Tag Archives: Planet Positive

Metso Outotec launches carbon-neutral and autonomous pelletising concept

Metso Outotec is launching NextGen Pelletizing™, a visionary concept for the next generation of pelletising plants that, it says, strive to be carbon-neutral and autonomous.

This concept is a part of the company’s Planet Positive offering focused on environmentally efficient technologies.

Attaul Ahmad, Vice President, Ferrous and Heat Transfer business at Metso Outotec, said: “NextGen Pelletizing is yet further proof of our strong commitment to building innovative pelletising solutions that are sustainable and contribute to climate targets. It offers significant benefits and will help the industry decarbonise, providing an 80-90% reduction in CO2 emissions.”

NextGen Pelletizing offers unmatched benefits, according to the company, including further energy reductions of 5-10%, production and availability increases of 10-15%, and improved product homogeneity and quality to support the transition of the steel industry.

The concept considers all relevant factors for energy efficiency, plant production and pellet quality to enable a holistic optimisation of the performance of the pelletising process, the company says. It follows a modular approach to minimise the sources of CO2 from the three carbon-intensive steps involved in pelletising and introduces further improved gas schemes, advanced combustion and burner technology (low NOx, hydrogen, and alternative fuels) as well as increased plant stability and performance through advanced process control.

Matthias Gabriel, Director, Ferrous technologies at Metso Outotec, added: “Pelletising is and will remain crucial in the future for the industry’s transition to green, carbon-neutral steel production. I am really excited about NextGen Pelletizing, which I firmly believe will completely revolutionise the way pelletising plants are built or operated in the future.

“The best part about NextGen Pelletizing is that it can be implemented fully or in parts, depending on the customer needs. And it can be easily upgraded in existing plants. Our experts will continue to evolve this vision with improved and innovative processes and tools.”

As the original inventor of the pelletising process, Metso Outotec’s NextGen Pelletizing also offers an exhaustive suite of digital solutions that help improve process performance, production capacity, and product quality as well as reduce energy consumption, environmental impact, and operation and maintenance costs, Metso Outotec says. These solutions include VisioPellet™ , Ferroflame LowNox burner, the Pallet Car Condition Monitoring System, and the Training Simulator, among others.

Metso Outotec has an installed worldwide base of over 120 pelletising plants.

Metso Outotec re-introduces Planet Positive TankCell flotation cells

Metso Outotec says it is re-introducing its TankCell® offering – the largest of its kind on the market – in an effort to further provide efficient and economical plant design with high availability and reduced plant footprint for any application.

Since the 1990s, Metso Outotec has delivered nearly 8,000 TankCell flotation cells to mining customers around the world, with a size range that goes from 5 cu.m to 630 cu.m.

“The energy-efficient TankCell flotation cells are part of our Planet Positive offering and are designed to provide optimal metallurgical performance sustainably,” Antti Rinne, Vice President, Flotation at Metso Outotec. “All components, as well as electrical equipment, have been selected for maximum availability and operating life.

“When combined with the Concorde Cell™, customers can unlock the potential for even further improved performance. Higher recovery, selectivity and final concentrate grade are just a few of the benefits. On top of this, we have a comprehensive automation, services and modernisation offering to support our customers’ flotation process improvement and optimisation needs.”

TankCell units are equipped with the FloatForce® mixing mechanism, which provides improved flotation hydrodynamics and pumping performance at high air dispersion rates. Thanks to this innovative mixing mechanism, particle recovery in the flotation cell is very efficient while power consumption and the risk of sanding is reduced, according to the company.

Metso Outotec says it is working on exciting new developments in the innovative FloatForcetechnology and expects to introduce the next-generation mixing mechanisms soon.

The TankCell flotation cells come with a wide selection of froth management tools, including different types of launders, optimised level control as well as various intelligent instruments, it added.

Metso Outotec also provides a range of services for the flotation units, including, for example, flotation process assessment, flotation inspections and various types of upgrades and life-cycle services packages for the optimisation of flotation cell performance.

TNG enlists Metso Outotec’s H2-based Circored process for Mount Peake concentrate plans

TNG Limited, an Australia-based resources company, has awarded Metso Outotec a study looking at reducing Mount Peake Ti-V magnetite concentrate using Circored™ technology, which uses hydrogen as its only reductant source.

As part of the study, Metso Outotec will perform a techno-economic assessment to integrate Circored technology into TNG’s TIVAN® process that provides for the extraction of high-quality products from Ti-V magnetite orebodies.

Metso Outotec has been granted this assignment following positive test work performed for TNG, which confirmed the applicability of hydrogen-based reduction for Mount Peake Ti-V magnetite concentrate.

The test work program, which was a precursor to a more detailed commercial and technical evaluation, was a success, TNG says, delivering the following results:

  • Achieved iron metallisation targets across a range of testwork parameters;
  • Demonstrated the viability of processing Mount Peake titanomagnetite concentrate with Metso Outotec’s Circored technology; and
  • Generated samples for downstream validation testwork.

Now, Metso Outotec will further define the process flowsheet for the Mount Peake project and prepare a preliminary capital cost and operating cost (+/-30%) for a Circored Plant.

The use of hydrogen is a key part of the TNG’s medium-to-longer-term strategy to reduce its net carbon footprint from processing operations at the Mount Peake project.

TNG Managing Director & CEO, Paul Burton, said the Metso Outotec study also complements its existing partnership with SMS group, which TNG has a strategic partnership with, to investigate green hydrogen production at Mount Peake.

Located 235 km north of Alice Springs, in the Northern Territory of Australia, Mount Peake will be a long-life project producing a suite of high-quality, high-purity strategic products for global markets including vanadium pentoxide, titanium dioxide pigment and iron ore fines, accordiing to TNG. The project has received Major Project Status from the Australian Federal Government and the Northern Territory Government.

Circored, part of Metso Outotec’s Planet Positive portfolio, is a process that uses hydrogen as the sole reducing agent in the reduction of fine ores, enabling carbon neutrality for metal processing plants.

Metso Outotec aims for higher capacities as ore sorting offering develops

The entry of Metso Outotec into the bulk ore sorting space arguably heralds the beginning of a new stage of market adoption – one that is focused on significant throughputs across multiple commodities.

In May, the mining OEM announced a collaboration agreement with Malvern Panalytical, a company that has been using Pulsed Fast Thermal Neutron Activation (PFTNA) technology onboard its cross-belt analysers to analyse and help divert ore and waste streams with improved accuracy.

Up until that announcement, Metso Outotec had mooted the benefits of bulk ore sorting in several industry articles. On the smaller scale, it had also renewed its ongoing agreement with particle ore sorting major player, TOMRA.

The company said its agreement with Malvern Panalytical, which has previously worked on bulk sorting projects with Anglo American among others, brought together its expertise in crushing and bulk material handling solutions with Malvern Panalytical’s ore analysis nous to offer an industry-leading portfolio of solutions for bulk ore sorting.

Rashmi Kasat, Vice President, Digital technologies at Metso Outotec, said in the press release that the pact with Malvern Panalytical would allow the company 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,” she said.

There are obvious positive benefits up- and down-stream of sensor-based sorting too, with the ability to carry out a low-cost mining method (upstream), as well as reduced capital investments in downstream equipment already shown with early-adopter projects.

That is before considering the relative energy and water reduction requirements that come with applying the technology.

Kasat later told IM that the company’s existing portfolio of material handling modules, crushing stations or mobile crushing equipment, as well as bulk material handling solutions, already “complement” the concept of bulk sorting.

“The addition of the bulk sensor is easily achieved,” she clarified. “The diversion mechanism will be included as well to be able to offer the whole plant out of one hand.”

With crushing stations – at least in the in-pit crushing and conveying (IPCC) space – that can go up to 15,000 t/h (see the company’s Foresight™ semi-mobile primary gyratory station), the prospect of Metso Outotec making a concerted effort to get into the bulk ore sorting space bodes well for the rising throughputs of projects.

NextOre recently claimed it had commissioned the world’s largest bulk ore sorting system at First Quantum Minerals’ Kansanshi copper mine in Zambia. This installation, which uses the company’s magnetic resonance technology, comes in at a 2,800 t/h-rated capacity.

Scantech, meanwhile, recently confirmed it has a GEOSCAN GOLD installation using prompt gamma neutron activation analysis technology for bulk sensing/sorting up and running that uses a diversion system at conveyed flow rates of more than 6,000 t/h.

Kasat, without naming a range, confirmed Metso Outotec was targeting “higher capacities” in line with the sensors available on the market. She also clarified that the agreement with Malvern Panalytical was “non-exclusive”.

“We will choose all our sensor/analyser partners strategically,” she explained. “Malvern Panalytical has a leading position and history in this field with proven technology for ore sensing. We will leverage our and their Tier 1 position in the industry for our bulk ore sorting offering.”

Malvern Panalytical uses Pulsed Fast Thermal Neutron Activation technology onboard its cross-belt analysers to analyse and help divert ore and waste streams with improved accuracy

As the type of sensor to be employed varies based on several factors including mineralogy, plant capacity, application of bulk ore sorting, etc, Metso Outotec will identify the right partners for the right need, she explained.

The major constraints for these sensors are often measurement times and sensor penetration, according to Kasat.

“There are very few sensors out there that can do sensing of a 500-mm-deep bed of rock on a conveyor belt, moving at 5-6 m/s,” she said. “But our current and future prospective partners are working on developing the technologies to reduce measurement times without compromising the accuracy of measurement.”

The mining OEM is looking to, in most cases, provide ‘plug and play’ flowsheets for bulk ore sorting and then carry out the required customisation per sensor.

This plan reinforces Kasat’s assertion that there is no ‘one-size-fits-all’ concept in bulk ore sorting applications.

For new projects, the process could see the company start with metallurgical testing, progress to mobile/fixed pilot plants in the “backyard” to test the accuracy of the sensors for the given application, and then find the right solution for the customer’s use case.

Renato Verdejo, Business Development Lead for Bulk Ore Sorting at Metso Outotec, added: “For existing plants, we will install the sensor over the belt conveyor and analyse the results after selecting the right sensor for this sorting application.”

Metso Outotec intends to focus on major commodities like copper, iron, nickel and gold, among others, with applications such as waste/ore sorting, low grade re-crushing and beneficiation process optimisation.

Within this wide remit – and in line with its non-exclusive agreements with Malvern Panalytical and TOMRA – the company is also considering the combination of both bulk and particle sorting in flowsheet designs.

Metso Outotec, in 2021, renewed its ongoing agreement with particle ore sorting major player, TOMRA

“The combination of the superior throughput of a bulk application with the selectivity of particle sorting in a rougher-scavenger setup is something that can bring sorting to high volume mines in the future,” Kasat said.

“Plant concepts and flowsheets have already been conceptualised and we expect the first deliveries to be in pilot stations to test the sensors on site,” she added, saying that the tonnage requirements for bulk ore sorting sensor validation meant a bulk sensor would have to be piloted in the field to get statistically meaningful data about the properties of the deposit.

Metso Outotec’s crushing system offering will form the “base” for these solutions, with ore sorting optionality available to all customers, she said.

This sensor-based optionality also overlaps with another in-demand part of Metso Outotec’s business: IPCC.

The company’s dedicated team in Germany are responsible for this area, developing projects backed by comprehensive studies.

They – like most of the industry – are aware of the potential application for sensor-based ore sorting in IPCC projects.

Markus Dammers, Senior Engineer of Mine Planning for Metso Outotec and one of the team members in Germany, said there were applications for both bulk and particle sorting in IPCC applications, with the former likely integrated after primary crushing and the latter after secondary/tertiary crushing.

“Bulk ore sorting in an IPCC application should be integrated after primary crushing in order to recover marginal material determined as waste in the block model, or reject waste from the ore stream,” he said.

Bulk ore sorting in an IPCC application should be integrated after primary crushing in order to recover marginal material determined as waste in the block model, or reject waste from the ore stream, according to Markus Dammers

If integrated after secondary or tertiary crushing, it becomes less effective, with the ore’s heterogeneity decreasing every time the ore is rehandled, transferred, crushed, blended, etc.

“In this manner one can take advantage of the natural variability in the deposit, rather than blending it out, with bulk ore sorting,” he said.

After secondary and tertiary crushing, particle sorting may be applied as a “standalone or subsequent ‘cleaner’ process step”, he added.

With Metso Outotec open to the inclusion of ore sorting in fully-mobile, semi-mobile and stationary crushing stations within an IPCC context, the company has many potential customers – existing and new – out there.

And that is just in IPCC applications.

The company also has hundreds of crushing stations on fixed plant installations that could represent potential sorting opportunities.

Metso Outotec, on top of this massive install base, has a few advantages over traditional ore sorting vendors in that it understands the plant that goes around the analysis and diversion process associated with ore sorting; knows how important uptime is to its customers; and, through sophisticated modelling, realises what impact changes in the flowsheet will have up- and down-stream of such equipment.

“The key point here is to have all the equipment to handle and process the ore to feed the sorter and, later, having the technology to divert the material and retain the availability of the plant without changes,” Kasat said.

Energised by its Planet Positive aims of responding to the sustainability requirements of its customers in the fields of energy or water efficiency, emissions, circularity and safety, the company is now ready to flex its processing plant muscles to increase the industry’s adoption of bulk and particle sorting technology.

Metso Outotec to supply Planet Positive Vertimills to iron ore project in South America

Metso Outotec says it has been awarded a contract to deliver sustainable grinding technology to an iron ore project producing premium pellet feed in South America.

The total value of the order exceeds €10 million ($10.2 million), the company says.

The OEM’s scope of delivery consists of the engineering, manufacturing and supply of four Vertimill® vertical grinding mills. In addition, Metso Outotec will provide installation and commissioning advisory services. The Planet Positive Vertimill grinding mills are expected to save more than 30% of the installed power compared with a conventional ball mill circuit, the company says.

“We are pleased that our customer has chosen the industry-leading Vertimill technology,” Christoph Hoetzel, Head of the Grinding business line at Metso Outotec, says. “The regrinding circuit will enable energy-efficient grinding combined with low operating and life-cycle costs.”

Metso Outotec to deliver Planet Positive milling, concentration and filtration tech to Kamoa

Kamoa Copper SA has selected Metso Outotec to supply key concentrator plant equipment to the company’s copper mining complex expansion in the Democratic Republic of Congo, the OEM reports.

Metso Outotec’s scope of delivery consists of Planet Positive processing equipment, including energy efficient HIGmill™ regrind mills (pictured) with polyurethane wear linings. The delivery also includes Larox® PF 60 Series concentrate filters and TankCell® flotation cells for the efficient recovery of valuables.

“One of the key missions for Kamoa Copper SA is to implement low-carbon technology to advance sustainable production of copper,” Charles Ntsele, Vice President, Minerals Sales for Metso Outotec in Africa, says. “Metso Outotec’s Planet Positive offering supports our customer’s ambition, allowing us to be a true partner for positive change.”

Early in July, Ivanhoe Mines, which owns 39.6% of Kamoa-Kakula, reported record producion in the June quarter of 87,314 t of copper in concentrate produced.

Metso Outotec also announced this week that it had signed an agreement with Larsen & Toubro Limited to supply four Symons™ cone crushers for an iron ore crushing and screening plant to National Mineral Development Corporation’s (NMDC) Kirandul complex in Chhattisgarh, Central India.

The new Symons cone crushers have advanced features that will make the customer’s operations more efficient and reduce maintenance efforts compared with earlier versions and to other equivalent crushers on the market, Metso Outotec says.

Metso Outotec to deliver world’s largest Premier grinding mills to Kansanshi copper mine

First Quantum Minerals (FQM) has awarded an order to Metso Outotec for two very large horizontal grinding mills for the company’s copper mine expansion at Kansanshi in Zambia.

Metso Outotec’s delivery includes two Planet Positive Premier™ grinding mills with a total installed power of 50 MW – the largest Premier grinding mills Metso Outotec has delivered to date.

To meet the need for efficient and fast replacement of the lining systems, as well as ensuring a long wear life, the ball mill will be equipped with the Metso Outotec Megaliner™ and the SAG mill will be equipped with Metso Outotec metallic mill lining and a high-performance discharge system, it explained.

FQM’s Kansanshi mine, located near Solwezi in the North-western Province of Zambia, is among the largest copper mines in the world and the largest in Africa.

First Quantum Minerals is currently working on its further expansion (the Kansanshi S3 Expansion), which includes a standalone 25 Mt/y processing plant that will increase copper production substantially.

Once the expansion is completed, copper production from Kansanshi is expected to average approximately 250,000 t/y for the remaining life of mine to 2044.

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

Earlier this week, Metso Outotec was awarded what it says was a major contract for the delivery of sustainable crushing, screening and grinding technologies to a greenfield iron ore project in South America.

Metso Outotec greenfield iron ore contract to include most sustainable tech available

Metso Outotec says it has been awarded a major contract for the delivery of sustainable crushing, screening and grinding technologies to a greenfield iron ore project in South America.

The concentrator plant has a targeted production of premium pellet feed, with the total value of the order approximately €45 million ($47 million).

The comminution circuit flowsheet developed for the new concentrator plant in cooperation with Metso Outotec represents the most sustainable technology currently available, according to the OEM. Conventional horizontal mills have been replaced with the combination of HRC™e high pressure grinding rolls (pictured above) and Vertimill® grinding mills to achieve the best energy-efficiency with the lowest operating and life cycle costs, it says.

By using this flowsheet, the plant is expected to save 25% of installed power compared with a conventional high pressure grinding roll (HPGR)/ball mill circuit and over 40% compared with a conventional SABC (SAG mill followed by pebble crusher and ball mill) circuit, the company claims.

Metso Outotec’s scope of delivery consists of the engineering, manufacturing, and supply of SuperiorTM MKIII Primary Crusher, HP SeriesTM cone crushers, HRC e HPGR high pressure grinding rolls, vibrating feeders, as well as banana, horizontal and dewatering screens and Vertimill grinding mills. In addition, Metso Outotec will provide installation and commissioning advisory services and wear and spare parts.

Christoph Hoetzel, Head of Grinding business line at Metso Outotec, said: “Metso Outotec is honoured to be chosen to deliver these state-of-the-art comminution technologies. The plant’s Planet Positive comminution flowsheet combines the best solutions available, allowing to achieve superior energy-efficiency and lower wear rates.”

Fernando Samanez, Vice President, Minerals Sales, South America market area at Metso Outotec, added: “This is a remarkable project and Metso Outotec will play a significant role also in the project start-up with its strong local operations and highly skilled service team.”

Metso Outotec wins major equipment order for Almalyk MOF-3 copper concentrator

Metso Outotec says it has signed a contract to deliver key process technology to Almalyk Mining and Metallurgical Company’s MOF3 copper-gold-molybdenum concentrator complex in Almalyk, in the Tashkent region of Uzbekistan.

The planned capacity of the plant, which is situated next to the Yoshlik-1 deposit, is 60 Mt/y, with the contract value exceeding €100 million ($107 million).

Metso Outotec’s scope of delivery consists of the basic engineering, manufacturing, and supply of the HIGMill® regrinding mills, TankCell® flotation equipment and high-rate thickeners, FrothSense+™ froth cameras, Larox® PF filters, slurry pumps and MHC™ Series hydrocyclones, as well as samplers, Courier™ 6X SL elemental on-line analysers and PSI500i particle size analysers, a state-of-the-art process control system, and installation and commissioning advisory services and spare parts.

Markku Teräsvasara, President of the Minerals business area at Metso Outotec, said: “We are very happy for being trusted with this landmark order.

“Special emphasis has been put on optimising metallurgical performance and energy efficiency of the concentrator plant. Our delivery will feature several Planet Positive technologies contributing to sustainable operations,” says .

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.