Birla Cements' operation near the city of Chittorgarh, in Rajasthan, northern India, is home to the world's largest fleet of 17 giant HB 10000 heavy breakers. The company runs a large fleet of HB 10000's in its limestone mining works. Thanks to a comprehensive Epiroc maintenance contract with an extensive spare parts inventory, Birla's breakers are up and running 24/7.
Headquartered in Kolkata, Birla Cements is part of the M.P. Birla Group, with cement production in seven locations in India and a total capacity of 15.5 million tonnes per annum. Chittogarh, where Birla Cements’ limestone mining operation is situated, is home to the historic Chittor Fort.
Since the Chittor Fort is a UNESCO World Heritage site, no conventional mining activities are allowed within a radius of 10km. Therefore, Birla Cements opted for blast-free mining using rig mounted heavy hydraulic breakers for primary rock excavation. For this purpose, they invested in a total of 17 Epiroc HB 10000 heavy breakers, and a further five HB 10000’s are on order.
In 2015 Birla Cements was looking for a reliable breaker which could work for 3,500 hours without major breakdowns. Epiroc introduced them to the HB 10000, a machine legendary for its sheer breaking power. The power generated in a single impact between piston and working tool is said to correspond to a weight force of around 760 tonnes. And impact frequency is up to 380 blows per minute.
However, to optimise the HB 10000 for the specific task of primary rock excavation, the customer discussed certain upgrades with Epiroc’s design engineers. These included features like double ContiLube II for enhanced lubrication, easy-to-fix split wear bushings and modified flange seals to withstand the high temperatures.
Epiroc’s patented Intelligent Protection System (IPS), a fully automated, state-of-the-art system that provides simpler, more efficient, and more economical operation, was implemented as well.
The terrain on the mining site near Chittogarh is compact strata, with compressive strength of 100-160mpa. The rig-mounted hydraulic breakers work three shifts continuously with production at more than 15,000 tonnes a day.
Within the scope of Birla Cements’ comprehensive maintenance and spare parts contract, Epiroc is on hand around the clock to ensure trouble-free operation with minimum machine downtime. The contract includes repair and maintenance support, with people available 24/7 to ensure availability and maintain productivity. Extensive aftermarket inventories are maintained at both the customer’s site and at Epiroc warehouse near to the site.
Jerry Andersson, general manager at Epiroc Mining India Limited, said: “Our thanks to Birla Cements for recognising the true potential of our HB 10000 in their application. They were looking for blast-free mining operations, and the technical team here at Epiroc were happy to respond to their suggestions for optimising our equipment for the task. Excellent results are being achieved with our heavy hydraulic breakers, and we have developed a strong partnership with the customer. We will continue to monitor the pulse of their operations and adapt to their needs.”
