Tag Archives: mineral processing

Kwatani branching out from South Africa roots

Vibrating screen and feeder specialist Kwatani says it is transitioning from equipment supplier to solutions provider, as it attracts customers from well beyond its South Africa headquarters.

According to Kwatani General Manager Sales and Service, Jan Schoepflin, the company’s strong in-house expertise and design capability – combined with the manufacturing quality it consistently achieves – ensures its customised solutions deliver optimal performance at the lowest possible lifecycle costs.

“Our recent orders show that our customer base in Southern Africa remains strong, while there is growing recognition of our cost-effective offerings in West Africa, East Africa and North Africa,” says Schoepflin. “At the same time, orders from countries like Canada and Russia indicate that our markets abroad continue to grow.”

Kwatani says it remains the market leader in the supply and servicing of vibrating screens and feeders on iron ore and manganese mines in South Africa’s Northern Cape province. It also counts platinum, coal, diamond and gold mines in its customer base. Its West Africa orders have been mainly to gold mines, and there is growing potential for gold mining in East Africa, Schoepflin says.

Over its four decades of operation, Kwatani has produced about 16,000 custom-designed screens, and is building, on average, 30 to 40 units a month in its ISO 9001:2015 certified facility close to OR Tambo International Airport in Johannesburg.

“Our reputation has been built on prioritising what our customers need, and doing business with integrity and trust,” Schoepflin says. “This means delivering on what we promise and making sure that customers achieve the expected value from our products.”

The company’s solution focus is underpinned by its significant and ongoing investment in local skills, ensuring that its designs leverage strong mechanical and metallurgical engineering expertise, according to Schoepflin.

“This confidence in our products allows us to offer a process guarantee to customers, to deliver the tonnage, throughput and fractions that they expect,” he says. “Depending on which country our customers operate in, they may also have different industry and quality standards/certification expectations and we work closely with them to understand these clearly and meet their requirements.”

Schoepflin also emphasises the company’s service capabilities, which include its local service centres closer to customers, and its support partners in other countries.

“The careful selection of these partners is vital to meet customers’ stringent technical expectations,” Schoepflin says. “In some countries, our partners can also manufacture components according to our drawings and specifications, should there be an urgent requirement from a customer.”

Metso Outotec to help modernise Nornickel’s Talnakh processing plant

Metso Outotec says it has signed an agreement to deliver its “industry-leading comminution equipment” to Norilsk Nickel’s refurbishment project at the Talnakh processing plant in Norilsk, Russia.

The contract includes delivery of one SAG mill and two ball mills with a total installed power of 36 MW, as well as two HP series pebble crushers. Metso Outotec will also supply spare parts and consumables, including metallic mill liners, and will supervise the installation of the equipment. The delivery is scheduled for 2022.

While the order value was not disclosed, Metso Outotec said the order has been booked in its December quarter 2020 orders received.

Sergey Dubovitsky, Senior Vice President, Strategy, Strategic Projects, Logistics & Procurement at Norilsk Nickel, said: “The modernisation of the Talnakh processing plant is one of the priority projects for Norilsk Nickel. Its implementation will significantly increase the volume and efficiency of production. To achieve this, we utilise the most modern technologies from Metso Outotec.”

Stephan Kirsch, President, Minerals business area, Metso Outotec, added: “We are pleased to continue our partnership with Norilsk Nickel. The supply of leading-edge equipment from Metso Outotec for the reconstruction of the comminution section at the Talnakh concentrator will enable an increase in the amount of ore processed. Our company has taken part in several projects with Norilsk Nickel to boost throughput rates of the processing facilities, and we are grateful for having been again selected to provide reliable solutions for a project as significant as Talnakh.”

Metso Outotec books zinc plant order as it agrees sale of aluminium business

Metso Outotec has signed a contract to deliver a complete package of key process equipment for a greenfield zinc plant in the Chelyabinsk region in Russia.

The contract value of approximately €100 million ($122 million) has been booked in Metso Outotec’s Decemeber quarter order intake, a quarter of which will be booked in Minerals segment and the rest in Metals segment.

The order for the Verkhny Ufaley plant includes an equipment package for zinc concentrate processing, iron precipitation, solution purification and electrowinning (EW) technologies for safe and sustainable zinc processing based on OKTOP® reactor and plant products.

The order also contains a circuit heat recovery system, zinc EW and ingot casting equipment, as well as high-efficiency cooling towers for zinc EW and gypsum removal with drastically reduced emissions compared with conventionally-designed cooling towers, the company said. Clarifying solutions for consistent solid-liquid separation, high-performance Larox® FP and RB filters with low energy consumption, as well as fully integrated digital process automation for more reliable and flexible operation are also part of the order.

“Metso Outotec has been supplying minerals processing and metals refining technologies to our customers in Russia for a long time,” Jari Ålgars, President, Metals business area at Metso Outotec, said. “The new zinc plant will utilise Metso Outotec’s proprietary technology, which is both sustainable and highly cost effective.”

Stephan Kirsch, President of the Minerals business area at Metso Outotec, added: “Metso Outotec provides leading-edge technology for extensive zinc processing plants. This includes proprietary process equipment and know-how from raw material to final zinc product and various by-products.”

The technology to be delivered is the most cost-efficient technology available for zinc raw material processing, enabling efficient zinc and by-product recovery from a wide range of primary zinc raw material, according to Metso Outotec.

In a separate press release, Metso Outotec announced it had agreed to sell its Aluminium business to REEL International, headquartered in France. The business was put up for sale a year ago and has since been reported under the company’s discontinued operations.

The business to be divested comprises of green anode plants, anode rodshops, and casthouses used in aluminium smelters as well as related equipment and services. Approximately 120 Metso Outotec employees will join REEL upon closing, which is expected to take place during the March quarter of 2021, Metso Outotec said.

The parties have agreed not to disclose the value of the transaction.

Hatch to commercialise CRC ORE’s Grade Engineering services

CRC ORE says it has taken an exciting step forward with Hatch, signing a deal that allows the multidisciplinary management, engineering and development consultancy to commercialise its Grade Engineering® Consulting Services.

Developed by the Brisbane-based Cooperative Research Centre for Optimising Resource Extraction (CRC ORE), Grade Engineering enables miners to reduce their energy, water and waste signatures while enhancing the productivity and profitability of their operations, according to CRC ORE.

It is an integrated approach to coarse rejection that matches a suite of separation technologies to ore specific characteristics and compares the net value of rejecting low value components in current feed streams with existing mine plans as part of a system-view.

Grade Engineering makes it possible to more efficiently treat lower grade ores and waste to extract valuable minerals, significantly increasing the life of mines and reducing their environmental footprint.

Achievable outcomes for mines, when deploying Grade Engineering at production scale, include significantly improved return on investment and lower capital intensity, according to CRC ORE.

BHP recently engaged CRC ORE and the Grade Engineering solution at its Olympic Dam mine, in South Australia, a location where the mine is actively examining bulk ore sensing and sorting opportunities.

“As Hatch adopts Grade Engineering and extends its reach into the mining industry, the value of such outcomes will increase for operations, clients and communities globally,” it added.

CRC ORE Chief Executive Officer, Dr Ben Adair (pictured signing the agreement on the left), said: “Hatch is a valued a long-term participant in CRC ORE and has actively championed Grade Engineering and its benefits to the industry. As a CRC ORE innovation, we are pleased that Grade Engineering will continue to be delivered by such a capable and engaged team.”

Dr Adair added: “At CRC ORE, our goal has been to develop our solutions to the highest possible standard and then ensure these are then managed by the most capable practitioners to take them to industry. Hatch is the perfect partner to ensure the long-term future of Grade Engineering.”

Under the terms of the commercialisation arrangement, Hatch will use Grade Engineering Intellectual Property for its consulting services.

Hatch Managing Director Australia and Asia, Jan Kwak (pictured signing the agreement on the right), said it was an honour to provide Grade Engineering consulting services.

“Being able to offer Grade Engineering as service is an exciting and positive step forward for Hatch and the mining industry,” Kwak said. “Grade Engineering enables miners to reduce their energy, water and waste signatures while enhancing the productivity and profitability of their operations.

“It also brings us a step closer to our vision for process intensification.”

The Grade Engineering team at Hatch will be headed by Dr Sevda Dehkhoda who has been working closely with CRC ORE since 2019.

“We look forward to continuing the legacy of CRC ORE by enabling the mining industry to intensify operational performance and minimise environmental footprint of the process by refining less waste,” Dr Dehkhoda said. “Adopting Grade Engineering into Hatch’s end-to-end value chain optimisation service offering strengthens Hatch’s position and its commitment to making positive change for mining operations and their communities.”

To facilitate the transition, CRC ORE’s Grade Engineering team will relocate to Hatch’s Brisbane office, supporting Hatch with current and potential users of Grade Engineering.

TAKRAF dry-stacked tailings test work boost for Los Andes Copper’s Vizcachitas project

Los Andes Copper says it has received additional positive results from the ongoing prefeasibility study (PFS) metallurgical test work at its Vizcachitas project in Chile.

These results show improved filtration rates for both the fine and coarse fraction tailings compared with previous testing, it said, reinforcing the decision to adopt dry-stacked tailings at the project.

An October press release regarding PFS metallurgical test work carried out by SGS demonstrated that the Vizcachitas tailings were amenable to being filtered and dry-stacked.

These same coarse and fine representative tailings samples were sent to the TAKRAF laboratories for further settling and filtration assessments. Los Andes said the TAKRAF work tested various settling and filtration parameters, including those previously tested.

The studies demonstrated that for the coarse fraction vacuum filtration, the rates improved from 1.9 t/h/sq.m to 3.4 t/h/sq.m when compared with the previous results. For the finer fraction, the settling velocities improved from 8.4 m/h to 16 m/h and the pressure filtration rates improved from 0.6 t/h/sq.m to 0.7 t/h/sq.m. The expected cake moistures for both filtration technologies were 15%.

These positive results mean that the Vizcachitas project, processing 110,000 t/d of ore, would only need to use eleven standard 162 sq.m belt filters and four 2.5 m x 2.5 m pressure filters for the tailings dewatering operation, Los Andes said, noting that other operations in the world were successfully operating with similar filter arrangements.

“Tailings filtration reduces water consumption by 50% when compared to thickened tailings disposal alternatives,” Los Andes said. “Furthermore, filtered tailings can be handled by trucks, conveyors and shovels, eliminating the need for the construction and operation of a tailings dam.

“The adoption of this technology puts the Vizcachitas project at the forefront of the environmentally responsible practices being adopted for the future of sustainable mining globally.”

Metso Outotec ups mill relinine equipment capacity with MRM

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.

JordProxa crystallises battery chemical market potential with Albermarle, Terrafame orders

Australia-based JordProxa Pty Ltd has recently delivered crystallisation plants for two major battery metal producers, solidifying, it says, its position in the growing new energy market.

JordProxa designed, fabricated and dispatched several large-scale orders to site, including an evaporator and two crystallisation plants to lithium producer Albemarle, in Western Australia, and nickel sulphate, cobalt sulphate and ammonium sulphate crystallisation plants to Terrafame, in Finland. The modular plants are now being installed in Western Australia and installation is underway on site in Finland with the last modules in transit (pictured above), JordProxa said.

The most recent crystallisation plant deliveries follow, in 2019, the arrival of a JordProxa nickel sulphate crystallisation plant at BHP’s Nickel West operations in Western Australia.

JordProxa Managing Director, John Warner, says the rapid uptake of battery-electric vehicles has led to a surge in demand for battery chemicals and associated technologies.

“Battery chemical producers need a technology provider that can meet and exceed the demands of product purity, with a focus on continued process improvement, to keep up with changing product specifications,” Warner said.

“JordProxa understands the process fundamentals that influence product quality through evaporation and crystallisation. We combine the project delivery skills and global footprint of Jord and Proxa and are perfectly positioned to deliver state of the art plant solutions for ultra-pure battery chemicals at large tonnage scales.”

He added: “We leverage an established network of fabrication alliances and modular design capabilities. This allows us to deliver key assemblies that are tested in the workshop before they are dispatched and installed on site. Our aim is to optimise project delivery time while minimising project risk.”

Jord International CEO, Angus Holden, said he was pleased the group is demonstrating its technical and operational expertise in the new energy market.

“Our track record over 50 years of business demonstrates that we can successfully design and build reliable plants with tangible process benefits,” he said.

“This important crystalliser work from JordProxa delivers on our goal of supporting clean energy technologies and is generating a new long-term, sustainable revenue stream. It has helped our group achieve a record revenue for the 2020 financial year, aided by other new areas of business, including enhanced minerals beneficiation and topside modules for offshore gas fields.”

Los Andes Copper commits to HPGR comminution route for Vizcachitas

Los Andes Copper says additional comminution test work has confirmed the selection of high pressure grinding rolls (HPGR) circuit technology for use in the processing circuit at its Vizcachitas copper project in Chile.

The use of HPGR, and the adoption of the previously announced dry-stack tailings, reinforces the company’s commitment to the environment and designing a sustainable operation with low energy and water consumption, it said.

At early stages of the Vizcachitas prefeasibility study (PFS), HPGR technology had been identified as the most attractive grinding alternative, given the data obtained from preliminary test work conducted in 2009, and in 2017-2018. As part of the PFS metallurgical test work, four representative samples from the mine plan were sent to a laboratory for pressure bed testing. The results of this test work confirmed the equipment sizing and its performance for a PFS-level study.

The results provided specific energy consumption readings of 2.17 kWh/t in the case of a HPGR circuit, which results in a global specific energy consumption of the comminution circuit of approximately 14 kWh/t. As compared with the semi-autogenous grinding alternative, the HPGR showed a reduction of up to 20% in energy and up to 50% in grinding media consumption, Los Andes Copper said. These results confirm the advantages of adopting this technology at the project.

The comminution circuit at Vizcachitas, where the HPGR circuit will be incorporated, is a three-stage crushing circuit using a gyratory primary crusher, three cone crushers in open circuit and two HPGR as a tertiary stage arranged in a closed circuit followed by ball mills. Through this process, and in addition to the lower energy consumption, the use of HPGR will reduce dust emissions related to dry crushing due to the removal of coarse recirculation in the secondary crushing stage, the company said.

Fernando Porcile, Executive Chairman of Los Andes, said: “I am pleased that the results from the test work carried out to date have confirmed the advantages of using HPGR in terms of enhancing project economics, lowering energy consumption and increasing operational flexibility.

“The use of HPGR technology favours the stability of the dry stacked tailings operation, as well as reducing the environmental impact by minimising energy usage, water consumption and dust emissions.”

FLSmidth tackles the need for higher power, throughputs with new TSUV Mark 5 gyratory crusher

FLSmidth has launched a new “digitally-enabled” gyratory crusher to, it says, deliver the lowest total cost per tonne of material processed, even when crushing the most challenging ore.

In response to the industry need for higher power crushing and throughputs for lower-grade ores, FLSmidth has developed the TSUV Mark 5 Top Service Gyratory Crusher, the world’s most opex- and capex-efficient gyratory crusher, it said.

FLSmidth’s latest generation gyratory crusher, the TSUV Mark 5, follows the success of the Top Service (TS) and Top Service Ultra Duty (TSU) models.

The unique top-service design prioritises safety, maintenance and efficient crushing performance, FLSmidth says. Unlike other gyratory crushers that require workers to get in underneath the crusher to perform high-risk maintenance, the TS range allows service and maintenance to be carried out from above, increasing speed, safety and simplicity. Additionally, the 100-plus tonne, fully-dressed main-shaft no longer needs to be guided into the eccentric assembly by hand. “Now, the shaft aligns automatically, dramatically reducing risk,” the company says.

All TS gyratory crushers are built for strength, durability and the ability to adapt to the various requirements of mine operators, but the TSUV design adds even more power, capacity and flexibility, to give mine operators a low total cost of ownership, according to FLSmidth.

The improved power handling capabilities of up to 1,500 kW allow miners to process more material as ore yields decline, enabling operations to remain competitive, while the crusher footprint has only nominally increased.

Optimised eccentric speeds ensure maximum throughput without incurring excessive wear rates, the company says. This is a finely balanced equation, based on extensive R&D work, which, together with the new service and operational features, gives operators the lowest possible cost per tonne of material processed, it explained.

“To offer even greater potential to optimise performance, the TSUV Gyratory Crusher is digitally enabled – giving operators more control over operations and availability,” FLSmidth says. “The ability to make fine adjustments to wear compensation, track equipment trends and instantly detect crusher obstructions will enable increased uptime, optimum equipment life and significantly reduce risk of unplanned downtime.”

The TSUV Gyratory Crusher can be connected to FLSmidth’s digital ecosystem, which provides operators with the benefits of both FLSmidth technologies and experience. A range of services is on offer, geared towards maintaining asset health and optimising performance, many of which can be carried out remotely, saving both time and money, the company says.

The TSUV Gyratory Crusher’s advanced control system gives operators a 24/7 view of performance metrics, enabling increased reliability, FLSmidth says. And, with further condition monitoring feedback and controls, maintenance can be more proactive, minimising the risk of unscheduled stops.

“Through a combination of all these features, the TSUV Gyratory Crusher achieves the lowest cost per metric tonne in operation of any crusher on the market and gives you the lowest total cost of ownership,” the company says. “This translates into a reduced environmental impact.”

Chris Reinbold, Head of Global Product Line Management, Senior Vice President, Mining, said: “We remain steadfast in our aim to reduce emissions from mining to zero by 2030. Increasing the sustainability of key equipment, like the gyratory crusher, is part of our core goal to invest in efficiency-focused R&D, to deliver the best available equipment to the minerals industry.”

Centerra Gold joins CEEC’s quest for eco-efficient comminution

Centerra Gold has become the latest miner to join the Coalition of Energy Efficient Comminution (CEEC) as a new sponsor.

Centerra, which follows in the footsteps of Hudbay Minerals in backing the not-for-profit organisation, is a Canada-based gold mining and exploration company with assets in Canada, the Kyrgyz Republic and Turkey. It is one of the largest Western-based gold producers in central Asia, and its Mount Milligan mine (pictured) is the first, large new operation in British Columbia in a generation.

The company’s vision is to build a team-based culture of excellence that responsibly delivers sustainable value and growth, according to CEEC.

CEEC CEO, Alison Keogh, said: “We are thrilled with Centerra’s decision to become a CEEC sponsor. Our sponsors work collaboratively to accelerate energy-efficient, productive mining processes. That’s vital for our industry and communities as we reduce impact, tackle costs and improve shareholder value.

“As a CEEC sponsor, Centerra helps CEEC provide industry with information and tools from experts and grow the network of committed professionals working to accelerate eco-efficient comminution and maximise the potential of their mineral resources and assets.”

Centerra Vice President and Chief Operating Officer, Daniel Desjardins, praised CEEC for its contributions towards environmental, social and governance (ESG) actions in the field and welcomed the opportunity to share information to advance business goals.

“Centerra’s financial and operational objectives are underpinned by a fundamental commitment to ethical and sustainable practices,” Desjardins said. “Our values are strongly aligned to CEEC’s mission for eco-efficient comminution; environmental, social and governance factors are our foremost priorities as we strive to continually improve the management of our operations.

“CEEC offers a pathway to share best practice and innovation in the international mining sector. We look forward to collaborating with like-minded organisations on shared challenges such as energy and water use.”

Centerra produced 783,308 oz of gold and 3,220 t of copper in 2019, making it one of the leading gold and copper producers based out of Canada.

The company’s major assets include the Kumtor Mine in the Kyrgyz Republic, which has produced more than 12.6 Moz of gold between 1997 and the end of 2019, and the long life, low-cost gold/copper Mount Milligan Mine, in British Columbia, Canada. The third operating mine, the Öksüt Gold Mine, in central Anatolia, Turkey, poured gold for the first time on January 31, 2020, after just 22 months of construction.