Tag Archives: Poly-Met

Centamin looks for partial diesel displacement with Cat DGB LNG trial

Centamin is to trial Caterpillar’s Dynamic Gas Blending (DGB) technology at its Sukari gold mine in Egypt as part of a plan to reduce greenhouse gas emissions and lower costs.

The mine will trial the technology on three or four its haul trucks next year, Centamin CEO, Martin Horgan, told attendees at its capital markets webcast today.

The DGB conversion kits, available on Cat 785C and 793D haul trucks, are a dual-fuel technology that enables miners to substitute diesel fuel with LNG, according to Cat. The use of LNG has been proven to reduce emissions by up to 30%, as well as lower costs by up to 30%, Cat says.

Just last week, Gold Fields’ CEO Nick Holland told a panel at IMARC Online that the company would trial DGB technology on four of its haul trucks at its Tarkwa gold mine in Ghana.

While the use of DGB technology will partially displace Centamin’s use of diesel fuel with LNG, the company said it was also working on “full displacement” with LNG as part of its efforts to reduce greenhouse gas emissions.

The company has already committed to delivering a Stage 1 30 MW solar plant at Sukari, expected to replace 18–20 million litres of diesel consumption per year through operation during daylight hours.

In other areas of technology development, Centamin said it would soon be adding new Cat 6040 hydraulic face shovels to its existing fleet at Sukari, it had four “lightweight truck trays” currently operating at the mine, and it was trialling Metso Outotec Poly-Met mill liners on ball mills in its processing plant.

Metso Outotec to discontinue North Bay operations as part of consumable wear parts restructuring

Metso Outotec is developing its global rubber and poly-met supply chain by restructuring its consumables wear parts manufacturing operations in North America, leading to the closure of its factory operations in North Bay, Canada.

Production will be ramped down by the end of the first half of 2021, with the closure affecting a total of around 65 employees.

Metso Outotec says it will use the existing North and Central American manufacturing footprint in order to serve customers.

Sami Takaluoma, President, Consumables business area at Metso Outotec, said: “We are continuously developing our global supply footprint to ensure sustainable and profitable growth. To close a factory is a hard but necessary decision, and we realise that it will have implications on our employees. We will work to support them through the transition.”

The North Bay unit produces rubber and poly-met wear parts used in the mining industry.

Metso Outotec is a leading provider of rubber and poly-met mill lining with an extensive service network in all main mining markets. The company currently operates 11 factories manufacturing synthetic solutions globally.

Metso Outotec and Boliden renew service contract for Aitik copper mine

Metso Outotec and Boliden have signed an extension of their service contract for Boliden’s Aitik copper mine in Gällivare, northern Sweden.

The “3+2-year extension” of the Life-Cycle Services agreement covers the supply of mill lining, chute lining solutions, preventive maintenance of the grinding circuit and recycling of used wear parts, the mining OEM said. The first part of the contract has been booked in Metso Outotec’s orders received in the September quarter of 2020.

The contract is a performance-based cost-per-tonne agreement, in which Metso Outotec gets paid according to the output of the customer’s process. The goal is to ensure the availability of the grinding circuit and to maximise valuable production time, striving for a common goal that benefits both parties, the company said.

Metso Outotec and Boliden have cooperated since the 1960s. Throughout the decades, the collaboration has evolved to meet new emerging needs, while continuing to improve uptime and annual production, Metso Outotec said.

“Safety is Boliden’s top priority and enhancing it is also embedded in the scope of the new contract,” the OEM said. “Metso Outotec will provide solutions that simultaneously cut maintenance time and increase the wear life of parts even further.”

The new contract also focuses more on the management of worn wear parts, with Metso Outotec developing capabilities to recycle and dispose of them more sustainably. The AG mills in Aitik will continue to use Metso Outotec’s innovative Megaliner™ mill lining.

Megaliner helps to maximise the availability of large mills by using an innovative design that speeds up liner replacement. The larger-than-average liners mean fewer individual pieces are needed. Megaliner also has fewer attachment points compared with conventional liners, further improving installation and removal time, Metso Outotec says. It also improves worker safety during maintenance as the liners are bolted into position from outside the mill.

The pebble mills and two regrind mills at Aitik will be lined with rubber and Poly-Met mill linings, Metso Outotec said.

Aitik is one of the largest copper mines in Europe. In 2019, the mine produced close to 41,000 t of copper, employing nearly 800 people.

Metso Outotec starts up mining wear parts facility in Lithuania

Metso Outotec’s new manufacturing site in the region of Šiauliai (Šiauliai län), northern Lithuania, has started its operations.

The new plant further strengthens the company’s capability to produce high-quality rubber and poly-met wear parts for its mining customers, the company said. The investment was announced back in March 2020.

“Our target is to continuously develop our global operations to ensure a competitive footprint and reliable deliveries for our customers globally,” Sami Takaluoma, President, Consumables business at Metso Outotec, said. “I am very pleased that the ramp-up of the new factory in Lithuania has been now completed by a very competent team. First products have been successfully sent to our customers.”

The factory uses fossil-free and renewable electricity in its production, and processes have been optimised for each customer segment. The location of the factory in Lithuania was decided based on a careful analysis of the current customer closeness in Europe and Russia, and with good logistical connections to the Middle East and Africa regions, Metso Outotec said. With access to many logistics options, customers will also benefit from the improved delivery and warehousing capabilities.

Metso Outotec, which operates currently 11 factories manufacturing synthetic solutions globally, said the factory will employ 80 people by the end of 2020.

In October 2019, the company opened a new Business Services centre in Vilnius, the capital of Lithuania. Currently the centre employs about 100 experts and offers services related to finance operations and customer logistics. The scope of the centre is growing and will cover new areas in the future, the company explained.

Metso’s Trelleborg facility to press ahead with mill lining additions

Metso says it is expanding the range, sizes and types of consumable products it manufactures with the help of an “innovative, mega-size compress press”.

The move will develop its consumables product range and production capacity, especially in larger consumables wear sizes, it said.

The press, being installed at its Trelleborg factory in Sweden, can produce products, such as mill lining wear parts, that weigh up to 8 t. Production with the new press will start in May, it said.

The press to be installed is the first in a series of three similar machines with a total value of €10 million ($10.8 million), according to Metso.

Sami Takaluoma, President, Consumables business, Metso, said: “We are continuously developing our operations to improve our flexibility in fulfilling our mining customers’ needs globally.

“For our customers, the ability to acquire and use larger, high-quality consumables in the process enables a longer operating time and reduces the time required for maintenance work. The new press has been developed together with the supplier, and it utilises unique, innovative technology.”

The ongoing COVID-19-related travel restrictions and increased employee safety measures globally created a need to find a sustainable and safe way to install the new machine in the Trelleborg facility, Metso said.

The installation process is monitored remotely by the supplier with dedicated installation support hubs in Australia and China. Through a variety of headsets and video cameras, the installation team has been able to obtain continuous online guidance and instructions.

“In this challenging situation, we found a workable solution to stay on schedule,” Takaluoma said. “Thanks to the continuous support and detailed online guidance provided to the on-site team, the installation work has proceeded as planned and with safety measures maintained.”

Metso is a leading provider of rubber and poly-met mill linings and has a strong service network in all the main mining markets. The Trelleborg unit produces rubber and poly-met wear parts used in the mining industry.

Metso currently operates 11 factories manufacturing synthetic solutions globally, and it will open a new factory for mining consumables wear parts in Lithuania in 2020.

Metso’s Ersmark rubber and poly-met wear parts facility to close

Following a review in its Minerals Consumables business area in EMEA, Metso has decided to discontinue operations at the rubber and poly-met wear parts manufacturing facility in Ersmark, Sweden.

Metso announced back in September it was starting “personnel negotiations” to review the implications at rubber and poly-met wear part production units in Ersmark and Trelleborg, Sweden. It has now decided to ramp down operations at Ersmark in stages from the beginning of the June quarter, with full closure expected in September quarter, it said.

The decision affects approximately 150 manufacturing related positions in Ersmark.

Sami Takaluoma, President, Minerals Consumables business area, said: “Our strategy is to improve productivity and reduce logistics costs by building on the most efficient manufacturing and sourcing opportunities at a regional and global level to ensure the best value and availability for our customers.

“During the negotiations, we evaluated the EMEA region as a whole and came to the conclusion that consolidating the rubber and poly-met manufacturing operations in Sweden was the only feasible solution.

“This is a very unpleasant yet necessary action. Going forward, our focus will be on ensuring a sustainable transition for Ersmark as well as uninterrupted service to our customers.”

The company concluded: “Today, Metso is the leading player in the rubber and poly-met mill lining business with a strong service network in all the main mining markets. In addition to Ersmark, Metso has another factory continuing synthetic wear part production in Trelleborg, Sweden, and nine other factories for synthetic solutions globally.”

Metso places rubber, poly-met wear parts facilities under review

Metso, as part of its Minerals Consumables business area review of manufacturing capabilities in the EMEA region, says it is starting “personnel negotiations” to review the implications at rubber and poly-met wear part production units in Ersmark and Trelleborg, Sweden.

The negotiations concern the potential closure of the factory in Ersmark and the restructuring of the manufacturing operation in Trelleborg, according to the company, and could affect manufacturing related functions and some 150 positions.

Metso confirmed other operations in Sweden are not in the scope of these negotiations.

The Ersmark and Trelleborg units produce rubber and poly-met wear parts used in the mining industry. Today, Metso is a leading player in the rubber and poly-met mill lining business, with a strong service network in all the main mining markets, it said. In addition to Ersmark and Trelleborg, Metso operates nine factories manufacturing synthetic solutions globally.

Sami Takaluoma, President, Minerals Consumables business area, said: “Our target is to utilise the full potential of the most efficient manufacturing methods and optimise sourcing opportunities and logistics. By developing our supply capabilities at the regional and global levels, we are actively responding to changes in the competitive environment, as well as improving our flexibility in fulfilling customers’ needs.”

Norilsk Nickel chooses Metso Megaliner for Talnakh concentrator

Norilsk Nickel has recently switched out the chrome and molybdenum alloy lining of a SAG mill at its Talnakh concentrator in Russia as the company looked to increase the life of these all-important wear parts.

Sever Minerals and Norilsknikelremont (a subsidiary of Norilsk) were contracted to complete the mill relining project, using liners supplied by Metso’s global team, which also used the OEM’s Megaliner™ concept.

The new lining is more durable, weighs less and ended up being safer to install than previous the previous lining, according to Norilsk.

A Norilsk spokesperson told IM that the mill lining was replaced with two elements, the Metso Poly-Met; a rubber-steel combination installed on the front-facing part of the mill; and the Metso Megaliner, which has large shell or head liners used to protect the drum.

The spokesperson added: “The cladding manufacturers guarantee that the mill can work for 5,600 hours uninterrupted (that is about eight months non-stop). The previous version required the SAG mill to be stopped for replacement every six months.”

By developing the technology, adopting better project management and using the specialised equipment, Norilsk said it was able to reduce the time taken to replace the mill lining by three days.

The Megaliner is, according to Metso, a new, innovative mill liner concept, dramatically improving worker safety and maximising mill availability. Each shell or head liner covers a large area, has few attachment components and an attachment system which gives a safer working environment for the installation crew, it said.

The weight of the mill lining also came down with the switch from pure metal to a metal-rubber compound, Norilsk said.

“The new mill liner weighs close to 130 t, which is 120 t less than the old mill liner. The average weight of one mill liner element is 1.8 t (elements have different configurations and respective mass),” the spokesperson said.

This reduced weight came with other benefits.

“Due to the lower weight of the capstan, the new mill liner is more wear resistant and better technologically-equipped to cope with an increased number of planned tasks,” the spokesperson explained.