METSO’S CUSTOMER MAGAZINE FOR THE MINING AND …

resultsminerals & aggregates

METSO’S CUSTOMER MAGAZINE FOR THE MINING AND CONSTRUCTION INDUSTRIES No. 1/2010

UMMC Gaiskiy Gok mine, RussiaDoubling the capacity with Metso 6

2 RESULTS minerals & aggreagtes 1/2010

Dear reader,You are holding the first issue of our new, global customer magazine Results – minerals & aggregates. The new magazine concretizes our customer promise “Expect results,” which is the essence of our strategy and the attitude we share globally – our business is to deliver results to you to help you to reach your goals.

After the severe economic turmoil that has influenced all of us, we are now seeing some early signs of recovery. However, the demand is expected to remain satisfactory or weak and uneven in most industries and regions in 2010. Difficult times always challenge the existing ways of operating and speed up renewal. Whatever the market situation is, we have to deliver maximized customer value by constantly developing our processes, solutions and services.

Today, our solutions embrace the latest technology and an extensive service offering. Our objective is to offer you a lifetime of reliability based on true day-to-day partnership. Our people around the world are located close to customers, to understand your operational realities. This unique industry insight enables us to create solutions that increase the productivity and environmental quality of your operations. Close cooperation leads to excellent results, as you can see on the pages of this issue.

Good customer service is one of our key cornerstones. It refers to our extensive solutions and services offering and our wide local presence, but first and foremost it refers to our mindset – we are here to serve you, to listen to your needs and to offer solutions. We stand ready at your service – full-time, globally and locally.

I hope that you enjoy your reading journey. I want to thank all our customers for the very fruitful cooperation we’ve shared so far. Furthermore, I hope you will continue challenging us to deliver even better results for your benefit.

Matti Kähkönen President, Mining and Construction Technology Metso Group

RESULTS minerals & aggreagtes 1/2010 3

16 Mobile pioneering in Algeria

18 New Metso service packages launchedNew liner concept in the world’s largest mills

19 Lokotrack LT110C – superior performance in a transport friendly, compact size

20 Meeting the growing Baltic demand

22 Making green business grow

24 Bulk moves efficiently in India

26 Vezzola, Italy – industrialized aggregates production

28 A heavy-duty mining success in China

29 Alcoa launches a new mine in Brazil

30 Barmac pregrinds copper ore in Chile

31 Metso around the world

2 Editorial

4 News in brief

6 Doubling the capacity with Metso

9 KCGM benefits from a life-cycle partnership

10 Service contracts secure smooth operations for Lafarge

12 Bruno simulates your process accurately

15 Focusing on Health, Safety and Environment

published by metso minerals, inc.Fabianinkatu 9 A , P.O. Box 1220, FI-00101 Helsinki, Finland tel. +358 20 484 100, fax +358 20 484 10 e-mail [email protected] www.metso.com/miningandconstruction

Results rock & minerals customer magazine is published 3-4 times a year in English, with Chinese, Russian and Portuguese insertions. To receive your personal copy, please contact your nearest Metso office or the e-mail mentioned above.

editor-in-chiefKaroliina Partanen [email protected]

editorEero Hämäläinen [email protected]

contributors in ths issue:Sara Caballero, Zhang Changjiu, Toby Cocks, Sanjay Datir, Eero Hämäläinen, Sheila Ivers, Gerhard Lenz, Maria Marklund, Osvaldo F. Pavez, Rodrigo A. Pizarro, Liz Rodd, Dinesh Sharda, Abraham Xavier

english language editing:Traduct Oy

lay-out and art work:Vanto Design Oy

printing:Libris Oy, March 2010

© Copyright 2010 Metso Minerals, Inc. All rights reserved

Printed on Galerie Art gloss 130/200 g/m2, Cyclus offset 115 g/m2

Reproduction permitted quoting “Results rock & minerals” as source

All product names used are trademarks of their respective owners.

Addresses: Metso Minerals, Inc. customer data

ISSN 1797-6480

www.metso.com/miningandconstruction

Printed matter441 014

COVER PHOTO: UMMC Gaiskiy Gok mine’s Manager for the underground conveyor transport area, Vladimir Aleksandrovich Utkin (right), at the primary crushing level with Metso’s Project Manager Tatyana Vyacheslavovna Krapivina.

In this issue


news in brief

News in brief

A complete fine crushing and screening system to Norsk Stein in Norway Metso will supply a complete fine crushing and screening system to Norsk Stein’s Jelsa quarry expansion in Norway. The delivery will be completed by June 2010. The value of the order is approxi-mately EUR 27 million.

The order comprises of four gyratory cone crushers, eight inclined screens, a stacker conveyor, and a significant amount of conveyors. It also includes the engineering, installation and project management of the new plant.

The stationary plant expansion will raise the production of the Jelsa quarry significantly. The yearly production of the quarry now exceeds 5 million tonnes. After completing the expansion, the targeted production for fine products will be 850 tonnes per hour (tph) in addition to existing plant production 650 tph, and total production more than 10 million tonnes per year.

Start-up scheduled in JuneThe assembly of the new Metso equipment was started in March, and will be completed in May.

The gyratory cone crushers are manufactured in Metso’s Tam-pere works in Finland, and the majority of screens and conveyors in Metso’s works in Mâcon, France.

Norsk Stein A/S is one of Europe’s biggest aggregates produc-ers. The Jelsa quarry, located north-east of Stavanger, produces high quality aggregates for road building, railways and offshore purposes. The end products are shipped to countries like Denmark, UK, France and Germany.

More info: Perttu Louhiluoto

Tel. +358 40 556 5774 [email protected]

Mill linings to Egypt’s first modern gold mineMetso delivers mill linings to Centamin Egypt Limited, currently developing Egypt’s first modern gold mine. It is located in the Sukari region in the eastern desert about 23 km southwest of the Red Sea coastal town of Marsa Alam and 750 km by highway from Cairo.

The region has a long history of mining and exploration dating back to Pharaonic times (ca 3,200 BC), through Ptolemaic, Roman, Arab and British colonial times to the present day.

The process plant design comprises coarse ore stockpile, milling and CIL circuits relocated from Newmont’s Kori Kollo operation in Bolivia.

Linings for big sized millsThe initial lining order was taken in competition with Elecmetal/ME. All mill linings were recently installed and Metso has received the first spare parts order. The order includes Skega Poly-Met Mill Linings to a SAG mill 28’x14’ and Skega Rubber Mill Linings to two secondary ball mills 16’6” x 30’6”. The SAG mill is Metso’s largest com-pletely lined SAG mill in the Europe, Middle East and Africa region.

The current resource at Sukari is 10.29 million ounces Measured and Indicated, and 3.45 million ounces Inferred, with ongoing drill-ing expected to add significantly to this resource. In February 2007 a definitive feasibility study was completed showing robust eco-nomics for a 4mtpa processing plant producing initially 200,000 oz per annum. Optimal design throughput at the Sukari Gold Project was achieved during December 2009 and on 11 January 2010, the Company announced that the Sukari Gold Project had achieved yet another important milestone with the commencement of gold exports to a nominated overseas gold refinery.

More info: Hans Persson

Tel. +46 70 214 05 83 [email protected]

Grinding equipment to Newcrest gold mine in AustraliaMetso will supply two complete grinding mills and related equip-ment to Newcrest Cadia Valley gold mine in New South Wales, Australia. The value of these two orders is over EUR 16 million, and the delivery will be completed by June 2010. The orders are included in Mining and Construction Technology’s Q4 orders received.

The orders comprise two grinding mills. The first is a ball mill with a diameter of 7.9 meters and an installed power of 16 MW, and it will be the most powerful ball mill supplied into Australia.

A picture of Skega type Poly-Met mill linings, installed at Centamin’s gold mine.

Aerial view of the Jelsa quarry, situated near the city of Stavanger. In front, the existing stationary plant, behind, the ongoing construction works for the new plant.


news in brief

The second is a vertical stirred mill (VTM3000 type) with an installed power of 2.2 MW, and it is the first of this size to be installed in the world, having twice the power of our previous largest machine.

The equipment will consist of a Metso complete flotation cell/scrubber; a Morse jaw crusher; a Marcy cone crusher; a Denver vacuum filter; several Marcy pulp density scales; a Denver pulp density scale; a Denver mineral jig; and all spares.

Each machine or item offered is a sample from the laboratory equipment product line that Metso offers. Operating manuals for each machine will be included in the donation with a commitment to future service as deemed necessary, and 50 copies of Metso’s basic mineral processing handbook will also be presented.

At the time of the presentation in May, Metso will launch an annual Best Student award consisting of a cash donation to the top mining and minerals engineering students. And Metso will insti-gate an annual mining school to train and update professionals and students in technological developments in the mining industry.

More info: Seth Quaye

Tel. +233 24 4322119 [email protected]

A profitable year Net sales of Mining and Construction Technology decreased by 20 percent on the comparison period and were EUR 2,075 million in 2009. The Mining business line’s net sales declined by about 12 percent, while the net sales of the Construction business line were down by about 31 percent. While the services business net sales decreased by 10 percent on the comparison period, they accounted for 47 percent of the segment’s net sales (42% in 2008).

Mining and Construction Technology’s operating profit for 2009 was EUR 198.8 million, i.e. 9.6 percent of net sales (EUR 358.4 million and 13.9%). The value of orders received decreased by 39 percent on the comparison period and at the end of the year stood at EUR 1,660 million (EUR 2,709 million in 2008). The value of new orders received declined in both business lines, and in all geographical areas.

Among the biggest new orders of the year was a fine crushing and screening system for Norsk Stein in Norway. We also signed a multi-year service agreement with AngloGold Ashanti Iduapriem Mine in Ghana including the maintenance management services and technical support, as well as hands-on training.

At the end of December, the order backlog was 30 percent lower than at the end of December 2008, amounting to EUR 1,041 million (EUR 1,492 million at December 31, 2008).

More info: Johanna Henttonen


The ball mill will be installed in the Newcrest Cadia concen-trator and the vertical mill at the company’s adjacent Ridgeway concentrator.

Newcrest is Australia’s largest gold producer and a global top ten gold mining company. The company has seven operating mines – five in Australia, one in Indonesia and one in Papua New Guinea.

More info: Ross Wotherspoon


Machinery donation to GhanaMetso has made a significant donation of equipment and serv-ices to the University of Mines and Technology (UMaT) in Tarkwa, Ghana. This is not only an exceptional benefit to the current students, but also to the university when recruiting the mining engineers of the future. The equipment has been installed in the laboratory of the mineral engineering department.

Two new grinding mills will be delivered to Newcrest operations in Cadia Valley, Australia.

The donation for the University of Mines and Technology in Ghana consists of complete laboratory-sized set of crushing and minerals processing equipment.


FEATURED ARTICLE

Doubling the capacity with Metso

Manager for the underground conveyor transport area, Vladimir Aleksandrovich Utkin (right), discussing business at the primary crushing level with Metso’s Project Manager Tatyana Vyacheslavovna Krapivina.


FEATURED ARTICLE

Metso has cooperated closely with Gaiskiy GOK for several years. The present mining machinery at the mine site comprises of a number of Metso equipment, from underground primary crushing to flotation process tanks.

The doubling of Gaiskiy GOK’s capacity from 4 to 8 million tonnes per year will have a vital impact on the mine’s profitability, and will also help the holding company Ural Mining Metallurgical Company (UMMC) to extend its raw material resources base.

“We appreciate Metso as a valued partner”According to Alexander Viktorovich Saraskin, Director of the Gaiskiy GOK mine, the demanding project, which aims at dou-bling the mine’s capacity, was started in 2006, and will be completed by 2012.

“Now, with some 60% of the project already completed, we appreciate Metso as a valued partner, one of the best perform-ers in this project. In addition to providing us with state-of-the art mining equipment, Metso helps us to implement studies to improve the whole minerals extraction process,” Alexander Viktorovich Saraskin comments.

“We are confident that we will achieve successful project compilation for the dou-bled production during 2012. Gaiskiy GOK, with its unique process flow design, will surely become an icon within the Russian mining industry,” he adds.

Going deeper with the mine extensionToday the ore is extracted mainly from the underground mine, reaching down to a level of 860 meters. With the mine expan-sion, new production levels are being opened down to 1,000 meters.

Gaiskiy GOK uses the chamber mining method, where the chamber height to be mined is 80 meters. After blasting, the ore is

fed into four Nordberg C140 jaw crushers. The copper-zinc ore is very abrasive. The jaws have already processed over 10 mil-lion tonnes of ore in seven years.

The extension project doubling the mine’s production means that a number of measures will take place in both Gaiskiy GOK’s underground and surface operations. In the underground mine, some of Metso’s jaw crushers will be relocated deeper, and a new shaft for the lifting of ore will be built.

After the secondary crushers, a new tertiary Nordberg HP500 cone crusher will be added to achieve better sized feed for the grinding mills. Energy-wise, crushing requires less energy than grinding.

“We are satisfied with the Metso crush-ers that are running 18 shifts of 5–6 hours a week. The first jaws installed in 2001 have already crushed over 10 million tonnes of ore. One of the main benefits of these jaw crushers is the possibility to disassem-ble and move the units where needed underground,” notes Andrey Vladimirovich Kharkov, Director of the underground mine.

“Original Metso wear parts last three times longer”At the 860-meter level below the surface, the blackish copper ore disappears quickly into the cavity of Metso’s jaw crushers, fed by specially-designed feeders. >

Alexander Viktorovich Saraskin, Director of the Gaiskiy GOK mine, ranks Metso among the best performing suppliers for the mine expansion project.

Situated close to the Ural mountains, which divide Russia into the European and Asian sides, the Gaiskiy GOK copper-zinc mine celebrates the 50th anniversary of its mining operations. The jubilee year also includes the start of the installation work on two new Metso mills, which will contribute to the doubling of the mine’s production during the coming years.

TEXT & PHOTOS Eero Hämäläinen

The Metso grinding mills were installed in a completely new process building.


FEATURED ARTICLE

Gaiskiy GOK mineSituated about 1,800 km southeast from Moscowowner: Ural Mining Metallurgical Company (UMMC)ore type: abrasive copper-zinc oreproduction in 2009: 5.5 mtpy (extracted ore)70,000 tpy (19.2% copper concentrate)production after the mine extension: 8 mtpy (extracted ore)113,000 tpy (19.2% copper concentrate)

metso equipment on site

• Nordberg C140 jaw crusher (4 units)

• Nordberg HP500 cone crusher (2 units)

• SAG type grinding mill (diameter 8.53 metres)

• Ball type grinding mill (diameter 5.48 metres)

• RCS50 flotation cells (3 units)• RCS100 flotation cells (14 units)• VASA 161pump (1 unit)• VT 40 pump (2 items)• VF 100 pump (2 units)• VF 150 pump (8 units)• VF 200 pump (8 units)• VF 250 pump (4 units)• XR 400 pump (4 units)

“Concerning the jaw wear parts, we compared several domestic manufac-turers against Metso’s original parts. The results were very clear: with Russian-made wears, we could crush only about 150,000 tonnes, but with the Metso parts up to 470,000 tonnes,” says Vladimir Viktorovich Korpachev, Chief Mechanical Engineer of the mine.

“Since then, we have been supplied regularly with the Metso wears thanks to their superior durability and better overall economy. In fact, I can frankly recommend that everybody use original parts only because of their high quality, providing much longer replacement times,” he adds.

Simplified process with new grinding millsThe processing of ore will be modernized and simplified. Instead of four grinding stages with several smaller, energy-consuming mills, the new process only includes two stages. Metso SAG and a ball mill will play a central role in grind-ing. In addition, several old flotation cells and pumps included in the process will be replaced by new ones. It is quite possible that they will be Metso flotation cells and pumps.

“With the new equipment, our process becomes smoother, more homogenized

Director of the concentrator, Sergey Aleksandrovich Zamaraev (right), with Flotation Area Manager Dmitriy Alekseevich Semenov.

Electrical engineer Vladimir Vasilyevich Chernega monitors the copper ore fed into the Nordberg C140 jaw crusher at the 860-meter level.

and predictable. It also helps us to add to our process capacity and achieve better recovery,” stresses Sergey Aleksandrovich Zamaraev, Director of the concentrator.

Bright future aheadWith the modern mining technology installed and its skilled personnel, the future of the Gaiskiy GOK mine looks bright. The presently known ore reserves guarantee mining operations for over 50 years. The company is also searching for new deposits nearby.


Reporting results

Long-term involvementMetso has been involved with KCGM (Kalgoorlie Consolidated Gold Mines) since 2001 as the preferred contractor for servic-ing and maintenance of the crushing and materials handling facility at Fimiston Plant in Kalgoorlie, Western Australia (i.e. the primary crusher at KCGM).

Metso has been awarded these long-term contracts with KCGM as a result of their technical expertise and their experi-ence with KCGM’s site. Over time, KCGM has seen the material produced from the largest open pit in Australia vary in both hardness and abrasiveness, but the tech-nology available from Metso has been able to keep up with these challenges.

A key achievement of Metso during this time was to optimize the wear packages and profiles used in the primary crusher. This optimization has increased concave life by as much as 300%, between changes, with the useful life of mantles increasing in a similar range.

A high availability crucialIt is also important to KCGM to have the guaranteed availability of the primary crusher at high levels. Metso upgraded the primary crusher from a superior Mk1 to an Mk2 model. Following the upgrade, KCGM has consistently seen a + 95% availability on the crusher and conveyor system with very little unplanned maintenance.

KCGM benefits from a life-cycle partnership KCGM’s Supply Superintendent Liz Rodd explains the benefits of a life-cycle partnership with Metso.

TEXT LIz Rodd and Toby Cocks

Metso at KCGM has also demonstrated a commitment to the core values culture through inclusion in the safety programs and continuous improvement initiatives on site.

The excellent working relationship seen between the two companies can be put down to professional onsite management and external technical excellence which Metso provides KCGM with to maintain the high standards over a long period of time.

“Controlling costs and downtime”Recently, Metso’s onsite Project Manager, Andre Swart, explained the nature of the partnership and why he feels it works so well.

Andre states that, in short, it was con-cern about controlling costs and downtime which formed the impetus for this life-cycle solution. Now, 15 years into the arrange-ment, some key fundamentals allow it to continue to flourish. Andre states: “Commu-nication is a big thing. The customer rarely needs to come to us to ask questions as we like to be proactive and solve any queries before they are asked.”

Andre goes on to say, “We should be reinforcing what we can offer the customer versus what the competitor can offer. We need to be looking into the future and say-ing: this is our latest innovation and these are the improvements we can make to your crushing circuit.”

To ensure the avenues of communica-tion remain constant and efficient, both KCGM and Metso attend weekly safety meetings, Friday mine to mill meetings, plus Andre’s team hold weekly internal ‘toolbox meetings’.

When discussing the benefits of this arrangement for both parties, Andre states:

“Apart from us being just sales focused, we can now stand up and say that we actu-ally run this machine day to day, too. We can say: These are the experiences we’ve had and this is the knowledge we’ve gained. This is priceless knowledge when you con-sider the potential to expand this service to other sites and other customers.”

More info:

Andre Swart

Tel. +61 417 414 850

[email protected]

Metso’s team at KCGM. Andre Swart (left), the on-site Project manager, along with Louis Koedyk and Jaco DeLange.

The gold ore is extracted from the largest open pit in Australia.


FEATURED ARTICLE

Service contracts secure smooth operations for LafargeThe inspections contracts signed with Metso support the sustainability of production tools, in particular jaw and cone crushers in the quarries of Lafarge Granulats Sud, a major player in aggregates production in Southern France. This Lafarge subsidiary operates 120 Metso crushers (Nordberg, Bergeaud, Dragon, Neyrtec, etc.) to produce over 26 million tonnes of aggregates per year. Most of the crushers are inspected by Metso technicians regularly.


“Thanks to the service contract with Metso, we can now minimize sudden machine breakdowns and secure continuous production in our 66 quarries. With the contract, better machine availability and reliability have been achieved,” explains Olivier Javelle, Director of Lafarge Granu-lats Sud’s Industrial Pole.

“Together with Metso, we can now optimize our production, and also better

plan the cooperation between different quarries,” Javelle adds.

In-depth crusher inspectionLafarge Granulats Sud and Metso France have cooperated under the service con-tract since 2007. In addition to the present product brands, the contract also includes all the classic Metso brands. It provides a thorough inspection of each crusher,

performed once a year by a technician. Metso inspections are conducted in two phases: an initial visit to the machine under load and a second during a replacement of wear parts.

“The inspection we offer is quite com-plete and is carried out with a detailed checklist which requires dismantling of the machine and testing. For example, in the case of an HP cone crusher, we will check

Olivier Javelle, Director of Industrial Pole (right), Rivolet Quarry Manager Eric Baudry (left), and Philippe Pajot, Service Contracts Manager of Metso France, checking an HP cone crusher at Lafarge’s Rivolet Quarry. (Lafarge Groupe and Colas)


Reporting results

more than 90 different points. The whole inspection takes about one and a half working days,” says Philippe Pajot, Service Contracts Manager at Metso France.

“We can really consider our inspection a ‘crusher health check’, in which we docu-ment the whole operational history of the unit for the customer. Based on the docu-ment, we then propose further preventive maintenance jobs to Lafarge, in order to guarantee continuous operation,” Philippe Pajot adds.

After the visit, a technical report is sent to the customer using a simple traffic light marking, from which it is easy to see which measures are urgently needed for each crusher.

Furthermore, the customer appreciates the fact that good maintenance practices can be reviewed during the inspection.

25 year’s crusher lifetime as a targetLafarge Granulats Sud gathers all the infor-mation related to its crushing equipment with exceptional care. The list of perform-ance identified for each crusher includes parameters such as productivity, availabil-ity, reassembly opportunities (complete or parts), and maintenance.

According to Olivier Javelle, it is not wise to stick to one figure, such as availability or capacity, alone:

“Some new crushers, which are more productive, may be more sensitive, some crushers are difficult to replace, some mod-els are unique. Thus, it is very important to make periodical and specialized controls, and despite have a long-term vision.”

Lafarge aims to increase the average life-time of its crushers to exceed the average age of 25 years. The Rivolet quarry where a BCS 4’1/4 Metso, aged over 30 years, con-tinues to function is a good example of the company’s long-term approach.

“We now know our responsibilities”Olivier Javelle summarizes the benefits of the service contracts with Metso:

“Now, both Lafarge and Metso person-nel have a better idea of who does what. With the service contract, we can be sure that inspections are done on time, preven-tive actions are accomplished, and that we will receive all the necessary process consulting and recommendations, as well as crucial spares and wears nearby. Further-more, this expertise will be educational and formative,” he adds.

A safe inspectionA prevention plan was signed between Lafarge and Metso. Metso technicians are aware and all procedures, guidelines and recommendations are known and respected.

Quarry Manager Eric Baudry showing the exceptionally hard tertiary aggregates.

Lafarge Granulats Sud• 66 quarries in Southern France• 26 million tonnes of annual

production• 1,100 workers

metso on site

• A total of over 120 operational crushers

• Also feeders, screens and conveyors

• A 3-year service contract

The Rivolet Quarry, named after a nearby, charming village in the Beaujolais wine district,

produces 400,000 tonnes of aggregates per year.


FEATURED ARTICLE

Bruno simulates your process accuratelyWhen you want to be sure to select the right crusher or screen for your forthcom-ing aggregates or mining process, you can play it safe and benefit from the infor-mation given by Metso’s Bruno simulation software. Bruno tells you accurately and in advance what your equipment will do in practice at your quarry or mine.

TEXT Eero Hämäläinen PHOTOS Ralf Salonen and Eero Hämäläinen

The Bruno simulation software is very useful when designing new, complicated stationary plant processes.


Products and solutions

“The base of the Bruno simulation software development is the field data, gathered and fed into the system from our different test laboratories and several thousands of customer sites worldwide,” says Saku Pursio, Development Engineer responsible for Bruno’s development.

“After more than a decade of extensive development, we can today frankly say that the Bruno simulation provides our custom-ers with information very close to the truth concerning the aggregates process,” Saku Pursio adds.

Named after Bruno NordbergThe Bruno simulation software was devel-oped by Metso’s Mining and Construction Technology in the 1990s. Already a few years earlier, a predecessor “Simu” was functional, providing simple, technical process data.

The first real Bruno version saw daylight in 1994. After a competition, the simulation software was named after Bruno Nord-berg, the Finnish immigrant to the US who founded Nordberg Manufacturing Co. in Milwaukee in 1889.

Today, the name Nordberg is known globally as the leading crusher and vibrat-ing equipment brand, and Bruno as the

most advanced process simulation soft-ware available.

Over the years, a total of ten different versions of Bruno have been published. Step by step more Metso crushing and screening equipment performance data has been added to the software.

Easy and visual to useUsing Bruno is quite simple. You just feed in the main facts of your process: feed material type and size, the machines with relevant settings and the process flow.

As a result, you get a visual process flow picture showing the estimate for the proc-ess performance including the percentage of different end products clearly marked.

“By using Bruno, we can secure the suitability of the crusher to the process our customers are planning. Our recent tests and comparisons are testimony that the simulation provided by Bruno is now very close to the actual ‘live’ aggregates process,” Saku Pursio comments.

New version with more featuresA new Bruno version 3.4. was released in the beginning of 2010. In addition to all present, proven features and updated product ranges, it forecasts the operating costs for the first 1,000 working hours.

“Among other things, a complete cal-culation can now also be made for Metso’s mobile Lokotrack mobile crushing plant and mobile screen range, adding new value for customers planning mobile proc-esses,” comments Development Engineer Marika Kovanen. >

Saku Pursio

BRUNO Process SimulationPLANT:INFO:LICENSED USER: Saku PursioDATE: 01.02.2010 13:25FILE: FlowsheetBruno v3.40, DB v4.60, c1.00 s1.00 nn 211

NOTE! The capacities are maximum capacities in a continuoustroublefree operation when feed material quality and grading curvecorresponds to the theoretical curve used in this calculation.Long term capacities will fluctuate due to the variations in the feedand operating intensity of the plant.

Metso does not guarantee any of the calculation resultswithout our separate written approval based on a detailed studyof the case.

t/h

GraniteSD 2.7 t/m3700mm coarse

Abr 1398 g/tCr 34 %

250

B13-44-2V

Load 43 %

Opening 75 mm250183

67

Setting 100 mm

C125

60 %quarry4.1

183

183

Stroke 32 mm

GP300S

53 %

extra coarse2

Setting 53 mm

250

250

A132L#40 mm/E95 %Not in use

355

105

250

Stroke 25 mm

GP500

47 %

medium2.8

Setting 20 mm

105

105

250

95

155

38 %16/32mm

95

62 %0/16mm

155

Copyright Metso Minerals. All rights reserved.

Development Engineers Saku Pursio (left) and Marika Kovanen, responsible for the Bruno simulation software, in the rock laboratory that provides important back-up, such as crushability tests, for accurate process simulation.

A Buno simulation of a wheel-mounted crushing and screening process.


Saku Pursio500mm coarse

LT106

LT200HPS

LT300HP

ST 4.8


ductivity could be achieved with the help of the process optimization. With Bruno, the accurate setting adjustments were easily found,” Saku Pursio says.

“To really play it safe in plant design, a crushability test of the rock or ore in Metso’s rock laboratories, and the data input into the Bruno simulation software, will certainly provide the most accurate process simulation,” he adds.

More info/Bruno:

Saku Pursio

Tel. + 358 40 773 9951

[email protected]

More info/Bruno training:

Jaakko Ruuskanen

Tel. + 358 40 867 3984

[email protected]

A typical Bruno simulation of a mobile process describes the equipment used, as well as the feed and end product percentages in an easily readable format.

Saving money while designing new plants

The widest possible benefits from the Bruno simulation software can be achieved when designing a new crushing and screening plant or a mining process. Any test run for a stationary or mobile process may be quite expensive and time consum-

ing. By using Bruno, the plant optimization can be achieved quickly and inexpensively.

In several countries, Bruno is used as an official design tool by Metso’s customers. When the same equipment is moved and used at several sites and applications, opti-mization for local conditions is needed.

“A recent example by a Finnish cus-tomer showed that up to 20% more pro-

“The new Bruno also covers more vibrat-ing products data. It also features more calculation models, resulting in improved simulation accuracy for screens,” she adds.

“The new version is easier to use, it calculates the required simulation faster, and provides a more visual process picture,” Saku Pursio concludes.

How to get your own Bruno?Today, there are about 3,000 licensed Bruno users worldwide. To get your own copy of the Bruno simulation software, please take the following steps:

Contact us by sending an e-mail to [email protected]. In the e-mail please inform us of your name, indicate whether you are a customer, a dealer or a university, the name of your company or

university, country of origin, and your con-tact person at Metso.

After receiving your message, we will send you an e-mail with a link to the Bruno installation page.

Metso’s Mining and Construction Technology organizes crusher and process training in Tampere, Finland, and Mâcon, France. The training will provide you with advice on how to use Bruno effectively.


column

Over the last few years, Metso has been allocating resources to effectively respond to these new challenges in alignment with the sustainable development needs of our customers. We are responsibly conducting our business in an environmentally sound manner to further help customers to live up to their social responsibilities.

The commitment to continuous improvement of the work environment is part of Metso’s history. Particularly in Brazil, stronger initiatives began in early 2009 when Metso hired DuPont to advise on the HSE implementation program. “We relied on DuPont’s support to implement tools that provide job safety analysis, behavior observation, inspections, safety meetings, safety dialogs, work permits and HSE first-day induction,” explains Luiz Roberto Silveira, Health, Safety & Environment Manager, Metso, Brazil.

It didn’t take long before the first results began to show: working community mem-bers got involved in safety management and started to internalize its practices. Major results were accomplished within just a year: “We have reduced our lost-day frequency rate by 43% and cut 52% in the number of lost-day injuries compared to the previous year,” says Luiz.

Motivating for cultural changeEstablishing a positive attitude towards safety was part of the HSE implementing process. Metso had successfully involved its workforce in managing safety issues: “Our HSE team worked together with Human Resources to develop the best approach for training and activities to promote a change in mindset,” states Luiz.

Furthermore, the importance placed on safety underscored how much leaders

value people. Employees at different levels were involved during the implementation program, but the personal engagement of the Board of Directors reinforced safety as an intrinsic value.

As part of the implementation program, safety committees and subcommittees were structured, giving everyone a voice and later sharing responsibility for safety issues throughout the company.

Metso has developed an HSE manage-ment system with 18 key control elements based on best practices and sustained by complementary actions called “supporting tools”. These control elements define the metrics of our performance and help to keep us on the path to our goals.

From 2010 on, the company’s HSE program will be continued through IMS (Integrated Management System). IMS will incorporate ISO 14001 and OHSAS 18001 into our management system, achieving certification in 2011. IMS will be respon-sible for two new goals: compliance with the OHSAS 18001 standard concerning the occupational health and safety of our employees and operations, and ISO 14001 standards related to environ mental management.

Metso has already set responsible growth targets for HSE in alignment with the sustainable development of our business. “Step by step we are creating a sustainable HSE culture in our organization to consolidate our position as a world-class company,” sums up Luiz.

More info:

Pirjo Virtanen

Tel. +358 40 736 8637

[email protected]

Focusing on Health, Safety and the Environment

TEXT Sheila Ivers

Responsible, sustainable growth strengthened through attention to Health, Safety and Environment (HSE) issues is at the top of Metso’s agenda. This means we are concentrating efforts to reduce our impact on the environment and to protect the safety of our employees, and ensuring our commitment to our customers’ operations.

A safety training session going on at Metso’s Sorocaba works, conducted by HSE Manager Luiz Roberto Silveira.


FEATURED ARTICLE

Algeria goes mobile with LokotracksBeing the second largest country in Africa in geographical terms, Algeria has quickly adopted mobile crushing and screening technology, in many cases replacing stationary operations. Lokotrack mobile crushing plants and mobile screens are today a common sight at Algerian quarry operations.


“The Lokotrack mobile concept has been adopted quickly in Algeria, as in other North African countries. Today, we have some 50 Lokotracks working in different parts of the country, from the northern coastline to the Sahara desert in the south,” says Pascal Florian, Vice President for Metso’s operations in the Middle East and Africa.

According to Pascal Florian, the mobile concept is often quicker and easier for the client, compared to a stationary installation:

Mustapha Bourega and Mohamed Djillali are responsible for operating the Lokotracks at Sidi Smoussi quarry.


LT1213S + ST620 – Unigranulats.

LT1213S + ST458 – Bejaoui.

Reporting results

“With Lokotracks, our customers can quickly start up quarry production and respond to the local demand for aggre-gates, avoiding the waiting time required for the stationary installation. In some cases, mobile equipment is bought to start the quarry operation while building the stationary plant.”

Two and three stage operationsA normal Lokotrack mobile crushing and screening process consists of a primary jaw or impactor plant, with a secondary cone plant, and a two- or three-deck mobile screen.

Normally, the classified end products include the 0–3 mm, 3–8 mm, 8–15 mm, 15–25 mm, and 0–25 mm grades. End products are generally used as railway ballast, road base materials, and as a raw material for the preparing of concrete and asphalt.

Thanks to its extensive oil and gas reserves, Algeria does not seem to be suffer-ing from a similar kind of economic reces-sion to be found in most of the Western world. There are a number of infrastructure projects going on, and concrete production statistics are showing growing figures.

Positive feedback from the clients“The overwhelming majority of our Loko-track clients find the mobile concept very attractive. Actually, the grapevine between our customers has been the most impor-tant sales concept,” says Hocine Mansouri, Metso’s Country Manager for Algeria.

“Another positive factor is the ease of use of the Lokotracks. The IC-series intel-ligent controlling system can be learnt quickly even by a new operator, and the language selection includes the two most important languages spoken here – French and Arabic.”

According to Hocine Mansouri, a good service and availability of spare and wear parts is crucial in a country with huge distances:

“We have a professional team of service technicians available for both training and servicing. Normally, the spares and wears are collected by our customers from Metso’s well equipped spares stock near the capital city Algiers.”

LT1213S – Azrou.

LT106 + LT200HPS + ST458 – Amenhyd.


New Metso service packages launched

In addition to a contract based service offering, Metso has launched four different service package levels to make the cus-tomer’s life easier. According to your needs, there is a choice of standard, advanced, superior and prime level service contracts.

Metso Performance Solution Standard helps you identify a critical spare and wear parts need to guarantee quick access to parts and other items that can be subject to unpredictable demand.

Metso Performance Solution Advanced is a more complete service system that analyzes your process for operational excellence, and furthermore saves time, reduces costs and makes plant design decisions easier.

A new Poly-Met shell liner concept has been developed by Metso’s Mill lining solu-tions. The new linings have been installed in two 38’ AG mills, the largest mills in the world by volume. The new liner concept is aimed at large AG mills where liner han-dlers are used for installation.

The new liner elements are made much larger than conventional Poly-Met or metallic liners. This will reduce the number of components to be installed/removed by the liner handler and will reduce installa-tion and downtime.

An additional feature of this liner concept is a new attachment system that eliminates the need for the installation crew to be in the drop zone of the liners while installing the liner bolts.

More info:

Kjell Nilsson

Tel. +46 70 687 06 19

[email protected]

Tage Möller

Tel. +46 70 675 72 31

[email protected]

New liner concept in the world’s largest mills

Metso Performance Solution Superior delivers integrated services and techno-logical solutions for your entire operation: from the mine to the processing plant, and from quarry face to the aggregates end product piles.

Metso Performance Solution Prime maximizes your process plant’s operational potential and efficiency. You can outsource the plant maintenance, and Metso organ-izes a full maintenance strategy and opera-tions that matches your business goals and industrial process.

More info:

Márcia Boscarato

Tel. +55 15 9789 0858

[email protected]

Liner handler installing new shell liner.




Lokotrack LT110C – superior performance in a transport friendly, compact size Metso’s proven Lokotrack range has a new member, the Lokotrack LT110C. Designed for primary crushing, its rugged design, but compact size, makes it easier to transport from one location to another.

Lokotrack LT110C can be equipped with either a standard 6 m3 or an optional 9 m3 feed hopper.

There is also a choice of discharge conveyors. In addition to the standard conveyor with a length of 11 m, there is the option of a 14-m folding conveyor, provid-ing a discharge height of 3.7 m.

Crusher automation makes operation easierThe IC500 intelligent control system is standard on the Lokotrack LT110C. Simply start up the Lokotrack, and the automation system monitors and optimizes the whole crushing process to ensure maximum throughput. If a problem arises, the IC500

provides the operator with clear informa-tion concerning the cause.

The Lokotrack LT110C primary jaw crusher can easily be combined with all secondary and fine crushing plants and mobile screens in the Lokotrack range to build complete mobile crushing and screening processes. Powered by a low-emission 310 kW Cat C13 diesel engine and weighing 58,000 kg, the LT110C is 15.6 m long, 3.0 m wide and 3.85 m high when being transported.

Optional accessories include wireless remote control, a dust-control system, a hydraulic hammer to clear feed blockages and a hydraulic-powered generator.

More info:

Timo Nakari

Tel. +358 40 701 6143

[email protected].

The new Lokotrack LT110C provides superior performance in an easily transportable compact size.

The LT110C can be equipped with a detachable screening unit.


FEATURED ARTICLE

Meeting the growing Baltic demandAS Kunda Nordic Tsement limestone quarry, owned by the Heidelberg Cement Group, meets the growing demand for aggregates and cement by acquiring a new, complete portable crushing and screening plant from Metso. With one plant, Kunda Nordic usually processes over a million tons of high quality limestone annually, the total extraction equaling over two million tons.


Mining Manager Riho Iskül is happy after replacing three old plants with a single new portable plant in Estonia.

“You can just imagine the effects for our company after discontinuing three old plants, and replacing them with the single, new Metso plant. We can now reach better efficiency with fewer machines, less energy, and less personnel than before,” comments Mining Manager Riho Iskül of Kunda Nordic Tsement.

The Kunda Nordic limestone quarry and the nearby cement factory serve the Baltic countries Estonia, Latvia, Russia and Finland. Its main products include different aggre-gates grades, portland cement, and clinker.


Amount of fines down by halfThe new portable plant comprises a feed chute, a portable jaw plant, secondary and tertiary cone plants, two portable screens, and all conveyors. For plant steering, a separate control cabin is set up, including two IC50 process automation units.

By replacing the old impactor plants with jaw and cone technology, the amount of fines produced dropped by a half – from 50% to 20–25% of the feed materials processed.

“For the cement factory, the cubical shape is not needed. It’s crucial only for the aggregates for road base and asphalt production and also for concrete facto-ries. With the help of Metso’s experts, we are fine-tuning the process and striving for continuous choke feeding for a better cubicity,” Riho Iskül notes.

Focus on productionPresently, Kunda Nordic Tsement is con-centrating all of its efforts on increasing production to meet the demand.

“Our 250 tons per hour capacity now gives us about 2,800–3,000 tons per day while the demand for aggregates in the summer period is around 4,000 tons per day. To meet the challenge, the availability of spares and wears is crucial to us. We will be very busy in 2010,” Riho Iskül believes.

Kunda Nordic has outsourced many of its plant operations. Drilling, blasting and loading are performed by OÜ Lõhketööd, part of the Lemmikäinen Group, and serv-ice in all three quarries and the cement factory is provided by ABB.

“Metso is always near to us”“The decision to choose Metso and its dealer Baltem as our partners was actually rather easy. We signed the first deal already in the 1980s, so we know the company’s background and products. For us in Esto-nia, Metso is also physically very near,” Riho Iskül stresses.

“The new plant has already shown us its capacity and flexibility. We can easily produce all the aggregates grades our cus-tomers ask for. When needed, we can run the plant to back up the feed required for the cement plant, too,” he adds.

More info:

Juha Tiilikka

Tel. +358 40 5476576

[email protected] a comfortable automation cabin, Vladimir Nikolajev steers and adjusts the whole operations of the Metso plant.

Kunda Nordic Tsement’s new, portable plant is comprised of a primary jaw plant, secondary and tertiary cone plants, two portable screens and conveyors.

Kunda Nordic Tsement quarrySituated about 100 km east from Estonia’s capital, Tallinnrock type: limestonequarry area: 400 hafeed size: 0–600 mm production in 2009: about 0.5 mtpy (aggregates production)1.5 mtpy (total rock extraction)

metso equipment on site

• Nordberg NW116 portable jaw plant - 110 mm closed side setting

• Nordberg NW200GP(S) portable cone plant - 40 mm closed side setting

• Nordberg NW300GP portable cone plant - 16 mm closed side setting

• Nordberg NW2060CVB portable screen - two decks

• Nordberg NW2060CVB portable screen - three decks

end products: 2–4 mm, 4–8 mm, 4–16 mm, 8–16 mm,16–32 mm, 0–32 mm, 0–64 mmcapacity: 250 mtph (average)

Reporting results


FEATURED ARTICLE

As a result, the company has been granted several environmental awards. Thanks to the sustainable operations, thousands of outstanding bird species can live undis-turbed in the neighborhood of the gravel pit operations.

Holcim – one of the leading suppliersHolcim Group is one of the leading global suppliers of cement, aggregates, ready-mix concrete, mortar and asphalt. It operates in over 70 countries, has a market presence on every continent and employs some 83,000 people.

The Group’s vision is to provide a foun-dation for society’s future, creating value for customers, employees, shareholders and the communities in which operates. Strongly oriented toward making sustain-ability an integral part of its strategy, Holcim

EL PUENTE GRAVEL PIT, SPAIN

Making green business growEl Puente gravel pit in Spain, owned by the Holcim Group, successfully combines green operating principles and a profitable aggregates business. Situated close to a cultural landscape protected by Unesco, El Puente already considered all environmental aspects before starting up production.

TEXT Sara Caballero PHOTOS Sara Caballero and Andrés Martínez

has been recognized as “Leader of the Industry” by the Dow Jones Sustainability Index (DJSI) for the fourth year in succession.

Holcim Spain, producer and supplier of construction materials, manages over 150 work sites in Spain. El Puente gravel pit has been operational for nearly 20 years, extracting sand and siliceous gravel from the Jarama River with respect for the environment.

El Puente gravel pit is located in an area which has a long tradition in this type of exploitation. In fact there are so many quar-ries in the vicinity that the road running along the Jarama River is called “quarry road”.

Rehabilitation plan prior to extractionAt El Puente, the planning of the rehabilita-tion process at the pit was carried out prior to the extraction work. Before initiating the

work, the technicians were already thinking about the restoration of the site.

As the excavation gets deeper, the extraction work gets more complicated, because earth has to be left for restoration. The excavation has established a depth limit at 9.3 meters. When excavators hit gypsum, this is a sign for the restoration team to start doing their job.

When extracting the materials, small lakes are formed in the excavated areas, assuming the characteristics of a wetland. In order to mimic the natural environment as much as possible, the excavation avoids straight lines and incorporates curved asymmetrical contours.

Up to 50 % of the rehabilitation is carried out using mudflats. The water is constantly flooding in during the extrac-tion process and is pumped out until the

Over 170 bird species, many of which are endangered, have been identified on the lakes neighboring the El Puente gravel pit in Spain.


extraction of material ends, at which point the water returns to its normal level.

Two production plantsThis installation is divided into two parts: the “naturals” plant and the crushing plant. The former processes the gravel as it comes out of the subsoil. It is washed and classified without applying any other pro-cedures. A series of mesh sieves separate the material according to size and places it on separate conveyor belts.

The larger sized gravel has to be crushed, for which powerful crushers are used. After crushing, a series of sieves are used to divide the fragments by size.

At the end of the process, the conveyors build up piles of a total of a dozen different

Reporting results

Holcim El Puente gravel pitlocated in Seseña , 44 km from Madrid, close to the Aranjuez cultural landscape protected by Unescoarea: 180 hectaresfound bird species: 171, of which 72 aquatic and 27 nestingmost outstanding species: Mediterranean gull, purple swamp hen, ferruginous duck, purple heron and flamingosenvironmental awards won by el puente gravel pit: First national prize for restora-tion from the Aggregates Federation (FdA), 2000; first European prize for reforestation from the European Aggre-gates Association (UEPG), 2001; first prize for environmental management

from the Association of Aggregates Pro-ducers of Castile La Mancha 2008; first national prize for biodiversity from the FdA for quarries and gravel pits, large company category, 2009; candidate for the European sustainable development prizes from the UEPG in the special category of Biodiversity, 2010.

metso equipent on site

• Nordberg HP100 cone crusher • Metso Babbitless C12000 screen

Gravera El Puente: a sustainable business, Holcim (España), S.A., 2010

sized aggregates. This work is carried out just a few meters from where hundreds of species of the most threatened birds in Spain live and breed.

Shelter for the birdsThe small lakes reformed throughout the rehabilitated and reforested zones of El Puente provide regular shelter for tens of thousands of birds. According to inventories, about 200 different species appear occasionally at the El Puente lakes. Throughout the year, over half of Spanish bird species pass through this reserve.

Advised by an independent biologist every step of the way, Holcim keeps a nurs-ery garden where the plants used in forest rehabilitation are grown. These species are

selected based on the best ability to adapt to the environment.

Holcim has enclosed the entire gravel pit with a hunting fence which allows for the free movement of animals and protects them from hunters and fishers.

More info:

duardo Díaz García-Bernardo

Tel. +34 606 43 78 01

[email protected]

César Álvarez

Tel. +34 649 80 44 18

[email protected]

With the help of Metso’s crushing and screening equipment, up to 12 aggregates grades are produced.

Cattle egret (Bubulcus ibis) is one of the bird species living in the neighborhood of the El Puente gravel pit.


FEATURED ARTICLE

Starting as a textiles manufacturer in 1948, today Grasim Cement’s business com-prises of viscose staple fiber (VSF), cement, sponge iron, chemicals and textiles. Its core businesses are VSF and cement, which con-tribute to over 90 percent of its revenues and operating profits.

Grasim’s cement operations today span the length and breadth of India, with 11 composite plants, 8 split grinding units, four bulk terminals and 53 ready-mix con-crete plants. Leveraging the strong equity and goodwill of the house mark, the com-pany has a strong national brand, UltraTech cement.

Bulk moves efficiently in IndiaGrasim Cement Industries, a flagship company of the Aditya Birla Group, ranks among India’s largest private sector companies. Metso’s bulk materials handling equipment secures prompt shipments from its expanded cement plants in Rajasthan and Andhra Pradesh.

TEXT Dinesh Sharda, Sanjay Datir, Abraham Xavier

Grasim Cement, together with its sub-sidiary UltraTech Cement, is expanding its capacity by 14 mtpy (million tonnes per year) through greenfield and brownfield projects to meet the cement demand. Grasim Cement is setting up a 4.5 mtpy greenfield plant at Kotputli and another 4.4 million mtpy plant at Shambhupura in Rajasthan.

UltraTech Cement is additionally setting up a 4.9 million mtpy project at Tadipatri in Andhra Pradesh. Post expansion, with a 49 million mtpy capacity, Grasim Cement will be among the top ten global cement players.

Extensive expansion projectsWhen Grasim Cement decided to expand its operations in Rajasthan to cater to the growing demand for cement in the north-ern region, the Shambhupura plant was already in operation. The expansion plans at Shambhupura and Kotputli were realized around the same time, resulting in a capac-ity expansion of almost 9 million tons.

“The volume of expansion in Shambhu-pura was rather significant, and we scru-tinized all the vendors and found Metso’s material handling equipment to suit our requirements well,” says H.P. Singh, Vice President, Aditya Cement.


Reporting results

“In our industry, success largely depends on the ability to meet crucial deadlines and maintain consistency in terms of quality and supply. As an organization, we have always treated every project with utmost importance,” he adds.

“Our search for a reliable company ended at Metso. We wanted a business partner rather than a supplier – a partner that would be competent enough to meet and match the technical requirements of the plant independently. Metso has complete solutions for bulk material han-dling that have made its products our first choice,” Mr Singh says.

According to H.P. Singh, Metso’s exper-tise in the field benefited Grasim Cement in strengthening their operational efficiencies and in becoming fully mechanized:

“We are increasing our capacity, but the basic principle that we follow is of being the lowest-cost producer, in which Metso has an important role to play. Metso’s proactive service and knowledge in the field are also an added advantage.”

Metso’s biggest bulk materials handling delivery in India

At Grasim Cement, vendor selection is entirely based on merits. The selection process involves a SWOT analysis for each company, conducted by many officials along with a consultant. The company analyzes the technological competence and capacity of the suppliers in all areas of operations. Levels of service and support are also analyzed comprehensively.

The order is Metso’s largest single bulk material handling installation in India. It includes a total of eight bulk materials han-dling systems, including three stackers for limestone, laterite, red ochre & coal/pet-coke, two bridge type reclaimers and three side scraper reclaimers.

At present, most of the equipment has been commissioned, the balance erected and the under load trials completed. The plant at Shambhupura has been opera-tional since the beginning of 2010.

Grasim Cement, Shambhupura

Rajashree Cement, Malkhed

UltraTech Cement, Hirml

6 stackers & 8 reclaimers 2 stackers, 2 reclaimers & associated conveyors

1 stacker, 2 reclaimers, 1 wagon tippler + side arm charger &

2 apron feeders

Grasim Cement, Kotputli

UltraTech Cement, Tadipatri

UltraTech Cement, Ginegera

3 stackers & 4 reclaimers 2 stackers & 3 reclaimers 1 stacker & 1 reclaimer, 1 wagon tippler + side arm charger & 2 apron feeders

Grasim Cement, Dadri

Grasim Cement, Ravan

Grasim Cement, Aligarh

1 wagon tippler + side arm charger & 2 apron feeders

1 reclaimer 1 wagon tippler + side arm charger & 2 apron feeders

Equipment supplied/under supply to Grasim Cement Industries/UltraTech Cement

Cementing successThe expansion at Tadipatri is a good exam-ple of Metso’s engineering capabilities. The 4.9 mtpy plant capacity was increased sig-nificantly, strengthening Grasim Cement’s position among the top ten global cement players.

“We wanted a partner with the ability to deliver complete materials handling solutions. Metso gave us that confidence with their combined expertise and turnkey abilities. Our expert team’s mutual decision was based on Metso’s past experience, performance and track record in the bulk material handling field,” said P S Mazumdar, Executive President & Unit Head, Ultratech Cement Ltd.

Metso had a tough challenge to follow the stringent timelines for manufacturing, installing and commissioning the plants. A simultaneous execution of three mega projects is not easy by any stretch of the imagination. But Metso took up the chal-lenge and met the deadlines to Grasim Cement’s satisfaction.

More info:

Abraham Xavier

Tel. +91 124 235 1541

[email protected]

Stacker conveyor in operation at Grasim Cement Shambhupura plant in Rajasthan in India.


FEATURED ARTICLE

Vezzola – industrialized aggregates productionTurning aggregates production into a truly industrial process and providing customers with accurately fine-tuned aggregates mixes is the secret behind the success of Vezzola, a family-owned company with operations in Italy’s Lake Garda region.


Stefano Vezzola, CEO, pictured here with a steam-powered vehicle from the old days.


Reporting results

Vezzola’s fully-equipped stationary plant in Montichiari, probably the country’s most modern facility of this type, can produce up to 500 different aggregates recipes. The plant is another successful delivery by Met-so’s Mining and Construction Technology.

Processing sand and gravel, the Mon-tichiari plant features a complete crush-ing, screening and washing installation including feeders, crushers and screens, conveyors and plant automation. Annual plant output totals 400,000 tonnes of high-quality aggregates.

A growing family businessFounded 42 years ago by Giovanni Vezzola, this family business has grown steadily over the years. In addition to four active quarries, the company’s 120 employees are engaged in operations within concrete and asphalt production, and in construction activities.

Giovanni is still the company’s presi-dent, and his son Stefano is CEO. A third generation is on its way – Mario, Stefanos’s son, is already working with the company’s technical department.

Quarries have been a playground for most members of the Vezzola family. Stefano Vezzola does not draw any dis-tinction – his first task was to transport aggregates to customers on Saturdays and collect the payments.

Optimized performance helps get through the recessionIn 2007, Vezzola invoiced a record EUR 53 million. Currently, the company is mak-ing preparations for the future, the next economic upturn. Vezzola personnel are offered a training program that includes 600 hours of instruction.

“When economic conditions are tight, optimized performance and supplying consistent high-quality end products are crucial. Successful operation of our new Metso plant plays an essential role in achieving this,” says Stefano Vezzola.

“According to our new philosophy, the new Montichiari operation is not a quarry but an industrial operation providing our customers with better quality and an improved selection of end products,” he adds.

Aggregates production and recycling Operating in four quarries, Vezzola makes good use of the possibilities offered by its different locations. Lonato de Garda, the oldest quarry, is now only used for recy-cling slag and concrete and for stockpiling aggregates. Vezzola’s recycling operations utilize two Lokotrack jaw plants.

New quarries in Montichiari, Gussola and Manerda del Garda are the main sites for Vezzola’s aggregates production.

As well as utilizing its own sand and gravel reserves, materials are transported to the Montichiari quarry from nearby sites.

Vezzola’s annual production totals one million cubic meters, half of which is sold outside the company.

Respect for the environmentThe Montichiari plant features several options for protecting the environment. A total of 2500 square meters of window panes installed in the main crusher build-ings eliminate noise and dust emissions. Process water is efficiently recycled in the washing plant.

The overall appearance of the plant is very tidy and green – a total of 2000 plants have been placed around the quarry area.

The Montichiari plant is one of Italy’s most modern crushing and screening installations.

Comprehensive plant automation means that Claudio Altemani can control and adjust all aspects of the production process using just one computer.


Reporting results

The main element of the restructuring was a new iron ore concentrator with heavy machinery for crushing ore. The set-up included two heavy-duty and semi-porta-ble crushing stations, providing a com-bined capacity of more than 10,600 tph.

Finest ball grinder feed achievedBoth crushing stations were installed with coarse gyratory crushers, six multi-bowl hydraulic cone crushers, three double-layer vibrating sieves and six heavy-duty ball mills.

With Metso’s equipment, the Qidashan mine reached the finest ball grinder feed, with 90–95% of sorted particles remaining between 0 and 10 mm and 60% under 6 mm.

Later, HP series secondary crushers were put to work at the company’s Dagushan, Hujiamiao and East Anshan sites. The collec-tive output of the Qidashan and Diaoyuntai crushers reaches 25 million tons per year.

Thanks to the automated control sys-tem, the HP cone crushers work stably and efficiently, increasing the amount of parti-cles qualifying for the 0–10mm bracket by 15–20%, and lowering the circulating load approximately by half.

More info:

Changjiu Zhang

Tel. +86 138 0128 8954

An impressive row of HP700 and HP800 cone crushers at Anshan Qidashan mine.

An HP700 cone crusher liner change taking place.

A heavy-duty mining success in ChinaDuring a long, well-planned process, Anshan’s iron ore mine in Qidashan, China, has built and completely restructured its mining process. After two remodeling phases, completed together with Metso, the mine today produces over 10 million tonnes of iron ore per year.

TEXT Zhang Changjiu


Reporting results

Alcoa’s bauxite mine in Juruti, located on the banks of the Amazon River, in western Pará, opened on September 15 and has bauxite reserves estimated at 280 million tonnes. The initial production of the mine is calculated at 2.6 million tonnes/year. In order to operate with such a significant quantity of ore, the conveying systems, processing and loading require specialized engineering.

Alcoa invested in Metso’s equipment such as car dumpers, apron feeders, stack-ers, reclaimer, belt conveyor systems, ship loader and vibrating screens. The equip-ment is installed throughout the complex formed by the mine, processing plant, railroad and port.

Installation and training includedAlso included in the package of equipment supplied were Metso’s commissioning, installation supervision, start-up, operations assistance and training services for the Alcoa operators.

According to Metso’ Sales Manager Silvino Marcos Garcia, few companies in

the world could provide such a range of equipment in a single package:

“Due to the challenges arising from the project location, Alcoa required a supplier that has a strong presence in Brazil. Not only with respect to the quality and reli-ability of its products and services, but also the ability to provide technical assistance and parts supply to meet the challenging conditions in Juruti,” says Garcia.

Metso’s Vice President for Proposal and Sales Support, Carlos Ivan Équi, empha-sizes that the bucket wheel reclaimer is one of the pieces of equipment with higher technological advance, ensuring the effi-ciency of the shipment of the bauxite.

“This equipment is automated, allowing forward movements and boom slewing to reclaim bauxite from the stock pile in vari-ous benches, and further achieve the rated capacity of the project.”

“Another very important piece of equip-ment is the ship loader which travels along the quay and uses boom slewing and extension, allowing it to reach all the ves-sels’ holds and enabling the loading to take

Alcoa launches a new mine in Brazil Alcoa, a Brazilian mining company, chooses Metso for the reliability and effective-ness of its solutions, already present in bauxite mining operations in Brazil.

TEXT Sheila Ivers

A complete ship loading system is being used for loading ore onto ships.

Metso’s stacker conveyor system in operation at Alcoa Juruti mine, Brazil.

place efficiently and in a timely manner. This helps avoid the extended stay of ships and, consequently, additional payments of demurrage by Alcoa,” Equi explains.

“The equipment supplied can work automatically, following its embedded pro-gramming, enabling greater operational efficiency and safety and also requiring fewer operators,” he adds.

More info:

Carlos Ivan Équi

Tel.: +55 15 2102 1625

[email protected]


Reporting results

The Coemin Cerrillos concentrator is located in Chile’s Atacama region, 800 km north of the capital, Santiago.

Coemin initially had one crushing circuit consisting of a Nordberg HP 300SX cone crusher at the secondary stage and with one Nordberg 1560 Omnicone and one Allis Chalmers 250HP 3-60 cone as tertiary crushers. A little later, Coemin installed a second crushing plant with a production capacity of 200 tph. This circuit contains a Nordberg HP300 as the secondary crusher and two Allis Chalmers 250HP 3-60 cones as tertiary crushers.

Because of the vibration occurring at the tertiary stage in the cone crushers’ sup-port structure, Coemin decided to replace the two cone crushers with two second-hand Barmac B8100 VSI crushers operating in closed circuit. Based on the results they gained from the operation of these two machines, Coemin decided to purchase a Barmac XD120 to be used as a ball mill pregrinder in a separate quaternary circuit.

coarser size fractions. The Barmac VSI has an autogenous crushing action which produces more fines, which are welcome in order to increase mill production and reduce power consumption.

New Barmac for quaternary crushingIn January 2009, a new Barmac XD120 was commissioned as a quaternary crusher for plant 1. A minus 25 mm feed from the terti-ary cones is fed to the quaternary circuit at a feed rate of approximately 250 tph. This material is first screened and then further reduced to minus 4 mm by the quaternary stage. The discharge gradation from the Barmac XD120 has approximately 80% passing 12 mm and 25% passing 4 mm. As a final product 90% was less than 4 mm, with 25% passing 0.2 mm.

With a 4 mm feed to the mill circuit, milling production will be increased due to the finer feed compared to the tertiary cone crusher stage.

Coemin made production comparisons between January 2008 and June 2009 at the milling section with eight mills in oper-ation. Total production has been similar for both years, but after the commissioning of the Barmac XD120 in 2009, Coemin has shut down mills 1, 2, 3 and 4 and only uses four mills, therefore achieving significant savings in power consumption.

More info:

Alfonso Escudero

Tel. +56 99158 9685

[email protected]

A new Barmac XD120 VSI crusher, installed at Coemin’s Cerrillos concentrator in the Atacama desert, Chile.

Efficient pregrinderThe first comparison is between the two plants, with one of them using cone crush-ers and the other using the Barmac VSI crushers. After this, the result of using the Barmac XD120 as a ball mill pregrinder is shown with the effect of capacity at the milling stage.

The results indicate the advantages of using a Barmac VSI crusher in a tertiary loca-tion, but mainly as a quaternary crusher.

When making comparisons between crushing plant number 1 and crushing plant 2, taking into account tonnage per hour produced from January to June 2008, it was established that plant 2 (where Barmac VSIs are installed) produces 7.66 tph more than plant 1. This equated to an increase of close to 4.8% more tons per hour from plant 2 compared to plant 1.

When comparing the products from both circuits, more fines were produced by the Barmac VSI circuit, while the cone crushers had better reduction of the

Barmac pregrinds copper ore in ChileVertical shaft impactors are used in quarrying applications worldwide for manu-facturing sand and aggregates. This article shows the success of Barmac VSI while employed as a tertiary and quaternary crusher in a Chilean mining application.

TEXT Osvaldo F. Pavez, Rodrigo A. Pizarro and Gerhard Lenz


metso news

an existing recovery boiler into a biomass fuelled power boiler, as well as a digester rebuild and brown stock washing upgrade, including the installation of the press tech-nology are part of the Laja Mill moderniza-tion project.

Metso and BHEL to extend Technology Collaboration Agreement

Bharat Heavy Electricals Limited (BHEL) of India and Metso have signed the exten-sion of the ongoing Technology Collabora-tion Agreement (TCA) between the two companies for Distributed Control System (DCS). The TCA extension is for a period of ten years, effective September 15, 2009.

BHEL is the largest supplier of power plant equipment in India. BHEL-supplied equipment contributes around 73% of the total power generated in India. The cumu-lative capacities of power projects installed by BHEL have exceeded 138,000 MW.

The TCA Extension documents were for-mally handed over by B. P Rao, Chairman & Managing Director BHEL to Pasi Laine, Presi-dent, Energy & Environmental Technology (EET) Metso in January 2010 in New Delhi.

LUC scrap shear – successful introduction on the recycling market

In the beginning of 2009, Metso Linde-mann launched the new series of scrap shears LUC. The world market leader for scrap shears recognized the need to design a scrap shear specifically suitable for medium volumes.

With the realization of this idea Metso is one step ahead, according to Andreas

New environmental waste gasification technology to Lahti Energia

Metso will supply a waste gasification plant utilizing a new type of technology to Lahti Energia Oy in Finland. The plant enables Lahti Energia to convert recycled waste into energy at high efficiency and in an environmentally friendly way.

In a CFB gasifier, waste is turned into combustible gas, which is cooled and cleaned and combusted in a gas boiler to produce steam for a steam turbine. The plant will annually use 250,000 tonnes of waste, corresponding to 160 MW, from which it will produce 50 MW electricity and 90 MW district heat.

Metso’s delivery includes a waste gasi-fication process, gas boiler and flue gas cleaning system with auxiliary systems and an automation system for the whole power plant.

Energy and pulping technology to CMPC, Chile

Metso has received an order to deliver energy and pulping technology for CMPC Celulosa S.A., Chile. The commercial opera-tion is scheduled to start in 2011–2012.

Metso’s delivery includes a new biomass fired power boiler, a conversion of an exist-ing recovery boiler into a biomass fired boiler, a digester rebuild and a brown stock washing upgrade. The new power boiler as well as power boiler conversion will utilize bubbling fluidized bed (BFB) technology.

The new power boiler will be part of CMPC’s Santa Fe pulp mill’s energy project for green energy generation. The rebuild of

Zöllner, Vice President Europe and Africa and Head of Marketing within Metso’s Recycling Business line. The scrap yard owners who have recently installed LUC shears are highly satisfied with the per-formance of their new machines. The first LUC scrap shears have started running in Keady, Ireland and in Freytal, Germany.

Metso to participate in World EXPO 2010 in Shanghai

Metso has signed an agreement to partici-pate in The World EXPO 2010 in Shanghai. The World EXPO, with more than 240 country participants, will be the largest in history and will be held between May 1 and October 31, 2010.

Metso is an official sponsor at the Finnish Pavilion.

More information about the EXPO in Shanghai can be found at http://www.expo2010.cn and about the Finnish Pavilion at http://www.finlandatexpo2010.fi

Metso around the world

Metso Corporation, tel. +358 20 484 100, www.metso.com

Expect resultsExpect results is our promise to our customers and the essence of our strategy. It is the attitude we share globally; our business is to deliver results to our customers, to help them reach their goals.

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