Tag Archives: cone crusher

Metso LT300HP mobile cone crusher hits new milestone for Danoher Group

Comminution of minerals, Mining equipment, , , , , , ,

A Metso LT300HP mobile cone crusher owned and operated by Danoher Group, a leading mining contractor in southern Africa, has clocked more than 30,000 hours and counting.

Acquired in 2012, the Metso LT300HP mobile cone crusher is currently deployed at a job in Mbombela, Mpumalanga, where Danoher Group is contracted to produce 350,000 tonnes of road stone.

Previously, the machine has been deployed on some flagship projects in South Africa and Botswana. In the past 12 years, the machine has been in Botswana on four occasions, where it executed some major projects at flagship mines such as Debswana’s Orapa diamond mine and Khoemacau, a long-life copper-silver mine located on the Kalahari Copper Belt. In addition, it has also been deployed at Danoher’s own Kgale Quarry in Gaborone.

With just over 30,000 hours on the clock, the machine is one of the several Metso units in Danoher’s crushing and screening fleet with such a long lifespan. In fact, says CEO Scott Danoher, the company has neither retired nor scrapped a single unit in the past 15 years, shining the spotlight on its drive to achieve extended operational lifecycles out of its capital assets and a testament to the quality of the Metso products.

Danoher Group places value on several factors when investing in capital equipment, such as standardisation of equipment and relationships with suppliers. However, one of the principle factors that informs the company’s buying decisions is equipment longevity. While there are various elements that influence longevity, Danoher stresses that the fundamental ‘raw material’ is the design of the machine, which is why the company trusts Metso for its comminution equipment needs.

“We do not necessarily buy a crusher or a screen, for example, for whatever amount, we buy the number of hours that the machine gives us,” Danoher says. “For us, it is also not about the price tag, it is more about the cost per tonne or cost per hour – ‘cradle to grave’, which is a totally different approach. We are prepared to pay a premium upfront in exchange for, say, 30,000 trouble-free hours out of our crushing equipment.”

By sticking to a trusted brand like Metso and Pilot Crushtec as well as implementing proactive maintenance strategies, Danoher Group not only extends the operational lifespan of its capital assets, but also optimises equipment performance, minimises downtime and reduces costs to ensure smooth and efficient operations, it says.

“Proper maintenance and care throughout the lifespan of equipment significantly contribute to its longevity,” Danoher says. “To get the best out of our maintenance efforts, we largely use Metso OEM parts and spares from Pilot Crushtec International.”

Over the years, Danoher Group and Pilot Crushtec, the Metso dealer in southern Africa, have built a strong working relationship.

“Relationships play a crucial role in what we buy. For us, Pilot Crushtec are more than just suppliers: they have become trusted business partners,” Danoher concludes.

Three-machine train Metso mobile crusher ups productivity at chrome mining project

Comminution of minerals, Mine operation news, Mining equipment, Mining services, Steel and iron ore, , , , , , , , , , , , ,

A newly acquired Metso Lokotrack® LT200HPS™ is winning the day for Zizwe Opencast Mining at one of its strategic chrome mining projects in Steelpoort, Limpopo, according to the leading South African mining contractor.

With productivity high on the agenda in a highly abrasive chrome-processing application, a three-machine train of Metso mobiles – comprising a Lokotrack LT120™ jaw crusher, a Nordtrack® S2.11 scalping screen and a Lokotrack LT200HPS™ cone crusher – is making light work of the 200 t/h production target.

Joe de Beer, Crushing and Screening Plant Manager at Zizwe Opencast Mining, has been impressed in particular by the new Lokotrack LT200HPS cone crusher, equipped with a hanging screen. By featuring a detachable screen and return conveyor on one tracked chassis, he says, the LT200HPS is basically ‘two machines in one’, thus eliminating double-handling on site.

“The fact that the LT200HPS does the job for two machines was central to our purchasing decision,” De Beer says. “It features a detachable screen and return conveyor which guides screened oversize material back to the cone crusher. It is essentially a cone crusher, a screen and a conveyor on one tracked chassis.”

Yeshen Achary, Sales Engineer at Pilot Crushtec, said: “Traditionally, we have always brought the LT200HP in a standard configuration. Because cone crushers by their nature are not 100% efficient, the added benefit of having a screen post the crushing chamber is that it allows for recirculation of any oversize material back to the cone crusher.”

This, explains Achary, eliminates the need for another machine to work in closed circuit with the cone crusher. Having a single machine doing the job of two machines offers significant cost benefits for the customer.

Achary says: “Apart from the obvious capital cost benefit, having the cone and screen on a single chassis means that the machine is powered by a single engine, making one less machine to maintain. Having a closed loop on a single chassis also makes it easy to transport the machine between sites.”

Francois Marais, Sales and Marketing Director at Pilot Crushtec, explains that the LT200HP now comes in three different configurations. Apart from the standard cone crusher configuration, it is now available with a pre-screen called the HPX™, which is placed just before the crushing chamber or alternatively with an overhanging screen called the HPS, located post the crushing chamber.

He said: “In traditional operations, you would need two machines – a cone crusher and a screen – to do the same job done by this single machine. In addition, you would probably have to deploy a minimum of two to three conveyor belts to recirculate oversize material from the screen back to the cone crusher.”

Sandvik Rock Processing navigates choppy waters to deliver Africa’s first SmartPlant

Automation, Comminution of minerals, Energy minerals, Mineral processing, Mining equipment, Mining services, , , , , , , , , , , , , ,

A fluorite mine some 100 km outside Pretoria, South Africa, has become the first recipient of Sandvik Rock Processing’s first locally-manufactured SmartPlant™ in Africa.

Following its recent commissioning, the 300 t/h plant has already met process guarantees and reached nameplate capacity, according to the OEM.

To improve efficiency and productivity, a South Africa-based fluorspar producer went into the market for a new processing plant in 2020. The SmartPlant concept from Sandvik Rock Processing appealed to the customer for several reasons, but mainly because of the fast delivery time, flexibility and substantial cost savings it would offer the operation.

SmartPlant is a range of pre-defined Sandvik SmartStations that can be mixed and matched to meet individual customer needs for maximum productivity and performance, thus reducing wait time, maximising uptime and increasing profitability, according to Sandvik. Delivery generally takes about 22-30 weeks ex-works. Where there are peripheral design changes to the pre-defined SmartStations, lead times may be shorter than the standard 22-30 weeks.

According to Jaco Benade, Project Manager– Crushing and Screening at Sandvik, the deal was negotiated midway through the COVID-19 hard lockdown of 2020. The order was placed during Level 5 of the lockdown, with manufacturing commencing during Level 4. Despite the challenges brought about by the travel restrictions, compounded by the global supply chain disruptions, the plant was still delivered on time and within budget.

“A major talking point of the project was the short delivery time of 22 weeks ex-works at a favourable capital cost for the customer,” Benade says. “The SmartPlant concept allowed the customer to choose from the pre-defined SmartStations, combine and configure them to meet specific site and operational needs, with no extra design and engineering costs.”

While the designs are very much pre-defined, the SmartPlant still offered a great deal of flexibility for the customer, according to Glen Schoeman, Vice President – Sub-Sahara Africa at Sandvik Rock Processing.

“The modular approach of the SmartPlant meant that the customer could tweak design parameters such as height, capacity and liner profiles, amongst others, without much concern about cost deviations and time implications,” Schoeman said.

Regarding flexibility, Sandvik’s approach to the project was also a major plus for the customer. For example, based on its understanding of the customer’s budget and time constraints, Sandvik opted for the mine to commission a conveyor supplier of its choice, purely to shorten the time to production and reduce costs for the customer.

In line with Sandvik’s ‘safety first’ culture, the project was delivered with no lost time injuries, all the way from project inception to commissioning.

“Despite the arduous conditions on site, ranging from excessive heat to wet weather conditions, the project was completed with an impeccable zero harm safety record,” Schoeman says.

The new plant comprises a full suite of Sandvik equipment, including jaw and cone crushers, screens and feeders. Informed by customer needs, Sandvik opted for a much bigger front end of the plant, comprising a large tip area and bigger jaw crusher. The Sandvik CJ412 primary jaw crusher, which takes a 750 mm top size, is fed by a box bin and a grizzly feeder.

The plant also employs two Sandvik CH840i cone crushers for secondary and tertiary crushing, the very first units of the company’s 800i series range of cone crushers in Africa. Another first in Africa is the rotary feeder on top of the cone used to distribute material into the crusher.

“This is a fantastic approach,” Benade says. “The rotary feeder turns slowly, evenly distributing material around the edges of the crusher. This reduces pressure peaks in the crusher caused by uneven feed, a common challenge in crushing plants. The rotary feeder has passed with flying colours in terms of its performance at this particular site.”

The CH840i cone crushers come with Sandvik’s Automation and Connectivity System as standard. The system continuously monitors and optimises crusher performance and controls the complete lubrication system, increasing uptime and reliability. It can automatically adjust crusher settings to compensate for crushing chamber wear, ensuring consistent product size, according to Sandvik.

In addition, the SAM by Sandvik digital service supports operational excellence in the plant.

Benade concluded: “SAM by Sandvik brings people, activities and data together in an easy-to-use, seamless and collaborative way. It allows both client and OEM remote access to the plant. The system itself provides a holistic view of the plant, enabling the customer to make informed decisions and the OEM to respond proactively to any equipment health and performance issues.”

Metso Outotec to deliver crushing, flotation and thickening tech to OZ Minerals West Musgrave

Base metals, Comminution of minerals, Mineral processing, Mineral project development, Mining equipment, Mining services, , , , , , , , , , ,

Metso Outotec says it has been awarded an order for the supply of key minerals processing technologies to OZ Minerals’ West Musgrave copper-nickel project in Western Australia.

The OEM’s scope of delivery includes an MP1250™ cone crusher, as well as Planet Positive classified flotation units and high-rate thickeners.

The TankCell® e630 flotation units (pictured) are the most proven large-scale cells in the 600 cu.m-plus category and come with the largest installed base of operating cells in the world, according to Metso Outotec.

Metso Outotec’s high-rate thickeners, meanwhile, were selected for their state-of-the-art technology and based on references from similar process plants, it said. Laboratory test work was conducted by Metso Outotec to aid thickener selection.

Kai Rönnberg, Vice President, Minerals Sales – Asia Pacific at Metso Outotec, said: “We are very excited to work on the West Musgrave project with OZ Minerals. We were able to align with the project’s key value drivers at an early stage and provide expert technical support.

“OZ Minerals has selected leading-class Planet Positive process equipment for their nickel and copper production process, and they will also be able to benefit from our extensive aftermarket capabilities and footprint in Western Australia.”

In September, the OZ Minerals Board greenlit the build of the West Musgrave copper-nickel project. The feasibility study the board signed off on detailed a 13.5 Mt/y operation with average production of circa-28,000 t/y of nickel and circa-35,000 t/y of copper over a 24-year operating life.

Superior Industries to showcase eight new products at CONEXPO-CON/AGG 2023

Bulk handling, Mining equipment, Mining events, Mining services, , , , , , , , , , , , , , , ,

US-based bulk material processing and handling systems specialist, Superior Industries Inc, is planning to showcase more than 250 tons (227 t) of products at CONEXPO-CON/AGG 2023 in Las Vegas, Nevada, in March, with at least eight of the products representing brand new launches.

Included among this new product offering is an expanded cone crusher portfolio, with two brand-new cone models introduced and shown alongside Superior’s Patriot® Bushing Cone.

Superior explained: “First, the Dakota™ Bearing Cone, which will earn credibility for its efficient use of horsepower per tonne, a straightforward lubrication system, and a wide range of liner profiles. The other new cone crusher will be called the Endeavor™ Spider Bushing Cone. Operationally, it’s an uncomplicated design that accepts a wide range of feed sizes with an adjustable stroke for fine tuning.”

Superior also plans to display its Liberty® Jaw, Valor® VSI, and Sentry® HSI crushers.

In addition to this, Superior plans to debut a new quick-to-erect modular wash plant.

According to Superior, its increasingly broad portfolio of Fusion® Modular Platforms are a good match for aggregate producers seeking semi-static plants that are easy to install and maintain with a more economical price tag than portable plants or design-build projects. On display, the company plans to erect a 8 x 20 ft (2.4 m x 6.1 m), three-deck Guardian® Horizontal Wet Screen Fusion Platform with an Aggredry® Dewatering Screen attached to one of the discharge points.

In 2023, it will mark the eighth time Superior will display its famed TeleStacker® Conveyor (pictured) at CONEXPO-CON/AGG – and each show there is new technology to showcase and new success stories to share. With radial travel, variable height and a telescopic conveyor, TeleStacker Conveyors stockpile material in a way that overcomes material segregation. This show, Superior will display a 42 in (1.06 m) x 170 ft (52 m) XTP Swing Axle model with a working automation panel that visitors can interact with in the booth.

Lastly, Superior will display a wide variety of its own conveyor components, with the manufacturer planning to show more than three dozen individual idlers, pulleys, scrapers and other conveyor accessories. New products include a redesigned line of Exterra® Belt Cleaners with some brand-new options, a modular Load Zone Skirting System for dust and spillage control, and unique Application-Specific Idler Bearing Seals for longer-lasting idlers in demanding conditions.

CONEXPO-CON/AGG 2023 will run from March 14-18, 2023, in Las Vegas, Nevada. International Mining is a media sponsor of the event

Tungsten West set to bring Hemerdon tungsten-tin mine back into production

Base metals, Mineral processing, Mineral project development, Mining equipment, Mining finance, Mining services, Precious metals, , , , , , , , , , , , ,

Tungsten West, the mining company focused on recommencing production at the Hemerdon tungsten and tin mine in Devon, England, has announced its intention to proceed with an initial public offering on London’s AIM market.

The company has conditionally raised £39 million ($53 million) before expenses, with plans to debut on the bourse on October 21 with a market capitalisation of approximately £106.2 million.

The net proceeds of the offer, together with the $49 million project financing from a fund managed by Orion Resource Partners, will be used to, among other things, execute the planned capital expenditure and corporate commitments of £44.6 million for improvement works at the Hemerdon Mine, bringing it back into commercial production.

Hemerdon is, Tungsten West says, the third largest tungsten resource globally, as well as being a previously producing mine that was operational from 2015-2018. Tungsten West purchased the Hemerdon Mine in 2019, and has since completed a bankable feasibility study that demonstrated an extensive reserve of approximately 63.3 Mt at 0.18% W and 0.03% Sn, as well as 37.4 Mt of saleable aggregate material. The company estimates that the life of mine is currently 18.5 years with the opportunity to extend this through future investment.

The mine already has the majority of its infrastructure in place, with previous owner Wolf Minerals Ltd having invested over £170 million into the development of the mine and its processing facilities, which include an open-pit mine, mineral processing facility and mine waste facility, the company says. With a substantial amount of existing infrastructure, the development costs associated with re-starting the mine are estimated to be £44.6 million. This existing infrastructure also means that the rebuild is only expected to take 12 months, with parts of the restart project already underway.

Having acquired the mine out of a receivership process, Tungsten West completed a significant amount of work to enable it to understand and address the issues historically experienced by Wolf Minerals, including a 6,113 m geological exploration drilling program and several technical studies. The company has identified the past issues experienced by Wolf Minerals that required rectifying.

“One of the main issues was a poor mineral process route design, with several items of equipment, particularly in the front end of the plant, causing plant downtime and hindering the recovery of the tungsten and tin minerals,” Tungsten West says. “Tungsten West has therefore designated a material proportion of its rebuild costs to modifying and updating the front-end of the processing plant. This will include replacing the existing crushing circuit with new duty and standby primary jaw crushers and secondary cone crushers.”

In addition, the introduction of X-ray Transmission ore sorting, which the company previously carried out tests on with TOMRA Mining in Germany, substantially reduces processing costs by rejecting around 70% of the ore fed to the sorters, it says.

Further upgrades to the plant commenced by the previous operator will be completed, including the dense media separation feed stockpile where 24 hours of surge capacity will be installed, decoupling the front-end of the plant from the concentrator circuit.

“Through these actions, the company expects plant operating time to improve from circa-53% under previous operatorship to the industry standard of circa-81% under Tungsten West,” Tungsten West says.

Tungsten West has identified further opportunities for by-product cash flow through the production and sale of aggregates. A new aggregate plant will be fed with ore sorter rejects and with the waste streams from the processing plant. The business plan is to sell to local aggregate consumers, such as GRS, providing them with a stable, long-term and sustainable source of these materials.

The company says it has implemented a number of initiatives to ensure a minimal impact on the surrounding environment and local community. These include optimising the plants low frequency noise to ensure minimal environmental impact and a fully cash funded £13.2 million restoration bond.

Max Denning, CEO of Tungsten West, says: “With the proposed £39 million raise announced today, and the £36 million funding package from Orion, we will be fully funded for the development of Hemerdon back into production. We look forward to welcoming new investors into this compelling business and working with all our stakeholders to ensure that the newly reinvigorated Hemerdon mine is a beacon of mining excellence in the UK.”

Metso Outotec to supply Vertimills, cone crusher to IAMGOLD’s Côté project

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

Metso Outotec is to supply key comminution technology to IAMGOLD Corporation and Sumitomo Metal Mining’s joint venture Côté gold project, in north-eastern Ontario, Canada.

The delivery consists of two energy-efficient Vertimill® 4500 grinding mills (pictured) and one MP1250 cone crusher for the Côté gold project.

Andy Lingenfelter, Vice President, Minerals Sales, North & Central America, Metso Outotec, said: “Low energy and wear part consumption, as well as process flexibility, were decisive factors for the Côté gold project team when selecting the comminution equipment.

“Metso Outotec was consulted during the prefeasibility study and supported IAMGOLD on several projects. IAMGOLD’s technical team had solid confidence in the Vertimill technology, and they were also familiar with the high-performance capability of the MP crushers.”

The value of the order exceeds €10 million ($11.9 million) and has been booked in Minerals’ March quarter 2021 orders received.

Côté comes with estimated contained gold reserves of over 7 Moz. Construction of the gold mine commenced in late 2020, and is expected be completed in mid-2023.

Metso celebrates 10,000th Nordberg HP cone crusher sale

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Metso says it has reached the significant milestone of 10,000 Nordberg® HP cone crushers sold globally.

The most popular modern cone crusher in the world, the company says, the HP Series™ celebrates its 30th anniversary this year.

The 10,000th HP cone crusher unit was handed over to the French aggregates and asphalt producer and urban infrastructure development company, Eurovia, in a ceremony held today at Metso’s Mâcon facility in France.

Arto Halonen, Vice President, Aggregates Crushers at Metso, said: “The HP is undoubtedly one of Metso’s most widely used innovations. It’s a technology that has been evolving throughout the years to meet customers’ changing needs, making their operations more successful through proven performance and reliable output. That’s most likely why HP has become an industry standard for a variety of aggregates and mining applications.”

The origin of the HP Series cone crusher can be tracked back to Milwaukee, USA, in the early to mid-1980s. “The technological breakthroughs by the Nordberg research program re-defined crushing performance and provided the basis for a new type of cone crusher introduced in 1989: the Nordberg High-Performance cone crusher series, today simply known as the HP,” Metso said.

Today, HP cone crushers are engineered and manufactured in Metso’s competence centre in Mâcon, France, with manufacturing also in Brazil, China and India.

A versatile crusher, it is used in a wide range of fixed and mobile applications, varying from limestone to taconite and ballast production to manufactured sand, Metso said.

Halonen continued: “Know-how from developing the HP and from thousands and thousands of customer applications around the world has played an integral part in Metso research and development initiatives in crushing.

“This is an important milestone for Metso and we want to thank our customers for their continued confidence in us during the first 30 years of the HP’s journey and look forward to explore new development possibilities in the years to come.”