Tag Archives: grinding mills

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.”

Swiss Tower Mills to deliver ‘largest, most powerful’ stirred mills in the world to Russian copper project

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

Swiss Tower Mills Minerals says it has been awarded an order for the delivery of four energy efficient VRM50000-6500 grinding mills for a large greenfield copper project in Russia.

The scope of the project, awarded in the June quarter of 2021, includes the design, manufacturing and delivery of four Vertical Regrind Mills (VRM), each complete with a 6,500 kW variable speed drive package and a user-friendly control system.

Each regrind circuit will process up to 500 t/h of flotation concentrate.

These mills will be by far the largest and most powerful stirred mills in the world, according to Swiss Tower Mills Minerals.

Deliveries will take place during 2022 and 2023.

Last month, Swiss Tower Mills Minerals confirmed the award of an order for the delivery of one VPM10 vertical stirred grinding mill for the Navachab gold mine plant expansion in Namibia.

Metso Outotec embeds virtual reality into mill lining inspection process

Comminution of minerals, Equipment maintenance, Mineral processing, Mining equipment, Mining maintenance, Mining services, Mining software, , , , , ,

Metso Outotec is launching a patented Virtual Inspection tool for horizontal grinding mill linings to, it says, take the benefits of 3D scanning to a new level.

The new tool enables the scanned mill linings to be viewed in virtual reality and offers an efficient and safe environment for technical discussions, according to the company.

“This innovation is a continuation of Metso Outotec’s pioneering role and its more than six decades of experience in engineering and manufacturing mill liners and grinding mills,” Metso Outotec said.

‘On-site’ mill lining inspections can be safely hosted while being off-site, thanks to the fully immersive virtual walkthroughs and the ability to comprehensively review any particular point of the mill lining. Features like remaining liner thickness measurements and profile review enable the users to make real-time assessments of the liners, while the colour-coded heatmap mode helps in analysing the wear patterns and in detecting problem areas, so that the mill lining design and performance can be improved.

The Virtual Inspection tool aligns with Metso Outotec’s aftermarket digital strategy by improving the efficiency and safety of its services through advanced wear-part analyses, it added.

Lars Furtenbach, Research and Technology Development Manager, Mill Lining Solutions, said: “Our patented MillMapper™ 3D scanning of mill linings has been the industry benchmark for years. The scans are used to understand the way the mill liners wear, to optimise the liner design, and to accurately predict the reline schedules. There is a growing need to find new ways to reach out to our customers and to discuss mill lining performance with them remotely. Our customers will benefit from our strong experience with over 8,000 mills worldwide combined with the market’s most comprehensive offering and the new software platform.”

Metso Outotec grinding mills and thickeners heading to greenfield nickel project

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

Metso Outotec says it has been awarded a contract for the delivery of several horizontal grinding mills and thickeners to a greenfield nickel project in Indonesia. The value of the order is approximately €24 million ($28 million), and it has been booked in the Minerals business Q3 (September quarter) 2021 orders received, the company said.

Metso Outotec’s scope of delivery includes five grinding mills with a total installed power of 10.6 MW, as well as 13 HCT high-compression thickeners, which are part of the company’s Planet Positive offering. “We are pleased to have been chosen as the supplier of this key equipment for this major project,” Markku Teräsvasara, President, Minerals and Deputy CEO of Metso Outotec, said.   “A diligent verification process with the customer confirmed that Metso Outotec grinding mills and thickeners will provide significant added value to their process.

“The customer selected our grinding mills based on robust, proven technology, and industry leading availability. The HCT thickeners are proven to provide the best washing efficiency, thus reducing the loss of nickel metal in leaching residue.”

Metso Outotec addresses standardisation and flexibility needs with new grinding mills

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

Metso Outotec has, after reviewing the combined horizontal mill product offering from the Metso and Outotec companies, unveiled a “harmonised” Metso Outotec horizontal mill product line that, it says, represent the best of both legacy companies.

The Metso Outotec Premier™ horizontal grinding mills and Select™ horizontal grinding mills are designed for different customer segments and markets, and they have distinctly different features and benefits. In both lines, there are various mill solutions available for a wide range of applications.

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

The Select horizontal grinding mills are a range of pre-engineered solutions that allow simple mill selection, simplified proposal preparation, and a streamlined order execution process. Select horizontal grinding mills feature a suite of technologies and conservative design parameters that meet or exceed operational goals, Metso Outotec claims. Select horizontal grinding mill sizes are available for applications up to 7.8 MW for both the SAG and ball mills. Rod mills are available up to Ø4.60 m x 6.10 m EGL.

“With the introduction of the Premier and Select horizontal grinding mills, Metso Outotec continues its over 100-year legacy in grinding,” Christoph Hoetzel, Head of Grinding business line at Metso Outotec, says. “Both lines have their own differences and benefits – but share the concepts and expertise that have made us an industry leader time and time again.”

He added: “As a combined company we have consistently led the way in grinding mill innovation. We’ve continuously pushed mill technology in the next size increment. Currently, we have the largest operating mills in the world, and we want to lean on that legacy in taking the next steps in mill size. In addition, it is important for us to continue to be a frontrunner in the development of a more robust suite of horizontal mill technologies, providing desirable options for customers looking for quick execution with reliable technology.”

The company says the Premier and Select mills come ready to be integrated with its mill reline equipment and full mining portfolio. The former includes the recently launched Mill Reline Machine (MRM), which has a capacity of 4,000 kg, as well as a broad selection of liner options, including the Megaliner™.

Metso Outotec ups mill relinine equipment capacity with MRM

Comminution of minerals, Equipment maintenance, Mineral processing, Mining equipment, Mining services, , , , ,

Metso Outotec is extending its mill reline equipment offering with a high-capacity Mill Reline Machine (MRM).

The new robust MRM has a capacity of 4,000 kg, enabling easy and safe replacement of steel lining systems inside even the largest grinding mills, according to the company.

“Replacing steel lining systems inside the confined space of grinding mills is a time-consuming and demanding job requiring strict safety measures and highly reliable equipment,” Jared Le Cras, Senior Manager, Mill Reline Equipment at Metso Outotec, said. “With the addition of the high-capacity MRM, Metso Outotec now provides a comprehensive range of Mill Reline Machines designed to ISO and IEC standards. The new MRM is designed for heavy-duty lining replacement tasks, with safety and efficiency as our top priorities.”

Benefits of the Metso Outotec MRM, according to the company, include efficient mill relining enabled by unique mechanical design features; maximised reliability, thanks to easy data access and spares replacement; minimised risk, thanks to safety features; and comprehensive service support via Metso Outotec’s global service network

In addition to mill reline machines, Metso Outotec’s mill reline equipment offering includes feed chute transporters, Tube MRMs and bolt hammers.

ABB to deliver drives and motors to Fortescue’s Iron Bridge Magnetite project

Comminution of minerals, Mineral processing, Mineral project development, Mining equipment, Mining services, Power supply for mines, Steel and iron ore, , , , , , , , , , ,

ABB has won a $26 million order from Fortescue Metals Group to deliver water-cooled variable speed drives and high voltage induction motors to FMG’s majority-owned Iron Bridge Magnetite project in Western Australia.

The project, operated under an unincorporated joint venture between Fortescue subsidiary, FMG Magnetite Pty Ltd, and Formosa Steel IB, covers the development of a new magnetite mine, including processing and transport facilities. The $2.6 billion development is expected to produce 22 Mt/y (wet) of high grade, magnetite concentrate, with first ore in 2022.

As part of the project, the Iron Bridge Joint Venture required a cost-effective energy efficient variable speed drive solution, according to ABB. These drives, to be installed in eight switch rooms, operate with a separate transformer that is located outside the room. This reduces the heat generated inside, resulting in less energy required to maintain the 25°C room temperature.

ABB’s water-cooled drives also directly support a higher voltage 33 kV network, it said. “This eliminates the need for a lower voltage intermediate switchboard and additional components, which ultimately reduces the total cost of the project,” the company explained.

Iron Bridge also selected ABB high voltage induction motors to power high pressure grinding rolls, grinding mills and baghouse fans used to separate the ore from the dust at Iron Bridge. Engineered to withstand harsh conditions, the motors offer high power efficiency, but in a frame size smaller than competitive alternatives, it said.

Mike Briggs, Business Manager for ABB Motion, Australia, said: “We have worked closely with the Iron Bridge team to ensure that we delivered an energy efficient, reliable and innovative solution. We are especially pleased to have won both the drive and the motor business, and look forward to continuing our strong relationship with Fortescue beyond the delivery of this project and supporting them throughout the mine’s lifecycle.”

Belzona’s new abrasion-resistant coating to help miners patch up equipment

Equipment maintenance, Mining consumables, Mining maintenance, Mining services, , , , , , , , , , , , , ,

Belzona Polymerics, a provider of high-performance polymeric repair composites and protective coatings, has launched a new product to add to its portfolio of solutions for industrial maintenance.

This new product, Belzona 1818, has been specially formulated for emergency patch repairs in highly abrasive environments typically found in industries such as mining, cement, pulp and paper, and biomass, among others, where equipment is commonly exposed to extensive erosion and abrasion from excavated or processed materials of varying type, size and shape.

What is easily identifiable about this new product is its distinctive blue colour. This vivid blue serves as a good mixing indicator and provides contrast where an application is carried out in poorly lit conditions or against dark background surfaces where the repair area should be easily identifiable, the company says. These conditions can be common in typical industrial applications where Belzona 1818 is likely to be used.

Based on initial research and feedback from engineers in the field, it is envisaged the product will be used on various types of equipment within abrasive environments such as slurry pumps, grinding mills, screw conveyors, chutes and hoppers, hydrocyclones, wear plates, dust extraction pipe work, agitator shafts, hubs and blades.

Belzona 1818 is the newest addition to the highly erosion resistant Belzona 1800 series product range and bridges the gap between surface tolerance, fast cure and high abrasion resistance, the company says. Its fast curing properties means minimal downtime for damaged equipment – so much so that the product can experience full mechanical loading and heavy abrasion just two hours after application, depending on cure temperatures.

“In these abrasive environments, surface preparation can also be an issue and contamination is common, therefore the equipment cannot always be fully cleaned or ideally profiled as required for many repair materials,” Belzona says. “The desire to deal with adverse application conditions creates a need for a not only fast-curing, but also a surface-tolerant material.”

As a result, Belzona 1818 has built-in surface tolerant technology, enabling it to bond onto steel substrates even when surface preparation is minimal or if the substrate is heavily contaminated with oil or water, the company says. The product can also be applied and cured underwater.

Kristine Savicka, Belzona R&D Technician, explains: “Belzona 1818 builds on our knowledge and experience of producing highly abrasion-resistant systems, and combines this technology with our know-how and expertise in producing fast-cure and surface-tolerant products for application in non-ideal conditions. Belzona 1818 offers the high erosion resistance expected of the Belzona 1800 series with added application benefits, offering ease of use and a fast return to service.”

This new product is supplied in 1 kg units where base and solidifier can be combined on a Belzona work surface. Belzona 1818 is easy to mix and apply and offers a good working life (16 minutes at 20°C) while still offering fast cure and a rapid return to service, according to the company. The product is suitable for emergency repairs where downtime must be kept to a minimum and optimal surface preparation cannot be achieved due to accessibility or environmental and application constraints.

Belzona 1818, as with all Belzona products, is made to the highest quality and safety standards and has undergone rigorous performance testing, the company says. Belzona 1818 is user friendly and can be applied without the need for hot work or specialist tools. In addition, it is formulated without solvents and is free from CMR classification and labelling, while maintaining cure speed and performance to give a durable and long-lasting repair.

Metso Outotec SMD mills to boost output at Boliden’s Harjavalta concentrator

Base metals, Comminution of minerals, Mine operation news, Mineral processing, Mining equipment, , , , , , , , , , ,

Boliden Harjavalta has chosen Metso Outotec’s SMD grinding mills to improve the capacity of its slag concentrator, in Finland, the mining OEM says.

Boliden Harjavalta produces high-quality metals for European industrial customers, churning out 120,000 t of copper and 26,000 t of nickel in 2019.

The purpose of the slag concentrator is to recover copper from the slag produced in the copper smelter and to return it to the copper production cycle as high-quality slag concentrate, Metso Outotec said, with grinding being an essential part of the slag concentration process.

The raw materials of the Boliden Harjavalta smelter consist of concentrates and recycled metals, according to Boliden, with the company’s two mines in Finland – Kylylahti and Kevitsa – providing the smelter with concentrates. Concentrates are also purchased from external mines, Boliden says.

The order has been booked in Metso Minerals’ June quarter 2020 orders received.

Based on tests, Metso SMD (stirred media detritor, specialised for fine grinding applications) was chosen as the grinding technology, Metso Outotec said.

“Maintenance for the SMD is safe and cost-effective thanks to the simple mechanical structure of the mill and the smaller number of moving parts compared to traditional grinding mills,” the company explained.

Timo Sarvijärvi, Metso Outotec’s Head of Mining in the Nordics market area, said the company, at testing stage, noticed slag could be processed very efficiently using SMD technology.

“Now the slag concentrator can process larger amounts of material, without compromising the targets set for copper recovery,” Sarvijärvi said.

Outotec to provide proactive condition monitoring system for grinding mills

Comminution of minerals, Equipment maintenance, IoT, Mineral processing, Mining equipment, Mining services, Mining software, , , , ,

Outotec is looking to maximise grinding mill availability with a new modular system that provides all control functions required for the safe operation of equipment, and its associated lubrication systems, as well as continuous condition monitoring.

The Outotec Mill Control System allows for advanced condition monitoring strategies, including remote expert support, to ensure maximum mill availability, the company says.

It proactively detects anomalies using diagnostic data from IO-Link instruments to determine instrument health and detect installation problems before they cause downtime, according to the company.

Remote connectivity hardware is included as standard, enabling connection to Outotec’s Connected Services for remote diagnostics and support. Plant owners can also take advantage of Outotec’s cloud-based Asset Analytics service to gain valuable insights over the condition and performance of their assets, the company says.

“The system uses standard hardware and software components that are common across Outotec product lines for improved availability of support resources and spare parts and meets all relevant EU safety directives and other key international safety standards,” Outotec said.

IO-Link technology, an international standard according to IEC 61131-9, enables digitalisation and smart instruments by allowing for extended diagnosis of sensors and actuators, and the use of IO-Link instruments contributes to time and cost savings as the single interface means fewer input/output spares are required, according to the company.

In addition to increased mill availability, Outotec says it Mill Control System significantly reduces the commissioning time and cost associated with implementing similar systems, provides a shorter engineering lead time and superior installation quality thanks to “simplified wiring and termination design” as well as standardised software and hardware modules; comes with reduced project risks as the complete solution is delivered under one contract; and ensures compliance and reduced risk with state-of-the-art safety-rated hardware.