Tag Archives: Metso

BHP to install Metso cone crushers at Whaleback iron ore mine

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

BHP has awarded Metso an order for three high-capacity Nordberg® MP Series™ cone crushers to be installed at its Whaleback iron ore mine in Western Australia, according to the OEM.

Vinicius Vilela, Vice President, Mining Crushers at Metso, said the MP800™ cone crushers will replace the long-serving MP cone crushers.

“The robust and high-capacity MP Series crushers are a step change in the crushing process, enabling maximum operator safety and easy maintenance, as the key components can be accessed from the top of the crushers,” he explained. “They provide a more sustainable solution, delivering high crushing force with relatively low energy consumption.”

Metso’s cone crusher offering includes four product families for different applications and operations. The Nordberg MP Series cone crushers feature high capacity and high crushing force for size reduction with good energy efficiency.

Just last month, Rio Tinto awarded Metso an order for 10 HP500™ cone crushers to be installed at the company’s Tom Price iron ore mine in Western Australia, replacing  the long-serving Symons cone crushers at the operation.

Metso expands ore sample, process testing with renovated Pori mineral processing lab

Base metals, Energy minerals, Environmental, Mineral processing, Mining services, Water management, , , ,

Metso has opened a renovated minerals processing laboratory in Pori, Finland, in the process significantly expanding its ore sample and process testing capability to allow for safe and efficient testing around the clock.

Elina Wiik, Manager, Minerals Processing Laboratories at Metso, said: “The number of minerals testing projects has increased steadily during recent years. The new facility enables us to better meet the needs of our customers, for example, by handling larger sample sizes, and boosts our capacity to serve also the expanding testing needs of the battery minerals sector.”

In the design of the laboratory, special emphasis was put on lean processes, a safe working environment and proper ventilation, Metso said.

The new setup enables optimised workflows; for instance, each Metso laboratory flotation cell is placed in a separate safety cabinet.

“This gives us the possibility to use a large number of flotation reagents and to perform complex separation tests for a wide range of samples and ore types,” Wiik says. “Our test work is enhanced by using state-of-the-art laboratory equipment. One of the unique features of the laboratory is the carefully designed facility for safe dry sample preparation, crushing, screening, and splitting.”

With its portfolio of advanced and reliable testing and process expertise as well as process simulation, Metso is a leading supplier in the industry. These capabilities not only help predict and gather test data to deliver optimised process flowsheets, they also support the mining operations to improve recovery, resource efficiency and sustainability with, for example, Metso’s Planet Positive solutions.

Metso hydrogen-ready tech helping Aurubis become sustainable copper smelting leader

Base metals, Environmental, Mining services, Power supply for mines, Sustainable mining, , , ,

Aurubis has partnered with Metso as part of its plans to invest in hydrogen-ready anode furnaces at its Hamburg copper processing plant in Germany.

The company relies on Metso’s proven technology, consisting of complete hydrogen-ready Outotec Anode Furnaces with hoods and auxiliary equipment, which will be used in the anode refining process, Metso says. Close collaboration with Aurubis was key in designing the hydrogen-ready furnace by Metso, a first in the copper industry. Design input was based on full-scale hydrogen testing carried out at the Aurubis plant in 2021.

Aurubis expects the new technology in copper production to provide potential savings of 5,000 t/y of CO2, with the Hamburg plant being one of the first copper smelters in the world to use hydrogen instead of natural gas for the reduction process in its anode furnaces.

Metso has supplied anode furnaces for copper refining and scrap melting since the 1970s. Metso’s Outotec Anode Furnaces are designed for safety and sustainability, enabling lower energy consumption, decreasing batch cycle time for more efficient refining and resulting in cleaner off-gases, the company says.

Metso says it can provide anode furnaces powered with steam reformation or hydrogen capabilities, both of which can significantly reduce process CO2 emissions compared with traditional processing media.

Rio Tinto bolsters HP Series cone crusher contingent with Metso order

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

Rio Tinto has awarded Metso an order for 10 HP Series cone crushers to be installed at the company’s Tom Price iron ore mine in Western Australia, the OEM says.

This order follows the initial award of six HP series cone crushers in late 2022. The crushers in the initial order are currently being delivered to the Paraburdoo iron ore mine and another Pilbara mine.

“The HP500™ cone crushers will replace the long-serving Symons cone crushers,” Julius Mäkelä, Vice President, Mid-size and Mobile Crushers at Metso, explains. “The compact and versatile HP Series crushers are a step change in the crushing process, enabling maximum operator safety and easy maintenance as the key components can be accessed from the top of the crushers. They provide a more sustainable solution, delivering high output with decreased energy consumption despite their smaller size. Additionally, the new crushers feature an option for digitising the operation.”

The compact size of the HP500 cone crusher is well suited as a replacement for Symons crushers, Metso says. The HP500 is used in aggregates production, quarrying applications and mining operations worldwide.

Metso to deliver two Vertimill 4500 grinding mills to Canadian iron ore producer

Comminution of minerals, Mineral processing, Mining equipment, Mining services, Steel and iron ore, , , , , , , , , ,

A Canadian iron ore producer has awarded Metso an order for two powerful Vertimill® 4500 grinding mills to be delivered in the September quarter of 2024. The value of the order, which exceeds €10 million ($10.6 million), has been booked in Minerals segment’s 2023 September-quarter orders received.

Graham Davey, Director, Stirred Mills at Metso, said: “We are very pleased to collaborate on projects that support decarbonisation of the steel industry through production of high-grade and high-purity iron ore with sustainable processes. The Vertimill stirred grinding mill technology is globally recognised as a leading solution for energy-efficient grinding. Compared to traditional technology, operators can typically save up to 30-35% of the electrical energy and grinding media consumption. A small footprint and easy installation are also big advantages.”

Vertimill technology is an example of Metso’s Planet Positive offering. It is capable of handling feed sizes of up to 6 mm and grinding to product sizes of 30 microns or less. Vertimills are available in standard mill sizes ranging from 11 kW to 3,352 kW.

Since the introduction of the technology in the 1990s, Metso says it has sold over 540 Vertimill units to nearly all types of minerals.

Metso says it is the only manufacturer worldwide that can offer several stirred mill technologies (Vertimill, HIGmill™ and SMD), enabling it to support customers with the most suitable and efficient mill for their application.

Metso expands crushing, screening manufacturing capacity in India

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

Metso has extended its manufacturing capacity of mobile track-mounted crushing and screening equipment in Alwar, India, by opening new manufacturing facilities.

After the extension is complete, the total size of the Alwar factory is approximately 340,000 sq.m, adding 35% more capacity to the factory initially opened in 2008.

The Alwar factory has become one of Metso’s biggest manufacturing sites, employing approximately 1,300 people in total. The official opening took place on September 19, 2023, and production ramp-up to reach full capacity will continue until the end of the year.

The new factory showcases the most modern manufacturing practices, hosting several sustainability-driven functions like automated warehousing, automated assembly lines, modern painting lines and 13,000 solar panels installed to enable the increased energy production. After the extension, solar energy covers 85% of Alwar’s total power generation, which is maximum permitted as per state government guidelines.

“With the increased manufacturing capacity, Alwar becomes the major Metso site for increased domestic business in India and exports to Metso’s customers globally,” Markku Simula, President of the Aggregates business area of Metso. “Additionally, significant investment has been made in engineering and R&D resources, making it one of our key global engineering hubs.”

The Alwar factory will facilitate the manufacturing of several Metso Group brands. In addition to the mobile Metso Lokotrack equipment, the increased capacity in India will be used for the manufacturing of mobile McCloskey and Tesab equipment. At the same site, Metso is also producing wear parts and pumps for the aggregates and mining industries.

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.”

Germany and Finland out for sustainable solutions at IMARC 2023

Mining equipment, Mining events, Mining services, , , , , , ,

Germany, often hailed for its technological prowess and commitment to environmental sustainability, finds itself at a crossroads when it comes to its mining and resources future.

Historically, mining has played a vital role in Germany’s economy, but the industry now faces a multitude of challenges that demand a balanced approach to ensure economic growth and environmental conservation while reducing the country’s reliance on imported resources.

The International Mining and Resources Conference (IMARC), to be held in Sydney later this year, will for the first time host a dedicated Germany Pavilion, where the country’s mining and METS companies will be looking to connect and collaborate with Australian and global industry partners to address the challenges of the global quest for the resources of the future.

Germany’s mining heritage dates back centuries, with coal and lignite mining significantly contributing to its industrialisation and economic growth. However, as the world moves towards cleaner and more sustainable energy sources, the prominence of coal has waned, leading to a gradual phase-out of coal mining in the country. This shift aligns with Germany’s commitment to reducing carbon emissions and transitioning to renewable energy.

Juergen Wallstabe from the German-Australian Chamber of Industry and Commerce says that although mining activities have declined across Europe over several decades, Germany has expanded its global presence in the resources sector. High-tech METS companies in Germany are increasing their export of innovative and technologically advanced solutions worldwide.

He is confident IMARC will open more doors for established and emerging German firms to enhance their reputation for technological excellence and innovation.

“Germany’s leading position in engineering and manufacturing has resulted in a world-leading METS sector,” Mr Wallstabe says.

“We are convinced that on the one hand, German METS companies can support the Australian and other mining industry operators to reach their targets related to safety, productivity, efficiency, and decarbonisation.

“On the other hand, Australia is a valuable partner for Germany’s resources needs.”

One of the key themes at IMARC in recent years has been the industry’s impact on the environment and its role in building a sustainable decarbonised economy. A particular focus has been the often-unwelcome legacy of operations, where mining activities have left lasting scars on landscapes, disrupted ecosystems, and polluted water sources.

Wallstabe says that IMARC provides an opportunity to showcase how Germany’s emphasis on environmental protection has led to stringent regulations for mitigating these legacy impacts.

“Germany’s commitment to remediating and restoring abandoned mining sites demonstrates our dedication to healing environmental wounds,” he says. “IMARC offers a chance to share our experiences and learn from others facing similar challenges.”

Meanwhile, energy security is once again a buzzword in Europe, partly driven by the ongoing war in Ukraine and the impact of reliable energy supply, but also as a result of shifting political environments in countries like Germany.

Germany’s ambitious Energiewende (energy transition) plan aims to eliminate nuclear power and significantly reduce carbon emissions by promoting renewable energy sources. Consequently, the focus has shifted towards sustainable mining practices that support the production of materials crucial for renewable energy technologies, such as lithium for batteries and rare earth elements for wind turbines and solar panels. This presents an opportunity for the mining sector to contribute positively to Germany’s energy transformation.

Wallstabe notes that, “To manage the energy transition, Germany’s and Europe’s need for critical minerals will increase dramatically for the foreseeable future. Australia is already and will continue to be a key player in securing a steady supply of critical minerals. Wind turbines need steel, copper and strong magnets with rare earths minerals. Batteries consist of a wide range of critical minerals like lithium, manganese, copper, nickel, cobalt and the hydrogen industry needs platinum, iridium or scandium. All resources that Europe struggles to produce in sufficient quantities.”

IMARC spokesperson Paul Phelan says it is significant to have Germany so strongly represented at this year’s event. He says delegates can look forward to a showcase of Germany’s renowned innovation, and how it extends to the mining sector.

Like most other advanced nations, Germany’s mining industry is intertwined with global supply chains, both as a consumer of raw materials and as a supplier of technology and machinery. Ensuring ethical sourcing and responsible procurement of minerals from abroad becomes crucial in upholding the nation’s commitment to sustainability.

Finland, on the other hand, is taking a different approach towards securing critical minerals by prioritising e-waste recycling. Birgit Tegethoff, Senior Advisor at Business Finland Australia, points out Finland’s position as a global leader in the e-waste recycling noting companies like Metso are leading the world with its hydrometallurgical battery black mass recycling process.

“The Finnish mineral industry has the circular economy heavily ingrained in its DNA which has given it a competitive advantage in the global market,” she says. “By increasing the number of recycled components in battery production we are able to reduce the carbon footprint throughout our battery supply chain but also reduce our dependencies on international supply chains.”

High on Finland’s agenda is developing strategic international partnerships in the green minerals sector. The head of the Finnish delegation, Ilkka Homanen, has extended an invitation to Australian research institutes and the broader resource industry to reach out at IMARC 2023 and become part of a consortia solving the challenges of the green minerals value chain.

Rolf Kuby, Director-General of Euromines, says the issues facing Germany and Finland are not unique to those countries, but are felt across Europe.

“Australia embraced its natural endowment as a major strategic asset, while Europe has been over the last decades focused more on acquiring raw materials from elsewhere to process them further,” Kuby says.

“In part, this is due to the lack of deposits but also due to lack of exploration and willingness to foster mining. This is now changing, with the increase in demand for critical raw materials, and the need to future-proof value chains and not to be naive towards the importance of building a degree of open strategic autonomy.”

Phelan says along with the Germany pavilion, there will be a 90-minute German Program at IMARC 2023, curated by the German delegation and Chamber within the Global Opportunities Theatre.

Other programs featured this year include Canada, Australia, Mongolia, Ecuador, Chile, Saudi Arabia, Quebec, Ontario and South Korea.

International Mining is a media sponsor of IMARC 2023

Metso reflects on mechanical flotation technology evolution

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

Metso is celebrating 50 years of mechnical flotation this month, reflecting on the pivotal role flotation technology has played in the company’s history over the last five decades.

Evolving from humble beginnings at Outokumpu, and then further developed by Outotec, Metso has shaped the course of mechanical flotation and propelled the industry forward, it says.

The OK cell was taken into commercial use in 1973 with a capacity of 16 cu.m. At that time in flotation history, tanks were square-shaped when viewed from the top. As demand for even larger tanks escalated, a 38-cu.m version was introduced to optimise processes and achieve higher recoveries, and, ultimately, to enhance profitability.

During development of the larger flotation cells, the team noticed square-shaped tanks posed challenges in terms of load-bearing capacity at the corners. As a result, the entire industry shifted to round-shaped tanks. Thus, the TankCell® was born in 1995.

“TankCell is a great example of our history in flotation,” Antti Rinne, VP, Flotation at Metso, said. “Everybody who talks of TankCell flotation cells is speaking of our technology. We remain the original and leading provider of TankCell technology.”

Today, Metso TankCell boasts the world’s best flotation performance and offers a wide variety of cell sizes, currently ranging from 5 to 630 cu.m, the company says. This enables compact and cost-effective plant designs, even for high-tonnage operations. Fewer large units result in significant savings in construction costs, piping, cables, instrumentation and auxiliary equipment.

Rinne said: “Now, the biggest cell is almost 20 times larger than the original 38 cu.m. And, when we introduced the FloatForce® mixing mechanism in the TankCell design, it gave customers up to 30% savings in energy consumption and significantly better recoveries.”

Today’s flotation circuits are often designed and optimised with Metso’s HSC simulation tool, thus enabling optimisation of total flotation cell volume and other key flotation parameters, the company says.

Metso Concorde Cell, entering the market as recently as 2021, stands out as a significant milestone in flotation, according to Metso. The Concorde Cell is capable of recovering the unachievable fine and ultra-fine particles, increasing profitability while reducing operating costs, energy consumption and water usage.

This patented technology – the first of its kind – is tailored for finely disseminated and complex orebodies that were once considered inaccessible. For optimal results, it is best when used in conjunction with TankCell technology, Metso claims. Both are part of Metso’s Planet Positive offering and ensure unmatched metallurgical performance, it added.

“Combining the well-proven TankCell technology with Concorde Cells is a low-risk and high-benefit approach,” Rinne says. “The cell produces very high shear and extremely fine bubbles, which increases recovery in particles under 20 microns. Despite being the newest technology in Metso’s flotation portfolio, it has already been deployed at several operations globally.”

Since flotation is a continuous process, maintaining high availability and efficiency is crucial. Metso’s developments in flotation cell technology enable upgrading and retrofitting of older flotation equipment for enhanced performance, the company says. These advancements not only extend the lifespan of existing equipment, but also align operations with environmental and safety standards, ensuring long-term viability and compliance.

For more information on this flotation technology evolution, click here

Metso books filter and pump orders from India iron ore projects

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

Metso has been awarded orders to deliver concentrate dewatering filters and pumps to two iron ore projects in India. The combined order value exceeds €10 million ($11.01 million) and was booked in the Minerals segment’s June-quarter 2023 orders received.

Metso’s scope of delivery consists of the engineering, manufacturing and supply of several VPA pressure filters and filter feed pumps as well as spare parts.

Vijay Dhar, Vice President for Minerals Sales in the Middle East and India market areas at Metso, said: “We are pleased having been chosen to deliver the pressure filters to the two sites. The VPA filters are one of the most sustainable filters available and are classified as Planet Positive products because of their water and energy efficiency.”

Metso says its filtration portfolio consists of 15 different filter types and a comprehensive service offering for various mining and industrial applications, with more than 5,000 installations globally. The Larox® legacy is carried over in five filters in the portfolio. Over 80% of the Metso filters are part of the company’s Planet Positive portfolio.