Mining and quarrying equipment
XX
Introduction
4
A reputation for reliability
“Hitachi has a reputation for reliability, performance and service in the mining industry”
8
Rodney Stuparyk, Vice President of Operations, Kumtor Operating Company
Hitachi is one of the strongest and most renowned brands in the mining and quarrying industries. Its large equipment is designed and built in Japan with the philosophy of delivering optimum reliability and performance to meet customer demand for high productivity. Hitachi Construction Machinery (Europe) NV (HCME) has established a mutual trust with mining and quarrying companies by creating a ‘win-win’ situation in conjunction with its dealer network. The experienced team of Hitachi product specialists maintains long-term customer partnerships to ensure that the total cost of ownership is favourable.
12 2
Hitachi Construction Machinery (Europe) NV
The technologically advanced range of mining and quarrying equipment encompasses Hitachi’s market-leading Zaxis-5 and EX-6 large excavators. By combining engineering excellence with a dedication to quality, Hitachi manufactures incredibly durable machines that come with a long life expectancy. Hitachi EH rigid dump trucks are highly productive and a perfect complement to its hydraulic excavators. A number of unique features ensure that they are extremely reliable. In addition, Hitachi ZW-5 wheel loaders are environmentally and user-friendly machines that work efficiently to deliver the lowest possible operating costs.
16 Mining and quarrying equipment
3
Zaxis-5 excavators
The priority is productivity
“The large Zaxis-5 excavator has enhanced the level of productivity and is helping us to achieve our objectives” Janusz Rydz, Manager, Pilawa Górna quarry, DSS Group Large Hitachi Zaxis-5 excavators – ranging in size from 40 to 90 tonnes – are well-designed and utterly reliable machines. They have been created with careful consideration of customer needs in challenging quarrying and mining environments. Hitachi has recognised the need for increased productivity with the HIOS IIIB hydraulic system. This allows for faster operation with up to 13% less fuel consumption and up to 8% more productivity (for the ZX470LCH-5, compared to the previous Zaxis model). Sustainability is another key requirement and the large Zaxis-5 range has powerful Stage IIIB-compliant engines that also help to deliver higher productivity with greater fuel efficiency. In addition, they incorporate a muffler filter and the auto shutdown and auto idler features, which enhance fuel consumption and reduce noise, exhaust emissions and CO2.
SPECIFICATIONS
ZX470LCH-5
ZX520LCH-5
ZX670LCH-5/ ZX670LCR-5
ZX870LCH-5/ ZX870LCR-5
Engine rated power (kW)
270
270
345
397
48,500-50,400
52,200-53,700
68,300-69,800
83,800-86,200
Operating weight (kg)
10,750
Maximum digging reach (mm)
(with 6.3m BE-boom and 2.9m BE-arm)
12,060
(with 7m H-boom and 3.4m H-arm)
6,130
Maximum digging depth (mm)
Maximum bucket digging force (kN)
4
Hitachi Construction Machinery (Europe) NV
(with 6.3m BE-boom and 2.9m BE-arm)
7,770
10,750
(with 6.3m BE-boom and 2.9m BE-arm)
12,060
(with 7m H-boom and 3.4m H-arm)
6,050
(with 6.8m BE-boom and 2.9m BE-arm)
7,690
11,800
(with 6.8m BE-boom and 2.9m BE-arm)
13,280
(with 7.8m H-boom and 3.6m H-arm)
7,120
(with 6.8m BE-boom and 2.9m BE-arm)
8,560
(with 7m H-boom and 3.4m H-arm)
(with 7m H-boom and 3.4m H-arm)
(with 7.8m H-boom and 3.6m H-arm)
296
296
(with 6.8m BE-boom and 2.9m BE-arm)
369
Tough working conditions require durability, so the machines have been designed with a reinforced undercarriage, and a strengthened boom and arm. Dual fuel main filters and pre-filters are provided
as standard to reduce system failures and the fuel injector is protected by a diamond-like carbon (DLC) coating. The ergonomically designed OPG (level II)compliant cab meets industry standards for comfort and safety. The laminated glass front window is fixed to shut out dirt and debris, and the fully adjustable air suspension seat absorbs vibrations and allows more legroom. Zaxis-5 large excavators incorporate easy maintenance solutions for an optimum level of performance and availability. The multi-function LCD monitor displays information at a glance and the fuel filters and engine oil filter can be easily replaced. Hitachi engineers have also developed an exclusive specification – the R series – for its large Zaxis-5 excavators. These models offer enhanced durability with reinforced components and added protection to further strengthen the undercarriage and front attachment. Wear-resistant steel buckets have been designed specifically for the rigours of handling hard and abrasive materials.
12,340
(with 7.1m BE-boom and 2.95m BE-arm)
14,100
(with 8.4m H-boom and 3.7m H-arm)
7,140
(with 7.1m BE-boom and 2.95m BE-arm)
8,870
(with 8.4m H-boom and 3.7m H-arm)
472
(with 7.1m BE-boom and 2.95m BE-arm)
Mining and quarrying equipment
5
Zaxis-5 excavators
CASE STUDY Schön + Hippelein
Job site:
Location:
Production:
Solution:
Calcitwerk Heidenheim limestone quarry Heidenheim, southern Germany one million tonnes of materials per annum ZX670LCH-5
Robert Hahn has worked with excavators for 20 years and is the sole operator of the Zaxis-5 machine: “The ZX670LCH-5 is powerful and offers excellent handling capabilities for loading rocks on to EH750 dump trucks. “The cab is spacious, there is more than enough leg room and the seat is comfortable. The control panel is similar to that of a car – it is so easy to understand the functionality and operate the monitor. “Productivity is so important in a quarry and that’s why I think the speed of the swing mechanism is the best thing about the ZX670LCH-5. It only takes four passes to fill one of the trucks and the loading cycle is fast, even when emptying the bucket.”
CASE STUDY DSS Group
Job site:
Location:
Pilawa Górna amphibolite and migmatite quarry Lower Silesia, southern Poland
Production:
four million tonnes of aggregates per annum
ZX670LC-5
Solution:
DSS Group’s Janusz Rydz has been the Manager of the 40-hectare site since it opened in 2007: “As the largest domestic producer of crushed aggregates for infrastructure projects in Poland, the DSS Group has acquired the ZX670LC-5 as a key part of its strategy for aggregates production. “It has been installed to help reduce the cost of every tonne of stone extracted from our flagship quarry. This 6
Hitachi Construction Machinery (Europe) NV
large Zaxis-5 excavator has also enhanced the level of productivity and is helping us to achieve our objectives. “To do this, we have renewed our fleet of construction machinery and in this case we have found the best solution. This is the first Hitachi that I’ve worked with, and I can concur with what I’ve heard in the market that Zaxis excavators are very reliable and durable.” Mining and quarrying equipment
7
EX-6 excavators
Achieving optimum availability
CASE STUDY Vale
“The availability of our Hitachi models has been excellent due to the support from Hitachi”
Job site:
Moatize coal mine
Location:
Tete, Mozambique
Production:
coal reserve of 954 million tonnes
Solution: EX8000-6 and EX5500-6
Mário Carpegiane, Maintenance Supervisor, Vale
Mário Carpegiane is the Maintenance Supervisor at Moatize: “Vale knows the level of equipment required to start operations at the mine and has in-depth knowledge of the machinery that we are using around the world. Hitachi has a good reputation and is renowned for continuously developing its mining equipment. “The high level of on-site support is an extremely important aspect of operating two Hitachi EX8000-6 and three EX5500-6 excavators. The conditions in
Since Hitachi introduced the UH801 mining shovel in 1979, it has manufactured and delivered hundreds of ultra-large excavators (over 120 tonnes) to mines and quarries all over the world. The latest range of EX-6 series models has been developed in response to the increase in demand for resources with a greater capacity for excavation and loading, and unprecedented levels of performance, efficiency and availability. To meet huge annual production targets, the bucket capacity on Hitachi ultra-large excavators has been optimised and the reach of the front attachment has been shortened. The engine output has also been
SPECIFICATIONS Engine rated power (kW) Operating weight (kg) Maximum digging depth (mm) Maximum bucket digging force (kN)
8
Hitachi Construction Machinery (Europe) NV
boosted to significantly increase production capacity and efficiency. The reliability of the tried-and-tested diesel engines helps the EX-6 excavators to consistently meet high availability rates for 24/7 mining operations. The cooling performance of the radiator and oil cooler adds to the protection and ultimate durability of the engine and hydraulic devices. All Hitachi ultra-large excavators come equipped with a spacious working environment providing excellent visibility for the operator. The cabs are fitted with LED lighting, an air-suspension seat, user-friendly control levers and a large LCD monitor.
Mozambique are so tough that the maintenance and service are crucial to our operation. Hitachi supplies the parts and service for the excavators, and if we didn’t have a good system in place, it would be very difficult to maintain our production levels. “The availability of both models has been excellent as a result of this support. Also, the design and layout are good, which is especially useful for replacing parts and general maintenance.”
Each machine has safely designed steps and walkways, which enhance the access to the machine for easy maintenance and servicing work. The EX-6 series is suitable for operating in extreme temperatures, from tropical regions to cold environments and highlands. They can also be supplied with an optional interface for the world’s leading PC-based mine management systems – manufactured by Wenco International Mining Systems Ltd (a Hitachi group company) – which help to effectively control a mine’s mobile assets for enhanced productivity, availability and efficiency.
EX1200-6
EX1900-6
EX2600-6
EX3600-6
EX5600-6
EX8000-6
567
775
1,119
1,450
1,119 x 2
1,400 x 2
114,000
192,000
254,000
361,000
537,000
811,000
9,380
14,430
8,250
8,580
8,800
13,800
569
671
830
1,050
1,480
2,230
Mining and quarrying equipment
9
EX-6 excavators
CASE STUDY Lime & Stone Production Company
CASE STUDY Kumtor Operating Company
Job site:
Location:
Kumtor gold mine (4,000 metres above sea level)
Job site:
Tien Shan mountain region, Kyrgyzstan
Location:
Modim Quarry near Tel Aviv, Israel
Production: 316.5 tonnes of gold reserves (mined by an open-pit method)
Production:
six million tonnes of aggregates per annum
EX1200-6
Solution:
EX3600-6
Solution:
The Quarry Manager Shmulik Nachumi has seen the significant impact that the company’s first excavator has had on the production: “The Hitachi EX1200-6 is very safe and stable for excavating the materials from the quarry face or floor. “This has been a successful project in terms of changing the method in which we load the materials. The site has been adjusted to suit the excavator and it’s already proved to be excellent in terms of its accessibility and loading time.” Nissim Gridish has been an operator for 21 years, with his latest charge being the EX1200-6: “The Hitachi excavator is very strong and extremely powerful, so it delivers a high level of productivity. It’s easy to excavate the materials and it is able to lift an incredible amount with each pass. The cab offers good all-round vision, is very stable and makes me feel confident and safe in my work.”
Rodney Stuparyk is Kumtor Operating Company’s Vice President of Operations, who is responsible for maintaining a safe and efficient operation to achieve the annual production targets: “We purchased five EX3600-6 excavators, because Hitachi has a reputation for reliability, performance and service in the mining industry. “Kumtor is a 24/7, 365-day operation that mines ice, moraine and rock, and the machines are working well to help us reach the gold veins. The commitment of our employees, service providers and equipment has to be 110%, and Hitachi is supporting our work processes and dedication to be a world-class operation.
10
Hitachi Construction Machinery (Europe) NV
“The EX3600-6s’ production capabilities also match those of our rigid dump trucks perfectly. The 21m3 bucket size means that one of the 105m3 payload trucks can be filled in four or five passes and we consider this to be the optimum level of productivity. “In addition, we have found that they deliver a favourable cost of ownership in comparison to the other excavators. Production is still our biggest priority and the Hitachi excavators need to run like clockwork – it’s all about ounces in a gold mine – and so they are allocated to the hard rock to move more tonnes of materials.”
Mining and quarrying equipment
11
Rigid dump trucks
The power of technology
The Talvivaara Mining Company runs a fleet of eight EH3500ACIIs (and two EX3600-6s) at the largest mine in Finland, located near Sotkamo, in temperatures as low as -32°C and as high as 35°C. The decision criteria to purchase these dump trucks and excavators were lifetime cost, reliability, performance/output and local support – and Hitachi ticked all of the boxes.
“Lifetime cost, reliability, performance/output and local support – all of these boxes were ticked with Hitachi” Arto Suokas, Mining Manager, Talvivaara Mining Company Hitachi rigid dump trucks are the ideal partner for EX-6 ultra-large excavators and offer similar benefits in terms of reliability, productivity and availability. An impressive model line-up and the development of advanced technology ensure that Hitachi sets the standard as the perfect solution for heavy-duty mining and quarrying operations. The specialist knowledge and extensive experience of Hitachi’s engineering teams across several industry sectors have contributed to the latest models. They benefit from Hitachi technologies at large – such as transportation, logistics, power and industrial services – and are subjected to months of rigorous testing before being rolled out into the European market. For example, the AC-3 products feature the Advanced Hitachi AC Drive System, which is the only one on the market designed and built by the same manufacturer. It was developed using propulsion technology –
that also powers Japan’s bullet trains – to ultimately outperform previous and rival systems due to its simplicity, efficiency and reliability. In addition, the latest rigid dump trucks feature the third generation of the Hitachi Drive Control System, incorporating slip control for traction (similar to active traction control) and slide control for grip (similar to an anti-lock brake system). They also have a pitching prevention feature for a smoother ride and control of bouncing when stopping, and a Slip Angle Control function for stable cornering on slippery roads. An advanced braking system allows precise braking and quick system responses, and a Hitachi system monitor provides display information and diagnostics of all onboard systems and controls. A camera monitoring system, SkyAngle – developed in conjunction with Clarion Co., Ltd (a Hitachi group company) – has been tested and introduced to enhance safety.
Spanish company Percasa utilised a fleet of up to 17 EH1100s (and an EX1200-6) on a project to transform the exterior port at Punta Langosteira near La Coruña. The Hitachi dump trucks and excavator were selected after a trial period, proving that they were more reliable and capable of working longer than the contractor’s previous machinery.
12
Hitachi Construction Machinery (Europe) NV
SPECIFICATIONS
EH1100-3 EH1700-3 EH3500ACII EH4000ACII EH5000AC-3
Engine rated power (kW) 520 710 1,414 1,864 2,125 Maximum travel speed (km/h) Maximum payload (kg) Body capacity, heaped (m3)
57.9
55.7
55.7 56 56
66,330
104,720
184,800
244,200
296,000
38.7
60.4
111
153
202
Mining and quarrying equipment
13
Rigid dump trucks
CASE STUDY First Quantum Minerals
Job site:
Location:
Kansanshi copper and gold mine Solwezi, Zambia
Production:
400,000 tonnes of copper per annum (by 2015)
EH3500ACII
Solution:
FQM’s Project Manager John Coleshaw oversaw the installation of a trolley assist system: “We have invested in 23 of the latest electric EH3500ACIIs to add to our existing fleet of 11 dump trucks for a new 2.75-kilometre trolley line. Hitachi offered the only solution for electric-drive 180-tonne trucks when we were in the market for these products. “The EH3500ACII is a good machine and our operators are happy with their working environment. A main benefit of these models is the automatic retarding control to regulate the downhill speed, which is excellent for safety and preserves the lifetime of the product.” Hugo Truter of Hitachi Construction Machinery (Zambia), Ltd. was the Assembly Coordinator for the Hitachi machines: “The advantages of using the trolley line are reduced running costs – due to less fuel consumption – and the increased life expectancy of the equipment. “The electric trucks excel in environmental performance, in terms of achieving low emissions and noise levels. They also have a lower risk of breakdown and require fewer parts, which in turn means lower costs, less maintenance and consequently minimum downtime.”
14
Hitachi Construction Machinery (Europe) NV
Mining and quarrying equipment
15
ZW-5 wheel loaders
The ultimate operating experience
Skyra Lima selected a large ZW-series wheel loader for its aggregates quarry, beside the Stavrovouni Monastery in Cyprus, due to its excellent mobility and reduced running costs. It is fast, stable and has a strong chassis, ideal for loading rock on the quarry floor and manoeuvring up and down the site’s 11 benches.
“I find the cab to be extremely comfortable and this also helps to make it easy to drive” Anders Fossum, ZW220-5 operator, Farbu & Gausen Hitachi has designed a new wheel loader range to satisfy the requirements of its European quarrying and mining customers. Each ZW-5 model has an exceptional level of comfort, excellent productivity and advanced technology, as well as a range of features for enhanced sustainability, safety and easy maintenance. The cab is spacious, with ample legroom and offers greater visibility from the operator’s seat thanks to the standard rear-view camera with built-in monitor, pillar-less windshield and large sun visor. The air-conditioning system and sound insulation also improve the experience of working on long shifts and in extreme conditions. Hitachi wheel loaders’ water-cooled turbo engines comply with EU regulations on emission standards and deliver a powerful digging performance, impressive travel speeds and excellent fuel consumption. They
are easy to operate on every job site and the advanced clutch cut-off system allows smooth operation while loading materials on to trucks. There are two simple work modes: ‘Standard’ for loading, regular operations and travelling on level terrain; and ‘P’ for heavy-duty excavation and travelling quickly uphill. A new hydraulic circuit facilitates the combined operation of the bucket and lift arm for loading, and prioritises the use of the bucket for unloading to maximise productivity. The optional auto-engine shutdown function avoids fuel wastage and a muffler filter captures air pollutants. A variety of easy maintenance features include: the redesigned engine and radiator covers that can be opened fully for accessible daily inspection; and the automatic reversible cooling fan for cleaning the radiator.
SPECIFICATIONS
ZW220-5
ZW250-5
ZW310-5
ZW330-5
ZW370-5
ZW550-5
Engine rated power (kW)
145
181
213
213
289
396
17,700-18,030
20,210-20,640
24,510-24,710
26,630-27,100
33,680-34,300
46,700-47,500
2.4-3.5
2.8-3.8
3.2-4.5
4.1-5.2
4.8-5.6
5.0-6.8
Operating weight (kg) Bucket ISO heaped (m3)
Maximum breakout force (kN)
16
Hitachi Construction Machinery (Europe) NV
185*
*Equipped with 2.4m3 rock bucket with bolt-on teeth
186*
*Equipped with 2.8m3 rock bucket with bolt-on teeth
231*
*Equipped with 3.2m3 rock bucket with weld-on adapter and teeth
225*
*Equipped with 4.6m3 general purpose bucket with bolt-on teeth
261*
*Equipped with 5.4m3 general purpose bucket with bolt-on teeth
463*
*Equipped with 6m3 rock bucket with weld-on adapter and teeth/ segment edge
Mining and quarrying equipment
17
ZW-5 wheel loaders
CASE STUDY Farbu & Gausen
Job site:
Location:
Hall Farm quarry Inderøy peninsula, Norway
Production:
400,000m3 of limestone
ZW220-5
Solution:
Farbu & Gausen Managing Director Even Gausen has taken delivery of the first ZW220-5 wheel loader in Europe: “The main decision criteria for us to buy construction machinery are reliability, running costs, and operator comfort and usability. The bottom line is the total cost of ownership and Hitachi machines are favourable in this respect, especially with regard to fuel economy. “The reliability of the ZW220-5 will help us to maintain our reasonable running costs. It is not only user friendly and comfortable to operate, but it also has a better loading capacity than the previous machine. With increased efficiency, it is more economical and making a positive impact on our business.” The machine’s operator, Anders Fossum, agrees: “I’ve only got positive feedback on the new Hitachi wheel loader. It is powerful, fills the bucket well and is very stable when moving with a full load. Overall, I find the cab to be extremely comfortable and this also helps to make it easy to drive.”
18
Hitachi Construction Machinery (Europe) NV
Mining and quarrying equipment
19
© Hitachi Construction Machinery (Europe) NV (HCME). All rights reserved. Reproduction in whole or in part is forbidden except with the written permission of HCME. While every effort is made to ensure the accuracy of information published, HCME is not responsible for inaccuracies or omissions. All views expressed are not necessarily those of HCME.
Hitachi Construction Machinery (Europe) NV Siciliëweg 5 – haven 5112, 1045 AT Amsterdam PO Box 59239, 1040 KE Amsterdam, The Netherlands T: +31-(0)20 44 76 700 F: +31-(0)20 33 44 045 www.hcme.com
KS-EN272EU Printed in Europe
