Equipment shortcomings cause production disruptions

The process of breaking down oversized material is critical to maintaining steady rock flow and production in the large-scale iron ore operation. A couple of years back, Rana Gruber was facing constant disruptions due to a breaker boom system that failed to meet their demanding requirements. Mechanical failures, substandard materials, and poor system design led to frequent hydraulic breakdowns and slack in the boom’s structure, leading to constant rescheduling and adjustments. Because the original parts did not fully meet the site’s production requirements, custom-made cylinders had to be manufactured locally. The breaker boom’s base did not allow for the necessary movement, leading to repeated stoppages in the crushing process. In addition, poor cabin placement limited visibility and further complicated this crucial material sizing task.

Xrock’s X88-650R boom system

“When the boom was down, we had to rely on an excavator as an emergency backup to break oversized rocks,” said Odd Gunnar Jacobsen, Planner for mass relocation at Rana Gruber. “This wasn’t just costly in terms of operator hours and emissions, it also created significant safety risks with heavy machinery moving around an already busy site.”

Whenever the breaker boom was out of service, an alternative dumping pocket outside the main operation area had to be used. All oversized rocks were rerouted there, creating logistical challenges and further delays. These emergency measures not only disrupted production but also strained the team’s ability to keep operations moving smoothly.

“This was unbearable and burdened our operators’ and service people’s workload in an unsustainable manner.” concluded Paul Olsen, Planner for mechanical maintenance at Rana Gruber.

The combination of the right equipment and expert support makes all the difference

Xrock’s X88-650R boom system and Xrock XB32 hammer

Efficient oversize rock processing and breaking boulders are essential to keep the material moving and prevent bottlenecks. Without a reliable breaker boom, the crusher becomes a blockage, slowing down material flow and impacting productivity across the site.

Determined to find a sustainable and reliable solution, Rana Gruber turned to Normet Xrock for help. Normet Xrock, formerly known as Rambooms, had already earned a strong reputation in the industry. Word was out that these breaker booms were robust, reliable, and well-suited to the demands of challenging mining environments.

From the feasibility study stage, Xrock focused on improving and adding value to the entire process, not just replacing the boom. It started with a thorough process assessment, during which the application expert from Xrock spent a week on-site developing a customized plan to integrate the new boom into Rana’s processes. As part of this overhaul, the overall layout was redesigned, a new right-sized breaker boom system was installed, and the operator room was relocated to maximize visibility and safety during rock-breaking.

Since the implementation of Xrock’s X88-650R boom system and Xrock XB32 hammer, Rana Gruber has seen great improvements in this critical part of their operation. Productivity has improved significantly, directly benefiting overall plant performance. Downtime has been substantially reduced, and servicing is now faster and easier, helping to keep production on schedule. Operator costs have dropped by 50%, as the new boom system only requires a single operator. Safety during secondary rock-breaking has improved, contributing to a safer and more efficient overall plant operation.

While some fine-tuning remains, the results have already been transformative. Xrock’s responsive team and reliable spare parts support rehave ensured that Rana Gruber’s challenges are firmly under control. With this new system, Rana Gruber is better positioned to maintain safe, efficient, and environmentally responsible production for decades to come.