Tag Archives: Crushing

Orica to further optimise blasting and mine-to-mill initiatives with FRAGTrack Crusher

Orica has announced the release of its latest fragmentation monitoring solution, FRAGTrack™ Crusher, an automated pre-crusher fragmentation measurement tool delivering, it says, operational continuity in a safe and reliable way.

Based on the success of the existing suite of automated post-blast fragmentation monitoring solutions, Orica has developed FRAGTrack Crusher to meet growing demand from customers for downstream monitoring and optimisation solutions at every stage of the mining value chain, the company said. The technology leverages the latest deep neural network artificial intelligence (AI) framework along with “industry-proven” hybrid 2D and 3D particle size distribution (PSD) processing methods to deliver a fully autonomous adaptive fragmentation monitoring solution at the crusher dump pocket, enabling customers to measure material on the truck during the tipping operations, according to the company.

The company said: “FRAGTrack Crusher provides truck-by-truck PSD analysis of rock fragments during the dumping operation with unmatched accuracy and without impacting operations or productivity.”

The technology delivers constant performance tracking for both the drill and blast operations and the downstream processing functions, driving continuous improvements end-to-end in the mining value chain. When bundled with Orica’s FRAGTrack Conveyor technology in a fragmentation monitoring solution, it enables further analysis of the crusher’s performance and the impact of blasting parameters in a production workflow in real time, according to Orica.

Orica Vice President – Digital Solutions, Raj Mathiravedu, said: “The full adoption of AI technology into our architecture, coupled with our strategic partnership with Microsoft, allows us to expedite the delivery of capabilities that were not previously possible, and FRAGTrack Crusher is an example of how we leverage AI to help deliver intelligence and value to our customers.”

PSD data is provided via a real-time application programming interface and industrial open platform communication unified architecture protocol to drill and blast software and crusher distributed control systems, allowing seamless integration into the existing site operation workflows, Orica says.

FRAGTrack Crusher has already been gaining traction globally in the mining and quarry markets, where it is being used as a critical enabler of blasting optimisation and mine-to-mill initiatives, according to the company. “This signals a significant transformation from the subjective nature of existing manual PSD analysis methods while eliminating the safety concerns of on-bench photography and the extensive time required to manually process and correlate to relevant data sets, including fleet management data to determine the material’s blast of origin.”

In the most recent application of FRAGTrack Crusher in a Tier One low-cost gold operation in Western Australia, it successfully delivered an automated blasting optimisation workflow on site leveraging PSD as a primary key performance indicator to throughput and overall mill performance. The project included installation of a FRAGTrack Conveyor system, post crusher, allowing pre- and post-crusher PSD to be monitored. When combined with a fragmentation improvement process, the FRAGTrack solution enabled a continuous feedback loop that enabled the operation to rapidly optimise blast designs that drive overall project profitability, according to Orica.

Weba Chute Systems solves choking problem at Botswana diamond mine

Weba Chute Systems has come to the rescue of a large Botswana diamond producer suffering from continuous chute maintenance with a customised solution that came with a 12-month guarantee.

This primary crusher discharge chute had been a headache for the company, with the crunch coming when, after considerable capital expenditure, the new conventional chute needed maintenance just six weeks after installation.

Hilton Buys, Regional Manager at Weba Chute Systems, said: “This could not continue and the mine needed a long-term solution which is why we believe they came to us for a proposal. Senior experts from our company visited the site to take a careful look at the conditions the chute needed to deal with, and we took our conclusions back to our design office.”

Among the challenges were large lump sizes in the ore stream, contributing to build-up of material in the chute and regular choking, Buys said. Also, while Botswana’s dry season is long, the rain that does fall causes considerable problems to the flow dynamics. The kimberlite on the mine – depending on which part of the pit it comes from – can become very sticky in wet weather, according to the company.

“We therefore had to pay particular attention to flow angles, and the design had to effectively accommodate both wet and dry conditions,” Buys said. The concept design – which included quick-release lips on dead boxes – was approved by the mine and the final design, manufacture and successful installation was conducted.

Adding to the complexity was that the feed end of the primary crusher was some 8 m below ground level, while the crusher itself stood about 10 m tall. The chute had to be positioned below the rock box, which stores the material from the crusher discharge, channelling the stream into the Weba chute at a transfer height of 9 m to the conveyor belt.

“The conventional chute also created excessive dust through uncontrolled rock velocity over this considerable transfer height,” Buys said. “By contrast, our chute’s controlled flow meant that the mine did not even have to apply its dust suppression system.”

After installation, Weba Chute Systems gave the customer a 12-month guarantee on this chute, as it does with all its new chutes. This guarantee, which comes with regular inspection reports, assures the customer that the performance will meet their expectations.

“These inspections allow us to monitor wear, so we can advise the customer on what action is required so that they can schedule maintenance and avoid unexpected downtime,” Buys said.

Installed in 2017, the chute is still operating with little maintenance, having been delivered at a highly competitive price compared to the one it replaced.

“Designing a long-lasting chute is not just about creating a box with some reinforcing where you think there will be wear,” Buys said. “It is an endeavour that must be scientific, based on in-depth analysis of material and flow conditions.”

Buys highlighted the importance of asking a range of technical questions about the specific application so the design answers those needs. The latest software and modelling tools are then applied by the Weba Chute Systems team to guide the most effective design.

CSI to deploy ‘innovative’ screening solution at Roy Hill iron ore operations

CSI Mining Services (CSI), a wholly owned subsidiary of Mineral Resources Limited (MRL), has been awarded a mining services contract by Roy Hill at its iron ore operation in Western Australia’s Pilbara region.

This new contract builds on CSI’s long-standing relationship with Roy Hill, which has seen CSI provide crushing and screening works since early project inception. The new contract will see CSI deliver an expanded scope of work which includes crushing, screening and haulage services.

CSI says it is uniquely positioned as a key service provider to Roy Hill given its strong track record of exceeding performance targets and detailed understanding of the mine and its operational processes and procedures.

In delivering the new contract CSI will deploy an innovative new screening solution to deliver industry-leading efficiencies to the project. The screening solution is an exclusive product to CSI and is not available on the market, giving CSI a distinct design advantage.

Mineral Resources’ Chief Executive Mining Services, Mike Grey, said: “We are very pleased to be selected as preferred mining contractor by Roy Hill to provide safe and efficient crushing, screening and haulage services, following the successful completion of our previous contract.

“Our track record at the operation demonstrates that we can mobilise quickly and exceed production targets, while maintaining an industry leading safety record.

“Our mining services business has delivered strong growth year-on-year and this new contract for Roy Hill reinforces CSI’s position as a market leading mining services contractor.”

Roy Hill Chief Operating Officer, Anthony Kirke, said: “CSI has been a valued partner to Roy Hill since February 2017, initially providing crushing services, followed by the addition of screening and associated haulage services for our Direct Shipped Ore. CSI’s agility in responding to changing operational requirements, commitment to innovation and continuous improvement and alignment with our values have resulted in positive outcomes for Roy Hill.

“The award of this new and expanded multi-year contract reflects the strong relationship between our two companies and we look forward to the deployment of CSI’s new screening solution at our mine site.”

Metso Outotec expands India facility on track-mounted crushing/screening equipment demand

Metso Outotec is to invest in extending its current manufacturing capacity of mobile track-mounted crushing and screening equipment in Alwar, India.

The total Alwar production value is planned to grow by 30% from the current level and global track-mounted mobile machine capacity by 15%, the OEM said. Construction of the new factory facilities is planned to start in early 2022, and be completed by the end of the year.

The increased capacity in India will be used for the manufacturing of McCloskey mobile and Lokotrack equipment, employing approximately 200 additional people. After the extension is completed, the Alwar factory will be one of the biggest manufacturing sites of Metso Outotec, employing some 800 people, the company said.

“This is another step in developing our domestic and export business in India,” Markku Simula, President of the Aggregates business area of Metso Outotec, said. “At the same time, we are also investing significantly in engineering and R&D resources in Alwar and making it one of our global engineering hubs.”

FLSmidth set to showcase lithium engineering expertise at ioneer’s Rhyolite Ridge

ioneer Ltd has awarded a major engineering and equipment supply contract to FLSmidth for the development of the Rhyolite Ridge lithium-boron project in Nevada, USA.

The contract has been awarded on a limited notice to proceed (LNTP) basis, with the supply of the equipment packages being conditional on a final investment decision on the project by ioneer’s Board of Directors.

Under the contract, FLSmidth has commenced work on product engineering for the equipment packages, which include crushing and material handling equipment, plus lithium carbonate and boric acid dryers.

FLSmidth, Ioneer says, has significant experience in providing technology, equipment, engineering and services expertise to the battery minerals sector. It has a strong US presence and is committed to improving project efficiency while reducing environmental impacts on site.

FLSmidth has also introduced ioneer to Denmark’s Export Credit Agency (EKF) regarding potential financing options.

ioneer Managing Director, Bernard Rowe, said: “The contract with FLSmidth is one of the more significant supply packages we will award at Rhyolite Ridge and represents another step in the development of the project.

“FLSmidth is focused on providing environmentally sound engineering and technology solutions. This aligns with ioneer’s ambition to not only produce materials necessary for electric vehicles and renewable energy infrastructure, but to do so in an efficient and environmentally responsible manner through lowered emissions, significantly reduced water usage and a small surface footprint.”

FLSmidth Mining President, Mikko Keto, said: “This contract provides clear recognition of our experience, know-how, and world-class technologies for processing lithium. It is also important to note that our localised approach and strength in service and aftermarket were important factors for ioneer when it came to choosing a partner.”

The lithium and boron resource at Rhyolite Ridge is estimated at 146.5 Mt, including a reserve of 60 Mt. The company expects to mine and process 63.8 Mt over the 26-year mine life at an average annual rate of 2.5 Mt/y. This will see it produce, on average, 22,340 t of lithium carbonate (99% purity) (years 1 to 3), 21,951 t of lithium hydroxide (99.5% purity) (year four onward) and 174,378 t boric acid (life of quarry).

Metso Outotec, Mineral Resources deliver the next generation of crushing

What will crushing plants of the future look like? Mineral Resources Ltd and Metso Outotec have pondered that question and have since gone on to answer it with the delivery of a modular, scalable and relocatable plant at an iron ore operation owned by one of the world’s biggest miners.

Called ‘NextGen II’, the solution represents a ground-breaking approach to delivering safe and reliable production to the hard-rock crushing industry, Mike Grey, Chief Executive of Mining Services for Mineral Resources, says.

And it all started with a test for one of the company’s most technically minded individuals.

“We were sitting around the boardroom table with David De Haas, one of our key engineers on this project, and gave him the challenge to come up with a crushing plant that we could literally relocate anywhere very quickly, build on a very small footprint, and have it plug and play,” Grey told IM in a recent IM Insight Interview.

Mineral Resources, which counts CSI Mining Services (CSI) as a wholly-owned subsidiary, was in a unique position to deliver on this.

A provider of world-class tailored crushing, screening and processing solutions for some of the world’s largest mining companies, CSI specialises in build, own, operate (BOO) projects where it provides both the capital infrastructure and the operational expertise to ensure these crushing plants operate to their potential on site.

It carries out crushing services for Mineral Resources’ own mines, as well others across the mining sector.

Crushing collaboration

When offering such ‘crushing as a service’ type of contracts, the service must be underpinned by the best equipment possible.

Enter Metso Outotec.

Having initially commenced discussions with the global OEM in early 2019 (when it was still Metso), Mineral Resources, later that year, agreed with Metso on the design and delivery of a new type of crushing solution.

The pair recognised early on in these conversations that the industry was changing and they, as service and solution providers, needed to change with it.

The largest bulk commodity operations in the world are made up of multiple pits that get mined over time. As these operations expand, miners are left with a dilemma: extend the haulage time from the pit to the plant or build another plant.

The NextGen II crushing plant has provided a third option.

(Credit: Mineral Resources Ltd)

De Haas, collaborating with Metso Outotec, has delivered on the board’s brief with the design for a crushing plant able to produce 15 Mt/y using a modular design made up of several stations. The plant can move with the mining, being erected and taken down quickly without the type of in-ground services that can scupper such moves.

The first plant delivered under this collaboration is now operating in the Pilbara at a very well-known iron ore operation.

Customised crushing

Guillaume Lambert, Vice President of Crushing for Metso Outotec, provided some specifics.

“The NextGen II is a crushing and screening plant to crush iron ore and produce lump and fine products,” he said in the IM Insight Interview. “The process starts with a primary station made up of a Metso Outotec apron feeder (below left), followed by a vibrating grizzly scalper.” Then starts the size reduction process with a Nordberg C150 jaw crusher (below middle).

From this primary station, the ore goes to three secondary crushing stations, each comprised of an MF3072 banana screen (below right) and Nordberg HP400 cone crusher.

(Credit: Metso Outotec)

Fines and lump are the products from this secondary station, with the oversize arranged in close circuit with the screen, Lambert said.

The screen was designed specifically for the project – offering the compact dimensions that could fit inside the station’s footprint. Other customised add-ons included specialised cooling rooms for the lubrication units and extensive steel fabrication works.

Lambert added: “Really, the tailoring of design is around the modularity of the different stations. Each station is made up of several modules. All those modules can be pre-assembled and tested in a factory and transported by road to the site. This has been established to enable a fast erection process.”

This turned out to be the case with the very first NextGen II installation.

Despite a timeline setback caused by the global pandemic, the 1,500 t of steel needed for the plant construction was built in 16 weeks, starting in March 2020 and ready by July 25 of that year. It was shipped to CSI’s Kwinana facility in Western Australia for pre-assembly before delivery to site.

Final commissioning took place in early 2021, and the crusher has been working well since.

(Credit: Mineral Resources Ltd)

R U OK?

A distinctive blue colour, the plant reflects Mineral Resources’ commitment to mental health awareness and support, carrying the phone number and colour of Lifeline, a Western Australia-based charity formed to prevent suicide, support people in crisis and reduce the stigmas which can be a barrier to seeking help.

“It is really important for us to promote mental health; our fly-in fly-out workforce has matured over some years, but the challenges around working remotely remain,” Grey said. “It is important that we demonstrate we have the support mechanisms in place to support our workers and their families.

“The NextGen II plant is at the forefront of that – it is the first thing people see when they come to work and the last thing they see when going home. They can always reflect and make sure their work mates are OK.”

(Credit: Mineral Resources Ltd)

Support and service

The plant’s operating success has been helped by a local service and support network from both companies, with Metso Outotec providing critical spares and all large “rotable refurbishments” serviced by CSI’s Kwinana facility.

This is underwritten by a remote condition monitoring service that can see personnel and parts from both companies deployed to site at a moment’s notice.

This comprehensive offering has seen close collaboration between Metso Outotec’s Minerals (capital equipment) business, Service business and MRL’s own service team.

Understanding the challenges and potential delays for parts deliveries due to MRL’s remote location, the companies agreed to a specific consignment inventory close to the site to ensure parts availability and exclusivity for MRL to better support the operation.

In addition, a Metso Outotec service expert is present for maintenance and shutdown events to provide expertise and support to the MRL maintenance team.

Grey and Lambert said the collaboration has been a win-win for both companies.

“Working with Metso Outotec on this project has allowed us to define the scope together, rather than remotely,” Grey reflected. “That allows us to ensure we deliver to the timelines and then make any necessary changes on the run, hand-in-hand. We deliver the solution together.”

Lambert added: “Metso Outotec is an indisputable leader in crushing and screening technology, as well as plant. However, working with MRL, we learned a lot about improving the design of our station to maximise safety and improve accessibility in a very, very compact environment for high-capacity plant.”

In demand

This is unlikely to be the first and last next generation crushing plant to come out of the OEM/service provider collaboration.

While iron ore was the commodity of choice for the first installation, Lambert said there was potential for these types of plants featuring in base and precious metal operations.

“The NextGen II plant is very flexible,” he said. “Each station is individually plugged into the solution, and we can easily upgrade the crusher, the screen, etc throughout the year depending on capacity needs.”

Adding or removing some stations could see the throughput reduced or increased, with Lambert even talking about the ability to construct a 30 Mt/y plant that can be built, erected and relocated in the same way as the first 15 Mt/y plant.

“In addition, NextGen II, today, is designed for iron ore applications with lump and fine products,” he said. “If we want, we can add a tertiary crushing stage in order to produce only fines for iron ore. This can match with copper and gold operations also.”

There are plenty of gold miners extracting ore from multiple pits that could provide a strong business case for the installation of such a plant. Similarly, there is potential for this working at major open-pit copper mines.

Lambert concluded: “There is, for sure, global demand for modular crushing plants. Today, having a fast and safe erection process is a must in many countries and locations. In addition, we have more and more short-term operations emerging in very remote locations, so having the possibility to minimise civil works is key for a lot of our customers.”

To watch the full IM Insight Interview on ‘Mining’s next generation of crushing solutions’, click here.

Pilot Crushtec and Metso Outotec extend partnership

After five years representing global leader Metso Outotec in southern Africa, South Africa-based Pilot Crushtec has renewed its distributorship for another half decade.

Pilot Crushtec, despite periods of challenging economic conditions in recent years, has earned global accolades within the Metso Outotec distributor network, with Francois Marais, Director Sales and Marketing at Pilot Crushtec, saying the company has already won annual awards for Best Aftersales Distributor and for Best Sales Growth.

“We value this partnership with one of the world’s leading brands and have demonstrated through our solid performance the positive synergies that we leverage,” Marais says. “The years from 2017 through to 2019, in particular, saw exceptional growth year-on-year for both our Metso Outotec offering and our business as a whole.”

He highlights that the two companies’ offerings in the crushing and screening market complement each other very well, and they share a commitment to high quality products, service and support.

“For customers, the renewal of our distributorship confirms their faith in our products and strengthens their security of investment going forward,” he says. “It assures the market once again that their capital investments are being well supported through our extensive parts holdings and service excellence.”

The new agreement covers additional products and territories within the region, facilitating a wider offering in terms of new equipment and aftermarket aspects. According to Adam Benn, Director Capital Sales, North EMEA, Russia & CIS and Southern Africa at Metso Outotec, there was no hesitation in renewing the distribution agreement with Pilot Crushtec.

“Having just celebrated its 30th anniversary in business, Pilot Crushtec has built a strong reputation,” Benn says. “This applies not only to their supply of equipment and associated services, but their experienced team’s hands-on knowledge and can-do attitude to opportunities and challenges.”

He emphasised Pilot Crushtec’s investment in time and resources training their teams and their customer base – an effective strategy for keeping skills current and for listening to customers’ development needs. With technical facilities that, it says, rank among the industry’s best, the company manufactures plant locally while also offering a one-stop repair and refurbishment solution.

“Having a distribution network that is close to its customers is a fundamental part of Metso Outotec’s group strategy,” he says. “In addition to being well located, our distributors need to keep a good inventory of equipment and parts, which is something that Pilot Crushtec prioritises as a vital cornerstone of their business strategy.”

Metso Outotec boosts end-user service offering in central, southern Sweden

Metso Outotec has signed a distribution contract with Mining and Construction Equipment Sweden AB and Värnamo Krosskonsult AB that will see the two Sweden-based firms distribute Metso Outotec’s mobile and stationary crushing and screening equipment, as well as crusher wear parts, to mining and aggregate customers in southern and central Sweden. The pair will also provide service support such as start-ups and repairs in the regions.

Roar Vasbø, who is heading Metso Outotec’s sales and service in the Nordics region, said: “We’re very pleased to enter this cooperation. For the customers, it means better and faster local service. For us, it means that we can improve customer experience and reach out to more potential customers in the region, especially contractors.”

Fredrik Wennberg, Managing Director of Mining and Construction Equipment Sweden, said: “Our aim is to serve the markets as one-stop-shop. We offer service, parts, equipment and know-how close to the customer.”

He added: “Flexibility is very important to our customers, especially for the contractors. We offer rental possibilities and stock units so that the customers are able to get their equipment quickly.”

Kristofer Almén, Managing Director of Värnamo Krosskonsult, concluded: “This is a great opportunity for us to be able offer Metso Outotec aggregate equipment to greenfield projects or to brownfield stationary plant projects. It will strengthen our competitiveness and help us serve the market better.”

The main location is Värnamo with equipment and parts stock, and a service workshop. Sales offices are in Stockholm, Värnamo and Ystad. The staff includes around 20 personnel in service, sales, and construction engineering.

MLG Oz bolsters NSR Jundee work, adds Norton Gold Fields and Mincor to contract mix

MLG Oz says it continues to experience historically high levels of tendering opportunities for its suite of mining services, with three new integrated site services and haulage contracts recently added to its remit across its Western Australia operations.

MLG, which listed on the ASX earlier this year, says it offers a range of value added services from bulk haulage, crushing and screening, aggregate and sand supplies through to export logistics.

At Northern Star’s Jundee gold operation in Western Australia, the company has been awarded preferred contractor status for an expansion of its services, providing integrated site support and haulage capacity at the mine. Subject to negotiation and execution, this new three-year contract is expected to commence around August and deliver some A$12 million/y ($9.2 million/y) in revenue.

The scope of works will consist of integrated site support to the company’s mill feed operations from both its Jundee central underground mines and its regional satellite operations, MLG said. It will see the ASX-listed contractor conduct all crusher feed, bulk haulage and site civil works for the operations under its integrated operating platform.

MLG has added two new clients to its roster, too – Norton Gold Fields and Mincor Resources.

Norton Gold Fields has chosen MLG as its successful tenderer to provide integrated site support services and haulage for its Paddington gold operation over a three-year period expected to commence in September. Revenue from this opportunity is estimated to be around A$14 million/y, with formal contract documentation anticipated to be finalised in the coming weeks.

And, in line with MLG’s desire to broaden its service offering across different commodities and, in particular, the battery metals space, it has executed a contract with Mincor Resources for the provision of the logistics services associated with its Kambalda nickel operation. The contract is expected to deliver approximately A$3 million/y in revenue over four years and is expected to commence in the March quarter of 2022.

Reviewing these contract awards, MLG Founder, Managing Director and majority shareholder, Murray Leahy, said: “We are very pleased to be given the opportunity to continue to support and grow with Northern Star which has been a long-standing customer of MLG.

“We are delighted that the Norton Gold Fields Board has selected MLG to support the Paddington processing facility. The mill is 35 km northwest of Kalgoorlie and aligns very strongly with our existing Kalgoorlie network.

“Our new contract at the Kambalda operations is an important first step for MLG in developing a longer-term relationship with Mincor in support of its goal of being a key supplier of nickel to the emerging battery metals market.”

In addition to announcing these contract awards, MLG also provided a market update on its crushing and screening activities.

It said: “MLG’s crushing and screening operations, which account for 20% of MLG’s forecast financial year 2021 revenue of A$241.6 million, have experienced a reduction in available material to process from several clients across the last quarter of financial year 2021, due to production constraints at various client operations. We anticipate this will negatively impact the crushing and screening revenue in the first half of financial year 2022. Despite this, and given the company’s current pipeline, including as evidenced above, the board expects the overall impact of this to be mitigated in the second half of financial year 2022.”

Metso Outotec ball mills, Vertimills heading to Mapa’s Liberia and Burkina Faso gold mines

The Turkish conglomerate, Mapa Group, has awarded Metso Outotec a contract for the delivery of key grinding technology to its gold mine expansion projects in Liberia and Burkina Faso.

The value of the order is approximately €19 million ($23 million), and it has been booked in the company’s Minerals June quarter orders received.

Mapa is a major conglomerate working in various industrial and construction sectors, including mining.

Mustafa Bülent Karaarslan, COO of the Mapa Group, said: “For us, good support, reliable project execution, and sustainable equipment and process performance are essential. Alongside the existing good relationship between the companies, they’re the reasons why we selected Metso Outotec for these projects.”

Metso Outotec will deliver identical grinding lines to both sites, consisting of state-of-the-art Premier™ ball mills (one pictured) and energy-efficient Vertimill® VTM-3000 stirred mills, each line featuring a capacity of 400 t/h. The deliveries are expected to take place in January 2022.

Mert Katkay, Head of Minerals Sales for Metso Outotec in the Middle East and Turkey, said: “We are excited that Mapa has chosen us to deliver the key equipment for the expansion of these two projects in Liberia and Burkina Faso. Previously, we have delivered the key crushing, screening and grinding equipment to these two mines.”