulic engineering project – unique in its kind in Germany – requires the excavation of 4,000,000 m³ of highly compacted „Lauenburg“ clay over a period of approximately two years. Thanks to the tremendous excavating forces and impressively rapid cycles, the combination of the MP 40 and the P 995 Litronic is predestined for this task. The P 995 Litronic is powered by a 1,600 kW/2,140 hp MTU diesel engine. The MP 40‘s longest working attachment is a 16 m monobloc boom, an 11 m bucket stick and a backhoe bucket with a capacity of 11 m³. This combination of equipment can achieve a maximum excavation depth of 22.5 m, a ripper force of 657 kN and a breakout force of 774 kNmale Grabtiefen bis 22,5 m erreicht. Die Reißkraft beträgt 657 kN, die Losbrechkraft 774 kN.

Pontoon-mounted mega excavator from Liebherr commissioned in Bremerhaven

Liebherr-International Deutschland GmbHHans-Liebherr-Strasse 45

88400 Biberach an der Riss | GermanyTel.: +49 (0)7351 - 41 0

Fax.: +49 (0)7351 - 41 2650eMail: [email protected]

Internet: www.liebherr.com

Der Liebherr P 995 Litronic in action.


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The rock excavation and processing industry is associated with high noise levels. Workers are exposed to a tremendous amount of noise that could lead to serious hearing impairment. In addition, the noise generated impacts the surrounding areas. For these reasons, in addition to legislative and regulatory requirements, employers are now aiming to achieve a better and quieter working environment.

Sandvik offers rubber wear protection for every type of truck box or hopper used in the rock mining industry. The boxes and feed bins are exposed to heavy wear during loading and unloading – from crushing damage to abrasive and cutting wear. Sandvik WT6000 rubber linings are extremely durable. They absorb kinetic energy upon impact and subsequently return to their initial shape, thus protecting the underlying structure.

Less noise and enhanced driver comfort with lined truck boxes

Multiple advantages of rubber linings

Noise-reducing •

Long life •

Reduced risk of buckles •and cracks in chassis or hopper

Reduced risk of fines •freezing during winter

Fewer maintenance •stoppages

Less structural repair •work

Lower cost per transpor-•ted ton

Better environmentSandvik rubber linings

reduce the noise level sig-nificantly. Measurements have shown that the noise level is reduced by up to 20 dB(A) compared with a steel lining. Sandvik rub-ber linings not only reduce noise levels, but they also absorb noise at a much faster rate. This considera-ble noise reduction results in greatly enhanced driver comfort and less risk of oc-cupational injuries.

Quick, secure installationSandvik offers a tailored solution for each application. Delive-

ry is complete with rubber elements, bolts and plugs. The lining is installed with stud welds or through-bolts for rapid, secure instal-lation. Sandvik can also arrange the removal of old linings and as-semblies.

Sandvik Mining and Construction

further more information: [email protected]

Internet: www.sandvik.com



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With no compromise on productivity new mobile crushing unit launched

The new Sandvik UH421 mobile secondary crushing unit is being launched. The crushing unit has been designed for an interruption-free process, producing first-class material.

New screen design improves capacity and product quality

One difference compared with the former, similar unit is that the screen is placed alongside of the unit, and has an optimal feed hopper. This means that the material is slowed down, and is well spread out by the time it re-aches the screening media and that, all in all, the scree-ning area is utilized better.

The efficiency of the Sandvik SS screen is perhaps best shown by the fact that during tests preceding the launch, 8-16 material taken directly from the crushing unit contained no fines at all. The result was very po-sitive, as the input material was screened shortly after primary crushing, and was therefore relatively dry.

“A good result depends of course on the conditions at that specific customer, but it still shows the improved screening process,” says Andreas Persson, Product Ma-nager of wheel mobile units, Sandvik Mining and Const-ruction. The screen and the conveyors are designed for optimal capacity. Thanks to the fact that the feed station can easily be removed, it is possible to feed the materi-al directly into the crusher. The conveyors are equipped with a robust drive, including external motors and angle gears.

Improved working conditionsThe working conditions around the UH421 are improved

thanks to Sandvik’s low-noise screening media, leading to high separation efficiency and long service life. In addition, the conveyors are equipped with dust encapsulation and dust filter reducing dust emissions to a minimum. The wor-king environment is greatly improved, the life of the equip-ment extended, and the maintenance and clean-up costs dramatically reduced.

Cone crusher and control systemcontribute to optimized performance

The crusher in the UH421 is the well proven and electri-cally powered CH440, featuring high capacity, high reduc-tion, low manganese wear and large feed acceptance ca-pacity. Furthermore, the crushing process is continuously and automatically monitored by the the intelligent automa-tic setting regulation system ASRi.


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User friendlyThe brand-new and user-friendly control panel provides

full control of the process with continuous information on current and historical production, facilitating troubleshoo-ting and minimizing operations disturbances.

The chassis of the crushing unit has been equipped with a third self-steering axle for flexibility during relocati-on, and it is designed to be registered as a towed vehicle. The fact that the crushing unit was designed to make re-

gistration possible is in line with Sandvik’s philosophy ai-ming at fulfilling inspections requirements. The UH421 has been inpected by the Swedish Road Administration and the Swedish Motor Vehicle Inspection authorities. “When our customers talk about safety, we can show that we are thinking along the same lines,” says Olov Andersson, De-sign Manager and Project Manager for development of the Sandvik UH421. Although road safety is the biggest reason for registration, it also makes higher speed possible during relocation. “For some customers, speed is an advantage and translates into cheaper transportation,” says Andreas Persson.

Efficient unitThanks to its versatility, low operating costs and high

productivity, the Sandvik UH421 gives quick return on in-vestment. Connection to electrical main supply or diesel generator is fast, using gloves. Together with the design in general, this means that the crushing unit can be made ready for operation quickly after transportation. As an un-divided plant, the crushing unit has a triple bogy load of 30 tonnes, but because it is possible to divide the unit, this can be reduced to 24 tonnes if necessary.

Sandvik is a global industrial group with advanced products and world-leading positions in selected are-as – tools for metal cutting, machinery and tools for

rock excavation, stainless materials, special alloys, metallic and ceramic resistance materials as well as process systems.Sandvik Mining and Construction is a business area within the Sandvik Group and a leading global supplier of machinery, cemented-carbide tools, service and technical solutions for the excavation and sizing of rock and minerals in the mining and construction industries.

Sandvik Mining and Constructionfurther more information:

[email protected]: www.sandvik.com


71Issue 02 | 2009

EVENTS


Energie u

nd Rohstoffe

2009

WORKSHOP

Stochastic ResourceModell ing and MinePlanning OptimizationSeptember 7th and 8th, 2009

in Goslar

ENERGIE undROHSTOFFE2009 Sicherung der Energie-

und Rohstoffversorgung

DMVDeutscher Markscheider-Verein e.V.

IGMCInstitut für Geotechnik und Markscheidewesen, TU Clausthal

September 7th and 8th, 2009 in Goslar

www.ENERGIE-UND-ROHSTOFFE.org/ 2009/anmeldung_und_information.php

http://www.dmv-ev.de



http://www.igmc.tu-clausthal.de



http://www.energie-und-rohstoffe.org

http://www.energie-und-rohstoffe.org/2009/anmeldung_und_information.php

72Issue 02 | 2009

EVENTS


ENERGIE undROHSTOFFE2009 Sicherung der Energie-

und Rohstoffversorgung

DMVDeutscher Markscheider-Verein e.V.

IGMCInstitut für Geotechnik und Markscheidewesen, TU Clausthal

Information and Registration:www.ENERGIE-UND-ROHSTOFFE.org/ 2009/anmeldung_und_information.php

Modern geostatistics and optimization tools for the mining industry

Participants will:Discover how and why risk-based models create value and opportunities Understand how to quantify and utilize grade/ tonnage/me-tal uncertainty and variability

Learn about new efficient simulation methods for modeling •ore bodies and how to utilize the results in a diversity of mi-ning applications

Understand how to use quantified ore body risk in ore reser-•ve estimation, mine planning and design, and mineral project valuation

Learn from actual industry examples and diverse applica-•tions

Participate in hands-on computer workshops using real case •studies

The final stage of the course is a series of computer work-shops, and introduces to participants new powerful pub-lic domain software (SGeMS). Data and software remains with the participants.

Content and ObjectivesGrowing volatility and uncertainty in global markets high-light the need to focus now, more than ever, on new tech-nologies that can add significant value to mine plans and evaluations.

This two-day course presents the new generation of ap-plied technologies integrating conditional simulation me-thods for reserve risk management with new risk-based mine-planning optimization, leading to improved cash flow assessments. Emphasis is placed on the downstream ap-plications pertinent to the feasibility, design, development and planning stages of mining ventures, as well as in the financial optimization of relevant aspects of operations and production.

Computer workshops introduce participants to the prac-

tical aspects of the technologies taught in lectures. New public domain software with graphic capabilities is intro-duced.

InstructorRoussos Dimitrakopoulos is currently Professor and the Canada Research Chair in Sustainable Mineral Resource Development and Optimization under Uncertainty – BHP Billiton, and Director of the COSMO Laboratory, McGill University, Montreal, Canada. Previously he was Professor and Director of the Bryan Research Centre, University of Queensland, Australia. He holds a PhD in Geostatistics from Ecole Polytechnique, Montreal, and a MSc from the Univer-sity of Alberta, Edmonton. He has been working in orebody risk analysis since 1983 and the last decade on risk-based optimization in open pit mine design. Roussos has been Se-nior Geostatistician with Newmont Mining Co., Denver, and Senior Consultant with Geostat Systems Int. He has taught short courses and worked in Australia, North America, South America, Europe, the Middle East, South Africa and Japan. (http://people.mcgill.ca/roussos.dimitrakopoulos/)

Contact-person:Dr. Steffen Knospe

Telefon: +49 (0) 53 23 72-27 94E-Mail: [email protected]

Stochastic ResourceModell ing and MinePlanning OptimizationSeptember 7th and 8th, 2009

in Goslar







http://www.energie-und-rohstoffe.org/2009/anmeldung_und_information.php

http://www.energie-und-rohstoffe.org

73Issue 02 | 2009

EVENTS


THE AMS-EVENT CALENDER2009

July 2009

08 Jul 2009 Computerorientierte Geologie 2009 (COG). Fachtagung für Angewandte Geologie im Rahmen der AGIT Salzburg www.agit.at/cog

28 - 30 Jul 2009 CGE09 — COAL-GEN Europe 2009 Warschau, Polen www.cge09.events.pennnet.com

12 - 16 Jul 2009 15. Tagung Festkörperanalytik Chemnitz www.tu-chemnitz.de/physik/AFKO/FKA15/

26 - 29 Jul 2009 GOLD 2009 Heidelberg www.gold2009.org

August 200903 - 05 Aug 2009 Diggers & Dealers Mining Forum 2009 Kalgoorie, Australia www.diggersndealers.com.au

08 - 09 Aug 2009 WSRMS - 2009 — International Workshop on "Winning Strategies to Revita-lize the Mineral Sector" Mangalore, Indien www.nitk.ac.in

17 - 19 Aug 2009 Seventh International Mining Geology Conference 2009 Perth, Australien www.ausimm.com.au/simgc2009

23 - 26 Aug 2009 48th Annual Conference of Metallurgists Nickel-Cobalt 2009 Sudbury, Ontario (Canada) www.metsoc.org

September 200907 - 08 Sep 2009 Stochastic resource modelling and mine planning optimization Clausthal-Zellerfeld www.igmc.tu-clausthal.de

08 Sep 2009 Radarinterferometrie zur Erfassung von Bodenbewegungen Goslar www.energie-und-rohstoffe.org /2009/workshop_radar.html

07 - 11 Sep 2009 10th International Symposium on Environmental Geotechnology and Sustai-nable Development Bochum www.iseg2009.tfh-bochum.de

09 - 12 Sep 2009 Energie und Rohstoffe 2009 - Sicherung der Energie- und Rohstoffversor-gung Goslar www.energie-und-rohstoffe.org

10 - 15 Sep 2009 NordBau 2009 Neumünster, Holstenhallen www.nordbau.de

13 - 17 Sep 2009 FRAGBLAST 9 - 9th International Conference on Rock Fragmentation by Blasting Granada, Spanien www.fragblast.org

14 - 16 Sep 2009 R'09 Twin World Congress - Resource Management and Technology for Material and Energy Efficiency Davos (Switzerland) www.r2009.org

14 - 18 Sep 2009 Extemin - Convention Minera 2009 Arequipa, Peru www.convencionminera.com

15 - 17 Sep 2009 Water in Mining 2009 (WIM 2009) Perth, Australien www.ausimm.com.au/wim2009

16 - 18 Sep 2009 MiningWorld Central Asia - 15th International Exhibition for the Mining and Processing of Metals and Minerals Almaty, Kazakhstan www.miningworld-events.com

20 - 23 Sep 2009 HMC 2009 — 7th Heavy Minerals Conference Drakensberg, Südafrika www.saimm.co.za/events/0909hmc

21 - 25 Sep 2009 Clays, clay minerals and layered materials Moskau, Russische Föderation www.cmlm2009.ru

22 - 24 Sep 2009 Intergeo 2009 Karlsruhe www.intergeo.de

22 - 24 Sep 2009 Mining & Energy NSW Muswellbrook, New South Wales, Australien www.miningandenergynsw.com.au

30 Sep - 02 Oct 2009 EnviroMine 2009 Santiago (Chile) www.enviromine2009.com

74Issue 02 | 2009

EVENTS


October 2009

05 - 07 Oct 2009 International Conference on Non-linearities and Upscaling in Porous Media Stuttgart www.nupus.uni-stuttgart.de/index.php?module=events&file=stuttgart

06 – 08 Oct 2009 MiningWorld Uzbekistan Tashkent, Uzbekistan www.miningworld-uzbekistan.com

12 - 15 Oct 2009 ConMex 2009 Middle East Sharijah, UAE www.conmex.ae

14 - 17 Oct 2009 Mining Indonesia Jakarta, Indonesia www.pamerindo.com/2009/mining

16 - 18 Oct 2009 Tag der Steine in der Stadt Berlinwww.geo.tu-berlin.de/steine-in-der-stadt/tag_der_steine_in_der_stadt

19 - 23 Oct 2009 IMWC — International Mine Water Conference Pretoria, Südafrika www.wisa.org.za/minewater2009.htm

20 - 22 Oct 2009 CHINA MINING Congress & Expo 2009 Tianjin, China www.china-mining.com

27 - 29 Oct 2009 Mining & Energy SA Adelaide, South Australia, Australien www.miningandenergysa.com.au

27 - 30 Oct 2009 China Coal and Mining Expo 2009 Beijing, China www.chinaminingcoal.com

November 200910 - 12 Nov 2009 China Mining 2009 Beijing, China www.china-mining.com

10 Nov 2009 Steinkohlentag 2009 Essen www.gvst.de

10 - 12 Nov 2009 Stainless Steel World Conference & Exhibition 2009 Maastricht (Netherlands) www.stainless-steel-world.net

10 - 13 Nov 2009 Metal-Expo 2009 Moscow (Russia) www.metal-expo.com

17 - 19 Nov 2009 Geothermiekongress 2009 Bochum www.geothermie.de

December 200901 - 03 Dec 2009 STUVA Tagung 2009 Hamburg www.stuva.de

02 - 05 Dec 2009 EuroMold 2009 Frankfurt www.euromold.com

10 - 13 Dec 2009 ENERGY INDIA, MDA INDIA, CeMAT INDIA, Industrial Automation INDIA Mumbai (India) www.cemat-india.com

THE AMS-EVENT CALENDER2009

Issue 02 | 2009

IMPRINT

75www.advanced-mining.com

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rohstoffe 2009