Tag Archives: Comminution

FLSmidth to deliver MissionZero comminution equipment to KCGM gold operations

Comminution of minerals, Mineral project development, Mining equipment, Precious metals, Sustainable mining, , , , , , , , ,

Northern Star Resources Ltd has placed an order for a wide range of FLSmidth mineral processing technologies for its Kalgoorlie Consolidated Gold Mines (KCGM) Operations’ mill expansion project, according to the Denmark-headquartered OEM.

KCGM Operations are east-northeast of Perth in Western Australia, part of one of the richest goldfields in the world, the so-called Golden Mile close to the city of Kalgoorlie-Boulder.

The order is valued at approximately DKK 515 million ($75.1 million) and was booked in the June quarter of 2023. The equipment is due to be delivered during 2024.

Under the agreement, FLSmidth will supply a range of MissionZero products covering most of the flowsheet, including SAG mill, ball mill, primary crusher, pebble crushers, flotation cells and a pre-leach thickener. In addition to these technologies, the order also includes spare and wear parts. Upon installation, these technologies will substantially reduce the mine’s energy consumption.

The 20 MW grinding mills will be the highest power, gear-driven mills in the world and the ball mill will be the first gear driven 28 ft (8.5 m) diameter ball mill, according to FLSmidth.

“This order is yet another important milestone in our ambition to enable zero emission mining by 2030, and we are very pleased with Northern Star Resources’ contribution to fulfilling this ambition,” Mikko Keto, CEO at FLSmidth, said.

This week, Northern Star announced the final investment decision on the KCGM Mill Expansion project, agreeing to invest A$1.5 billion ($1 billion) to boost the mill’s capacity to 27 Mt/y, from 13 Mt/y.

Northern Star Resources’ Managing Director, Stuart Tonkin, said of the FLSmidth order: “Northern Star’s purpose is to generate superior returns for our shareholders, while providing positive benefits for our stakeholders through operational effectiveness, exploration and active portfolio management. Being a responsible producer for the benefit of our shareholders, employees, other stakeholders and the communities in which we operate is key to our sustainable operations. We are pleased to partner with globally leading technology suppliers like FLSmidth in advancing our five-year profitable growth strategy.”

Metso boosts comminution power at Zijin Mining’s Julong copper concentrator

Base metals, Comminution of minerals, Mine operation news, Mining equipment, Mining services, , , , , , , , , , , ,

Metso says it has been awarded an order for key concentrator plant equipment by Zijin Mining Group for its Julong copper project in the Tibetan Autonomous region.

The value of the order is approximately €85 million ($93 million).

The comminution circuit will be one of the highest powered in China, including a Superior™ MKIII primary gyratory crusher, a geared Premier™ SAG mill and gearless mill drive (GMD) Premier ball mill with 24 MW of installed power, as well as four Nordberg® HP900™ cone crushers, Metso says.

To ensure efficient and sustainable concentrate separation, Metso will deliver 24 TankCell® TC630 flotation cells, five HRT Hight Rate Thickeners, and two Larox® FFP2512 filters. Thanks to their superior energy- and water-efficiency, most of the equipment are part of Metso’s Planet Positive offering, the company added.

Xun Fang, Head of Metso’s Minerals Sales in Greater China, said: “We are very pleased to have been chosen as the partner to deliver the concentrator plant equipment for this ambitious project. The Julong copper mine is located on the Qinghai-Tibetan Plateau at an altitude of 5,300 m, one of the highest mining sites in the world. The elevation of the plant places tough requirements for the equipment. This is one of the reasons Zijin Mining chose Metso, as our technology is known for its sustainability, reliability and high performance. The delivery includes a GMD ball mill, the first GMD mill to be delivered to China and the most powerful ball mill ever made. TankCells and High Rate Thickeners to be delivered are high-capacity equipment, reducing embedded carbon and increasing overall plant availability. Two of the thickeners are for tailings and are 100 meters in diameter. In addition, our local service capability is highly appreciated by the customer.”

Starkey’s SAGDesign comminution testing solution to be used at major miner’s project

Comminution of minerals, Mineral exploration, Mining services, ,

Starkey & Associates says it has arranged a sole source $1 million value contract with a major international mining company looking for geometallurgical ore hardness testing using its patented SAGDesign solution for process plant design.

The company in question is developing two orebodies and requires this testing to design SAG mills using data from the entire orebody for each plant. The goal is to size the initial SAG mills and related process equipment to maximise profits for each life of mine operation.

To do this before any equipment is purchased, ore grades and hardness test results (which control capacity) must be kriged into the mine plan. That will allow the whole operation to be designed, first by optimising the initial equipment capital costs and then by maximising the profits in the plant constructed, as metal prices vary during normal market cycles, Starkey said.

Starkey says it has developed the most accurate ore hardness test (SAGDesign) that uses 15 kg drill core samples with accuracy within +/- 5% and repeatability of +/- 3%. This technology has been patented and used since 2004 to design AG and SAG mills with no failures in achieving specified grinding capacity, the company claims. It has also been used in Russia since 2006 on almost every SAG mill design project, until February 2022, when Starkey’s cordial agreement with TOMS was halted by war.

To better introduce its technology in North America, Starkey will sell several Master Licences (MLs) to major mining companies that will forgive clients paying royalties for the SAGDesign tests that they do, it explained. One ML has been sold in the USA and royalty-free testing has started. All 16 Starkey partner test labs will benefit from MLs because ore hardness test work will increase. Companies who do not buy MLs will continue to pay for tests including royalties payable to Starkey.

Starkey said: “Mining companies are realising that since an orebody is their biggest asset, and the advent of accurate ore hardness testing data is available, that the era of testing minimal holes, designing for constant hardness and never questioning original mine designs, has changed for large mining projects. Mining operations are becoming more sensitive to metal pricing while at the same time optimising their equipment capital expenditure, plant operating expenses and ore reserves. For example, it may be better to run low-grade soft ore at high t/h, when metal prices are high. Most plant designs and t/h forecasting to date have not used such detailed analysis because previous hardness data was not accurate enough to use in this way.

“SAGDesign testing is practical and accepted by clients. It has also been used effectively where legal challenges are involved.”

MetsoOutotec-testing

Metso Outotec on the need for holistic testing

Automation, Base metals, Comminution of minerals, Energy minerals, Environmental, Metallurgy, Mineral exploration, Mineral processing, Mining equipment, Mining services, Precious metals, Sustainable mining, Water management, , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , ,

The Metso Outotec global network of testing, research and product development facilities covers the whole process flowsheet from comminution through separation, to filtration, refining and pyrometallurgical/hydrometallurgical processing.

It has centres all over the globe – in Australia, Brazil, Chile, Germany, Finland, Peru, USA and more – able to, the company says, offer extensive expertise and circuit simulation to a wide range of industries.

Metso Outotec’s research and testing services include evaluation of ore types, mineralogical characterisation, feed material testing, sampling, materials selection, analytical chemistry and flowsheet development.

To get a flavour of this extensive research and testing portfolio, IM spoke to Alan Boylston, Director, Process Engineering at Metso Outotec, and Rodrigo Grau, Technology Director – Minerals Processing at Metso Outotec, about the capabilities of two of the company’s facilities – York (USA) and Pori (Finland), respectively, while also touching on Metso Outotec’s global testing and research capabilities.

In 2022, the company announced a consolidation of its minerals testing services in USA into a single 5,500 sq.m facility in York able to eventually cover the full minerals value chain and support the mining industry worldwide. Pori, meanwhile, focuses on mineral technology, hydrometallurgical processes development, pyrometallurgy and ferroalloys technology and material technology. In other words, the company conducts laboratory and pilot test work, flowsheet development as well as validation and development of new technologies for the industry.

IM: Will the York facility now be seen as your ‘testing centre of excellence’?

AB: The York facility is a centre of excellence for testing, but we have many of these within the company. Our global presence, the knowledge and our expertise at each of these locations is one of the factors that sets us apart.

Each of our locations is a centre for excellence in its own field. Pori, for example, has extensive research capabilities, Sorocaba in Brazil focuses on comminution and beneficiation testing, while Lappeenranta Dewatering Technology Center concentrates on thickening and filtration. Each location is an integral part of our global testing offering. In addition to these, we have various facilities around the globe covering also aggregates and pyrometallurgical testing, research and development.

That being said, the effort we have made to expand the York Test Center gives us a much better advantage for research and testing in North America, compared to a few years ago. We can now do more pilot-scale testing, especially with equipment like our HRC™800e high pressure grinding roll (HPGR). We can also carry out pyrometallurgical testing, plus conduct magnetic separation tests. At some point in 2023, we also expect to add thickening and filtration testing to this remit. But this is a very high-level view of what we have to offer in the York location.

Metso Outotec has a global network of testing, research and product development locations

IM: Even with this consolidation in USA, are you expecting to collaborate with other global facilities when it comes to testing processes throughout the flowsheet?

AB: Yes, absolutely. For example, we have a project coming in right now where the sample was first in Tampere (Finland) for some crushing test work, before they split off a sample for us for grinding test work in York and then Pori is also receiving a sample for some broader mineralogy testing.

This speaks to why we are able to claim to have global capabilities. No matter the testing or research need, we are able to assist our customers to get the job done. This all goes towards one goal – the customer’s benefit.

IM: How do you see these testing capabilities interacting and benefitting from other modelling work you carry out in-house? For example, do you anticipate using these facilities and the likes of the Geminex digital twin in unison to offer clients physical and digital representations of flowsheet options?

RG: Modelling is very important for us. In each project we work on, modelling and simulation are at the heart. Here in Pori, we carry out flowsheet development and technology validation. One of the outputs of our work is to end with a simulation of an industrial plant. Going from that simulation into Geminex is just one more step we will be taking in the future.

AB: At the York lab, we are now moving to a SCADA-based system to run everything: when a sample comes in, it gets tagged and identified and we then automatically know what test to run. We have tablets to, for instance, setup all the parameters of a test for an HRC 800e. We can start and stop the test on that tablet and see the real-time information coming in as the test is being carried out. That data is also being stored for future use.

We’re undergoing a program right now to build out a database function where all the post processing of this data goes on in the background and can then be seamlessly integrated into things like our HRC simulation software. We are building the backbone to carry out that real-time digital twinning.

IM: Do you anticipate your global testing capabilities to lead to a higher uptake of Planet Positive solutions?

AB: With our customers having a huge focus on sustainability, I do. As an example, since we have had the pilot-scale HRC 800e available for testing, it has been fully booked. In 2023, we are preparing for a test plan where we could take the HRC product and go directly into a pilot Vertimill. Those are two Planet Positive approaches we are putting together in a single test plant to show how far we can push energy efficiency and media consumption reduction.

RG: I would definitely agree with Alan. And to add to that – for example at Pori, we do a lot of hydrometallurgical testing and piloting, and that is only increasing with the rising demand for lithium and other battery minerals. And our customers are really looking at how our equipment is reducing their carbon footprint and other sustainability benefits.

You will hear us say it time and time again, but this is definitely a trend that we are seeing at all of our facilities.

Metso Outotec testing and research capabilities cover the entire flowsheet – from comminution through the entire operation to pyrometallurgical/hydrometallurgical processing

IM: Will these expanded testing facilities also benefit your equipment and process R&D work?

AB: I think so. We built this lab to not just be a materials testing facility, but also a research hub, especially for grinding, but also for any other Metso Outotec business area needs. There is definitely a huge opportunity out there for us!

RG: And this rings true around the globe at all our facilities. For example, in separation, we have been testing the Concorde Cell™ flotation technology in Pori for a long time. And that is how we’ve approached development of a lot of our other innovations that go to market.

IM: How would you say industry testing requirements have changed over, say, the last five years?

AB: From our perspective, I am seeing more comprehensive test programs come through.

Instead of, say, one certain test, it is an entire test program with specific timings around evaluations and the ability to develop the flowsheet through the testing required. There is more collaborative designing of the flowsheet taking place through testing than there was five or 10 years ago.

RG: It is certainly more comprehensive now than it previously was.

For example, we carry out early engagement with our customers in Pori and start developing a flowsheet and evaluating the ore types.

The amount of material that is tested nowadays is much bigger than it was before. Obviously, it is not just limited to this example, because, as Alan mentioned before, we’ve got this connection between all our facilities to ensure our customers get exactly what they need from their testing program.

Also, our customers think about different drivers in the process very carefully and want that reflected in the test work. That could be more evaluation on the water they consume. They also look at the energy expended, on top of the expected recoveries and metal grades.

There is more emphasis on sustainability, even at these early stages, in addition to looking at how the ore types may change over time and what impact this will have on the processing requirements.

This is where our extensive simulation and modelling capabilities are leveraged for the biggest impact.

IM: Anything else to add?

RG: Pori and York are but a fraction of the expertise of the wider Metso Outotec research and testing portfolio; one that continues to expand in line with customer requirements. We don’t just cover mining, either – like our equipment offering, we provide research and testing services for the whole flowsheet.

And we are continually improving our capabilities in this space for our customers. So, stay tuned for the future and where we can take research and testing!

Metso Outotec energy-efficient comminution tech heading to Engebø rutile and garnet project

Comminution of minerals, Energy minerals, Mining equipment, Mining services, Sustainable mining, , , , , , , , , , , ,

Nordic Mining ASA has awarded Metso Outotec with an order for the delivery of an energy-efficient comminution technology package for its Engebø rutile and garnet greenfield project in Norway, the OEM says.

Metso Outotec’s scope of delivery includes key comminution and classification equipment, comprising a C-type jaw crusher, Premier™ Rod mill, Vertimill™, and 12 UltraFine Series™ screens, as well as pre-production pilot-scale confirmatory test work.

Ivar S Fossum, CEO at Nordic Mining ASA, said: “This is another important milestone for the Engebø project. We are very pleased to partner with Metso Outotec as the technology and service provider for this vital process equipment.”

Christoph Hoetzel, Senior Vice President, Grinding at Metso Outotec, added: “The combination of Metso Outotec’s Planet Positive equipment is exceptional in this project. By utilising our Premier Rod mill and Vertimill for primary and secondary grinding, as well as our UltraFine Screens for classification, this solution not only provides excellent energy efficiency but also superior sharpness of product particle size distribution. This will maximise the liberation and minimise losses in fines.”

Roar Vasbø, Vice President, Sales and Services, Nordics at Metso Outotec, said Engebø is the first greenfield industrial mineral production site developed in Norway in almost 40 years.

Nordic Mining is expected to produce high-quality rutile and garnet products from an annual run of mine of 1.5 Mt ore at Engebø. The average production and sales volumes of rutile and garnet will be approximately 35,000 t/y and 180,000 t/y, respectively, for the first 10 years of operation, according to the company.

Metso Outotec pyro processing and comminution lines set for Albemarle’s Kemerton lithium plant

Energy minerals, Mineral processing, Mineral project development, Mining equipment, Mining services, , , , , ,

Albemarle Lithium Pty Ltd has awarded Metso Outotec an order for two pyro processing and comminution lines for its Kemerton lithium hydroxide processing plant in Western Australia, the OEM says.

Previously, Metso Outotec delivered two similar pyro process lines to the plant as part of another order.

Metso Outotec’s delivery consists of rotary calciner kilns and coolers, Premier™ ball mills, acid roast indirect rotary kilns and coolers for the pyro processing lines, as well as advisory services for installation and commissioning. Over 90% of the approximately €55 million ($58.6 million) order value is booked in Metso Outotec’s Metals fourth-quarter (December-quarter) orders received and the rest in its Minerals’ orders received.

Chris Urban, Vice President, Heat Transfer at Metso Outotec, said: “Albemarle is one of the largest lithium producers in the world. Commissioning and ramp up of the first two pyro lines delivered by us is currently taking place at the Kemerton plant in Western Australia, and we are delighted to now have received orders for two additional Metso Outotec pyro processing lines.”

The Kemerton plant initially consisted of three production trains, each producing 20,000 t/y of lithium hydroxide, with a potential expansion to five trains that will see production increase to 100,000 t/y by around 2025. The plant will be supplied with lithium concentrate produced at the nearby Greenbushes mine.

Metso Outotec confirms Premier grinding mill order for West African’s Kiaka gold project

Mineral processing, Mineral project development, Mining equipment, Precious metals, , , , , , , , , ,

Australia-based West African Resources has awarded Metso Outotec an order for state-of-the-art comminution equipment worth €30 million ($32 million) to be delivered to its greenfield Kiaka gold project in Burkina Faso.

Metso Outotec’s delivery includes two Planet Positive Premier™ grinding mills with a total installed power of 27 MW, as well as Metso Outotec’s proprietary metal and rubber mill linings and spare parts.

Kiaka, an asset with 7.7 Moz of reserves and resources on its books, is West African Resources’ second gold mine in the country on top of its operating Sanbrado asset.

WAF’s feasibility study, released in August 2022, outlined pre-production capital costs of $430 million and a 2.5-year pre-tax pay back at a $1,750/oz gold price for the project. Kiaka was expected to operate over an 18.5-year life of mine, producing, on average, 219,000 oz/y of gold (on a 100% basis).

Matt Scully, Project Director, West African Resources, said: “We are pleased to again team up with Metso Outotec for this project. West African is in an exciting growth phase, as we aim to be a multi-project, producing more than 400,000 oz/y of gold in 2025.”

Oskar Gustavson, Technology Director, Grinding at Metso Outotec, said: “The Premier SAG mill to be delivered to the Kiaka project is one of the largest gear-driven grinding mills in the world with its 18 MW of installed power. The Premier ball mill has been designed to pair smoothly with the SAG mill. Both mills are equipped with fail-safe Metso Outotec Polymer Hydrostatic Shoe Bearing systems, significantly increasing reliability and reducing maintenance costs. We are delighted to work with West African Resources on this project.”

Weir and Swiss Tower Mills align on energy efficient comminution pathway

Comminution of minerals, Environmental, Mining equipment, Mining services, Sustainable mining, , , , , , , , , ,

The Weir Group has announced a new alliance with Swiss Tower Mills Minerals (STM) in which Weir will market STM’s vertical stirred grinding mills for coarse grinding applications worldwide.

Integrating vertical stirred grinding mills into Weir’s minerals processing flowsheet will provide customers substantial improvements in throughput and energy efficiency, helping them to meet their productivity and sustainability goals, Weir says.

STM’s vertical stirred grinding technology is proven for energy efficient comminution in the mining market with more than 80 units currently operating in the hard-rock mineral processing industry across the globe, according to the company. It is used within the comminution segment of the minerals processing circuit as part of a series of crushing and grinding processes that create the fine particles from which minerals can be extracted through flotation.

Comminution, as has been well documented, is one of the most energy intensive parts of the mine, accounting for 25% of the final energy consumption of an average mine site.

Weir says it is already a leader in comminution technologies, offering solutions such as Enduron® high pressure grinding rolls (HPGRs) to drive down energy consumption by around 40% for customers.

This new alliance with STM takes things to the next level, offering the mining and minerals industry a proven low energy alternative to traditional high energy consuming tumbling mills, it said. Combining and integrating these energy-efficient technologies into a single, optimised flowsheet will deliver significant reductions in energy use, driving down costs and carbon emissions.

In order to prove the most beneficial flowsheet for specific projects, STM has already supplied two vertical test mills to the Weir Minerals HPGR test facility in Venlo (Netherlands). This will put Weir and STM in the unique position to provide clients combined energy efficient grinding test work of HPGR followed by STM’s vertical stirred mill, they said.

Ricardo Garib, Weir Minerals Divisional President, said: “Weir and STM share the same vision of enabling primary resource providers to produce resources in the most sustainable manner. This is a perfect match of best-in-class technology providers. Integrating STM mills with Weir’s comminution products, which includes Enduron HPGRs and Enduron screens, will improve throughput and help bring substantial reductions in carbon emissions.

“This is a real win-win.”

Fritz Moser, STM Chairman, said “Both the HPGR and the STM vertical stirred mills provide significant energy savings compared to conventional grinding technologies. Our new supply agreement with Weir will enable us to fast track the roll out of an innovative flowsheet using STM mills in conjunction with Weir’s Enduron HPGR.”

FLSmidth to highlight full flowsheet expertise with ShalkiyaZinc project delivery

Automation, Base metals, Comminution of minerals, Mineral processing, Mining equipment, Mining services, , , , , , , , , , , , , , , , , , , , , ,

FLSmidth has signed a contract, valued at around DKK950 million ($130 million), to supply a range of mineral processing equipment to ShalkiyaZinc, the operator of a zinc-lead mine in the Kyzylorda Region of Kazakhstan.

The equipment will transform the plant into a world-class facility that efficiently separates minerals with a minimised environmental impact, the OEM says.

Under the agreement, FLSmidth will supply two underground crushing stations with a materials handling system to the process plant; a full package of comminution and separation equipment, including SAG and ball mills, mill circuit pumps and cyclones; the zinc-lead concentrate flotation and regrinding circuit, including nextSTEP, VXP vertical mills, concentrate thickeners and Pneumapress filters; and reagents preparation and dosing area. Full plant automation is also included, as well as installation and commissioning supervision services.

The new concentrator will be supported from FLSmidth’s new in-country service Supercentre in Karaganda, Kazakhstan.

The equipment delivery is to be completed during 2024, with commissioning to start before the end of that year.

Mikko Keto, Group CEO at FLSmidth, said: “We are excited to receive this first order from ShalkiyaZinc, which highlights our full flowsheet expertise. The wide range of equipment included in the order will help ShalkiyaZinc save on both capital expenditure and operating expenditure; our new nextSTEP flotation technology will improve the quality of the concentrates, the SAG mill will provide more flexibility, while the automation and digital solutions will further enable water and energy savings alongside safer operations.

“We look forward to making this a success on so many levels.”

Assel Rakhimova, Chief Project Director of Tau-Ken Samruk, which owns ShalkiyaZinc, said: “After testing and basic design work executed by FLSmidth, we are pleased to enter this new phase of collaboration with the procurement of critical technologies to improve the productivity and sustainability of our plant. We believe in successful execution and look forward to receiving the ordered equipment according to the schedule for installation and to continue working with FLSmidth on commissioning services and spare parts.”

Metso Outotec to deliver world’s largest Premier grinding mills to Kansanshi copper mine

Base metals, Comminution of minerals, Equipment maintenance, Mine operation news, Mineral processing, Mineral project development, Mining equipment, , , , , , , , , , ,

First Quantum Minerals (FQM) has awarded an order to Metso Outotec for two very large horizontal grinding mills for the company’s copper mine expansion at Kansanshi in Zambia.

Metso Outotec’s delivery includes two Planet Positive Premier™ grinding mills with a total installed power of 50 MW – the largest Premier grinding mills Metso Outotec has delivered to date.

To meet the need for efficient and fast replacement of the lining systems, as well as ensuring a long wear life, the ball mill will be equipped with the Metso Outotec Megaliner™ and the SAG mill will be equipped with Metso Outotec metallic mill lining and a high-performance discharge system, it explained.

FQM’s Kansanshi mine, located near Solwezi in the North-western Province of Zambia, is among the largest copper mines in the world and the largest in Africa.

First Quantum Minerals is currently working on its further expansion (the Kansanshi S3 Expansion), which includes a standalone 25 Mt/y processing plant that will increase copper production substantially.

Once the expansion is completed, copper production from Kansanshi is expected to average approximately 250,000 t/y for the remaining life of mine to 2044.

The Premier horizontal grinding mills are customisable solutions built on state-of-the-art grinding mill technology, process expertise, and design capability, Metso Outotec says. The Premier horizontal grinding mills are engineered to “excel and create vast possibilities” for customers and applications.

Earlier this week, Metso Outotec was awarded what it says was a major contract for the delivery of sustainable crushing, screening and grinding technologies to a greenfield iron ore project in South America.