Mini crusher eliminates need to move rubble.

System provides cost-effective method for building roadbeds

After mine operators blast a new underground passageway, there are a couple of major jobs that need to be done before the new tunnel is operational. First, rubble left behind by the blasting usually has to be moved out Second, vehicles need to move around in the tunnels and that means bringing in crushed rock to lay down a roadbed. These are two expensive and time-consuming jobs. But what if the rocks didn't have to be moved out? Instead, what if they could be crushed into rubble tiny enough to build a roadbed?. It's now possible thanks to a new product called the HydraCrusher from Sudbury-based Mining Technologies International Inc. (MTI)

"If you're a miner and you know what you have to deal with, it (the product) just jumps right out at you," says Carl Storey, product manager for MTI. Last fall the new product created quite a stir when introduced at a mining convention in Las Vegas, he adds.

The HydraCrusher fits on the front a scoop tram, a type of front-end loader used in mines. Powered by the hydraulics on the scoop tram, the HydraCrusher's powerful jaws can chomp through about 85 tons of rock every hour.

With its employee list at about 200, MTI may be relatively small, but it is a major player in the mining industry. The company is well known for producing a complete line of rock drilling, loading, haulage and crushing systems. The Hydra Crusher is just the latest addition to an arsenal of unique products, Storey says.

The unit retails for about $130,000, but has the potential to pay for itself rather quickly. Bringing in crushed rock to build underground roads can cost between $40 to $60 a ton. This figure doesn't take into account the cost of removing the blasted rock, he adds.

In contrast, the Hydra Crusher can deliver crushed rock for a cost of about $5 to $8 a ton.

"Every mine is different," says Storey. "But it's a product everyone can use."

Crushing one's own rock does not mean compromising on quality or selection either. One nice feature on the unit is that it can deliver specific-sized rubble, he adds. The HydraCrusher can be set to crush rocks into stones as small as one inch, or as large as eight inches.

Having that kind of flexibility is important when it comes to actually building a roadbed, Storey adds. MTI recommends using its product to first create a base with larger stones, then add a finishing level with smaller ones. A well-constructed roadbed can lead to some big operational savings. A quality road means a smoother ride for vehicles, which will result in less vehicle maintenance, says Storey.

It also means underground vehicles can travel at faster speeds. Vehicles can travel at a pace up to 30 per cent faster on a good roadbed, allowing vehicles to make more trips in a day, thereby improving the overall efficiency of the mine, he adds.

Taking the time to build good roadbeds also means a mine operator can expect to do less maintenance on the roadbed. Grading intervals can actually be extended by as much as 500 per cent, Storey says.

The HydraCrusher is the brain child of Louis Gervais, a backhoe owner and operator from Manitouwage. Ten years ago he started to work on his idea and after plenty of experimentation he brought a successful prototype to MTI.

"Our owner was astute enough to see the opportunity to put this product to market," says Storey.

The HydraCrusher is certainly not the most expensive item in MTI's line of products, but the company is expecting it to make a noticeable impact on annual sales that are already just under $100 million. The first unit is all set to help Falconbridge Ltd. go deeper at its Kid Creek mine. Eventually MTI hopes to sell the HydraCrusher as a package deal with the scoop trains it already manufactures.

Storey is getting inquiries from around the world about the unit. "Everyone who sees this products says, 'I've gotta have one of these,'" he says. Sales are initially expected to be between six and eight units a year and Storey expects to eventually produce the crusher in much larger quantities.