Tag Archives: Planet Positive

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 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 to ‘enrich’ mining, metallurgy decision making with Geminex digital twin

The value a ‘true’ digital twin could provide the mineral processing and metallurgical industries has been spoken of continuously throughout the last few years, and Metso Outotec believes it is on the cusp of realising such value with its “science-based” Metso Outotec Geminex™ digital twin.

Designed to manage variability and optimise resources, the solution simulates and optimises seamless sustainable operations in minerals, pyro- and hydro-metallurgical processes by combining operational data from both internal and external data sources, the company says.

For simulation and production, Geminex uses the renowned HSC process models that already have over 20,000 users worldwide. These models – which combine versatile chemical, thermodynamic and mineral processing features – have been successfully implemented in hundreds of minerals and metals processing flowsheet development cases, with the same models used in plant run-time optimisation, according to Metso Outotec.

There’s more to this digital twin than the HSC process models alone, according to Veli-Matti Järvinen, Vice President, Automation at Metso Outotec.

Geminex uses “first-principle” dynamic process and equipment models for calibrated performance to help provide an ‘accurate’ digital twin for existing operations, he says.

“Here, both quality and availability of key process data are important,” he told IM, mentioning that normally available instrument and laboratory data tend to be sufficient inputs for generating the digital twin’s simulations.

And Geminex, through a series of “soft sensors”, also produces a vast amount of data that cannot be measured directly yet is leveraged through the dynamic process models, according to Järvinen.

“These soft sensors, as they are called, give an insight to the process that was not available before,” he explained, with examples including element or mineral content by particle size fractions in the process streams. This goes one step further than the feedback from, for instance, Metso Outotec’s Courier® on-stream analysers, which provide real-time elemental analysis measurements.

This makes the digital twin that much more powerful than existing solutions on the market, as it can introduce a new dataset to the equation.

And, as with all ‘true’ digital twins, the models are adapted to live data and continuously improved by machine-learning algorithms, Järvinen said.

“An example of this is model adaptation for variable ore types with different processing performance to help manage variability,” he said. “The resulting metallurgical digital twin is accurate, and its behaviour reflects the physical process.”

All this means Geminex can simulate and test alternative operational scenarios and parameters based on accurate process models and real data, providing the sort of decision-making tools the industry has been after for decades.

While the resource sustainability angle is key here – reinforced by the fact Metso Outotec has labelled Geminex as a Planet Positive product: a collection of the company’s most environmentally efficient technologies – the digital twin’s ability to use resources in an optimal way while considering both impacts and constraints is only a fraction of the industries’ value case.

The ability to incorporate new equipment and tools in a ‘live’ flowsheet that considers the specific characteristics of the orebody at hand and the conditions in which each processing stage receives material is very powerful. One can see it easily aiding the incorporation of new technology in the plant, with the simulations able to provide operators with the confidence to leverage innovations.

Järvinen says the digital twin’s use will also enable the company to start process flowsheet design that much earlier in the mine exploration/development stage.

“As soon as the customer has metallurgical data, the process can be designed and optimised to match the required economic optimum,” he said.

Metso Outotec’s strong experience in developing metallurgical processes, as well as incorporation of the process models of Metso Outotec’s HSC simulation package for minerals processing, pyro- and hydro-metallurgical processes, enables this early analysis.

“These models provide great value in the exploratory phase by enabling scenario analysis, which will help find alternatives for process flowsheets, equipment selection and even blending of different types of ore, if needed,” Järvinen said.

At the same time, Järvinen expects the Geminex digital twin to reduce the plant ramp-up time and “time to market” in the later mining project stages as operators will be that much better prepared for the likes of cold and hot commissioning.

“Great value and impact towards a positive change can be achieved in the run-time of the mining operation and the operating strategy by enriching decisions with the help of Geminex,” he said.

Geminex may be Metso Outotec’s own proprietary digital twin, but, thanks to an extensive back catalogue of process plant modelling references, it is able to run dynamic simulations that incorporate competitor equipment, according to Järvinen.

Similarly, while the company has sustainability and Planet Positive aims for Geminex, the equipment to feature in simulations does not have to be classified as Planet Positive, Järvinen says.

“The processes or assets do not need to be Planet Positive equipment, but those can become such with proper control and optimisation,” he said. “With Metso Outotec Geminex, the full value chain of mineral processing plants and hydro- and pyro-metallurgical plants are considered for Planet Positive production.”

Able to be implemented in modules, Geminex can be deployed piece by piece as part of customers’ digital transformation and continuous improvement projects, he added, opening the possibilities for Metso Outotec to leverage its capabilities beyond full flowsheet design.

In the development phase of Geminex, Metso Outotec carried out several successful pilots with universities and, now commercially available, the company has three ongoing projects in the delivery/commissioning phase with early adopters.

“These projects are already providing good results,” Järvinen said.

“With the good and growing process expertise, we are well prepared to support numerous customers with various optimisation targets in mind.”

Metso Outotec to provide PT Huafei Nickel Cobalt with Planet Positive Larox filters

Metso Outotec has been awarded what it says is a major contract for the delivery of sustainable tailings filtration technology to PT Huafei Nickel Cobalt’s greenfield laterite nickel ore project in Indonesia.

Metso Outotec’s scope of delivery consists of the engineering, manufacturing and supply of the Planet Positive Larox® FFP3512 filters, as well as installation and commissioning advisory services and spare parts.

The fully automatic fast-opening filter press (FFP) combines the benefits of membrane technology and sidebar design with high mechanical and process performance, providing safe and sustainable high-volume dewatering of tailings with low operating and life cycle costs, Metso Outotec said.

The hydrometallurgical plant has a targeted annual output of 120,000 t of nickel metal and is expected to be in operation during the June quarter of 2023.

Metso Outotec’s Planet Positive portfolio, which the Larox FFP3512 filters are a part of, focuses on the most environmentally efficient technologies – of which there are more than 100 – in the company’s current portfolio, responding to the sustainability requirements of its customers. The customer requirements relate to energy or water efficiency, reduction of emissions, circularity and safety, Metso Outotec says.

Jussi Venäläinen, Vice President, Filtration business line at Metso Outotec, said: “For our customer, the key criterion for selecting Metso Outotec’s filtration technology was safe and sustainable tailings processing with proven service capability. In addition, we were able to meet the customer’s wish for a quick delivery time.

“We are very pleased to have been chosen as the solution supplier, and we look forward to working together with our customer on this important project.”

Metso Outotec’s filtration product portfolio is the largest in the field and the energy, emission and water efficiency is in a league of its own, the company said. It has carried out over 14,000 filtration tests and delivered more than 5,000 filters for various applications worldwide. Most of the filters are sold under the Larox product name along with Metso Outotec corporate branding. Metso Outotec also accommodates all filtration-related service and spare parts needs through its global service network.

The value of the order is over €30 million ($33 million), and it has been booked in Minerals’ Q1 (March quarter) 2022 orders received.

Metso Outotec launches Ferroflame LowNOx burner for pelletising plants

Metso Outotec has launched the Ferroflame™ LowNOx burner for travelling grate pelletising plants to enable pellet plant operators to, it says, achieve the stringent nitrogen oxide emission targets with ease.

The new burner is part of the company’s Planet Positive offering focused on environmentally-efficient technologies.

The Ferroflame LowNOx burner uses high-speed dilution, which is an effective way to improve the combustion process and reduce NOx emissions. It works seamlessly with natural gas, and tests demonstrate that can also be used with diesel and coke oven gas, according to Metso Outotec.

“We are very excited about the Ferroflame LowNOx burner, our emission- and cost-efficient alternative to minimise NOx emissions from the combustion process,” Dr Andreas Munko, Senior Product Manager, Ferrous and Heat Transfer at Metso Outotec, said. “Its functionality and performance with natural gas have been proven on site. The burners have been operating successfully at a client site since 2019.”

Metso Outotec says its Ferroflame LowNOx burner offers an up to 80% reduction of NOx emissions, an expected thermal penalty on natural gas circa-10% and an increased pellet homogeneity and quality.

Metso Outotec adds to Planet Positive range with Activated Carbon filter for battery metals

Metso Outotec is launching the Activated Carbon (AC) filter for, it says, efficient recovery and recycling of valuable battery chemicals.

The energy- and water-efficient AC filter responds to the market’s increasing demand for advanced and sustainable battery metals processing technologies and is part of Metso Outotec’s Planet Positive portfolio, it said.

Planet Positive is Metso Outotec’s all-encompassing approach to sustainability. It covers the environmental, social and financial aspects of sustainability, focusing on the positive impact on the environment and people through further growing its sustainable offering through products that are demonstrably more energy or water efficient than the market standard, or help customers achieve other priorities such as circularity and safety, as well as services that help customers improve their productivity.

Mika Vuorikari, Director of Industrial Filtration at Metso Outotec, said: “This launch will strengthen our capability to serve a large variety of industries and processes. Together with the Dual Media (DM) filter, Metso Outotec now has a complete filtration portfolio for solvent extraction (SX), electrowinning and crystallisation processes. We have strong know-how from the hydrometallurgical industry with more than 50 successful filtration solutions references from SX and crystallisation processes globally.”

The modular AC filtration technology is designed for smaller side streams of copper and other metal-loaded aqueous streams. It is specifically suited for efficient organics removal before the electrowinning and crystallisation processes. The AC filter uses the already proven design and operation philosophy of the Metso Outotec DM filter product family and is suitable for both greenfield and brownfield installations, the company added.

Benefits of the AC filter outlined by Metso Outotec include:

  • Increased end-product yield and quality;
  • Increased recovery and recycling of valuable process chemicals;
  • Cost-effective and modular design;
  • Low energy consumption, due to low pumping pressure;
  • Minimised water consumption with optimised back washing; and
  • Safe to use and operate, due to sealed pressure vessel and piping.

Metso Outotec ups the pumping ante with its MDM900

Metso Outotec has released its largest mill discharge pump to date, the MDM900, in a move that will see it compete for orders from the highest throughput processing operations in the world.

The MDM900 is the latest addition to Metso Outotec’s flagship Mill Discharge (MD) pump series, a pump designed for heavy-duty use in concentrator plants, where capacity and wear resistance are very important.

The MDM900 is an all-metal, thick-walled, extra heavy-duty pump designed specifically for extremely arduous mill duty applications. Its release comes less than a year after Metso Outotec officially launched the MDM800, which was then its largest metal pump model size.

Coming with an inlet size of 900 mm (36 in), the MDM900 is designed for flows up to 13,500 cu.m/h and heads up to 40 m. It is fitted with a FR2100 frame and has an impeller diameter of 2,100 mm.

Diwakar Aduri, Product Manager for MD Pumps at Metso Outotec, said: “Slurry handling is vital in maximising a minerals processing plant’s productivity and efficiency. The advanced design of the MDM900 enables minimised slurry velocities in the pumps, thus reducing the rate of wear significantly. This translates to increased uptime and productivity for our customers.

“We are also proud to have implemented many environmentally sustainable design initiatives in the MDM900 pump, which is part of our Planet Positive offering, as are all our MD Series pumps.”

Examples of these “environmentally sustainable” features include the reduced footprint of the MDM900 and its standard low-flow shaft seal to minimise the pump’s freshwater requirement during operation, Aduri added.

Metso Outotec MD Series pumps have been designed to match a mill’s uptime. They come in two tailored solutions, MDM and MDR. The MDM (Mill Discharge Metal) pumps are available in inlet size ranges of 250-900 mm, and the MDR (Mill Discharge Rubber) models come in inlet size ranges of 250-700 mm. Both pump types are suited for heavy-duty use in concentrator plants offering excellent resistance to abrasion and erosion, according to the company.

Metso Outotec to conduct strategic review in Metals business area segments

Metso Outotec says it will take the next structural development steps in its business portfolio, following the completed integration of its Minerals business and the successful turnaround of its Metals business.

The company plans to change its business area structure and related reporting segments by transferring the Hydrometallurgy business from Metals to Minerals. The objective of the change is to accelerate Metso Outotec’s profitable growth in the minerals processing industry by more efficiently leveraging the opportunities and synergies in the minerals and hydrometallurgical processes.

Having Hydrometallurgy as part of the Minerals business will, Metso Outotec, enable enhanced customer service with a competitive and fully integrated Planet Positive product offering, as well as closer integration with the customers’ processes through digitalisation. Going forward, gold and battery chemicals businesses are among the interesting new synergistic growth areas.

A strategic review will be conducted in the remaining Metals business area, consisting of the Smelting, Metals & Chemical Processing and the Ferrous & Heat Transfer business lines, as well as related aftermarket services. The review will focus on evaluating the best environment for developing the Metals business and its strategic fit in Metso Outotec’s business portfolio. All potential options will be considered, including development by Metso Outotec, co-development with a partner, or divestment. The review has no impact on Metals’ daily business conduct, sales, or project execution, which will continue with full commitment.

ArcelorMittal contracts Metso Outotec for iron ore processing plant revamp in Mexico

Metso Outotec says it has been awarded a contract to supply key grinding equipment for ArcelorMittal’s Las Truchas 2.3 Mt/y iron ore processing plant revamp project in Mexico.

The value of the order is approximately €17 million ($19 million), to be booked in the Minerals division’s Q4 (December quarter), 2021 orders received.

The order includes two Metso Outotec Premier™ grinding mills with a total installed power of 19 MW. In addition, Metso Outotec will deliver an in-house designed Mill Reline Machine, enabling efficient and safe replacement of the steel and rubber lining systems, an operations-friendly Select™ Ball Feeder and spare parts, the company said.

Andy Lingenfelter, Vice President, Minerals Sales, North and Central America at Metso Outotec, said: “We are pleased to have been chosen for this project. In Mexico, Metso Outotec is a leading grinding mill supplier and is supported by our strong local service and consumables presence.

“With our Planet Positive Premier grinding mills and associated life cycle service offerings, our customer will be able to expand their iron ore production in a safe, efficient and environmentally responsible way in partnership with us.”

Metso Outotec to supply VSFX tech for Li-Cycle battery recycling plant

Metso Outotec says it has signed an agreement with Li-Cycle North America Hub Inc for the supply of manganese, cobalt, and nickel solvent extraction technology for a battery recycling plant to be built in Rochester, New York in the US.

The contract value, which is not disclosed, has been booked in the Metals December quarter 2021 orders received.

The Metso Outotec delivery includes three modular VSF®X solvent extraction plants and related Dual Media Filters, and basic engineering.

Jari Ålgars, President of the Metals business area at Metso Outotec, said: “We are looking forward to working with Li-Cycle on this battery recycling project. The energy-efficient, modular VSFX solvent extraction plant, which is part of our Planet Positive product range, reduces emissions and is safe to operate. The Li-Cycle project will be an important new reference for Metso Outotec in the battery recycling business.”