Tag Archives: Megaliner

Metso Outotec addresses standardisation and flexibility needs with new grinding mills

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 and Boliden renew service contract for Aitik copper mine

Metso Outotec and Boliden have signed an extension of their service contract for Boliden’s Aitik copper mine in Gällivare, northern Sweden.

The “3+2-year extension” of the Life-Cycle Services agreement covers the supply of mill lining, chute lining solutions, preventive maintenance of the grinding circuit and recycling of used wear parts, the mining OEM said. The first part of the contract has been booked in Metso Outotec’s orders received in the September quarter of 2020.

The contract is a performance-based cost-per-tonne agreement, in which Metso Outotec gets paid according to the output of the customer’s process. The goal is to ensure the availability of the grinding circuit and to maximise valuable production time, striving for a common goal that benefits both parties, the company said.

Metso Outotec and Boliden have cooperated since the 1960s. Throughout the decades, the collaboration has evolved to meet new emerging needs, while continuing to improve uptime and annual production, Metso Outotec said.

“Safety is Boliden’s top priority and enhancing it is also embedded in the scope of the new contract,” the OEM said. “Metso Outotec will provide solutions that simultaneously cut maintenance time and increase the wear life of parts even further.”

The new contract also focuses more on the management of worn wear parts, with Metso Outotec developing capabilities to recycle and dispose of them more sustainably. The AG mills in Aitik will continue to use Metso Outotec’s innovative Megaliner™ mill lining.

Megaliner helps to maximise the availability of large mills by using an innovative design that speeds up liner replacement. The larger-than-average liners mean fewer individual pieces are needed. Megaliner also has fewer attachment points compared with conventional liners, further improving installation and removal time, Metso Outotec says. It also improves worker safety during maintenance as the liners are bolted into position from outside the mill.

The pebble mills and two regrind mills at Aitik will be lined with rubber and Poly-Met mill linings, Metso Outotec said.

Aitik is one of the largest copper mines in Europe. In 2019, the mine produced close to 41,000 t of copper, employing nearly 800 people.

Metso completes mill lining hat-trick with Discharge End Megaliner

Metso has once again flexed its R&D muscles, launching a new and innovative product that, it says, can speed up and improve the safety of one of the trickiest and riskiest processes mill personnel carry out.

The Discharge End Megaliner builds on the Metso Megaliner™ concept the company introduced in 2012. Designed to reduce downtime by minimising the number of parts and people inside the mill during a relining process, the Megaliner has so far been installed in over 30 mills around the world.

A Megaliner element integrates multiple lifter and plate rows and has a minimum number of attachment points. Covering an area several times larger than conventional liners, these liners are light weight in relation to their size and, with threaded bushings, enable safer and faster relining processes to be conducted.

The initial 2012 Megaliner launch saw these lightweight liner parts developed for the mill shell. In 2015, Metso expanded the lining concept to the feed end of grinding mills. The company is now ready to tackle the tricky mill discharge end to complete the hat-trick.

Anssi Poutanen, Vice President of Metso’s Mill Lining product line, said the mill shell was the obvious starting point in the Megaliner evolution.

“The shell represents the largest number of components to install so the potential for time savings for customers was large, hence why the Megaliner started there,” he told IM. “We have since extended to the feed end of the mill and now to the discharge end.”

The new product, which has been in the development pipeline for some time, according to Poutanen, is by no means just a bolt on to the existing Megaliner range.

“Even though the discharge section of the mill lining process is not as big from a volume perspective, the need for long bolts and a complex fixing arrangement in conventional installations makes it one of the most time-consuming and risky processes to carry out,” he said. “The Discharge End Megaliner is a highly valued addition to our Megaliner range as many of our customers struggle with the process.”

The conventional process Poutanen references here is worth spelling out.

With grate discharge mills – typically SAG, AG and ball mills – the conventional relining process at the discharge end usually involves removing the dischargers and grates, replacing with new lined versions and hammering in large, long bolts through the layers to secure the liner components.

“Even if modern recoilless hammers are used, it is still a challenge,” Poutanen said. “When the bolts become loose, they are hazardous and can potentially injure personnel.” In this process, personnel are also inside the mill – one of the most dangerous sections of the whole process plant.

On top of the large, long bolts, nuts are also required to fix the panels in place with conventional lining processes, adding up to multiple individual pieces and attachment points that must be fixed securely from inside the mill, Poutanen explained.

The Discharge End Megaliner, meanwhile, sees dischargers, grates and segments preassembled into one large unit. These are equipped with threaded bushings that are secured with “short bolts” from – very importantly – outside of the mill, he said.

This makes for an up to 50% faster lining installation using up to 70% fewer parts than the conventional process, according to Metso.

Poutanen says the new Discharge End Megaliner can be applied to any type of grate discharge mill – there is no prerequisite for Megaliner liners in the shell and feed end, for example – as long as there is a wide enough trunnion opening to remove and replace the liners, and a liner handler of sufficient capacity.

Metso is targeting the large end of the grinding mill market with this new development. The larger the mill, the greater the throughput, which has a direct impact on the costs associated with potential downtime caused by the relining process, Poutanen explained.

This has already been tested out at Boliden’s Aitik mine, in Gällivare, Sweden, which is currently undergoing an expansion to 45 Mt/y throughput.

The base metal mine already has Megaliner mill liners on the shell and feed end of both of its primary AG mills and has tested the new Discharge End Megaliner over nine months at one of these 38 ft (11.6 m) mills.

The Aitik trial has proven around 70% fewer parts are required compared with the conventional process. Relining has also been carried out much quicker and safer, according to Poutanen.

Similar to LHD operators being removed from the cab in order to remotely operate loaders in potentially unstable areas of underground mines, the ability to carry out the relining process from outside of the mill ‘danger zone’ could be considered an initial stage towards a fully automated relining process.

Poutanen agreed: “I think at some point, we will see a higher degree of automation. It is unlikely to be binary; it will be a gradual process.”

He said the combination of the Megaliner and Metso’s camera-based liner positioning system – which is offered to all Megaliner customers as an “add on” to the liner handling equipment – could help make the process more autonomous.

In order to be able to develop this kind of fully autonomous package, a close collaboration with customers and liner handler suppliers is required, he said. “I think we are still a few years away from having the process move to fully autonomous mode.”

Norilsk Nickel chooses Metso Megaliner for Talnakh concentrator

Norilsk Nickel has recently switched out the chrome and molybdenum alloy lining of a SAG mill at its Talnakh concentrator in Russia as the company looked to increase the life of these all-important wear parts.

Sever Minerals and Norilsknikelremont (a subsidiary of Norilsk) were contracted to complete the mill relining project, using liners supplied by Metso’s global team, which also used the OEM’s Megaliner™ concept.

The new lining is more durable, weighs less and ended up being safer to install than previous the previous lining, according to Norilsk.

A Norilsk spokesperson told IM that the mill lining was replaced with two elements, the Metso Poly-Met; a rubber-steel combination installed on the front-facing part of the mill; and the Metso Megaliner, which has large shell or head liners used to protect the drum.

The spokesperson added: “The cladding manufacturers guarantee that the mill can work for 5,600 hours uninterrupted (that is about eight months non-stop). The previous version required the SAG mill to be stopped for replacement every six months.”

By developing the technology, adopting better project management and using the specialised equipment, Norilsk said it was able to reduce the time taken to replace the mill lining by three days.

The Megaliner is, according to Metso, a new, innovative mill liner concept, dramatically improving worker safety and maximising mill availability. Each shell or head liner covers a large area, has few attachment components and an attachment system which gives a safer working environment for the installation crew, it said.

The weight of the mill lining also came down with the switch from pure metal to a metal-rubber compound, Norilsk said.

“The new mill liner weighs close to 130 t, which is 120 t less than the old mill liner. The average weight of one mill liner element is 1.8 t (elements have different configurations and respective mass),” the spokesperson said.

This reduced weight came with other benefits.

“Due to the lower weight of the capstan, the new mill liner is more wear resistant and better technologically-equipped to cope with an increased number of planned tasks,” the spokesperson explained.