Tag Archives: Metso Outotec

Metso Outotec and Malvern Panalytical to collaborate on bulk ore sorting projects

Metso Outotec and Malvern Panalytical have signed a collaboration agreement to, the OEM says, provide sensor-based bulk ore sorting solutions to the mining industry.

The combination of the companies’ expertise in crushing and bulk material handling solutions, and ore analysers enables the parties to offer an industry-leading portfolio of solutions for bulk ore sorting, Metso Outotec said.

“With this offering, mining customers can substantially improve the head grade by pre-concentrating the ore at the crushing stage and, thereby, reduce their energy consumption and related environmental footprint in the comminution stage,” Metso Outotec said.

The agreemeent will see Metso Outotec’s crushing and bulk material handing solutions integrated with Malvern Panalytical’s cross-belt analysers. The latest generation of cross-belt analysers, CNA³, has been designed for tough environments such as underground mines, and features the Sodern neutron solution, which is powered by Pulsed Fast Thermal Neutron Activation (PFTNA) technology. The technology has been used by Anglo American, among others.

Rashmi Kasat, Vice President, Digital technologies at Metso Outotec, said: “Sustainability is a top priority for our entire industry. Collaboration with partners like Malvern Panalytical will allow us to meet the industry’s increasing sustainability and resource efficiency needs in an enhanced way in the early comminution stage. Sensor-based bulk ore sorting and data-driven analysis upgrades low grade or waste stockpiles making them economical and far less energy-intensive to treat.”

Jarmo Lohilahti, Sales Manager at Malvern Panalytical, said: “Malvern Panalytical’s cross-belt analysers provide high-frequency online data for cost-efficient bulk material analysis of major commodities. This collaboration enables customers to benefit from the in-depth know-how from both companies.”

Renato Verdejo, Business Development Lead for Bulk Ore Sorting at Metso Outotec, concluded: “Bulk ore sorting allows waste rock elimination early in the process and, when combined with Metso Outotec’s complementary crushing and bulk material handing solutions portfolio, it provides more sustainable flowsheets for our customers. Enhanced bulk ore sorting will contribute to Metso Outotec’s Planet Positive portfolio.”

On the particle sorting side of the business, Metso Outotec and TOMRA have a non-exclusive cooperation in place to supply particle ore sorting solutions for the mining and metallurgical industries.

Metso Outotec to add to Grate Kiln iron ore pellet reference list with Oman order

Metso Outotec has signed an agreement for the delivery of engineering and key equipment for an iron ore Grate Kiln pellet plant to Vulcan Pelletizing LLC.

The plant is located in the industrial port of Sohar, the Sultanate of Oman, with the value of the order being approximately €33 million ($35 million). The pellet plant will supply pellets to Jindal Shadeed Iron & Steel LLC, Oman.

Metso Outotec’s scope of delivery consists of the supply of core pelletising plant equipment, including the traveling grate, rotary kiln and annular cooler. The design is based on the Grate Kiln plants that Metso Outotec is currently supplying for a customer in India. The plant, which is planned to produce 6 Mt/y of high-quality iron ore pellets, is scheduled to be operational by the end of 2023.

Chris Urban, Vice President, Heat Transfer Products at Metso Outotec, said: “This is the third order for a 6 Mt/y Grate-Kiln pelletising plant within the last 16 months. Metso Outotec is proud to be the Vulcan group’s selected partner in iron ore pelletising, and we look forward to propelling the Vulcan group to be a global leader with world-class pellet products.”

Metso Outotec says it is the world’s leading supplier of Grate Kiln pellet plants, with more than 50 installations globally totaling over 130 Mt/y of production.

Metso Outotec cuts environmental impact of smelting with modular Converter Hood System

Metso Outotec is launching a modular Converter Hood System for horizontal converter vessels used in the smelting process.

The new system, which is suitable for greenfield and brownfield installations, has an impressive SO2 (sulphur dioxide) gas capture capability of 99%, minimising the environmental impact, it says. The modular design enables quick on-site assembly, so the system is ready to use with minimum plant downtime.

Jonny Eliasson, Director, Precious Metals at Metso Outotec, said: “We are excited to launch the new Converter Hood System. Besides its excellent gas capture capability, the system design ensures a well-controlled ingress air flow that improves process gas quality. The primary converter hood’s advanced water-cooling system increases process reliability and improves safety in the converter aisle, while also reducing maintenance needs and prolonging equipment lifetime.”

Metso Outotec says it has extensive experience in the field of Converter Off-Gas plant design and construction, developed over several decades and enhanced by the company’s continued activities in the research and development of the process.

Metso Outotec and CSIRO to cooperate on SwirlFlow agitation tech for bauxite, alumina sector

Metso Outotec and Australia’s national science agency, CSIRO, have signed a global exclusive cooperation agreement on the delivery of SwirlFlow® agitation technology for the bauxite and alumina sector outside of China.

The combination of the companies’ leading expertise in their respective fields will allow the parties to create the strongest offering to the market for the use of SwirlFlow technology in the refinery precipitation tanks, Metso Outotec said.

“Sustainability is a top priority for Metso Outotec,” Dr Alessio Scarsella, Director of Light Metals at Metso Outotec, said. “In addition to our own investments to develop technology for sustainable alumina processing, we are pleased to be able to announce our cooperation with CSIRO. This will allow us to meet our customers’ growing demand such as lower capital installation, reduced spare parts costs and increase in precipitation tank availability.”

Andrew Jenkin, Research Program Director for Processing at CSIRO, added: “CSIRO’s leading technology in SwirlFlow agitation has been pioneered at a Tier One refinery precipitation tanks, leading to significantly reduced maintenance costs and improved operational time between descaling events.”

SwirlFlow, according to CSIRO, enhances the agitation process by mixing liquids and suspended solids to create a tornado-like vortex in a tank. The solution uses a motor, gearbox and a specially-designed radial impeller with a short shaft near the top of the tank. The system improves agitator reliability, resulting in reduced maintenance and shutdowns. And, due to higher and more uniform wall veolcities, the scale formation rate is also reduced.

Metso Outotec consolidates, adds to minerals and hydromet digital tools with Sense series

Metso Outotec has reorganised its portfolio of intelligent instruments under the Sense series; tools that are designed to solve specific process challenges and enable optimisation for minerals and hydrometallurgical processes.

The market’s most comprehensive portfolio of intelligent instruments is part of Metso Outotec’s Planet Positive offering, the company said. Covering the entire flowsheet, Sense series instruments are suited for both new and existing operations.

“Metso Outotec Sense series includes specialised instruments that provide data for analytics and a better understanding of processes,” Veli-Matti Järvinen, Vice President, Automation product group at Metso Outotec, said. “They utilise the latest technologies, such as artificial intelligence (AI) and neural networks for extra insight. These additional tools for process problem solving and data mining can significantly help improve production within customer operations.”

Included in the series are:

Metso Outotec FrothSense+™ – takes flotation optimisation to the next level with the latest technology and capabilities. It has completely new and redesigned software and hardware. It includes the best features from two legacy systems, FrothSense and VisioFroth™, and adds new capabilities such as froth height measurement, history analysis and AI with deep learning algorithms to detect flotation properties.

The new Metso Outotec RockSense™ product family will take comminution optimisation to the next level with better knowledge of particle size distribution (PSD) on the belt, the company says. RockSense consists of a renewed, two-level offering: RockSense 3D and RockSense 2D, formerly known as VisioRock™. They enable online, continuous on-belt coarse PSD. RockSense 3D also adds new capabilities with AI and deep learning algorithms to detect oversized lumps and foreign objects, for example.

Metso Outotec MillSense™ provides online volumetric charge analysis by direct measurement of charge position. It is now available, together with SmartEar™, as a bundle. SmartEar uses sound to give an additional measurement of charge impacts and liner wear. The bundle fuses acoustic, vibration and force sensor information for improved online analytics of mill operations. This enables new ways of optimising grinding performance, according to Metso Outotec.

In total, Metso Outotec intelligent instruments include more than 10 technologies to optimise the mining process:

  • RockSense 2D: An online particle size analyser system for rocks moving on a conveyor belt that uses 2D imaging technology;
  • RockSense 3D: Accurate, continuous on belt coarse particle size distribution and volume flow using 3D imaging;
  • MillSense: Analysis of toe and shoulder position and total volume of the charge. Enables load control and mill optimisation;
  • FrothSense+: New system with best features and capabilities for froth flotation analysis. It adds AI neural network, multiple regions of interest and froth height measurement;
  • CycloneSense™: An online measurement of hydrocyclone air core data enables measuring and visualisation of their performance.
  • LevelSense™: Using electrical impedance tomography, LevelSense improves the slurry level measurement of flotation cells;
  • CarbonSense™: An online measurement of carbon concentration in carbon-in-pulp and carbon-in-leach applications;
  • CellSense™: Tankhouse monitoring system that automatically measures electrolyte temperature and voltage in individual cells;
  • SmartEar: Online impact analyser uses sound to provide additional measurements of charge impacts and lifter/liner wear;
  • VisioTruck™: Advanced vision technology for estimating rock size distribution of mine truck loads;
  • SmartTag™: An innovative system for open-pit and underground mines to track ore from the mine to the processing plant, and beyond; and
  • VisioPellet™: A pellet size-control system that measures the size of green pellets using proven camera technology installed in a pelletising disc or drum.

Metso Outotec to supply electrowinning equipment to copper cathode plant in Africa

Metso Outotec says it has been awarded a contract for the delivery of advanced electrowinning equipment to a copper cathode production plant in Africa.

The order value amounting to approximately €11 million ($11.5 million) is booked in the company’s Minerals Q2/2022 orders received.

Metso Outotec’s scope of delivery includes the supply of basic engineering and equipment for the copper electrowinning plant expansion, it said.

The OEM’s offering for copper electrowinning tankhouses comprises pre-engineered solutions, key equipment and services to ensure superior process performance, increased safety and minimised environmental impact.

Metso Outotec renews crusher wear parts commitment with three new product ranges

Metso Outotec says it is introducing its renewed crusher wears solution offering that provides the industry’s widest variety of wear parts and services to enable customers’ sustainable, predictable and profitable crushing.

The portfolio is categorised in three different product ranges – Metso Outotec O-Series, Expert Series and Max Series. The renewed crusher wears and services offering, from seasonal crushing to high-volume, and high-value operations, has been developed in response to customers’ demand for continuous improvements in crushing process performance.

Through the renewed offering, aggregates and mining customers can, together with Metso Outotec experts, easily compare the advantages and select just the right level of parts and services to reach the best crushing economy, it said.

Mika Saariaho, Senior Vice President, Crusher Wears business line, Metso Outotec, said: “Keeping our customers’ crushers running is our core expertise. Whatever is the scale of crushing, customers need crusher wear parts that suit specifically for their demand, they need services to keep their operation running, and they need expertise that helps them to develop the efficiency, profitability and sustainability in crushing. We are now very excited to introduce our renewed crusher wears offering, which will answer to our customers’ unique needs and can improve their crusher economy in a sustainable way.”

The crushing circuit is one of the biggest cost generators in mining and aggregate operations. It is also one of the most critical ones. The selection of the crusher chamber impacts the whole crushing process and its efficiency. Being able to select the optimal chamber requires insight into the process and the customer key performance indicators, Metso Outotec said. Therefore, an integral part of the offering is digital tools that enable the gathering and use of process data, such as  Metso Outotec Metrics and simulation tools.

“We think that the optimal selection of the chamber is the key to a better crusher economy,” Saariaho continued. “It can only be achieved with a deep understanding and expertise of the process, and its requirements to the crusher wear material and technology.”

The O-Series provides affordable standard parts from stock – quickly and flexibly, according to the company. With the right, reliable parts selected through Chamber Selection Service, customers working days are more productive and the operating costs are lower, it said.

The Expert Series provides the broadest range of wear parts in the market with a wide, easy-to-order selection of materials and designs with the Chamber Expert Service enabling more efficient, optimised processes, helping customers get the most value out of their crusher, Metso Outotec said.

With the holistic approach of the Max Series, Metso Outotec can optimise with the Chamber Optimization Service each step of the customer’s process with custom parts to maximise performance, economy and sustainability, it said. The company says it has experience from 700-plus optimisation cases, with Chamber Optimization being part of Metso Outotec’s Planet Positive portfolio.

Boliden on mining’s differentiation pathway

When Mikael Staffas joins a panel on stage at the EIT Raw Materials Summit in Berlin, Germany, to discuss building a world-leading raw materials industry for Europe next month, he will be able to reference more than a few examples of sector excellence from his own company.

The Sweden-based mining and metals company has been leading from the front for decades, leveraging new and innovative technology, employing a more diverse workforce and engaging local stakeholders and regulators in a manner viewed as progressive from peers across the globe.

Gaining recognition from your mining company peers is one thing but gaining it from the public and EU-based decision makers is something altogether different.

According to Staffas, CEO of the company, the latest summit, which takes place on May 23-25, is part of a series of actions and events slowly getting these two groups to understand the importance of raw materials and the companies that produce them.

“We are moving this industry away from a perception that we are part of the problem, to an environment where we are seen to be part of the solution,” he told IM.

Staffas says the raw materials industry has been viewed as fundamentally important to Europe for several years in terms of tackling the climate change challenge – which will be reinforced at the summit – but the “regionalisation of economies” that has been brought about by COVID and the more recent geopolitical situation means this importance has, once again, been reinforced.

Within this context, Staffas is due to discuss at the event the fundamental need for copper and nickel in the energy transition. He will also shine a light on the importance of lead and zinc in this evolving landscape.

Boliden, through its mines and smelters in Finland, Sweden, Norway and Ireland, is a producer of all four of these metals. It can also add gold, silver, sulphuric acid, cobalt and palladium to the list.

As the general population is beginning to understand the importance of these raw materials and metals to their future, Boliden is trying to differentiate its own offering from the rest of its peers.

Not satisfied with simply matching the industry’s carbon emission and net zero goals to 2030 and beyond, Boliden has laid the gauntlet down to the rest of its competitors by registering two new products: Low-Carbon Copper and Low-Carbon Zinc.

The formula for these two low-carbon products is based on the production of finished metal, from cradle to gate, that has emissions of less than 1.5 t of CO2 per tonne of copper, compared with the global average of around 4 t of CO2 per tonne. For zinc, the threshold is even lower – less than 1 t of CO2 emissions per tonne of zinc, compared with the industry average of 2.5 t.

To this point, the introduction of both products has resulted in a slim premium over other products on the market, but Staffas still deems the launches as successful.

“The point was to differentiate our products, with many people expected to receive this differentiation,” he said.

The customers represented just one set of recipients, but Staffas said these new products also play into the ‘licence to operate’ equation, as well as discussions with authorities and non-governmental organisations.

The intention was to also lay down a benchmark the rest of the industry could start to use or discuss, he added.

Boliden’s carbon dioxide calculations include emissions along the entire value chain up to the customer according to the Scope 1, 2 and 3 Greenhouse Gas Protocol Product Life Cycle, following the ISO 14064-3 standard.

“While this might not be the only way to measure CO2, we think it is the best one,” Staffas said. “We are trying to force the industry to adopt a common way of measuring the CO2 footprint.”

This has led some of Boliden’s customers to enquire about how much embedded CO2 is in competitor zinc and copper products, ensuring the discussion spreads throughout the industry.

The obvious intention of devising such products is price, but Staffas said they also provide protection.

“When things get bad from an economical perspective, these products could really make a difference,” he said. “The customers might not pay extra for them, but if they scale down their purchases, our contracts should be the last to be cancelled.”

Staffas says Boliden is also aiming to add nickel and lead to its suite of low-carbon products in the future.

“Nickel is a special case for us as we don’t produce finished nickel; we produce a nickel matte,” he said. “We may team up with a refinery to make a joint product or do something else to ensure we can quantify the emissions according to our chosen protocols.

“Whichever way this development goes, we have to ensure we cover cradle-to-gate with these calculations otherwise it is not a true representation of the embedded carbon in that product.”

Electrification

While quantifying the carbon emissions of products is still relatively new in mining and smelting, Boliden has been using a carbon price in its internal technical studies and projections for close to a decade now.

It has been leveraging electrified sources of power for even longer. For instance, its Rönnskär copper smelter in Sweden has been using an electric oven since the 1990s.

More recently, the company has added trolley assist at Aitik and Kevitsa to this electrified base and employed ventilation on demand and heat exchangers at underground mines (the former) and smelters (the latter) to optimise its energy use.

It also has plans for underground trolley-battery haulage operation at its Rävliden (part of Kristineberg) project in Sweden through a project with Epiroc and ABB, while it is conducting a battery-electric vehicle loading trial at the Garpenberg mine, also in Sweden, with Sandvik. On the transport side, the company has recently teamed up with Scania to electrify part of its heavy-duty road transport in northern Sweden.

“It is one thing to review where we started; it is another to look at where we are going,” Staffas said on this topic. “We are planning to get better and better and go on to reduce our CO2 footprint further.”

On its way to achieving a goal of reducing its carbon dioxide intensity by 40% by 2030, the company is also looking at, among other levers, its use of explosives and cement: two key scope 3 inputs.

Staffas is confident Boliden can hit these ambitious goals by leveraging the innovation ecosystem within the Nordic region.

“For the CO2 journey we are now on, the Nordic mining cluster has and will continue to be very important,” he said. “We have big suppliers like Epiroc, Sandvik, Metso Outotec, ABB, Volvo and Scania on our doorstep. They have always worked closely with us, and we work closely with them on joint development projects.

“I think that is the main reason we are so far ahead of our competitors when it comes to our use of technology and innovation, and why we are confident in achieving our ambitious climate goals.”

Metso Outotec integrates tailings and water treatment solutions into one TMS offering

Metso Outotec says is introducing its comprehensive Tailings Management Solutions offering for the sustainable management of mine tailings.

The offering unites products with decades of process expertise and covers tailings thickening and dewatering as well as handling through conveying and dry stacking, it said. In addition, Metso Outotec offers a portfolio of solutions for the treatment of water produced during dewatering, enabling closed water loops while managing the level of impurities within the recycled water.

Dr Piia Suvio, Director, Tailings and Water, Metso Outotec, said: “The rising demand for sustainably mined materials and stricter environmental legislation are pushing the need for more advanced technology for safe processing and storing of the tailings. Water resource efficiency is also becoming more and more important. These factors, combined with the need to capture the full value of ore, for example, by reprocessing the tailings to extract the remaining valuable minerals, lead to a continuously increasing need for sophisticated tailings management solutions.”

Dr Suvio added: “With our extensive process expertise, we can offer cutting-edge technology solutions for any tailings management need to reduce water use, environmental impact, risks, and costs. Together with our customers, we can reshape the future of tailings and drive responsible management practices that help the business and society to prosper,” says Suvio.

Metso Outotec has been involved in the development of tailings management solutions and equipment for over 50 years. Today, a lot of emphasis is put on the design stage, which includes, for example, test work and studies supported by process simulations carried out with the recently launched Metso Outotec Geminex™ digital twin, allowing accurate plant design and sizing.

Metso Outotec’s Tailings Management Solutions consist of a wide range of Planet Positive equipment and feature performance and capacity guarantees:

  • Thickening plant units are based on Metso Outotec IPS, HRT, HCT and PT technologies. The Reactorwell™ feed system and Vane Feedwell™ provide enhanced mixing, dilution, and retention of the feed, maximising flocculant adsorption and aggregate growth. The advanced Metso Outotec control systems, such as the thickener optimiser, help improve the overall performance of the thickening plant unit;
  • Filtration plant units are based on proven FFP or FP-S filtration technology. The Metso Outotec filtration plant unit is specifically designed for high-volume tailings processing, leading to savings in operational and maintenance costs;
  • The company’s extensive conveying and stacking portfolio consists of robust components and is built to last and perform under even the toughest conditions; and
  • Metso Outotec process water recycling plants enable the recovery and reuse of water within the production process with enhanced metal recovery within the flotation circuit.

Metso Outotec says it supports its tailings management portfolio with a full range of parts, inspections, process optimisation and Life Cycle Services.

Metso Outotec secures major mineral processing order from South-East Asia copper-gold mine

Metso Outotec says it has been awarded a major order for the supply of key minerals processing technologies to a copper and gold mine project in South-East Asia.

The contract value of €40 million ($43 million) has been booked to the company’s Minerals Q1 (March quarter) 2022 orders received.

Metso Outotec says it has a strong presence in South-East Asia including a Service Center, which is able to support local mining customers.