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Cutting as an Alternative to Blasting
This was also the standard method used for many years by Gesso Integral at their open-cast mine. However, for CEO Marcos Vasconcelos Ferreira, the not exactly environmentally friendly mining method with its particular need for strict safety precautions no longer represented a forward-looking, state-of-the-art solution. During the search for a more efficient extraction method, he came across the Surface Miner from Wirtgen, which cuts, crushes, and, if required, also loads the cut and crushed rock into trucks in a single pass. The raw materials are selectively extracted in purest quality, which allows optimum exploitation of mineral deposits. The deployment of the first Surface Miner was a technological game changer that more than doubled productivity at the open-cast mine. The purchase of a second 220 SM Surface Miner enabled production at the mine to be increased by a further 84%. The success story also has a personal side to it. The company was deliberately looking for someone with no previous experience with large machines as an operator for the new Surface Miner. Marlete Ribeiro Souza Guajajára was recruited locally and trained as a machine operator. “My boss told me that he needed an unskilled person he could train from scratch for the job. And that person turned out to be me. At the time, I had never even learned how to ride a bike, a motorcycle, or drive a car.” His trust in the abilities of his new employee paid off. In the meantime, working with the Surface Miner has become second nature to Marlete, and she knows how to make the best of the machine’s advantages. “It’s a very comfortable machine that makes our daily work here much easier,” said Ms. Guajajára. Mining by cutting enables the selective extraction of raw materials with outstanding purity. At the same time, it reduces noise and dust emissions and increases safety at the mine. Thanks to low-vibration extraction, the method also enables the exploitation of mineral deposits in the immediate neighborhood of infrastructure or residential areas. With an average cutting depth of 23 cm and a cutting width of 2.2 m, the Surface Miner enables the company to achieve a production volume of 1.25 million t/y of gypsum. The piece sizes of the cut and crushed material are already ideal for numerous commercial uses and eliminate the need for a classical pre-crushing stage.
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