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8202019 Metso Minerals Aggregates 3 2011
httpslidepdfcomreaderfullmetso-minerals-aggregates-3-2011 136
Clean washed Metso
sand to build Sochi
Winter Olympics
in Russia 6
minerals amp aggregates
METSOrsquoS CUSTOMER MAGAZINE FOR THE MINING AND CONSTRUCTION INDUSTRIES No 983091983090983088983089983089
results
8202019 Metso Minerals Aggregates 3 2011
httpslidepdfcomreaderfullmetso-minerals-aggregates-3-2011 236
Joatildeo Ney Colagrossi President
Services Business Line Metsorsquos
Mining and Construction
Technology
983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983089
Helping you grow your businessWe live in a time of uncertainty with considerable volatility in the global economy While certain countries are still
struggling to find ways to achieve economic stability and growth other countries continue to show signs of great
economic activity
Regardless of the economic situation in the countries where our customers operate Metsorsquos Services business
is prepared to provide support in helping customers to achieve their goals and results In struggling markets
we can contribute with our products and services designed to improve operational effi ciency reduce costs and
optimize the use of assets etc For our customers with operations in rising markets we offer services to maximize
production capacity increase plant availability and improve utilization In addition we can offer specialized
manpowerOur goal is to continue expanding our services offering far beyond our traditional offer of wear and spare parts
We are prepared to support our customers worldwide with field services process technology engineering-to-
order life-cycle services and more We also provide extensions of our product portfolio via performance-based
contracts cost-per-ton contracts and equipment protection plans
One outstanding example of a performance-based contract providing mutual benefits (the theme of one
of the articles in this edition) is the case of RCC (Russian Copper Company) Under this contract we committed
to developing our entire service structure in a remote region thereby ensuring the support required for our
customerrsquos success and honoring our motto ldquoWe deliver what we promiserdquo
We are also seeking geographic expansion improving our operations via ldquoServices Hubsrdquo (centers for specialized
services) located near our customers so that we can better adjust our specialized knowledge to their needs
providing agility and quality in aftermarket service
The greatest evidence of the importance of the subject to Metso is that ldquoservicesrdquo stands as a strategic corporate
pillar that helps us to become ndash in addition to the leading provider of services ndash a genuine service companylistening to and understanding the needs of customers so that we can continually improve upon our operations
Over the past two years since the creation of the Services Business Line for the mining and construction
segments we have observed a great evolution in the services area thanks to the commitment of our personnel
and to the mutual learning achieved with our customers Itrsquos a continuous learning process that will lead to
success ndash for Metso and for our customers
8202019 Metso Minerals Aggregates 3 2011
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2 Editorial
4 News in brief
6 Sochi Winter Olympics are built on top
quality aggregates
10 New products
14 First modular plant to Nepal
quarrying a reality
16 Outokumpursquos Kemi mine set to
double production
20 Multi-stage Lokotrack process
a success in Senegal
21 Finer ore through wear profile study
at El Abra mine in Chile
22 Services success in Surabaya
24 Creating value with Metso
in Hong Kong
26 Zinkgruvanrsquos twin C160 jaws secure
good uptime
29 A complete impact crusher solution
for Lafarge
30 Cost-per-ton wear agreements deepen
customer relationships
32 Primary challenge at Pleasant Gap
quarry
35 Metso around the world
983152983157983138983148983145983155983144983141983140 983138983161 983149983141983156983155983151 983149983145983150983141983154983137983148983155 983145983150983139
Fabianinkatu 9 A PO Box 1220
FI-00101 Helsinki Finland
tel +358 20 484 100 fax +358 20 484 10
e-mail mineralsinfocsrmetsocom
wwwmetsocomminingandconstruction
Results minerals amp aggregates customer maga-
zine is published 3-4 times a year in English with
Chinese French Portuguese Russian Spanish
and Asia-Pacific insertions To receive your per-
sonal copy please contact your nearest Metso
Minerals offi ce or the e-mail mentioned above
983141983140983145983156983151983154-983145983150-983139983144983145983141983142
Eero Haumlmaumllaumlineneerohamalainenmetsocom
983139983151983150983156983154983145983138983157983156983151983154983155 983145983150 983156983144983155 983145983155983155983157983141
Linda Bergmann Elisabetta Cataluffi Gilles
Dombey Atoshi Nayak Ghosh Ou He Eero
Haumlmaumllaumlinen Olli Kellokumpu David LeRoy
and Macarena Vallejo
983141983150983143983148983145983155983144 983148983137983150983143983157983137983143983141 983141983140983145983156983145983150983143
Traduct Oy and Kathleen Kuosmanen
983148983137983161-983151983157983156 983137983150983140 983137983154983156 983159983151983154983147
Vanto Design Oy
983152983154983145983150983156983145983150983143
November 2011
copy Copyright 2011 Metso Minerals IncAll rights reserved
Printed on MultiArt Silk 130200 gm2
Cocoon offset 120 gm2
Reproduction permitted quoting
ldquoResults minerals amp aggregatesrdquo as source
All product names used are trademarks
of their respective owners
Addresses Metso Minerals Inc customer data
ISSN 1797-6480
wwwmetsocomminingandconstruction
Printed matter
441 014
COVER PHOTO Washed high-quality sand produced by Maykop Nerud with Metsorsquos stationary
washing plant for the Sochi 2014 Winter Olympics sites in Russia Stanislav Steblyansky shows the
sand for concrete production
In this issue
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983150983141983159983155 983145983150 983138983154983145983141983142
Services for Northland Resources in Sweden
The services supply at Kaunisvaara covers Metso Poly-Met mill
liners liner handlers and essential tools technical assistance including
maintenance and shutdown planning as well as monthly audits and
annual inspection services for the Tapuli grinding mill
The SmartTagtrade system utilizes Radio Frequency Identification (RFID) tags
and detectors to track ores as they 1047298ow from the blast to the downstream
processes and beyond
Metso has signed a contract with Northland Resources AB con-
cerning a five-year mill lining service and inspection program for
the Kaunisvaara project in northern Sweden The contract comple-ments previous project orders by Northland Resources announced
by Metso earlier this year The value of the order is EUR 19 million
The Metso Life-Cycle Services (LCS) program at Kaunisvaara
includes both the supply and installation of mill liners and techni-
cal and maintenance support for the semi-autogenous mill on the
Tapuli process line Metsorsquos on-site resources will also conduct liner
inspections to maximize mill availability The contract period will
commence when installation of the Tapuli process line is com-
pleted at the end of 2012
ldquoWe are pleased to have concluded this contract as it maxi-
mizes the availability of our grinding linerdquo says Shane Williams Vice
President Projects Northland Resources AB ldquoAs this is a cost-per-
ton contract we will be able to forecast expenditure over extendedperiods of time It will be a very useful asset in view of the total
investment involvedrdquo
ldquoWe embrace the opportunity to partner with Northland in a
five-year LCS commitmentrdquo says Joatildeo Ney Colagrossi President
of Services Business Line Metso ldquoThe speed at which operations
at Kaunisvaara are progressing is impressive and we are look-
ing forward to a rewarding working relationship with Northland
Resourcesrdquo
First SmartTagtrade systems for Europe
Somincor Neves-Corvo an underground copper-zinc mining
operation in southern Portugal owned by Lundin Mining hasrecently installed the first Metso SmartTagtrade system in Europe The
SmartTagtrade system was developed by Metso Process Technology
and Innovation (PTI) to track ore andor waste from mines to the
plant using Radio Frequency Identification (RFID) technology The
RFID tags have been designed to withstand blasting handling by
mining equipment and passing through primary and sometimes
secondary crushers
Somincor is using the SmartTagtrade system to track ore and waste
from post-blast muck piles through underground loading hauling
ore passes crushing storage and finally hoisting and conveying to
surface stockpiles The information will be used to better under-
stand and improve ore and waste handling logistics
Knowledge and interest in the Metso SmartTagtrade system isgrowing in Europe Boliden Tara Mines Ltd has also placed an order
for the SmartTagtrade system Tara is an underground zinc mine in
Ireland processing around 26 Mtpa of ore using Metso equipment
such as a C200 jaw crusher and VPA filters and pumps
The main objective of the SmartTagtrade system at this site will
be to track ore being mined from different stopes and headings
as part of their reconciliation process Waste in ore streams can
increase transport and processing costs reduce the head grade
and produce additional waste tailings
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Lokotrack LT116 attracts customers in Thailand
A group photo taken during a demo day at Thassana Cholburi quarry in
Central Thailand
A Vertimillreg vertical grinding mill under construction
983150983141983159983155 983145983150 983138
TISCO to receive minerals processing equipment
Metsorsquos Lokotrack LT116 mobile jaw plant attracted a number of
customers during a recent demo day organized at Thassana Chol-
buri Thailandrsquos biggest quarry
Marketed by Uawithya Machinery Co Metsorsquos tracked crush-
ing concept has been well received in Thailand Recent deliveries
include Lokotracks both for quarrying and mining purposes
The LT116 jaw plant is now being operated by PTK an iron ore
mine situated in Loei Province in northeastern Thailand
Tandem railcar dumper replacement
for Ridley Terminals in Canada
Metso will supply a tandem railcar dumper replacement to Ridley
Terminals Inc for its Ridley Island Coal Terminal in Prince Rupert
British Columbia Canada The value of the order is EUR 85 million
Metsorsquos delivery includes the replacement of two railcar dumpers
in a tandem installation with commissioning services To facilitate
the unloading of both Canadian and US length cars the dumpers
Metso will supply minerals processing equipment to Taigang
Group Lanxian Mining Co Ltd ( TISCO) the largest stainless steel
manufacturer in China The delivery is scheduled for the first
quarter of 2012 The order comprises seven units of vertical plate pressure filters
wear and spare parts as well as services related to installation
start-up commissioning and technical supervision The delivery
is for concentrate filtering for TISCOrsquos Yuanjiacun iron ore process-
ing plant in Lan County Shanxi province The plant is expected to
start operations in May 2012 with a daily processing capacity of
22000ndash23000 tons of iron ore concentrate
The Yuanjiacun plant is designed to process 22 million tons of
raw iron ore per year When completed Yuanjiacun will be the
largest iron ore processing plant in China
TISCO is among the worldrsquos largest producers of stainless steel
In 2010 the companyrsquos net sales were EUR 117 billion
Stronger services in the North American mining sector
Metso has acquired the service business assets of Copperstate
Industrial Services Inc a mining services provider based in Phoenix
Arizona The acquisition strengthens Metsorsquos position as a leading
service and technology provider for the mining and construction
sectors The company was transferred to Metso on August 1 2011
Established in 1999 Copperstate has built a highly compe-
tent team of service personnel in the American hard rock mining
region Approximately 40 employees will transfer to Metso The
team will be integrated into the Services business line of Metsorsquos
Mining and Construction Technology segment where they willcontinue to serve existing clients The team will be expanded to
further reinforce Metsorsquos maintenance repair and retrofit business
in the USA Canada and Mexico
ldquoThis fits right in with Metsorsquos profitable growth and develop-
ment strategyrdquo says Randy Reisinger Senior Vice President of
Engineered Services Solutions ldquoMetsorsquos objective is to enhance
customer satisfaction by employing a larger team of knowledge-
able well-trained service people to meet customersrsquo skills and
availability needsrdquo
will be equipped with a drawbridgeknife gate system that indexes
and dumps trains of both lengths The tandem railcar unloading
system will be capable of handling 74 railcars per hour Metsorsquos
delivery will be completed by the end of 2011
Wholly owned by the Federal Government of Canada Ridley
Terminals Inc operates an advanced marine terminal providing
high-performance railcar unloading product storage and vessel
loading services
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Facilities for the
Sochi Winter Olympicsconstructed with high-quality aggregates
Metsorsquos stationary washing plant was delivered to Maykop Nerud and so far has processed over
500000 tons of high-quality aggregates and sand for the construction of Olympic facilities in Sochi
Positive estimate of the end product quality
General Director of Maykop Nedud Company
Alexander Kozhanov (in the middle) with hisdeputies Alexey Poddubny and Stanislav
Steblyansky
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983110983141983137983156983157983154983141983140 983137983154983156
The City of Sochi despite
its subtropical climate
is preparing to host the
Winter Olympic Games in
2014 In connection withthis event major sports and
infrastructure facilities are
being built
TEXT amp PHOTOS Eero Haumlmaumllaumlinen
Because the Olympic site is classified as
a 12-magnitude seismic zone the State
Corporation ldquoOlympstroyrdquo and Russian
construction regulations require the use of
high-quality washed aggregates in concrete
when constructing critical objects in Sochi
These requirements are being met
in full by the company Maykop Nerudwhich produces crushed stone of various
fractions and sand using Metsorsquos mobile
crushing and screening plant and a station-
ary washing complex to process ancientmetamorphic alluvial formations into high-
quality construction materials
To date Maykop Nerud has shipped
to Sochi more than a million tons of inert
materialsaggregates produced in its in-
house production and in adjacent quarries
Inert materials are delivered to Sochi exclu-
sively by rail due to the diffi cult mountain-
ous conditions The company dispatches
one to two trains containing 3000 ndash 6000
tons of crushed stone and building sand to
the Olympic city daily
Aggregates from Maykop Nerud arebeing used in many Olympic projects
including Bolshoi ice palace and in tunnel
complex No 1 consisting of 25 kilometers
of road railway and service tunnels which
will be used to transport guests at the
Sochi 2014 Olympic Games between the
Olympic Village and a ski complex in Kras-
naya Polyana
Maykop Nerudrsquos washed sand is also
being used by manufacturers of tubing for
five tunnels under construction
ldquoMetso is a true partnerrdquo
Maykop Nerud was established just four
years ago and was supplying the inert
materials of other producers using anin-house railroad warehouse Later the
company entered into contracts with
quarry It is the first complex of its kind
in Russia
ldquoIn the initial stages of preparation for
the technical requirements of the equip-
ment we had planned to purchase a
mobile washing plant but Metsorsquos engi-
neers convinced us of the advantages of
stationary washing and screening equip-ment Today with the complex working
247 at full capacity it is easy to see that
major construction companies running
operations in Sochi and purchased its ownequipment for crushing and screening
ldquoWhile looking for an equipment sup-
plier we were approached by leading
manufacturers of crushing and screening
equipment After their proposals were
subsequently cross-checked Metso was
deservedly appreciated as a supplier of
high-quality equipment by all other bid-
dersrdquo says Alexander Kozhanov General
Director of Maykop Nerud
ldquoSince choosing Metso as our equip-
ment supplier and during the course of our
cooperation we have come to the realiza-tion that Metso is a true partner for us In
close cooperation with Metso we develop
and implement processes unavailable to
competitors work together as a united
team and share valuable experiencerdquo
Kozhanov adds
A good example is Metsorsquos washing
complex operated at Maykop Nerudrsquos
we made the right choicerdquo says Maykop
Nerudrsquos Deputy General Director AlexeyPoddubny
From sand-gravel mix
to quality aggregates
The raw material Maykop Nerud uses is
metamorphic alluvial sediments of hard
rock deposited in the Belaya River valley
millions of years ago The sand-gravel mix
in the companyrsquos quarry features some
properties of granite with excellent hard-
ness making it a good feed for the produc-
tion of quality aggregates
Straightforward quarrying technology isutilized excavators dig up the sand-gravel
mix and move it to stockpiles From the
stockpiles the sand-gravel mix is reclaimed
to Metsorsquos three-stage crushing and
screening process consisting of tracked
jaw and cone crushing plants and a mobile
screen gt
The sand amp gravel mix is crushed and screened
into 0ndash20 mm fractions using jaw and cone
crushing plants combined with a mobile screen
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The Maykop Nerud Company has supplied more than 150000 tons of 0ndash5 mm washed sand and aggregates in fractions of 5ndash10 mm 10ndash20 mm and
5ndash20 mm for shotcreting and for the concrete lining of the constructed tunnels
Crushed to the size of 0ndash20 mm the
material is transported by conveyors to a
washing complex consisting of a feed hop-
per conveyors a 4-deck washing screen aspiral classifier and an automated control
system
In order to facilitate the operations of its
customers Metso has established a stock of
spares and consumables in Maykop Nerudrsquos
territory Maykop Nerud can use the stock
for its own purposes and parts can also
be delivered to other Metso customers as
required The reliability of the equipment
983110983141983137983156983157983154983141983140 983137983154983156983145983139983148983141
and its operational effectiveness mainly
depend on the availability and prompt
replacement of spares and consumables ndash a
prerequisite ensured by the mutual effortsof Metso personnel and Maykop Nerud staff
Powerful crushing complex in
combination with washing plant
Having taken into account the growing
demand for high-quality end products
Maykop Nerud and Metso agreed to
extend their cooperation and create an
even more powerful stationary crushing
and screening complex including a pri-
mary jaw crusher and two stationary cone
crushers for operation in combination with
a stationary washing plantldquoBeginning in the second quarter of
2012 we will use the new stationary crush-
ing and screening complex along with the
mobile equipment thus allowing us to
increase our capacity to 130000 ndash 140000
tons per month in order to meet the con-
stantly growing demandrdquo says Stanislav
Steblyansky Deputy General Director of
Maykop Nerud
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The construction budget of EUR 534 billion
for projects in Sochi includes three major
sites the Olympic Park along the shore of
Black Sea the Olympic Village residences
for the athletes and the Krasnaya Polyana
ski resort in the Caucasus Mountains
These three sites will be interconnected
by numerous new highways roads bridges
Construction projects at a total budget of EUR 534 billion
983110983141983137983156983157983154983141983140 983137983154983156
The companyrsquos sand-gravel-mix
resources are expected to last upwards of
20 years Upon the completion of mining
and once the territory has been rehabili-
tated the quarry will be transformed into
an artificial lake for recreation and fishing
for the residents of the City of Maykop
More info
Alexey Shevyakhov
Tel +7 495 915 29 30
alexeyshevyakhovmetsocom
LOCATION City of Maykop Republic of
Adygea southern Russia
RAW MATERIAL hard rock sand-gravel mixhardness 40 kN
CAPACITY 250 th with increase up to 550
th in 2012
RESOURCES over 10 million cubic meters
END PRODUCTS Washed building sand 0ndash5
mm and crushed aggregates 5ndash10 mm
10ndash20 mm 5ndash20 mm 20ndash40 mm
ON-SITE MЕTSО EQUIPMENT
bull 1 Lokotrack LT106 jaw plant
bull 1 Lokotrack LT200HP cone plantbull 1 Lokotrack ST35 mobile screen
bull 1 Nordberg CVB 2060-4 inclined
screen
bull 1 Nordberg SF2870 sand trap
EQUIPMENT BEING INSTALLED WITH
COMMISSIONING IN 2ND QUARTER OF 2012
bull 1 Nordberg C80 jaw crusherbull 2 Nordberg HP4 cone crushers
bull 2 Nordberg CVB2060-4 inclined
screens
bull 1 Nordberg SF2360 sand trap
bull 1 Nordberg SF2870 sand trap
Maykop quarry owned by the Maykop Nerud Company
and tunnels Essentially the entire infra-
structure within and around the 110-km-
long Sochi will be renewed
More than 155000 workers are involved
in the construction projects In total more
than 300000 cubic meters of concrete
will be used for shotcreting and for the
solid cladding of the tunnels A consider-
able proportion of that concrete will be
prepared using the aggregates and sand of
Maykop Nerud
The company Severstroy is producing
concrete elements for lining 23 kilometers
of various tunnels All of the washed aggre-
gates and sand for those projects is also
being supplied by Maykop Nerud
Metsorsquos sand trap is a critical component of the washing complex
In August 2011 construction of the new ice stadium in Olympic Park was at full speed
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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155
The new Metso C120 jaw crusher combines effi ciency versatility and safety
Metsorsquos new C120 jaw crusher made its worldwide debut at the Steinexpo exhibition in Germany
New products
Metso is proud to announce that we have developed the first fully
recyclable modular screening media ndash Metso Trellex LS-Eco
In response to customer requests for sustainable and environ-
mentally friendly screening media solutions and in line with our
own sustainability program we have taken the acclaimed Metso Trellex LS rubber modular screening media systems and success-
fully replaced the traditional steel reinforcement with an environ-
mentally friendly composite material This unique solution makes it
possible to effectively recycle our customersrsquo screening media
In the past screening media modules that were no longer
suitable for production were treated as waste and could not be
recycled Metso has introduced a new future for the product and a
sustainable solution
Sustainable solution for screening media
Metso has launched the
first fully recyclable
modular screening
media ndash Metso
Trellex LS-Eco
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Metsorsquos Mining and Construction Technology has introduced the
Metso C120 jaw crusher ndash the 13th member of the field-proven
C-series range of crushers The C120 combines uncompromising
reliability crushing effi ciency and versatility in both stationary and
mobile applications with safety and ease of use
Even at first glance it is clear that Metso has paid special atten-
tion to the C120rsquos new durable and user-friendly design start-
ing with the casting the design of which is based on thorough
FEA analysis and casting simulations Every detail of the C120 is
engineered for reliable operation and long life resulting in high
constant crushing capacity and uptime
ldquoWhen starting the C120 project we listened closely to our cus-
tomers and collected field data from a number of sites Based onthat information we decided to design the crusher cavity and kin-
ematics first As a result Metso can now offer aggregates produc-
ers large-scale contractors and mining companies a new crusher
that meets all the standards set for any demanding applicationrdquo
says Ilkka Somero Metsorsquos Product Manager for jaw crushers
New design brings outstanding productivity
The outstanding productivity of the C120 is guaranteed thanks
to several new design elements The crusher features a long and
aggressively directed stroke and a fixed jaw die longer than previ-
ously seen in this crusher size class The C120 has a large feed
opening of 1200 x 870 mm (34 x 47rsquorsquo) and an aggressive cavity cross
section securing a high per formance and reduction ratioIn terms of cavity volume and crusher weight the C120 is posi-
tioned between the existing Metso C116 and C125 jaw crusher
models
The Metso C120rsquos nominal power is 160 kW (200 HP) operating
speed 230 rpm closed side setting between 70 ndash 200 mm (2 34rsquorsquo
ndash 8rsquorsquo) The operational weight is 26000 kg (57200 lbs) excluding
options
More infoIlkka Somero
Tel + 358 50 317 0769
Ilkkasomerometsocom
The optional robust composite 1047298ywheel guards allow quick and safe
access to the service points
983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156
In addition to providing environmentally friendly screening
media panels Metso will implement a unique program to provide
its customers with a suitable range of recycling services
The Metso Trellex LS-Eco offers a wide range of health safety
and environmental benefits Each screening media panel is up to40 lighter than standard steel reinforced Trellex LS panels This
makes handling easier and the working environment safer Lighter
panels also help to reduce the overall stress on the entire screening
installation
Compared to steel-reinforced panels the composite-reinforced
panels of the Metso Trellex LS-Eco are more 1047298exible and will reduce
the effects of pegging and blinding during screening operations
The Metso Trellex LS-Eco promises reduced downtime and
increased productivity
The Trellex 300LS and Trellex 305LS rubber and polyurethane
panels are already acclaimed worldwide as being among the most
versatile modular screening media solutions They can be attached
to most screening media systems and can handle all types of
screening applications ndash fine and coarse wet and dry In the futurewhen Metso customers need new screening media panels for
their existing system they can choose Metso Trellex LS-Eco and be
assured that their panels will be safely and effectively recycled
More info
Claes Larsson
Tel +46 410 525 73
claeslarssonmetsocom
8202019 Metso Minerals Aggregates 3 2011
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The new Lokotrack LT120 with its world premiere at the Steinexpo
exhibition in Germany combines crushing performance and user-
friendly design in a new revolutionary way For the first time the
same Lokotrack model is now available in a hydraulically or electri-
cally driven version to meet customer needs
New Lokotrack LT120 jaw plant introduced
Lokotrack LT120 is the latest and most advanced of Metsorsquos track-mounted jaw crusher plants
Lokotrack LT120 combines user-friendly design and good crushing
performance in a new way
power supply or a 420-kV onboard diesel generator Having the
possibility to use an external power supply enables a highly eco-
nomical and ecological crushing process
The Lokotrack LT120 is built around the new C120 jaw crusher
See page 10 for information about the C120
Safe to use move and service
Safety is the highest priority for Metso when designing new equip-ment The Lokotrack LT120 is designed to be safe to operate move
and service
ldquoA safe operating environment is created by practical solutions
When service points can be reached easily the possibility of dan-
gerous situations diminishesrdquo says Product Manager Timo Nakari
ldquoGood examples of safety built in to the Lokotrack LT120 include
sturdy easy-to-open composite 1047298ywheel guards and hydraulically
folding and locking feed hopper sidesrdquo Nakari adds
The Lokotrack LT120 can be fine-tuned to suit the customerrsquos
application by selecting the required options from a long main
conveyor and hammer and boom to a water spraying system and
rubber lining for the feeder and hopper for example
The Lokotrack LT120 features a Caterpillar C13 310 kW (415 hp)engine Its transport dimensions are length 16 m (52rsquo 6rdquo) width 3 m
(9rsquo10rdquo) height 39 m (12rsquo 10rdquo) and weight 57 tons (114000 lbs) The
LT120E version weighs 63 tons (126000 lbs)
More info
Timo Nakari
Tel + 358 40 701 6143
timonakarimetsocom
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The Lokotrack LT120 uses the same field-proven technology
seen in Metsorsquos tracked units for over 26 years Every detail of thenew jaw plant has been thoroughly designed for reliability and
long life The main targets when designing the unit have been
energy effi ciency good performance reliability and product safety
Field tests have demonstrated its good fuel economy and high
crushing capacity
Environment-friendly economy
The Lokotrack LT120 is also available as an electrically driven unit
ndash the Lokotrack LT120E ndash which can take energy from an external
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The TS range of screens is characterized by its innovative design
comprising two technologies combined multi-variable slopes with
a variable elliptical motion This proven range is being comple-
mented with the new TS63 screen
The TS63rsquos unique combination increases both the screenrsquos effi -
ciency and its capacity Material speed is high at the feed end and
slows down at the discharge end
Metso TS series screens offer more space between decks mak-
ing maintenance easier and improving service conditions for the
operators as well as meeting all safety requirements
Metso has recently sold several 25-m2 multi-slope screens for
mining applications such as a TS63 for Ferrostaal in Mauritania andalso for the construction industry for example Holcim in Lynwood
Australia Georyt in Poland Apaxco in Mexico and Newmont in
Peru
More info
Denis Pradon
Tel +33 680 64 39 67
denispradonmetsocom
New TS63 screen ndash the largest three-deck banana screen on the market
The new Metso TS63 banana screen features a 25-m2 screening area
Following the success of the HP4 and HP5 Metso has broadened
the product range with the new HP3 cone crusher This mid-range
cone crusher benefits from 70+ years of experience in crushing
technology while specifically addressing customer requirements
for large capacity ease of operation and a high reduction ratio
The HP3 responds to market demands for increased productionquality reduced maintenance time and low operating costs The
new generation HP models are comparable to their predecessors
but offer increased versatility
The HP3 features the size of an HP200 with the output of an
HP300 The power performance and robustness of the new gen-
eration models allow in certain cases two crushers to be replaced
with just one so investment production and operation costs are
greatly reduced
The HP3 has been tested at two different quarry sites in France
over the past seven months ndash at a gravel pit and a rock quarry
The Metso factory in France began production of the HP3
series in September Several orders have already been received for
secondary and tertiary applications Since 2009 nearly 300 HP newgeneration cone crushers have been commissioned The HP3 mar-
ket will be primarily centered on gravel pit applications (70)
The HP3 has a nominal feed opening of 220 mm (865rsquorsquo) a
motor size of up to 220 kW (300 hp) and a weight of 13280 kg
(29277 lbs)
More info
Carlos Padin
Tel +33 6 0727 2002
carlospadinmetsocomMetso HP3 at a stationary installation in France
HP3 cone ndash another new-generation cone crusher
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
First modular plant to NepalMetso delivered its first modular crushing and screening plant to MS Palchowke Mai Roda Dunga Udyog Limited (PMRD)
in Melamchi Nepal The modular plant solution offers PMRD a fast and effective response to productivity and qualityrequirements
TEXT amp PHOTOS Atoshi Nayak Ghosh
The diversity of operations at a typical con-
struction site involves quick decision-mak-
ing and often a lot of pressure to ensure a
timely execution
High performance guaranteed
Considering todayrsquos volatile market sce-
nario business partners must maintainpace with their customersrsquo ever-changing
requirements Understanding custom-
ersrsquo strategic business needs is of utmost
importance PMRDrsquos plant was commis-
sioned in January 2011 and has logged
about 1200 hours of operation to date
The plant is much more compact than
the traditional skid-mounted plant and
provides space for free movement of utility
equipment within the plant area One of
the key features of the plant is the totally
bolted structure It can be easily disman-
tled into sub-assemblies transported and
re-assembled effortlessly at a new location
which is one of the biggest advantages in
helping to meet new market demand
Due to the use of pre-assembled mod-ules for each crushing station the instal-
lation work on site takes less time thus
decreasing the plantrsquos installation lead time
The plant also includes a foldable conveyor
for maintenance of the cone crushers
Stepping up with Metso
PMRD operates a two-stage plant compris-
ing a C80 jaw crusher an HP200 high-
performance cone crusher and a CVB1845
screen with circular motion MV2 vibra-
tory mechanism for final product recovery
resulting in an aggregate plant of 150 tph
capacity for producing size fractions of 0-40
mm The plant is an example of world-class
craftsmanship and excellent material han-
dling capacityModular and non-welded construction
supported by durable pitman assembly sin-
gle-piece cast steel frame bearing housings
with repairable crusher construction and
the right cavity design results in aggressive
kinematics and high power that best suits
the requirements of the customer
PMRD has immense pride in the plant
ldquoThe performance has been astounding
A drawing of typical modular plant
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with applications ranging from road aggre-
gates commercial sand production to
ready-mix concretes The modular plant is
almost set to create a new niche in aggre-
gates processing in Nepalrsquos construction
industry It is one of a kind and we are sur-
prised at the plant rsquos production capacity
It is easy to operate and requires minimalmanpower Our cost per ton has signifi-
cantly gone down and so has the cost of
productionrdquo says Mr Sandeep K Agarwal
Director PMRD
Safety as a key issue
Health safety and environmental solutions
are key concerns for Metso and they are
addressed with the same sense of responsi-
bility as quality productivity and cost-
effi ciency issues Metso is responsible for
conducting operations in an environmen-
tally sound way and offers products and
services that can help customers fulfill their
environmental responsibilities
Metso provides the plant offi ce and site
with operation and maintenance manu-als for each and every piece of equipment
including safety issues which are entrusted
to all the operators
All conveyors are equipped with pull-
cord safety switches along with emergency
stop buttons The working area and walk-
ways are all equipped with safety hand rails
and checkered plates for anti-skidding The
entire plant is equipped with earth pits for
electrical current earth leakage prevention
Metso has ensured all possible measures
to maintain high safety standards for all
operation and maintenance personnel
More info
Suhen Agarwal
Tel +91 124 2351566suhenagarwalmetsocom
Nepalrsquos first modularcrushing and screening plant deliv ered by Metso
E ffi cien t C VB1845 inclined screen wi th
an M V2 vibra tor y mechanism handles
the classi fica tion o f crushed ma terials
A s turd y f eeder dis tribu tes the ma terials to be crushed to
a
Me tso C80 ja w crusher
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Outokumpursquos Kemi
mine set to doubleproduction The only mine unit owned by Outokumpu
the chrome mine in Kemi northern Finland
is busy making preparations to double its
production set to begin next year In co-
operation with Metso Outokumpu willincrease the number of underground
feeders and optimize the durabil-
ity of wear parts in the massive
primary gyratory crusher
TEXT amp PHOTOS Eero Haumlmaumllaumlinen
Chrome ore is fed into Metsorsquos
Superiorreg 50-65 primary
gyratory crusher by three
different vibrating feeders
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983122983141983152983151983154983156983145983150983143 983154983141983155
Up until now the entire production of the
chrome mine totaling about 13 million
tons annually has been transported to the
Tornio ferrochrome plant for processing
and on to the Tornio stainless steel plant
The increase in production which will
begin in autumn 2012 is intended also to
enable Outokumpu to sell ferrochrome tocompanies outside the Group The produc-
tion target for 2013 is 27 million tons of
ore and of the ferrochrome produced from
the ore nearly a half (gt 200000 tons) is to
be sold outside
Underground expansion
work almost complete
About 500 meters underground the
majority of the work involved in increasing
the capacity the F3 project has already
been completed Doubling the production
is no problem for the Superiorreg primarygyratory crusher delivered to the mine
by Metso in 2002 which can digest more
than 2700 tons of feed material per hour if
necessary
At the moment the primary gyratory
crusher can be fed by three different vibrat-
ing feeders The crusher currently runs for
less than one-fifth of the production time
The increase in ore production will increase
the effective crushing time to about one-
third of the production time
A lot of work has been done for orestorage after the primary crusher The
two currently used storage silos are now
accompanied by two new 8000-ton silos
The number of Metso feeders transporting
the ore from the primary crusher has also
been doubled
Optimization of wear parts under way
Chrome ore has been a challenge to the
primary gyratory crusherrsquos wear parts The
wear is contributed to by the pulsating
feed which rarely fills the entire crushing
chamber There are also great differences inore type since brittle feed material prone
to chalking is occasionally replaced by hard
ore that requires a lot of crushing power
before it is crushed with a bang gt
Mika Saari (right) Foreman of ore line technicians at Outokumpursquos chrome mine in conversation with
Mikko Malkamaumlki Metsorsquos crusher wear parts specialist
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
last did in July for the replacement of the
crusherrsquos wear parts Our work is also facili-
tated by product development like the
addition of maintenance hatches to the
feedersrdquo he continues
Lasting technology
According to Mika Saarirsquos calculations the
Superiorreg primary gyratory crusher has so
far crushed more than six million tons of
ore in totalldquoThe factory polishing marks still show
on the bottom thrust bearing so we
believe that the bearing will last the entire
remaining service life of the crusher which
is about ten years and 30 million tons
Metsorsquos feeders have been equally reliablerdquo
Saari says
After the next 30 million tons of ore
it will be time to deepen the mine
More info
Jukka Raumlisaumlnen
Tel +358 50 317 1787 jukkaraisanenmetsocom
Mikko Malkamaumlki
Tel + 358 40 827 8223
mikkomalkamakimetsocom
The Kemi mine and Metso are currently
carrying out a development project to
increase the service life of the mantle and
outer concave and thus minimize down-
time due to replacement While the modu-
lar feed hopper enables quick replacement
of the mantle replacing the outer concave
can easily take more than a week The cooperation between the Kemi
mine and Metsorsquos wear parts team in
Tampere aims to extend the service life
of the parts to at least 4 million crushed
tons Durability is sought by optimizing the
chamber structure and selecting the r ight
materials for the outer concave
ldquoSmooth cooperationrdquo
Mika Saari Foreman of ore line technicians
working in the underground mainte-
nance of the Kemi mine leads a small but
experienced team of technicians The tidymodern offi ce spaces are located close to
the action at a depth of 500 meters
ldquoCooperation with Metso has been
smooth Increasing our own crushing
expertise takes time so all know-how
shared by the manufacturer is very wel-
come to usrdquo Mika Saari says
ldquoWe can also use Metsorsquos profession-
als for servicing when necessary like we
The Superiorreg 50-65 has provided reliable
crushing performance at a depth of 500 metres
in the Kemi chrome mine
Technicians Sari Kulju (left) and Marko Jaako ensure that the primary gyratory crusherrsquos hydraulicand electrical unit remains very tidy which contributes to trouble-free operation of the crusher
Outokumpu Oyrsquos Kemi
chrome mine
LOCATION Keminmaa northern
Finland
ORE TYPE chrome oxide (26)
ORE ESTIMATE ON 1 JANUARY 2011
ndash ore reserves 36 million tons
ndash mineral resources 87 million
tons
MINING METHOD bench and cut fillFEED MATERIAL SIZE 0ndash1000 mm
METSO EQUIPMENT IN THE MINE
bull 1 Superiorreg 50-65 primary
gyratory crusher
ndash open side setting 152 cm (6rdquo)
bull 8 VMOU 25-125 feeders
bull 1 VMOU 30-16 feeder
bull 1 VMOU 40125 feeder
bull 2 Symons cone crushers
bull 1 C80 jaw crusher
bull 4 HM75 pumps
bull 11HM100 pumps
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983122983141983152983151983154983156983145983150983143 983154983141983155
Metso was responsible for the design
development and construction of the
entire secondary and tertiary arrangement
The primary station will be the subject of a
subsequent investment
Latest environmental protection used
This installation has been designed in strict
compliance with the environmental quality
approach developed by Metso and its
partners using the latest technologies
in dust control including confinement
technology as well as dust encapsulation
technology for screens
To ensure an annual capacity of 15 mil-lion tons for a nominal output of 560th of
02 mm and 220 mm the clientrsquos choice
for the secondary stage naturally fell upon
the NP 1520 impact crusher
A complete impact crusher solution for Lafarge The Lafarge Group has entrusted Metso with the implementation of its new aggregates installation in southern France
It comprises a new secondary crushing stage equipped with an NP1520 impact crusher featuring a power range of2 x 250kW and equipped with hydraulic adjustment
TEXT amp PHOTO Gilles Dombey
The NP 1520 crusher has long proved
its performance not only in terms of capac-
ity and reduction rate but also quality of
the finished product and durability
More info
Arnaud Bertucat
Tel +33 (0)6 81 44 68 26
arnaudbertucatmetsocom
About 15 million tons of aggregates feed will be crushed with the NP1520 impact crusher at Lafargersquos stationary installation in southern France
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Multi-stage Lokotrack process a success in Senegal
A multi-stage crushing and screening process has proven its effi ciency in the production of concrete aggregates in
Senegal Western Africa With the mobile process Xewell Cimenteries SA now exploits its quarry better has reduced
its operating costs and can meet strict environmental requirements
TEXT Elisabetta Cataluffi PHOTOS Carlo Rinolfi
Senegal is a rapidly developing country
offering a good deal of potential activities
for crushing companies too At the sametime the country has several areas of high
environmental value Therefore contractors
must opt for state-of-the-art equipment that
offers reduced environmental emissions
The company Xewell Cimenteries SA
was founded in 2008 as a partnership
between Italian Swiss and Senegalesecontractors Xewell operates a limestone
quarry located in the Pout area east of the
capital city of Dakar
According to Alessandro Crestani Technical
Director of the Pout quarry a mobile process
was selected to better exploit the quarry and
reduce costsLokotrack process drawing made by Bruno simulation software
After assembling the Lokotrack units the process was tested by Xewell Cimenteries
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983122983141983152983151983154983156983145983150983143 983154983141983155
Owned by Freeport-McMoRan Copper amp
Gold (51) and CODELCO (49) the ElAbra mine has leachable oxide and sulfide
mineralization The minersquos processing facil-
ity has an annual capacity of 226000 tons
of copper cathode
Smaller size matters
Reducing the size of the crushed oxide
ore from the present 15 mm to 12 mm
was the main target of the mine and the
Metso team The changes that were carried
out in the process included a size varia-
tion change in the cut of the tertiary sieve
installation of rate-level sensors in thesecondary crushers and enabling speed
variables in the conveyor belt feeders of
the secondary crushing circuit
ldquoGoing from 15mm to 12mm may seem
small but the operational impact is very
important and significant for usrdquo explains
Juan Torres Carvajal Metallurgical Engi-
neer at the El Abra mine
ldquoOur goal is to reach 115000 tons with
a minimum of 80 of 12-mm-sized ore permonth The record to date is 105000 tons
and we will increase it until we reach our
project goalrdquo he adds
New design for cone liners
In addition to the work mentioned above
Metso is currently carrying out a project to
design the lining profiles for the secondary
and tertiary crushers of the plant which
will affect the smaller size of the material
In cooperation with Nelson Mella from
Metso and Rodolfo Navarro Crushing
Superintendent at the El Abra mine testswere carried out in July on the re-designed
Metso linings One set was tested for sec-
ondary crushing and two sets for tertiary
crushing
More info
Nelson Mella
Tel +56 99158 0576
nelsonmellametsocom
Finer ore through wear pro1047297lestudy at El Abra mine in ChileEl Abra is a porphyry copper open-pit mine and processing facility located in
Chile near the city of Calama some 4000 meters above sea level With the helpof Metsorsquos technical support the mine was able to achieve finer ore throughoutthe crushing process
TEXT amp PHOTOS Macarena Vallejo
Xewell Cimenteries produces a selec-
tion of dry processed aggregates for con-
crete Operations started at the end of 2009
with the aim of reaching 150000 metric
tons produced per year
Lokotracks chosen to reduce costs
To build up their tracked mobile processXewell Cimenteries decided to buy three
mobile plants from Metso two impactor
plants the Lokotrack LT1110 and LT1213
feeding a three-deck mobile screen the
ST620 The machines were sold by SCAI
SpA Metsorsquos Lokotrack distributor in Italy
ldquoWe chose tracked machines to bet-
ter exploit our quarry and to reduce
costs Mobile plants have low initial costs
because they donrsquot need any special foun-
dations or supply of electricity This obvi-
ously gives us a quicker process set-up and
better uptimerdquo says Alessandro Crestani Technical Director of the Pout quarry
ldquoThe mobile plant can also follow the
quarry face as the exploitation proceeds
reducing the transport costs of raw materi-
als in the same jobsite We chose Metso
because they ensured us the best cost-per-
ton ratiordquo he adds
Good customer service is crucial
According to Alessandro Crestani good
customer service also played a major role
when choosing the manufacturer of the
mobile equipmentldquoMetsorsquos distributor SCAI SpA was able
to provide us with a complete product
support and customer service package
Obviously service is a very important
aspect for us in a country like Senegal Any
downtime represents a clear loss of pro-
ductivity for usrdquo
The average level of productivity of the
mobile Lokotrack process is 200 metric
tons per hour
More info
Carlo Rinolfi Tel +39 335 1253159
crinolfiscaispacom
Example of the development of the Metso study
on the crusher lining profiles
Liner change for smaller ore size in the
MP1000 cone crusher
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Services success in Surabaya The Metso Surabaya workshop and offi ce complex opened in April 2008 provides Life Cycle Services and maintenance
solutions for Metso equipment in the Indonesia region The facility is strategically located in an industrial precinct on theouter rim of Surabaya the second largest city in Indonesia Its close proximity to an international airport major shipping
port and several engineering companies simplifies support for the regionrsquos key customers which include PT Newmont
and PT Freeport
TEXT amp PHOTOS David LeRoy amp Gary Whittred
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983122983141983152983151983154983156983145983150983143 983154983141983155
The Surabaya site operates through Metso
in Australia with assistance from key sales
and technical staff Handling regional ser-vice and repair business in-house allows
Metso to manage intellectual property and
closely control quality
It also enables the development of a
team of skilled service personnel who can
be utilized both internally and at key cus-
tomer sites as is common with the backup
service the workshop provides for screen
contracts
Innovation at work
Since 2008 the Surabaya facility has suc-
cessfully refurbished a wide variety ofcomponents Recently two ball mill heads
weighing 22 tons each were modified in
order to strengthen the 1047298ange of the ball
mill shell The modification included tap-
ping out existing 1047298ange holes and drilling
new ones so that finger plates could be
installed and welded to the 1047298anges
Positioning the head borer to properly
align the new 1047298ange holes proved diffi cult
Four roller support frames were manufac-
tured to support the heads and allow them
to be rotated easily Each hole was then
drilled and tapped at the correct angleusing the CNC five axis head The job had a
tight delivery as it was required for a shut-
down but with advance planning and inno-
vation it was completed ahead of schedule
MP1000 mainframe on
CNC vertical borer
Well equipped for fabricating and machin-
ing heavy components the Surabaya
The Surabaya facility has proven to be
a success for Metso The workshop offers a
wide variety of services in the region Qual-ity products and competitive pricing and
delivery times have led to strong customer
relationships
Turnover and customer service levels
have increased annually since the open-
ing and between 2008 and 2010 sales
increased 450 These excellent trends
are expected to continue as the operation
expands and the customer base grows
Since 2008 the Surabaya facility has
successfully refurbished
bull MP1000 counter shaft boxes headassemblies mainframes bowls adjust-
ment rings counterweights sockets and
tramp release cylinders
bull 7rsquo Symons bowls heads and countershaft
boxes
bull Vertimill screw and drive shafts
bull Ball mill heads
bull Ball mill trommel
bull VPA cylinders
bull Eaton clutches
bull Exciter screen mechanisms
bull 42x65 main shafts and eccentrics
More info
Gary Whittred
Tel +62 31 8430349
garywhittredmetsocom
workshop handles the majority of Metsorsquos
refurbishment work with ease But when
necessary PT PAL ndash a government facilitywith shipbuilding and heavy engineering
capabilities ndash offers a ldquoone stop shoprdquo Spe-
cially trained PT PAL staff ensures that the
work they perform complies with all Metso
specifications and quality standards
PT PAL also demonstrated their innova-
tive ability with the first MP1000 main-
frame refurbishment they completed The
mainframersquos shaft location bore needed
to be re-machined However the distance
from the top of the mainframe to the
tapered bore made it very hard to achieve
an accurate surface finish with the correctstandoff
To overcome this the shop decided to
machine the mainframe upside down and
elevated on support beams They posi-
tioned a new shaft under the mainframe in
a custom-made cradle Using an overhead
crane they could then lsquotrial fitrsquo the shaft in
the bore to make sure it seated correctly
and the mating tapers met specification
The method worked so well it has since
been used for four more mainframe refur-
bishments
Diversity and growth
Today Metso Surabaya continues to invest
in additional equipment in order to diver-
sify its service offering A new hydraulic
power pack which allows the facility to test
refurbished components to Metso specifi-
cations was recently used in the refurbish-
ment and testing of several VPA cylinders
for PT Freeport
Refurbished MP1000 mainframe dispatched by truck to
PT Freeport mine
Machining of MP1000 upper frame
at Metsorsquos Surabaya workshop
Mainframe at vertical CNC machining
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Creating Value with Metso in Hong KongIn Hong Kong the aggregates needed for construction are mostly supplied by two local quarries KWP Quarry Company
Limitedrsquos Anderson Road Quarry accounts for 60ndash70 making it the pillar of Hong Kongrsquos construction materials industry
TEXT amp PHOTOS Ou He
When arriving at the Anderson Road
Quarry the most impressive view at the850000 square-meter facility is the Metso
machines including equipment from the
primary secondary and tertiary crushing
circuits and the screens I t is Metsorsquos equip-
ment that secures the supply of aggregates
for Hong Kong
KWP Quarry Company Limited has been
working with Metso since its establishment
in 1997
Due to Hong Kongrsquos stringent dust and noise control standards Metso has paid special attention to the related suppression systems
ldquoOur quarry mainly lies on granite and
volcanic rock which are so hard they canonly be processed by equipment with
strong durability and stabilityrdquo explains
Mr Eddie Hung Manager of KWP ldquoWith a
long history of and experience in quarry-
ing we are very familiar with the equip-
ment of different brands Comparatively
Metsorsquos products are better than others in
terms of durability stability and effi ciency
Besides this the reason we selected Metso
is because of the simple maintenance of
their equipment and the easy access tomaintenance informationrdquo
Flexible modular solution
Based on extensive experience in crushing
and screening worldwide Metso presented
the Anderson Road Quarry with a modu-
lar solution and delivered it as a turn-key
project Through a four-stage crushing
circuit which contains three Metso C160
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jaw crushers for primary crushing two
Omnicone 1560SX crushers for secondary
crushing two HP 500SX cone crushers for
tertiary crushing and one HP500SX cone
crusher for extra-fine crushing the plant
was able to produce aggregates of optimal
shape with minimal 1047298akiness
The fine products include three sizes
0 to 5 mm 5 to 10 mm and 10 to 20mm
Since the employment of this system in
2000 production has reached 1250 th
which is far beyond the design capacityAccording to Mr Hung ldquoThe machines
always run effi ciently and seldom malfunc-
tion The occasional shutdown of some
machines does not affect production very
much the plant still could reach 60-70
of its normal production It gives us the
best 1047298exibility for the plant rsquos operation and
I believe this is the best feature of Metsorsquos
solution
Eddie Hung
Manager of KWPrsquos
Anderson Road
Quarry is happy with
the product quality
and service provided
by Metso
ldquoMetsorsquos equipment is expensive com-
paratively but in the long run you will find
that the investment is worthwhile on the
whole Metso secures superior stability reli-
ability and fewer downtimes and it guaran-
tees continuous operation and brings us
greater valuerdquo
Great service team
Metso sent a group of service engineers
to the plant within the warranty period
not only to provide service but to train theoperators Mr Hung speaks highly of Met-
sorsquos service team he is impressed with its
experienced experts and with their strong
sense of responsibility and customer-
oriented ways of working
ldquoMetsorsquos service team never fails to find
hidden problems and helps us to prevent
any mechanical failures And they are
available whenever we need them they
work closely with us to solve the problem
effi cientlyrdquo he said
Excellent environment-friendly designIn order to achieve the worldrsquos most strin-
gent noise and dust control standards
developed by the Environment Protection
Department of Hong Kong Metso has
incorporated a dust and noise suppression
system into the plant This includes the
infrared-triggered spray systems at feed
points encapsulation of individual crush-
ers and conveyors and the ability to select
specific sectors of the system for treatment
depending on feed and operating condi-
tions encapsulation of equipment and the
enclosure of all major sections of the plant
With these advanced environment-
friendly solutions Anderson Road Quarry
has won numerous safety and environmen-
tal awards In 2003 it was presented with a
silver medal in the prestigious Environmen-
tal Performance Awards in recognition of
its commitment to the environment and
community In 2004 KWP achieved certifi-cation of ISO 14001 it is the first quarry site
to have achieved this in Hong Kong and
southern China
ldquoA reliable partnerrdquo
The promulgation of the top ten infrastruc-
ture policies in Hong Kong boosted the
market for aggregates and demand will
keep rising over the next five to six years
ldquoWersquoll definitely keep our cooperation with
Metso once we have a need for expansion
because we regard Metso as a reliable part-
ner With their highly effi cient equipmentsatisfying service and great efforts in help-
ing us to achieve our environmental pro-
tection targets Metso is our best choicerdquo
says Hung
More info
Ziqiang Li
Tel +86 13601289027
ziqianglimetsocom
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The sturdy Metso C160
jaw crushers are fed
using huge feed chutes
and feeders
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983122983141983152983151983154983156983145983150983143 983154983141983155
Similar to hundreds of mine sites world-
wide Zinkgruvan is being operated on a
non-stop 247 basis with just a few main-
tenance breaks during the year Crusher
availability is crucial because 100 of the
ore has to pass through the jaws before
being hoisted up for further processing
In addition to the zinc- lead- copper-
and silver-containing ore the C jaws chop
all the host rock extracted along the min-
ing process With a sturdy design Metsorsquos
proven C jaws can easily reduce even the
hardest type of rock Every year more thanone million tons are crushed with the jaws
ldquoMinimal service neededrdquo
Crushing with the first C160B jaw crusher
began at Zinkgruvanrsquos -800 meter level in
2000 with the primary crushing of zinc-lead
ore The second jaw was installed in 2008
for the new copper process gt
The sight and sound of two C160 jaw crushers operating side by side in the underground
crushing station of the Swedish Zinkgruvan mine is impressive Good proactive service
secures good uptime and reliable continuous operation of Metsorsquos second-largest
C160 series jaw crushers and prepares the way for the ongoing plans to expand the
production of zinc concentrate
TEXT amp PHOTOS Eero Haumlmaumllaumlinen
New PolyMet liners are being tested with the grinding mill delivered by Metso
Zinkgruvanrsquos twin C160
jaws secure good uptime
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Blasted ore is taken from the presently
operated -850 meter level with normal
trucks as an outsourced process One full
truckload is fed to the C160s every
10 minutes
ldquoWe are happy with the high reliability
of the C jaws They only require some minor
service therefore providing us with good
uptime and steady continuous feed to our
secondary and tertiary crushing and grind-ing circuitsrdquo says Mine Manager Jan Klaumlre
ldquoBasic crusher service and wear part
changes are made by our own staff using
Metsorsquos partsrdquo he adds
Service contract with grinding
mills and conveyors
Zinkgruvan and Metso Sweden have more
than 11 yearsrsquo experience with a service
contract that contains grinding mills and
conveyors At the mine site two Metso
service people and one contractor take
care of all the related service jobs Man-
power can also be borrowed from Metsorsquos
Graumlngesberg mine service team of 20
people
Presently Zinkgruvan is testing Metsorsquos
new PolyMet mill linings in its big grinding
mills With previously used rubber partsthe linings had to be changed in the shell
every 9 to 11 months and in the feed head
every 6 months
ldquoWe expect a better lifetime with Poly-
Met linings Longer change intervals mean
a lot to our productivity because lining
changes takes two full working daysrdquo Mine
Manager Jan Klaumlre says
New mine goes deeper
With an expected mine life of more than 10
years Zinkgruvan is actively mapping new
ore reserves Experimental holes are being
drilled at the new mine section at the
-1110 meter level
More info
Fredrik Wennberg
Tel +46 70 657 00 08fredrikwennbergmetsocom
Mine Manager Jan Klaumlre (left) with Backfilling Manager Kjell Tillman at the underground -800 meter level mine cafeteria
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The Zinkgruvan mine located approxi-
mately 200 km southwest of Stockholm
Sweden is one of the oldest underground
mines in Northern Europe The mine has
been in production since 1857
The mining methods used are panel
stoping and benching The processing
facilities include a zinc concentrating plant
with a 11 mtpa and a copper plant with a04 mtpa capacity Tailings are recycled in
an impounding basin and host rock in the
backfill plant
Continuous mining since 1857
Even as one of the oldest mines in Northern
Europe Zinkgruvan exploits modern mining
and minerals processing installations
Zinkgruvan mine
OWNER Lundin Mining
PRODUCTION PER YEAR 1 million tons
ORE TYPE sedimentary exhalative
zinc lead copper and silver
NUMBER OF EMPLOYEES 320
2011 PRODUCTION TARGETS 78000 tonsof zinc 36000 tons of lead and
3400 tons of copper concentrate
METSO EQUIPMENT ON SITE
bull 1 extra long VF feeder
bull 2 C160 jaw crushers
ndash zinc process css 220ndash240 mm
ndash copper process css 150 mm
bull 1 GP300S cone crusher
ndash css 45mm
bull 1 HP4 cone crusher
ndash css 18 mm
bull 1 DS screen
bull 1 FS402 screenbull 1 grinding mill
bull Pumps VPAs
A normal truck feeds the C jaws with ore coming from the lower production levels
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Cost-per-ton wear agreements deepencustomer relationshipsCrusher wear parts are traditionally marketed purely based on transactional sales and mainly depend on
the weight of manganese Metso has recently introduced a new type of wear agreement based on thecost-per-ton crushed and the wear occurred Thus far the experience has been very positive increasing
transparency and deepening the operational relationship between the manufacturer and the customer
TEXT Olli Kellokumpu and Eero Haumlmaumllaumlinen PHOTOS Eero Haumlmaumllaumlinen
Arto Hiedanniemi (left)
Hannu Heman and Juha
Laukka of Metsorsquos Finnish
Service team checking the
cone crusher mantles shipped
for a cost-per-ton customer
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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156
Wear parts and parts changes
can be included
The structure of a cost-per-ton wearcontract is based on the number of tons
crushed and the estimated wear occurred
The amount and monetary value of the
wear is calculated per crushed ton
ldquoEither plain wear parts or parts changes
carried out by Metsorsquos service personnel
can be included in the contract In the latter
case we ask our Finnish customers to inform
us about an upcoming wear change opera-
tion one week in advancerdquo Heman explains
ldquoWe see good opportunities to market
cost-per-ton contracts further in Finland
and also abroad It really develops therelationship of Metso and our customers
towards a trusted partnershiprdquo he notes
Perfect tool for accurate planning
Soraliike Ikola Oy is a mid-sized contrac-
tor with three Metso two- and three-
stage mobile and portable crushing and
screening plants operating in Central and
Since 2002 Metsorsquos sales team in Finland
has developed the cost-per-ton-based
service offeringldquoOur aim has been to seek through
a cost-per-ton offering possibilities to
serve our customers better to differentiate
Metso from the other players as an OEM
manufacturer and to offer deeper profes-
sionalism and know-howrdquo says Hannu
Heman General Manager of service
operations
ldquoUntil now both our experience and
that of our customers has been quite posi-
tive When properly prepared cost-per-ton
contracts seem to create a win-win situa-
tionrdquo Heman adds Today Metso has operational cost-per-
ton agreements with several Finnish cus-
tomers The first contract was concluded
with a customer operating a stationary
plant Based on the results gathered new
cost-per-ton contracts have been signed
with customers operating wheeled and
tracked equipment too
Eastern Finland Because of the size of the
contracts up to 50 equipment moves are
made during the yearEntrepreneur Pasi Ikola has had a cost-
per-ton contract with Metso for nearly
two years and he is quite happy with the
outcome
ldquoThe cost-per-ton contract has provided
me with a perfect tool for accurate financial
planning Now I know in detail my actual
future wear parts costs This helps a lot
when calculating bidsrdquo
ldquoEarlier I used to buy a big batch of
Metso wear parts in one go and had to
reserve a reasonable amount of money for
that Today all wear costs are evenly sharedwhich gives us a welcomed 1047298exibility to
our cost structure Now we just pay Metso
afterwards based on our crushed tonsrdquo
he adds
More info
Olli Kellokumpu
Tel +358 50 354 1189
ollikellokumpumetsocom
According to crushing contractor Pasi Ikola the cost-per-ton contract with Metso has provided the entrepreneur with better economical 1047298exibility
and more accurate calculating of bids
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Pleasant Gap is owned and operated by
Glenn O Hawbaker Inc of State College
Pennsylvania This family-owned company
began in 1952 as a small excavation busi-
ness founded by Glenn O Hawbaker and
his wife Thelma Over the years the com-
pany grew by adding an integrated mix ofproducts and services and taking on larger
projects
In 1983 Hawbaker acquired Pleasant
Gap Quarry and built its first aggregates
processing plant Today Glenn O Haw-
baker Inc operates 21 quarries and eight
asphalt production facilities across Penn-
sylvania and southern New York as well as
five regional operation centers
Primary
challenge atPleasant GapQuarryA good part of what makes for a successful crushing
operation is the willingness to tackle challenges and to do
whatrsquos necessary to meet demand The team at Pleasant
Gap Quarry in central Pennsylvania recently met the chal-
lenge when they successfully addressed problems with
the plantrsquos primary crushing plant First they purchased
a new Metso C160 jaw to replace the existing primary
impact crusher Then they devised an innovative plan to
get the primary plant back in operation while awaitingdelivery of the new jaw crusher
TEXT Linda Bergmann PHOTOS John Rickinger
983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Time for a change
With the goal of increasing reliability and
output the management at Pleasant Gap
Quarry recently decided it was time to
replace the plantrsquos primary impact crusher
Following a thorough search they chose a
new Metso C160 jaw According to ScottReck Plant Manager it no longer made
sense to repair and rebuild the existing
impactor
ldquoBefore we purchased the Metso C160
we had a few other impact crushers and
they served us well but as our custom-
ersrsquo needs increased our plant production
had to match that demand We found our
formerly reliable unit was being overcome
by our demands for output and creative
work-around solutions We continued to
need more but there was only so much we
could do until we hit the breaking point ndash
literallyrdquo
In addition to performance improve-
ments the new crusher also needed to fitinto Pleasant Gaprsquos unique infrastructure
As Plant Project ManagerEngineer Jeremy
Fahr explains ldquoOur height restraint was 274
meters (108rdquo) This height was the distance
from the feed lip of the existing 6x12 scalp-
ing screen and the existing structure that
the crusher rests onrdquo
The normal C160 crusher is 307
meters (121rdquo) tall but Metso gave GOH
Scott Reck Plant Manager (left) and
Jeremy Fahr Plant Project Manager
Engineer at Pleasant Gap Quarry
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983122983141983152983151983154983156983145983150983143 983154983141983155
a 10-degree mounting option (which is
normally used on their portable crushers)
to overcome the height restraint Reck and
Fahr worked with Dave Rhoa of Cleveland
Brothers Equipment Metsorsquos crushing and
screening distributor in Pennsylvania to
pull everything together and fit the newcrusher into their plant
The C160 crusher selected for Pleasant
Gap is one of the latest models in Metsorsquos
C Series of jaws These jaw crushers feature
a large throw and steep toggle plate angle
resulting in a higher crusher output In
addition the C Series has a compact foot-
print that makes it an ideal choice for the
replacement of existing machines
According to Reck ldquoWe had heard about
the new Metso C160 and started doing our
own research and found Metso not only
had developed the output capacity we
needed but fit the uniqueness of our oper-
ationsrdquo The new Metso crusher will allow
the plant to increase tons per hour andgive them the 1047298exibility to meet demands
for varying products on short notice
Mobile solution
Purchasing the new primary jaw addressed
the long-term issues but still left Pleasant
Gap without a functioning primary plant
Reck continues ldquoOur main line was still
down leaving us with a big hole in hitting
customer needs but knowing that our new
Metso C160 was on its wayhellipwe needed an
immediate solution to keep our produc-
tion demands with an out-of-commission
crusherrdquo
The team at Pleasant Gap brainstormed
the problem and came up with a plan toget the primary plant back in operation
Their solution was to use the Lokotrack
LT1213 impactor plant and another mobile
unit to keep the main line crushing To do
this they removed the guts on the existing
impact crusher essentially turning it into a
rock chute They then moved the LT1213
and another manufacturerrsquos mobile unit
over to the existing dump hopper gt
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
ldquoWe had our haul trucks drop off mate-
rial while two excavators fed the two
mobile unitsrdquo Reck explains ldquoFor two-and-
a-half months the Lokotrack LT1213 unit
was producing 254 cm (10rdquo) minus at
700 tons per hour The other similar-sized
mobile unit was doing 400 tons an hour
maxed out The difference was unbeliev-
able to say the least Our unique solution
using the two mobile units especially the
LT1213 helped Glenn O Hawbaker achieve
a record output in 2010rdquoAccording to Fahr ldquoWe were not new to
Metsorsquos quality and supportrdquo because GOH
had been using Metsorsquos portable crushing
equipment for 3 years prior to the primary
plantrsquos impact crusher failure In another
part of our operation we have a system that
our team relies on every day a Lokotrack
LT1213 and ST272 working in tandem with
two portable conveyorsrdquo This highly effi -
cient mobile processing system turns out
300 tons of specialized blended material
per hour GOH has been so impressed with
Metso equipment its last two purchaseswere an LT106 tracked jaw plant and a
second ST272 mobile screen in 2010
Maintaining high productivity
The Metso C160 jaw was delivered to Pleas-
ant Gap Quarry in January of 2011 and
since start-up it has more than met expec-
tations The crusher is fed minus 910 mm
(36rdquo) limestone with the jaw set at 140 mm
(5 12rdquo) According to Reck ldquoFrom moment
we started up we knew we had a winner
Not only were we kicking out as much
product as our previous units without even
breathing hard but we immediately had a
2-cent per ton savings to the bottom line
without having to run a second 350 HP
motor as required by other units Plus by
adding on the new automatic lube system
the maintenance team had more time to
devote to keeping other areas of the com-
plex running more effi cientlyrdquoReck says ldquoThe Metso unit was a perfect
fit and with the improved features it pre-
sented it had it all We just turn it on load
it up and we are moving 600 tons per hour
through the crusher without any effort and
we know it can do so much morerdquo With
the primary crushing plant back in opera-
tion the entire team at Pleasant Gap will
continue to do what they do best produce
and sell high-quality products and meet
their customersrsquo expectations
More info
Scott Yablonsky Tel +1 262 717 793
scottyablonskymetsocom
The Metso C160 jaw
was installed at a 10deg
angle to fit Pleasant
Gaprsquos existing
infrastructure
The Lokotrack LT1213 impactor plant and ST272 mobile screen operate in tandem with two
portable conveyors at Pleasant Gap
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983149983141983156983155983151 983150
Paper amp fiberNew OptiConcept M paper
and board making line
The new OptiConcept M paper and board
making line stands for economy safety and
usability
Metso has launched a new modular paper
and board making line called OptiConceptM A member of the proven OptiConcept
production line family the new OptiCon-
cept M optimizes machine investment in
line with each millrsquos capacity needs
Savings in operating costs are achieved
through precise dimensioning of pro-
cesses proven technological solutions
optimal running parameters effective
maintenance operations and fully inte-
grated automation solutions
Optimized processes innovations
smart controls and accurate dimensioning
decrease the use of steam gas electricitywater chemicals and other raw materials
and reduce emission levels
OptiConcept M has been designed
both visually and physically with the
requirements of users in mind For exam-
ple the design of the machinery allows for
easy and safe changing of rolls and wear
parts thus reducing the total duration and
cost of maintenance shutdowns
RecyclingGreen energy technology to
Elektrociepłownia Białystok in Poland
Metso will convert a coal-fired boiler to
a biomass-fired Bubbling Fluidized Bed
boiler for Elektrociepłownia Białystok SArsquos
combined heat and power plant (CHP) in
Białystok Poland The new boiler system
will cut the power plantrsquos CO2 emissions
significantly by partly replacing the coal
fuel supply with biomass fuel
ldquoPoland is one of the largest countries
in Europe to have such a high depend-ence on energy derived from coal to
meet national electricity needs This is an
important incentive for us to reduce future
CO2 emissions and produce more green
electricity and with Metso technology
we are certain to accomplish our goalrdquo
states Mr Andrzej Schroeder President of
Elektrociepłownia Białystok SA
Since 2000 Metso has received a total
of 7 biomass boiler conversion orders in
Poland and the renewable energy share
in Poland is only 75 (2010) compared to
the target of 20 by 2020 set by the EUApproximately 80 of the current energy
boilers turbines and generators installed in
Polish power plants are over 20 years old In
order to meet the strict EU environmental
requirements modernization of existing
installations is necessary
Automation
Metso DNA automation system expands
to mining and construction
Using Metsorsquos control room automation
an entire crushing and screening plant can
be effi ciently managed
Metso is a leading supplier of mining and
construction machinery This expertise has
now been combined with a scalable Metso
DNA automation system that adapts to
the range of industry needs from single
machine controls to plant-wide automation
and information management systems
An example of Metsorsquos new offering is a
new crushing plant control room solution
that connects crushers and screens ensur-
ing the effective management of the entire
plant from a pleasant and safe control
room The Metso DNA user interface pro-vides the production information to ensure
a proper and rapid response to plant
events Automatic controls stabilize the
process and allow the operators to monitor
the plant as a whole
ldquoThe benefits of automation for the min-
ing and construction industry are signifi-
cant As an example of the services we offer
performance studies to crushing plants
utilizing Metsorsquos multi-disciplinary teams of
experts to determine the present level of
the plant and process effi ciency and to esti-
mate the improvement potential and thebenefits of optimization and automation
including ROI calculationsrdquo says Mikko Maumlki-
nen Product Manager of minerals applica-
tions in Metsorsquos Automation business line
ldquoAs another example our machine
condition monitoring solutions can reduce
plant and machine downtimes as well as
help to avoid safety and environmental
hazardsrdquo he adds
Metso around the world
Aerial view of the Elektrociepłownia Białystok combined heat and power plant in Poland
8202019 Metso Minerals Aggregates 3 2011
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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
8202019 Metso Minerals Aggregates 3 2011
httpslidepdfcomreaderfullmetso-minerals-aggregates-3-2011 236
Joatildeo Ney Colagrossi President
Services Business Line Metsorsquos
Mining and Construction
Technology
983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983089
Helping you grow your businessWe live in a time of uncertainty with considerable volatility in the global economy While certain countries are still
struggling to find ways to achieve economic stability and growth other countries continue to show signs of great
economic activity
Regardless of the economic situation in the countries where our customers operate Metsorsquos Services business
is prepared to provide support in helping customers to achieve their goals and results In struggling markets
we can contribute with our products and services designed to improve operational effi ciency reduce costs and
optimize the use of assets etc For our customers with operations in rising markets we offer services to maximize
production capacity increase plant availability and improve utilization In addition we can offer specialized
manpowerOur goal is to continue expanding our services offering far beyond our traditional offer of wear and spare parts
We are prepared to support our customers worldwide with field services process technology engineering-to-
order life-cycle services and more We also provide extensions of our product portfolio via performance-based
contracts cost-per-ton contracts and equipment protection plans
One outstanding example of a performance-based contract providing mutual benefits (the theme of one
of the articles in this edition) is the case of RCC (Russian Copper Company) Under this contract we committed
to developing our entire service structure in a remote region thereby ensuring the support required for our
customerrsquos success and honoring our motto ldquoWe deliver what we promiserdquo
We are also seeking geographic expansion improving our operations via ldquoServices Hubsrdquo (centers for specialized
services) located near our customers so that we can better adjust our specialized knowledge to their needs
providing agility and quality in aftermarket service
The greatest evidence of the importance of the subject to Metso is that ldquoservicesrdquo stands as a strategic corporate
pillar that helps us to become ndash in addition to the leading provider of services ndash a genuine service companylistening to and understanding the needs of customers so that we can continually improve upon our operations
Over the past two years since the creation of the Services Business Line for the mining and construction
segments we have observed a great evolution in the services area thanks to the commitment of our personnel
and to the mutual learning achieved with our customers Itrsquos a continuous learning process that will lead to
success ndash for Metso and for our customers
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2 Editorial
4 News in brief
6 Sochi Winter Olympics are built on top
quality aggregates
10 New products
14 First modular plant to Nepal
quarrying a reality
16 Outokumpursquos Kemi mine set to
double production
20 Multi-stage Lokotrack process
a success in Senegal
21 Finer ore through wear profile study
at El Abra mine in Chile
22 Services success in Surabaya
24 Creating value with Metso
in Hong Kong
26 Zinkgruvanrsquos twin C160 jaws secure
good uptime
29 A complete impact crusher solution
for Lafarge
30 Cost-per-ton wear agreements deepen
customer relationships
32 Primary challenge at Pleasant Gap
quarry
35 Metso around the world
983152983157983138983148983145983155983144983141983140 983138983161 983149983141983156983155983151 983149983145983150983141983154983137983148983155 983145983150983139
Fabianinkatu 9 A PO Box 1220
FI-00101 Helsinki Finland
tel +358 20 484 100 fax +358 20 484 10
e-mail mineralsinfocsrmetsocom
wwwmetsocomminingandconstruction
Results minerals amp aggregates customer maga-
zine is published 3-4 times a year in English with
Chinese French Portuguese Russian Spanish
and Asia-Pacific insertions To receive your per-
sonal copy please contact your nearest Metso
Minerals offi ce or the e-mail mentioned above
983141983140983145983156983151983154-983145983150-983139983144983145983141983142
Eero Haumlmaumllaumlineneerohamalainenmetsocom
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Linda Bergmann Elisabetta Cataluffi Gilles
Dombey Atoshi Nayak Ghosh Ou He Eero
Haumlmaumllaumlinen Olli Kellokumpu David LeRoy
and Macarena Vallejo
983141983150983143983148983145983155983144 983148983137983150983143983157983137983143983141 983141983140983145983156983145983150983143
Traduct Oy and Kathleen Kuosmanen
983148983137983161-983151983157983156 983137983150983140 983137983154983156 983159983151983154983147
Vanto Design Oy
983152983154983145983150983156983145983150983143
November 2011
copy Copyright 2011 Metso Minerals IncAll rights reserved
Printed on MultiArt Silk 130200 gm2
Cocoon offset 120 gm2
Reproduction permitted quoting
ldquoResults minerals amp aggregatesrdquo as source
All product names used are trademarks
of their respective owners
Addresses Metso Minerals Inc customer data
ISSN 1797-6480
wwwmetsocomminingandconstruction
Printed matter
441 014
COVER PHOTO Washed high-quality sand produced by Maykop Nerud with Metsorsquos stationary
washing plant for the Sochi 2014 Winter Olympics sites in Russia Stanislav Steblyansky shows the
sand for concrete production
In this issue
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983150983141983159983155 983145983150 983138983154983145983141983142
Services for Northland Resources in Sweden
The services supply at Kaunisvaara covers Metso Poly-Met mill
liners liner handlers and essential tools technical assistance including
maintenance and shutdown planning as well as monthly audits and
annual inspection services for the Tapuli grinding mill
The SmartTagtrade system utilizes Radio Frequency Identification (RFID) tags
and detectors to track ores as they 1047298ow from the blast to the downstream
processes and beyond
Metso has signed a contract with Northland Resources AB con-
cerning a five-year mill lining service and inspection program for
the Kaunisvaara project in northern Sweden The contract comple-ments previous project orders by Northland Resources announced
by Metso earlier this year The value of the order is EUR 19 million
The Metso Life-Cycle Services (LCS) program at Kaunisvaara
includes both the supply and installation of mill liners and techni-
cal and maintenance support for the semi-autogenous mill on the
Tapuli process line Metsorsquos on-site resources will also conduct liner
inspections to maximize mill availability The contract period will
commence when installation of the Tapuli process line is com-
pleted at the end of 2012
ldquoWe are pleased to have concluded this contract as it maxi-
mizes the availability of our grinding linerdquo says Shane Williams Vice
President Projects Northland Resources AB ldquoAs this is a cost-per-
ton contract we will be able to forecast expenditure over extendedperiods of time It will be a very useful asset in view of the total
investment involvedrdquo
ldquoWe embrace the opportunity to partner with Northland in a
five-year LCS commitmentrdquo says Joatildeo Ney Colagrossi President
of Services Business Line Metso ldquoThe speed at which operations
at Kaunisvaara are progressing is impressive and we are look-
ing forward to a rewarding working relationship with Northland
Resourcesrdquo
First SmartTagtrade systems for Europe
Somincor Neves-Corvo an underground copper-zinc mining
operation in southern Portugal owned by Lundin Mining hasrecently installed the first Metso SmartTagtrade system in Europe The
SmartTagtrade system was developed by Metso Process Technology
and Innovation (PTI) to track ore andor waste from mines to the
plant using Radio Frequency Identification (RFID) technology The
RFID tags have been designed to withstand blasting handling by
mining equipment and passing through primary and sometimes
secondary crushers
Somincor is using the SmartTagtrade system to track ore and waste
from post-blast muck piles through underground loading hauling
ore passes crushing storage and finally hoisting and conveying to
surface stockpiles The information will be used to better under-
stand and improve ore and waste handling logistics
Knowledge and interest in the Metso SmartTagtrade system isgrowing in Europe Boliden Tara Mines Ltd has also placed an order
for the SmartTagtrade system Tara is an underground zinc mine in
Ireland processing around 26 Mtpa of ore using Metso equipment
such as a C200 jaw crusher and VPA filters and pumps
The main objective of the SmartTagtrade system at this site will
be to track ore being mined from different stopes and headings
as part of their reconciliation process Waste in ore streams can
increase transport and processing costs reduce the head grade
and produce additional waste tailings
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Lokotrack LT116 attracts customers in Thailand
A group photo taken during a demo day at Thassana Cholburi quarry in
Central Thailand
A Vertimillreg vertical grinding mill under construction
983150983141983159983155 983145983150 983138
TISCO to receive minerals processing equipment
Metsorsquos Lokotrack LT116 mobile jaw plant attracted a number of
customers during a recent demo day organized at Thassana Chol-
buri Thailandrsquos biggest quarry
Marketed by Uawithya Machinery Co Metsorsquos tracked crush-
ing concept has been well received in Thailand Recent deliveries
include Lokotracks both for quarrying and mining purposes
The LT116 jaw plant is now being operated by PTK an iron ore
mine situated in Loei Province in northeastern Thailand
Tandem railcar dumper replacement
for Ridley Terminals in Canada
Metso will supply a tandem railcar dumper replacement to Ridley
Terminals Inc for its Ridley Island Coal Terminal in Prince Rupert
British Columbia Canada The value of the order is EUR 85 million
Metsorsquos delivery includes the replacement of two railcar dumpers
in a tandem installation with commissioning services To facilitate
the unloading of both Canadian and US length cars the dumpers
Metso will supply minerals processing equipment to Taigang
Group Lanxian Mining Co Ltd ( TISCO) the largest stainless steel
manufacturer in China The delivery is scheduled for the first
quarter of 2012 The order comprises seven units of vertical plate pressure filters
wear and spare parts as well as services related to installation
start-up commissioning and technical supervision The delivery
is for concentrate filtering for TISCOrsquos Yuanjiacun iron ore process-
ing plant in Lan County Shanxi province The plant is expected to
start operations in May 2012 with a daily processing capacity of
22000ndash23000 tons of iron ore concentrate
The Yuanjiacun plant is designed to process 22 million tons of
raw iron ore per year When completed Yuanjiacun will be the
largest iron ore processing plant in China
TISCO is among the worldrsquos largest producers of stainless steel
In 2010 the companyrsquos net sales were EUR 117 billion
Stronger services in the North American mining sector
Metso has acquired the service business assets of Copperstate
Industrial Services Inc a mining services provider based in Phoenix
Arizona The acquisition strengthens Metsorsquos position as a leading
service and technology provider for the mining and construction
sectors The company was transferred to Metso on August 1 2011
Established in 1999 Copperstate has built a highly compe-
tent team of service personnel in the American hard rock mining
region Approximately 40 employees will transfer to Metso The
team will be integrated into the Services business line of Metsorsquos
Mining and Construction Technology segment where they willcontinue to serve existing clients The team will be expanded to
further reinforce Metsorsquos maintenance repair and retrofit business
in the USA Canada and Mexico
ldquoThis fits right in with Metsorsquos profitable growth and develop-
ment strategyrdquo says Randy Reisinger Senior Vice President of
Engineered Services Solutions ldquoMetsorsquos objective is to enhance
customer satisfaction by employing a larger team of knowledge-
able well-trained service people to meet customersrsquo skills and
availability needsrdquo
will be equipped with a drawbridgeknife gate system that indexes
and dumps trains of both lengths The tandem railcar unloading
system will be capable of handling 74 railcars per hour Metsorsquos
delivery will be completed by the end of 2011
Wholly owned by the Federal Government of Canada Ridley
Terminals Inc operates an advanced marine terminal providing
high-performance railcar unloading product storage and vessel
loading services
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Facilities for the
Sochi Winter Olympicsconstructed with high-quality aggregates
Metsorsquos stationary washing plant was delivered to Maykop Nerud and so far has processed over
500000 tons of high-quality aggregates and sand for the construction of Olympic facilities in Sochi
Positive estimate of the end product quality
General Director of Maykop Nedud Company
Alexander Kozhanov (in the middle) with hisdeputies Alexey Poddubny and Stanislav
Steblyansky
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983110983141983137983156983157983154983141983140 983137983154983156
The City of Sochi despite
its subtropical climate
is preparing to host the
Winter Olympic Games in
2014 In connection withthis event major sports and
infrastructure facilities are
being built
TEXT amp PHOTOS Eero Haumlmaumllaumlinen
Because the Olympic site is classified as
a 12-magnitude seismic zone the State
Corporation ldquoOlympstroyrdquo and Russian
construction regulations require the use of
high-quality washed aggregates in concrete
when constructing critical objects in Sochi
These requirements are being met
in full by the company Maykop Nerudwhich produces crushed stone of various
fractions and sand using Metsorsquos mobile
crushing and screening plant and a station-
ary washing complex to process ancientmetamorphic alluvial formations into high-
quality construction materials
To date Maykop Nerud has shipped
to Sochi more than a million tons of inert
materialsaggregates produced in its in-
house production and in adjacent quarries
Inert materials are delivered to Sochi exclu-
sively by rail due to the diffi cult mountain-
ous conditions The company dispatches
one to two trains containing 3000 ndash 6000
tons of crushed stone and building sand to
the Olympic city daily
Aggregates from Maykop Nerud arebeing used in many Olympic projects
including Bolshoi ice palace and in tunnel
complex No 1 consisting of 25 kilometers
of road railway and service tunnels which
will be used to transport guests at the
Sochi 2014 Olympic Games between the
Olympic Village and a ski complex in Kras-
naya Polyana
Maykop Nerudrsquos washed sand is also
being used by manufacturers of tubing for
five tunnels under construction
ldquoMetso is a true partnerrdquo
Maykop Nerud was established just four
years ago and was supplying the inert
materials of other producers using anin-house railroad warehouse Later the
company entered into contracts with
quarry It is the first complex of its kind
in Russia
ldquoIn the initial stages of preparation for
the technical requirements of the equip-
ment we had planned to purchase a
mobile washing plant but Metsorsquos engi-
neers convinced us of the advantages of
stationary washing and screening equip-ment Today with the complex working
247 at full capacity it is easy to see that
major construction companies running
operations in Sochi and purchased its ownequipment for crushing and screening
ldquoWhile looking for an equipment sup-
plier we were approached by leading
manufacturers of crushing and screening
equipment After their proposals were
subsequently cross-checked Metso was
deservedly appreciated as a supplier of
high-quality equipment by all other bid-
dersrdquo says Alexander Kozhanov General
Director of Maykop Nerud
ldquoSince choosing Metso as our equip-
ment supplier and during the course of our
cooperation we have come to the realiza-tion that Metso is a true partner for us In
close cooperation with Metso we develop
and implement processes unavailable to
competitors work together as a united
team and share valuable experiencerdquo
Kozhanov adds
A good example is Metsorsquos washing
complex operated at Maykop Nerudrsquos
we made the right choicerdquo says Maykop
Nerudrsquos Deputy General Director AlexeyPoddubny
From sand-gravel mix
to quality aggregates
The raw material Maykop Nerud uses is
metamorphic alluvial sediments of hard
rock deposited in the Belaya River valley
millions of years ago The sand-gravel mix
in the companyrsquos quarry features some
properties of granite with excellent hard-
ness making it a good feed for the produc-
tion of quality aggregates
Straightforward quarrying technology isutilized excavators dig up the sand-gravel
mix and move it to stockpiles From the
stockpiles the sand-gravel mix is reclaimed
to Metsorsquos three-stage crushing and
screening process consisting of tracked
jaw and cone crushing plants and a mobile
screen gt
The sand amp gravel mix is crushed and screened
into 0ndash20 mm fractions using jaw and cone
crushing plants combined with a mobile screen
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The Maykop Nerud Company has supplied more than 150000 tons of 0ndash5 mm washed sand and aggregates in fractions of 5ndash10 mm 10ndash20 mm and
5ndash20 mm for shotcreting and for the concrete lining of the constructed tunnels
Crushed to the size of 0ndash20 mm the
material is transported by conveyors to a
washing complex consisting of a feed hop-
per conveyors a 4-deck washing screen aspiral classifier and an automated control
system
In order to facilitate the operations of its
customers Metso has established a stock of
spares and consumables in Maykop Nerudrsquos
territory Maykop Nerud can use the stock
for its own purposes and parts can also
be delivered to other Metso customers as
required The reliability of the equipment
983110983141983137983156983157983154983141983140 983137983154983156983145983139983148983141
and its operational effectiveness mainly
depend on the availability and prompt
replacement of spares and consumables ndash a
prerequisite ensured by the mutual effortsof Metso personnel and Maykop Nerud staff
Powerful crushing complex in
combination with washing plant
Having taken into account the growing
demand for high-quality end products
Maykop Nerud and Metso agreed to
extend their cooperation and create an
even more powerful stationary crushing
and screening complex including a pri-
mary jaw crusher and two stationary cone
crushers for operation in combination with
a stationary washing plantldquoBeginning in the second quarter of
2012 we will use the new stationary crush-
ing and screening complex along with the
mobile equipment thus allowing us to
increase our capacity to 130000 ndash 140000
tons per month in order to meet the con-
stantly growing demandrdquo says Stanislav
Steblyansky Deputy General Director of
Maykop Nerud
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The construction budget of EUR 534 billion
for projects in Sochi includes three major
sites the Olympic Park along the shore of
Black Sea the Olympic Village residences
for the athletes and the Krasnaya Polyana
ski resort in the Caucasus Mountains
These three sites will be interconnected
by numerous new highways roads bridges
Construction projects at a total budget of EUR 534 billion
983110983141983137983156983157983154983141983140 983137983154983156
The companyrsquos sand-gravel-mix
resources are expected to last upwards of
20 years Upon the completion of mining
and once the territory has been rehabili-
tated the quarry will be transformed into
an artificial lake for recreation and fishing
for the residents of the City of Maykop
More info
Alexey Shevyakhov
Tel +7 495 915 29 30
alexeyshevyakhovmetsocom
LOCATION City of Maykop Republic of
Adygea southern Russia
RAW MATERIAL hard rock sand-gravel mixhardness 40 kN
CAPACITY 250 th with increase up to 550
th in 2012
RESOURCES over 10 million cubic meters
END PRODUCTS Washed building sand 0ndash5
mm and crushed aggregates 5ndash10 mm
10ndash20 mm 5ndash20 mm 20ndash40 mm
ON-SITE MЕTSО EQUIPMENT
bull 1 Lokotrack LT106 jaw plant
bull 1 Lokotrack LT200HP cone plantbull 1 Lokotrack ST35 mobile screen
bull 1 Nordberg CVB 2060-4 inclined
screen
bull 1 Nordberg SF2870 sand trap
EQUIPMENT BEING INSTALLED WITH
COMMISSIONING IN 2ND QUARTER OF 2012
bull 1 Nordberg C80 jaw crusherbull 2 Nordberg HP4 cone crushers
bull 2 Nordberg CVB2060-4 inclined
screens
bull 1 Nordberg SF2360 sand trap
bull 1 Nordberg SF2870 sand trap
Maykop quarry owned by the Maykop Nerud Company
and tunnels Essentially the entire infra-
structure within and around the 110-km-
long Sochi will be renewed
More than 155000 workers are involved
in the construction projects In total more
than 300000 cubic meters of concrete
will be used for shotcreting and for the
solid cladding of the tunnels A consider-
able proportion of that concrete will be
prepared using the aggregates and sand of
Maykop Nerud
The company Severstroy is producing
concrete elements for lining 23 kilometers
of various tunnels All of the washed aggre-
gates and sand for those projects is also
being supplied by Maykop Nerud
Metsorsquos sand trap is a critical component of the washing complex
In August 2011 construction of the new ice stadium in Olympic Park was at full speed
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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155
The new Metso C120 jaw crusher combines effi ciency versatility and safety
Metsorsquos new C120 jaw crusher made its worldwide debut at the Steinexpo exhibition in Germany
New products
Metso is proud to announce that we have developed the first fully
recyclable modular screening media ndash Metso Trellex LS-Eco
In response to customer requests for sustainable and environ-
mentally friendly screening media solutions and in line with our
own sustainability program we have taken the acclaimed Metso Trellex LS rubber modular screening media systems and success-
fully replaced the traditional steel reinforcement with an environ-
mentally friendly composite material This unique solution makes it
possible to effectively recycle our customersrsquo screening media
In the past screening media modules that were no longer
suitable for production were treated as waste and could not be
recycled Metso has introduced a new future for the product and a
sustainable solution
Sustainable solution for screening media
Metso has launched the
first fully recyclable
modular screening
media ndash Metso
Trellex LS-Eco
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Metsorsquos Mining and Construction Technology has introduced the
Metso C120 jaw crusher ndash the 13th member of the field-proven
C-series range of crushers The C120 combines uncompromising
reliability crushing effi ciency and versatility in both stationary and
mobile applications with safety and ease of use
Even at first glance it is clear that Metso has paid special atten-
tion to the C120rsquos new durable and user-friendly design start-
ing with the casting the design of which is based on thorough
FEA analysis and casting simulations Every detail of the C120 is
engineered for reliable operation and long life resulting in high
constant crushing capacity and uptime
ldquoWhen starting the C120 project we listened closely to our cus-
tomers and collected field data from a number of sites Based onthat information we decided to design the crusher cavity and kin-
ematics first As a result Metso can now offer aggregates produc-
ers large-scale contractors and mining companies a new crusher
that meets all the standards set for any demanding applicationrdquo
says Ilkka Somero Metsorsquos Product Manager for jaw crushers
New design brings outstanding productivity
The outstanding productivity of the C120 is guaranteed thanks
to several new design elements The crusher features a long and
aggressively directed stroke and a fixed jaw die longer than previ-
ously seen in this crusher size class The C120 has a large feed
opening of 1200 x 870 mm (34 x 47rsquorsquo) and an aggressive cavity cross
section securing a high per formance and reduction ratioIn terms of cavity volume and crusher weight the C120 is posi-
tioned between the existing Metso C116 and C125 jaw crusher
models
The Metso C120rsquos nominal power is 160 kW (200 HP) operating
speed 230 rpm closed side setting between 70 ndash 200 mm (2 34rsquorsquo
ndash 8rsquorsquo) The operational weight is 26000 kg (57200 lbs) excluding
options
More infoIlkka Somero
Tel + 358 50 317 0769
Ilkkasomerometsocom
The optional robust composite 1047298ywheel guards allow quick and safe
access to the service points
983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156
In addition to providing environmentally friendly screening
media panels Metso will implement a unique program to provide
its customers with a suitable range of recycling services
The Metso Trellex LS-Eco offers a wide range of health safety
and environmental benefits Each screening media panel is up to40 lighter than standard steel reinforced Trellex LS panels This
makes handling easier and the working environment safer Lighter
panels also help to reduce the overall stress on the entire screening
installation
Compared to steel-reinforced panels the composite-reinforced
panels of the Metso Trellex LS-Eco are more 1047298exible and will reduce
the effects of pegging and blinding during screening operations
The Metso Trellex LS-Eco promises reduced downtime and
increased productivity
The Trellex 300LS and Trellex 305LS rubber and polyurethane
panels are already acclaimed worldwide as being among the most
versatile modular screening media solutions They can be attached
to most screening media systems and can handle all types of
screening applications ndash fine and coarse wet and dry In the futurewhen Metso customers need new screening media panels for
their existing system they can choose Metso Trellex LS-Eco and be
assured that their panels will be safely and effectively recycled
More info
Claes Larsson
Tel +46 410 525 73
claeslarssonmetsocom
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The new Lokotrack LT120 with its world premiere at the Steinexpo
exhibition in Germany combines crushing performance and user-
friendly design in a new revolutionary way For the first time the
same Lokotrack model is now available in a hydraulically or electri-
cally driven version to meet customer needs
New Lokotrack LT120 jaw plant introduced
Lokotrack LT120 is the latest and most advanced of Metsorsquos track-mounted jaw crusher plants
Lokotrack LT120 combines user-friendly design and good crushing
performance in a new way
power supply or a 420-kV onboard diesel generator Having the
possibility to use an external power supply enables a highly eco-
nomical and ecological crushing process
The Lokotrack LT120 is built around the new C120 jaw crusher
See page 10 for information about the C120
Safe to use move and service
Safety is the highest priority for Metso when designing new equip-ment The Lokotrack LT120 is designed to be safe to operate move
and service
ldquoA safe operating environment is created by practical solutions
When service points can be reached easily the possibility of dan-
gerous situations diminishesrdquo says Product Manager Timo Nakari
ldquoGood examples of safety built in to the Lokotrack LT120 include
sturdy easy-to-open composite 1047298ywheel guards and hydraulically
folding and locking feed hopper sidesrdquo Nakari adds
The Lokotrack LT120 can be fine-tuned to suit the customerrsquos
application by selecting the required options from a long main
conveyor and hammer and boom to a water spraying system and
rubber lining for the feeder and hopper for example
The Lokotrack LT120 features a Caterpillar C13 310 kW (415 hp)engine Its transport dimensions are length 16 m (52rsquo 6rdquo) width 3 m
(9rsquo10rdquo) height 39 m (12rsquo 10rdquo) and weight 57 tons (114000 lbs) The
LT120E version weighs 63 tons (126000 lbs)
More info
Timo Nakari
Tel + 358 40 701 6143
timonakarimetsocom
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The Lokotrack LT120 uses the same field-proven technology
seen in Metsorsquos tracked units for over 26 years Every detail of thenew jaw plant has been thoroughly designed for reliability and
long life The main targets when designing the unit have been
energy effi ciency good performance reliability and product safety
Field tests have demonstrated its good fuel economy and high
crushing capacity
Environment-friendly economy
The Lokotrack LT120 is also available as an electrically driven unit
ndash the Lokotrack LT120E ndash which can take energy from an external
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The TS range of screens is characterized by its innovative design
comprising two technologies combined multi-variable slopes with
a variable elliptical motion This proven range is being comple-
mented with the new TS63 screen
The TS63rsquos unique combination increases both the screenrsquos effi -
ciency and its capacity Material speed is high at the feed end and
slows down at the discharge end
Metso TS series screens offer more space between decks mak-
ing maintenance easier and improving service conditions for the
operators as well as meeting all safety requirements
Metso has recently sold several 25-m2 multi-slope screens for
mining applications such as a TS63 for Ferrostaal in Mauritania andalso for the construction industry for example Holcim in Lynwood
Australia Georyt in Poland Apaxco in Mexico and Newmont in
Peru
More info
Denis Pradon
Tel +33 680 64 39 67
denispradonmetsocom
New TS63 screen ndash the largest three-deck banana screen on the market
The new Metso TS63 banana screen features a 25-m2 screening area
Following the success of the HP4 and HP5 Metso has broadened
the product range with the new HP3 cone crusher This mid-range
cone crusher benefits from 70+ years of experience in crushing
technology while specifically addressing customer requirements
for large capacity ease of operation and a high reduction ratio
The HP3 responds to market demands for increased productionquality reduced maintenance time and low operating costs The
new generation HP models are comparable to their predecessors
but offer increased versatility
The HP3 features the size of an HP200 with the output of an
HP300 The power performance and robustness of the new gen-
eration models allow in certain cases two crushers to be replaced
with just one so investment production and operation costs are
greatly reduced
The HP3 has been tested at two different quarry sites in France
over the past seven months ndash at a gravel pit and a rock quarry
The Metso factory in France began production of the HP3
series in September Several orders have already been received for
secondary and tertiary applications Since 2009 nearly 300 HP newgeneration cone crushers have been commissioned The HP3 mar-
ket will be primarily centered on gravel pit applications (70)
The HP3 has a nominal feed opening of 220 mm (865rsquorsquo) a
motor size of up to 220 kW (300 hp) and a weight of 13280 kg
(29277 lbs)
More info
Carlos Padin
Tel +33 6 0727 2002
carlospadinmetsocomMetso HP3 at a stationary installation in France
HP3 cone ndash another new-generation cone crusher
983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
First modular plant to NepalMetso delivered its first modular crushing and screening plant to MS Palchowke Mai Roda Dunga Udyog Limited (PMRD)
in Melamchi Nepal The modular plant solution offers PMRD a fast and effective response to productivity and qualityrequirements
TEXT amp PHOTOS Atoshi Nayak Ghosh
The diversity of operations at a typical con-
struction site involves quick decision-mak-
ing and often a lot of pressure to ensure a
timely execution
High performance guaranteed
Considering todayrsquos volatile market sce-
nario business partners must maintainpace with their customersrsquo ever-changing
requirements Understanding custom-
ersrsquo strategic business needs is of utmost
importance PMRDrsquos plant was commis-
sioned in January 2011 and has logged
about 1200 hours of operation to date
The plant is much more compact than
the traditional skid-mounted plant and
provides space for free movement of utility
equipment within the plant area One of
the key features of the plant is the totally
bolted structure It can be easily disman-
tled into sub-assemblies transported and
re-assembled effortlessly at a new location
which is one of the biggest advantages in
helping to meet new market demand
Due to the use of pre-assembled mod-ules for each crushing station the instal-
lation work on site takes less time thus
decreasing the plantrsquos installation lead time
The plant also includes a foldable conveyor
for maintenance of the cone crushers
Stepping up with Metso
PMRD operates a two-stage plant compris-
ing a C80 jaw crusher an HP200 high-
performance cone crusher and a CVB1845
screen with circular motion MV2 vibra-
tory mechanism for final product recovery
resulting in an aggregate plant of 150 tph
capacity for producing size fractions of 0-40
mm The plant is an example of world-class
craftsmanship and excellent material han-
dling capacityModular and non-welded construction
supported by durable pitman assembly sin-
gle-piece cast steel frame bearing housings
with repairable crusher construction and
the right cavity design results in aggressive
kinematics and high power that best suits
the requirements of the customer
PMRD has immense pride in the plant
ldquoThe performance has been astounding
A drawing of typical modular plant
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983122983141983152983151983154983156983145983150983143 983154983141983155
with applications ranging from road aggre-
gates commercial sand production to
ready-mix concretes The modular plant is
almost set to create a new niche in aggre-
gates processing in Nepalrsquos construction
industry It is one of a kind and we are sur-
prised at the plant rsquos production capacity
It is easy to operate and requires minimalmanpower Our cost per ton has signifi-
cantly gone down and so has the cost of
productionrdquo says Mr Sandeep K Agarwal
Director PMRD
Safety as a key issue
Health safety and environmental solutions
are key concerns for Metso and they are
addressed with the same sense of responsi-
bility as quality productivity and cost-
effi ciency issues Metso is responsible for
conducting operations in an environmen-
tally sound way and offers products and
services that can help customers fulfill their
environmental responsibilities
Metso provides the plant offi ce and site
with operation and maintenance manu-als for each and every piece of equipment
including safety issues which are entrusted
to all the operators
All conveyors are equipped with pull-
cord safety switches along with emergency
stop buttons The working area and walk-
ways are all equipped with safety hand rails
and checkered plates for anti-skidding The
entire plant is equipped with earth pits for
electrical current earth leakage prevention
Metso has ensured all possible measures
to maintain high safety standards for all
operation and maintenance personnel
More info
Suhen Agarwal
Tel +91 124 2351566suhenagarwalmetsocom
Nepalrsquos first modularcrushing and screening plant deliv ered by Metso
E ffi cien t C VB1845 inclined screen wi th
an M V2 vibra tor y mechanism handles
the classi fica tion o f crushed ma terials
A s turd y f eeder dis tribu tes the ma terials to be crushed to
a
Me tso C80 ja w crusher
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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155
Outokumpursquos Kemi
mine set to doubleproduction The only mine unit owned by Outokumpu
the chrome mine in Kemi northern Finland
is busy making preparations to double its
production set to begin next year In co-
operation with Metso Outokumpu willincrease the number of underground
feeders and optimize the durabil-
ity of wear parts in the massive
primary gyratory crusher
TEXT amp PHOTOS Eero Haumlmaumllaumlinen
Chrome ore is fed into Metsorsquos
Superiorreg 50-65 primary
gyratory crusher by three
different vibrating feeders
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983122983141983152983151983154983156983145983150983143 983154983141983155
Up until now the entire production of the
chrome mine totaling about 13 million
tons annually has been transported to the
Tornio ferrochrome plant for processing
and on to the Tornio stainless steel plant
The increase in production which will
begin in autumn 2012 is intended also to
enable Outokumpu to sell ferrochrome tocompanies outside the Group The produc-
tion target for 2013 is 27 million tons of
ore and of the ferrochrome produced from
the ore nearly a half (gt 200000 tons) is to
be sold outside
Underground expansion
work almost complete
About 500 meters underground the
majority of the work involved in increasing
the capacity the F3 project has already
been completed Doubling the production
is no problem for the Superiorreg primarygyratory crusher delivered to the mine
by Metso in 2002 which can digest more
than 2700 tons of feed material per hour if
necessary
At the moment the primary gyratory
crusher can be fed by three different vibrat-
ing feeders The crusher currently runs for
less than one-fifth of the production time
The increase in ore production will increase
the effective crushing time to about one-
third of the production time
A lot of work has been done for orestorage after the primary crusher The
two currently used storage silos are now
accompanied by two new 8000-ton silos
The number of Metso feeders transporting
the ore from the primary crusher has also
been doubled
Optimization of wear parts under way
Chrome ore has been a challenge to the
primary gyratory crusherrsquos wear parts The
wear is contributed to by the pulsating
feed which rarely fills the entire crushing
chamber There are also great differences inore type since brittle feed material prone
to chalking is occasionally replaced by hard
ore that requires a lot of crushing power
before it is crushed with a bang gt
Mika Saari (right) Foreman of ore line technicians at Outokumpursquos chrome mine in conversation with
Mikko Malkamaumlki Metsorsquos crusher wear parts specialist
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
last did in July for the replacement of the
crusherrsquos wear parts Our work is also facili-
tated by product development like the
addition of maintenance hatches to the
feedersrdquo he continues
Lasting technology
According to Mika Saarirsquos calculations the
Superiorreg primary gyratory crusher has so
far crushed more than six million tons of
ore in totalldquoThe factory polishing marks still show
on the bottom thrust bearing so we
believe that the bearing will last the entire
remaining service life of the crusher which
is about ten years and 30 million tons
Metsorsquos feeders have been equally reliablerdquo
Saari says
After the next 30 million tons of ore
it will be time to deepen the mine
More info
Jukka Raumlisaumlnen
Tel +358 50 317 1787 jukkaraisanenmetsocom
Mikko Malkamaumlki
Tel + 358 40 827 8223
mikkomalkamakimetsocom
The Kemi mine and Metso are currently
carrying out a development project to
increase the service life of the mantle and
outer concave and thus minimize down-
time due to replacement While the modu-
lar feed hopper enables quick replacement
of the mantle replacing the outer concave
can easily take more than a week The cooperation between the Kemi
mine and Metsorsquos wear parts team in
Tampere aims to extend the service life
of the parts to at least 4 million crushed
tons Durability is sought by optimizing the
chamber structure and selecting the r ight
materials for the outer concave
ldquoSmooth cooperationrdquo
Mika Saari Foreman of ore line technicians
working in the underground mainte-
nance of the Kemi mine leads a small but
experienced team of technicians The tidymodern offi ce spaces are located close to
the action at a depth of 500 meters
ldquoCooperation with Metso has been
smooth Increasing our own crushing
expertise takes time so all know-how
shared by the manufacturer is very wel-
come to usrdquo Mika Saari says
ldquoWe can also use Metsorsquos profession-
als for servicing when necessary like we
The Superiorreg 50-65 has provided reliable
crushing performance at a depth of 500 metres
in the Kemi chrome mine
Technicians Sari Kulju (left) and Marko Jaako ensure that the primary gyratory crusherrsquos hydraulicand electrical unit remains very tidy which contributes to trouble-free operation of the crusher
Outokumpu Oyrsquos Kemi
chrome mine
LOCATION Keminmaa northern
Finland
ORE TYPE chrome oxide (26)
ORE ESTIMATE ON 1 JANUARY 2011
ndash ore reserves 36 million tons
ndash mineral resources 87 million
tons
MINING METHOD bench and cut fillFEED MATERIAL SIZE 0ndash1000 mm
METSO EQUIPMENT IN THE MINE
bull 1 Superiorreg 50-65 primary
gyratory crusher
ndash open side setting 152 cm (6rdquo)
bull 8 VMOU 25-125 feeders
bull 1 VMOU 30-16 feeder
bull 1 VMOU 40125 feeder
bull 2 Symons cone crushers
bull 1 C80 jaw crusher
bull 4 HM75 pumps
bull 11HM100 pumps
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983122983141983152983151983154983156983145983150983143 983154983141983155
Metso was responsible for the design
development and construction of the
entire secondary and tertiary arrangement
The primary station will be the subject of a
subsequent investment
Latest environmental protection used
This installation has been designed in strict
compliance with the environmental quality
approach developed by Metso and its
partners using the latest technologies
in dust control including confinement
technology as well as dust encapsulation
technology for screens
To ensure an annual capacity of 15 mil-lion tons for a nominal output of 560th of
02 mm and 220 mm the clientrsquos choice
for the secondary stage naturally fell upon
the NP 1520 impact crusher
A complete impact crusher solution for Lafarge The Lafarge Group has entrusted Metso with the implementation of its new aggregates installation in southern France
It comprises a new secondary crushing stage equipped with an NP1520 impact crusher featuring a power range of2 x 250kW and equipped with hydraulic adjustment
TEXT amp PHOTO Gilles Dombey
The NP 1520 crusher has long proved
its performance not only in terms of capac-
ity and reduction rate but also quality of
the finished product and durability
More info
Arnaud Bertucat
Tel +33 (0)6 81 44 68 26
arnaudbertucatmetsocom
About 15 million tons of aggregates feed will be crushed with the NP1520 impact crusher at Lafargersquos stationary installation in southern France
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Multi-stage Lokotrack process a success in Senegal
A multi-stage crushing and screening process has proven its effi ciency in the production of concrete aggregates in
Senegal Western Africa With the mobile process Xewell Cimenteries SA now exploits its quarry better has reduced
its operating costs and can meet strict environmental requirements
TEXT Elisabetta Cataluffi PHOTOS Carlo Rinolfi
Senegal is a rapidly developing country
offering a good deal of potential activities
for crushing companies too At the sametime the country has several areas of high
environmental value Therefore contractors
must opt for state-of-the-art equipment that
offers reduced environmental emissions
The company Xewell Cimenteries SA
was founded in 2008 as a partnership
between Italian Swiss and Senegalesecontractors Xewell operates a limestone
quarry located in the Pout area east of the
capital city of Dakar
According to Alessandro Crestani Technical
Director of the Pout quarry a mobile process
was selected to better exploit the quarry and
reduce costsLokotrack process drawing made by Bruno simulation software
After assembling the Lokotrack units the process was tested by Xewell Cimenteries
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983122983141983152983151983154983156983145983150983143 983154983141983155
Owned by Freeport-McMoRan Copper amp
Gold (51) and CODELCO (49) the ElAbra mine has leachable oxide and sulfide
mineralization The minersquos processing facil-
ity has an annual capacity of 226000 tons
of copper cathode
Smaller size matters
Reducing the size of the crushed oxide
ore from the present 15 mm to 12 mm
was the main target of the mine and the
Metso team The changes that were carried
out in the process included a size varia-
tion change in the cut of the tertiary sieve
installation of rate-level sensors in thesecondary crushers and enabling speed
variables in the conveyor belt feeders of
the secondary crushing circuit
ldquoGoing from 15mm to 12mm may seem
small but the operational impact is very
important and significant for usrdquo explains
Juan Torres Carvajal Metallurgical Engi-
neer at the El Abra mine
ldquoOur goal is to reach 115000 tons with
a minimum of 80 of 12-mm-sized ore permonth The record to date is 105000 tons
and we will increase it until we reach our
project goalrdquo he adds
New design for cone liners
In addition to the work mentioned above
Metso is currently carrying out a project to
design the lining profiles for the secondary
and tertiary crushers of the plant which
will affect the smaller size of the material
In cooperation with Nelson Mella from
Metso and Rodolfo Navarro Crushing
Superintendent at the El Abra mine testswere carried out in July on the re-designed
Metso linings One set was tested for sec-
ondary crushing and two sets for tertiary
crushing
More info
Nelson Mella
Tel +56 99158 0576
nelsonmellametsocom
Finer ore through wear pro1047297lestudy at El Abra mine in ChileEl Abra is a porphyry copper open-pit mine and processing facility located in
Chile near the city of Calama some 4000 meters above sea level With the helpof Metsorsquos technical support the mine was able to achieve finer ore throughoutthe crushing process
TEXT amp PHOTOS Macarena Vallejo
Xewell Cimenteries produces a selec-
tion of dry processed aggregates for con-
crete Operations started at the end of 2009
with the aim of reaching 150000 metric
tons produced per year
Lokotracks chosen to reduce costs
To build up their tracked mobile processXewell Cimenteries decided to buy three
mobile plants from Metso two impactor
plants the Lokotrack LT1110 and LT1213
feeding a three-deck mobile screen the
ST620 The machines were sold by SCAI
SpA Metsorsquos Lokotrack distributor in Italy
ldquoWe chose tracked machines to bet-
ter exploit our quarry and to reduce
costs Mobile plants have low initial costs
because they donrsquot need any special foun-
dations or supply of electricity This obvi-
ously gives us a quicker process set-up and
better uptimerdquo says Alessandro Crestani Technical Director of the Pout quarry
ldquoThe mobile plant can also follow the
quarry face as the exploitation proceeds
reducing the transport costs of raw materi-
als in the same jobsite We chose Metso
because they ensured us the best cost-per-
ton ratiordquo he adds
Good customer service is crucial
According to Alessandro Crestani good
customer service also played a major role
when choosing the manufacturer of the
mobile equipmentldquoMetsorsquos distributor SCAI SpA was able
to provide us with a complete product
support and customer service package
Obviously service is a very important
aspect for us in a country like Senegal Any
downtime represents a clear loss of pro-
ductivity for usrdquo
The average level of productivity of the
mobile Lokotrack process is 200 metric
tons per hour
More info
Carlo Rinolfi Tel +39 335 1253159
crinolfiscaispacom
Example of the development of the Metso study
on the crusher lining profiles
Liner change for smaller ore size in the
MP1000 cone crusher
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Services success in Surabaya The Metso Surabaya workshop and offi ce complex opened in April 2008 provides Life Cycle Services and maintenance
solutions for Metso equipment in the Indonesia region The facility is strategically located in an industrial precinct on theouter rim of Surabaya the second largest city in Indonesia Its close proximity to an international airport major shipping
port and several engineering companies simplifies support for the regionrsquos key customers which include PT Newmont
and PT Freeport
TEXT amp PHOTOS David LeRoy amp Gary Whittred
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983122983141983152983151983154983156983145983150983143 983154983141983155
The Surabaya site operates through Metso
in Australia with assistance from key sales
and technical staff Handling regional ser-vice and repair business in-house allows
Metso to manage intellectual property and
closely control quality
It also enables the development of a
team of skilled service personnel who can
be utilized both internally and at key cus-
tomer sites as is common with the backup
service the workshop provides for screen
contracts
Innovation at work
Since 2008 the Surabaya facility has suc-
cessfully refurbished a wide variety ofcomponents Recently two ball mill heads
weighing 22 tons each were modified in
order to strengthen the 1047298ange of the ball
mill shell The modification included tap-
ping out existing 1047298ange holes and drilling
new ones so that finger plates could be
installed and welded to the 1047298anges
Positioning the head borer to properly
align the new 1047298ange holes proved diffi cult
Four roller support frames were manufac-
tured to support the heads and allow them
to be rotated easily Each hole was then
drilled and tapped at the correct angleusing the CNC five axis head The job had a
tight delivery as it was required for a shut-
down but with advance planning and inno-
vation it was completed ahead of schedule
MP1000 mainframe on
CNC vertical borer
Well equipped for fabricating and machin-
ing heavy components the Surabaya
The Surabaya facility has proven to be
a success for Metso The workshop offers a
wide variety of services in the region Qual-ity products and competitive pricing and
delivery times have led to strong customer
relationships
Turnover and customer service levels
have increased annually since the open-
ing and between 2008 and 2010 sales
increased 450 These excellent trends
are expected to continue as the operation
expands and the customer base grows
Since 2008 the Surabaya facility has
successfully refurbished
bull MP1000 counter shaft boxes headassemblies mainframes bowls adjust-
ment rings counterweights sockets and
tramp release cylinders
bull 7rsquo Symons bowls heads and countershaft
boxes
bull Vertimill screw and drive shafts
bull Ball mill heads
bull Ball mill trommel
bull VPA cylinders
bull Eaton clutches
bull Exciter screen mechanisms
bull 42x65 main shafts and eccentrics
More info
Gary Whittred
Tel +62 31 8430349
garywhittredmetsocom
workshop handles the majority of Metsorsquos
refurbishment work with ease But when
necessary PT PAL ndash a government facilitywith shipbuilding and heavy engineering
capabilities ndash offers a ldquoone stop shoprdquo Spe-
cially trained PT PAL staff ensures that the
work they perform complies with all Metso
specifications and quality standards
PT PAL also demonstrated their innova-
tive ability with the first MP1000 main-
frame refurbishment they completed The
mainframersquos shaft location bore needed
to be re-machined However the distance
from the top of the mainframe to the
tapered bore made it very hard to achieve
an accurate surface finish with the correctstandoff
To overcome this the shop decided to
machine the mainframe upside down and
elevated on support beams They posi-
tioned a new shaft under the mainframe in
a custom-made cradle Using an overhead
crane they could then lsquotrial fitrsquo the shaft in
the bore to make sure it seated correctly
and the mating tapers met specification
The method worked so well it has since
been used for four more mainframe refur-
bishments
Diversity and growth
Today Metso Surabaya continues to invest
in additional equipment in order to diver-
sify its service offering A new hydraulic
power pack which allows the facility to test
refurbished components to Metso specifi-
cations was recently used in the refurbish-
ment and testing of several VPA cylinders
for PT Freeport
Refurbished MP1000 mainframe dispatched by truck to
PT Freeport mine
Machining of MP1000 upper frame
at Metsorsquos Surabaya workshop
Mainframe at vertical CNC machining
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Creating Value with Metso in Hong KongIn Hong Kong the aggregates needed for construction are mostly supplied by two local quarries KWP Quarry Company
Limitedrsquos Anderson Road Quarry accounts for 60ndash70 making it the pillar of Hong Kongrsquos construction materials industry
TEXT amp PHOTOS Ou He
When arriving at the Anderson Road
Quarry the most impressive view at the850000 square-meter facility is the Metso
machines including equipment from the
primary secondary and tertiary crushing
circuits and the screens I t is Metsorsquos equip-
ment that secures the supply of aggregates
for Hong Kong
KWP Quarry Company Limited has been
working with Metso since its establishment
in 1997
Due to Hong Kongrsquos stringent dust and noise control standards Metso has paid special attention to the related suppression systems
ldquoOur quarry mainly lies on granite and
volcanic rock which are so hard they canonly be processed by equipment with
strong durability and stabilityrdquo explains
Mr Eddie Hung Manager of KWP ldquoWith a
long history of and experience in quarry-
ing we are very familiar with the equip-
ment of different brands Comparatively
Metsorsquos products are better than others in
terms of durability stability and effi ciency
Besides this the reason we selected Metso
is because of the simple maintenance of
their equipment and the easy access tomaintenance informationrdquo
Flexible modular solution
Based on extensive experience in crushing
and screening worldwide Metso presented
the Anderson Road Quarry with a modu-
lar solution and delivered it as a turn-key
project Through a four-stage crushing
circuit which contains three Metso C160
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983122983141983152983151983154983156983145983150983143 983154983141983155
jaw crushers for primary crushing two
Omnicone 1560SX crushers for secondary
crushing two HP 500SX cone crushers for
tertiary crushing and one HP500SX cone
crusher for extra-fine crushing the plant
was able to produce aggregates of optimal
shape with minimal 1047298akiness
The fine products include three sizes
0 to 5 mm 5 to 10 mm and 10 to 20mm
Since the employment of this system in
2000 production has reached 1250 th
which is far beyond the design capacityAccording to Mr Hung ldquoThe machines
always run effi ciently and seldom malfunc-
tion The occasional shutdown of some
machines does not affect production very
much the plant still could reach 60-70
of its normal production It gives us the
best 1047298exibility for the plant rsquos operation and
I believe this is the best feature of Metsorsquos
solution
Eddie Hung
Manager of KWPrsquos
Anderson Road
Quarry is happy with
the product quality
and service provided
by Metso
ldquoMetsorsquos equipment is expensive com-
paratively but in the long run you will find
that the investment is worthwhile on the
whole Metso secures superior stability reli-
ability and fewer downtimes and it guaran-
tees continuous operation and brings us
greater valuerdquo
Great service team
Metso sent a group of service engineers
to the plant within the warranty period
not only to provide service but to train theoperators Mr Hung speaks highly of Met-
sorsquos service team he is impressed with its
experienced experts and with their strong
sense of responsibility and customer-
oriented ways of working
ldquoMetsorsquos service team never fails to find
hidden problems and helps us to prevent
any mechanical failures And they are
available whenever we need them they
work closely with us to solve the problem
effi cientlyrdquo he said
Excellent environment-friendly designIn order to achieve the worldrsquos most strin-
gent noise and dust control standards
developed by the Environment Protection
Department of Hong Kong Metso has
incorporated a dust and noise suppression
system into the plant This includes the
infrared-triggered spray systems at feed
points encapsulation of individual crush-
ers and conveyors and the ability to select
specific sectors of the system for treatment
depending on feed and operating condi-
tions encapsulation of equipment and the
enclosure of all major sections of the plant
With these advanced environment-
friendly solutions Anderson Road Quarry
has won numerous safety and environmen-
tal awards In 2003 it was presented with a
silver medal in the prestigious Environmen-
tal Performance Awards in recognition of
its commitment to the environment and
community In 2004 KWP achieved certifi-cation of ISO 14001 it is the first quarry site
to have achieved this in Hong Kong and
southern China
ldquoA reliable partnerrdquo
The promulgation of the top ten infrastruc-
ture policies in Hong Kong boosted the
market for aggregates and demand will
keep rising over the next five to six years
ldquoWersquoll definitely keep our cooperation with
Metso once we have a need for expansion
because we regard Metso as a reliable part-
ner With their highly effi cient equipmentsatisfying service and great efforts in help-
ing us to achieve our environmental pro-
tection targets Metso is our best choicerdquo
says Hung
More info
Ziqiang Li
Tel +86 13601289027
ziqianglimetsocom
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
The sturdy Metso C160
jaw crushers are fed
using huge feed chutes
and feeders
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983122983141983152983151983154983156983145983150983143 983154983141983155
Similar to hundreds of mine sites world-
wide Zinkgruvan is being operated on a
non-stop 247 basis with just a few main-
tenance breaks during the year Crusher
availability is crucial because 100 of the
ore has to pass through the jaws before
being hoisted up for further processing
In addition to the zinc- lead- copper-
and silver-containing ore the C jaws chop
all the host rock extracted along the min-
ing process With a sturdy design Metsorsquos
proven C jaws can easily reduce even the
hardest type of rock Every year more thanone million tons are crushed with the jaws
ldquoMinimal service neededrdquo
Crushing with the first C160B jaw crusher
began at Zinkgruvanrsquos -800 meter level in
2000 with the primary crushing of zinc-lead
ore The second jaw was installed in 2008
for the new copper process gt
The sight and sound of two C160 jaw crushers operating side by side in the underground
crushing station of the Swedish Zinkgruvan mine is impressive Good proactive service
secures good uptime and reliable continuous operation of Metsorsquos second-largest
C160 series jaw crushers and prepares the way for the ongoing plans to expand the
production of zinc concentrate
TEXT amp PHOTOS Eero Haumlmaumllaumlinen
New PolyMet liners are being tested with the grinding mill delivered by Metso
Zinkgruvanrsquos twin C160
jaws secure good uptime
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Blasted ore is taken from the presently
operated -850 meter level with normal
trucks as an outsourced process One full
truckload is fed to the C160s every
10 minutes
ldquoWe are happy with the high reliability
of the C jaws They only require some minor
service therefore providing us with good
uptime and steady continuous feed to our
secondary and tertiary crushing and grind-ing circuitsrdquo says Mine Manager Jan Klaumlre
ldquoBasic crusher service and wear part
changes are made by our own staff using
Metsorsquos partsrdquo he adds
Service contract with grinding
mills and conveyors
Zinkgruvan and Metso Sweden have more
than 11 yearsrsquo experience with a service
contract that contains grinding mills and
conveyors At the mine site two Metso
service people and one contractor take
care of all the related service jobs Man-
power can also be borrowed from Metsorsquos
Graumlngesberg mine service team of 20
people
Presently Zinkgruvan is testing Metsorsquos
new PolyMet mill linings in its big grinding
mills With previously used rubber partsthe linings had to be changed in the shell
every 9 to 11 months and in the feed head
every 6 months
ldquoWe expect a better lifetime with Poly-
Met linings Longer change intervals mean
a lot to our productivity because lining
changes takes two full working daysrdquo Mine
Manager Jan Klaumlre says
New mine goes deeper
With an expected mine life of more than 10
years Zinkgruvan is actively mapping new
ore reserves Experimental holes are being
drilled at the new mine section at the
-1110 meter level
More info
Fredrik Wennberg
Tel +46 70 657 00 08fredrikwennbergmetsocom
Mine Manager Jan Klaumlre (left) with Backfilling Manager Kjell Tillman at the underground -800 meter level mine cafeteria
983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
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The Zinkgruvan mine located approxi-
mately 200 km southwest of Stockholm
Sweden is one of the oldest underground
mines in Northern Europe The mine has
been in production since 1857
The mining methods used are panel
stoping and benching The processing
facilities include a zinc concentrating plant
with a 11 mtpa and a copper plant with a04 mtpa capacity Tailings are recycled in
an impounding basin and host rock in the
backfill plant
Continuous mining since 1857
Even as one of the oldest mines in Northern
Europe Zinkgruvan exploits modern mining
and minerals processing installations
Zinkgruvan mine
OWNER Lundin Mining
PRODUCTION PER YEAR 1 million tons
ORE TYPE sedimentary exhalative
zinc lead copper and silver
NUMBER OF EMPLOYEES 320
2011 PRODUCTION TARGETS 78000 tonsof zinc 36000 tons of lead and
3400 tons of copper concentrate
METSO EQUIPMENT ON SITE
bull 1 extra long VF feeder
bull 2 C160 jaw crushers
ndash zinc process css 220ndash240 mm
ndash copper process css 150 mm
bull 1 GP300S cone crusher
ndash css 45mm
bull 1 HP4 cone crusher
ndash css 18 mm
bull 1 DS screen
bull 1 FS402 screenbull 1 grinding mill
bull Pumps VPAs
A normal truck feeds the C jaws with ore coming from the lower production levels
983122983141983152983151983154983156983145983150983143 983154983141983155
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Cost-per-ton wear agreements deepencustomer relationshipsCrusher wear parts are traditionally marketed purely based on transactional sales and mainly depend on
the weight of manganese Metso has recently introduced a new type of wear agreement based on thecost-per-ton crushed and the wear occurred Thus far the experience has been very positive increasing
transparency and deepening the operational relationship between the manufacturer and the customer
TEXT Olli Kellokumpu and Eero Haumlmaumllaumlinen PHOTOS Eero Haumlmaumllaumlinen
Arto Hiedanniemi (left)
Hannu Heman and Juha
Laukka of Metsorsquos Finnish
Service team checking the
cone crusher mantles shipped
for a cost-per-ton customer
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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156
Wear parts and parts changes
can be included
The structure of a cost-per-ton wearcontract is based on the number of tons
crushed and the estimated wear occurred
The amount and monetary value of the
wear is calculated per crushed ton
ldquoEither plain wear parts or parts changes
carried out by Metsorsquos service personnel
can be included in the contract In the latter
case we ask our Finnish customers to inform
us about an upcoming wear change opera-
tion one week in advancerdquo Heman explains
ldquoWe see good opportunities to market
cost-per-ton contracts further in Finland
and also abroad It really develops therelationship of Metso and our customers
towards a trusted partnershiprdquo he notes
Perfect tool for accurate planning
Soraliike Ikola Oy is a mid-sized contrac-
tor with three Metso two- and three-
stage mobile and portable crushing and
screening plants operating in Central and
Since 2002 Metsorsquos sales team in Finland
has developed the cost-per-ton-based
service offeringldquoOur aim has been to seek through
a cost-per-ton offering possibilities to
serve our customers better to differentiate
Metso from the other players as an OEM
manufacturer and to offer deeper profes-
sionalism and know-howrdquo says Hannu
Heman General Manager of service
operations
ldquoUntil now both our experience and
that of our customers has been quite posi-
tive When properly prepared cost-per-ton
contracts seem to create a win-win situa-
tionrdquo Heman adds Today Metso has operational cost-per-
ton agreements with several Finnish cus-
tomers The first contract was concluded
with a customer operating a stationary
plant Based on the results gathered new
cost-per-ton contracts have been signed
with customers operating wheeled and
tracked equipment too
Eastern Finland Because of the size of the
contracts up to 50 equipment moves are
made during the yearEntrepreneur Pasi Ikola has had a cost-
per-ton contract with Metso for nearly
two years and he is quite happy with the
outcome
ldquoThe cost-per-ton contract has provided
me with a perfect tool for accurate financial
planning Now I know in detail my actual
future wear parts costs This helps a lot
when calculating bidsrdquo
ldquoEarlier I used to buy a big batch of
Metso wear parts in one go and had to
reserve a reasonable amount of money for
that Today all wear costs are evenly sharedwhich gives us a welcomed 1047298exibility to
our cost structure Now we just pay Metso
afterwards based on our crushed tonsrdquo
he adds
More info
Olli Kellokumpu
Tel +358 50 354 1189
ollikellokumpumetsocom
According to crushing contractor Pasi Ikola the cost-per-ton contract with Metso has provided the entrepreneur with better economical 1047298exibility
and more accurate calculating of bids
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Pleasant Gap is owned and operated by
Glenn O Hawbaker Inc of State College
Pennsylvania This family-owned company
began in 1952 as a small excavation busi-
ness founded by Glenn O Hawbaker and
his wife Thelma Over the years the com-
pany grew by adding an integrated mix ofproducts and services and taking on larger
projects
In 1983 Hawbaker acquired Pleasant
Gap Quarry and built its first aggregates
processing plant Today Glenn O Haw-
baker Inc operates 21 quarries and eight
asphalt production facilities across Penn-
sylvania and southern New York as well as
five regional operation centers
Primary
challenge atPleasant GapQuarryA good part of what makes for a successful crushing
operation is the willingness to tackle challenges and to do
whatrsquos necessary to meet demand The team at Pleasant
Gap Quarry in central Pennsylvania recently met the chal-
lenge when they successfully addressed problems with
the plantrsquos primary crushing plant First they purchased
a new Metso C160 jaw to replace the existing primary
impact crusher Then they devised an innovative plan to
get the primary plant back in operation while awaitingdelivery of the new jaw crusher
TEXT Linda Bergmann PHOTOS John Rickinger
983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Time for a change
With the goal of increasing reliability and
output the management at Pleasant Gap
Quarry recently decided it was time to
replace the plantrsquos primary impact crusher
Following a thorough search they chose a
new Metso C160 jaw According to ScottReck Plant Manager it no longer made
sense to repair and rebuild the existing
impactor
ldquoBefore we purchased the Metso C160
we had a few other impact crushers and
they served us well but as our custom-
ersrsquo needs increased our plant production
had to match that demand We found our
formerly reliable unit was being overcome
by our demands for output and creative
work-around solutions We continued to
need more but there was only so much we
could do until we hit the breaking point ndash
literallyrdquo
In addition to performance improve-
ments the new crusher also needed to fitinto Pleasant Gaprsquos unique infrastructure
As Plant Project ManagerEngineer Jeremy
Fahr explains ldquoOur height restraint was 274
meters (108rdquo) This height was the distance
from the feed lip of the existing 6x12 scalp-
ing screen and the existing structure that
the crusher rests onrdquo
The normal C160 crusher is 307
meters (121rdquo) tall but Metso gave GOH
Scott Reck Plant Manager (left) and
Jeremy Fahr Plant Project Manager
Engineer at Pleasant Gap Quarry
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983122983141983152983151983154983156983145983150983143 983154983141983155
a 10-degree mounting option (which is
normally used on their portable crushers)
to overcome the height restraint Reck and
Fahr worked with Dave Rhoa of Cleveland
Brothers Equipment Metsorsquos crushing and
screening distributor in Pennsylvania to
pull everything together and fit the newcrusher into their plant
The C160 crusher selected for Pleasant
Gap is one of the latest models in Metsorsquos
C Series of jaws These jaw crushers feature
a large throw and steep toggle plate angle
resulting in a higher crusher output In
addition the C Series has a compact foot-
print that makes it an ideal choice for the
replacement of existing machines
According to Reck ldquoWe had heard about
the new Metso C160 and started doing our
own research and found Metso not only
had developed the output capacity we
needed but fit the uniqueness of our oper-
ationsrdquo The new Metso crusher will allow
the plant to increase tons per hour andgive them the 1047298exibility to meet demands
for varying products on short notice
Mobile solution
Purchasing the new primary jaw addressed
the long-term issues but still left Pleasant
Gap without a functioning primary plant
Reck continues ldquoOur main line was still
down leaving us with a big hole in hitting
customer needs but knowing that our new
Metso C160 was on its wayhellipwe needed an
immediate solution to keep our produc-
tion demands with an out-of-commission
crusherrdquo
The team at Pleasant Gap brainstormed
the problem and came up with a plan toget the primary plant back in operation
Their solution was to use the Lokotrack
LT1213 impactor plant and another mobile
unit to keep the main line crushing To do
this they removed the guts on the existing
impact crusher essentially turning it into a
rock chute They then moved the LT1213
and another manufacturerrsquos mobile unit
over to the existing dump hopper gt
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
ldquoWe had our haul trucks drop off mate-
rial while two excavators fed the two
mobile unitsrdquo Reck explains ldquoFor two-and-
a-half months the Lokotrack LT1213 unit
was producing 254 cm (10rdquo) minus at
700 tons per hour The other similar-sized
mobile unit was doing 400 tons an hour
maxed out The difference was unbeliev-
able to say the least Our unique solution
using the two mobile units especially the
LT1213 helped Glenn O Hawbaker achieve
a record output in 2010rdquoAccording to Fahr ldquoWe were not new to
Metsorsquos quality and supportrdquo because GOH
had been using Metsorsquos portable crushing
equipment for 3 years prior to the primary
plantrsquos impact crusher failure In another
part of our operation we have a system that
our team relies on every day a Lokotrack
LT1213 and ST272 working in tandem with
two portable conveyorsrdquo This highly effi -
cient mobile processing system turns out
300 tons of specialized blended material
per hour GOH has been so impressed with
Metso equipment its last two purchaseswere an LT106 tracked jaw plant and a
second ST272 mobile screen in 2010
Maintaining high productivity
The Metso C160 jaw was delivered to Pleas-
ant Gap Quarry in January of 2011 and
since start-up it has more than met expec-
tations The crusher is fed minus 910 mm
(36rdquo) limestone with the jaw set at 140 mm
(5 12rdquo) According to Reck ldquoFrom moment
we started up we knew we had a winner
Not only were we kicking out as much
product as our previous units without even
breathing hard but we immediately had a
2-cent per ton savings to the bottom line
without having to run a second 350 HP
motor as required by other units Plus by
adding on the new automatic lube system
the maintenance team had more time to
devote to keeping other areas of the com-
plex running more effi cientlyrdquoReck says ldquoThe Metso unit was a perfect
fit and with the improved features it pre-
sented it had it all We just turn it on load
it up and we are moving 600 tons per hour
through the crusher without any effort and
we know it can do so much morerdquo With
the primary crushing plant back in opera-
tion the entire team at Pleasant Gap will
continue to do what they do best produce
and sell high-quality products and meet
their customersrsquo expectations
More info
Scott Yablonsky Tel +1 262 717 793
scottyablonskymetsocom
The Metso C160 jaw
was installed at a 10deg
angle to fit Pleasant
Gaprsquos existing
infrastructure
The Lokotrack LT1213 impactor plant and ST272 mobile screen operate in tandem with two
portable conveyors at Pleasant Gap
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983149983141983156983155983151 983150
Paper amp fiberNew OptiConcept M paper
and board making line
The new OptiConcept M paper and board
making line stands for economy safety and
usability
Metso has launched a new modular paper
and board making line called OptiConceptM A member of the proven OptiConcept
production line family the new OptiCon-
cept M optimizes machine investment in
line with each millrsquos capacity needs
Savings in operating costs are achieved
through precise dimensioning of pro-
cesses proven technological solutions
optimal running parameters effective
maintenance operations and fully inte-
grated automation solutions
Optimized processes innovations
smart controls and accurate dimensioning
decrease the use of steam gas electricitywater chemicals and other raw materials
and reduce emission levels
OptiConcept M has been designed
both visually and physically with the
requirements of users in mind For exam-
ple the design of the machinery allows for
easy and safe changing of rolls and wear
parts thus reducing the total duration and
cost of maintenance shutdowns
RecyclingGreen energy technology to
Elektrociepłownia Białystok in Poland
Metso will convert a coal-fired boiler to
a biomass-fired Bubbling Fluidized Bed
boiler for Elektrociepłownia Białystok SArsquos
combined heat and power plant (CHP) in
Białystok Poland The new boiler system
will cut the power plantrsquos CO2 emissions
significantly by partly replacing the coal
fuel supply with biomass fuel
ldquoPoland is one of the largest countries
in Europe to have such a high depend-ence on energy derived from coal to
meet national electricity needs This is an
important incentive for us to reduce future
CO2 emissions and produce more green
electricity and with Metso technology
we are certain to accomplish our goalrdquo
states Mr Andrzej Schroeder President of
Elektrociepłownia Białystok SA
Since 2000 Metso has received a total
of 7 biomass boiler conversion orders in
Poland and the renewable energy share
in Poland is only 75 (2010) compared to
the target of 20 by 2020 set by the EUApproximately 80 of the current energy
boilers turbines and generators installed in
Polish power plants are over 20 years old In
order to meet the strict EU environmental
requirements modernization of existing
installations is necessary
Automation
Metso DNA automation system expands
to mining and construction
Using Metsorsquos control room automation
an entire crushing and screening plant can
be effi ciently managed
Metso is a leading supplier of mining and
construction machinery This expertise has
now been combined with a scalable Metso
DNA automation system that adapts to
the range of industry needs from single
machine controls to plant-wide automation
and information management systems
An example of Metsorsquos new offering is a
new crushing plant control room solution
that connects crushers and screens ensur-
ing the effective management of the entire
plant from a pleasant and safe control
room The Metso DNA user interface pro-vides the production information to ensure
a proper and rapid response to plant
events Automatic controls stabilize the
process and allow the operators to monitor
the plant as a whole
ldquoThe benefits of automation for the min-
ing and construction industry are signifi-
cant As an example of the services we offer
performance studies to crushing plants
utilizing Metsorsquos multi-disciplinary teams of
experts to determine the present level of
the plant and process effi ciency and to esti-
mate the improvement potential and thebenefits of optimization and automation
including ROI calculationsrdquo says Mikko Maumlki-
nen Product Manager of minerals applica-
tions in Metsorsquos Automation business line
ldquoAs another example our machine
condition monitoring solutions can reduce
plant and machine downtimes as well as
help to avoid safety and environmental
hazardsrdquo he adds
Metso around the world
Aerial view of the Elektrociepłownia Białystok combined heat and power plant in Poland
8202019 Metso Minerals Aggregates 3 2011
httpslidepdfcomreaderfullmetso-minerals-aggregates-3-2011 3636
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
8202019 Metso Minerals Aggregates 3 2011
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2 Editorial
4 News in brief
6 Sochi Winter Olympics are built on top
quality aggregates
10 New products
14 First modular plant to Nepal
quarrying a reality
16 Outokumpursquos Kemi mine set to
double production
20 Multi-stage Lokotrack process
a success in Senegal
21 Finer ore through wear profile study
at El Abra mine in Chile
22 Services success in Surabaya
24 Creating value with Metso
in Hong Kong
26 Zinkgruvanrsquos twin C160 jaws secure
good uptime
29 A complete impact crusher solution
for Lafarge
30 Cost-per-ton wear agreements deepen
customer relationships
32 Primary challenge at Pleasant Gap
quarry
35 Metso around the world
983152983157983138983148983145983155983144983141983140 983138983161 983149983141983156983155983151 983149983145983150983141983154983137983148983155 983145983150983139
Fabianinkatu 9 A PO Box 1220
FI-00101 Helsinki Finland
tel +358 20 484 100 fax +358 20 484 10
e-mail mineralsinfocsrmetsocom
wwwmetsocomminingandconstruction
Results minerals amp aggregates customer maga-
zine is published 3-4 times a year in English with
Chinese French Portuguese Russian Spanish
and Asia-Pacific insertions To receive your per-
sonal copy please contact your nearest Metso
Minerals offi ce or the e-mail mentioned above
983141983140983145983156983151983154-983145983150-983139983144983145983141983142
Eero Haumlmaumllaumlineneerohamalainenmetsocom
983139983151983150983156983154983145983138983157983156983151983154983155 983145983150 983156983144983155 983145983155983155983157983141
Linda Bergmann Elisabetta Cataluffi Gilles
Dombey Atoshi Nayak Ghosh Ou He Eero
Haumlmaumllaumlinen Olli Kellokumpu David LeRoy
and Macarena Vallejo
983141983150983143983148983145983155983144 983148983137983150983143983157983137983143983141 983141983140983145983156983145983150983143
Traduct Oy and Kathleen Kuosmanen
983148983137983161-983151983157983156 983137983150983140 983137983154983156 983159983151983154983147
Vanto Design Oy
983152983154983145983150983156983145983150983143
November 2011
copy Copyright 2011 Metso Minerals IncAll rights reserved
Printed on MultiArt Silk 130200 gm2
Cocoon offset 120 gm2
Reproduction permitted quoting
ldquoResults minerals amp aggregatesrdquo as source
All product names used are trademarks
of their respective owners
Addresses Metso Minerals Inc customer data
ISSN 1797-6480
wwwmetsocomminingandconstruction
Printed matter
441 014
COVER PHOTO Washed high-quality sand produced by Maykop Nerud with Metsorsquos stationary
washing plant for the Sochi 2014 Winter Olympics sites in Russia Stanislav Steblyansky shows the
sand for concrete production
In this issue
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983150983141983159983155 983145983150 983138983154983145983141983142
Services for Northland Resources in Sweden
The services supply at Kaunisvaara covers Metso Poly-Met mill
liners liner handlers and essential tools technical assistance including
maintenance and shutdown planning as well as monthly audits and
annual inspection services for the Tapuli grinding mill
The SmartTagtrade system utilizes Radio Frequency Identification (RFID) tags
and detectors to track ores as they 1047298ow from the blast to the downstream
processes and beyond
Metso has signed a contract with Northland Resources AB con-
cerning a five-year mill lining service and inspection program for
the Kaunisvaara project in northern Sweden The contract comple-ments previous project orders by Northland Resources announced
by Metso earlier this year The value of the order is EUR 19 million
The Metso Life-Cycle Services (LCS) program at Kaunisvaara
includes both the supply and installation of mill liners and techni-
cal and maintenance support for the semi-autogenous mill on the
Tapuli process line Metsorsquos on-site resources will also conduct liner
inspections to maximize mill availability The contract period will
commence when installation of the Tapuli process line is com-
pleted at the end of 2012
ldquoWe are pleased to have concluded this contract as it maxi-
mizes the availability of our grinding linerdquo says Shane Williams Vice
President Projects Northland Resources AB ldquoAs this is a cost-per-
ton contract we will be able to forecast expenditure over extendedperiods of time It will be a very useful asset in view of the total
investment involvedrdquo
ldquoWe embrace the opportunity to partner with Northland in a
five-year LCS commitmentrdquo says Joatildeo Ney Colagrossi President
of Services Business Line Metso ldquoThe speed at which operations
at Kaunisvaara are progressing is impressive and we are look-
ing forward to a rewarding working relationship with Northland
Resourcesrdquo
First SmartTagtrade systems for Europe
Somincor Neves-Corvo an underground copper-zinc mining
operation in southern Portugal owned by Lundin Mining hasrecently installed the first Metso SmartTagtrade system in Europe The
SmartTagtrade system was developed by Metso Process Technology
and Innovation (PTI) to track ore andor waste from mines to the
plant using Radio Frequency Identification (RFID) technology The
RFID tags have been designed to withstand blasting handling by
mining equipment and passing through primary and sometimes
secondary crushers
Somincor is using the SmartTagtrade system to track ore and waste
from post-blast muck piles through underground loading hauling
ore passes crushing storage and finally hoisting and conveying to
surface stockpiles The information will be used to better under-
stand and improve ore and waste handling logistics
Knowledge and interest in the Metso SmartTagtrade system isgrowing in Europe Boliden Tara Mines Ltd has also placed an order
for the SmartTagtrade system Tara is an underground zinc mine in
Ireland processing around 26 Mtpa of ore using Metso equipment
such as a C200 jaw crusher and VPA filters and pumps
The main objective of the SmartTagtrade system at this site will
be to track ore being mined from different stopes and headings
as part of their reconciliation process Waste in ore streams can
increase transport and processing costs reduce the head grade
and produce additional waste tailings
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Lokotrack LT116 attracts customers in Thailand
A group photo taken during a demo day at Thassana Cholburi quarry in
Central Thailand
A Vertimillreg vertical grinding mill under construction
983150983141983159983155 983145983150 983138
TISCO to receive minerals processing equipment
Metsorsquos Lokotrack LT116 mobile jaw plant attracted a number of
customers during a recent demo day organized at Thassana Chol-
buri Thailandrsquos biggest quarry
Marketed by Uawithya Machinery Co Metsorsquos tracked crush-
ing concept has been well received in Thailand Recent deliveries
include Lokotracks both for quarrying and mining purposes
The LT116 jaw plant is now being operated by PTK an iron ore
mine situated in Loei Province in northeastern Thailand
Tandem railcar dumper replacement
for Ridley Terminals in Canada
Metso will supply a tandem railcar dumper replacement to Ridley
Terminals Inc for its Ridley Island Coal Terminal in Prince Rupert
British Columbia Canada The value of the order is EUR 85 million
Metsorsquos delivery includes the replacement of two railcar dumpers
in a tandem installation with commissioning services To facilitate
the unloading of both Canadian and US length cars the dumpers
Metso will supply minerals processing equipment to Taigang
Group Lanxian Mining Co Ltd ( TISCO) the largest stainless steel
manufacturer in China The delivery is scheduled for the first
quarter of 2012 The order comprises seven units of vertical plate pressure filters
wear and spare parts as well as services related to installation
start-up commissioning and technical supervision The delivery
is for concentrate filtering for TISCOrsquos Yuanjiacun iron ore process-
ing plant in Lan County Shanxi province The plant is expected to
start operations in May 2012 with a daily processing capacity of
22000ndash23000 tons of iron ore concentrate
The Yuanjiacun plant is designed to process 22 million tons of
raw iron ore per year When completed Yuanjiacun will be the
largest iron ore processing plant in China
TISCO is among the worldrsquos largest producers of stainless steel
In 2010 the companyrsquos net sales were EUR 117 billion
Stronger services in the North American mining sector
Metso has acquired the service business assets of Copperstate
Industrial Services Inc a mining services provider based in Phoenix
Arizona The acquisition strengthens Metsorsquos position as a leading
service and technology provider for the mining and construction
sectors The company was transferred to Metso on August 1 2011
Established in 1999 Copperstate has built a highly compe-
tent team of service personnel in the American hard rock mining
region Approximately 40 employees will transfer to Metso The
team will be integrated into the Services business line of Metsorsquos
Mining and Construction Technology segment where they willcontinue to serve existing clients The team will be expanded to
further reinforce Metsorsquos maintenance repair and retrofit business
in the USA Canada and Mexico
ldquoThis fits right in with Metsorsquos profitable growth and develop-
ment strategyrdquo says Randy Reisinger Senior Vice President of
Engineered Services Solutions ldquoMetsorsquos objective is to enhance
customer satisfaction by employing a larger team of knowledge-
able well-trained service people to meet customersrsquo skills and
availability needsrdquo
will be equipped with a drawbridgeknife gate system that indexes
and dumps trains of both lengths The tandem railcar unloading
system will be capable of handling 74 railcars per hour Metsorsquos
delivery will be completed by the end of 2011
Wholly owned by the Federal Government of Canada Ridley
Terminals Inc operates an advanced marine terminal providing
high-performance railcar unloading product storage and vessel
loading services
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Facilities for the
Sochi Winter Olympicsconstructed with high-quality aggregates
Metsorsquos stationary washing plant was delivered to Maykop Nerud and so far has processed over
500000 tons of high-quality aggregates and sand for the construction of Olympic facilities in Sochi
Positive estimate of the end product quality
General Director of Maykop Nedud Company
Alexander Kozhanov (in the middle) with hisdeputies Alexey Poddubny and Stanislav
Steblyansky
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983110983141983137983156983157983154983141983140 983137983154983156
The City of Sochi despite
its subtropical climate
is preparing to host the
Winter Olympic Games in
2014 In connection withthis event major sports and
infrastructure facilities are
being built
TEXT amp PHOTOS Eero Haumlmaumllaumlinen
Because the Olympic site is classified as
a 12-magnitude seismic zone the State
Corporation ldquoOlympstroyrdquo and Russian
construction regulations require the use of
high-quality washed aggregates in concrete
when constructing critical objects in Sochi
These requirements are being met
in full by the company Maykop Nerudwhich produces crushed stone of various
fractions and sand using Metsorsquos mobile
crushing and screening plant and a station-
ary washing complex to process ancientmetamorphic alluvial formations into high-
quality construction materials
To date Maykop Nerud has shipped
to Sochi more than a million tons of inert
materialsaggregates produced in its in-
house production and in adjacent quarries
Inert materials are delivered to Sochi exclu-
sively by rail due to the diffi cult mountain-
ous conditions The company dispatches
one to two trains containing 3000 ndash 6000
tons of crushed stone and building sand to
the Olympic city daily
Aggregates from Maykop Nerud arebeing used in many Olympic projects
including Bolshoi ice palace and in tunnel
complex No 1 consisting of 25 kilometers
of road railway and service tunnels which
will be used to transport guests at the
Sochi 2014 Olympic Games between the
Olympic Village and a ski complex in Kras-
naya Polyana
Maykop Nerudrsquos washed sand is also
being used by manufacturers of tubing for
five tunnels under construction
ldquoMetso is a true partnerrdquo
Maykop Nerud was established just four
years ago and was supplying the inert
materials of other producers using anin-house railroad warehouse Later the
company entered into contracts with
quarry It is the first complex of its kind
in Russia
ldquoIn the initial stages of preparation for
the technical requirements of the equip-
ment we had planned to purchase a
mobile washing plant but Metsorsquos engi-
neers convinced us of the advantages of
stationary washing and screening equip-ment Today with the complex working
247 at full capacity it is easy to see that
major construction companies running
operations in Sochi and purchased its ownequipment for crushing and screening
ldquoWhile looking for an equipment sup-
plier we were approached by leading
manufacturers of crushing and screening
equipment After their proposals were
subsequently cross-checked Metso was
deservedly appreciated as a supplier of
high-quality equipment by all other bid-
dersrdquo says Alexander Kozhanov General
Director of Maykop Nerud
ldquoSince choosing Metso as our equip-
ment supplier and during the course of our
cooperation we have come to the realiza-tion that Metso is a true partner for us In
close cooperation with Metso we develop
and implement processes unavailable to
competitors work together as a united
team and share valuable experiencerdquo
Kozhanov adds
A good example is Metsorsquos washing
complex operated at Maykop Nerudrsquos
we made the right choicerdquo says Maykop
Nerudrsquos Deputy General Director AlexeyPoddubny
From sand-gravel mix
to quality aggregates
The raw material Maykop Nerud uses is
metamorphic alluvial sediments of hard
rock deposited in the Belaya River valley
millions of years ago The sand-gravel mix
in the companyrsquos quarry features some
properties of granite with excellent hard-
ness making it a good feed for the produc-
tion of quality aggregates
Straightforward quarrying technology isutilized excavators dig up the sand-gravel
mix and move it to stockpiles From the
stockpiles the sand-gravel mix is reclaimed
to Metsorsquos three-stage crushing and
screening process consisting of tracked
jaw and cone crushing plants and a mobile
screen gt
The sand amp gravel mix is crushed and screened
into 0ndash20 mm fractions using jaw and cone
crushing plants combined with a mobile screen
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The Maykop Nerud Company has supplied more than 150000 tons of 0ndash5 mm washed sand and aggregates in fractions of 5ndash10 mm 10ndash20 mm and
5ndash20 mm for shotcreting and for the concrete lining of the constructed tunnels
Crushed to the size of 0ndash20 mm the
material is transported by conveyors to a
washing complex consisting of a feed hop-
per conveyors a 4-deck washing screen aspiral classifier and an automated control
system
In order to facilitate the operations of its
customers Metso has established a stock of
spares and consumables in Maykop Nerudrsquos
territory Maykop Nerud can use the stock
for its own purposes and parts can also
be delivered to other Metso customers as
required The reliability of the equipment
983110983141983137983156983157983154983141983140 983137983154983156983145983139983148983141
and its operational effectiveness mainly
depend on the availability and prompt
replacement of spares and consumables ndash a
prerequisite ensured by the mutual effortsof Metso personnel and Maykop Nerud staff
Powerful crushing complex in
combination with washing plant
Having taken into account the growing
demand for high-quality end products
Maykop Nerud and Metso agreed to
extend their cooperation and create an
even more powerful stationary crushing
and screening complex including a pri-
mary jaw crusher and two stationary cone
crushers for operation in combination with
a stationary washing plantldquoBeginning in the second quarter of
2012 we will use the new stationary crush-
ing and screening complex along with the
mobile equipment thus allowing us to
increase our capacity to 130000 ndash 140000
tons per month in order to meet the con-
stantly growing demandrdquo says Stanislav
Steblyansky Deputy General Director of
Maykop Nerud
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The construction budget of EUR 534 billion
for projects in Sochi includes three major
sites the Olympic Park along the shore of
Black Sea the Olympic Village residences
for the athletes and the Krasnaya Polyana
ski resort in the Caucasus Mountains
These three sites will be interconnected
by numerous new highways roads bridges
Construction projects at a total budget of EUR 534 billion
983110983141983137983156983157983154983141983140 983137983154983156
The companyrsquos sand-gravel-mix
resources are expected to last upwards of
20 years Upon the completion of mining
and once the territory has been rehabili-
tated the quarry will be transformed into
an artificial lake for recreation and fishing
for the residents of the City of Maykop
More info
Alexey Shevyakhov
Tel +7 495 915 29 30
alexeyshevyakhovmetsocom
LOCATION City of Maykop Republic of
Adygea southern Russia
RAW MATERIAL hard rock sand-gravel mixhardness 40 kN
CAPACITY 250 th with increase up to 550
th in 2012
RESOURCES over 10 million cubic meters
END PRODUCTS Washed building sand 0ndash5
mm and crushed aggregates 5ndash10 mm
10ndash20 mm 5ndash20 mm 20ndash40 mm
ON-SITE MЕTSО EQUIPMENT
bull 1 Lokotrack LT106 jaw plant
bull 1 Lokotrack LT200HP cone plantbull 1 Lokotrack ST35 mobile screen
bull 1 Nordberg CVB 2060-4 inclined
screen
bull 1 Nordberg SF2870 sand trap
EQUIPMENT BEING INSTALLED WITH
COMMISSIONING IN 2ND QUARTER OF 2012
bull 1 Nordberg C80 jaw crusherbull 2 Nordberg HP4 cone crushers
bull 2 Nordberg CVB2060-4 inclined
screens
bull 1 Nordberg SF2360 sand trap
bull 1 Nordberg SF2870 sand trap
Maykop quarry owned by the Maykop Nerud Company
and tunnels Essentially the entire infra-
structure within and around the 110-km-
long Sochi will be renewed
More than 155000 workers are involved
in the construction projects In total more
than 300000 cubic meters of concrete
will be used for shotcreting and for the
solid cladding of the tunnels A consider-
able proportion of that concrete will be
prepared using the aggregates and sand of
Maykop Nerud
The company Severstroy is producing
concrete elements for lining 23 kilometers
of various tunnels All of the washed aggre-
gates and sand for those projects is also
being supplied by Maykop Nerud
Metsorsquos sand trap is a critical component of the washing complex
In August 2011 construction of the new ice stadium in Olympic Park was at full speed
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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155
The new Metso C120 jaw crusher combines effi ciency versatility and safety
Metsorsquos new C120 jaw crusher made its worldwide debut at the Steinexpo exhibition in Germany
New products
Metso is proud to announce that we have developed the first fully
recyclable modular screening media ndash Metso Trellex LS-Eco
In response to customer requests for sustainable and environ-
mentally friendly screening media solutions and in line with our
own sustainability program we have taken the acclaimed Metso Trellex LS rubber modular screening media systems and success-
fully replaced the traditional steel reinforcement with an environ-
mentally friendly composite material This unique solution makes it
possible to effectively recycle our customersrsquo screening media
In the past screening media modules that were no longer
suitable for production were treated as waste and could not be
recycled Metso has introduced a new future for the product and a
sustainable solution
Sustainable solution for screening media
Metso has launched the
first fully recyclable
modular screening
media ndash Metso
Trellex LS-Eco
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Metsorsquos Mining and Construction Technology has introduced the
Metso C120 jaw crusher ndash the 13th member of the field-proven
C-series range of crushers The C120 combines uncompromising
reliability crushing effi ciency and versatility in both stationary and
mobile applications with safety and ease of use
Even at first glance it is clear that Metso has paid special atten-
tion to the C120rsquos new durable and user-friendly design start-
ing with the casting the design of which is based on thorough
FEA analysis and casting simulations Every detail of the C120 is
engineered for reliable operation and long life resulting in high
constant crushing capacity and uptime
ldquoWhen starting the C120 project we listened closely to our cus-
tomers and collected field data from a number of sites Based onthat information we decided to design the crusher cavity and kin-
ematics first As a result Metso can now offer aggregates produc-
ers large-scale contractors and mining companies a new crusher
that meets all the standards set for any demanding applicationrdquo
says Ilkka Somero Metsorsquos Product Manager for jaw crushers
New design brings outstanding productivity
The outstanding productivity of the C120 is guaranteed thanks
to several new design elements The crusher features a long and
aggressively directed stroke and a fixed jaw die longer than previ-
ously seen in this crusher size class The C120 has a large feed
opening of 1200 x 870 mm (34 x 47rsquorsquo) and an aggressive cavity cross
section securing a high per formance and reduction ratioIn terms of cavity volume and crusher weight the C120 is posi-
tioned between the existing Metso C116 and C125 jaw crusher
models
The Metso C120rsquos nominal power is 160 kW (200 HP) operating
speed 230 rpm closed side setting between 70 ndash 200 mm (2 34rsquorsquo
ndash 8rsquorsquo) The operational weight is 26000 kg (57200 lbs) excluding
options
More infoIlkka Somero
Tel + 358 50 317 0769
Ilkkasomerometsocom
The optional robust composite 1047298ywheel guards allow quick and safe
access to the service points
983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156
In addition to providing environmentally friendly screening
media panels Metso will implement a unique program to provide
its customers with a suitable range of recycling services
The Metso Trellex LS-Eco offers a wide range of health safety
and environmental benefits Each screening media panel is up to40 lighter than standard steel reinforced Trellex LS panels This
makes handling easier and the working environment safer Lighter
panels also help to reduce the overall stress on the entire screening
installation
Compared to steel-reinforced panels the composite-reinforced
panels of the Metso Trellex LS-Eco are more 1047298exible and will reduce
the effects of pegging and blinding during screening operations
The Metso Trellex LS-Eco promises reduced downtime and
increased productivity
The Trellex 300LS and Trellex 305LS rubber and polyurethane
panels are already acclaimed worldwide as being among the most
versatile modular screening media solutions They can be attached
to most screening media systems and can handle all types of
screening applications ndash fine and coarse wet and dry In the futurewhen Metso customers need new screening media panels for
their existing system they can choose Metso Trellex LS-Eco and be
assured that their panels will be safely and effectively recycled
More info
Claes Larsson
Tel +46 410 525 73
claeslarssonmetsocom
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The new Lokotrack LT120 with its world premiere at the Steinexpo
exhibition in Germany combines crushing performance and user-
friendly design in a new revolutionary way For the first time the
same Lokotrack model is now available in a hydraulically or electri-
cally driven version to meet customer needs
New Lokotrack LT120 jaw plant introduced
Lokotrack LT120 is the latest and most advanced of Metsorsquos track-mounted jaw crusher plants
Lokotrack LT120 combines user-friendly design and good crushing
performance in a new way
power supply or a 420-kV onboard diesel generator Having the
possibility to use an external power supply enables a highly eco-
nomical and ecological crushing process
The Lokotrack LT120 is built around the new C120 jaw crusher
See page 10 for information about the C120
Safe to use move and service
Safety is the highest priority for Metso when designing new equip-ment The Lokotrack LT120 is designed to be safe to operate move
and service
ldquoA safe operating environment is created by practical solutions
When service points can be reached easily the possibility of dan-
gerous situations diminishesrdquo says Product Manager Timo Nakari
ldquoGood examples of safety built in to the Lokotrack LT120 include
sturdy easy-to-open composite 1047298ywheel guards and hydraulically
folding and locking feed hopper sidesrdquo Nakari adds
The Lokotrack LT120 can be fine-tuned to suit the customerrsquos
application by selecting the required options from a long main
conveyor and hammer and boom to a water spraying system and
rubber lining for the feeder and hopper for example
The Lokotrack LT120 features a Caterpillar C13 310 kW (415 hp)engine Its transport dimensions are length 16 m (52rsquo 6rdquo) width 3 m
(9rsquo10rdquo) height 39 m (12rsquo 10rdquo) and weight 57 tons (114000 lbs) The
LT120E version weighs 63 tons (126000 lbs)
More info
Timo Nakari
Tel + 358 40 701 6143
timonakarimetsocom
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The Lokotrack LT120 uses the same field-proven technology
seen in Metsorsquos tracked units for over 26 years Every detail of thenew jaw plant has been thoroughly designed for reliability and
long life The main targets when designing the unit have been
energy effi ciency good performance reliability and product safety
Field tests have demonstrated its good fuel economy and high
crushing capacity
Environment-friendly economy
The Lokotrack LT120 is also available as an electrically driven unit
ndash the Lokotrack LT120E ndash which can take energy from an external
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The TS range of screens is characterized by its innovative design
comprising two technologies combined multi-variable slopes with
a variable elliptical motion This proven range is being comple-
mented with the new TS63 screen
The TS63rsquos unique combination increases both the screenrsquos effi -
ciency and its capacity Material speed is high at the feed end and
slows down at the discharge end
Metso TS series screens offer more space between decks mak-
ing maintenance easier and improving service conditions for the
operators as well as meeting all safety requirements
Metso has recently sold several 25-m2 multi-slope screens for
mining applications such as a TS63 for Ferrostaal in Mauritania andalso for the construction industry for example Holcim in Lynwood
Australia Georyt in Poland Apaxco in Mexico and Newmont in
Peru
More info
Denis Pradon
Tel +33 680 64 39 67
denispradonmetsocom
New TS63 screen ndash the largest three-deck banana screen on the market
The new Metso TS63 banana screen features a 25-m2 screening area
Following the success of the HP4 and HP5 Metso has broadened
the product range with the new HP3 cone crusher This mid-range
cone crusher benefits from 70+ years of experience in crushing
technology while specifically addressing customer requirements
for large capacity ease of operation and a high reduction ratio
The HP3 responds to market demands for increased productionquality reduced maintenance time and low operating costs The
new generation HP models are comparable to their predecessors
but offer increased versatility
The HP3 features the size of an HP200 with the output of an
HP300 The power performance and robustness of the new gen-
eration models allow in certain cases two crushers to be replaced
with just one so investment production and operation costs are
greatly reduced
The HP3 has been tested at two different quarry sites in France
over the past seven months ndash at a gravel pit and a rock quarry
The Metso factory in France began production of the HP3
series in September Several orders have already been received for
secondary and tertiary applications Since 2009 nearly 300 HP newgeneration cone crushers have been commissioned The HP3 mar-
ket will be primarily centered on gravel pit applications (70)
The HP3 has a nominal feed opening of 220 mm (865rsquorsquo) a
motor size of up to 220 kW (300 hp) and a weight of 13280 kg
(29277 lbs)
More info
Carlos Padin
Tel +33 6 0727 2002
carlospadinmetsocomMetso HP3 at a stationary installation in France
HP3 cone ndash another new-generation cone crusher
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
First modular plant to NepalMetso delivered its first modular crushing and screening plant to MS Palchowke Mai Roda Dunga Udyog Limited (PMRD)
in Melamchi Nepal The modular plant solution offers PMRD a fast and effective response to productivity and qualityrequirements
TEXT amp PHOTOS Atoshi Nayak Ghosh
The diversity of operations at a typical con-
struction site involves quick decision-mak-
ing and often a lot of pressure to ensure a
timely execution
High performance guaranteed
Considering todayrsquos volatile market sce-
nario business partners must maintainpace with their customersrsquo ever-changing
requirements Understanding custom-
ersrsquo strategic business needs is of utmost
importance PMRDrsquos plant was commis-
sioned in January 2011 and has logged
about 1200 hours of operation to date
The plant is much more compact than
the traditional skid-mounted plant and
provides space for free movement of utility
equipment within the plant area One of
the key features of the plant is the totally
bolted structure It can be easily disman-
tled into sub-assemblies transported and
re-assembled effortlessly at a new location
which is one of the biggest advantages in
helping to meet new market demand
Due to the use of pre-assembled mod-ules for each crushing station the instal-
lation work on site takes less time thus
decreasing the plantrsquos installation lead time
The plant also includes a foldable conveyor
for maintenance of the cone crushers
Stepping up with Metso
PMRD operates a two-stage plant compris-
ing a C80 jaw crusher an HP200 high-
performance cone crusher and a CVB1845
screen with circular motion MV2 vibra-
tory mechanism for final product recovery
resulting in an aggregate plant of 150 tph
capacity for producing size fractions of 0-40
mm The plant is an example of world-class
craftsmanship and excellent material han-
dling capacityModular and non-welded construction
supported by durable pitman assembly sin-
gle-piece cast steel frame bearing housings
with repairable crusher construction and
the right cavity design results in aggressive
kinematics and high power that best suits
the requirements of the customer
PMRD has immense pride in the plant
ldquoThe performance has been astounding
A drawing of typical modular plant
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with applications ranging from road aggre-
gates commercial sand production to
ready-mix concretes The modular plant is
almost set to create a new niche in aggre-
gates processing in Nepalrsquos construction
industry It is one of a kind and we are sur-
prised at the plant rsquos production capacity
It is easy to operate and requires minimalmanpower Our cost per ton has signifi-
cantly gone down and so has the cost of
productionrdquo says Mr Sandeep K Agarwal
Director PMRD
Safety as a key issue
Health safety and environmental solutions
are key concerns for Metso and they are
addressed with the same sense of responsi-
bility as quality productivity and cost-
effi ciency issues Metso is responsible for
conducting operations in an environmen-
tally sound way and offers products and
services that can help customers fulfill their
environmental responsibilities
Metso provides the plant offi ce and site
with operation and maintenance manu-als for each and every piece of equipment
including safety issues which are entrusted
to all the operators
All conveyors are equipped with pull-
cord safety switches along with emergency
stop buttons The working area and walk-
ways are all equipped with safety hand rails
and checkered plates for anti-skidding The
entire plant is equipped with earth pits for
electrical current earth leakage prevention
Metso has ensured all possible measures
to maintain high safety standards for all
operation and maintenance personnel
More info
Suhen Agarwal
Tel +91 124 2351566suhenagarwalmetsocom
Nepalrsquos first modularcrushing and screening plant deliv ered by Metso
E ffi cien t C VB1845 inclined screen wi th
an M V2 vibra tor y mechanism handles
the classi fica tion o f crushed ma terials
A s turd y f eeder dis tribu tes the ma terials to be crushed to
a
Me tso C80 ja w crusher
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Outokumpursquos Kemi
mine set to doubleproduction The only mine unit owned by Outokumpu
the chrome mine in Kemi northern Finland
is busy making preparations to double its
production set to begin next year In co-
operation with Metso Outokumpu willincrease the number of underground
feeders and optimize the durabil-
ity of wear parts in the massive
primary gyratory crusher
TEXT amp PHOTOS Eero Haumlmaumllaumlinen
Chrome ore is fed into Metsorsquos
Superiorreg 50-65 primary
gyratory crusher by three
different vibrating feeders
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983122983141983152983151983154983156983145983150983143 983154983141983155
Up until now the entire production of the
chrome mine totaling about 13 million
tons annually has been transported to the
Tornio ferrochrome plant for processing
and on to the Tornio stainless steel plant
The increase in production which will
begin in autumn 2012 is intended also to
enable Outokumpu to sell ferrochrome tocompanies outside the Group The produc-
tion target for 2013 is 27 million tons of
ore and of the ferrochrome produced from
the ore nearly a half (gt 200000 tons) is to
be sold outside
Underground expansion
work almost complete
About 500 meters underground the
majority of the work involved in increasing
the capacity the F3 project has already
been completed Doubling the production
is no problem for the Superiorreg primarygyratory crusher delivered to the mine
by Metso in 2002 which can digest more
than 2700 tons of feed material per hour if
necessary
At the moment the primary gyratory
crusher can be fed by three different vibrat-
ing feeders The crusher currently runs for
less than one-fifth of the production time
The increase in ore production will increase
the effective crushing time to about one-
third of the production time
A lot of work has been done for orestorage after the primary crusher The
two currently used storage silos are now
accompanied by two new 8000-ton silos
The number of Metso feeders transporting
the ore from the primary crusher has also
been doubled
Optimization of wear parts under way
Chrome ore has been a challenge to the
primary gyratory crusherrsquos wear parts The
wear is contributed to by the pulsating
feed which rarely fills the entire crushing
chamber There are also great differences inore type since brittle feed material prone
to chalking is occasionally replaced by hard
ore that requires a lot of crushing power
before it is crushed with a bang gt
Mika Saari (right) Foreman of ore line technicians at Outokumpursquos chrome mine in conversation with
Mikko Malkamaumlki Metsorsquos crusher wear parts specialist
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
last did in July for the replacement of the
crusherrsquos wear parts Our work is also facili-
tated by product development like the
addition of maintenance hatches to the
feedersrdquo he continues
Lasting technology
According to Mika Saarirsquos calculations the
Superiorreg primary gyratory crusher has so
far crushed more than six million tons of
ore in totalldquoThe factory polishing marks still show
on the bottom thrust bearing so we
believe that the bearing will last the entire
remaining service life of the crusher which
is about ten years and 30 million tons
Metsorsquos feeders have been equally reliablerdquo
Saari says
After the next 30 million tons of ore
it will be time to deepen the mine
More info
Jukka Raumlisaumlnen
Tel +358 50 317 1787 jukkaraisanenmetsocom
Mikko Malkamaumlki
Tel + 358 40 827 8223
mikkomalkamakimetsocom
The Kemi mine and Metso are currently
carrying out a development project to
increase the service life of the mantle and
outer concave and thus minimize down-
time due to replacement While the modu-
lar feed hopper enables quick replacement
of the mantle replacing the outer concave
can easily take more than a week The cooperation between the Kemi
mine and Metsorsquos wear parts team in
Tampere aims to extend the service life
of the parts to at least 4 million crushed
tons Durability is sought by optimizing the
chamber structure and selecting the r ight
materials for the outer concave
ldquoSmooth cooperationrdquo
Mika Saari Foreman of ore line technicians
working in the underground mainte-
nance of the Kemi mine leads a small but
experienced team of technicians The tidymodern offi ce spaces are located close to
the action at a depth of 500 meters
ldquoCooperation with Metso has been
smooth Increasing our own crushing
expertise takes time so all know-how
shared by the manufacturer is very wel-
come to usrdquo Mika Saari says
ldquoWe can also use Metsorsquos profession-
als for servicing when necessary like we
The Superiorreg 50-65 has provided reliable
crushing performance at a depth of 500 metres
in the Kemi chrome mine
Technicians Sari Kulju (left) and Marko Jaako ensure that the primary gyratory crusherrsquos hydraulicand electrical unit remains very tidy which contributes to trouble-free operation of the crusher
Outokumpu Oyrsquos Kemi
chrome mine
LOCATION Keminmaa northern
Finland
ORE TYPE chrome oxide (26)
ORE ESTIMATE ON 1 JANUARY 2011
ndash ore reserves 36 million tons
ndash mineral resources 87 million
tons
MINING METHOD bench and cut fillFEED MATERIAL SIZE 0ndash1000 mm
METSO EQUIPMENT IN THE MINE
bull 1 Superiorreg 50-65 primary
gyratory crusher
ndash open side setting 152 cm (6rdquo)
bull 8 VMOU 25-125 feeders
bull 1 VMOU 30-16 feeder
bull 1 VMOU 40125 feeder
bull 2 Symons cone crushers
bull 1 C80 jaw crusher
bull 4 HM75 pumps
bull 11HM100 pumps
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983122983141983152983151983154983156983145983150983143 983154983141983155
Metso was responsible for the design
development and construction of the
entire secondary and tertiary arrangement
The primary station will be the subject of a
subsequent investment
Latest environmental protection used
This installation has been designed in strict
compliance with the environmental quality
approach developed by Metso and its
partners using the latest technologies
in dust control including confinement
technology as well as dust encapsulation
technology for screens
To ensure an annual capacity of 15 mil-lion tons for a nominal output of 560th of
02 mm and 220 mm the clientrsquos choice
for the secondary stage naturally fell upon
the NP 1520 impact crusher
A complete impact crusher solution for Lafarge The Lafarge Group has entrusted Metso with the implementation of its new aggregates installation in southern France
It comprises a new secondary crushing stage equipped with an NP1520 impact crusher featuring a power range of2 x 250kW and equipped with hydraulic adjustment
TEXT amp PHOTO Gilles Dombey
The NP 1520 crusher has long proved
its performance not only in terms of capac-
ity and reduction rate but also quality of
the finished product and durability
More info
Arnaud Bertucat
Tel +33 (0)6 81 44 68 26
arnaudbertucatmetsocom
About 15 million tons of aggregates feed will be crushed with the NP1520 impact crusher at Lafargersquos stationary installation in southern France
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Multi-stage Lokotrack process a success in Senegal
A multi-stage crushing and screening process has proven its effi ciency in the production of concrete aggregates in
Senegal Western Africa With the mobile process Xewell Cimenteries SA now exploits its quarry better has reduced
its operating costs and can meet strict environmental requirements
TEXT Elisabetta Cataluffi PHOTOS Carlo Rinolfi
Senegal is a rapidly developing country
offering a good deal of potential activities
for crushing companies too At the sametime the country has several areas of high
environmental value Therefore contractors
must opt for state-of-the-art equipment that
offers reduced environmental emissions
The company Xewell Cimenteries SA
was founded in 2008 as a partnership
between Italian Swiss and Senegalesecontractors Xewell operates a limestone
quarry located in the Pout area east of the
capital city of Dakar
According to Alessandro Crestani Technical
Director of the Pout quarry a mobile process
was selected to better exploit the quarry and
reduce costsLokotrack process drawing made by Bruno simulation software
After assembling the Lokotrack units the process was tested by Xewell Cimenteries
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983122983141983152983151983154983156983145983150983143 983154983141983155
Owned by Freeport-McMoRan Copper amp
Gold (51) and CODELCO (49) the ElAbra mine has leachable oxide and sulfide
mineralization The minersquos processing facil-
ity has an annual capacity of 226000 tons
of copper cathode
Smaller size matters
Reducing the size of the crushed oxide
ore from the present 15 mm to 12 mm
was the main target of the mine and the
Metso team The changes that were carried
out in the process included a size varia-
tion change in the cut of the tertiary sieve
installation of rate-level sensors in thesecondary crushers and enabling speed
variables in the conveyor belt feeders of
the secondary crushing circuit
ldquoGoing from 15mm to 12mm may seem
small but the operational impact is very
important and significant for usrdquo explains
Juan Torres Carvajal Metallurgical Engi-
neer at the El Abra mine
ldquoOur goal is to reach 115000 tons with
a minimum of 80 of 12-mm-sized ore permonth The record to date is 105000 tons
and we will increase it until we reach our
project goalrdquo he adds
New design for cone liners
In addition to the work mentioned above
Metso is currently carrying out a project to
design the lining profiles for the secondary
and tertiary crushers of the plant which
will affect the smaller size of the material
In cooperation with Nelson Mella from
Metso and Rodolfo Navarro Crushing
Superintendent at the El Abra mine testswere carried out in July on the re-designed
Metso linings One set was tested for sec-
ondary crushing and two sets for tertiary
crushing
More info
Nelson Mella
Tel +56 99158 0576
nelsonmellametsocom
Finer ore through wear pro1047297lestudy at El Abra mine in ChileEl Abra is a porphyry copper open-pit mine and processing facility located in
Chile near the city of Calama some 4000 meters above sea level With the helpof Metsorsquos technical support the mine was able to achieve finer ore throughoutthe crushing process
TEXT amp PHOTOS Macarena Vallejo
Xewell Cimenteries produces a selec-
tion of dry processed aggregates for con-
crete Operations started at the end of 2009
with the aim of reaching 150000 metric
tons produced per year
Lokotracks chosen to reduce costs
To build up their tracked mobile processXewell Cimenteries decided to buy three
mobile plants from Metso two impactor
plants the Lokotrack LT1110 and LT1213
feeding a three-deck mobile screen the
ST620 The machines were sold by SCAI
SpA Metsorsquos Lokotrack distributor in Italy
ldquoWe chose tracked machines to bet-
ter exploit our quarry and to reduce
costs Mobile plants have low initial costs
because they donrsquot need any special foun-
dations or supply of electricity This obvi-
ously gives us a quicker process set-up and
better uptimerdquo says Alessandro Crestani Technical Director of the Pout quarry
ldquoThe mobile plant can also follow the
quarry face as the exploitation proceeds
reducing the transport costs of raw materi-
als in the same jobsite We chose Metso
because they ensured us the best cost-per-
ton ratiordquo he adds
Good customer service is crucial
According to Alessandro Crestani good
customer service also played a major role
when choosing the manufacturer of the
mobile equipmentldquoMetsorsquos distributor SCAI SpA was able
to provide us with a complete product
support and customer service package
Obviously service is a very important
aspect for us in a country like Senegal Any
downtime represents a clear loss of pro-
ductivity for usrdquo
The average level of productivity of the
mobile Lokotrack process is 200 metric
tons per hour
More info
Carlo Rinolfi Tel +39 335 1253159
crinolfiscaispacom
Example of the development of the Metso study
on the crusher lining profiles
Liner change for smaller ore size in the
MP1000 cone crusher
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Services success in Surabaya The Metso Surabaya workshop and offi ce complex opened in April 2008 provides Life Cycle Services and maintenance
solutions for Metso equipment in the Indonesia region The facility is strategically located in an industrial precinct on theouter rim of Surabaya the second largest city in Indonesia Its close proximity to an international airport major shipping
port and several engineering companies simplifies support for the regionrsquos key customers which include PT Newmont
and PT Freeport
TEXT amp PHOTOS David LeRoy amp Gary Whittred
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983122983141983152983151983154983156983145983150983143 983154983141983155
The Surabaya site operates through Metso
in Australia with assistance from key sales
and technical staff Handling regional ser-vice and repair business in-house allows
Metso to manage intellectual property and
closely control quality
It also enables the development of a
team of skilled service personnel who can
be utilized both internally and at key cus-
tomer sites as is common with the backup
service the workshop provides for screen
contracts
Innovation at work
Since 2008 the Surabaya facility has suc-
cessfully refurbished a wide variety ofcomponents Recently two ball mill heads
weighing 22 tons each were modified in
order to strengthen the 1047298ange of the ball
mill shell The modification included tap-
ping out existing 1047298ange holes and drilling
new ones so that finger plates could be
installed and welded to the 1047298anges
Positioning the head borer to properly
align the new 1047298ange holes proved diffi cult
Four roller support frames were manufac-
tured to support the heads and allow them
to be rotated easily Each hole was then
drilled and tapped at the correct angleusing the CNC five axis head The job had a
tight delivery as it was required for a shut-
down but with advance planning and inno-
vation it was completed ahead of schedule
MP1000 mainframe on
CNC vertical borer
Well equipped for fabricating and machin-
ing heavy components the Surabaya
The Surabaya facility has proven to be
a success for Metso The workshop offers a
wide variety of services in the region Qual-ity products and competitive pricing and
delivery times have led to strong customer
relationships
Turnover and customer service levels
have increased annually since the open-
ing and between 2008 and 2010 sales
increased 450 These excellent trends
are expected to continue as the operation
expands and the customer base grows
Since 2008 the Surabaya facility has
successfully refurbished
bull MP1000 counter shaft boxes headassemblies mainframes bowls adjust-
ment rings counterweights sockets and
tramp release cylinders
bull 7rsquo Symons bowls heads and countershaft
boxes
bull Vertimill screw and drive shafts
bull Ball mill heads
bull Ball mill trommel
bull VPA cylinders
bull Eaton clutches
bull Exciter screen mechanisms
bull 42x65 main shafts and eccentrics
More info
Gary Whittred
Tel +62 31 8430349
garywhittredmetsocom
workshop handles the majority of Metsorsquos
refurbishment work with ease But when
necessary PT PAL ndash a government facilitywith shipbuilding and heavy engineering
capabilities ndash offers a ldquoone stop shoprdquo Spe-
cially trained PT PAL staff ensures that the
work they perform complies with all Metso
specifications and quality standards
PT PAL also demonstrated their innova-
tive ability with the first MP1000 main-
frame refurbishment they completed The
mainframersquos shaft location bore needed
to be re-machined However the distance
from the top of the mainframe to the
tapered bore made it very hard to achieve
an accurate surface finish with the correctstandoff
To overcome this the shop decided to
machine the mainframe upside down and
elevated on support beams They posi-
tioned a new shaft under the mainframe in
a custom-made cradle Using an overhead
crane they could then lsquotrial fitrsquo the shaft in
the bore to make sure it seated correctly
and the mating tapers met specification
The method worked so well it has since
been used for four more mainframe refur-
bishments
Diversity and growth
Today Metso Surabaya continues to invest
in additional equipment in order to diver-
sify its service offering A new hydraulic
power pack which allows the facility to test
refurbished components to Metso specifi-
cations was recently used in the refurbish-
ment and testing of several VPA cylinders
for PT Freeport
Refurbished MP1000 mainframe dispatched by truck to
PT Freeport mine
Machining of MP1000 upper frame
at Metsorsquos Surabaya workshop
Mainframe at vertical CNC machining
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Creating Value with Metso in Hong KongIn Hong Kong the aggregates needed for construction are mostly supplied by two local quarries KWP Quarry Company
Limitedrsquos Anderson Road Quarry accounts for 60ndash70 making it the pillar of Hong Kongrsquos construction materials industry
TEXT amp PHOTOS Ou He
When arriving at the Anderson Road
Quarry the most impressive view at the850000 square-meter facility is the Metso
machines including equipment from the
primary secondary and tertiary crushing
circuits and the screens I t is Metsorsquos equip-
ment that secures the supply of aggregates
for Hong Kong
KWP Quarry Company Limited has been
working with Metso since its establishment
in 1997
Due to Hong Kongrsquos stringent dust and noise control standards Metso has paid special attention to the related suppression systems
ldquoOur quarry mainly lies on granite and
volcanic rock which are so hard they canonly be processed by equipment with
strong durability and stabilityrdquo explains
Mr Eddie Hung Manager of KWP ldquoWith a
long history of and experience in quarry-
ing we are very familiar with the equip-
ment of different brands Comparatively
Metsorsquos products are better than others in
terms of durability stability and effi ciency
Besides this the reason we selected Metso
is because of the simple maintenance of
their equipment and the easy access tomaintenance informationrdquo
Flexible modular solution
Based on extensive experience in crushing
and screening worldwide Metso presented
the Anderson Road Quarry with a modu-
lar solution and delivered it as a turn-key
project Through a four-stage crushing
circuit which contains three Metso C160
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jaw crushers for primary crushing two
Omnicone 1560SX crushers for secondary
crushing two HP 500SX cone crushers for
tertiary crushing and one HP500SX cone
crusher for extra-fine crushing the plant
was able to produce aggregates of optimal
shape with minimal 1047298akiness
The fine products include three sizes
0 to 5 mm 5 to 10 mm and 10 to 20mm
Since the employment of this system in
2000 production has reached 1250 th
which is far beyond the design capacityAccording to Mr Hung ldquoThe machines
always run effi ciently and seldom malfunc-
tion The occasional shutdown of some
machines does not affect production very
much the plant still could reach 60-70
of its normal production It gives us the
best 1047298exibility for the plant rsquos operation and
I believe this is the best feature of Metsorsquos
solution
Eddie Hung
Manager of KWPrsquos
Anderson Road
Quarry is happy with
the product quality
and service provided
by Metso
ldquoMetsorsquos equipment is expensive com-
paratively but in the long run you will find
that the investment is worthwhile on the
whole Metso secures superior stability reli-
ability and fewer downtimes and it guaran-
tees continuous operation and brings us
greater valuerdquo
Great service team
Metso sent a group of service engineers
to the plant within the warranty period
not only to provide service but to train theoperators Mr Hung speaks highly of Met-
sorsquos service team he is impressed with its
experienced experts and with their strong
sense of responsibility and customer-
oriented ways of working
ldquoMetsorsquos service team never fails to find
hidden problems and helps us to prevent
any mechanical failures And they are
available whenever we need them they
work closely with us to solve the problem
effi cientlyrdquo he said
Excellent environment-friendly designIn order to achieve the worldrsquos most strin-
gent noise and dust control standards
developed by the Environment Protection
Department of Hong Kong Metso has
incorporated a dust and noise suppression
system into the plant This includes the
infrared-triggered spray systems at feed
points encapsulation of individual crush-
ers and conveyors and the ability to select
specific sectors of the system for treatment
depending on feed and operating condi-
tions encapsulation of equipment and the
enclosure of all major sections of the plant
With these advanced environment-
friendly solutions Anderson Road Quarry
has won numerous safety and environmen-
tal awards In 2003 it was presented with a
silver medal in the prestigious Environmen-
tal Performance Awards in recognition of
its commitment to the environment and
community In 2004 KWP achieved certifi-cation of ISO 14001 it is the first quarry site
to have achieved this in Hong Kong and
southern China
ldquoA reliable partnerrdquo
The promulgation of the top ten infrastruc-
ture policies in Hong Kong boosted the
market for aggregates and demand will
keep rising over the next five to six years
ldquoWersquoll definitely keep our cooperation with
Metso once we have a need for expansion
because we regard Metso as a reliable part-
ner With their highly effi cient equipmentsatisfying service and great efforts in help-
ing us to achieve our environmental pro-
tection targets Metso is our best choicerdquo
says Hung
More info
Ziqiang Li
Tel +86 13601289027
ziqianglimetsocom
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The sturdy Metso C160
jaw crushers are fed
using huge feed chutes
and feeders
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983122983141983152983151983154983156983145983150983143 983154983141983155
Similar to hundreds of mine sites world-
wide Zinkgruvan is being operated on a
non-stop 247 basis with just a few main-
tenance breaks during the year Crusher
availability is crucial because 100 of the
ore has to pass through the jaws before
being hoisted up for further processing
In addition to the zinc- lead- copper-
and silver-containing ore the C jaws chop
all the host rock extracted along the min-
ing process With a sturdy design Metsorsquos
proven C jaws can easily reduce even the
hardest type of rock Every year more thanone million tons are crushed with the jaws
ldquoMinimal service neededrdquo
Crushing with the first C160B jaw crusher
began at Zinkgruvanrsquos -800 meter level in
2000 with the primary crushing of zinc-lead
ore The second jaw was installed in 2008
for the new copper process gt
The sight and sound of two C160 jaw crushers operating side by side in the underground
crushing station of the Swedish Zinkgruvan mine is impressive Good proactive service
secures good uptime and reliable continuous operation of Metsorsquos second-largest
C160 series jaw crushers and prepares the way for the ongoing plans to expand the
production of zinc concentrate
TEXT amp PHOTOS Eero Haumlmaumllaumlinen
New PolyMet liners are being tested with the grinding mill delivered by Metso
Zinkgruvanrsquos twin C160
jaws secure good uptime
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Blasted ore is taken from the presently
operated -850 meter level with normal
trucks as an outsourced process One full
truckload is fed to the C160s every
10 minutes
ldquoWe are happy with the high reliability
of the C jaws They only require some minor
service therefore providing us with good
uptime and steady continuous feed to our
secondary and tertiary crushing and grind-ing circuitsrdquo says Mine Manager Jan Klaumlre
ldquoBasic crusher service and wear part
changes are made by our own staff using
Metsorsquos partsrdquo he adds
Service contract with grinding
mills and conveyors
Zinkgruvan and Metso Sweden have more
than 11 yearsrsquo experience with a service
contract that contains grinding mills and
conveyors At the mine site two Metso
service people and one contractor take
care of all the related service jobs Man-
power can also be borrowed from Metsorsquos
Graumlngesberg mine service team of 20
people
Presently Zinkgruvan is testing Metsorsquos
new PolyMet mill linings in its big grinding
mills With previously used rubber partsthe linings had to be changed in the shell
every 9 to 11 months and in the feed head
every 6 months
ldquoWe expect a better lifetime with Poly-
Met linings Longer change intervals mean
a lot to our productivity because lining
changes takes two full working daysrdquo Mine
Manager Jan Klaumlre says
New mine goes deeper
With an expected mine life of more than 10
years Zinkgruvan is actively mapping new
ore reserves Experimental holes are being
drilled at the new mine section at the
-1110 meter level
More info
Fredrik Wennberg
Tel +46 70 657 00 08fredrikwennbergmetsocom
Mine Manager Jan Klaumlre (left) with Backfilling Manager Kjell Tillman at the underground -800 meter level mine cafeteria
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The Zinkgruvan mine located approxi-
mately 200 km southwest of Stockholm
Sweden is one of the oldest underground
mines in Northern Europe The mine has
been in production since 1857
The mining methods used are panel
stoping and benching The processing
facilities include a zinc concentrating plant
with a 11 mtpa and a copper plant with a04 mtpa capacity Tailings are recycled in
an impounding basin and host rock in the
backfill plant
Continuous mining since 1857
Even as one of the oldest mines in Northern
Europe Zinkgruvan exploits modern mining
and minerals processing installations
Zinkgruvan mine
OWNER Lundin Mining
PRODUCTION PER YEAR 1 million tons
ORE TYPE sedimentary exhalative
zinc lead copper and silver
NUMBER OF EMPLOYEES 320
2011 PRODUCTION TARGETS 78000 tonsof zinc 36000 tons of lead and
3400 tons of copper concentrate
METSO EQUIPMENT ON SITE
bull 1 extra long VF feeder
bull 2 C160 jaw crushers
ndash zinc process css 220ndash240 mm
ndash copper process css 150 mm
bull 1 GP300S cone crusher
ndash css 45mm
bull 1 HP4 cone crusher
ndash css 18 mm
bull 1 DS screen
bull 1 FS402 screenbull 1 grinding mill
bull Pumps VPAs
A normal truck feeds the C jaws with ore coming from the lower production levels
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Cost-per-ton wear agreements deepencustomer relationshipsCrusher wear parts are traditionally marketed purely based on transactional sales and mainly depend on
the weight of manganese Metso has recently introduced a new type of wear agreement based on thecost-per-ton crushed and the wear occurred Thus far the experience has been very positive increasing
transparency and deepening the operational relationship between the manufacturer and the customer
TEXT Olli Kellokumpu and Eero Haumlmaumllaumlinen PHOTOS Eero Haumlmaumllaumlinen
Arto Hiedanniemi (left)
Hannu Heman and Juha
Laukka of Metsorsquos Finnish
Service team checking the
cone crusher mantles shipped
for a cost-per-ton customer
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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156
Wear parts and parts changes
can be included
The structure of a cost-per-ton wearcontract is based on the number of tons
crushed and the estimated wear occurred
The amount and monetary value of the
wear is calculated per crushed ton
ldquoEither plain wear parts or parts changes
carried out by Metsorsquos service personnel
can be included in the contract In the latter
case we ask our Finnish customers to inform
us about an upcoming wear change opera-
tion one week in advancerdquo Heman explains
ldquoWe see good opportunities to market
cost-per-ton contracts further in Finland
and also abroad It really develops therelationship of Metso and our customers
towards a trusted partnershiprdquo he notes
Perfect tool for accurate planning
Soraliike Ikola Oy is a mid-sized contrac-
tor with three Metso two- and three-
stage mobile and portable crushing and
screening plants operating in Central and
Since 2002 Metsorsquos sales team in Finland
has developed the cost-per-ton-based
service offeringldquoOur aim has been to seek through
a cost-per-ton offering possibilities to
serve our customers better to differentiate
Metso from the other players as an OEM
manufacturer and to offer deeper profes-
sionalism and know-howrdquo says Hannu
Heman General Manager of service
operations
ldquoUntil now both our experience and
that of our customers has been quite posi-
tive When properly prepared cost-per-ton
contracts seem to create a win-win situa-
tionrdquo Heman adds Today Metso has operational cost-per-
ton agreements with several Finnish cus-
tomers The first contract was concluded
with a customer operating a stationary
plant Based on the results gathered new
cost-per-ton contracts have been signed
with customers operating wheeled and
tracked equipment too
Eastern Finland Because of the size of the
contracts up to 50 equipment moves are
made during the yearEntrepreneur Pasi Ikola has had a cost-
per-ton contract with Metso for nearly
two years and he is quite happy with the
outcome
ldquoThe cost-per-ton contract has provided
me with a perfect tool for accurate financial
planning Now I know in detail my actual
future wear parts costs This helps a lot
when calculating bidsrdquo
ldquoEarlier I used to buy a big batch of
Metso wear parts in one go and had to
reserve a reasonable amount of money for
that Today all wear costs are evenly sharedwhich gives us a welcomed 1047298exibility to
our cost structure Now we just pay Metso
afterwards based on our crushed tonsrdquo
he adds
More info
Olli Kellokumpu
Tel +358 50 354 1189
ollikellokumpumetsocom
According to crushing contractor Pasi Ikola the cost-per-ton contract with Metso has provided the entrepreneur with better economical 1047298exibility
and more accurate calculating of bids
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Pleasant Gap is owned and operated by
Glenn O Hawbaker Inc of State College
Pennsylvania This family-owned company
began in 1952 as a small excavation busi-
ness founded by Glenn O Hawbaker and
his wife Thelma Over the years the com-
pany grew by adding an integrated mix ofproducts and services and taking on larger
projects
In 1983 Hawbaker acquired Pleasant
Gap Quarry and built its first aggregates
processing plant Today Glenn O Haw-
baker Inc operates 21 quarries and eight
asphalt production facilities across Penn-
sylvania and southern New York as well as
five regional operation centers
Primary
challenge atPleasant GapQuarryA good part of what makes for a successful crushing
operation is the willingness to tackle challenges and to do
whatrsquos necessary to meet demand The team at Pleasant
Gap Quarry in central Pennsylvania recently met the chal-
lenge when they successfully addressed problems with
the plantrsquos primary crushing plant First they purchased
a new Metso C160 jaw to replace the existing primary
impact crusher Then they devised an innovative plan to
get the primary plant back in operation while awaitingdelivery of the new jaw crusher
TEXT Linda Bergmann PHOTOS John Rickinger
983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Time for a change
With the goal of increasing reliability and
output the management at Pleasant Gap
Quarry recently decided it was time to
replace the plantrsquos primary impact crusher
Following a thorough search they chose a
new Metso C160 jaw According to ScottReck Plant Manager it no longer made
sense to repair and rebuild the existing
impactor
ldquoBefore we purchased the Metso C160
we had a few other impact crushers and
they served us well but as our custom-
ersrsquo needs increased our plant production
had to match that demand We found our
formerly reliable unit was being overcome
by our demands for output and creative
work-around solutions We continued to
need more but there was only so much we
could do until we hit the breaking point ndash
literallyrdquo
In addition to performance improve-
ments the new crusher also needed to fitinto Pleasant Gaprsquos unique infrastructure
As Plant Project ManagerEngineer Jeremy
Fahr explains ldquoOur height restraint was 274
meters (108rdquo) This height was the distance
from the feed lip of the existing 6x12 scalp-
ing screen and the existing structure that
the crusher rests onrdquo
The normal C160 crusher is 307
meters (121rdquo) tall but Metso gave GOH
Scott Reck Plant Manager (left) and
Jeremy Fahr Plant Project Manager
Engineer at Pleasant Gap Quarry
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983122983141983152983151983154983156983145983150983143 983154983141983155
a 10-degree mounting option (which is
normally used on their portable crushers)
to overcome the height restraint Reck and
Fahr worked with Dave Rhoa of Cleveland
Brothers Equipment Metsorsquos crushing and
screening distributor in Pennsylvania to
pull everything together and fit the newcrusher into their plant
The C160 crusher selected for Pleasant
Gap is one of the latest models in Metsorsquos
C Series of jaws These jaw crushers feature
a large throw and steep toggle plate angle
resulting in a higher crusher output In
addition the C Series has a compact foot-
print that makes it an ideal choice for the
replacement of existing machines
According to Reck ldquoWe had heard about
the new Metso C160 and started doing our
own research and found Metso not only
had developed the output capacity we
needed but fit the uniqueness of our oper-
ationsrdquo The new Metso crusher will allow
the plant to increase tons per hour andgive them the 1047298exibility to meet demands
for varying products on short notice
Mobile solution
Purchasing the new primary jaw addressed
the long-term issues but still left Pleasant
Gap without a functioning primary plant
Reck continues ldquoOur main line was still
down leaving us with a big hole in hitting
customer needs but knowing that our new
Metso C160 was on its wayhellipwe needed an
immediate solution to keep our produc-
tion demands with an out-of-commission
crusherrdquo
The team at Pleasant Gap brainstormed
the problem and came up with a plan toget the primary plant back in operation
Their solution was to use the Lokotrack
LT1213 impactor plant and another mobile
unit to keep the main line crushing To do
this they removed the guts on the existing
impact crusher essentially turning it into a
rock chute They then moved the LT1213
and another manufacturerrsquos mobile unit
over to the existing dump hopper gt
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
ldquoWe had our haul trucks drop off mate-
rial while two excavators fed the two
mobile unitsrdquo Reck explains ldquoFor two-and-
a-half months the Lokotrack LT1213 unit
was producing 254 cm (10rdquo) minus at
700 tons per hour The other similar-sized
mobile unit was doing 400 tons an hour
maxed out The difference was unbeliev-
able to say the least Our unique solution
using the two mobile units especially the
LT1213 helped Glenn O Hawbaker achieve
a record output in 2010rdquoAccording to Fahr ldquoWe were not new to
Metsorsquos quality and supportrdquo because GOH
had been using Metsorsquos portable crushing
equipment for 3 years prior to the primary
plantrsquos impact crusher failure In another
part of our operation we have a system that
our team relies on every day a Lokotrack
LT1213 and ST272 working in tandem with
two portable conveyorsrdquo This highly effi -
cient mobile processing system turns out
300 tons of specialized blended material
per hour GOH has been so impressed with
Metso equipment its last two purchaseswere an LT106 tracked jaw plant and a
second ST272 mobile screen in 2010
Maintaining high productivity
The Metso C160 jaw was delivered to Pleas-
ant Gap Quarry in January of 2011 and
since start-up it has more than met expec-
tations The crusher is fed minus 910 mm
(36rdquo) limestone with the jaw set at 140 mm
(5 12rdquo) According to Reck ldquoFrom moment
we started up we knew we had a winner
Not only were we kicking out as much
product as our previous units without even
breathing hard but we immediately had a
2-cent per ton savings to the bottom line
without having to run a second 350 HP
motor as required by other units Plus by
adding on the new automatic lube system
the maintenance team had more time to
devote to keeping other areas of the com-
plex running more effi cientlyrdquoReck says ldquoThe Metso unit was a perfect
fit and with the improved features it pre-
sented it had it all We just turn it on load
it up and we are moving 600 tons per hour
through the crusher without any effort and
we know it can do so much morerdquo With
the primary crushing plant back in opera-
tion the entire team at Pleasant Gap will
continue to do what they do best produce
and sell high-quality products and meet
their customersrsquo expectations
More info
Scott Yablonsky Tel +1 262 717 793
scottyablonskymetsocom
The Metso C160 jaw
was installed at a 10deg
angle to fit Pleasant
Gaprsquos existing
infrastructure
The Lokotrack LT1213 impactor plant and ST272 mobile screen operate in tandem with two
portable conveyors at Pleasant Gap
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983149983141983156983155983151 983150
Paper amp fiberNew OptiConcept M paper
and board making line
The new OptiConcept M paper and board
making line stands for economy safety and
usability
Metso has launched a new modular paper
and board making line called OptiConceptM A member of the proven OptiConcept
production line family the new OptiCon-
cept M optimizes machine investment in
line with each millrsquos capacity needs
Savings in operating costs are achieved
through precise dimensioning of pro-
cesses proven technological solutions
optimal running parameters effective
maintenance operations and fully inte-
grated automation solutions
Optimized processes innovations
smart controls and accurate dimensioning
decrease the use of steam gas electricitywater chemicals and other raw materials
and reduce emission levels
OptiConcept M has been designed
both visually and physically with the
requirements of users in mind For exam-
ple the design of the machinery allows for
easy and safe changing of rolls and wear
parts thus reducing the total duration and
cost of maintenance shutdowns
RecyclingGreen energy technology to
Elektrociepłownia Białystok in Poland
Metso will convert a coal-fired boiler to
a biomass-fired Bubbling Fluidized Bed
boiler for Elektrociepłownia Białystok SArsquos
combined heat and power plant (CHP) in
Białystok Poland The new boiler system
will cut the power plantrsquos CO2 emissions
significantly by partly replacing the coal
fuel supply with biomass fuel
ldquoPoland is one of the largest countries
in Europe to have such a high depend-ence on energy derived from coal to
meet national electricity needs This is an
important incentive for us to reduce future
CO2 emissions and produce more green
electricity and with Metso technology
we are certain to accomplish our goalrdquo
states Mr Andrzej Schroeder President of
Elektrociepłownia Białystok SA
Since 2000 Metso has received a total
of 7 biomass boiler conversion orders in
Poland and the renewable energy share
in Poland is only 75 (2010) compared to
the target of 20 by 2020 set by the EUApproximately 80 of the current energy
boilers turbines and generators installed in
Polish power plants are over 20 years old In
order to meet the strict EU environmental
requirements modernization of existing
installations is necessary
Automation
Metso DNA automation system expands
to mining and construction
Using Metsorsquos control room automation
an entire crushing and screening plant can
be effi ciently managed
Metso is a leading supplier of mining and
construction machinery This expertise has
now been combined with a scalable Metso
DNA automation system that adapts to
the range of industry needs from single
machine controls to plant-wide automation
and information management systems
An example of Metsorsquos new offering is a
new crushing plant control room solution
that connects crushers and screens ensur-
ing the effective management of the entire
plant from a pleasant and safe control
room The Metso DNA user interface pro-vides the production information to ensure
a proper and rapid response to plant
events Automatic controls stabilize the
process and allow the operators to monitor
the plant as a whole
ldquoThe benefits of automation for the min-
ing and construction industry are signifi-
cant As an example of the services we offer
performance studies to crushing plants
utilizing Metsorsquos multi-disciplinary teams of
experts to determine the present level of
the plant and process effi ciency and to esti-
mate the improvement potential and thebenefits of optimization and automation
including ROI calculationsrdquo says Mikko Maumlki-
nen Product Manager of minerals applica-
tions in Metsorsquos Automation business line
ldquoAs another example our machine
condition monitoring solutions can reduce
plant and machine downtimes as well as
help to avoid safety and environmental
hazardsrdquo he adds
Metso around the world
Aerial view of the Elektrociepłownia Białystok combined heat and power plant in Poland
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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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Services for Northland Resources in Sweden
The services supply at Kaunisvaara covers Metso Poly-Met mill
liners liner handlers and essential tools technical assistance including
maintenance and shutdown planning as well as monthly audits and
annual inspection services for the Tapuli grinding mill
The SmartTagtrade system utilizes Radio Frequency Identification (RFID) tags
and detectors to track ores as they 1047298ow from the blast to the downstream
processes and beyond
Metso has signed a contract with Northland Resources AB con-
cerning a five-year mill lining service and inspection program for
the Kaunisvaara project in northern Sweden The contract comple-ments previous project orders by Northland Resources announced
by Metso earlier this year The value of the order is EUR 19 million
The Metso Life-Cycle Services (LCS) program at Kaunisvaara
includes both the supply and installation of mill liners and techni-
cal and maintenance support for the semi-autogenous mill on the
Tapuli process line Metsorsquos on-site resources will also conduct liner
inspections to maximize mill availability The contract period will
commence when installation of the Tapuli process line is com-
pleted at the end of 2012
ldquoWe are pleased to have concluded this contract as it maxi-
mizes the availability of our grinding linerdquo says Shane Williams Vice
President Projects Northland Resources AB ldquoAs this is a cost-per-
ton contract we will be able to forecast expenditure over extendedperiods of time It will be a very useful asset in view of the total
investment involvedrdquo
ldquoWe embrace the opportunity to partner with Northland in a
five-year LCS commitmentrdquo says Joatildeo Ney Colagrossi President
of Services Business Line Metso ldquoThe speed at which operations
at Kaunisvaara are progressing is impressive and we are look-
ing forward to a rewarding working relationship with Northland
Resourcesrdquo
First SmartTagtrade systems for Europe
Somincor Neves-Corvo an underground copper-zinc mining
operation in southern Portugal owned by Lundin Mining hasrecently installed the first Metso SmartTagtrade system in Europe The
SmartTagtrade system was developed by Metso Process Technology
and Innovation (PTI) to track ore andor waste from mines to the
plant using Radio Frequency Identification (RFID) technology The
RFID tags have been designed to withstand blasting handling by
mining equipment and passing through primary and sometimes
secondary crushers
Somincor is using the SmartTagtrade system to track ore and waste
from post-blast muck piles through underground loading hauling
ore passes crushing storage and finally hoisting and conveying to
surface stockpiles The information will be used to better under-
stand and improve ore and waste handling logistics
Knowledge and interest in the Metso SmartTagtrade system isgrowing in Europe Boliden Tara Mines Ltd has also placed an order
for the SmartTagtrade system Tara is an underground zinc mine in
Ireland processing around 26 Mtpa of ore using Metso equipment
such as a C200 jaw crusher and VPA filters and pumps
The main objective of the SmartTagtrade system at this site will
be to track ore being mined from different stopes and headings
as part of their reconciliation process Waste in ore streams can
increase transport and processing costs reduce the head grade
and produce additional waste tailings
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Lokotrack LT116 attracts customers in Thailand
A group photo taken during a demo day at Thassana Cholburi quarry in
Central Thailand
A Vertimillreg vertical grinding mill under construction
983150983141983159983155 983145983150 983138
TISCO to receive minerals processing equipment
Metsorsquos Lokotrack LT116 mobile jaw plant attracted a number of
customers during a recent demo day organized at Thassana Chol-
buri Thailandrsquos biggest quarry
Marketed by Uawithya Machinery Co Metsorsquos tracked crush-
ing concept has been well received in Thailand Recent deliveries
include Lokotracks both for quarrying and mining purposes
The LT116 jaw plant is now being operated by PTK an iron ore
mine situated in Loei Province in northeastern Thailand
Tandem railcar dumper replacement
for Ridley Terminals in Canada
Metso will supply a tandem railcar dumper replacement to Ridley
Terminals Inc for its Ridley Island Coal Terminal in Prince Rupert
British Columbia Canada The value of the order is EUR 85 million
Metsorsquos delivery includes the replacement of two railcar dumpers
in a tandem installation with commissioning services To facilitate
the unloading of both Canadian and US length cars the dumpers
Metso will supply minerals processing equipment to Taigang
Group Lanxian Mining Co Ltd ( TISCO) the largest stainless steel
manufacturer in China The delivery is scheduled for the first
quarter of 2012 The order comprises seven units of vertical plate pressure filters
wear and spare parts as well as services related to installation
start-up commissioning and technical supervision The delivery
is for concentrate filtering for TISCOrsquos Yuanjiacun iron ore process-
ing plant in Lan County Shanxi province The plant is expected to
start operations in May 2012 with a daily processing capacity of
22000ndash23000 tons of iron ore concentrate
The Yuanjiacun plant is designed to process 22 million tons of
raw iron ore per year When completed Yuanjiacun will be the
largest iron ore processing plant in China
TISCO is among the worldrsquos largest producers of stainless steel
In 2010 the companyrsquos net sales were EUR 117 billion
Stronger services in the North American mining sector
Metso has acquired the service business assets of Copperstate
Industrial Services Inc a mining services provider based in Phoenix
Arizona The acquisition strengthens Metsorsquos position as a leading
service and technology provider for the mining and construction
sectors The company was transferred to Metso on August 1 2011
Established in 1999 Copperstate has built a highly compe-
tent team of service personnel in the American hard rock mining
region Approximately 40 employees will transfer to Metso The
team will be integrated into the Services business line of Metsorsquos
Mining and Construction Technology segment where they willcontinue to serve existing clients The team will be expanded to
further reinforce Metsorsquos maintenance repair and retrofit business
in the USA Canada and Mexico
ldquoThis fits right in with Metsorsquos profitable growth and develop-
ment strategyrdquo says Randy Reisinger Senior Vice President of
Engineered Services Solutions ldquoMetsorsquos objective is to enhance
customer satisfaction by employing a larger team of knowledge-
able well-trained service people to meet customersrsquo skills and
availability needsrdquo
will be equipped with a drawbridgeknife gate system that indexes
and dumps trains of both lengths The tandem railcar unloading
system will be capable of handling 74 railcars per hour Metsorsquos
delivery will be completed by the end of 2011
Wholly owned by the Federal Government of Canada Ridley
Terminals Inc operates an advanced marine terminal providing
high-performance railcar unloading product storage and vessel
loading services
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Facilities for the
Sochi Winter Olympicsconstructed with high-quality aggregates
Metsorsquos stationary washing plant was delivered to Maykop Nerud and so far has processed over
500000 tons of high-quality aggregates and sand for the construction of Olympic facilities in Sochi
Positive estimate of the end product quality
General Director of Maykop Nedud Company
Alexander Kozhanov (in the middle) with hisdeputies Alexey Poddubny and Stanislav
Steblyansky
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The City of Sochi despite
its subtropical climate
is preparing to host the
Winter Olympic Games in
2014 In connection withthis event major sports and
infrastructure facilities are
being built
TEXT amp PHOTOS Eero Haumlmaumllaumlinen
Because the Olympic site is classified as
a 12-magnitude seismic zone the State
Corporation ldquoOlympstroyrdquo and Russian
construction regulations require the use of
high-quality washed aggregates in concrete
when constructing critical objects in Sochi
These requirements are being met
in full by the company Maykop Nerudwhich produces crushed stone of various
fractions and sand using Metsorsquos mobile
crushing and screening plant and a station-
ary washing complex to process ancientmetamorphic alluvial formations into high-
quality construction materials
To date Maykop Nerud has shipped
to Sochi more than a million tons of inert
materialsaggregates produced in its in-
house production and in adjacent quarries
Inert materials are delivered to Sochi exclu-
sively by rail due to the diffi cult mountain-
ous conditions The company dispatches
one to two trains containing 3000 ndash 6000
tons of crushed stone and building sand to
the Olympic city daily
Aggregates from Maykop Nerud arebeing used in many Olympic projects
including Bolshoi ice palace and in tunnel
complex No 1 consisting of 25 kilometers
of road railway and service tunnels which
will be used to transport guests at the
Sochi 2014 Olympic Games between the
Olympic Village and a ski complex in Kras-
naya Polyana
Maykop Nerudrsquos washed sand is also
being used by manufacturers of tubing for
five tunnels under construction
ldquoMetso is a true partnerrdquo
Maykop Nerud was established just four
years ago and was supplying the inert
materials of other producers using anin-house railroad warehouse Later the
company entered into contracts with
quarry It is the first complex of its kind
in Russia
ldquoIn the initial stages of preparation for
the technical requirements of the equip-
ment we had planned to purchase a
mobile washing plant but Metsorsquos engi-
neers convinced us of the advantages of
stationary washing and screening equip-ment Today with the complex working
247 at full capacity it is easy to see that
major construction companies running
operations in Sochi and purchased its ownequipment for crushing and screening
ldquoWhile looking for an equipment sup-
plier we were approached by leading
manufacturers of crushing and screening
equipment After their proposals were
subsequently cross-checked Metso was
deservedly appreciated as a supplier of
high-quality equipment by all other bid-
dersrdquo says Alexander Kozhanov General
Director of Maykop Nerud
ldquoSince choosing Metso as our equip-
ment supplier and during the course of our
cooperation we have come to the realiza-tion that Metso is a true partner for us In
close cooperation with Metso we develop
and implement processes unavailable to
competitors work together as a united
team and share valuable experiencerdquo
Kozhanov adds
A good example is Metsorsquos washing
complex operated at Maykop Nerudrsquos
we made the right choicerdquo says Maykop
Nerudrsquos Deputy General Director AlexeyPoddubny
From sand-gravel mix
to quality aggregates
The raw material Maykop Nerud uses is
metamorphic alluvial sediments of hard
rock deposited in the Belaya River valley
millions of years ago The sand-gravel mix
in the companyrsquos quarry features some
properties of granite with excellent hard-
ness making it a good feed for the produc-
tion of quality aggregates
Straightforward quarrying technology isutilized excavators dig up the sand-gravel
mix and move it to stockpiles From the
stockpiles the sand-gravel mix is reclaimed
to Metsorsquos three-stage crushing and
screening process consisting of tracked
jaw and cone crushing plants and a mobile
screen gt
The sand amp gravel mix is crushed and screened
into 0ndash20 mm fractions using jaw and cone
crushing plants combined with a mobile screen
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The Maykop Nerud Company has supplied more than 150000 tons of 0ndash5 mm washed sand and aggregates in fractions of 5ndash10 mm 10ndash20 mm and
5ndash20 mm for shotcreting and for the concrete lining of the constructed tunnels
Crushed to the size of 0ndash20 mm the
material is transported by conveyors to a
washing complex consisting of a feed hop-
per conveyors a 4-deck washing screen aspiral classifier and an automated control
system
In order to facilitate the operations of its
customers Metso has established a stock of
spares and consumables in Maykop Nerudrsquos
territory Maykop Nerud can use the stock
for its own purposes and parts can also
be delivered to other Metso customers as
required The reliability of the equipment
983110983141983137983156983157983154983141983140 983137983154983156983145983139983148983141
and its operational effectiveness mainly
depend on the availability and prompt
replacement of spares and consumables ndash a
prerequisite ensured by the mutual effortsof Metso personnel and Maykop Nerud staff
Powerful crushing complex in
combination with washing plant
Having taken into account the growing
demand for high-quality end products
Maykop Nerud and Metso agreed to
extend their cooperation and create an
even more powerful stationary crushing
and screening complex including a pri-
mary jaw crusher and two stationary cone
crushers for operation in combination with
a stationary washing plantldquoBeginning in the second quarter of
2012 we will use the new stationary crush-
ing and screening complex along with the
mobile equipment thus allowing us to
increase our capacity to 130000 ndash 140000
tons per month in order to meet the con-
stantly growing demandrdquo says Stanislav
Steblyansky Deputy General Director of
Maykop Nerud
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The construction budget of EUR 534 billion
for projects in Sochi includes three major
sites the Olympic Park along the shore of
Black Sea the Olympic Village residences
for the athletes and the Krasnaya Polyana
ski resort in the Caucasus Mountains
These three sites will be interconnected
by numerous new highways roads bridges
Construction projects at a total budget of EUR 534 billion
983110983141983137983156983157983154983141983140 983137983154983156
The companyrsquos sand-gravel-mix
resources are expected to last upwards of
20 years Upon the completion of mining
and once the territory has been rehabili-
tated the quarry will be transformed into
an artificial lake for recreation and fishing
for the residents of the City of Maykop
More info
Alexey Shevyakhov
Tel +7 495 915 29 30
alexeyshevyakhovmetsocom
LOCATION City of Maykop Republic of
Adygea southern Russia
RAW MATERIAL hard rock sand-gravel mixhardness 40 kN
CAPACITY 250 th with increase up to 550
th in 2012
RESOURCES over 10 million cubic meters
END PRODUCTS Washed building sand 0ndash5
mm and crushed aggregates 5ndash10 mm
10ndash20 mm 5ndash20 mm 20ndash40 mm
ON-SITE MЕTSО EQUIPMENT
bull 1 Lokotrack LT106 jaw plant
bull 1 Lokotrack LT200HP cone plantbull 1 Lokotrack ST35 mobile screen
bull 1 Nordberg CVB 2060-4 inclined
screen
bull 1 Nordberg SF2870 sand trap
EQUIPMENT BEING INSTALLED WITH
COMMISSIONING IN 2ND QUARTER OF 2012
bull 1 Nordberg C80 jaw crusherbull 2 Nordberg HP4 cone crushers
bull 2 Nordberg CVB2060-4 inclined
screens
bull 1 Nordberg SF2360 sand trap
bull 1 Nordberg SF2870 sand trap
Maykop quarry owned by the Maykop Nerud Company
and tunnels Essentially the entire infra-
structure within and around the 110-km-
long Sochi will be renewed
More than 155000 workers are involved
in the construction projects In total more
than 300000 cubic meters of concrete
will be used for shotcreting and for the
solid cladding of the tunnels A consider-
able proportion of that concrete will be
prepared using the aggregates and sand of
Maykop Nerud
The company Severstroy is producing
concrete elements for lining 23 kilometers
of various tunnels All of the washed aggre-
gates and sand for those projects is also
being supplied by Maykop Nerud
Metsorsquos sand trap is a critical component of the washing complex
In August 2011 construction of the new ice stadium in Olympic Park was at full speed
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The new Metso C120 jaw crusher combines effi ciency versatility and safety
Metsorsquos new C120 jaw crusher made its worldwide debut at the Steinexpo exhibition in Germany
New products
Metso is proud to announce that we have developed the first fully
recyclable modular screening media ndash Metso Trellex LS-Eco
In response to customer requests for sustainable and environ-
mentally friendly screening media solutions and in line with our
own sustainability program we have taken the acclaimed Metso Trellex LS rubber modular screening media systems and success-
fully replaced the traditional steel reinforcement with an environ-
mentally friendly composite material This unique solution makes it
possible to effectively recycle our customersrsquo screening media
In the past screening media modules that were no longer
suitable for production were treated as waste and could not be
recycled Metso has introduced a new future for the product and a
sustainable solution
Sustainable solution for screening media
Metso has launched the
first fully recyclable
modular screening
media ndash Metso
Trellex LS-Eco
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Metsorsquos Mining and Construction Technology has introduced the
Metso C120 jaw crusher ndash the 13th member of the field-proven
C-series range of crushers The C120 combines uncompromising
reliability crushing effi ciency and versatility in both stationary and
mobile applications with safety and ease of use
Even at first glance it is clear that Metso has paid special atten-
tion to the C120rsquos new durable and user-friendly design start-
ing with the casting the design of which is based on thorough
FEA analysis and casting simulations Every detail of the C120 is
engineered for reliable operation and long life resulting in high
constant crushing capacity and uptime
ldquoWhen starting the C120 project we listened closely to our cus-
tomers and collected field data from a number of sites Based onthat information we decided to design the crusher cavity and kin-
ematics first As a result Metso can now offer aggregates produc-
ers large-scale contractors and mining companies a new crusher
that meets all the standards set for any demanding applicationrdquo
says Ilkka Somero Metsorsquos Product Manager for jaw crushers
New design brings outstanding productivity
The outstanding productivity of the C120 is guaranteed thanks
to several new design elements The crusher features a long and
aggressively directed stroke and a fixed jaw die longer than previ-
ously seen in this crusher size class The C120 has a large feed
opening of 1200 x 870 mm (34 x 47rsquorsquo) and an aggressive cavity cross
section securing a high per formance and reduction ratioIn terms of cavity volume and crusher weight the C120 is posi-
tioned between the existing Metso C116 and C125 jaw crusher
models
The Metso C120rsquos nominal power is 160 kW (200 HP) operating
speed 230 rpm closed side setting between 70 ndash 200 mm (2 34rsquorsquo
ndash 8rsquorsquo) The operational weight is 26000 kg (57200 lbs) excluding
options
More infoIlkka Somero
Tel + 358 50 317 0769
Ilkkasomerometsocom
The optional robust composite 1047298ywheel guards allow quick and safe
access to the service points
983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156
In addition to providing environmentally friendly screening
media panels Metso will implement a unique program to provide
its customers with a suitable range of recycling services
The Metso Trellex LS-Eco offers a wide range of health safety
and environmental benefits Each screening media panel is up to40 lighter than standard steel reinforced Trellex LS panels This
makes handling easier and the working environment safer Lighter
panels also help to reduce the overall stress on the entire screening
installation
Compared to steel-reinforced panels the composite-reinforced
panels of the Metso Trellex LS-Eco are more 1047298exible and will reduce
the effects of pegging and blinding during screening operations
The Metso Trellex LS-Eco promises reduced downtime and
increased productivity
The Trellex 300LS and Trellex 305LS rubber and polyurethane
panels are already acclaimed worldwide as being among the most
versatile modular screening media solutions They can be attached
to most screening media systems and can handle all types of
screening applications ndash fine and coarse wet and dry In the futurewhen Metso customers need new screening media panels for
their existing system they can choose Metso Trellex LS-Eco and be
assured that their panels will be safely and effectively recycled
More info
Claes Larsson
Tel +46 410 525 73
claeslarssonmetsocom
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The new Lokotrack LT120 with its world premiere at the Steinexpo
exhibition in Germany combines crushing performance and user-
friendly design in a new revolutionary way For the first time the
same Lokotrack model is now available in a hydraulically or electri-
cally driven version to meet customer needs
New Lokotrack LT120 jaw plant introduced
Lokotrack LT120 is the latest and most advanced of Metsorsquos track-mounted jaw crusher plants
Lokotrack LT120 combines user-friendly design and good crushing
performance in a new way
power supply or a 420-kV onboard diesel generator Having the
possibility to use an external power supply enables a highly eco-
nomical and ecological crushing process
The Lokotrack LT120 is built around the new C120 jaw crusher
See page 10 for information about the C120
Safe to use move and service
Safety is the highest priority for Metso when designing new equip-ment The Lokotrack LT120 is designed to be safe to operate move
and service
ldquoA safe operating environment is created by practical solutions
When service points can be reached easily the possibility of dan-
gerous situations diminishesrdquo says Product Manager Timo Nakari
ldquoGood examples of safety built in to the Lokotrack LT120 include
sturdy easy-to-open composite 1047298ywheel guards and hydraulically
folding and locking feed hopper sidesrdquo Nakari adds
The Lokotrack LT120 can be fine-tuned to suit the customerrsquos
application by selecting the required options from a long main
conveyor and hammer and boom to a water spraying system and
rubber lining for the feeder and hopper for example
The Lokotrack LT120 features a Caterpillar C13 310 kW (415 hp)engine Its transport dimensions are length 16 m (52rsquo 6rdquo) width 3 m
(9rsquo10rdquo) height 39 m (12rsquo 10rdquo) and weight 57 tons (114000 lbs) The
LT120E version weighs 63 tons (126000 lbs)
More info
Timo Nakari
Tel + 358 40 701 6143
timonakarimetsocom
983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155
The Lokotrack LT120 uses the same field-proven technology
seen in Metsorsquos tracked units for over 26 years Every detail of thenew jaw plant has been thoroughly designed for reliability and
long life The main targets when designing the unit have been
energy effi ciency good performance reliability and product safety
Field tests have demonstrated its good fuel economy and high
crushing capacity
Environment-friendly economy
The Lokotrack LT120 is also available as an electrically driven unit
ndash the Lokotrack LT120E ndash which can take energy from an external
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The TS range of screens is characterized by its innovative design
comprising two technologies combined multi-variable slopes with
a variable elliptical motion This proven range is being comple-
mented with the new TS63 screen
The TS63rsquos unique combination increases both the screenrsquos effi -
ciency and its capacity Material speed is high at the feed end and
slows down at the discharge end
Metso TS series screens offer more space between decks mak-
ing maintenance easier and improving service conditions for the
operators as well as meeting all safety requirements
Metso has recently sold several 25-m2 multi-slope screens for
mining applications such as a TS63 for Ferrostaal in Mauritania andalso for the construction industry for example Holcim in Lynwood
Australia Georyt in Poland Apaxco in Mexico and Newmont in
Peru
More info
Denis Pradon
Tel +33 680 64 39 67
denispradonmetsocom
New TS63 screen ndash the largest three-deck banana screen on the market
The new Metso TS63 banana screen features a 25-m2 screening area
Following the success of the HP4 and HP5 Metso has broadened
the product range with the new HP3 cone crusher This mid-range
cone crusher benefits from 70+ years of experience in crushing
technology while specifically addressing customer requirements
for large capacity ease of operation and a high reduction ratio
The HP3 responds to market demands for increased productionquality reduced maintenance time and low operating costs The
new generation HP models are comparable to their predecessors
but offer increased versatility
The HP3 features the size of an HP200 with the output of an
HP300 The power performance and robustness of the new gen-
eration models allow in certain cases two crushers to be replaced
with just one so investment production and operation costs are
greatly reduced
The HP3 has been tested at two different quarry sites in France
over the past seven months ndash at a gravel pit and a rock quarry
The Metso factory in France began production of the HP3
series in September Several orders have already been received for
secondary and tertiary applications Since 2009 nearly 300 HP newgeneration cone crushers have been commissioned The HP3 mar-
ket will be primarily centered on gravel pit applications (70)
The HP3 has a nominal feed opening of 220 mm (865rsquorsquo) a
motor size of up to 220 kW (300 hp) and a weight of 13280 kg
(29277 lbs)
More info
Carlos Padin
Tel +33 6 0727 2002
carlospadinmetsocomMetso HP3 at a stationary installation in France
HP3 cone ndash another new-generation cone crusher
983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
First modular plant to NepalMetso delivered its first modular crushing and screening plant to MS Palchowke Mai Roda Dunga Udyog Limited (PMRD)
in Melamchi Nepal The modular plant solution offers PMRD a fast and effective response to productivity and qualityrequirements
TEXT amp PHOTOS Atoshi Nayak Ghosh
The diversity of operations at a typical con-
struction site involves quick decision-mak-
ing and often a lot of pressure to ensure a
timely execution
High performance guaranteed
Considering todayrsquos volatile market sce-
nario business partners must maintainpace with their customersrsquo ever-changing
requirements Understanding custom-
ersrsquo strategic business needs is of utmost
importance PMRDrsquos plant was commis-
sioned in January 2011 and has logged
about 1200 hours of operation to date
The plant is much more compact than
the traditional skid-mounted plant and
provides space for free movement of utility
equipment within the plant area One of
the key features of the plant is the totally
bolted structure It can be easily disman-
tled into sub-assemblies transported and
re-assembled effortlessly at a new location
which is one of the biggest advantages in
helping to meet new market demand
Due to the use of pre-assembled mod-ules for each crushing station the instal-
lation work on site takes less time thus
decreasing the plantrsquos installation lead time
The plant also includes a foldable conveyor
for maintenance of the cone crushers
Stepping up with Metso
PMRD operates a two-stage plant compris-
ing a C80 jaw crusher an HP200 high-
performance cone crusher and a CVB1845
screen with circular motion MV2 vibra-
tory mechanism for final product recovery
resulting in an aggregate plant of 150 tph
capacity for producing size fractions of 0-40
mm The plant is an example of world-class
craftsmanship and excellent material han-
dling capacityModular and non-welded construction
supported by durable pitman assembly sin-
gle-piece cast steel frame bearing housings
with repairable crusher construction and
the right cavity design results in aggressive
kinematics and high power that best suits
the requirements of the customer
PMRD has immense pride in the plant
ldquoThe performance has been astounding
A drawing of typical modular plant
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983122983141983152983151983154983156983145983150983143 983154983141983155
with applications ranging from road aggre-
gates commercial sand production to
ready-mix concretes The modular plant is
almost set to create a new niche in aggre-
gates processing in Nepalrsquos construction
industry It is one of a kind and we are sur-
prised at the plant rsquos production capacity
It is easy to operate and requires minimalmanpower Our cost per ton has signifi-
cantly gone down and so has the cost of
productionrdquo says Mr Sandeep K Agarwal
Director PMRD
Safety as a key issue
Health safety and environmental solutions
are key concerns for Metso and they are
addressed with the same sense of responsi-
bility as quality productivity and cost-
effi ciency issues Metso is responsible for
conducting operations in an environmen-
tally sound way and offers products and
services that can help customers fulfill their
environmental responsibilities
Metso provides the plant offi ce and site
with operation and maintenance manu-als for each and every piece of equipment
including safety issues which are entrusted
to all the operators
All conveyors are equipped with pull-
cord safety switches along with emergency
stop buttons The working area and walk-
ways are all equipped with safety hand rails
and checkered plates for anti-skidding The
entire plant is equipped with earth pits for
electrical current earth leakage prevention
Metso has ensured all possible measures
to maintain high safety standards for all
operation and maintenance personnel
More info
Suhen Agarwal
Tel +91 124 2351566suhenagarwalmetsocom
Nepalrsquos first modularcrushing and screening plant deliv ered by Metso
E ffi cien t C VB1845 inclined screen wi th
an M V2 vibra tor y mechanism handles
the classi fica tion o f crushed ma terials
A s turd y f eeder dis tribu tes the ma terials to be crushed to
a
Me tso C80 ja w crusher
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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155
Outokumpursquos Kemi
mine set to doubleproduction The only mine unit owned by Outokumpu
the chrome mine in Kemi northern Finland
is busy making preparations to double its
production set to begin next year In co-
operation with Metso Outokumpu willincrease the number of underground
feeders and optimize the durabil-
ity of wear parts in the massive
primary gyratory crusher
TEXT amp PHOTOS Eero Haumlmaumllaumlinen
Chrome ore is fed into Metsorsquos
Superiorreg 50-65 primary
gyratory crusher by three
different vibrating feeders
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Up until now the entire production of the
chrome mine totaling about 13 million
tons annually has been transported to the
Tornio ferrochrome plant for processing
and on to the Tornio stainless steel plant
The increase in production which will
begin in autumn 2012 is intended also to
enable Outokumpu to sell ferrochrome tocompanies outside the Group The produc-
tion target for 2013 is 27 million tons of
ore and of the ferrochrome produced from
the ore nearly a half (gt 200000 tons) is to
be sold outside
Underground expansion
work almost complete
About 500 meters underground the
majority of the work involved in increasing
the capacity the F3 project has already
been completed Doubling the production
is no problem for the Superiorreg primarygyratory crusher delivered to the mine
by Metso in 2002 which can digest more
than 2700 tons of feed material per hour if
necessary
At the moment the primary gyratory
crusher can be fed by three different vibrat-
ing feeders The crusher currently runs for
less than one-fifth of the production time
The increase in ore production will increase
the effective crushing time to about one-
third of the production time
A lot of work has been done for orestorage after the primary crusher The
two currently used storage silos are now
accompanied by two new 8000-ton silos
The number of Metso feeders transporting
the ore from the primary crusher has also
been doubled
Optimization of wear parts under way
Chrome ore has been a challenge to the
primary gyratory crusherrsquos wear parts The
wear is contributed to by the pulsating
feed which rarely fills the entire crushing
chamber There are also great differences inore type since brittle feed material prone
to chalking is occasionally replaced by hard
ore that requires a lot of crushing power
before it is crushed with a bang gt
Mika Saari (right) Foreman of ore line technicians at Outokumpursquos chrome mine in conversation with
Mikko Malkamaumlki Metsorsquos crusher wear parts specialist
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
last did in July for the replacement of the
crusherrsquos wear parts Our work is also facili-
tated by product development like the
addition of maintenance hatches to the
feedersrdquo he continues
Lasting technology
According to Mika Saarirsquos calculations the
Superiorreg primary gyratory crusher has so
far crushed more than six million tons of
ore in totalldquoThe factory polishing marks still show
on the bottom thrust bearing so we
believe that the bearing will last the entire
remaining service life of the crusher which
is about ten years and 30 million tons
Metsorsquos feeders have been equally reliablerdquo
Saari says
After the next 30 million tons of ore
it will be time to deepen the mine
More info
Jukka Raumlisaumlnen
Tel +358 50 317 1787 jukkaraisanenmetsocom
Mikko Malkamaumlki
Tel + 358 40 827 8223
mikkomalkamakimetsocom
The Kemi mine and Metso are currently
carrying out a development project to
increase the service life of the mantle and
outer concave and thus minimize down-
time due to replacement While the modu-
lar feed hopper enables quick replacement
of the mantle replacing the outer concave
can easily take more than a week The cooperation between the Kemi
mine and Metsorsquos wear parts team in
Tampere aims to extend the service life
of the parts to at least 4 million crushed
tons Durability is sought by optimizing the
chamber structure and selecting the r ight
materials for the outer concave
ldquoSmooth cooperationrdquo
Mika Saari Foreman of ore line technicians
working in the underground mainte-
nance of the Kemi mine leads a small but
experienced team of technicians The tidymodern offi ce spaces are located close to
the action at a depth of 500 meters
ldquoCooperation with Metso has been
smooth Increasing our own crushing
expertise takes time so all know-how
shared by the manufacturer is very wel-
come to usrdquo Mika Saari says
ldquoWe can also use Metsorsquos profession-
als for servicing when necessary like we
The Superiorreg 50-65 has provided reliable
crushing performance at a depth of 500 metres
in the Kemi chrome mine
Technicians Sari Kulju (left) and Marko Jaako ensure that the primary gyratory crusherrsquos hydraulicand electrical unit remains very tidy which contributes to trouble-free operation of the crusher
Outokumpu Oyrsquos Kemi
chrome mine
LOCATION Keminmaa northern
Finland
ORE TYPE chrome oxide (26)
ORE ESTIMATE ON 1 JANUARY 2011
ndash ore reserves 36 million tons
ndash mineral resources 87 million
tons
MINING METHOD bench and cut fillFEED MATERIAL SIZE 0ndash1000 mm
METSO EQUIPMENT IN THE MINE
bull 1 Superiorreg 50-65 primary
gyratory crusher
ndash open side setting 152 cm (6rdquo)
bull 8 VMOU 25-125 feeders
bull 1 VMOU 30-16 feeder
bull 1 VMOU 40125 feeder
bull 2 Symons cone crushers
bull 1 C80 jaw crusher
bull 4 HM75 pumps
bull 11HM100 pumps
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983122983141983152983151983154983156983145983150983143 983154983141983155
Metso was responsible for the design
development and construction of the
entire secondary and tertiary arrangement
The primary station will be the subject of a
subsequent investment
Latest environmental protection used
This installation has been designed in strict
compliance with the environmental quality
approach developed by Metso and its
partners using the latest technologies
in dust control including confinement
technology as well as dust encapsulation
technology for screens
To ensure an annual capacity of 15 mil-lion tons for a nominal output of 560th of
02 mm and 220 mm the clientrsquos choice
for the secondary stage naturally fell upon
the NP 1520 impact crusher
A complete impact crusher solution for Lafarge The Lafarge Group has entrusted Metso with the implementation of its new aggregates installation in southern France
It comprises a new secondary crushing stage equipped with an NP1520 impact crusher featuring a power range of2 x 250kW and equipped with hydraulic adjustment
TEXT amp PHOTO Gilles Dombey
The NP 1520 crusher has long proved
its performance not only in terms of capac-
ity and reduction rate but also quality of
the finished product and durability
More info
Arnaud Bertucat
Tel +33 (0)6 81 44 68 26
arnaudbertucatmetsocom
About 15 million tons of aggregates feed will be crushed with the NP1520 impact crusher at Lafargersquos stationary installation in southern France
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Multi-stage Lokotrack process a success in Senegal
A multi-stage crushing and screening process has proven its effi ciency in the production of concrete aggregates in
Senegal Western Africa With the mobile process Xewell Cimenteries SA now exploits its quarry better has reduced
its operating costs and can meet strict environmental requirements
TEXT Elisabetta Cataluffi PHOTOS Carlo Rinolfi
Senegal is a rapidly developing country
offering a good deal of potential activities
for crushing companies too At the sametime the country has several areas of high
environmental value Therefore contractors
must opt for state-of-the-art equipment that
offers reduced environmental emissions
The company Xewell Cimenteries SA
was founded in 2008 as a partnership
between Italian Swiss and Senegalesecontractors Xewell operates a limestone
quarry located in the Pout area east of the
capital city of Dakar
According to Alessandro Crestani Technical
Director of the Pout quarry a mobile process
was selected to better exploit the quarry and
reduce costsLokotrack process drawing made by Bruno simulation software
After assembling the Lokotrack units the process was tested by Xewell Cimenteries
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983122983141983152983151983154983156983145983150983143 983154983141983155
Owned by Freeport-McMoRan Copper amp
Gold (51) and CODELCO (49) the ElAbra mine has leachable oxide and sulfide
mineralization The minersquos processing facil-
ity has an annual capacity of 226000 tons
of copper cathode
Smaller size matters
Reducing the size of the crushed oxide
ore from the present 15 mm to 12 mm
was the main target of the mine and the
Metso team The changes that were carried
out in the process included a size varia-
tion change in the cut of the tertiary sieve
installation of rate-level sensors in thesecondary crushers and enabling speed
variables in the conveyor belt feeders of
the secondary crushing circuit
ldquoGoing from 15mm to 12mm may seem
small but the operational impact is very
important and significant for usrdquo explains
Juan Torres Carvajal Metallurgical Engi-
neer at the El Abra mine
ldquoOur goal is to reach 115000 tons with
a minimum of 80 of 12-mm-sized ore permonth The record to date is 105000 tons
and we will increase it until we reach our
project goalrdquo he adds
New design for cone liners
In addition to the work mentioned above
Metso is currently carrying out a project to
design the lining profiles for the secondary
and tertiary crushers of the plant which
will affect the smaller size of the material
In cooperation with Nelson Mella from
Metso and Rodolfo Navarro Crushing
Superintendent at the El Abra mine testswere carried out in July on the re-designed
Metso linings One set was tested for sec-
ondary crushing and two sets for tertiary
crushing
More info
Nelson Mella
Tel +56 99158 0576
nelsonmellametsocom
Finer ore through wear pro1047297lestudy at El Abra mine in ChileEl Abra is a porphyry copper open-pit mine and processing facility located in
Chile near the city of Calama some 4000 meters above sea level With the helpof Metsorsquos technical support the mine was able to achieve finer ore throughoutthe crushing process
TEXT amp PHOTOS Macarena Vallejo
Xewell Cimenteries produces a selec-
tion of dry processed aggregates for con-
crete Operations started at the end of 2009
with the aim of reaching 150000 metric
tons produced per year
Lokotracks chosen to reduce costs
To build up their tracked mobile processXewell Cimenteries decided to buy three
mobile plants from Metso two impactor
plants the Lokotrack LT1110 and LT1213
feeding a three-deck mobile screen the
ST620 The machines were sold by SCAI
SpA Metsorsquos Lokotrack distributor in Italy
ldquoWe chose tracked machines to bet-
ter exploit our quarry and to reduce
costs Mobile plants have low initial costs
because they donrsquot need any special foun-
dations or supply of electricity This obvi-
ously gives us a quicker process set-up and
better uptimerdquo says Alessandro Crestani Technical Director of the Pout quarry
ldquoThe mobile plant can also follow the
quarry face as the exploitation proceeds
reducing the transport costs of raw materi-
als in the same jobsite We chose Metso
because they ensured us the best cost-per-
ton ratiordquo he adds
Good customer service is crucial
According to Alessandro Crestani good
customer service also played a major role
when choosing the manufacturer of the
mobile equipmentldquoMetsorsquos distributor SCAI SpA was able
to provide us with a complete product
support and customer service package
Obviously service is a very important
aspect for us in a country like Senegal Any
downtime represents a clear loss of pro-
ductivity for usrdquo
The average level of productivity of the
mobile Lokotrack process is 200 metric
tons per hour
More info
Carlo Rinolfi Tel +39 335 1253159
crinolfiscaispacom
Example of the development of the Metso study
on the crusher lining profiles
Liner change for smaller ore size in the
MP1000 cone crusher
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Services success in Surabaya The Metso Surabaya workshop and offi ce complex opened in April 2008 provides Life Cycle Services and maintenance
solutions for Metso equipment in the Indonesia region The facility is strategically located in an industrial precinct on theouter rim of Surabaya the second largest city in Indonesia Its close proximity to an international airport major shipping
port and several engineering companies simplifies support for the regionrsquos key customers which include PT Newmont
and PT Freeport
TEXT amp PHOTOS David LeRoy amp Gary Whittred
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983122983141983152983151983154983156983145983150983143 983154983141983155
The Surabaya site operates through Metso
in Australia with assistance from key sales
and technical staff Handling regional ser-vice and repair business in-house allows
Metso to manage intellectual property and
closely control quality
It also enables the development of a
team of skilled service personnel who can
be utilized both internally and at key cus-
tomer sites as is common with the backup
service the workshop provides for screen
contracts
Innovation at work
Since 2008 the Surabaya facility has suc-
cessfully refurbished a wide variety ofcomponents Recently two ball mill heads
weighing 22 tons each were modified in
order to strengthen the 1047298ange of the ball
mill shell The modification included tap-
ping out existing 1047298ange holes and drilling
new ones so that finger plates could be
installed and welded to the 1047298anges
Positioning the head borer to properly
align the new 1047298ange holes proved diffi cult
Four roller support frames were manufac-
tured to support the heads and allow them
to be rotated easily Each hole was then
drilled and tapped at the correct angleusing the CNC five axis head The job had a
tight delivery as it was required for a shut-
down but with advance planning and inno-
vation it was completed ahead of schedule
MP1000 mainframe on
CNC vertical borer
Well equipped for fabricating and machin-
ing heavy components the Surabaya
The Surabaya facility has proven to be
a success for Metso The workshop offers a
wide variety of services in the region Qual-ity products and competitive pricing and
delivery times have led to strong customer
relationships
Turnover and customer service levels
have increased annually since the open-
ing and between 2008 and 2010 sales
increased 450 These excellent trends
are expected to continue as the operation
expands and the customer base grows
Since 2008 the Surabaya facility has
successfully refurbished
bull MP1000 counter shaft boxes headassemblies mainframes bowls adjust-
ment rings counterweights sockets and
tramp release cylinders
bull 7rsquo Symons bowls heads and countershaft
boxes
bull Vertimill screw and drive shafts
bull Ball mill heads
bull Ball mill trommel
bull VPA cylinders
bull Eaton clutches
bull Exciter screen mechanisms
bull 42x65 main shafts and eccentrics
More info
Gary Whittred
Tel +62 31 8430349
garywhittredmetsocom
workshop handles the majority of Metsorsquos
refurbishment work with ease But when
necessary PT PAL ndash a government facilitywith shipbuilding and heavy engineering
capabilities ndash offers a ldquoone stop shoprdquo Spe-
cially trained PT PAL staff ensures that the
work they perform complies with all Metso
specifications and quality standards
PT PAL also demonstrated their innova-
tive ability with the first MP1000 main-
frame refurbishment they completed The
mainframersquos shaft location bore needed
to be re-machined However the distance
from the top of the mainframe to the
tapered bore made it very hard to achieve
an accurate surface finish with the correctstandoff
To overcome this the shop decided to
machine the mainframe upside down and
elevated on support beams They posi-
tioned a new shaft under the mainframe in
a custom-made cradle Using an overhead
crane they could then lsquotrial fitrsquo the shaft in
the bore to make sure it seated correctly
and the mating tapers met specification
The method worked so well it has since
been used for four more mainframe refur-
bishments
Diversity and growth
Today Metso Surabaya continues to invest
in additional equipment in order to diver-
sify its service offering A new hydraulic
power pack which allows the facility to test
refurbished components to Metso specifi-
cations was recently used in the refurbish-
ment and testing of several VPA cylinders
for PT Freeport
Refurbished MP1000 mainframe dispatched by truck to
PT Freeport mine
Machining of MP1000 upper frame
at Metsorsquos Surabaya workshop
Mainframe at vertical CNC machining
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Creating Value with Metso in Hong KongIn Hong Kong the aggregates needed for construction are mostly supplied by two local quarries KWP Quarry Company
Limitedrsquos Anderson Road Quarry accounts for 60ndash70 making it the pillar of Hong Kongrsquos construction materials industry
TEXT amp PHOTOS Ou He
When arriving at the Anderson Road
Quarry the most impressive view at the850000 square-meter facility is the Metso
machines including equipment from the
primary secondary and tertiary crushing
circuits and the screens I t is Metsorsquos equip-
ment that secures the supply of aggregates
for Hong Kong
KWP Quarry Company Limited has been
working with Metso since its establishment
in 1997
Due to Hong Kongrsquos stringent dust and noise control standards Metso has paid special attention to the related suppression systems
ldquoOur quarry mainly lies on granite and
volcanic rock which are so hard they canonly be processed by equipment with
strong durability and stabilityrdquo explains
Mr Eddie Hung Manager of KWP ldquoWith a
long history of and experience in quarry-
ing we are very familiar with the equip-
ment of different brands Comparatively
Metsorsquos products are better than others in
terms of durability stability and effi ciency
Besides this the reason we selected Metso
is because of the simple maintenance of
their equipment and the easy access tomaintenance informationrdquo
Flexible modular solution
Based on extensive experience in crushing
and screening worldwide Metso presented
the Anderson Road Quarry with a modu-
lar solution and delivered it as a turn-key
project Through a four-stage crushing
circuit which contains three Metso C160
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983122983141983152983151983154983156983145983150983143 983154983141983155
jaw crushers for primary crushing two
Omnicone 1560SX crushers for secondary
crushing two HP 500SX cone crushers for
tertiary crushing and one HP500SX cone
crusher for extra-fine crushing the plant
was able to produce aggregates of optimal
shape with minimal 1047298akiness
The fine products include three sizes
0 to 5 mm 5 to 10 mm and 10 to 20mm
Since the employment of this system in
2000 production has reached 1250 th
which is far beyond the design capacityAccording to Mr Hung ldquoThe machines
always run effi ciently and seldom malfunc-
tion The occasional shutdown of some
machines does not affect production very
much the plant still could reach 60-70
of its normal production It gives us the
best 1047298exibility for the plant rsquos operation and
I believe this is the best feature of Metsorsquos
solution
Eddie Hung
Manager of KWPrsquos
Anderson Road
Quarry is happy with
the product quality
and service provided
by Metso
ldquoMetsorsquos equipment is expensive com-
paratively but in the long run you will find
that the investment is worthwhile on the
whole Metso secures superior stability reli-
ability and fewer downtimes and it guaran-
tees continuous operation and brings us
greater valuerdquo
Great service team
Metso sent a group of service engineers
to the plant within the warranty period
not only to provide service but to train theoperators Mr Hung speaks highly of Met-
sorsquos service team he is impressed with its
experienced experts and with their strong
sense of responsibility and customer-
oriented ways of working
ldquoMetsorsquos service team never fails to find
hidden problems and helps us to prevent
any mechanical failures And they are
available whenever we need them they
work closely with us to solve the problem
effi cientlyrdquo he said
Excellent environment-friendly designIn order to achieve the worldrsquos most strin-
gent noise and dust control standards
developed by the Environment Protection
Department of Hong Kong Metso has
incorporated a dust and noise suppression
system into the plant This includes the
infrared-triggered spray systems at feed
points encapsulation of individual crush-
ers and conveyors and the ability to select
specific sectors of the system for treatment
depending on feed and operating condi-
tions encapsulation of equipment and the
enclosure of all major sections of the plant
With these advanced environment-
friendly solutions Anderson Road Quarry
has won numerous safety and environmen-
tal awards In 2003 it was presented with a
silver medal in the prestigious Environmen-
tal Performance Awards in recognition of
its commitment to the environment and
community In 2004 KWP achieved certifi-cation of ISO 14001 it is the first quarry site
to have achieved this in Hong Kong and
southern China
ldquoA reliable partnerrdquo
The promulgation of the top ten infrastruc-
ture policies in Hong Kong boosted the
market for aggregates and demand will
keep rising over the next five to six years
ldquoWersquoll definitely keep our cooperation with
Metso once we have a need for expansion
because we regard Metso as a reliable part-
ner With their highly effi cient equipmentsatisfying service and great efforts in help-
ing us to achieve our environmental pro-
tection targets Metso is our best choicerdquo
says Hung
More info
Ziqiang Li
Tel +86 13601289027
ziqianglimetsocom
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The sturdy Metso C160
jaw crushers are fed
using huge feed chutes
and feeders
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Similar to hundreds of mine sites world-
wide Zinkgruvan is being operated on a
non-stop 247 basis with just a few main-
tenance breaks during the year Crusher
availability is crucial because 100 of the
ore has to pass through the jaws before
being hoisted up for further processing
In addition to the zinc- lead- copper-
and silver-containing ore the C jaws chop
all the host rock extracted along the min-
ing process With a sturdy design Metsorsquos
proven C jaws can easily reduce even the
hardest type of rock Every year more thanone million tons are crushed with the jaws
ldquoMinimal service neededrdquo
Crushing with the first C160B jaw crusher
began at Zinkgruvanrsquos -800 meter level in
2000 with the primary crushing of zinc-lead
ore The second jaw was installed in 2008
for the new copper process gt
The sight and sound of two C160 jaw crushers operating side by side in the underground
crushing station of the Swedish Zinkgruvan mine is impressive Good proactive service
secures good uptime and reliable continuous operation of Metsorsquos second-largest
C160 series jaw crushers and prepares the way for the ongoing plans to expand the
production of zinc concentrate
TEXT amp PHOTOS Eero Haumlmaumllaumlinen
New PolyMet liners are being tested with the grinding mill delivered by Metso
Zinkgruvanrsquos twin C160
jaws secure good uptime
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Blasted ore is taken from the presently
operated -850 meter level with normal
trucks as an outsourced process One full
truckload is fed to the C160s every
10 minutes
ldquoWe are happy with the high reliability
of the C jaws They only require some minor
service therefore providing us with good
uptime and steady continuous feed to our
secondary and tertiary crushing and grind-ing circuitsrdquo says Mine Manager Jan Klaumlre
ldquoBasic crusher service and wear part
changes are made by our own staff using
Metsorsquos partsrdquo he adds
Service contract with grinding
mills and conveyors
Zinkgruvan and Metso Sweden have more
than 11 yearsrsquo experience with a service
contract that contains grinding mills and
conveyors At the mine site two Metso
service people and one contractor take
care of all the related service jobs Man-
power can also be borrowed from Metsorsquos
Graumlngesberg mine service team of 20
people
Presently Zinkgruvan is testing Metsorsquos
new PolyMet mill linings in its big grinding
mills With previously used rubber partsthe linings had to be changed in the shell
every 9 to 11 months and in the feed head
every 6 months
ldquoWe expect a better lifetime with Poly-
Met linings Longer change intervals mean
a lot to our productivity because lining
changes takes two full working daysrdquo Mine
Manager Jan Klaumlre says
New mine goes deeper
With an expected mine life of more than 10
years Zinkgruvan is actively mapping new
ore reserves Experimental holes are being
drilled at the new mine section at the
-1110 meter level
More info
Fredrik Wennberg
Tel +46 70 657 00 08fredrikwennbergmetsocom
Mine Manager Jan Klaumlre (left) with Backfilling Manager Kjell Tillman at the underground -800 meter level mine cafeteria
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The Zinkgruvan mine located approxi-
mately 200 km southwest of Stockholm
Sweden is one of the oldest underground
mines in Northern Europe The mine has
been in production since 1857
The mining methods used are panel
stoping and benching The processing
facilities include a zinc concentrating plant
with a 11 mtpa and a copper plant with a04 mtpa capacity Tailings are recycled in
an impounding basin and host rock in the
backfill plant
Continuous mining since 1857
Even as one of the oldest mines in Northern
Europe Zinkgruvan exploits modern mining
and minerals processing installations
Zinkgruvan mine
OWNER Lundin Mining
PRODUCTION PER YEAR 1 million tons
ORE TYPE sedimentary exhalative
zinc lead copper and silver
NUMBER OF EMPLOYEES 320
2011 PRODUCTION TARGETS 78000 tonsof zinc 36000 tons of lead and
3400 tons of copper concentrate
METSO EQUIPMENT ON SITE
bull 1 extra long VF feeder
bull 2 C160 jaw crushers
ndash zinc process css 220ndash240 mm
ndash copper process css 150 mm
bull 1 GP300S cone crusher
ndash css 45mm
bull 1 HP4 cone crusher
ndash css 18 mm
bull 1 DS screen
bull 1 FS402 screenbull 1 grinding mill
bull Pumps VPAs
A normal truck feeds the C jaws with ore coming from the lower production levels
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Cost-per-ton wear agreements deepencustomer relationshipsCrusher wear parts are traditionally marketed purely based on transactional sales and mainly depend on
the weight of manganese Metso has recently introduced a new type of wear agreement based on thecost-per-ton crushed and the wear occurred Thus far the experience has been very positive increasing
transparency and deepening the operational relationship between the manufacturer and the customer
TEXT Olli Kellokumpu and Eero Haumlmaumllaumlinen PHOTOS Eero Haumlmaumllaumlinen
Arto Hiedanniemi (left)
Hannu Heman and Juha
Laukka of Metsorsquos Finnish
Service team checking the
cone crusher mantles shipped
for a cost-per-ton customer
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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156
Wear parts and parts changes
can be included
The structure of a cost-per-ton wearcontract is based on the number of tons
crushed and the estimated wear occurred
The amount and monetary value of the
wear is calculated per crushed ton
ldquoEither plain wear parts or parts changes
carried out by Metsorsquos service personnel
can be included in the contract In the latter
case we ask our Finnish customers to inform
us about an upcoming wear change opera-
tion one week in advancerdquo Heman explains
ldquoWe see good opportunities to market
cost-per-ton contracts further in Finland
and also abroad It really develops therelationship of Metso and our customers
towards a trusted partnershiprdquo he notes
Perfect tool for accurate planning
Soraliike Ikola Oy is a mid-sized contrac-
tor with three Metso two- and three-
stage mobile and portable crushing and
screening plants operating in Central and
Since 2002 Metsorsquos sales team in Finland
has developed the cost-per-ton-based
service offeringldquoOur aim has been to seek through
a cost-per-ton offering possibilities to
serve our customers better to differentiate
Metso from the other players as an OEM
manufacturer and to offer deeper profes-
sionalism and know-howrdquo says Hannu
Heman General Manager of service
operations
ldquoUntil now both our experience and
that of our customers has been quite posi-
tive When properly prepared cost-per-ton
contracts seem to create a win-win situa-
tionrdquo Heman adds Today Metso has operational cost-per-
ton agreements with several Finnish cus-
tomers The first contract was concluded
with a customer operating a stationary
plant Based on the results gathered new
cost-per-ton contracts have been signed
with customers operating wheeled and
tracked equipment too
Eastern Finland Because of the size of the
contracts up to 50 equipment moves are
made during the yearEntrepreneur Pasi Ikola has had a cost-
per-ton contract with Metso for nearly
two years and he is quite happy with the
outcome
ldquoThe cost-per-ton contract has provided
me with a perfect tool for accurate financial
planning Now I know in detail my actual
future wear parts costs This helps a lot
when calculating bidsrdquo
ldquoEarlier I used to buy a big batch of
Metso wear parts in one go and had to
reserve a reasonable amount of money for
that Today all wear costs are evenly sharedwhich gives us a welcomed 1047298exibility to
our cost structure Now we just pay Metso
afterwards based on our crushed tonsrdquo
he adds
More info
Olli Kellokumpu
Tel +358 50 354 1189
ollikellokumpumetsocom
According to crushing contractor Pasi Ikola the cost-per-ton contract with Metso has provided the entrepreneur with better economical 1047298exibility
and more accurate calculating of bids
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Pleasant Gap is owned and operated by
Glenn O Hawbaker Inc of State College
Pennsylvania This family-owned company
began in 1952 as a small excavation busi-
ness founded by Glenn O Hawbaker and
his wife Thelma Over the years the com-
pany grew by adding an integrated mix ofproducts and services and taking on larger
projects
In 1983 Hawbaker acquired Pleasant
Gap Quarry and built its first aggregates
processing plant Today Glenn O Haw-
baker Inc operates 21 quarries and eight
asphalt production facilities across Penn-
sylvania and southern New York as well as
five regional operation centers
Primary
challenge atPleasant GapQuarryA good part of what makes for a successful crushing
operation is the willingness to tackle challenges and to do
whatrsquos necessary to meet demand The team at Pleasant
Gap Quarry in central Pennsylvania recently met the chal-
lenge when they successfully addressed problems with
the plantrsquos primary crushing plant First they purchased
a new Metso C160 jaw to replace the existing primary
impact crusher Then they devised an innovative plan to
get the primary plant back in operation while awaitingdelivery of the new jaw crusher
TEXT Linda Bergmann PHOTOS John Rickinger
983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Time for a change
With the goal of increasing reliability and
output the management at Pleasant Gap
Quarry recently decided it was time to
replace the plantrsquos primary impact crusher
Following a thorough search they chose a
new Metso C160 jaw According to ScottReck Plant Manager it no longer made
sense to repair and rebuild the existing
impactor
ldquoBefore we purchased the Metso C160
we had a few other impact crushers and
they served us well but as our custom-
ersrsquo needs increased our plant production
had to match that demand We found our
formerly reliable unit was being overcome
by our demands for output and creative
work-around solutions We continued to
need more but there was only so much we
could do until we hit the breaking point ndash
literallyrdquo
In addition to performance improve-
ments the new crusher also needed to fitinto Pleasant Gaprsquos unique infrastructure
As Plant Project ManagerEngineer Jeremy
Fahr explains ldquoOur height restraint was 274
meters (108rdquo) This height was the distance
from the feed lip of the existing 6x12 scalp-
ing screen and the existing structure that
the crusher rests onrdquo
The normal C160 crusher is 307
meters (121rdquo) tall but Metso gave GOH
Scott Reck Plant Manager (left) and
Jeremy Fahr Plant Project Manager
Engineer at Pleasant Gap Quarry
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983122983141983152983151983154983156983145983150983143 983154983141983155
a 10-degree mounting option (which is
normally used on their portable crushers)
to overcome the height restraint Reck and
Fahr worked with Dave Rhoa of Cleveland
Brothers Equipment Metsorsquos crushing and
screening distributor in Pennsylvania to
pull everything together and fit the newcrusher into their plant
The C160 crusher selected for Pleasant
Gap is one of the latest models in Metsorsquos
C Series of jaws These jaw crushers feature
a large throw and steep toggle plate angle
resulting in a higher crusher output In
addition the C Series has a compact foot-
print that makes it an ideal choice for the
replacement of existing machines
According to Reck ldquoWe had heard about
the new Metso C160 and started doing our
own research and found Metso not only
had developed the output capacity we
needed but fit the uniqueness of our oper-
ationsrdquo The new Metso crusher will allow
the plant to increase tons per hour andgive them the 1047298exibility to meet demands
for varying products on short notice
Mobile solution
Purchasing the new primary jaw addressed
the long-term issues but still left Pleasant
Gap without a functioning primary plant
Reck continues ldquoOur main line was still
down leaving us with a big hole in hitting
customer needs but knowing that our new
Metso C160 was on its wayhellipwe needed an
immediate solution to keep our produc-
tion demands with an out-of-commission
crusherrdquo
The team at Pleasant Gap brainstormed
the problem and came up with a plan toget the primary plant back in operation
Their solution was to use the Lokotrack
LT1213 impactor plant and another mobile
unit to keep the main line crushing To do
this they removed the guts on the existing
impact crusher essentially turning it into a
rock chute They then moved the LT1213
and another manufacturerrsquos mobile unit
over to the existing dump hopper gt
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
ldquoWe had our haul trucks drop off mate-
rial while two excavators fed the two
mobile unitsrdquo Reck explains ldquoFor two-and-
a-half months the Lokotrack LT1213 unit
was producing 254 cm (10rdquo) minus at
700 tons per hour The other similar-sized
mobile unit was doing 400 tons an hour
maxed out The difference was unbeliev-
able to say the least Our unique solution
using the two mobile units especially the
LT1213 helped Glenn O Hawbaker achieve
a record output in 2010rdquoAccording to Fahr ldquoWe were not new to
Metsorsquos quality and supportrdquo because GOH
had been using Metsorsquos portable crushing
equipment for 3 years prior to the primary
plantrsquos impact crusher failure In another
part of our operation we have a system that
our team relies on every day a Lokotrack
LT1213 and ST272 working in tandem with
two portable conveyorsrdquo This highly effi -
cient mobile processing system turns out
300 tons of specialized blended material
per hour GOH has been so impressed with
Metso equipment its last two purchaseswere an LT106 tracked jaw plant and a
second ST272 mobile screen in 2010
Maintaining high productivity
The Metso C160 jaw was delivered to Pleas-
ant Gap Quarry in January of 2011 and
since start-up it has more than met expec-
tations The crusher is fed minus 910 mm
(36rdquo) limestone with the jaw set at 140 mm
(5 12rdquo) According to Reck ldquoFrom moment
we started up we knew we had a winner
Not only were we kicking out as much
product as our previous units without even
breathing hard but we immediately had a
2-cent per ton savings to the bottom line
without having to run a second 350 HP
motor as required by other units Plus by
adding on the new automatic lube system
the maintenance team had more time to
devote to keeping other areas of the com-
plex running more effi cientlyrdquoReck says ldquoThe Metso unit was a perfect
fit and with the improved features it pre-
sented it had it all We just turn it on load
it up and we are moving 600 tons per hour
through the crusher without any effort and
we know it can do so much morerdquo With
the primary crushing plant back in opera-
tion the entire team at Pleasant Gap will
continue to do what they do best produce
and sell high-quality products and meet
their customersrsquo expectations
More info
Scott Yablonsky Tel +1 262 717 793
scottyablonskymetsocom
The Metso C160 jaw
was installed at a 10deg
angle to fit Pleasant
Gaprsquos existing
infrastructure
The Lokotrack LT1213 impactor plant and ST272 mobile screen operate in tandem with two
portable conveyors at Pleasant Gap
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983149983141983156983155983151 983150
Paper amp fiberNew OptiConcept M paper
and board making line
The new OptiConcept M paper and board
making line stands for economy safety and
usability
Metso has launched a new modular paper
and board making line called OptiConceptM A member of the proven OptiConcept
production line family the new OptiCon-
cept M optimizes machine investment in
line with each millrsquos capacity needs
Savings in operating costs are achieved
through precise dimensioning of pro-
cesses proven technological solutions
optimal running parameters effective
maintenance operations and fully inte-
grated automation solutions
Optimized processes innovations
smart controls and accurate dimensioning
decrease the use of steam gas electricitywater chemicals and other raw materials
and reduce emission levels
OptiConcept M has been designed
both visually and physically with the
requirements of users in mind For exam-
ple the design of the machinery allows for
easy and safe changing of rolls and wear
parts thus reducing the total duration and
cost of maintenance shutdowns
RecyclingGreen energy technology to
Elektrociepłownia Białystok in Poland
Metso will convert a coal-fired boiler to
a biomass-fired Bubbling Fluidized Bed
boiler for Elektrociepłownia Białystok SArsquos
combined heat and power plant (CHP) in
Białystok Poland The new boiler system
will cut the power plantrsquos CO2 emissions
significantly by partly replacing the coal
fuel supply with biomass fuel
ldquoPoland is one of the largest countries
in Europe to have such a high depend-ence on energy derived from coal to
meet national electricity needs This is an
important incentive for us to reduce future
CO2 emissions and produce more green
electricity and with Metso technology
we are certain to accomplish our goalrdquo
states Mr Andrzej Schroeder President of
Elektrociepłownia Białystok SA
Since 2000 Metso has received a total
of 7 biomass boiler conversion orders in
Poland and the renewable energy share
in Poland is only 75 (2010) compared to
the target of 20 by 2020 set by the EUApproximately 80 of the current energy
boilers turbines and generators installed in
Polish power plants are over 20 years old In
order to meet the strict EU environmental
requirements modernization of existing
installations is necessary
Automation
Metso DNA automation system expands
to mining and construction
Using Metsorsquos control room automation
an entire crushing and screening plant can
be effi ciently managed
Metso is a leading supplier of mining and
construction machinery This expertise has
now been combined with a scalable Metso
DNA automation system that adapts to
the range of industry needs from single
machine controls to plant-wide automation
and information management systems
An example of Metsorsquos new offering is a
new crushing plant control room solution
that connects crushers and screens ensur-
ing the effective management of the entire
plant from a pleasant and safe control
room The Metso DNA user interface pro-vides the production information to ensure
a proper and rapid response to plant
events Automatic controls stabilize the
process and allow the operators to monitor
the plant as a whole
ldquoThe benefits of automation for the min-
ing and construction industry are signifi-
cant As an example of the services we offer
performance studies to crushing plants
utilizing Metsorsquos multi-disciplinary teams of
experts to determine the present level of
the plant and process effi ciency and to esti-
mate the improvement potential and thebenefits of optimization and automation
including ROI calculationsrdquo says Mikko Maumlki-
nen Product Manager of minerals applica-
tions in Metsorsquos Automation business line
ldquoAs another example our machine
condition monitoring solutions can reduce
plant and machine downtimes as well as
help to avoid safety and environmental
hazardsrdquo he adds
Metso around the world
Aerial view of the Elektrociepłownia Białystok combined heat and power plant in Poland
8202019 Metso Minerals Aggregates 3 2011
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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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Lokotrack LT116 attracts customers in Thailand
A group photo taken during a demo day at Thassana Cholburi quarry in
Central Thailand
A Vertimillreg vertical grinding mill under construction
983150983141983159983155 983145983150 983138
TISCO to receive minerals processing equipment
Metsorsquos Lokotrack LT116 mobile jaw plant attracted a number of
customers during a recent demo day organized at Thassana Chol-
buri Thailandrsquos biggest quarry
Marketed by Uawithya Machinery Co Metsorsquos tracked crush-
ing concept has been well received in Thailand Recent deliveries
include Lokotracks both for quarrying and mining purposes
The LT116 jaw plant is now being operated by PTK an iron ore
mine situated in Loei Province in northeastern Thailand
Tandem railcar dumper replacement
for Ridley Terminals in Canada
Metso will supply a tandem railcar dumper replacement to Ridley
Terminals Inc for its Ridley Island Coal Terminal in Prince Rupert
British Columbia Canada The value of the order is EUR 85 million
Metsorsquos delivery includes the replacement of two railcar dumpers
in a tandem installation with commissioning services To facilitate
the unloading of both Canadian and US length cars the dumpers
Metso will supply minerals processing equipment to Taigang
Group Lanxian Mining Co Ltd ( TISCO) the largest stainless steel
manufacturer in China The delivery is scheduled for the first
quarter of 2012 The order comprises seven units of vertical plate pressure filters
wear and spare parts as well as services related to installation
start-up commissioning and technical supervision The delivery
is for concentrate filtering for TISCOrsquos Yuanjiacun iron ore process-
ing plant in Lan County Shanxi province The plant is expected to
start operations in May 2012 with a daily processing capacity of
22000ndash23000 tons of iron ore concentrate
The Yuanjiacun plant is designed to process 22 million tons of
raw iron ore per year When completed Yuanjiacun will be the
largest iron ore processing plant in China
TISCO is among the worldrsquos largest producers of stainless steel
In 2010 the companyrsquos net sales were EUR 117 billion
Stronger services in the North American mining sector
Metso has acquired the service business assets of Copperstate
Industrial Services Inc a mining services provider based in Phoenix
Arizona The acquisition strengthens Metsorsquos position as a leading
service and technology provider for the mining and construction
sectors The company was transferred to Metso on August 1 2011
Established in 1999 Copperstate has built a highly compe-
tent team of service personnel in the American hard rock mining
region Approximately 40 employees will transfer to Metso The
team will be integrated into the Services business line of Metsorsquos
Mining and Construction Technology segment where they willcontinue to serve existing clients The team will be expanded to
further reinforce Metsorsquos maintenance repair and retrofit business
in the USA Canada and Mexico
ldquoThis fits right in with Metsorsquos profitable growth and develop-
ment strategyrdquo says Randy Reisinger Senior Vice President of
Engineered Services Solutions ldquoMetsorsquos objective is to enhance
customer satisfaction by employing a larger team of knowledge-
able well-trained service people to meet customersrsquo skills and
availability needsrdquo
will be equipped with a drawbridgeknife gate system that indexes
and dumps trains of both lengths The tandem railcar unloading
system will be capable of handling 74 railcars per hour Metsorsquos
delivery will be completed by the end of 2011
Wholly owned by the Federal Government of Canada Ridley
Terminals Inc operates an advanced marine terminal providing
high-performance railcar unloading product storage and vessel
loading services
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Facilities for the
Sochi Winter Olympicsconstructed with high-quality aggregates
Metsorsquos stationary washing plant was delivered to Maykop Nerud and so far has processed over
500000 tons of high-quality aggregates and sand for the construction of Olympic facilities in Sochi
Positive estimate of the end product quality
General Director of Maykop Nedud Company
Alexander Kozhanov (in the middle) with hisdeputies Alexey Poddubny and Stanislav
Steblyansky
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983110983141983137983156983157983154983141983140 983137983154983156
The City of Sochi despite
its subtropical climate
is preparing to host the
Winter Olympic Games in
2014 In connection withthis event major sports and
infrastructure facilities are
being built
TEXT amp PHOTOS Eero Haumlmaumllaumlinen
Because the Olympic site is classified as
a 12-magnitude seismic zone the State
Corporation ldquoOlympstroyrdquo and Russian
construction regulations require the use of
high-quality washed aggregates in concrete
when constructing critical objects in Sochi
These requirements are being met
in full by the company Maykop Nerudwhich produces crushed stone of various
fractions and sand using Metsorsquos mobile
crushing and screening plant and a station-
ary washing complex to process ancientmetamorphic alluvial formations into high-
quality construction materials
To date Maykop Nerud has shipped
to Sochi more than a million tons of inert
materialsaggregates produced in its in-
house production and in adjacent quarries
Inert materials are delivered to Sochi exclu-
sively by rail due to the diffi cult mountain-
ous conditions The company dispatches
one to two trains containing 3000 ndash 6000
tons of crushed stone and building sand to
the Olympic city daily
Aggregates from Maykop Nerud arebeing used in many Olympic projects
including Bolshoi ice palace and in tunnel
complex No 1 consisting of 25 kilometers
of road railway and service tunnels which
will be used to transport guests at the
Sochi 2014 Olympic Games between the
Olympic Village and a ski complex in Kras-
naya Polyana
Maykop Nerudrsquos washed sand is also
being used by manufacturers of tubing for
five tunnels under construction
ldquoMetso is a true partnerrdquo
Maykop Nerud was established just four
years ago and was supplying the inert
materials of other producers using anin-house railroad warehouse Later the
company entered into contracts with
quarry It is the first complex of its kind
in Russia
ldquoIn the initial stages of preparation for
the technical requirements of the equip-
ment we had planned to purchase a
mobile washing plant but Metsorsquos engi-
neers convinced us of the advantages of
stationary washing and screening equip-ment Today with the complex working
247 at full capacity it is easy to see that
major construction companies running
operations in Sochi and purchased its ownequipment for crushing and screening
ldquoWhile looking for an equipment sup-
plier we were approached by leading
manufacturers of crushing and screening
equipment After their proposals were
subsequently cross-checked Metso was
deservedly appreciated as a supplier of
high-quality equipment by all other bid-
dersrdquo says Alexander Kozhanov General
Director of Maykop Nerud
ldquoSince choosing Metso as our equip-
ment supplier and during the course of our
cooperation we have come to the realiza-tion that Metso is a true partner for us In
close cooperation with Metso we develop
and implement processes unavailable to
competitors work together as a united
team and share valuable experiencerdquo
Kozhanov adds
A good example is Metsorsquos washing
complex operated at Maykop Nerudrsquos
we made the right choicerdquo says Maykop
Nerudrsquos Deputy General Director AlexeyPoddubny
From sand-gravel mix
to quality aggregates
The raw material Maykop Nerud uses is
metamorphic alluvial sediments of hard
rock deposited in the Belaya River valley
millions of years ago The sand-gravel mix
in the companyrsquos quarry features some
properties of granite with excellent hard-
ness making it a good feed for the produc-
tion of quality aggregates
Straightforward quarrying technology isutilized excavators dig up the sand-gravel
mix and move it to stockpiles From the
stockpiles the sand-gravel mix is reclaimed
to Metsorsquos three-stage crushing and
screening process consisting of tracked
jaw and cone crushing plants and a mobile
screen gt
The sand amp gravel mix is crushed and screened
into 0ndash20 mm fractions using jaw and cone
crushing plants combined with a mobile screen
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The Maykop Nerud Company has supplied more than 150000 tons of 0ndash5 mm washed sand and aggregates in fractions of 5ndash10 mm 10ndash20 mm and
5ndash20 mm for shotcreting and for the concrete lining of the constructed tunnels
Crushed to the size of 0ndash20 mm the
material is transported by conveyors to a
washing complex consisting of a feed hop-
per conveyors a 4-deck washing screen aspiral classifier and an automated control
system
In order to facilitate the operations of its
customers Metso has established a stock of
spares and consumables in Maykop Nerudrsquos
territory Maykop Nerud can use the stock
for its own purposes and parts can also
be delivered to other Metso customers as
required The reliability of the equipment
983110983141983137983156983157983154983141983140 983137983154983156983145983139983148983141
and its operational effectiveness mainly
depend on the availability and prompt
replacement of spares and consumables ndash a
prerequisite ensured by the mutual effortsof Metso personnel and Maykop Nerud staff
Powerful crushing complex in
combination with washing plant
Having taken into account the growing
demand for high-quality end products
Maykop Nerud and Metso agreed to
extend their cooperation and create an
even more powerful stationary crushing
and screening complex including a pri-
mary jaw crusher and two stationary cone
crushers for operation in combination with
a stationary washing plantldquoBeginning in the second quarter of
2012 we will use the new stationary crush-
ing and screening complex along with the
mobile equipment thus allowing us to
increase our capacity to 130000 ndash 140000
tons per month in order to meet the con-
stantly growing demandrdquo says Stanislav
Steblyansky Deputy General Director of
Maykop Nerud
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The construction budget of EUR 534 billion
for projects in Sochi includes three major
sites the Olympic Park along the shore of
Black Sea the Olympic Village residences
for the athletes and the Krasnaya Polyana
ski resort in the Caucasus Mountains
These three sites will be interconnected
by numerous new highways roads bridges
Construction projects at a total budget of EUR 534 billion
983110983141983137983156983157983154983141983140 983137983154983156
The companyrsquos sand-gravel-mix
resources are expected to last upwards of
20 years Upon the completion of mining
and once the territory has been rehabili-
tated the quarry will be transformed into
an artificial lake for recreation and fishing
for the residents of the City of Maykop
More info
Alexey Shevyakhov
Tel +7 495 915 29 30
alexeyshevyakhovmetsocom
LOCATION City of Maykop Republic of
Adygea southern Russia
RAW MATERIAL hard rock sand-gravel mixhardness 40 kN
CAPACITY 250 th with increase up to 550
th in 2012
RESOURCES over 10 million cubic meters
END PRODUCTS Washed building sand 0ndash5
mm and crushed aggregates 5ndash10 mm
10ndash20 mm 5ndash20 mm 20ndash40 mm
ON-SITE MЕTSО EQUIPMENT
bull 1 Lokotrack LT106 jaw plant
bull 1 Lokotrack LT200HP cone plantbull 1 Lokotrack ST35 mobile screen
bull 1 Nordberg CVB 2060-4 inclined
screen
bull 1 Nordberg SF2870 sand trap
EQUIPMENT BEING INSTALLED WITH
COMMISSIONING IN 2ND QUARTER OF 2012
bull 1 Nordberg C80 jaw crusherbull 2 Nordberg HP4 cone crushers
bull 2 Nordberg CVB2060-4 inclined
screens
bull 1 Nordberg SF2360 sand trap
bull 1 Nordberg SF2870 sand trap
Maykop quarry owned by the Maykop Nerud Company
and tunnels Essentially the entire infra-
structure within and around the 110-km-
long Sochi will be renewed
More than 155000 workers are involved
in the construction projects In total more
than 300000 cubic meters of concrete
will be used for shotcreting and for the
solid cladding of the tunnels A consider-
able proportion of that concrete will be
prepared using the aggregates and sand of
Maykop Nerud
The company Severstroy is producing
concrete elements for lining 23 kilometers
of various tunnels All of the washed aggre-
gates and sand for those projects is also
being supplied by Maykop Nerud
Metsorsquos sand trap is a critical component of the washing complex
In August 2011 construction of the new ice stadium in Olympic Park was at full speed
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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155
The new Metso C120 jaw crusher combines effi ciency versatility and safety
Metsorsquos new C120 jaw crusher made its worldwide debut at the Steinexpo exhibition in Germany
New products
Metso is proud to announce that we have developed the first fully
recyclable modular screening media ndash Metso Trellex LS-Eco
In response to customer requests for sustainable and environ-
mentally friendly screening media solutions and in line with our
own sustainability program we have taken the acclaimed Metso Trellex LS rubber modular screening media systems and success-
fully replaced the traditional steel reinforcement with an environ-
mentally friendly composite material This unique solution makes it
possible to effectively recycle our customersrsquo screening media
In the past screening media modules that were no longer
suitable for production were treated as waste and could not be
recycled Metso has introduced a new future for the product and a
sustainable solution
Sustainable solution for screening media
Metso has launched the
first fully recyclable
modular screening
media ndash Metso
Trellex LS-Eco
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Metsorsquos Mining and Construction Technology has introduced the
Metso C120 jaw crusher ndash the 13th member of the field-proven
C-series range of crushers The C120 combines uncompromising
reliability crushing effi ciency and versatility in both stationary and
mobile applications with safety and ease of use
Even at first glance it is clear that Metso has paid special atten-
tion to the C120rsquos new durable and user-friendly design start-
ing with the casting the design of which is based on thorough
FEA analysis and casting simulations Every detail of the C120 is
engineered for reliable operation and long life resulting in high
constant crushing capacity and uptime
ldquoWhen starting the C120 project we listened closely to our cus-
tomers and collected field data from a number of sites Based onthat information we decided to design the crusher cavity and kin-
ematics first As a result Metso can now offer aggregates produc-
ers large-scale contractors and mining companies a new crusher
that meets all the standards set for any demanding applicationrdquo
says Ilkka Somero Metsorsquos Product Manager for jaw crushers
New design brings outstanding productivity
The outstanding productivity of the C120 is guaranteed thanks
to several new design elements The crusher features a long and
aggressively directed stroke and a fixed jaw die longer than previ-
ously seen in this crusher size class The C120 has a large feed
opening of 1200 x 870 mm (34 x 47rsquorsquo) and an aggressive cavity cross
section securing a high per formance and reduction ratioIn terms of cavity volume and crusher weight the C120 is posi-
tioned between the existing Metso C116 and C125 jaw crusher
models
The Metso C120rsquos nominal power is 160 kW (200 HP) operating
speed 230 rpm closed side setting between 70 ndash 200 mm (2 34rsquorsquo
ndash 8rsquorsquo) The operational weight is 26000 kg (57200 lbs) excluding
options
More infoIlkka Somero
Tel + 358 50 317 0769
Ilkkasomerometsocom
The optional robust composite 1047298ywheel guards allow quick and safe
access to the service points
983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156
In addition to providing environmentally friendly screening
media panels Metso will implement a unique program to provide
its customers with a suitable range of recycling services
The Metso Trellex LS-Eco offers a wide range of health safety
and environmental benefits Each screening media panel is up to40 lighter than standard steel reinforced Trellex LS panels This
makes handling easier and the working environment safer Lighter
panels also help to reduce the overall stress on the entire screening
installation
Compared to steel-reinforced panels the composite-reinforced
panels of the Metso Trellex LS-Eco are more 1047298exible and will reduce
the effects of pegging and blinding during screening operations
The Metso Trellex LS-Eco promises reduced downtime and
increased productivity
The Trellex 300LS and Trellex 305LS rubber and polyurethane
panels are already acclaimed worldwide as being among the most
versatile modular screening media solutions They can be attached
to most screening media systems and can handle all types of
screening applications ndash fine and coarse wet and dry In the futurewhen Metso customers need new screening media panels for
their existing system they can choose Metso Trellex LS-Eco and be
assured that their panels will be safely and effectively recycled
More info
Claes Larsson
Tel +46 410 525 73
claeslarssonmetsocom
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The new Lokotrack LT120 with its world premiere at the Steinexpo
exhibition in Germany combines crushing performance and user-
friendly design in a new revolutionary way For the first time the
same Lokotrack model is now available in a hydraulically or electri-
cally driven version to meet customer needs
New Lokotrack LT120 jaw plant introduced
Lokotrack LT120 is the latest and most advanced of Metsorsquos track-mounted jaw crusher plants
Lokotrack LT120 combines user-friendly design and good crushing
performance in a new way
power supply or a 420-kV onboard diesel generator Having the
possibility to use an external power supply enables a highly eco-
nomical and ecological crushing process
The Lokotrack LT120 is built around the new C120 jaw crusher
See page 10 for information about the C120
Safe to use move and service
Safety is the highest priority for Metso when designing new equip-ment The Lokotrack LT120 is designed to be safe to operate move
and service
ldquoA safe operating environment is created by practical solutions
When service points can be reached easily the possibility of dan-
gerous situations diminishesrdquo says Product Manager Timo Nakari
ldquoGood examples of safety built in to the Lokotrack LT120 include
sturdy easy-to-open composite 1047298ywheel guards and hydraulically
folding and locking feed hopper sidesrdquo Nakari adds
The Lokotrack LT120 can be fine-tuned to suit the customerrsquos
application by selecting the required options from a long main
conveyor and hammer and boom to a water spraying system and
rubber lining for the feeder and hopper for example
The Lokotrack LT120 features a Caterpillar C13 310 kW (415 hp)engine Its transport dimensions are length 16 m (52rsquo 6rdquo) width 3 m
(9rsquo10rdquo) height 39 m (12rsquo 10rdquo) and weight 57 tons (114000 lbs) The
LT120E version weighs 63 tons (126000 lbs)
More info
Timo Nakari
Tel + 358 40 701 6143
timonakarimetsocom
983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155
The Lokotrack LT120 uses the same field-proven technology
seen in Metsorsquos tracked units for over 26 years Every detail of thenew jaw plant has been thoroughly designed for reliability and
long life The main targets when designing the unit have been
energy effi ciency good performance reliability and product safety
Field tests have demonstrated its good fuel economy and high
crushing capacity
Environment-friendly economy
The Lokotrack LT120 is also available as an electrically driven unit
ndash the Lokotrack LT120E ndash which can take energy from an external
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The TS range of screens is characterized by its innovative design
comprising two technologies combined multi-variable slopes with
a variable elliptical motion This proven range is being comple-
mented with the new TS63 screen
The TS63rsquos unique combination increases both the screenrsquos effi -
ciency and its capacity Material speed is high at the feed end and
slows down at the discharge end
Metso TS series screens offer more space between decks mak-
ing maintenance easier and improving service conditions for the
operators as well as meeting all safety requirements
Metso has recently sold several 25-m2 multi-slope screens for
mining applications such as a TS63 for Ferrostaal in Mauritania andalso for the construction industry for example Holcim in Lynwood
Australia Georyt in Poland Apaxco in Mexico and Newmont in
Peru
More info
Denis Pradon
Tel +33 680 64 39 67
denispradonmetsocom
New TS63 screen ndash the largest three-deck banana screen on the market
The new Metso TS63 banana screen features a 25-m2 screening area
Following the success of the HP4 and HP5 Metso has broadened
the product range with the new HP3 cone crusher This mid-range
cone crusher benefits from 70+ years of experience in crushing
technology while specifically addressing customer requirements
for large capacity ease of operation and a high reduction ratio
The HP3 responds to market demands for increased productionquality reduced maintenance time and low operating costs The
new generation HP models are comparable to their predecessors
but offer increased versatility
The HP3 features the size of an HP200 with the output of an
HP300 The power performance and robustness of the new gen-
eration models allow in certain cases two crushers to be replaced
with just one so investment production and operation costs are
greatly reduced
The HP3 has been tested at two different quarry sites in France
over the past seven months ndash at a gravel pit and a rock quarry
The Metso factory in France began production of the HP3
series in September Several orders have already been received for
secondary and tertiary applications Since 2009 nearly 300 HP newgeneration cone crushers have been commissioned The HP3 mar-
ket will be primarily centered on gravel pit applications (70)
The HP3 has a nominal feed opening of 220 mm (865rsquorsquo) a
motor size of up to 220 kW (300 hp) and a weight of 13280 kg
(29277 lbs)
More info
Carlos Padin
Tel +33 6 0727 2002
carlospadinmetsocomMetso HP3 at a stationary installation in France
HP3 cone ndash another new-generation cone crusher
983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
First modular plant to NepalMetso delivered its first modular crushing and screening plant to MS Palchowke Mai Roda Dunga Udyog Limited (PMRD)
in Melamchi Nepal The modular plant solution offers PMRD a fast and effective response to productivity and qualityrequirements
TEXT amp PHOTOS Atoshi Nayak Ghosh
The diversity of operations at a typical con-
struction site involves quick decision-mak-
ing and often a lot of pressure to ensure a
timely execution
High performance guaranteed
Considering todayrsquos volatile market sce-
nario business partners must maintainpace with their customersrsquo ever-changing
requirements Understanding custom-
ersrsquo strategic business needs is of utmost
importance PMRDrsquos plant was commis-
sioned in January 2011 and has logged
about 1200 hours of operation to date
The plant is much more compact than
the traditional skid-mounted plant and
provides space for free movement of utility
equipment within the plant area One of
the key features of the plant is the totally
bolted structure It can be easily disman-
tled into sub-assemblies transported and
re-assembled effortlessly at a new location
which is one of the biggest advantages in
helping to meet new market demand
Due to the use of pre-assembled mod-ules for each crushing station the instal-
lation work on site takes less time thus
decreasing the plantrsquos installation lead time
The plant also includes a foldable conveyor
for maintenance of the cone crushers
Stepping up with Metso
PMRD operates a two-stage plant compris-
ing a C80 jaw crusher an HP200 high-
performance cone crusher and a CVB1845
screen with circular motion MV2 vibra-
tory mechanism for final product recovery
resulting in an aggregate plant of 150 tph
capacity for producing size fractions of 0-40
mm The plant is an example of world-class
craftsmanship and excellent material han-
dling capacityModular and non-welded construction
supported by durable pitman assembly sin-
gle-piece cast steel frame bearing housings
with repairable crusher construction and
the right cavity design results in aggressive
kinematics and high power that best suits
the requirements of the customer
PMRD has immense pride in the plant
ldquoThe performance has been astounding
A drawing of typical modular plant
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983122983141983152983151983154983156983145983150983143 983154983141983155
with applications ranging from road aggre-
gates commercial sand production to
ready-mix concretes The modular plant is
almost set to create a new niche in aggre-
gates processing in Nepalrsquos construction
industry It is one of a kind and we are sur-
prised at the plant rsquos production capacity
It is easy to operate and requires minimalmanpower Our cost per ton has signifi-
cantly gone down and so has the cost of
productionrdquo says Mr Sandeep K Agarwal
Director PMRD
Safety as a key issue
Health safety and environmental solutions
are key concerns for Metso and they are
addressed with the same sense of responsi-
bility as quality productivity and cost-
effi ciency issues Metso is responsible for
conducting operations in an environmen-
tally sound way and offers products and
services that can help customers fulfill their
environmental responsibilities
Metso provides the plant offi ce and site
with operation and maintenance manu-als for each and every piece of equipment
including safety issues which are entrusted
to all the operators
All conveyors are equipped with pull-
cord safety switches along with emergency
stop buttons The working area and walk-
ways are all equipped with safety hand rails
and checkered plates for anti-skidding The
entire plant is equipped with earth pits for
electrical current earth leakage prevention
Metso has ensured all possible measures
to maintain high safety standards for all
operation and maintenance personnel
More info
Suhen Agarwal
Tel +91 124 2351566suhenagarwalmetsocom
Nepalrsquos first modularcrushing and screening plant deliv ered by Metso
E ffi cien t C VB1845 inclined screen wi th
an M V2 vibra tor y mechanism handles
the classi fica tion o f crushed ma terials
A s turd y f eeder dis tribu tes the ma terials to be crushed to
a
Me tso C80 ja w crusher
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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155
Outokumpursquos Kemi
mine set to doubleproduction The only mine unit owned by Outokumpu
the chrome mine in Kemi northern Finland
is busy making preparations to double its
production set to begin next year In co-
operation with Metso Outokumpu willincrease the number of underground
feeders and optimize the durabil-
ity of wear parts in the massive
primary gyratory crusher
TEXT amp PHOTOS Eero Haumlmaumllaumlinen
Chrome ore is fed into Metsorsquos
Superiorreg 50-65 primary
gyratory crusher by three
different vibrating feeders
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983122983141983152983151983154983156983145983150983143 983154983141983155
Up until now the entire production of the
chrome mine totaling about 13 million
tons annually has been transported to the
Tornio ferrochrome plant for processing
and on to the Tornio stainless steel plant
The increase in production which will
begin in autumn 2012 is intended also to
enable Outokumpu to sell ferrochrome tocompanies outside the Group The produc-
tion target for 2013 is 27 million tons of
ore and of the ferrochrome produced from
the ore nearly a half (gt 200000 tons) is to
be sold outside
Underground expansion
work almost complete
About 500 meters underground the
majority of the work involved in increasing
the capacity the F3 project has already
been completed Doubling the production
is no problem for the Superiorreg primarygyratory crusher delivered to the mine
by Metso in 2002 which can digest more
than 2700 tons of feed material per hour if
necessary
At the moment the primary gyratory
crusher can be fed by three different vibrat-
ing feeders The crusher currently runs for
less than one-fifth of the production time
The increase in ore production will increase
the effective crushing time to about one-
third of the production time
A lot of work has been done for orestorage after the primary crusher The
two currently used storage silos are now
accompanied by two new 8000-ton silos
The number of Metso feeders transporting
the ore from the primary crusher has also
been doubled
Optimization of wear parts under way
Chrome ore has been a challenge to the
primary gyratory crusherrsquos wear parts The
wear is contributed to by the pulsating
feed which rarely fills the entire crushing
chamber There are also great differences inore type since brittle feed material prone
to chalking is occasionally replaced by hard
ore that requires a lot of crushing power
before it is crushed with a bang gt
Mika Saari (right) Foreman of ore line technicians at Outokumpursquos chrome mine in conversation with
Mikko Malkamaumlki Metsorsquos crusher wear parts specialist
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last did in July for the replacement of the
crusherrsquos wear parts Our work is also facili-
tated by product development like the
addition of maintenance hatches to the
feedersrdquo he continues
Lasting technology
According to Mika Saarirsquos calculations the
Superiorreg primary gyratory crusher has so
far crushed more than six million tons of
ore in totalldquoThe factory polishing marks still show
on the bottom thrust bearing so we
believe that the bearing will last the entire
remaining service life of the crusher which
is about ten years and 30 million tons
Metsorsquos feeders have been equally reliablerdquo
Saari says
After the next 30 million tons of ore
it will be time to deepen the mine
More info
Jukka Raumlisaumlnen
Tel +358 50 317 1787 jukkaraisanenmetsocom
Mikko Malkamaumlki
Tel + 358 40 827 8223
mikkomalkamakimetsocom
The Kemi mine and Metso are currently
carrying out a development project to
increase the service life of the mantle and
outer concave and thus minimize down-
time due to replacement While the modu-
lar feed hopper enables quick replacement
of the mantle replacing the outer concave
can easily take more than a week The cooperation between the Kemi
mine and Metsorsquos wear parts team in
Tampere aims to extend the service life
of the parts to at least 4 million crushed
tons Durability is sought by optimizing the
chamber structure and selecting the r ight
materials for the outer concave
ldquoSmooth cooperationrdquo
Mika Saari Foreman of ore line technicians
working in the underground mainte-
nance of the Kemi mine leads a small but
experienced team of technicians The tidymodern offi ce spaces are located close to
the action at a depth of 500 meters
ldquoCooperation with Metso has been
smooth Increasing our own crushing
expertise takes time so all know-how
shared by the manufacturer is very wel-
come to usrdquo Mika Saari says
ldquoWe can also use Metsorsquos profession-
als for servicing when necessary like we
The Superiorreg 50-65 has provided reliable
crushing performance at a depth of 500 metres
in the Kemi chrome mine
Technicians Sari Kulju (left) and Marko Jaako ensure that the primary gyratory crusherrsquos hydraulicand electrical unit remains very tidy which contributes to trouble-free operation of the crusher
Outokumpu Oyrsquos Kemi
chrome mine
LOCATION Keminmaa northern
Finland
ORE TYPE chrome oxide (26)
ORE ESTIMATE ON 1 JANUARY 2011
ndash ore reserves 36 million tons
ndash mineral resources 87 million
tons
MINING METHOD bench and cut fillFEED MATERIAL SIZE 0ndash1000 mm
METSO EQUIPMENT IN THE MINE
bull 1 Superiorreg 50-65 primary
gyratory crusher
ndash open side setting 152 cm (6rdquo)
bull 8 VMOU 25-125 feeders
bull 1 VMOU 30-16 feeder
bull 1 VMOU 40125 feeder
bull 2 Symons cone crushers
bull 1 C80 jaw crusher
bull 4 HM75 pumps
bull 11HM100 pumps
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Metso was responsible for the design
development and construction of the
entire secondary and tertiary arrangement
The primary station will be the subject of a
subsequent investment
Latest environmental protection used
This installation has been designed in strict
compliance with the environmental quality
approach developed by Metso and its
partners using the latest technologies
in dust control including confinement
technology as well as dust encapsulation
technology for screens
To ensure an annual capacity of 15 mil-lion tons for a nominal output of 560th of
02 mm and 220 mm the clientrsquos choice
for the secondary stage naturally fell upon
the NP 1520 impact crusher
A complete impact crusher solution for Lafarge The Lafarge Group has entrusted Metso with the implementation of its new aggregates installation in southern France
It comprises a new secondary crushing stage equipped with an NP1520 impact crusher featuring a power range of2 x 250kW and equipped with hydraulic adjustment
TEXT amp PHOTO Gilles Dombey
The NP 1520 crusher has long proved
its performance not only in terms of capac-
ity and reduction rate but also quality of
the finished product and durability
More info
Arnaud Bertucat
Tel +33 (0)6 81 44 68 26
arnaudbertucatmetsocom
About 15 million tons of aggregates feed will be crushed with the NP1520 impact crusher at Lafargersquos stationary installation in southern France
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Multi-stage Lokotrack process a success in Senegal
A multi-stage crushing and screening process has proven its effi ciency in the production of concrete aggregates in
Senegal Western Africa With the mobile process Xewell Cimenteries SA now exploits its quarry better has reduced
its operating costs and can meet strict environmental requirements
TEXT Elisabetta Cataluffi PHOTOS Carlo Rinolfi
Senegal is a rapidly developing country
offering a good deal of potential activities
for crushing companies too At the sametime the country has several areas of high
environmental value Therefore contractors
must opt for state-of-the-art equipment that
offers reduced environmental emissions
The company Xewell Cimenteries SA
was founded in 2008 as a partnership
between Italian Swiss and Senegalesecontractors Xewell operates a limestone
quarry located in the Pout area east of the
capital city of Dakar
According to Alessandro Crestani Technical
Director of the Pout quarry a mobile process
was selected to better exploit the quarry and
reduce costsLokotrack process drawing made by Bruno simulation software
After assembling the Lokotrack units the process was tested by Xewell Cimenteries
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983122983141983152983151983154983156983145983150983143 983154983141983155
Owned by Freeport-McMoRan Copper amp
Gold (51) and CODELCO (49) the ElAbra mine has leachable oxide and sulfide
mineralization The minersquos processing facil-
ity has an annual capacity of 226000 tons
of copper cathode
Smaller size matters
Reducing the size of the crushed oxide
ore from the present 15 mm to 12 mm
was the main target of the mine and the
Metso team The changes that were carried
out in the process included a size varia-
tion change in the cut of the tertiary sieve
installation of rate-level sensors in thesecondary crushers and enabling speed
variables in the conveyor belt feeders of
the secondary crushing circuit
ldquoGoing from 15mm to 12mm may seem
small but the operational impact is very
important and significant for usrdquo explains
Juan Torres Carvajal Metallurgical Engi-
neer at the El Abra mine
ldquoOur goal is to reach 115000 tons with
a minimum of 80 of 12-mm-sized ore permonth The record to date is 105000 tons
and we will increase it until we reach our
project goalrdquo he adds
New design for cone liners
In addition to the work mentioned above
Metso is currently carrying out a project to
design the lining profiles for the secondary
and tertiary crushers of the plant which
will affect the smaller size of the material
In cooperation with Nelson Mella from
Metso and Rodolfo Navarro Crushing
Superintendent at the El Abra mine testswere carried out in July on the re-designed
Metso linings One set was tested for sec-
ondary crushing and two sets for tertiary
crushing
More info
Nelson Mella
Tel +56 99158 0576
nelsonmellametsocom
Finer ore through wear pro1047297lestudy at El Abra mine in ChileEl Abra is a porphyry copper open-pit mine and processing facility located in
Chile near the city of Calama some 4000 meters above sea level With the helpof Metsorsquos technical support the mine was able to achieve finer ore throughoutthe crushing process
TEXT amp PHOTOS Macarena Vallejo
Xewell Cimenteries produces a selec-
tion of dry processed aggregates for con-
crete Operations started at the end of 2009
with the aim of reaching 150000 metric
tons produced per year
Lokotracks chosen to reduce costs
To build up their tracked mobile processXewell Cimenteries decided to buy three
mobile plants from Metso two impactor
plants the Lokotrack LT1110 and LT1213
feeding a three-deck mobile screen the
ST620 The machines were sold by SCAI
SpA Metsorsquos Lokotrack distributor in Italy
ldquoWe chose tracked machines to bet-
ter exploit our quarry and to reduce
costs Mobile plants have low initial costs
because they donrsquot need any special foun-
dations or supply of electricity This obvi-
ously gives us a quicker process set-up and
better uptimerdquo says Alessandro Crestani Technical Director of the Pout quarry
ldquoThe mobile plant can also follow the
quarry face as the exploitation proceeds
reducing the transport costs of raw materi-
als in the same jobsite We chose Metso
because they ensured us the best cost-per-
ton ratiordquo he adds
Good customer service is crucial
According to Alessandro Crestani good
customer service also played a major role
when choosing the manufacturer of the
mobile equipmentldquoMetsorsquos distributor SCAI SpA was able
to provide us with a complete product
support and customer service package
Obviously service is a very important
aspect for us in a country like Senegal Any
downtime represents a clear loss of pro-
ductivity for usrdquo
The average level of productivity of the
mobile Lokotrack process is 200 metric
tons per hour
More info
Carlo Rinolfi Tel +39 335 1253159
crinolfiscaispacom
Example of the development of the Metso study
on the crusher lining profiles
Liner change for smaller ore size in the
MP1000 cone crusher
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Services success in Surabaya The Metso Surabaya workshop and offi ce complex opened in April 2008 provides Life Cycle Services and maintenance
solutions for Metso equipment in the Indonesia region The facility is strategically located in an industrial precinct on theouter rim of Surabaya the second largest city in Indonesia Its close proximity to an international airport major shipping
port and several engineering companies simplifies support for the regionrsquos key customers which include PT Newmont
and PT Freeport
TEXT amp PHOTOS David LeRoy amp Gary Whittred
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983122983141983152983151983154983156983145983150983143 983154983141983155
The Surabaya site operates through Metso
in Australia with assistance from key sales
and technical staff Handling regional ser-vice and repair business in-house allows
Metso to manage intellectual property and
closely control quality
It also enables the development of a
team of skilled service personnel who can
be utilized both internally and at key cus-
tomer sites as is common with the backup
service the workshop provides for screen
contracts
Innovation at work
Since 2008 the Surabaya facility has suc-
cessfully refurbished a wide variety ofcomponents Recently two ball mill heads
weighing 22 tons each were modified in
order to strengthen the 1047298ange of the ball
mill shell The modification included tap-
ping out existing 1047298ange holes and drilling
new ones so that finger plates could be
installed and welded to the 1047298anges
Positioning the head borer to properly
align the new 1047298ange holes proved diffi cult
Four roller support frames were manufac-
tured to support the heads and allow them
to be rotated easily Each hole was then
drilled and tapped at the correct angleusing the CNC five axis head The job had a
tight delivery as it was required for a shut-
down but with advance planning and inno-
vation it was completed ahead of schedule
MP1000 mainframe on
CNC vertical borer
Well equipped for fabricating and machin-
ing heavy components the Surabaya
The Surabaya facility has proven to be
a success for Metso The workshop offers a
wide variety of services in the region Qual-ity products and competitive pricing and
delivery times have led to strong customer
relationships
Turnover and customer service levels
have increased annually since the open-
ing and between 2008 and 2010 sales
increased 450 These excellent trends
are expected to continue as the operation
expands and the customer base grows
Since 2008 the Surabaya facility has
successfully refurbished
bull MP1000 counter shaft boxes headassemblies mainframes bowls adjust-
ment rings counterweights sockets and
tramp release cylinders
bull 7rsquo Symons bowls heads and countershaft
boxes
bull Vertimill screw and drive shafts
bull Ball mill heads
bull Ball mill trommel
bull VPA cylinders
bull Eaton clutches
bull Exciter screen mechanisms
bull 42x65 main shafts and eccentrics
More info
Gary Whittred
Tel +62 31 8430349
garywhittredmetsocom
workshop handles the majority of Metsorsquos
refurbishment work with ease But when
necessary PT PAL ndash a government facilitywith shipbuilding and heavy engineering
capabilities ndash offers a ldquoone stop shoprdquo Spe-
cially trained PT PAL staff ensures that the
work they perform complies with all Metso
specifications and quality standards
PT PAL also demonstrated their innova-
tive ability with the first MP1000 main-
frame refurbishment they completed The
mainframersquos shaft location bore needed
to be re-machined However the distance
from the top of the mainframe to the
tapered bore made it very hard to achieve
an accurate surface finish with the correctstandoff
To overcome this the shop decided to
machine the mainframe upside down and
elevated on support beams They posi-
tioned a new shaft under the mainframe in
a custom-made cradle Using an overhead
crane they could then lsquotrial fitrsquo the shaft in
the bore to make sure it seated correctly
and the mating tapers met specification
The method worked so well it has since
been used for four more mainframe refur-
bishments
Diversity and growth
Today Metso Surabaya continues to invest
in additional equipment in order to diver-
sify its service offering A new hydraulic
power pack which allows the facility to test
refurbished components to Metso specifi-
cations was recently used in the refurbish-
ment and testing of several VPA cylinders
for PT Freeport
Refurbished MP1000 mainframe dispatched by truck to
PT Freeport mine
Machining of MP1000 upper frame
at Metsorsquos Surabaya workshop
Mainframe at vertical CNC machining
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Creating Value with Metso in Hong KongIn Hong Kong the aggregates needed for construction are mostly supplied by two local quarries KWP Quarry Company
Limitedrsquos Anderson Road Quarry accounts for 60ndash70 making it the pillar of Hong Kongrsquos construction materials industry
TEXT amp PHOTOS Ou He
When arriving at the Anderson Road
Quarry the most impressive view at the850000 square-meter facility is the Metso
machines including equipment from the
primary secondary and tertiary crushing
circuits and the screens I t is Metsorsquos equip-
ment that secures the supply of aggregates
for Hong Kong
KWP Quarry Company Limited has been
working with Metso since its establishment
in 1997
Due to Hong Kongrsquos stringent dust and noise control standards Metso has paid special attention to the related suppression systems
ldquoOur quarry mainly lies on granite and
volcanic rock which are so hard they canonly be processed by equipment with
strong durability and stabilityrdquo explains
Mr Eddie Hung Manager of KWP ldquoWith a
long history of and experience in quarry-
ing we are very familiar with the equip-
ment of different brands Comparatively
Metsorsquos products are better than others in
terms of durability stability and effi ciency
Besides this the reason we selected Metso
is because of the simple maintenance of
their equipment and the easy access tomaintenance informationrdquo
Flexible modular solution
Based on extensive experience in crushing
and screening worldwide Metso presented
the Anderson Road Quarry with a modu-
lar solution and delivered it as a turn-key
project Through a four-stage crushing
circuit which contains three Metso C160
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jaw crushers for primary crushing two
Omnicone 1560SX crushers for secondary
crushing two HP 500SX cone crushers for
tertiary crushing and one HP500SX cone
crusher for extra-fine crushing the plant
was able to produce aggregates of optimal
shape with minimal 1047298akiness
The fine products include three sizes
0 to 5 mm 5 to 10 mm and 10 to 20mm
Since the employment of this system in
2000 production has reached 1250 th
which is far beyond the design capacityAccording to Mr Hung ldquoThe machines
always run effi ciently and seldom malfunc-
tion The occasional shutdown of some
machines does not affect production very
much the plant still could reach 60-70
of its normal production It gives us the
best 1047298exibility for the plant rsquos operation and
I believe this is the best feature of Metsorsquos
solution
Eddie Hung
Manager of KWPrsquos
Anderson Road
Quarry is happy with
the product quality
and service provided
by Metso
ldquoMetsorsquos equipment is expensive com-
paratively but in the long run you will find
that the investment is worthwhile on the
whole Metso secures superior stability reli-
ability and fewer downtimes and it guaran-
tees continuous operation and brings us
greater valuerdquo
Great service team
Metso sent a group of service engineers
to the plant within the warranty period
not only to provide service but to train theoperators Mr Hung speaks highly of Met-
sorsquos service team he is impressed with its
experienced experts and with their strong
sense of responsibility and customer-
oriented ways of working
ldquoMetsorsquos service team never fails to find
hidden problems and helps us to prevent
any mechanical failures And they are
available whenever we need them they
work closely with us to solve the problem
effi cientlyrdquo he said
Excellent environment-friendly designIn order to achieve the worldrsquos most strin-
gent noise and dust control standards
developed by the Environment Protection
Department of Hong Kong Metso has
incorporated a dust and noise suppression
system into the plant This includes the
infrared-triggered spray systems at feed
points encapsulation of individual crush-
ers and conveyors and the ability to select
specific sectors of the system for treatment
depending on feed and operating condi-
tions encapsulation of equipment and the
enclosure of all major sections of the plant
With these advanced environment-
friendly solutions Anderson Road Quarry
has won numerous safety and environmen-
tal awards In 2003 it was presented with a
silver medal in the prestigious Environmen-
tal Performance Awards in recognition of
its commitment to the environment and
community In 2004 KWP achieved certifi-cation of ISO 14001 it is the first quarry site
to have achieved this in Hong Kong and
southern China
ldquoA reliable partnerrdquo
The promulgation of the top ten infrastruc-
ture policies in Hong Kong boosted the
market for aggregates and demand will
keep rising over the next five to six years
ldquoWersquoll definitely keep our cooperation with
Metso once we have a need for expansion
because we regard Metso as a reliable part-
ner With their highly effi cient equipmentsatisfying service and great efforts in help-
ing us to achieve our environmental pro-
tection targets Metso is our best choicerdquo
says Hung
More info
Ziqiang Li
Tel +86 13601289027
ziqianglimetsocom
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
The sturdy Metso C160
jaw crushers are fed
using huge feed chutes
and feeders
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983122983141983152983151983154983156983145983150983143 983154983141983155
Similar to hundreds of mine sites world-
wide Zinkgruvan is being operated on a
non-stop 247 basis with just a few main-
tenance breaks during the year Crusher
availability is crucial because 100 of the
ore has to pass through the jaws before
being hoisted up for further processing
In addition to the zinc- lead- copper-
and silver-containing ore the C jaws chop
all the host rock extracted along the min-
ing process With a sturdy design Metsorsquos
proven C jaws can easily reduce even the
hardest type of rock Every year more thanone million tons are crushed with the jaws
ldquoMinimal service neededrdquo
Crushing with the first C160B jaw crusher
began at Zinkgruvanrsquos -800 meter level in
2000 with the primary crushing of zinc-lead
ore The second jaw was installed in 2008
for the new copper process gt
The sight and sound of two C160 jaw crushers operating side by side in the underground
crushing station of the Swedish Zinkgruvan mine is impressive Good proactive service
secures good uptime and reliable continuous operation of Metsorsquos second-largest
C160 series jaw crushers and prepares the way for the ongoing plans to expand the
production of zinc concentrate
TEXT amp PHOTOS Eero Haumlmaumllaumlinen
New PolyMet liners are being tested with the grinding mill delivered by Metso
Zinkgruvanrsquos twin C160
jaws secure good uptime
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Blasted ore is taken from the presently
operated -850 meter level with normal
trucks as an outsourced process One full
truckload is fed to the C160s every
10 minutes
ldquoWe are happy with the high reliability
of the C jaws They only require some minor
service therefore providing us with good
uptime and steady continuous feed to our
secondary and tertiary crushing and grind-ing circuitsrdquo says Mine Manager Jan Klaumlre
ldquoBasic crusher service and wear part
changes are made by our own staff using
Metsorsquos partsrdquo he adds
Service contract with grinding
mills and conveyors
Zinkgruvan and Metso Sweden have more
than 11 yearsrsquo experience with a service
contract that contains grinding mills and
conveyors At the mine site two Metso
service people and one contractor take
care of all the related service jobs Man-
power can also be borrowed from Metsorsquos
Graumlngesberg mine service team of 20
people
Presently Zinkgruvan is testing Metsorsquos
new PolyMet mill linings in its big grinding
mills With previously used rubber partsthe linings had to be changed in the shell
every 9 to 11 months and in the feed head
every 6 months
ldquoWe expect a better lifetime with Poly-
Met linings Longer change intervals mean
a lot to our productivity because lining
changes takes two full working daysrdquo Mine
Manager Jan Klaumlre says
New mine goes deeper
With an expected mine life of more than 10
years Zinkgruvan is actively mapping new
ore reserves Experimental holes are being
drilled at the new mine section at the
-1110 meter level
More info
Fredrik Wennberg
Tel +46 70 657 00 08fredrikwennbergmetsocom
Mine Manager Jan Klaumlre (left) with Backfilling Manager Kjell Tillman at the underground -800 meter level mine cafeteria
983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
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The Zinkgruvan mine located approxi-
mately 200 km southwest of Stockholm
Sweden is one of the oldest underground
mines in Northern Europe The mine has
been in production since 1857
The mining methods used are panel
stoping and benching The processing
facilities include a zinc concentrating plant
with a 11 mtpa and a copper plant with a04 mtpa capacity Tailings are recycled in
an impounding basin and host rock in the
backfill plant
Continuous mining since 1857
Even as one of the oldest mines in Northern
Europe Zinkgruvan exploits modern mining
and minerals processing installations
Zinkgruvan mine
OWNER Lundin Mining
PRODUCTION PER YEAR 1 million tons
ORE TYPE sedimentary exhalative
zinc lead copper and silver
NUMBER OF EMPLOYEES 320
2011 PRODUCTION TARGETS 78000 tonsof zinc 36000 tons of lead and
3400 tons of copper concentrate
METSO EQUIPMENT ON SITE
bull 1 extra long VF feeder
bull 2 C160 jaw crushers
ndash zinc process css 220ndash240 mm
ndash copper process css 150 mm
bull 1 GP300S cone crusher
ndash css 45mm
bull 1 HP4 cone crusher
ndash css 18 mm
bull 1 DS screen
bull 1 FS402 screenbull 1 grinding mill
bull Pumps VPAs
A normal truck feeds the C jaws with ore coming from the lower production levels
983122983141983152983151983154983156983145983150983143 983154983141983155
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Cost-per-ton wear agreements deepencustomer relationshipsCrusher wear parts are traditionally marketed purely based on transactional sales and mainly depend on
the weight of manganese Metso has recently introduced a new type of wear agreement based on thecost-per-ton crushed and the wear occurred Thus far the experience has been very positive increasing
transparency and deepening the operational relationship between the manufacturer and the customer
TEXT Olli Kellokumpu and Eero Haumlmaumllaumlinen PHOTOS Eero Haumlmaumllaumlinen
Arto Hiedanniemi (left)
Hannu Heman and Juha
Laukka of Metsorsquos Finnish
Service team checking the
cone crusher mantles shipped
for a cost-per-ton customer
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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156
Wear parts and parts changes
can be included
The structure of a cost-per-ton wearcontract is based on the number of tons
crushed and the estimated wear occurred
The amount and monetary value of the
wear is calculated per crushed ton
ldquoEither plain wear parts or parts changes
carried out by Metsorsquos service personnel
can be included in the contract In the latter
case we ask our Finnish customers to inform
us about an upcoming wear change opera-
tion one week in advancerdquo Heman explains
ldquoWe see good opportunities to market
cost-per-ton contracts further in Finland
and also abroad It really develops therelationship of Metso and our customers
towards a trusted partnershiprdquo he notes
Perfect tool for accurate planning
Soraliike Ikola Oy is a mid-sized contrac-
tor with three Metso two- and three-
stage mobile and portable crushing and
screening plants operating in Central and
Since 2002 Metsorsquos sales team in Finland
has developed the cost-per-ton-based
service offeringldquoOur aim has been to seek through
a cost-per-ton offering possibilities to
serve our customers better to differentiate
Metso from the other players as an OEM
manufacturer and to offer deeper profes-
sionalism and know-howrdquo says Hannu
Heman General Manager of service
operations
ldquoUntil now both our experience and
that of our customers has been quite posi-
tive When properly prepared cost-per-ton
contracts seem to create a win-win situa-
tionrdquo Heman adds Today Metso has operational cost-per-
ton agreements with several Finnish cus-
tomers The first contract was concluded
with a customer operating a stationary
plant Based on the results gathered new
cost-per-ton contracts have been signed
with customers operating wheeled and
tracked equipment too
Eastern Finland Because of the size of the
contracts up to 50 equipment moves are
made during the yearEntrepreneur Pasi Ikola has had a cost-
per-ton contract with Metso for nearly
two years and he is quite happy with the
outcome
ldquoThe cost-per-ton contract has provided
me with a perfect tool for accurate financial
planning Now I know in detail my actual
future wear parts costs This helps a lot
when calculating bidsrdquo
ldquoEarlier I used to buy a big batch of
Metso wear parts in one go and had to
reserve a reasonable amount of money for
that Today all wear costs are evenly sharedwhich gives us a welcomed 1047298exibility to
our cost structure Now we just pay Metso
afterwards based on our crushed tonsrdquo
he adds
More info
Olli Kellokumpu
Tel +358 50 354 1189
ollikellokumpumetsocom
According to crushing contractor Pasi Ikola the cost-per-ton contract with Metso has provided the entrepreneur with better economical 1047298exibility
and more accurate calculating of bids
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Pleasant Gap is owned and operated by
Glenn O Hawbaker Inc of State College
Pennsylvania This family-owned company
began in 1952 as a small excavation busi-
ness founded by Glenn O Hawbaker and
his wife Thelma Over the years the com-
pany grew by adding an integrated mix ofproducts and services and taking on larger
projects
In 1983 Hawbaker acquired Pleasant
Gap Quarry and built its first aggregates
processing plant Today Glenn O Haw-
baker Inc operates 21 quarries and eight
asphalt production facilities across Penn-
sylvania and southern New York as well as
five regional operation centers
Primary
challenge atPleasant GapQuarryA good part of what makes for a successful crushing
operation is the willingness to tackle challenges and to do
whatrsquos necessary to meet demand The team at Pleasant
Gap Quarry in central Pennsylvania recently met the chal-
lenge when they successfully addressed problems with
the plantrsquos primary crushing plant First they purchased
a new Metso C160 jaw to replace the existing primary
impact crusher Then they devised an innovative plan to
get the primary plant back in operation while awaitingdelivery of the new jaw crusher
TEXT Linda Bergmann PHOTOS John Rickinger
983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Time for a change
With the goal of increasing reliability and
output the management at Pleasant Gap
Quarry recently decided it was time to
replace the plantrsquos primary impact crusher
Following a thorough search they chose a
new Metso C160 jaw According to ScottReck Plant Manager it no longer made
sense to repair and rebuild the existing
impactor
ldquoBefore we purchased the Metso C160
we had a few other impact crushers and
they served us well but as our custom-
ersrsquo needs increased our plant production
had to match that demand We found our
formerly reliable unit was being overcome
by our demands for output and creative
work-around solutions We continued to
need more but there was only so much we
could do until we hit the breaking point ndash
literallyrdquo
In addition to performance improve-
ments the new crusher also needed to fitinto Pleasant Gaprsquos unique infrastructure
As Plant Project ManagerEngineer Jeremy
Fahr explains ldquoOur height restraint was 274
meters (108rdquo) This height was the distance
from the feed lip of the existing 6x12 scalp-
ing screen and the existing structure that
the crusher rests onrdquo
The normal C160 crusher is 307
meters (121rdquo) tall but Metso gave GOH
Scott Reck Plant Manager (left) and
Jeremy Fahr Plant Project Manager
Engineer at Pleasant Gap Quarry
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983122983141983152983151983154983156983145983150983143 983154983141983155
a 10-degree mounting option (which is
normally used on their portable crushers)
to overcome the height restraint Reck and
Fahr worked with Dave Rhoa of Cleveland
Brothers Equipment Metsorsquos crushing and
screening distributor in Pennsylvania to
pull everything together and fit the newcrusher into their plant
The C160 crusher selected for Pleasant
Gap is one of the latest models in Metsorsquos
C Series of jaws These jaw crushers feature
a large throw and steep toggle plate angle
resulting in a higher crusher output In
addition the C Series has a compact foot-
print that makes it an ideal choice for the
replacement of existing machines
According to Reck ldquoWe had heard about
the new Metso C160 and started doing our
own research and found Metso not only
had developed the output capacity we
needed but fit the uniqueness of our oper-
ationsrdquo The new Metso crusher will allow
the plant to increase tons per hour andgive them the 1047298exibility to meet demands
for varying products on short notice
Mobile solution
Purchasing the new primary jaw addressed
the long-term issues but still left Pleasant
Gap without a functioning primary plant
Reck continues ldquoOur main line was still
down leaving us with a big hole in hitting
customer needs but knowing that our new
Metso C160 was on its wayhellipwe needed an
immediate solution to keep our produc-
tion demands with an out-of-commission
crusherrdquo
The team at Pleasant Gap brainstormed
the problem and came up with a plan toget the primary plant back in operation
Their solution was to use the Lokotrack
LT1213 impactor plant and another mobile
unit to keep the main line crushing To do
this they removed the guts on the existing
impact crusher essentially turning it into a
rock chute They then moved the LT1213
and another manufacturerrsquos mobile unit
over to the existing dump hopper gt
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
ldquoWe had our haul trucks drop off mate-
rial while two excavators fed the two
mobile unitsrdquo Reck explains ldquoFor two-and-
a-half months the Lokotrack LT1213 unit
was producing 254 cm (10rdquo) minus at
700 tons per hour The other similar-sized
mobile unit was doing 400 tons an hour
maxed out The difference was unbeliev-
able to say the least Our unique solution
using the two mobile units especially the
LT1213 helped Glenn O Hawbaker achieve
a record output in 2010rdquoAccording to Fahr ldquoWe were not new to
Metsorsquos quality and supportrdquo because GOH
had been using Metsorsquos portable crushing
equipment for 3 years prior to the primary
plantrsquos impact crusher failure In another
part of our operation we have a system that
our team relies on every day a Lokotrack
LT1213 and ST272 working in tandem with
two portable conveyorsrdquo This highly effi -
cient mobile processing system turns out
300 tons of specialized blended material
per hour GOH has been so impressed with
Metso equipment its last two purchaseswere an LT106 tracked jaw plant and a
second ST272 mobile screen in 2010
Maintaining high productivity
The Metso C160 jaw was delivered to Pleas-
ant Gap Quarry in January of 2011 and
since start-up it has more than met expec-
tations The crusher is fed minus 910 mm
(36rdquo) limestone with the jaw set at 140 mm
(5 12rdquo) According to Reck ldquoFrom moment
we started up we knew we had a winner
Not only were we kicking out as much
product as our previous units without even
breathing hard but we immediately had a
2-cent per ton savings to the bottom line
without having to run a second 350 HP
motor as required by other units Plus by
adding on the new automatic lube system
the maintenance team had more time to
devote to keeping other areas of the com-
plex running more effi cientlyrdquoReck says ldquoThe Metso unit was a perfect
fit and with the improved features it pre-
sented it had it all We just turn it on load
it up and we are moving 600 tons per hour
through the crusher without any effort and
we know it can do so much morerdquo With
the primary crushing plant back in opera-
tion the entire team at Pleasant Gap will
continue to do what they do best produce
and sell high-quality products and meet
their customersrsquo expectations
More info
Scott Yablonsky Tel +1 262 717 793
scottyablonskymetsocom
The Metso C160 jaw
was installed at a 10deg
angle to fit Pleasant
Gaprsquos existing
infrastructure
The Lokotrack LT1213 impactor plant and ST272 mobile screen operate in tandem with two
portable conveyors at Pleasant Gap
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983149983141983156983155983151 983150
Paper amp fiberNew OptiConcept M paper
and board making line
The new OptiConcept M paper and board
making line stands for economy safety and
usability
Metso has launched a new modular paper
and board making line called OptiConceptM A member of the proven OptiConcept
production line family the new OptiCon-
cept M optimizes machine investment in
line with each millrsquos capacity needs
Savings in operating costs are achieved
through precise dimensioning of pro-
cesses proven technological solutions
optimal running parameters effective
maintenance operations and fully inte-
grated automation solutions
Optimized processes innovations
smart controls and accurate dimensioning
decrease the use of steam gas electricitywater chemicals and other raw materials
and reduce emission levels
OptiConcept M has been designed
both visually and physically with the
requirements of users in mind For exam-
ple the design of the machinery allows for
easy and safe changing of rolls and wear
parts thus reducing the total duration and
cost of maintenance shutdowns
RecyclingGreen energy technology to
Elektrociepłownia Białystok in Poland
Metso will convert a coal-fired boiler to
a biomass-fired Bubbling Fluidized Bed
boiler for Elektrociepłownia Białystok SArsquos
combined heat and power plant (CHP) in
Białystok Poland The new boiler system
will cut the power plantrsquos CO2 emissions
significantly by partly replacing the coal
fuel supply with biomass fuel
ldquoPoland is one of the largest countries
in Europe to have such a high depend-ence on energy derived from coal to
meet national electricity needs This is an
important incentive for us to reduce future
CO2 emissions and produce more green
electricity and with Metso technology
we are certain to accomplish our goalrdquo
states Mr Andrzej Schroeder President of
Elektrociepłownia Białystok SA
Since 2000 Metso has received a total
of 7 biomass boiler conversion orders in
Poland and the renewable energy share
in Poland is only 75 (2010) compared to
the target of 20 by 2020 set by the EUApproximately 80 of the current energy
boilers turbines and generators installed in
Polish power plants are over 20 years old In
order to meet the strict EU environmental
requirements modernization of existing
installations is necessary
Automation
Metso DNA automation system expands
to mining and construction
Using Metsorsquos control room automation
an entire crushing and screening plant can
be effi ciently managed
Metso is a leading supplier of mining and
construction machinery This expertise has
now been combined with a scalable Metso
DNA automation system that adapts to
the range of industry needs from single
machine controls to plant-wide automation
and information management systems
An example of Metsorsquos new offering is a
new crushing plant control room solution
that connects crushers and screens ensur-
ing the effective management of the entire
plant from a pleasant and safe control
room The Metso DNA user interface pro-vides the production information to ensure
a proper and rapid response to plant
events Automatic controls stabilize the
process and allow the operators to monitor
the plant as a whole
ldquoThe benefits of automation for the min-
ing and construction industry are signifi-
cant As an example of the services we offer
performance studies to crushing plants
utilizing Metsorsquos multi-disciplinary teams of
experts to determine the present level of
the plant and process effi ciency and to esti-
mate the improvement potential and thebenefits of optimization and automation
including ROI calculationsrdquo says Mikko Maumlki-
nen Product Manager of minerals applica-
tions in Metsorsquos Automation business line
ldquoAs another example our machine
condition monitoring solutions can reduce
plant and machine downtimes as well as
help to avoid safety and environmental
hazardsrdquo he adds
Metso around the world
Aerial view of the Elektrociepłownia Białystok combined heat and power plant in Poland
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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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Facilities for the
Sochi Winter Olympicsconstructed with high-quality aggregates
Metsorsquos stationary washing plant was delivered to Maykop Nerud and so far has processed over
500000 tons of high-quality aggregates and sand for the construction of Olympic facilities in Sochi
Positive estimate of the end product quality
General Director of Maykop Nedud Company
Alexander Kozhanov (in the middle) with hisdeputies Alexey Poddubny and Stanislav
Steblyansky
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983110983141983137983156983157983154983141983140 983137983154983156
The City of Sochi despite
its subtropical climate
is preparing to host the
Winter Olympic Games in
2014 In connection withthis event major sports and
infrastructure facilities are
being built
TEXT amp PHOTOS Eero Haumlmaumllaumlinen
Because the Olympic site is classified as
a 12-magnitude seismic zone the State
Corporation ldquoOlympstroyrdquo and Russian
construction regulations require the use of
high-quality washed aggregates in concrete
when constructing critical objects in Sochi
These requirements are being met
in full by the company Maykop Nerudwhich produces crushed stone of various
fractions and sand using Metsorsquos mobile
crushing and screening plant and a station-
ary washing complex to process ancientmetamorphic alluvial formations into high-
quality construction materials
To date Maykop Nerud has shipped
to Sochi more than a million tons of inert
materialsaggregates produced in its in-
house production and in adjacent quarries
Inert materials are delivered to Sochi exclu-
sively by rail due to the diffi cult mountain-
ous conditions The company dispatches
one to two trains containing 3000 ndash 6000
tons of crushed stone and building sand to
the Olympic city daily
Aggregates from Maykop Nerud arebeing used in many Olympic projects
including Bolshoi ice palace and in tunnel
complex No 1 consisting of 25 kilometers
of road railway and service tunnels which
will be used to transport guests at the
Sochi 2014 Olympic Games between the
Olympic Village and a ski complex in Kras-
naya Polyana
Maykop Nerudrsquos washed sand is also
being used by manufacturers of tubing for
five tunnels under construction
ldquoMetso is a true partnerrdquo
Maykop Nerud was established just four
years ago and was supplying the inert
materials of other producers using anin-house railroad warehouse Later the
company entered into contracts with
quarry It is the first complex of its kind
in Russia
ldquoIn the initial stages of preparation for
the technical requirements of the equip-
ment we had planned to purchase a
mobile washing plant but Metsorsquos engi-
neers convinced us of the advantages of
stationary washing and screening equip-ment Today with the complex working
247 at full capacity it is easy to see that
major construction companies running
operations in Sochi and purchased its ownequipment for crushing and screening
ldquoWhile looking for an equipment sup-
plier we were approached by leading
manufacturers of crushing and screening
equipment After their proposals were
subsequently cross-checked Metso was
deservedly appreciated as a supplier of
high-quality equipment by all other bid-
dersrdquo says Alexander Kozhanov General
Director of Maykop Nerud
ldquoSince choosing Metso as our equip-
ment supplier and during the course of our
cooperation we have come to the realiza-tion that Metso is a true partner for us In
close cooperation with Metso we develop
and implement processes unavailable to
competitors work together as a united
team and share valuable experiencerdquo
Kozhanov adds
A good example is Metsorsquos washing
complex operated at Maykop Nerudrsquos
we made the right choicerdquo says Maykop
Nerudrsquos Deputy General Director AlexeyPoddubny
From sand-gravel mix
to quality aggregates
The raw material Maykop Nerud uses is
metamorphic alluvial sediments of hard
rock deposited in the Belaya River valley
millions of years ago The sand-gravel mix
in the companyrsquos quarry features some
properties of granite with excellent hard-
ness making it a good feed for the produc-
tion of quality aggregates
Straightforward quarrying technology isutilized excavators dig up the sand-gravel
mix and move it to stockpiles From the
stockpiles the sand-gravel mix is reclaimed
to Metsorsquos three-stage crushing and
screening process consisting of tracked
jaw and cone crushing plants and a mobile
screen gt
The sand amp gravel mix is crushed and screened
into 0ndash20 mm fractions using jaw and cone
crushing plants combined with a mobile screen
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The Maykop Nerud Company has supplied more than 150000 tons of 0ndash5 mm washed sand and aggregates in fractions of 5ndash10 mm 10ndash20 mm and
5ndash20 mm for shotcreting and for the concrete lining of the constructed tunnels
Crushed to the size of 0ndash20 mm the
material is transported by conveyors to a
washing complex consisting of a feed hop-
per conveyors a 4-deck washing screen aspiral classifier and an automated control
system
In order to facilitate the operations of its
customers Metso has established a stock of
spares and consumables in Maykop Nerudrsquos
territory Maykop Nerud can use the stock
for its own purposes and parts can also
be delivered to other Metso customers as
required The reliability of the equipment
983110983141983137983156983157983154983141983140 983137983154983156983145983139983148983141
and its operational effectiveness mainly
depend on the availability and prompt
replacement of spares and consumables ndash a
prerequisite ensured by the mutual effortsof Metso personnel and Maykop Nerud staff
Powerful crushing complex in
combination with washing plant
Having taken into account the growing
demand for high-quality end products
Maykop Nerud and Metso agreed to
extend their cooperation and create an
even more powerful stationary crushing
and screening complex including a pri-
mary jaw crusher and two stationary cone
crushers for operation in combination with
a stationary washing plantldquoBeginning in the second quarter of
2012 we will use the new stationary crush-
ing and screening complex along with the
mobile equipment thus allowing us to
increase our capacity to 130000 ndash 140000
tons per month in order to meet the con-
stantly growing demandrdquo says Stanislav
Steblyansky Deputy General Director of
Maykop Nerud
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The construction budget of EUR 534 billion
for projects in Sochi includes three major
sites the Olympic Park along the shore of
Black Sea the Olympic Village residences
for the athletes and the Krasnaya Polyana
ski resort in the Caucasus Mountains
These three sites will be interconnected
by numerous new highways roads bridges
Construction projects at a total budget of EUR 534 billion
983110983141983137983156983157983154983141983140 983137983154983156
The companyrsquos sand-gravel-mix
resources are expected to last upwards of
20 years Upon the completion of mining
and once the territory has been rehabili-
tated the quarry will be transformed into
an artificial lake for recreation and fishing
for the residents of the City of Maykop
More info
Alexey Shevyakhov
Tel +7 495 915 29 30
alexeyshevyakhovmetsocom
LOCATION City of Maykop Republic of
Adygea southern Russia
RAW MATERIAL hard rock sand-gravel mixhardness 40 kN
CAPACITY 250 th with increase up to 550
th in 2012
RESOURCES over 10 million cubic meters
END PRODUCTS Washed building sand 0ndash5
mm and crushed aggregates 5ndash10 mm
10ndash20 mm 5ndash20 mm 20ndash40 mm
ON-SITE MЕTSО EQUIPMENT
bull 1 Lokotrack LT106 jaw plant
bull 1 Lokotrack LT200HP cone plantbull 1 Lokotrack ST35 mobile screen
bull 1 Nordberg CVB 2060-4 inclined
screen
bull 1 Nordberg SF2870 sand trap
EQUIPMENT BEING INSTALLED WITH
COMMISSIONING IN 2ND QUARTER OF 2012
bull 1 Nordberg C80 jaw crusherbull 2 Nordberg HP4 cone crushers
bull 2 Nordberg CVB2060-4 inclined
screens
bull 1 Nordberg SF2360 sand trap
bull 1 Nordberg SF2870 sand trap
Maykop quarry owned by the Maykop Nerud Company
and tunnels Essentially the entire infra-
structure within and around the 110-km-
long Sochi will be renewed
More than 155000 workers are involved
in the construction projects In total more
than 300000 cubic meters of concrete
will be used for shotcreting and for the
solid cladding of the tunnels A consider-
able proportion of that concrete will be
prepared using the aggregates and sand of
Maykop Nerud
The company Severstroy is producing
concrete elements for lining 23 kilometers
of various tunnels All of the washed aggre-
gates and sand for those projects is also
being supplied by Maykop Nerud
Metsorsquos sand trap is a critical component of the washing complex
In August 2011 construction of the new ice stadium in Olympic Park was at full speed
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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155
The new Metso C120 jaw crusher combines effi ciency versatility and safety
Metsorsquos new C120 jaw crusher made its worldwide debut at the Steinexpo exhibition in Germany
New products
Metso is proud to announce that we have developed the first fully
recyclable modular screening media ndash Metso Trellex LS-Eco
In response to customer requests for sustainable and environ-
mentally friendly screening media solutions and in line with our
own sustainability program we have taken the acclaimed Metso Trellex LS rubber modular screening media systems and success-
fully replaced the traditional steel reinforcement with an environ-
mentally friendly composite material This unique solution makes it
possible to effectively recycle our customersrsquo screening media
In the past screening media modules that were no longer
suitable for production were treated as waste and could not be
recycled Metso has introduced a new future for the product and a
sustainable solution
Sustainable solution for screening media
Metso has launched the
first fully recyclable
modular screening
media ndash Metso
Trellex LS-Eco
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Metsorsquos Mining and Construction Technology has introduced the
Metso C120 jaw crusher ndash the 13th member of the field-proven
C-series range of crushers The C120 combines uncompromising
reliability crushing effi ciency and versatility in both stationary and
mobile applications with safety and ease of use
Even at first glance it is clear that Metso has paid special atten-
tion to the C120rsquos new durable and user-friendly design start-
ing with the casting the design of which is based on thorough
FEA analysis and casting simulations Every detail of the C120 is
engineered for reliable operation and long life resulting in high
constant crushing capacity and uptime
ldquoWhen starting the C120 project we listened closely to our cus-
tomers and collected field data from a number of sites Based onthat information we decided to design the crusher cavity and kin-
ematics first As a result Metso can now offer aggregates produc-
ers large-scale contractors and mining companies a new crusher
that meets all the standards set for any demanding applicationrdquo
says Ilkka Somero Metsorsquos Product Manager for jaw crushers
New design brings outstanding productivity
The outstanding productivity of the C120 is guaranteed thanks
to several new design elements The crusher features a long and
aggressively directed stroke and a fixed jaw die longer than previ-
ously seen in this crusher size class The C120 has a large feed
opening of 1200 x 870 mm (34 x 47rsquorsquo) and an aggressive cavity cross
section securing a high per formance and reduction ratioIn terms of cavity volume and crusher weight the C120 is posi-
tioned between the existing Metso C116 and C125 jaw crusher
models
The Metso C120rsquos nominal power is 160 kW (200 HP) operating
speed 230 rpm closed side setting between 70 ndash 200 mm (2 34rsquorsquo
ndash 8rsquorsquo) The operational weight is 26000 kg (57200 lbs) excluding
options
More infoIlkka Somero
Tel + 358 50 317 0769
Ilkkasomerometsocom
The optional robust composite 1047298ywheel guards allow quick and safe
access to the service points
983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156
In addition to providing environmentally friendly screening
media panels Metso will implement a unique program to provide
its customers with a suitable range of recycling services
The Metso Trellex LS-Eco offers a wide range of health safety
and environmental benefits Each screening media panel is up to40 lighter than standard steel reinforced Trellex LS panels This
makes handling easier and the working environment safer Lighter
panels also help to reduce the overall stress on the entire screening
installation
Compared to steel-reinforced panels the composite-reinforced
panels of the Metso Trellex LS-Eco are more 1047298exible and will reduce
the effects of pegging and blinding during screening operations
The Metso Trellex LS-Eco promises reduced downtime and
increased productivity
The Trellex 300LS and Trellex 305LS rubber and polyurethane
panels are already acclaimed worldwide as being among the most
versatile modular screening media solutions They can be attached
to most screening media systems and can handle all types of
screening applications ndash fine and coarse wet and dry In the futurewhen Metso customers need new screening media panels for
their existing system they can choose Metso Trellex LS-Eco and be
assured that their panels will be safely and effectively recycled
More info
Claes Larsson
Tel +46 410 525 73
claeslarssonmetsocom
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The new Lokotrack LT120 with its world premiere at the Steinexpo
exhibition in Germany combines crushing performance and user-
friendly design in a new revolutionary way For the first time the
same Lokotrack model is now available in a hydraulically or electri-
cally driven version to meet customer needs
New Lokotrack LT120 jaw plant introduced
Lokotrack LT120 is the latest and most advanced of Metsorsquos track-mounted jaw crusher plants
Lokotrack LT120 combines user-friendly design and good crushing
performance in a new way
power supply or a 420-kV onboard diesel generator Having the
possibility to use an external power supply enables a highly eco-
nomical and ecological crushing process
The Lokotrack LT120 is built around the new C120 jaw crusher
See page 10 for information about the C120
Safe to use move and service
Safety is the highest priority for Metso when designing new equip-ment The Lokotrack LT120 is designed to be safe to operate move
and service
ldquoA safe operating environment is created by practical solutions
When service points can be reached easily the possibility of dan-
gerous situations diminishesrdquo says Product Manager Timo Nakari
ldquoGood examples of safety built in to the Lokotrack LT120 include
sturdy easy-to-open composite 1047298ywheel guards and hydraulically
folding and locking feed hopper sidesrdquo Nakari adds
The Lokotrack LT120 can be fine-tuned to suit the customerrsquos
application by selecting the required options from a long main
conveyor and hammer and boom to a water spraying system and
rubber lining for the feeder and hopper for example
The Lokotrack LT120 features a Caterpillar C13 310 kW (415 hp)engine Its transport dimensions are length 16 m (52rsquo 6rdquo) width 3 m
(9rsquo10rdquo) height 39 m (12rsquo 10rdquo) and weight 57 tons (114000 lbs) The
LT120E version weighs 63 tons (126000 lbs)
More info
Timo Nakari
Tel + 358 40 701 6143
timonakarimetsocom
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The Lokotrack LT120 uses the same field-proven technology
seen in Metsorsquos tracked units for over 26 years Every detail of thenew jaw plant has been thoroughly designed for reliability and
long life The main targets when designing the unit have been
energy effi ciency good performance reliability and product safety
Field tests have demonstrated its good fuel economy and high
crushing capacity
Environment-friendly economy
The Lokotrack LT120 is also available as an electrically driven unit
ndash the Lokotrack LT120E ndash which can take energy from an external
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The TS range of screens is characterized by its innovative design
comprising two technologies combined multi-variable slopes with
a variable elliptical motion This proven range is being comple-
mented with the new TS63 screen
The TS63rsquos unique combination increases both the screenrsquos effi -
ciency and its capacity Material speed is high at the feed end and
slows down at the discharge end
Metso TS series screens offer more space between decks mak-
ing maintenance easier and improving service conditions for the
operators as well as meeting all safety requirements
Metso has recently sold several 25-m2 multi-slope screens for
mining applications such as a TS63 for Ferrostaal in Mauritania andalso for the construction industry for example Holcim in Lynwood
Australia Georyt in Poland Apaxco in Mexico and Newmont in
Peru
More info
Denis Pradon
Tel +33 680 64 39 67
denispradonmetsocom
New TS63 screen ndash the largest three-deck banana screen on the market
The new Metso TS63 banana screen features a 25-m2 screening area
Following the success of the HP4 and HP5 Metso has broadened
the product range with the new HP3 cone crusher This mid-range
cone crusher benefits from 70+ years of experience in crushing
technology while specifically addressing customer requirements
for large capacity ease of operation and a high reduction ratio
The HP3 responds to market demands for increased productionquality reduced maintenance time and low operating costs The
new generation HP models are comparable to their predecessors
but offer increased versatility
The HP3 features the size of an HP200 with the output of an
HP300 The power performance and robustness of the new gen-
eration models allow in certain cases two crushers to be replaced
with just one so investment production and operation costs are
greatly reduced
The HP3 has been tested at two different quarry sites in France
over the past seven months ndash at a gravel pit and a rock quarry
The Metso factory in France began production of the HP3
series in September Several orders have already been received for
secondary and tertiary applications Since 2009 nearly 300 HP newgeneration cone crushers have been commissioned The HP3 mar-
ket will be primarily centered on gravel pit applications (70)
The HP3 has a nominal feed opening of 220 mm (865rsquorsquo) a
motor size of up to 220 kW (300 hp) and a weight of 13280 kg
(29277 lbs)
More info
Carlos Padin
Tel +33 6 0727 2002
carlospadinmetsocomMetso HP3 at a stationary installation in France
HP3 cone ndash another new-generation cone crusher
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First modular plant to NepalMetso delivered its first modular crushing and screening plant to MS Palchowke Mai Roda Dunga Udyog Limited (PMRD)
in Melamchi Nepal The modular plant solution offers PMRD a fast and effective response to productivity and qualityrequirements
TEXT amp PHOTOS Atoshi Nayak Ghosh
The diversity of operations at a typical con-
struction site involves quick decision-mak-
ing and often a lot of pressure to ensure a
timely execution
High performance guaranteed
Considering todayrsquos volatile market sce-
nario business partners must maintainpace with their customersrsquo ever-changing
requirements Understanding custom-
ersrsquo strategic business needs is of utmost
importance PMRDrsquos plant was commis-
sioned in January 2011 and has logged
about 1200 hours of operation to date
The plant is much more compact than
the traditional skid-mounted plant and
provides space for free movement of utility
equipment within the plant area One of
the key features of the plant is the totally
bolted structure It can be easily disman-
tled into sub-assemblies transported and
re-assembled effortlessly at a new location
which is one of the biggest advantages in
helping to meet new market demand
Due to the use of pre-assembled mod-ules for each crushing station the instal-
lation work on site takes less time thus
decreasing the plantrsquos installation lead time
The plant also includes a foldable conveyor
for maintenance of the cone crushers
Stepping up with Metso
PMRD operates a two-stage plant compris-
ing a C80 jaw crusher an HP200 high-
performance cone crusher and a CVB1845
screen with circular motion MV2 vibra-
tory mechanism for final product recovery
resulting in an aggregate plant of 150 tph
capacity for producing size fractions of 0-40
mm The plant is an example of world-class
craftsmanship and excellent material han-
dling capacityModular and non-welded construction
supported by durable pitman assembly sin-
gle-piece cast steel frame bearing housings
with repairable crusher construction and
the right cavity design results in aggressive
kinematics and high power that best suits
the requirements of the customer
PMRD has immense pride in the plant
ldquoThe performance has been astounding
A drawing of typical modular plant
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with applications ranging from road aggre-
gates commercial sand production to
ready-mix concretes The modular plant is
almost set to create a new niche in aggre-
gates processing in Nepalrsquos construction
industry It is one of a kind and we are sur-
prised at the plant rsquos production capacity
It is easy to operate and requires minimalmanpower Our cost per ton has signifi-
cantly gone down and so has the cost of
productionrdquo says Mr Sandeep K Agarwal
Director PMRD
Safety as a key issue
Health safety and environmental solutions
are key concerns for Metso and they are
addressed with the same sense of responsi-
bility as quality productivity and cost-
effi ciency issues Metso is responsible for
conducting operations in an environmen-
tally sound way and offers products and
services that can help customers fulfill their
environmental responsibilities
Metso provides the plant offi ce and site
with operation and maintenance manu-als for each and every piece of equipment
including safety issues which are entrusted
to all the operators
All conveyors are equipped with pull-
cord safety switches along with emergency
stop buttons The working area and walk-
ways are all equipped with safety hand rails
and checkered plates for anti-skidding The
entire plant is equipped with earth pits for
electrical current earth leakage prevention
Metso has ensured all possible measures
to maintain high safety standards for all
operation and maintenance personnel
More info
Suhen Agarwal
Tel +91 124 2351566suhenagarwalmetsocom
Nepalrsquos first modularcrushing and screening plant deliv ered by Metso
E ffi cien t C VB1845 inclined screen wi th
an M V2 vibra tor y mechanism handles
the classi fica tion o f crushed ma terials
A s turd y f eeder dis tribu tes the ma terials to be crushed to
a
Me tso C80 ja w crusher
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Outokumpursquos Kemi
mine set to doubleproduction The only mine unit owned by Outokumpu
the chrome mine in Kemi northern Finland
is busy making preparations to double its
production set to begin next year In co-
operation with Metso Outokumpu willincrease the number of underground
feeders and optimize the durabil-
ity of wear parts in the massive
primary gyratory crusher
TEXT amp PHOTOS Eero Haumlmaumllaumlinen
Chrome ore is fed into Metsorsquos
Superiorreg 50-65 primary
gyratory crusher by three
different vibrating feeders
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Up until now the entire production of the
chrome mine totaling about 13 million
tons annually has been transported to the
Tornio ferrochrome plant for processing
and on to the Tornio stainless steel plant
The increase in production which will
begin in autumn 2012 is intended also to
enable Outokumpu to sell ferrochrome tocompanies outside the Group The produc-
tion target for 2013 is 27 million tons of
ore and of the ferrochrome produced from
the ore nearly a half (gt 200000 tons) is to
be sold outside
Underground expansion
work almost complete
About 500 meters underground the
majority of the work involved in increasing
the capacity the F3 project has already
been completed Doubling the production
is no problem for the Superiorreg primarygyratory crusher delivered to the mine
by Metso in 2002 which can digest more
than 2700 tons of feed material per hour if
necessary
At the moment the primary gyratory
crusher can be fed by three different vibrat-
ing feeders The crusher currently runs for
less than one-fifth of the production time
The increase in ore production will increase
the effective crushing time to about one-
third of the production time
A lot of work has been done for orestorage after the primary crusher The
two currently used storage silos are now
accompanied by two new 8000-ton silos
The number of Metso feeders transporting
the ore from the primary crusher has also
been doubled
Optimization of wear parts under way
Chrome ore has been a challenge to the
primary gyratory crusherrsquos wear parts The
wear is contributed to by the pulsating
feed which rarely fills the entire crushing
chamber There are also great differences inore type since brittle feed material prone
to chalking is occasionally replaced by hard
ore that requires a lot of crushing power
before it is crushed with a bang gt
Mika Saari (right) Foreman of ore line technicians at Outokumpursquos chrome mine in conversation with
Mikko Malkamaumlki Metsorsquos crusher wear parts specialist
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
last did in July for the replacement of the
crusherrsquos wear parts Our work is also facili-
tated by product development like the
addition of maintenance hatches to the
feedersrdquo he continues
Lasting technology
According to Mika Saarirsquos calculations the
Superiorreg primary gyratory crusher has so
far crushed more than six million tons of
ore in totalldquoThe factory polishing marks still show
on the bottom thrust bearing so we
believe that the bearing will last the entire
remaining service life of the crusher which
is about ten years and 30 million tons
Metsorsquos feeders have been equally reliablerdquo
Saari says
After the next 30 million tons of ore
it will be time to deepen the mine
More info
Jukka Raumlisaumlnen
Tel +358 50 317 1787 jukkaraisanenmetsocom
Mikko Malkamaumlki
Tel + 358 40 827 8223
mikkomalkamakimetsocom
The Kemi mine and Metso are currently
carrying out a development project to
increase the service life of the mantle and
outer concave and thus minimize down-
time due to replacement While the modu-
lar feed hopper enables quick replacement
of the mantle replacing the outer concave
can easily take more than a week The cooperation between the Kemi
mine and Metsorsquos wear parts team in
Tampere aims to extend the service life
of the parts to at least 4 million crushed
tons Durability is sought by optimizing the
chamber structure and selecting the r ight
materials for the outer concave
ldquoSmooth cooperationrdquo
Mika Saari Foreman of ore line technicians
working in the underground mainte-
nance of the Kemi mine leads a small but
experienced team of technicians The tidymodern offi ce spaces are located close to
the action at a depth of 500 meters
ldquoCooperation with Metso has been
smooth Increasing our own crushing
expertise takes time so all know-how
shared by the manufacturer is very wel-
come to usrdquo Mika Saari says
ldquoWe can also use Metsorsquos profession-
als for servicing when necessary like we
The Superiorreg 50-65 has provided reliable
crushing performance at a depth of 500 metres
in the Kemi chrome mine
Technicians Sari Kulju (left) and Marko Jaako ensure that the primary gyratory crusherrsquos hydraulicand electrical unit remains very tidy which contributes to trouble-free operation of the crusher
Outokumpu Oyrsquos Kemi
chrome mine
LOCATION Keminmaa northern
Finland
ORE TYPE chrome oxide (26)
ORE ESTIMATE ON 1 JANUARY 2011
ndash ore reserves 36 million tons
ndash mineral resources 87 million
tons
MINING METHOD bench and cut fillFEED MATERIAL SIZE 0ndash1000 mm
METSO EQUIPMENT IN THE MINE
bull 1 Superiorreg 50-65 primary
gyratory crusher
ndash open side setting 152 cm (6rdquo)
bull 8 VMOU 25-125 feeders
bull 1 VMOU 30-16 feeder
bull 1 VMOU 40125 feeder
bull 2 Symons cone crushers
bull 1 C80 jaw crusher
bull 4 HM75 pumps
bull 11HM100 pumps
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983122983141983152983151983154983156983145983150983143 983154983141983155
Metso was responsible for the design
development and construction of the
entire secondary and tertiary arrangement
The primary station will be the subject of a
subsequent investment
Latest environmental protection used
This installation has been designed in strict
compliance with the environmental quality
approach developed by Metso and its
partners using the latest technologies
in dust control including confinement
technology as well as dust encapsulation
technology for screens
To ensure an annual capacity of 15 mil-lion tons for a nominal output of 560th of
02 mm and 220 mm the clientrsquos choice
for the secondary stage naturally fell upon
the NP 1520 impact crusher
A complete impact crusher solution for Lafarge The Lafarge Group has entrusted Metso with the implementation of its new aggregates installation in southern France
It comprises a new secondary crushing stage equipped with an NP1520 impact crusher featuring a power range of2 x 250kW and equipped with hydraulic adjustment
TEXT amp PHOTO Gilles Dombey
The NP 1520 crusher has long proved
its performance not only in terms of capac-
ity and reduction rate but also quality of
the finished product and durability
More info
Arnaud Bertucat
Tel +33 (0)6 81 44 68 26
arnaudbertucatmetsocom
About 15 million tons of aggregates feed will be crushed with the NP1520 impact crusher at Lafargersquos stationary installation in southern France
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Multi-stage Lokotrack process a success in Senegal
A multi-stage crushing and screening process has proven its effi ciency in the production of concrete aggregates in
Senegal Western Africa With the mobile process Xewell Cimenteries SA now exploits its quarry better has reduced
its operating costs and can meet strict environmental requirements
TEXT Elisabetta Cataluffi PHOTOS Carlo Rinolfi
Senegal is a rapidly developing country
offering a good deal of potential activities
for crushing companies too At the sametime the country has several areas of high
environmental value Therefore contractors
must opt for state-of-the-art equipment that
offers reduced environmental emissions
The company Xewell Cimenteries SA
was founded in 2008 as a partnership
between Italian Swiss and Senegalesecontractors Xewell operates a limestone
quarry located in the Pout area east of the
capital city of Dakar
According to Alessandro Crestani Technical
Director of the Pout quarry a mobile process
was selected to better exploit the quarry and
reduce costsLokotrack process drawing made by Bruno simulation software
After assembling the Lokotrack units the process was tested by Xewell Cimenteries
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983122983141983152983151983154983156983145983150983143 983154983141983155
Owned by Freeport-McMoRan Copper amp
Gold (51) and CODELCO (49) the ElAbra mine has leachable oxide and sulfide
mineralization The minersquos processing facil-
ity has an annual capacity of 226000 tons
of copper cathode
Smaller size matters
Reducing the size of the crushed oxide
ore from the present 15 mm to 12 mm
was the main target of the mine and the
Metso team The changes that were carried
out in the process included a size varia-
tion change in the cut of the tertiary sieve
installation of rate-level sensors in thesecondary crushers and enabling speed
variables in the conveyor belt feeders of
the secondary crushing circuit
ldquoGoing from 15mm to 12mm may seem
small but the operational impact is very
important and significant for usrdquo explains
Juan Torres Carvajal Metallurgical Engi-
neer at the El Abra mine
ldquoOur goal is to reach 115000 tons with
a minimum of 80 of 12-mm-sized ore permonth The record to date is 105000 tons
and we will increase it until we reach our
project goalrdquo he adds
New design for cone liners
In addition to the work mentioned above
Metso is currently carrying out a project to
design the lining profiles for the secondary
and tertiary crushers of the plant which
will affect the smaller size of the material
In cooperation with Nelson Mella from
Metso and Rodolfo Navarro Crushing
Superintendent at the El Abra mine testswere carried out in July on the re-designed
Metso linings One set was tested for sec-
ondary crushing and two sets for tertiary
crushing
More info
Nelson Mella
Tel +56 99158 0576
nelsonmellametsocom
Finer ore through wear pro1047297lestudy at El Abra mine in ChileEl Abra is a porphyry copper open-pit mine and processing facility located in
Chile near the city of Calama some 4000 meters above sea level With the helpof Metsorsquos technical support the mine was able to achieve finer ore throughoutthe crushing process
TEXT amp PHOTOS Macarena Vallejo
Xewell Cimenteries produces a selec-
tion of dry processed aggregates for con-
crete Operations started at the end of 2009
with the aim of reaching 150000 metric
tons produced per year
Lokotracks chosen to reduce costs
To build up their tracked mobile processXewell Cimenteries decided to buy three
mobile plants from Metso two impactor
plants the Lokotrack LT1110 and LT1213
feeding a three-deck mobile screen the
ST620 The machines were sold by SCAI
SpA Metsorsquos Lokotrack distributor in Italy
ldquoWe chose tracked machines to bet-
ter exploit our quarry and to reduce
costs Mobile plants have low initial costs
because they donrsquot need any special foun-
dations or supply of electricity This obvi-
ously gives us a quicker process set-up and
better uptimerdquo says Alessandro Crestani Technical Director of the Pout quarry
ldquoThe mobile plant can also follow the
quarry face as the exploitation proceeds
reducing the transport costs of raw materi-
als in the same jobsite We chose Metso
because they ensured us the best cost-per-
ton ratiordquo he adds
Good customer service is crucial
According to Alessandro Crestani good
customer service also played a major role
when choosing the manufacturer of the
mobile equipmentldquoMetsorsquos distributor SCAI SpA was able
to provide us with a complete product
support and customer service package
Obviously service is a very important
aspect for us in a country like Senegal Any
downtime represents a clear loss of pro-
ductivity for usrdquo
The average level of productivity of the
mobile Lokotrack process is 200 metric
tons per hour
More info
Carlo Rinolfi Tel +39 335 1253159
crinolfiscaispacom
Example of the development of the Metso study
on the crusher lining profiles
Liner change for smaller ore size in the
MP1000 cone crusher
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Services success in Surabaya The Metso Surabaya workshop and offi ce complex opened in April 2008 provides Life Cycle Services and maintenance
solutions for Metso equipment in the Indonesia region The facility is strategically located in an industrial precinct on theouter rim of Surabaya the second largest city in Indonesia Its close proximity to an international airport major shipping
port and several engineering companies simplifies support for the regionrsquos key customers which include PT Newmont
and PT Freeport
TEXT amp PHOTOS David LeRoy amp Gary Whittred
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The Surabaya site operates through Metso
in Australia with assistance from key sales
and technical staff Handling regional ser-vice and repair business in-house allows
Metso to manage intellectual property and
closely control quality
It also enables the development of a
team of skilled service personnel who can
be utilized both internally and at key cus-
tomer sites as is common with the backup
service the workshop provides for screen
contracts
Innovation at work
Since 2008 the Surabaya facility has suc-
cessfully refurbished a wide variety ofcomponents Recently two ball mill heads
weighing 22 tons each were modified in
order to strengthen the 1047298ange of the ball
mill shell The modification included tap-
ping out existing 1047298ange holes and drilling
new ones so that finger plates could be
installed and welded to the 1047298anges
Positioning the head borer to properly
align the new 1047298ange holes proved diffi cult
Four roller support frames were manufac-
tured to support the heads and allow them
to be rotated easily Each hole was then
drilled and tapped at the correct angleusing the CNC five axis head The job had a
tight delivery as it was required for a shut-
down but with advance planning and inno-
vation it was completed ahead of schedule
MP1000 mainframe on
CNC vertical borer
Well equipped for fabricating and machin-
ing heavy components the Surabaya
The Surabaya facility has proven to be
a success for Metso The workshop offers a
wide variety of services in the region Qual-ity products and competitive pricing and
delivery times have led to strong customer
relationships
Turnover and customer service levels
have increased annually since the open-
ing and between 2008 and 2010 sales
increased 450 These excellent trends
are expected to continue as the operation
expands and the customer base grows
Since 2008 the Surabaya facility has
successfully refurbished
bull MP1000 counter shaft boxes headassemblies mainframes bowls adjust-
ment rings counterweights sockets and
tramp release cylinders
bull 7rsquo Symons bowls heads and countershaft
boxes
bull Vertimill screw and drive shafts
bull Ball mill heads
bull Ball mill trommel
bull VPA cylinders
bull Eaton clutches
bull Exciter screen mechanisms
bull 42x65 main shafts and eccentrics
More info
Gary Whittred
Tel +62 31 8430349
garywhittredmetsocom
workshop handles the majority of Metsorsquos
refurbishment work with ease But when
necessary PT PAL ndash a government facilitywith shipbuilding and heavy engineering
capabilities ndash offers a ldquoone stop shoprdquo Spe-
cially trained PT PAL staff ensures that the
work they perform complies with all Metso
specifications and quality standards
PT PAL also demonstrated their innova-
tive ability with the first MP1000 main-
frame refurbishment they completed The
mainframersquos shaft location bore needed
to be re-machined However the distance
from the top of the mainframe to the
tapered bore made it very hard to achieve
an accurate surface finish with the correctstandoff
To overcome this the shop decided to
machine the mainframe upside down and
elevated on support beams They posi-
tioned a new shaft under the mainframe in
a custom-made cradle Using an overhead
crane they could then lsquotrial fitrsquo the shaft in
the bore to make sure it seated correctly
and the mating tapers met specification
The method worked so well it has since
been used for four more mainframe refur-
bishments
Diversity and growth
Today Metso Surabaya continues to invest
in additional equipment in order to diver-
sify its service offering A new hydraulic
power pack which allows the facility to test
refurbished components to Metso specifi-
cations was recently used in the refurbish-
ment and testing of several VPA cylinders
for PT Freeport
Refurbished MP1000 mainframe dispatched by truck to
PT Freeport mine
Machining of MP1000 upper frame
at Metsorsquos Surabaya workshop
Mainframe at vertical CNC machining
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Creating Value with Metso in Hong KongIn Hong Kong the aggregates needed for construction are mostly supplied by two local quarries KWP Quarry Company
Limitedrsquos Anderson Road Quarry accounts for 60ndash70 making it the pillar of Hong Kongrsquos construction materials industry
TEXT amp PHOTOS Ou He
When arriving at the Anderson Road
Quarry the most impressive view at the850000 square-meter facility is the Metso
machines including equipment from the
primary secondary and tertiary crushing
circuits and the screens I t is Metsorsquos equip-
ment that secures the supply of aggregates
for Hong Kong
KWP Quarry Company Limited has been
working with Metso since its establishment
in 1997
Due to Hong Kongrsquos stringent dust and noise control standards Metso has paid special attention to the related suppression systems
ldquoOur quarry mainly lies on granite and
volcanic rock which are so hard they canonly be processed by equipment with
strong durability and stabilityrdquo explains
Mr Eddie Hung Manager of KWP ldquoWith a
long history of and experience in quarry-
ing we are very familiar with the equip-
ment of different brands Comparatively
Metsorsquos products are better than others in
terms of durability stability and effi ciency
Besides this the reason we selected Metso
is because of the simple maintenance of
their equipment and the easy access tomaintenance informationrdquo
Flexible modular solution
Based on extensive experience in crushing
and screening worldwide Metso presented
the Anderson Road Quarry with a modu-
lar solution and delivered it as a turn-key
project Through a four-stage crushing
circuit which contains three Metso C160
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jaw crushers for primary crushing two
Omnicone 1560SX crushers for secondary
crushing two HP 500SX cone crushers for
tertiary crushing and one HP500SX cone
crusher for extra-fine crushing the plant
was able to produce aggregates of optimal
shape with minimal 1047298akiness
The fine products include three sizes
0 to 5 mm 5 to 10 mm and 10 to 20mm
Since the employment of this system in
2000 production has reached 1250 th
which is far beyond the design capacityAccording to Mr Hung ldquoThe machines
always run effi ciently and seldom malfunc-
tion The occasional shutdown of some
machines does not affect production very
much the plant still could reach 60-70
of its normal production It gives us the
best 1047298exibility for the plant rsquos operation and
I believe this is the best feature of Metsorsquos
solution
Eddie Hung
Manager of KWPrsquos
Anderson Road
Quarry is happy with
the product quality
and service provided
by Metso
ldquoMetsorsquos equipment is expensive com-
paratively but in the long run you will find
that the investment is worthwhile on the
whole Metso secures superior stability reli-
ability and fewer downtimes and it guaran-
tees continuous operation and brings us
greater valuerdquo
Great service team
Metso sent a group of service engineers
to the plant within the warranty period
not only to provide service but to train theoperators Mr Hung speaks highly of Met-
sorsquos service team he is impressed with its
experienced experts and with their strong
sense of responsibility and customer-
oriented ways of working
ldquoMetsorsquos service team never fails to find
hidden problems and helps us to prevent
any mechanical failures And they are
available whenever we need them they
work closely with us to solve the problem
effi cientlyrdquo he said
Excellent environment-friendly designIn order to achieve the worldrsquos most strin-
gent noise and dust control standards
developed by the Environment Protection
Department of Hong Kong Metso has
incorporated a dust and noise suppression
system into the plant This includes the
infrared-triggered spray systems at feed
points encapsulation of individual crush-
ers and conveyors and the ability to select
specific sectors of the system for treatment
depending on feed and operating condi-
tions encapsulation of equipment and the
enclosure of all major sections of the plant
With these advanced environment-
friendly solutions Anderson Road Quarry
has won numerous safety and environmen-
tal awards In 2003 it was presented with a
silver medal in the prestigious Environmen-
tal Performance Awards in recognition of
its commitment to the environment and
community In 2004 KWP achieved certifi-cation of ISO 14001 it is the first quarry site
to have achieved this in Hong Kong and
southern China
ldquoA reliable partnerrdquo
The promulgation of the top ten infrastruc-
ture policies in Hong Kong boosted the
market for aggregates and demand will
keep rising over the next five to six years
ldquoWersquoll definitely keep our cooperation with
Metso once we have a need for expansion
because we regard Metso as a reliable part-
ner With their highly effi cient equipmentsatisfying service and great efforts in help-
ing us to achieve our environmental pro-
tection targets Metso is our best choicerdquo
says Hung
More info
Ziqiang Li
Tel +86 13601289027
ziqianglimetsocom
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The sturdy Metso C160
jaw crushers are fed
using huge feed chutes
and feeders
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Similar to hundreds of mine sites world-
wide Zinkgruvan is being operated on a
non-stop 247 basis with just a few main-
tenance breaks during the year Crusher
availability is crucial because 100 of the
ore has to pass through the jaws before
being hoisted up for further processing
In addition to the zinc- lead- copper-
and silver-containing ore the C jaws chop
all the host rock extracted along the min-
ing process With a sturdy design Metsorsquos
proven C jaws can easily reduce even the
hardest type of rock Every year more thanone million tons are crushed with the jaws
ldquoMinimal service neededrdquo
Crushing with the first C160B jaw crusher
began at Zinkgruvanrsquos -800 meter level in
2000 with the primary crushing of zinc-lead
ore The second jaw was installed in 2008
for the new copper process gt
The sight and sound of two C160 jaw crushers operating side by side in the underground
crushing station of the Swedish Zinkgruvan mine is impressive Good proactive service
secures good uptime and reliable continuous operation of Metsorsquos second-largest
C160 series jaw crushers and prepares the way for the ongoing plans to expand the
production of zinc concentrate
TEXT amp PHOTOS Eero Haumlmaumllaumlinen
New PolyMet liners are being tested with the grinding mill delivered by Metso
Zinkgruvanrsquos twin C160
jaws secure good uptime
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Blasted ore is taken from the presently
operated -850 meter level with normal
trucks as an outsourced process One full
truckload is fed to the C160s every
10 minutes
ldquoWe are happy with the high reliability
of the C jaws They only require some minor
service therefore providing us with good
uptime and steady continuous feed to our
secondary and tertiary crushing and grind-ing circuitsrdquo says Mine Manager Jan Klaumlre
ldquoBasic crusher service and wear part
changes are made by our own staff using
Metsorsquos partsrdquo he adds
Service contract with grinding
mills and conveyors
Zinkgruvan and Metso Sweden have more
than 11 yearsrsquo experience with a service
contract that contains grinding mills and
conveyors At the mine site two Metso
service people and one contractor take
care of all the related service jobs Man-
power can also be borrowed from Metsorsquos
Graumlngesberg mine service team of 20
people
Presently Zinkgruvan is testing Metsorsquos
new PolyMet mill linings in its big grinding
mills With previously used rubber partsthe linings had to be changed in the shell
every 9 to 11 months and in the feed head
every 6 months
ldquoWe expect a better lifetime with Poly-
Met linings Longer change intervals mean
a lot to our productivity because lining
changes takes two full working daysrdquo Mine
Manager Jan Klaumlre says
New mine goes deeper
With an expected mine life of more than 10
years Zinkgruvan is actively mapping new
ore reserves Experimental holes are being
drilled at the new mine section at the
-1110 meter level
More info
Fredrik Wennberg
Tel +46 70 657 00 08fredrikwennbergmetsocom
Mine Manager Jan Klaumlre (left) with Backfilling Manager Kjell Tillman at the underground -800 meter level mine cafeteria
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The Zinkgruvan mine located approxi-
mately 200 km southwest of Stockholm
Sweden is one of the oldest underground
mines in Northern Europe The mine has
been in production since 1857
The mining methods used are panel
stoping and benching The processing
facilities include a zinc concentrating plant
with a 11 mtpa and a copper plant with a04 mtpa capacity Tailings are recycled in
an impounding basin and host rock in the
backfill plant
Continuous mining since 1857
Even as one of the oldest mines in Northern
Europe Zinkgruvan exploits modern mining
and minerals processing installations
Zinkgruvan mine
OWNER Lundin Mining
PRODUCTION PER YEAR 1 million tons
ORE TYPE sedimentary exhalative
zinc lead copper and silver
NUMBER OF EMPLOYEES 320
2011 PRODUCTION TARGETS 78000 tonsof zinc 36000 tons of lead and
3400 tons of copper concentrate
METSO EQUIPMENT ON SITE
bull 1 extra long VF feeder
bull 2 C160 jaw crushers
ndash zinc process css 220ndash240 mm
ndash copper process css 150 mm
bull 1 GP300S cone crusher
ndash css 45mm
bull 1 HP4 cone crusher
ndash css 18 mm
bull 1 DS screen
bull 1 FS402 screenbull 1 grinding mill
bull Pumps VPAs
A normal truck feeds the C jaws with ore coming from the lower production levels
983122983141983152983151983154983156983145983150983143 983154983141983155
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Cost-per-ton wear agreements deepencustomer relationshipsCrusher wear parts are traditionally marketed purely based on transactional sales and mainly depend on
the weight of manganese Metso has recently introduced a new type of wear agreement based on thecost-per-ton crushed and the wear occurred Thus far the experience has been very positive increasing
transparency and deepening the operational relationship between the manufacturer and the customer
TEXT Olli Kellokumpu and Eero Haumlmaumllaumlinen PHOTOS Eero Haumlmaumllaumlinen
Arto Hiedanniemi (left)
Hannu Heman and Juha
Laukka of Metsorsquos Finnish
Service team checking the
cone crusher mantles shipped
for a cost-per-ton customer
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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156
Wear parts and parts changes
can be included
The structure of a cost-per-ton wearcontract is based on the number of tons
crushed and the estimated wear occurred
The amount and monetary value of the
wear is calculated per crushed ton
ldquoEither plain wear parts or parts changes
carried out by Metsorsquos service personnel
can be included in the contract In the latter
case we ask our Finnish customers to inform
us about an upcoming wear change opera-
tion one week in advancerdquo Heman explains
ldquoWe see good opportunities to market
cost-per-ton contracts further in Finland
and also abroad It really develops therelationship of Metso and our customers
towards a trusted partnershiprdquo he notes
Perfect tool for accurate planning
Soraliike Ikola Oy is a mid-sized contrac-
tor with three Metso two- and three-
stage mobile and portable crushing and
screening plants operating in Central and
Since 2002 Metsorsquos sales team in Finland
has developed the cost-per-ton-based
service offeringldquoOur aim has been to seek through
a cost-per-ton offering possibilities to
serve our customers better to differentiate
Metso from the other players as an OEM
manufacturer and to offer deeper profes-
sionalism and know-howrdquo says Hannu
Heman General Manager of service
operations
ldquoUntil now both our experience and
that of our customers has been quite posi-
tive When properly prepared cost-per-ton
contracts seem to create a win-win situa-
tionrdquo Heman adds Today Metso has operational cost-per-
ton agreements with several Finnish cus-
tomers The first contract was concluded
with a customer operating a stationary
plant Based on the results gathered new
cost-per-ton contracts have been signed
with customers operating wheeled and
tracked equipment too
Eastern Finland Because of the size of the
contracts up to 50 equipment moves are
made during the yearEntrepreneur Pasi Ikola has had a cost-
per-ton contract with Metso for nearly
two years and he is quite happy with the
outcome
ldquoThe cost-per-ton contract has provided
me with a perfect tool for accurate financial
planning Now I know in detail my actual
future wear parts costs This helps a lot
when calculating bidsrdquo
ldquoEarlier I used to buy a big batch of
Metso wear parts in one go and had to
reserve a reasonable amount of money for
that Today all wear costs are evenly sharedwhich gives us a welcomed 1047298exibility to
our cost structure Now we just pay Metso
afterwards based on our crushed tonsrdquo
he adds
More info
Olli Kellokumpu
Tel +358 50 354 1189
ollikellokumpumetsocom
According to crushing contractor Pasi Ikola the cost-per-ton contract with Metso has provided the entrepreneur with better economical 1047298exibility
and more accurate calculating of bids
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Pleasant Gap is owned and operated by
Glenn O Hawbaker Inc of State College
Pennsylvania This family-owned company
began in 1952 as a small excavation busi-
ness founded by Glenn O Hawbaker and
his wife Thelma Over the years the com-
pany grew by adding an integrated mix ofproducts and services and taking on larger
projects
In 1983 Hawbaker acquired Pleasant
Gap Quarry and built its first aggregates
processing plant Today Glenn O Haw-
baker Inc operates 21 quarries and eight
asphalt production facilities across Penn-
sylvania and southern New York as well as
five regional operation centers
Primary
challenge atPleasant GapQuarryA good part of what makes for a successful crushing
operation is the willingness to tackle challenges and to do
whatrsquos necessary to meet demand The team at Pleasant
Gap Quarry in central Pennsylvania recently met the chal-
lenge when they successfully addressed problems with
the plantrsquos primary crushing plant First they purchased
a new Metso C160 jaw to replace the existing primary
impact crusher Then they devised an innovative plan to
get the primary plant back in operation while awaitingdelivery of the new jaw crusher
TEXT Linda Bergmann PHOTOS John Rickinger
983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Time for a change
With the goal of increasing reliability and
output the management at Pleasant Gap
Quarry recently decided it was time to
replace the plantrsquos primary impact crusher
Following a thorough search they chose a
new Metso C160 jaw According to ScottReck Plant Manager it no longer made
sense to repair and rebuild the existing
impactor
ldquoBefore we purchased the Metso C160
we had a few other impact crushers and
they served us well but as our custom-
ersrsquo needs increased our plant production
had to match that demand We found our
formerly reliable unit was being overcome
by our demands for output and creative
work-around solutions We continued to
need more but there was only so much we
could do until we hit the breaking point ndash
literallyrdquo
In addition to performance improve-
ments the new crusher also needed to fitinto Pleasant Gaprsquos unique infrastructure
As Plant Project ManagerEngineer Jeremy
Fahr explains ldquoOur height restraint was 274
meters (108rdquo) This height was the distance
from the feed lip of the existing 6x12 scalp-
ing screen and the existing structure that
the crusher rests onrdquo
The normal C160 crusher is 307
meters (121rdquo) tall but Metso gave GOH
Scott Reck Plant Manager (left) and
Jeremy Fahr Plant Project Manager
Engineer at Pleasant Gap Quarry
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983122983141983152983151983154983156983145983150983143 983154983141983155
a 10-degree mounting option (which is
normally used on their portable crushers)
to overcome the height restraint Reck and
Fahr worked with Dave Rhoa of Cleveland
Brothers Equipment Metsorsquos crushing and
screening distributor in Pennsylvania to
pull everything together and fit the newcrusher into their plant
The C160 crusher selected for Pleasant
Gap is one of the latest models in Metsorsquos
C Series of jaws These jaw crushers feature
a large throw and steep toggle plate angle
resulting in a higher crusher output In
addition the C Series has a compact foot-
print that makes it an ideal choice for the
replacement of existing machines
According to Reck ldquoWe had heard about
the new Metso C160 and started doing our
own research and found Metso not only
had developed the output capacity we
needed but fit the uniqueness of our oper-
ationsrdquo The new Metso crusher will allow
the plant to increase tons per hour andgive them the 1047298exibility to meet demands
for varying products on short notice
Mobile solution
Purchasing the new primary jaw addressed
the long-term issues but still left Pleasant
Gap without a functioning primary plant
Reck continues ldquoOur main line was still
down leaving us with a big hole in hitting
customer needs but knowing that our new
Metso C160 was on its wayhellipwe needed an
immediate solution to keep our produc-
tion demands with an out-of-commission
crusherrdquo
The team at Pleasant Gap brainstormed
the problem and came up with a plan toget the primary plant back in operation
Their solution was to use the Lokotrack
LT1213 impactor plant and another mobile
unit to keep the main line crushing To do
this they removed the guts on the existing
impact crusher essentially turning it into a
rock chute They then moved the LT1213
and another manufacturerrsquos mobile unit
over to the existing dump hopper gt
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
ldquoWe had our haul trucks drop off mate-
rial while two excavators fed the two
mobile unitsrdquo Reck explains ldquoFor two-and-
a-half months the Lokotrack LT1213 unit
was producing 254 cm (10rdquo) minus at
700 tons per hour The other similar-sized
mobile unit was doing 400 tons an hour
maxed out The difference was unbeliev-
able to say the least Our unique solution
using the two mobile units especially the
LT1213 helped Glenn O Hawbaker achieve
a record output in 2010rdquoAccording to Fahr ldquoWe were not new to
Metsorsquos quality and supportrdquo because GOH
had been using Metsorsquos portable crushing
equipment for 3 years prior to the primary
plantrsquos impact crusher failure In another
part of our operation we have a system that
our team relies on every day a Lokotrack
LT1213 and ST272 working in tandem with
two portable conveyorsrdquo This highly effi -
cient mobile processing system turns out
300 tons of specialized blended material
per hour GOH has been so impressed with
Metso equipment its last two purchaseswere an LT106 tracked jaw plant and a
second ST272 mobile screen in 2010
Maintaining high productivity
The Metso C160 jaw was delivered to Pleas-
ant Gap Quarry in January of 2011 and
since start-up it has more than met expec-
tations The crusher is fed minus 910 mm
(36rdquo) limestone with the jaw set at 140 mm
(5 12rdquo) According to Reck ldquoFrom moment
we started up we knew we had a winner
Not only were we kicking out as much
product as our previous units without even
breathing hard but we immediately had a
2-cent per ton savings to the bottom line
without having to run a second 350 HP
motor as required by other units Plus by
adding on the new automatic lube system
the maintenance team had more time to
devote to keeping other areas of the com-
plex running more effi cientlyrdquoReck says ldquoThe Metso unit was a perfect
fit and with the improved features it pre-
sented it had it all We just turn it on load
it up and we are moving 600 tons per hour
through the crusher without any effort and
we know it can do so much morerdquo With
the primary crushing plant back in opera-
tion the entire team at Pleasant Gap will
continue to do what they do best produce
and sell high-quality products and meet
their customersrsquo expectations
More info
Scott Yablonsky Tel +1 262 717 793
scottyablonskymetsocom
The Metso C160 jaw
was installed at a 10deg
angle to fit Pleasant
Gaprsquos existing
infrastructure
The Lokotrack LT1213 impactor plant and ST272 mobile screen operate in tandem with two
portable conveyors at Pleasant Gap
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983149983141983156983155983151 983150
Paper amp fiberNew OptiConcept M paper
and board making line
The new OptiConcept M paper and board
making line stands for economy safety and
usability
Metso has launched a new modular paper
and board making line called OptiConceptM A member of the proven OptiConcept
production line family the new OptiCon-
cept M optimizes machine investment in
line with each millrsquos capacity needs
Savings in operating costs are achieved
through precise dimensioning of pro-
cesses proven technological solutions
optimal running parameters effective
maintenance operations and fully inte-
grated automation solutions
Optimized processes innovations
smart controls and accurate dimensioning
decrease the use of steam gas electricitywater chemicals and other raw materials
and reduce emission levels
OptiConcept M has been designed
both visually and physically with the
requirements of users in mind For exam-
ple the design of the machinery allows for
easy and safe changing of rolls and wear
parts thus reducing the total duration and
cost of maintenance shutdowns
RecyclingGreen energy technology to
Elektrociepłownia Białystok in Poland
Metso will convert a coal-fired boiler to
a biomass-fired Bubbling Fluidized Bed
boiler for Elektrociepłownia Białystok SArsquos
combined heat and power plant (CHP) in
Białystok Poland The new boiler system
will cut the power plantrsquos CO2 emissions
significantly by partly replacing the coal
fuel supply with biomass fuel
ldquoPoland is one of the largest countries
in Europe to have such a high depend-ence on energy derived from coal to
meet national electricity needs This is an
important incentive for us to reduce future
CO2 emissions and produce more green
electricity and with Metso technology
we are certain to accomplish our goalrdquo
states Mr Andrzej Schroeder President of
Elektrociepłownia Białystok SA
Since 2000 Metso has received a total
of 7 biomass boiler conversion orders in
Poland and the renewable energy share
in Poland is only 75 (2010) compared to
the target of 20 by 2020 set by the EUApproximately 80 of the current energy
boilers turbines and generators installed in
Polish power plants are over 20 years old In
order to meet the strict EU environmental
requirements modernization of existing
installations is necessary
Automation
Metso DNA automation system expands
to mining and construction
Using Metsorsquos control room automation
an entire crushing and screening plant can
be effi ciently managed
Metso is a leading supplier of mining and
construction machinery This expertise has
now been combined with a scalable Metso
DNA automation system that adapts to
the range of industry needs from single
machine controls to plant-wide automation
and information management systems
An example of Metsorsquos new offering is a
new crushing plant control room solution
that connects crushers and screens ensur-
ing the effective management of the entire
plant from a pleasant and safe control
room The Metso DNA user interface pro-vides the production information to ensure
a proper and rapid response to plant
events Automatic controls stabilize the
process and allow the operators to monitor
the plant as a whole
ldquoThe benefits of automation for the min-
ing and construction industry are signifi-
cant As an example of the services we offer
performance studies to crushing plants
utilizing Metsorsquos multi-disciplinary teams of
experts to determine the present level of
the plant and process effi ciency and to esti-
mate the improvement potential and thebenefits of optimization and automation
including ROI calculationsrdquo says Mikko Maumlki-
nen Product Manager of minerals applica-
tions in Metsorsquos Automation business line
ldquoAs another example our machine
condition monitoring solutions can reduce
plant and machine downtimes as well as
help to avoid safety and environmental
hazardsrdquo he adds
Metso around the world
Aerial view of the Elektrociepłownia Białystok combined heat and power plant in Poland
8202019 Metso Minerals Aggregates 3 2011
httpslidepdfcomreaderfullmetso-minerals-aggregates-3-2011 3636
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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983110983141983137983156983157983154983141983140 983137983154983156
The City of Sochi despite
its subtropical climate
is preparing to host the
Winter Olympic Games in
2014 In connection withthis event major sports and
infrastructure facilities are
being built
TEXT amp PHOTOS Eero Haumlmaumllaumlinen
Because the Olympic site is classified as
a 12-magnitude seismic zone the State
Corporation ldquoOlympstroyrdquo and Russian
construction regulations require the use of
high-quality washed aggregates in concrete
when constructing critical objects in Sochi
These requirements are being met
in full by the company Maykop Nerudwhich produces crushed stone of various
fractions and sand using Metsorsquos mobile
crushing and screening plant and a station-
ary washing complex to process ancientmetamorphic alluvial formations into high-
quality construction materials
To date Maykop Nerud has shipped
to Sochi more than a million tons of inert
materialsaggregates produced in its in-
house production and in adjacent quarries
Inert materials are delivered to Sochi exclu-
sively by rail due to the diffi cult mountain-
ous conditions The company dispatches
one to two trains containing 3000 ndash 6000
tons of crushed stone and building sand to
the Olympic city daily
Aggregates from Maykop Nerud arebeing used in many Olympic projects
including Bolshoi ice palace and in tunnel
complex No 1 consisting of 25 kilometers
of road railway and service tunnels which
will be used to transport guests at the
Sochi 2014 Olympic Games between the
Olympic Village and a ski complex in Kras-
naya Polyana
Maykop Nerudrsquos washed sand is also
being used by manufacturers of tubing for
five tunnels under construction
ldquoMetso is a true partnerrdquo
Maykop Nerud was established just four
years ago and was supplying the inert
materials of other producers using anin-house railroad warehouse Later the
company entered into contracts with
quarry It is the first complex of its kind
in Russia
ldquoIn the initial stages of preparation for
the technical requirements of the equip-
ment we had planned to purchase a
mobile washing plant but Metsorsquos engi-
neers convinced us of the advantages of
stationary washing and screening equip-ment Today with the complex working
247 at full capacity it is easy to see that
major construction companies running
operations in Sochi and purchased its ownequipment for crushing and screening
ldquoWhile looking for an equipment sup-
plier we were approached by leading
manufacturers of crushing and screening
equipment After their proposals were
subsequently cross-checked Metso was
deservedly appreciated as a supplier of
high-quality equipment by all other bid-
dersrdquo says Alexander Kozhanov General
Director of Maykop Nerud
ldquoSince choosing Metso as our equip-
ment supplier and during the course of our
cooperation we have come to the realiza-tion that Metso is a true partner for us In
close cooperation with Metso we develop
and implement processes unavailable to
competitors work together as a united
team and share valuable experiencerdquo
Kozhanov adds
A good example is Metsorsquos washing
complex operated at Maykop Nerudrsquos
we made the right choicerdquo says Maykop
Nerudrsquos Deputy General Director AlexeyPoddubny
From sand-gravel mix
to quality aggregates
The raw material Maykop Nerud uses is
metamorphic alluvial sediments of hard
rock deposited in the Belaya River valley
millions of years ago The sand-gravel mix
in the companyrsquos quarry features some
properties of granite with excellent hard-
ness making it a good feed for the produc-
tion of quality aggregates
Straightforward quarrying technology isutilized excavators dig up the sand-gravel
mix and move it to stockpiles From the
stockpiles the sand-gravel mix is reclaimed
to Metsorsquos three-stage crushing and
screening process consisting of tracked
jaw and cone crushing plants and a mobile
screen gt
The sand amp gravel mix is crushed and screened
into 0ndash20 mm fractions using jaw and cone
crushing plants combined with a mobile screen
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The Maykop Nerud Company has supplied more than 150000 tons of 0ndash5 mm washed sand and aggregates in fractions of 5ndash10 mm 10ndash20 mm and
5ndash20 mm for shotcreting and for the concrete lining of the constructed tunnels
Crushed to the size of 0ndash20 mm the
material is transported by conveyors to a
washing complex consisting of a feed hop-
per conveyors a 4-deck washing screen aspiral classifier and an automated control
system
In order to facilitate the operations of its
customers Metso has established a stock of
spares and consumables in Maykop Nerudrsquos
territory Maykop Nerud can use the stock
for its own purposes and parts can also
be delivered to other Metso customers as
required The reliability of the equipment
983110983141983137983156983157983154983141983140 983137983154983156983145983139983148983141
and its operational effectiveness mainly
depend on the availability and prompt
replacement of spares and consumables ndash a
prerequisite ensured by the mutual effortsof Metso personnel and Maykop Nerud staff
Powerful crushing complex in
combination with washing plant
Having taken into account the growing
demand for high-quality end products
Maykop Nerud and Metso agreed to
extend their cooperation and create an
even more powerful stationary crushing
and screening complex including a pri-
mary jaw crusher and two stationary cone
crushers for operation in combination with
a stationary washing plantldquoBeginning in the second quarter of
2012 we will use the new stationary crush-
ing and screening complex along with the
mobile equipment thus allowing us to
increase our capacity to 130000 ndash 140000
tons per month in order to meet the con-
stantly growing demandrdquo says Stanislav
Steblyansky Deputy General Director of
Maykop Nerud
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The construction budget of EUR 534 billion
for projects in Sochi includes three major
sites the Olympic Park along the shore of
Black Sea the Olympic Village residences
for the athletes and the Krasnaya Polyana
ski resort in the Caucasus Mountains
These three sites will be interconnected
by numerous new highways roads bridges
Construction projects at a total budget of EUR 534 billion
983110983141983137983156983157983154983141983140 983137983154983156
The companyrsquos sand-gravel-mix
resources are expected to last upwards of
20 years Upon the completion of mining
and once the territory has been rehabili-
tated the quarry will be transformed into
an artificial lake for recreation and fishing
for the residents of the City of Maykop
More info
Alexey Shevyakhov
Tel +7 495 915 29 30
alexeyshevyakhovmetsocom
LOCATION City of Maykop Republic of
Adygea southern Russia
RAW MATERIAL hard rock sand-gravel mixhardness 40 kN
CAPACITY 250 th with increase up to 550
th in 2012
RESOURCES over 10 million cubic meters
END PRODUCTS Washed building sand 0ndash5
mm and crushed aggregates 5ndash10 mm
10ndash20 mm 5ndash20 mm 20ndash40 mm
ON-SITE MЕTSО EQUIPMENT
bull 1 Lokotrack LT106 jaw plant
bull 1 Lokotrack LT200HP cone plantbull 1 Lokotrack ST35 mobile screen
bull 1 Nordberg CVB 2060-4 inclined
screen
bull 1 Nordberg SF2870 sand trap
EQUIPMENT BEING INSTALLED WITH
COMMISSIONING IN 2ND QUARTER OF 2012
bull 1 Nordberg C80 jaw crusherbull 2 Nordberg HP4 cone crushers
bull 2 Nordberg CVB2060-4 inclined
screens
bull 1 Nordberg SF2360 sand trap
bull 1 Nordberg SF2870 sand trap
Maykop quarry owned by the Maykop Nerud Company
and tunnels Essentially the entire infra-
structure within and around the 110-km-
long Sochi will be renewed
More than 155000 workers are involved
in the construction projects In total more
than 300000 cubic meters of concrete
will be used for shotcreting and for the
solid cladding of the tunnels A consider-
able proportion of that concrete will be
prepared using the aggregates and sand of
Maykop Nerud
The company Severstroy is producing
concrete elements for lining 23 kilometers
of various tunnels All of the washed aggre-
gates and sand for those projects is also
being supplied by Maykop Nerud
Metsorsquos sand trap is a critical component of the washing complex
In August 2011 construction of the new ice stadium in Olympic Park was at full speed
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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155
The new Metso C120 jaw crusher combines effi ciency versatility and safety
Metsorsquos new C120 jaw crusher made its worldwide debut at the Steinexpo exhibition in Germany
New products
Metso is proud to announce that we have developed the first fully
recyclable modular screening media ndash Metso Trellex LS-Eco
In response to customer requests for sustainable and environ-
mentally friendly screening media solutions and in line with our
own sustainability program we have taken the acclaimed Metso Trellex LS rubber modular screening media systems and success-
fully replaced the traditional steel reinforcement with an environ-
mentally friendly composite material This unique solution makes it
possible to effectively recycle our customersrsquo screening media
In the past screening media modules that were no longer
suitable for production were treated as waste and could not be
recycled Metso has introduced a new future for the product and a
sustainable solution
Sustainable solution for screening media
Metso has launched the
first fully recyclable
modular screening
media ndash Metso
Trellex LS-Eco
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Metsorsquos Mining and Construction Technology has introduced the
Metso C120 jaw crusher ndash the 13th member of the field-proven
C-series range of crushers The C120 combines uncompromising
reliability crushing effi ciency and versatility in both stationary and
mobile applications with safety and ease of use
Even at first glance it is clear that Metso has paid special atten-
tion to the C120rsquos new durable and user-friendly design start-
ing with the casting the design of which is based on thorough
FEA analysis and casting simulations Every detail of the C120 is
engineered for reliable operation and long life resulting in high
constant crushing capacity and uptime
ldquoWhen starting the C120 project we listened closely to our cus-
tomers and collected field data from a number of sites Based onthat information we decided to design the crusher cavity and kin-
ematics first As a result Metso can now offer aggregates produc-
ers large-scale contractors and mining companies a new crusher
that meets all the standards set for any demanding applicationrdquo
says Ilkka Somero Metsorsquos Product Manager for jaw crushers
New design brings outstanding productivity
The outstanding productivity of the C120 is guaranteed thanks
to several new design elements The crusher features a long and
aggressively directed stroke and a fixed jaw die longer than previ-
ously seen in this crusher size class The C120 has a large feed
opening of 1200 x 870 mm (34 x 47rsquorsquo) and an aggressive cavity cross
section securing a high per formance and reduction ratioIn terms of cavity volume and crusher weight the C120 is posi-
tioned between the existing Metso C116 and C125 jaw crusher
models
The Metso C120rsquos nominal power is 160 kW (200 HP) operating
speed 230 rpm closed side setting between 70 ndash 200 mm (2 34rsquorsquo
ndash 8rsquorsquo) The operational weight is 26000 kg (57200 lbs) excluding
options
More infoIlkka Somero
Tel + 358 50 317 0769
Ilkkasomerometsocom
The optional robust composite 1047298ywheel guards allow quick and safe
access to the service points
983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156
In addition to providing environmentally friendly screening
media panels Metso will implement a unique program to provide
its customers with a suitable range of recycling services
The Metso Trellex LS-Eco offers a wide range of health safety
and environmental benefits Each screening media panel is up to40 lighter than standard steel reinforced Trellex LS panels This
makes handling easier and the working environment safer Lighter
panels also help to reduce the overall stress on the entire screening
installation
Compared to steel-reinforced panels the composite-reinforced
panels of the Metso Trellex LS-Eco are more 1047298exible and will reduce
the effects of pegging and blinding during screening operations
The Metso Trellex LS-Eco promises reduced downtime and
increased productivity
The Trellex 300LS and Trellex 305LS rubber and polyurethane
panels are already acclaimed worldwide as being among the most
versatile modular screening media solutions They can be attached
to most screening media systems and can handle all types of
screening applications ndash fine and coarse wet and dry In the futurewhen Metso customers need new screening media panels for
their existing system they can choose Metso Trellex LS-Eco and be
assured that their panels will be safely and effectively recycled
More info
Claes Larsson
Tel +46 410 525 73
claeslarssonmetsocom
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The new Lokotrack LT120 with its world premiere at the Steinexpo
exhibition in Germany combines crushing performance and user-
friendly design in a new revolutionary way For the first time the
same Lokotrack model is now available in a hydraulically or electri-
cally driven version to meet customer needs
New Lokotrack LT120 jaw plant introduced
Lokotrack LT120 is the latest and most advanced of Metsorsquos track-mounted jaw crusher plants
Lokotrack LT120 combines user-friendly design and good crushing
performance in a new way
power supply or a 420-kV onboard diesel generator Having the
possibility to use an external power supply enables a highly eco-
nomical and ecological crushing process
The Lokotrack LT120 is built around the new C120 jaw crusher
See page 10 for information about the C120
Safe to use move and service
Safety is the highest priority for Metso when designing new equip-ment The Lokotrack LT120 is designed to be safe to operate move
and service
ldquoA safe operating environment is created by practical solutions
When service points can be reached easily the possibility of dan-
gerous situations diminishesrdquo says Product Manager Timo Nakari
ldquoGood examples of safety built in to the Lokotrack LT120 include
sturdy easy-to-open composite 1047298ywheel guards and hydraulically
folding and locking feed hopper sidesrdquo Nakari adds
The Lokotrack LT120 can be fine-tuned to suit the customerrsquos
application by selecting the required options from a long main
conveyor and hammer and boom to a water spraying system and
rubber lining for the feeder and hopper for example
The Lokotrack LT120 features a Caterpillar C13 310 kW (415 hp)engine Its transport dimensions are length 16 m (52rsquo 6rdquo) width 3 m
(9rsquo10rdquo) height 39 m (12rsquo 10rdquo) and weight 57 tons (114000 lbs) The
LT120E version weighs 63 tons (126000 lbs)
More info
Timo Nakari
Tel + 358 40 701 6143
timonakarimetsocom
983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155
The Lokotrack LT120 uses the same field-proven technology
seen in Metsorsquos tracked units for over 26 years Every detail of thenew jaw plant has been thoroughly designed for reliability and
long life The main targets when designing the unit have been
energy effi ciency good performance reliability and product safety
Field tests have demonstrated its good fuel economy and high
crushing capacity
Environment-friendly economy
The Lokotrack LT120 is also available as an electrically driven unit
ndash the Lokotrack LT120E ndash which can take energy from an external
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The TS range of screens is characterized by its innovative design
comprising two technologies combined multi-variable slopes with
a variable elliptical motion This proven range is being comple-
mented with the new TS63 screen
The TS63rsquos unique combination increases both the screenrsquos effi -
ciency and its capacity Material speed is high at the feed end and
slows down at the discharge end
Metso TS series screens offer more space between decks mak-
ing maintenance easier and improving service conditions for the
operators as well as meeting all safety requirements
Metso has recently sold several 25-m2 multi-slope screens for
mining applications such as a TS63 for Ferrostaal in Mauritania andalso for the construction industry for example Holcim in Lynwood
Australia Georyt in Poland Apaxco in Mexico and Newmont in
Peru
More info
Denis Pradon
Tel +33 680 64 39 67
denispradonmetsocom
New TS63 screen ndash the largest three-deck banana screen on the market
The new Metso TS63 banana screen features a 25-m2 screening area
Following the success of the HP4 and HP5 Metso has broadened
the product range with the new HP3 cone crusher This mid-range
cone crusher benefits from 70+ years of experience in crushing
technology while specifically addressing customer requirements
for large capacity ease of operation and a high reduction ratio
The HP3 responds to market demands for increased productionquality reduced maintenance time and low operating costs The
new generation HP models are comparable to their predecessors
but offer increased versatility
The HP3 features the size of an HP200 with the output of an
HP300 The power performance and robustness of the new gen-
eration models allow in certain cases two crushers to be replaced
with just one so investment production and operation costs are
greatly reduced
The HP3 has been tested at two different quarry sites in France
over the past seven months ndash at a gravel pit and a rock quarry
The Metso factory in France began production of the HP3
series in September Several orders have already been received for
secondary and tertiary applications Since 2009 nearly 300 HP newgeneration cone crushers have been commissioned The HP3 mar-
ket will be primarily centered on gravel pit applications (70)
The HP3 has a nominal feed opening of 220 mm (865rsquorsquo) a
motor size of up to 220 kW (300 hp) and a weight of 13280 kg
(29277 lbs)
More info
Carlos Padin
Tel +33 6 0727 2002
carlospadinmetsocomMetso HP3 at a stationary installation in France
HP3 cone ndash another new-generation cone crusher
983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
First modular plant to NepalMetso delivered its first modular crushing and screening plant to MS Palchowke Mai Roda Dunga Udyog Limited (PMRD)
in Melamchi Nepal The modular plant solution offers PMRD a fast and effective response to productivity and qualityrequirements
TEXT amp PHOTOS Atoshi Nayak Ghosh
The diversity of operations at a typical con-
struction site involves quick decision-mak-
ing and often a lot of pressure to ensure a
timely execution
High performance guaranteed
Considering todayrsquos volatile market sce-
nario business partners must maintainpace with their customersrsquo ever-changing
requirements Understanding custom-
ersrsquo strategic business needs is of utmost
importance PMRDrsquos plant was commis-
sioned in January 2011 and has logged
about 1200 hours of operation to date
The plant is much more compact than
the traditional skid-mounted plant and
provides space for free movement of utility
equipment within the plant area One of
the key features of the plant is the totally
bolted structure It can be easily disman-
tled into sub-assemblies transported and
re-assembled effortlessly at a new location
which is one of the biggest advantages in
helping to meet new market demand
Due to the use of pre-assembled mod-ules for each crushing station the instal-
lation work on site takes less time thus
decreasing the plantrsquos installation lead time
The plant also includes a foldable conveyor
for maintenance of the cone crushers
Stepping up with Metso
PMRD operates a two-stage plant compris-
ing a C80 jaw crusher an HP200 high-
performance cone crusher and a CVB1845
screen with circular motion MV2 vibra-
tory mechanism for final product recovery
resulting in an aggregate plant of 150 tph
capacity for producing size fractions of 0-40
mm The plant is an example of world-class
craftsmanship and excellent material han-
dling capacityModular and non-welded construction
supported by durable pitman assembly sin-
gle-piece cast steel frame bearing housings
with repairable crusher construction and
the right cavity design results in aggressive
kinematics and high power that best suits
the requirements of the customer
PMRD has immense pride in the plant
ldquoThe performance has been astounding
A drawing of typical modular plant
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983122983141983152983151983154983156983145983150983143 983154983141983155
with applications ranging from road aggre-
gates commercial sand production to
ready-mix concretes The modular plant is
almost set to create a new niche in aggre-
gates processing in Nepalrsquos construction
industry It is one of a kind and we are sur-
prised at the plant rsquos production capacity
It is easy to operate and requires minimalmanpower Our cost per ton has signifi-
cantly gone down and so has the cost of
productionrdquo says Mr Sandeep K Agarwal
Director PMRD
Safety as a key issue
Health safety and environmental solutions
are key concerns for Metso and they are
addressed with the same sense of responsi-
bility as quality productivity and cost-
effi ciency issues Metso is responsible for
conducting operations in an environmen-
tally sound way and offers products and
services that can help customers fulfill their
environmental responsibilities
Metso provides the plant offi ce and site
with operation and maintenance manu-als for each and every piece of equipment
including safety issues which are entrusted
to all the operators
All conveyors are equipped with pull-
cord safety switches along with emergency
stop buttons The working area and walk-
ways are all equipped with safety hand rails
and checkered plates for anti-skidding The
entire plant is equipped with earth pits for
electrical current earth leakage prevention
Metso has ensured all possible measures
to maintain high safety standards for all
operation and maintenance personnel
More info
Suhen Agarwal
Tel +91 124 2351566suhenagarwalmetsocom
Nepalrsquos first modularcrushing and screening plant deliv ered by Metso
E ffi cien t C VB1845 inclined screen wi th
an M V2 vibra tor y mechanism handles
the classi fica tion o f crushed ma terials
A s turd y f eeder dis tribu tes the ma terials to be crushed to
a
Me tso C80 ja w crusher
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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155
Outokumpursquos Kemi
mine set to doubleproduction The only mine unit owned by Outokumpu
the chrome mine in Kemi northern Finland
is busy making preparations to double its
production set to begin next year In co-
operation with Metso Outokumpu willincrease the number of underground
feeders and optimize the durabil-
ity of wear parts in the massive
primary gyratory crusher
TEXT amp PHOTOS Eero Haumlmaumllaumlinen
Chrome ore is fed into Metsorsquos
Superiorreg 50-65 primary
gyratory crusher by three
different vibrating feeders
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Up until now the entire production of the
chrome mine totaling about 13 million
tons annually has been transported to the
Tornio ferrochrome plant for processing
and on to the Tornio stainless steel plant
The increase in production which will
begin in autumn 2012 is intended also to
enable Outokumpu to sell ferrochrome tocompanies outside the Group The produc-
tion target for 2013 is 27 million tons of
ore and of the ferrochrome produced from
the ore nearly a half (gt 200000 tons) is to
be sold outside
Underground expansion
work almost complete
About 500 meters underground the
majority of the work involved in increasing
the capacity the F3 project has already
been completed Doubling the production
is no problem for the Superiorreg primarygyratory crusher delivered to the mine
by Metso in 2002 which can digest more
than 2700 tons of feed material per hour if
necessary
At the moment the primary gyratory
crusher can be fed by three different vibrat-
ing feeders The crusher currently runs for
less than one-fifth of the production time
The increase in ore production will increase
the effective crushing time to about one-
third of the production time
A lot of work has been done for orestorage after the primary crusher The
two currently used storage silos are now
accompanied by two new 8000-ton silos
The number of Metso feeders transporting
the ore from the primary crusher has also
been doubled
Optimization of wear parts under way
Chrome ore has been a challenge to the
primary gyratory crusherrsquos wear parts The
wear is contributed to by the pulsating
feed which rarely fills the entire crushing
chamber There are also great differences inore type since brittle feed material prone
to chalking is occasionally replaced by hard
ore that requires a lot of crushing power
before it is crushed with a bang gt
Mika Saari (right) Foreman of ore line technicians at Outokumpursquos chrome mine in conversation with
Mikko Malkamaumlki Metsorsquos crusher wear parts specialist
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
last did in July for the replacement of the
crusherrsquos wear parts Our work is also facili-
tated by product development like the
addition of maintenance hatches to the
feedersrdquo he continues
Lasting technology
According to Mika Saarirsquos calculations the
Superiorreg primary gyratory crusher has so
far crushed more than six million tons of
ore in totalldquoThe factory polishing marks still show
on the bottom thrust bearing so we
believe that the bearing will last the entire
remaining service life of the crusher which
is about ten years and 30 million tons
Metsorsquos feeders have been equally reliablerdquo
Saari says
After the next 30 million tons of ore
it will be time to deepen the mine
More info
Jukka Raumlisaumlnen
Tel +358 50 317 1787 jukkaraisanenmetsocom
Mikko Malkamaumlki
Tel + 358 40 827 8223
mikkomalkamakimetsocom
The Kemi mine and Metso are currently
carrying out a development project to
increase the service life of the mantle and
outer concave and thus minimize down-
time due to replacement While the modu-
lar feed hopper enables quick replacement
of the mantle replacing the outer concave
can easily take more than a week The cooperation between the Kemi
mine and Metsorsquos wear parts team in
Tampere aims to extend the service life
of the parts to at least 4 million crushed
tons Durability is sought by optimizing the
chamber structure and selecting the r ight
materials for the outer concave
ldquoSmooth cooperationrdquo
Mika Saari Foreman of ore line technicians
working in the underground mainte-
nance of the Kemi mine leads a small but
experienced team of technicians The tidymodern offi ce spaces are located close to
the action at a depth of 500 meters
ldquoCooperation with Metso has been
smooth Increasing our own crushing
expertise takes time so all know-how
shared by the manufacturer is very wel-
come to usrdquo Mika Saari says
ldquoWe can also use Metsorsquos profession-
als for servicing when necessary like we
The Superiorreg 50-65 has provided reliable
crushing performance at a depth of 500 metres
in the Kemi chrome mine
Technicians Sari Kulju (left) and Marko Jaako ensure that the primary gyratory crusherrsquos hydraulicand electrical unit remains very tidy which contributes to trouble-free operation of the crusher
Outokumpu Oyrsquos Kemi
chrome mine
LOCATION Keminmaa northern
Finland
ORE TYPE chrome oxide (26)
ORE ESTIMATE ON 1 JANUARY 2011
ndash ore reserves 36 million tons
ndash mineral resources 87 million
tons
MINING METHOD bench and cut fillFEED MATERIAL SIZE 0ndash1000 mm
METSO EQUIPMENT IN THE MINE
bull 1 Superiorreg 50-65 primary
gyratory crusher
ndash open side setting 152 cm (6rdquo)
bull 8 VMOU 25-125 feeders
bull 1 VMOU 30-16 feeder
bull 1 VMOU 40125 feeder
bull 2 Symons cone crushers
bull 1 C80 jaw crusher
bull 4 HM75 pumps
bull 11HM100 pumps
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983122983141983152983151983154983156983145983150983143 983154983141983155
Metso was responsible for the design
development and construction of the
entire secondary and tertiary arrangement
The primary station will be the subject of a
subsequent investment
Latest environmental protection used
This installation has been designed in strict
compliance with the environmental quality
approach developed by Metso and its
partners using the latest technologies
in dust control including confinement
technology as well as dust encapsulation
technology for screens
To ensure an annual capacity of 15 mil-lion tons for a nominal output of 560th of
02 mm and 220 mm the clientrsquos choice
for the secondary stage naturally fell upon
the NP 1520 impact crusher
A complete impact crusher solution for Lafarge The Lafarge Group has entrusted Metso with the implementation of its new aggregates installation in southern France
It comprises a new secondary crushing stage equipped with an NP1520 impact crusher featuring a power range of2 x 250kW and equipped with hydraulic adjustment
TEXT amp PHOTO Gilles Dombey
The NP 1520 crusher has long proved
its performance not only in terms of capac-
ity and reduction rate but also quality of
the finished product and durability
More info
Arnaud Bertucat
Tel +33 (0)6 81 44 68 26
arnaudbertucatmetsocom
About 15 million tons of aggregates feed will be crushed with the NP1520 impact crusher at Lafargersquos stationary installation in southern France
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Multi-stage Lokotrack process a success in Senegal
A multi-stage crushing and screening process has proven its effi ciency in the production of concrete aggregates in
Senegal Western Africa With the mobile process Xewell Cimenteries SA now exploits its quarry better has reduced
its operating costs and can meet strict environmental requirements
TEXT Elisabetta Cataluffi PHOTOS Carlo Rinolfi
Senegal is a rapidly developing country
offering a good deal of potential activities
for crushing companies too At the sametime the country has several areas of high
environmental value Therefore contractors
must opt for state-of-the-art equipment that
offers reduced environmental emissions
The company Xewell Cimenteries SA
was founded in 2008 as a partnership
between Italian Swiss and Senegalesecontractors Xewell operates a limestone
quarry located in the Pout area east of the
capital city of Dakar
According to Alessandro Crestani Technical
Director of the Pout quarry a mobile process
was selected to better exploit the quarry and
reduce costsLokotrack process drawing made by Bruno simulation software
After assembling the Lokotrack units the process was tested by Xewell Cimenteries
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983122983141983152983151983154983156983145983150983143 983154983141983155
Owned by Freeport-McMoRan Copper amp
Gold (51) and CODELCO (49) the ElAbra mine has leachable oxide and sulfide
mineralization The minersquos processing facil-
ity has an annual capacity of 226000 tons
of copper cathode
Smaller size matters
Reducing the size of the crushed oxide
ore from the present 15 mm to 12 mm
was the main target of the mine and the
Metso team The changes that were carried
out in the process included a size varia-
tion change in the cut of the tertiary sieve
installation of rate-level sensors in thesecondary crushers and enabling speed
variables in the conveyor belt feeders of
the secondary crushing circuit
ldquoGoing from 15mm to 12mm may seem
small but the operational impact is very
important and significant for usrdquo explains
Juan Torres Carvajal Metallurgical Engi-
neer at the El Abra mine
ldquoOur goal is to reach 115000 tons with
a minimum of 80 of 12-mm-sized ore permonth The record to date is 105000 tons
and we will increase it until we reach our
project goalrdquo he adds
New design for cone liners
In addition to the work mentioned above
Metso is currently carrying out a project to
design the lining profiles for the secondary
and tertiary crushers of the plant which
will affect the smaller size of the material
In cooperation with Nelson Mella from
Metso and Rodolfo Navarro Crushing
Superintendent at the El Abra mine testswere carried out in July on the re-designed
Metso linings One set was tested for sec-
ondary crushing and two sets for tertiary
crushing
More info
Nelson Mella
Tel +56 99158 0576
nelsonmellametsocom
Finer ore through wear pro1047297lestudy at El Abra mine in ChileEl Abra is a porphyry copper open-pit mine and processing facility located in
Chile near the city of Calama some 4000 meters above sea level With the helpof Metsorsquos technical support the mine was able to achieve finer ore throughoutthe crushing process
TEXT amp PHOTOS Macarena Vallejo
Xewell Cimenteries produces a selec-
tion of dry processed aggregates for con-
crete Operations started at the end of 2009
with the aim of reaching 150000 metric
tons produced per year
Lokotracks chosen to reduce costs
To build up their tracked mobile processXewell Cimenteries decided to buy three
mobile plants from Metso two impactor
plants the Lokotrack LT1110 and LT1213
feeding a three-deck mobile screen the
ST620 The machines were sold by SCAI
SpA Metsorsquos Lokotrack distributor in Italy
ldquoWe chose tracked machines to bet-
ter exploit our quarry and to reduce
costs Mobile plants have low initial costs
because they donrsquot need any special foun-
dations or supply of electricity This obvi-
ously gives us a quicker process set-up and
better uptimerdquo says Alessandro Crestani Technical Director of the Pout quarry
ldquoThe mobile plant can also follow the
quarry face as the exploitation proceeds
reducing the transport costs of raw materi-
als in the same jobsite We chose Metso
because they ensured us the best cost-per-
ton ratiordquo he adds
Good customer service is crucial
According to Alessandro Crestani good
customer service also played a major role
when choosing the manufacturer of the
mobile equipmentldquoMetsorsquos distributor SCAI SpA was able
to provide us with a complete product
support and customer service package
Obviously service is a very important
aspect for us in a country like Senegal Any
downtime represents a clear loss of pro-
ductivity for usrdquo
The average level of productivity of the
mobile Lokotrack process is 200 metric
tons per hour
More info
Carlo Rinolfi Tel +39 335 1253159
crinolfiscaispacom
Example of the development of the Metso study
on the crusher lining profiles
Liner change for smaller ore size in the
MP1000 cone crusher
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Services success in Surabaya The Metso Surabaya workshop and offi ce complex opened in April 2008 provides Life Cycle Services and maintenance
solutions for Metso equipment in the Indonesia region The facility is strategically located in an industrial precinct on theouter rim of Surabaya the second largest city in Indonesia Its close proximity to an international airport major shipping
port and several engineering companies simplifies support for the regionrsquos key customers which include PT Newmont
and PT Freeport
TEXT amp PHOTOS David LeRoy amp Gary Whittred
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983122983141983152983151983154983156983145983150983143 983154983141983155
The Surabaya site operates through Metso
in Australia with assistance from key sales
and technical staff Handling regional ser-vice and repair business in-house allows
Metso to manage intellectual property and
closely control quality
It also enables the development of a
team of skilled service personnel who can
be utilized both internally and at key cus-
tomer sites as is common with the backup
service the workshop provides for screen
contracts
Innovation at work
Since 2008 the Surabaya facility has suc-
cessfully refurbished a wide variety ofcomponents Recently two ball mill heads
weighing 22 tons each were modified in
order to strengthen the 1047298ange of the ball
mill shell The modification included tap-
ping out existing 1047298ange holes and drilling
new ones so that finger plates could be
installed and welded to the 1047298anges
Positioning the head borer to properly
align the new 1047298ange holes proved diffi cult
Four roller support frames were manufac-
tured to support the heads and allow them
to be rotated easily Each hole was then
drilled and tapped at the correct angleusing the CNC five axis head The job had a
tight delivery as it was required for a shut-
down but with advance planning and inno-
vation it was completed ahead of schedule
MP1000 mainframe on
CNC vertical borer
Well equipped for fabricating and machin-
ing heavy components the Surabaya
The Surabaya facility has proven to be
a success for Metso The workshop offers a
wide variety of services in the region Qual-ity products and competitive pricing and
delivery times have led to strong customer
relationships
Turnover and customer service levels
have increased annually since the open-
ing and between 2008 and 2010 sales
increased 450 These excellent trends
are expected to continue as the operation
expands and the customer base grows
Since 2008 the Surabaya facility has
successfully refurbished
bull MP1000 counter shaft boxes headassemblies mainframes bowls adjust-
ment rings counterweights sockets and
tramp release cylinders
bull 7rsquo Symons bowls heads and countershaft
boxes
bull Vertimill screw and drive shafts
bull Ball mill heads
bull Ball mill trommel
bull VPA cylinders
bull Eaton clutches
bull Exciter screen mechanisms
bull 42x65 main shafts and eccentrics
More info
Gary Whittred
Tel +62 31 8430349
garywhittredmetsocom
workshop handles the majority of Metsorsquos
refurbishment work with ease But when
necessary PT PAL ndash a government facilitywith shipbuilding and heavy engineering
capabilities ndash offers a ldquoone stop shoprdquo Spe-
cially trained PT PAL staff ensures that the
work they perform complies with all Metso
specifications and quality standards
PT PAL also demonstrated their innova-
tive ability with the first MP1000 main-
frame refurbishment they completed The
mainframersquos shaft location bore needed
to be re-machined However the distance
from the top of the mainframe to the
tapered bore made it very hard to achieve
an accurate surface finish with the correctstandoff
To overcome this the shop decided to
machine the mainframe upside down and
elevated on support beams They posi-
tioned a new shaft under the mainframe in
a custom-made cradle Using an overhead
crane they could then lsquotrial fitrsquo the shaft in
the bore to make sure it seated correctly
and the mating tapers met specification
The method worked so well it has since
been used for four more mainframe refur-
bishments
Diversity and growth
Today Metso Surabaya continues to invest
in additional equipment in order to diver-
sify its service offering A new hydraulic
power pack which allows the facility to test
refurbished components to Metso specifi-
cations was recently used in the refurbish-
ment and testing of several VPA cylinders
for PT Freeport
Refurbished MP1000 mainframe dispatched by truck to
PT Freeport mine
Machining of MP1000 upper frame
at Metsorsquos Surabaya workshop
Mainframe at vertical CNC machining
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Creating Value with Metso in Hong KongIn Hong Kong the aggregates needed for construction are mostly supplied by two local quarries KWP Quarry Company
Limitedrsquos Anderson Road Quarry accounts for 60ndash70 making it the pillar of Hong Kongrsquos construction materials industry
TEXT amp PHOTOS Ou He
When arriving at the Anderson Road
Quarry the most impressive view at the850000 square-meter facility is the Metso
machines including equipment from the
primary secondary and tertiary crushing
circuits and the screens I t is Metsorsquos equip-
ment that secures the supply of aggregates
for Hong Kong
KWP Quarry Company Limited has been
working with Metso since its establishment
in 1997
Due to Hong Kongrsquos stringent dust and noise control standards Metso has paid special attention to the related suppression systems
ldquoOur quarry mainly lies on granite and
volcanic rock which are so hard they canonly be processed by equipment with
strong durability and stabilityrdquo explains
Mr Eddie Hung Manager of KWP ldquoWith a
long history of and experience in quarry-
ing we are very familiar with the equip-
ment of different brands Comparatively
Metsorsquos products are better than others in
terms of durability stability and effi ciency
Besides this the reason we selected Metso
is because of the simple maintenance of
their equipment and the easy access tomaintenance informationrdquo
Flexible modular solution
Based on extensive experience in crushing
and screening worldwide Metso presented
the Anderson Road Quarry with a modu-
lar solution and delivered it as a turn-key
project Through a four-stage crushing
circuit which contains three Metso C160
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983122983141983152983151983154983156983145983150983143 983154983141983155
jaw crushers for primary crushing two
Omnicone 1560SX crushers for secondary
crushing two HP 500SX cone crushers for
tertiary crushing and one HP500SX cone
crusher for extra-fine crushing the plant
was able to produce aggregates of optimal
shape with minimal 1047298akiness
The fine products include three sizes
0 to 5 mm 5 to 10 mm and 10 to 20mm
Since the employment of this system in
2000 production has reached 1250 th
which is far beyond the design capacityAccording to Mr Hung ldquoThe machines
always run effi ciently and seldom malfunc-
tion The occasional shutdown of some
machines does not affect production very
much the plant still could reach 60-70
of its normal production It gives us the
best 1047298exibility for the plant rsquos operation and
I believe this is the best feature of Metsorsquos
solution
Eddie Hung
Manager of KWPrsquos
Anderson Road
Quarry is happy with
the product quality
and service provided
by Metso
ldquoMetsorsquos equipment is expensive com-
paratively but in the long run you will find
that the investment is worthwhile on the
whole Metso secures superior stability reli-
ability and fewer downtimes and it guaran-
tees continuous operation and brings us
greater valuerdquo
Great service team
Metso sent a group of service engineers
to the plant within the warranty period
not only to provide service but to train theoperators Mr Hung speaks highly of Met-
sorsquos service team he is impressed with its
experienced experts and with their strong
sense of responsibility and customer-
oriented ways of working
ldquoMetsorsquos service team never fails to find
hidden problems and helps us to prevent
any mechanical failures And they are
available whenever we need them they
work closely with us to solve the problem
effi cientlyrdquo he said
Excellent environment-friendly designIn order to achieve the worldrsquos most strin-
gent noise and dust control standards
developed by the Environment Protection
Department of Hong Kong Metso has
incorporated a dust and noise suppression
system into the plant This includes the
infrared-triggered spray systems at feed
points encapsulation of individual crush-
ers and conveyors and the ability to select
specific sectors of the system for treatment
depending on feed and operating condi-
tions encapsulation of equipment and the
enclosure of all major sections of the plant
With these advanced environment-
friendly solutions Anderson Road Quarry
has won numerous safety and environmen-
tal awards In 2003 it was presented with a
silver medal in the prestigious Environmen-
tal Performance Awards in recognition of
its commitment to the environment and
community In 2004 KWP achieved certifi-cation of ISO 14001 it is the first quarry site
to have achieved this in Hong Kong and
southern China
ldquoA reliable partnerrdquo
The promulgation of the top ten infrastruc-
ture policies in Hong Kong boosted the
market for aggregates and demand will
keep rising over the next five to six years
ldquoWersquoll definitely keep our cooperation with
Metso once we have a need for expansion
because we regard Metso as a reliable part-
ner With their highly effi cient equipmentsatisfying service and great efforts in help-
ing us to achieve our environmental pro-
tection targets Metso is our best choicerdquo
says Hung
More info
Ziqiang Li
Tel +86 13601289027
ziqianglimetsocom
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
The sturdy Metso C160
jaw crushers are fed
using huge feed chutes
and feeders
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983122983141983152983151983154983156983145983150983143 983154983141983155
Similar to hundreds of mine sites world-
wide Zinkgruvan is being operated on a
non-stop 247 basis with just a few main-
tenance breaks during the year Crusher
availability is crucial because 100 of the
ore has to pass through the jaws before
being hoisted up for further processing
In addition to the zinc- lead- copper-
and silver-containing ore the C jaws chop
all the host rock extracted along the min-
ing process With a sturdy design Metsorsquos
proven C jaws can easily reduce even the
hardest type of rock Every year more thanone million tons are crushed with the jaws
ldquoMinimal service neededrdquo
Crushing with the first C160B jaw crusher
began at Zinkgruvanrsquos -800 meter level in
2000 with the primary crushing of zinc-lead
ore The second jaw was installed in 2008
for the new copper process gt
The sight and sound of two C160 jaw crushers operating side by side in the underground
crushing station of the Swedish Zinkgruvan mine is impressive Good proactive service
secures good uptime and reliable continuous operation of Metsorsquos second-largest
C160 series jaw crushers and prepares the way for the ongoing plans to expand the
production of zinc concentrate
TEXT amp PHOTOS Eero Haumlmaumllaumlinen
New PolyMet liners are being tested with the grinding mill delivered by Metso
Zinkgruvanrsquos twin C160
jaws secure good uptime
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Blasted ore is taken from the presently
operated -850 meter level with normal
trucks as an outsourced process One full
truckload is fed to the C160s every
10 minutes
ldquoWe are happy with the high reliability
of the C jaws They only require some minor
service therefore providing us with good
uptime and steady continuous feed to our
secondary and tertiary crushing and grind-ing circuitsrdquo says Mine Manager Jan Klaumlre
ldquoBasic crusher service and wear part
changes are made by our own staff using
Metsorsquos partsrdquo he adds
Service contract with grinding
mills and conveyors
Zinkgruvan and Metso Sweden have more
than 11 yearsrsquo experience with a service
contract that contains grinding mills and
conveyors At the mine site two Metso
service people and one contractor take
care of all the related service jobs Man-
power can also be borrowed from Metsorsquos
Graumlngesberg mine service team of 20
people
Presently Zinkgruvan is testing Metsorsquos
new PolyMet mill linings in its big grinding
mills With previously used rubber partsthe linings had to be changed in the shell
every 9 to 11 months and in the feed head
every 6 months
ldquoWe expect a better lifetime with Poly-
Met linings Longer change intervals mean
a lot to our productivity because lining
changes takes two full working daysrdquo Mine
Manager Jan Klaumlre says
New mine goes deeper
With an expected mine life of more than 10
years Zinkgruvan is actively mapping new
ore reserves Experimental holes are being
drilled at the new mine section at the
-1110 meter level
More info
Fredrik Wennberg
Tel +46 70 657 00 08fredrikwennbergmetsocom
Mine Manager Jan Klaumlre (left) with Backfilling Manager Kjell Tillman at the underground -800 meter level mine cafeteria
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The Zinkgruvan mine located approxi-
mately 200 km southwest of Stockholm
Sweden is one of the oldest underground
mines in Northern Europe The mine has
been in production since 1857
The mining methods used are panel
stoping and benching The processing
facilities include a zinc concentrating plant
with a 11 mtpa and a copper plant with a04 mtpa capacity Tailings are recycled in
an impounding basin and host rock in the
backfill plant
Continuous mining since 1857
Even as one of the oldest mines in Northern
Europe Zinkgruvan exploits modern mining
and minerals processing installations
Zinkgruvan mine
OWNER Lundin Mining
PRODUCTION PER YEAR 1 million tons
ORE TYPE sedimentary exhalative
zinc lead copper and silver
NUMBER OF EMPLOYEES 320
2011 PRODUCTION TARGETS 78000 tonsof zinc 36000 tons of lead and
3400 tons of copper concentrate
METSO EQUIPMENT ON SITE
bull 1 extra long VF feeder
bull 2 C160 jaw crushers
ndash zinc process css 220ndash240 mm
ndash copper process css 150 mm
bull 1 GP300S cone crusher
ndash css 45mm
bull 1 HP4 cone crusher
ndash css 18 mm
bull 1 DS screen
bull 1 FS402 screenbull 1 grinding mill
bull Pumps VPAs
A normal truck feeds the C jaws with ore coming from the lower production levels
983122983141983152983151983154983156983145983150983143 983154983141983155
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Cost-per-ton wear agreements deepencustomer relationshipsCrusher wear parts are traditionally marketed purely based on transactional sales and mainly depend on
the weight of manganese Metso has recently introduced a new type of wear agreement based on thecost-per-ton crushed and the wear occurred Thus far the experience has been very positive increasing
transparency and deepening the operational relationship between the manufacturer and the customer
TEXT Olli Kellokumpu and Eero Haumlmaumllaumlinen PHOTOS Eero Haumlmaumllaumlinen
Arto Hiedanniemi (left)
Hannu Heman and Juha
Laukka of Metsorsquos Finnish
Service team checking the
cone crusher mantles shipped
for a cost-per-ton customer
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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156
Wear parts and parts changes
can be included
The structure of a cost-per-ton wearcontract is based on the number of tons
crushed and the estimated wear occurred
The amount and monetary value of the
wear is calculated per crushed ton
ldquoEither plain wear parts or parts changes
carried out by Metsorsquos service personnel
can be included in the contract In the latter
case we ask our Finnish customers to inform
us about an upcoming wear change opera-
tion one week in advancerdquo Heman explains
ldquoWe see good opportunities to market
cost-per-ton contracts further in Finland
and also abroad It really develops therelationship of Metso and our customers
towards a trusted partnershiprdquo he notes
Perfect tool for accurate planning
Soraliike Ikola Oy is a mid-sized contrac-
tor with three Metso two- and three-
stage mobile and portable crushing and
screening plants operating in Central and
Since 2002 Metsorsquos sales team in Finland
has developed the cost-per-ton-based
service offeringldquoOur aim has been to seek through
a cost-per-ton offering possibilities to
serve our customers better to differentiate
Metso from the other players as an OEM
manufacturer and to offer deeper profes-
sionalism and know-howrdquo says Hannu
Heman General Manager of service
operations
ldquoUntil now both our experience and
that of our customers has been quite posi-
tive When properly prepared cost-per-ton
contracts seem to create a win-win situa-
tionrdquo Heman adds Today Metso has operational cost-per-
ton agreements with several Finnish cus-
tomers The first contract was concluded
with a customer operating a stationary
plant Based on the results gathered new
cost-per-ton contracts have been signed
with customers operating wheeled and
tracked equipment too
Eastern Finland Because of the size of the
contracts up to 50 equipment moves are
made during the yearEntrepreneur Pasi Ikola has had a cost-
per-ton contract with Metso for nearly
two years and he is quite happy with the
outcome
ldquoThe cost-per-ton contract has provided
me with a perfect tool for accurate financial
planning Now I know in detail my actual
future wear parts costs This helps a lot
when calculating bidsrdquo
ldquoEarlier I used to buy a big batch of
Metso wear parts in one go and had to
reserve a reasonable amount of money for
that Today all wear costs are evenly sharedwhich gives us a welcomed 1047298exibility to
our cost structure Now we just pay Metso
afterwards based on our crushed tonsrdquo
he adds
More info
Olli Kellokumpu
Tel +358 50 354 1189
ollikellokumpumetsocom
According to crushing contractor Pasi Ikola the cost-per-ton contract with Metso has provided the entrepreneur with better economical 1047298exibility
and more accurate calculating of bids
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Pleasant Gap is owned and operated by
Glenn O Hawbaker Inc of State College
Pennsylvania This family-owned company
began in 1952 as a small excavation busi-
ness founded by Glenn O Hawbaker and
his wife Thelma Over the years the com-
pany grew by adding an integrated mix ofproducts and services and taking on larger
projects
In 1983 Hawbaker acquired Pleasant
Gap Quarry and built its first aggregates
processing plant Today Glenn O Haw-
baker Inc operates 21 quarries and eight
asphalt production facilities across Penn-
sylvania and southern New York as well as
five regional operation centers
Primary
challenge atPleasant GapQuarryA good part of what makes for a successful crushing
operation is the willingness to tackle challenges and to do
whatrsquos necessary to meet demand The team at Pleasant
Gap Quarry in central Pennsylvania recently met the chal-
lenge when they successfully addressed problems with
the plantrsquos primary crushing plant First they purchased
a new Metso C160 jaw to replace the existing primary
impact crusher Then they devised an innovative plan to
get the primary plant back in operation while awaitingdelivery of the new jaw crusher
TEXT Linda Bergmann PHOTOS John Rickinger
983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Time for a change
With the goal of increasing reliability and
output the management at Pleasant Gap
Quarry recently decided it was time to
replace the plantrsquos primary impact crusher
Following a thorough search they chose a
new Metso C160 jaw According to ScottReck Plant Manager it no longer made
sense to repair and rebuild the existing
impactor
ldquoBefore we purchased the Metso C160
we had a few other impact crushers and
they served us well but as our custom-
ersrsquo needs increased our plant production
had to match that demand We found our
formerly reliable unit was being overcome
by our demands for output and creative
work-around solutions We continued to
need more but there was only so much we
could do until we hit the breaking point ndash
literallyrdquo
In addition to performance improve-
ments the new crusher also needed to fitinto Pleasant Gaprsquos unique infrastructure
As Plant Project ManagerEngineer Jeremy
Fahr explains ldquoOur height restraint was 274
meters (108rdquo) This height was the distance
from the feed lip of the existing 6x12 scalp-
ing screen and the existing structure that
the crusher rests onrdquo
The normal C160 crusher is 307
meters (121rdquo) tall but Metso gave GOH
Scott Reck Plant Manager (left) and
Jeremy Fahr Plant Project Manager
Engineer at Pleasant Gap Quarry
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983122983141983152983151983154983156983145983150983143 983154983141983155
a 10-degree mounting option (which is
normally used on their portable crushers)
to overcome the height restraint Reck and
Fahr worked with Dave Rhoa of Cleveland
Brothers Equipment Metsorsquos crushing and
screening distributor in Pennsylvania to
pull everything together and fit the newcrusher into their plant
The C160 crusher selected for Pleasant
Gap is one of the latest models in Metsorsquos
C Series of jaws These jaw crushers feature
a large throw and steep toggle plate angle
resulting in a higher crusher output In
addition the C Series has a compact foot-
print that makes it an ideal choice for the
replacement of existing machines
According to Reck ldquoWe had heard about
the new Metso C160 and started doing our
own research and found Metso not only
had developed the output capacity we
needed but fit the uniqueness of our oper-
ationsrdquo The new Metso crusher will allow
the plant to increase tons per hour andgive them the 1047298exibility to meet demands
for varying products on short notice
Mobile solution
Purchasing the new primary jaw addressed
the long-term issues but still left Pleasant
Gap without a functioning primary plant
Reck continues ldquoOur main line was still
down leaving us with a big hole in hitting
customer needs but knowing that our new
Metso C160 was on its wayhellipwe needed an
immediate solution to keep our produc-
tion demands with an out-of-commission
crusherrdquo
The team at Pleasant Gap brainstormed
the problem and came up with a plan toget the primary plant back in operation
Their solution was to use the Lokotrack
LT1213 impactor plant and another mobile
unit to keep the main line crushing To do
this they removed the guts on the existing
impact crusher essentially turning it into a
rock chute They then moved the LT1213
and another manufacturerrsquos mobile unit
over to the existing dump hopper gt
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
ldquoWe had our haul trucks drop off mate-
rial while two excavators fed the two
mobile unitsrdquo Reck explains ldquoFor two-and-
a-half months the Lokotrack LT1213 unit
was producing 254 cm (10rdquo) minus at
700 tons per hour The other similar-sized
mobile unit was doing 400 tons an hour
maxed out The difference was unbeliev-
able to say the least Our unique solution
using the two mobile units especially the
LT1213 helped Glenn O Hawbaker achieve
a record output in 2010rdquoAccording to Fahr ldquoWe were not new to
Metsorsquos quality and supportrdquo because GOH
had been using Metsorsquos portable crushing
equipment for 3 years prior to the primary
plantrsquos impact crusher failure In another
part of our operation we have a system that
our team relies on every day a Lokotrack
LT1213 and ST272 working in tandem with
two portable conveyorsrdquo This highly effi -
cient mobile processing system turns out
300 tons of specialized blended material
per hour GOH has been so impressed with
Metso equipment its last two purchaseswere an LT106 tracked jaw plant and a
second ST272 mobile screen in 2010
Maintaining high productivity
The Metso C160 jaw was delivered to Pleas-
ant Gap Quarry in January of 2011 and
since start-up it has more than met expec-
tations The crusher is fed minus 910 mm
(36rdquo) limestone with the jaw set at 140 mm
(5 12rdquo) According to Reck ldquoFrom moment
we started up we knew we had a winner
Not only were we kicking out as much
product as our previous units without even
breathing hard but we immediately had a
2-cent per ton savings to the bottom line
without having to run a second 350 HP
motor as required by other units Plus by
adding on the new automatic lube system
the maintenance team had more time to
devote to keeping other areas of the com-
plex running more effi cientlyrdquoReck says ldquoThe Metso unit was a perfect
fit and with the improved features it pre-
sented it had it all We just turn it on load
it up and we are moving 600 tons per hour
through the crusher without any effort and
we know it can do so much morerdquo With
the primary crushing plant back in opera-
tion the entire team at Pleasant Gap will
continue to do what they do best produce
and sell high-quality products and meet
their customersrsquo expectations
More info
Scott Yablonsky Tel +1 262 717 793
scottyablonskymetsocom
The Metso C160 jaw
was installed at a 10deg
angle to fit Pleasant
Gaprsquos existing
infrastructure
The Lokotrack LT1213 impactor plant and ST272 mobile screen operate in tandem with two
portable conveyors at Pleasant Gap
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983149983141983156983155983151 983150
Paper amp fiberNew OptiConcept M paper
and board making line
The new OptiConcept M paper and board
making line stands for economy safety and
usability
Metso has launched a new modular paper
and board making line called OptiConceptM A member of the proven OptiConcept
production line family the new OptiCon-
cept M optimizes machine investment in
line with each millrsquos capacity needs
Savings in operating costs are achieved
through precise dimensioning of pro-
cesses proven technological solutions
optimal running parameters effective
maintenance operations and fully inte-
grated automation solutions
Optimized processes innovations
smart controls and accurate dimensioning
decrease the use of steam gas electricitywater chemicals and other raw materials
and reduce emission levels
OptiConcept M has been designed
both visually and physically with the
requirements of users in mind For exam-
ple the design of the machinery allows for
easy and safe changing of rolls and wear
parts thus reducing the total duration and
cost of maintenance shutdowns
RecyclingGreen energy technology to
Elektrociepłownia Białystok in Poland
Metso will convert a coal-fired boiler to
a biomass-fired Bubbling Fluidized Bed
boiler for Elektrociepłownia Białystok SArsquos
combined heat and power plant (CHP) in
Białystok Poland The new boiler system
will cut the power plantrsquos CO2 emissions
significantly by partly replacing the coal
fuel supply with biomass fuel
ldquoPoland is one of the largest countries
in Europe to have such a high depend-ence on energy derived from coal to
meet national electricity needs This is an
important incentive for us to reduce future
CO2 emissions and produce more green
electricity and with Metso technology
we are certain to accomplish our goalrdquo
states Mr Andrzej Schroeder President of
Elektrociepłownia Białystok SA
Since 2000 Metso has received a total
of 7 biomass boiler conversion orders in
Poland and the renewable energy share
in Poland is only 75 (2010) compared to
the target of 20 by 2020 set by the EUApproximately 80 of the current energy
boilers turbines and generators installed in
Polish power plants are over 20 years old In
order to meet the strict EU environmental
requirements modernization of existing
installations is necessary
Automation
Metso DNA automation system expands
to mining and construction
Using Metsorsquos control room automation
an entire crushing and screening plant can
be effi ciently managed
Metso is a leading supplier of mining and
construction machinery This expertise has
now been combined with a scalable Metso
DNA automation system that adapts to
the range of industry needs from single
machine controls to plant-wide automation
and information management systems
An example of Metsorsquos new offering is a
new crushing plant control room solution
that connects crushers and screens ensur-
ing the effective management of the entire
plant from a pleasant and safe control
room The Metso DNA user interface pro-vides the production information to ensure
a proper and rapid response to plant
events Automatic controls stabilize the
process and allow the operators to monitor
the plant as a whole
ldquoThe benefits of automation for the min-
ing and construction industry are signifi-
cant As an example of the services we offer
performance studies to crushing plants
utilizing Metsorsquos multi-disciplinary teams of
experts to determine the present level of
the plant and process effi ciency and to esti-
mate the improvement potential and thebenefits of optimization and automation
including ROI calculationsrdquo says Mikko Maumlki-
nen Product Manager of minerals applica-
tions in Metsorsquos Automation business line
ldquoAs another example our machine
condition monitoring solutions can reduce
plant and machine downtimes as well as
help to avoid safety and environmental
hazardsrdquo he adds
Metso around the world
Aerial view of the Elektrociepłownia Białystok combined heat and power plant in Poland
8202019 Metso Minerals Aggregates 3 2011
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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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The Maykop Nerud Company has supplied more than 150000 tons of 0ndash5 mm washed sand and aggregates in fractions of 5ndash10 mm 10ndash20 mm and
5ndash20 mm for shotcreting and for the concrete lining of the constructed tunnels
Crushed to the size of 0ndash20 mm the
material is transported by conveyors to a
washing complex consisting of a feed hop-
per conveyors a 4-deck washing screen aspiral classifier and an automated control
system
In order to facilitate the operations of its
customers Metso has established a stock of
spares and consumables in Maykop Nerudrsquos
territory Maykop Nerud can use the stock
for its own purposes and parts can also
be delivered to other Metso customers as
required The reliability of the equipment
983110983141983137983156983157983154983141983140 983137983154983156983145983139983148983141
and its operational effectiveness mainly
depend on the availability and prompt
replacement of spares and consumables ndash a
prerequisite ensured by the mutual effortsof Metso personnel and Maykop Nerud staff
Powerful crushing complex in
combination with washing plant
Having taken into account the growing
demand for high-quality end products
Maykop Nerud and Metso agreed to
extend their cooperation and create an
even more powerful stationary crushing
and screening complex including a pri-
mary jaw crusher and two stationary cone
crushers for operation in combination with
a stationary washing plantldquoBeginning in the second quarter of
2012 we will use the new stationary crush-
ing and screening complex along with the
mobile equipment thus allowing us to
increase our capacity to 130000 ndash 140000
tons per month in order to meet the con-
stantly growing demandrdquo says Stanislav
Steblyansky Deputy General Director of
Maykop Nerud
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The construction budget of EUR 534 billion
for projects in Sochi includes three major
sites the Olympic Park along the shore of
Black Sea the Olympic Village residences
for the athletes and the Krasnaya Polyana
ski resort in the Caucasus Mountains
These three sites will be interconnected
by numerous new highways roads bridges
Construction projects at a total budget of EUR 534 billion
983110983141983137983156983157983154983141983140 983137983154983156
The companyrsquos sand-gravel-mix
resources are expected to last upwards of
20 years Upon the completion of mining
and once the territory has been rehabili-
tated the quarry will be transformed into
an artificial lake for recreation and fishing
for the residents of the City of Maykop
More info
Alexey Shevyakhov
Tel +7 495 915 29 30
alexeyshevyakhovmetsocom
LOCATION City of Maykop Republic of
Adygea southern Russia
RAW MATERIAL hard rock sand-gravel mixhardness 40 kN
CAPACITY 250 th with increase up to 550
th in 2012
RESOURCES over 10 million cubic meters
END PRODUCTS Washed building sand 0ndash5
mm and crushed aggregates 5ndash10 mm
10ndash20 mm 5ndash20 mm 20ndash40 mm
ON-SITE MЕTSО EQUIPMENT
bull 1 Lokotrack LT106 jaw plant
bull 1 Lokotrack LT200HP cone plantbull 1 Lokotrack ST35 mobile screen
bull 1 Nordberg CVB 2060-4 inclined
screen
bull 1 Nordberg SF2870 sand trap
EQUIPMENT BEING INSTALLED WITH
COMMISSIONING IN 2ND QUARTER OF 2012
bull 1 Nordberg C80 jaw crusherbull 2 Nordberg HP4 cone crushers
bull 2 Nordberg CVB2060-4 inclined
screens
bull 1 Nordberg SF2360 sand trap
bull 1 Nordberg SF2870 sand trap
Maykop quarry owned by the Maykop Nerud Company
and tunnels Essentially the entire infra-
structure within and around the 110-km-
long Sochi will be renewed
More than 155000 workers are involved
in the construction projects In total more
than 300000 cubic meters of concrete
will be used for shotcreting and for the
solid cladding of the tunnels A consider-
able proportion of that concrete will be
prepared using the aggregates and sand of
Maykop Nerud
The company Severstroy is producing
concrete elements for lining 23 kilometers
of various tunnels All of the washed aggre-
gates and sand for those projects is also
being supplied by Maykop Nerud
Metsorsquos sand trap is a critical component of the washing complex
In August 2011 construction of the new ice stadium in Olympic Park was at full speed
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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155
The new Metso C120 jaw crusher combines effi ciency versatility and safety
Metsorsquos new C120 jaw crusher made its worldwide debut at the Steinexpo exhibition in Germany
New products
Metso is proud to announce that we have developed the first fully
recyclable modular screening media ndash Metso Trellex LS-Eco
In response to customer requests for sustainable and environ-
mentally friendly screening media solutions and in line with our
own sustainability program we have taken the acclaimed Metso Trellex LS rubber modular screening media systems and success-
fully replaced the traditional steel reinforcement with an environ-
mentally friendly composite material This unique solution makes it
possible to effectively recycle our customersrsquo screening media
In the past screening media modules that were no longer
suitable for production were treated as waste and could not be
recycled Metso has introduced a new future for the product and a
sustainable solution
Sustainable solution for screening media
Metso has launched the
first fully recyclable
modular screening
media ndash Metso
Trellex LS-Eco
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Metsorsquos Mining and Construction Technology has introduced the
Metso C120 jaw crusher ndash the 13th member of the field-proven
C-series range of crushers The C120 combines uncompromising
reliability crushing effi ciency and versatility in both stationary and
mobile applications with safety and ease of use
Even at first glance it is clear that Metso has paid special atten-
tion to the C120rsquos new durable and user-friendly design start-
ing with the casting the design of which is based on thorough
FEA analysis and casting simulations Every detail of the C120 is
engineered for reliable operation and long life resulting in high
constant crushing capacity and uptime
ldquoWhen starting the C120 project we listened closely to our cus-
tomers and collected field data from a number of sites Based onthat information we decided to design the crusher cavity and kin-
ematics first As a result Metso can now offer aggregates produc-
ers large-scale contractors and mining companies a new crusher
that meets all the standards set for any demanding applicationrdquo
says Ilkka Somero Metsorsquos Product Manager for jaw crushers
New design brings outstanding productivity
The outstanding productivity of the C120 is guaranteed thanks
to several new design elements The crusher features a long and
aggressively directed stroke and a fixed jaw die longer than previ-
ously seen in this crusher size class The C120 has a large feed
opening of 1200 x 870 mm (34 x 47rsquorsquo) and an aggressive cavity cross
section securing a high per formance and reduction ratioIn terms of cavity volume and crusher weight the C120 is posi-
tioned between the existing Metso C116 and C125 jaw crusher
models
The Metso C120rsquos nominal power is 160 kW (200 HP) operating
speed 230 rpm closed side setting between 70 ndash 200 mm (2 34rsquorsquo
ndash 8rsquorsquo) The operational weight is 26000 kg (57200 lbs) excluding
options
More infoIlkka Somero
Tel + 358 50 317 0769
Ilkkasomerometsocom
The optional robust composite 1047298ywheel guards allow quick and safe
access to the service points
983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156
In addition to providing environmentally friendly screening
media panels Metso will implement a unique program to provide
its customers with a suitable range of recycling services
The Metso Trellex LS-Eco offers a wide range of health safety
and environmental benefits Each screening media panel is up to40 lighter than standard steel reinforced Trellex LS panels This
makes handling easier and the working environment safer Lighter
panels also help to reduce the overall stress on the entire screening
installation
Compared to steel-reinforced panels the composite-reinforced
panels of the Metso Trellex LS-Eco are more 1047298exible and will reduce
the effects of pegging and blinding during screening operations
The Metso Trellex LS-Eco promises reduced downtime and
increased productivity
The Trellex 300LS and Trellex 305LS rubber and polyurethane
panels are already acclaimed worldwide as being among the most
versatile modular screening media solutions They can be attached
to most screening media systems and can handle all types of
screening applications ndash fine and coarse wet and dry In the futurewhen Metso customers need new screening media panels for
their existing system they can choose Metso Trellex LS-Eco and be
assured that their panels will be safely and effectively recycled
More info
Claes Larsson
Tel +46 410 525 73
claeslarssonmetsocom
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The new Lokotrack LT120 with its world premiere at the Steinexpo
exhibition in Germany combines crushing performance and user-
friendly design in a new revolutionary way For the first time the
same Lokotrack model is now available in a hydraulically or electri-
cally driven version to meet customer needs
New Lokotrack LT120 jaw plant introduced
Lokotrack LT120 is the latest and most advanced of Metsorsquos track-mounted jaw crusher plants
Lokotrack LT120 combines user-friendly design and good crushing
performance in a new way
power supply or a 420-kV onboard diesel generator Having the
possibility to use an external power supply enables a highly eco-
nomical and ecological crushing process
The Lokotrack LT120 is built around the new C120 jaw crusher
See page 10 for information about the C120
Safe to use move and service
Safety is the highest priority for Metso when designing new equip-ment The Lokotrack LT120 is designed to be safe to operate move
and service
ldquoA safe operating environment is created by practical solutions
When service points can be reached easily the possibility of dan-
gerous situations diminishesrdquo says Product Manager Timo Nakari
ldquoGood examples of safety built in to the Lokotrack LT120 include
sturdy easy-to-open composite 1047298ywheel guards and hydraulically
folding and locking feed hopper sidesrdquo Nakari adds
The Lokotrack LT120 can be fine-tuned to suit the customerrsquos
application by selecting the required options from a long main
conveyor and hammer and boom to a water spraying system and
rubber lining for the feeder and hopper for example
The Lokotrack LT120 features a Caterpillar C13 310 kW (415 hp)engine Its transport dimensions are length 16 m (52rsquo 6rdquo) width 3 m
(9rsquo10rdquo) height 39 m (12rsquo 10rdquo) and weight 57 tons (114000 lbs) The
LT120E version weighs 63 tons (126000 lbs)
More info
Timo Nakari
Tel + 358 40 701 6143
timonakarimetsocom
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The Lokotrack LT120 uses the same field-proven technology
seen in Metsorsquos tracked units for over 26 years Every detail of thenew jaw plant has been thoroughly designed for reliability and
long life The main targets when designing the unit have been
energy effi ciency good performance reliability and product safety
Field tests have demonstrated its good fuel economy and high
crushing capacity
Environment-friendly economy
The Lokotrack LT120 is also available as an electrically driven unit
ndash the Lokotrack LT120E ndash which can take energy from an external
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The TS range of screens is characterized by its innovative design
comprising two technologies combined multi-variable slopes with
a variable elliptical motion This proven range is being comple-
mented with the new TS63 screen
The TS63rsquos unique combination increases both the screenrsquos effi -
ciency and its capacity Material speed is high at the feed end and
slows down at the discharge end
Metso TS series screens offer more space between decks mak-
ing maintenance easier and improving service conditions for the
operators as well as meeting all safety requirements
Metso has recently sold several 25-m2 multi-slope screens for
mining applications such as a TS63 for Ferrostaal in Mauritania andalso for the construction industry for example Holcim in Lynwood
Australia Georyt in Poland Apaxco in Mexico and Newmont in
Peru
More info
Denis Pradon
Tel +33 680 64 39 67
denispradonmetsocom
New TS63 screen ndash the largest three-deck banana screen on the market
The new Metso TS63 banana screen features a 25-m2 screening area
Following the success of the HP4 and HP5 Metso has broadened
the product range with the new HP3 cone crusher This mid-range
cone crusher benefits from 70+ years of experience in crushing
technology while specifically addressing customer requirements
for large capacity ease of operation and a high reduction ratio
The HP3 responds to market demands for increased productionquality reduced maintenance time and low operating costs The
new generation HP models are comparable to their predecessors
but offer increased versatility
The HP3 features the size of an HP200 with the output of an
HP300 The power performance and robustness of the new gen-
eration models allow in certain cases two crushers to be replaced
with just one so investment production and operation costs are
greatly reduced
The HP3 has been tested at two different quarry sites in France
over the past seven months ndash at a gravel pit and a rock quarry
The Metso factory in France began production of the HP3
series in September Several orders have already been received for
secondary and tertiary applications Since 2009 nearly 300 HP newgeneration cone crushers have been commissioned The HP3 mar-
ket will be primarily centered on gravel pit applications (70)
The HP3 has a nominal feed opening of 220 mm (865rsquorsquo) a
motor size of up to 220 kW (300 hp) and a weight of 13280 kg
(29277 lbs)
More info
Carlos Padin
Tel +33 6 0727 2002
carlospadinmetsocomMetso HP3 at a stationary installation in France
HP3 cone ndash another new-generation cone crusher
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
First modular plant to NepalMetso delivered its first modular crushing and screening plant to MS Palchowke Mai Roda Dunga Udyog Limited (PMRD)
in Melamchi Nepal The modular plant solution offers PMRD a fast and effective response to productivity and qualityrequirements
TEXT amp PHOTOS Atoshi Nayak Ghosh
The diversity of operations at a typical con-
struction site involves quick decision-mak-
ing and often a lot of pressure to ensure a
timely execution
High performance guaranteed
Considering todayrsquos volatile market sce-
nario business partners must maintainpace with their customersrsquo ever-changing
requirements Understanding custom-
ersrsquo strategic business needs is of utmost
importance PMRDrsquos plant was commis-
sioned in January 2011 and has logged
about 1200 hours of operation to date
The plant is much more compact than
the traditional skid-mounted plant and
provides space for free movement of utility
equipment within the plant area One of
the key features of the plant is the totally
bolted structure It can be easily disman-
tled into sub-assemblies transported and
re-assembled effortlessly at a new location
which is one of the biggest advantages in
helping to meet new market demand
Due to the use of pre-assembled mod-ules for each crushing station the instal-
lation work on site takes less time thus
decreasing the plantrsquos installation lead time
The plant also includes a foldable conveyor
for maintenance of the cone crushers
Stepping up with Metso
PMRD operates a two-stage plant compris-
ing a C80 jaw crusher an HP200 high-
performance cone crusher and a CVB1845
screen with circular motion MV2 vibra-
tory mechanism for final product recovery
resulting in an aggregate plant of 150 tph
capacity for producing size fractions of 0-40
mm The plant is an example of world-class
craftsmanship and excellent material han-
dling capacityModular and non-welded construction
supported by durable pitman assembly sin-
gle-piece cast steel frame bearing housings
with repairable crusher construction and
the right cavity design results in aggressive
kinematics and high power that best suits
the requirements of the customer
PMRD has immense pride in the plant
ldquoThe performance has been astounding
A drawing of typical modular plant
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with applications ranging from road aggre-
gates commercial sand production to
ready-mix concretes The modular plant is
almost set to create a new niche in aggre-
gates processing in Nepalrsquos construction
industry It is one of a kind and we are sur-
prised at the plant rsquos production capacity
It is easy to operate and requires minimalmanpower Our cost per ton has signifi-
cantly gone down and so has the cost of
productionrdquo says Mr Sandeep K Agarwal
Director PMRD
Safety as a key issue
Health safety and environmental solutions
are key concerns for Metso and they are
addressed with the same sense of responsi-
bility as quality productivity and cost-
effi ciency issues Metso is responsible for
conducting operations in an environmen-
tally sound way and offers products and
services that can help customers fulfill their
environmental responsibilities
Metso provides the plant offi ce and site
with operation and maintenance manu-als for each and every piece of equipment
including safety issues which are entrusted
to all the operators
All conveyors are equipped with pull-
cord safety switches along with emergency
stop buttons The working area and walk-
ways are all equipped with safety hand rails
and checkered plates for anti-skidding The
entire plant is equipped with earth pits for
electrical current earth leakage prevention
Metso has ensured all possible measures
to maintain high safety standards for all
operation and maintenance personnel
More info
Suhen Agarwal
Tel +91 124 2351566suhenagarwalmetsocom
Nepalrsquos first modularcrushing and screening plant deliv ered by Metso
E ffi cien t C VB1845 inclined screen wi th
an M V2 vibra tor y mechanism handles
the classi fica tion o f crushed ma terials
A s turd y f eeder dis tribu tes the ma terials to be crushed to
a
Me tso C80 ja w crusher
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Outokumpursquos Kemi
mine set to doubleproduction The only mine unit owned by Outokumpu
the chrome mine in Kemi northern Finland
is busy making preparations to double its
production set to begin next year In co-
operation with Metso Outokumpu willincrease the number of underground
feeders and optimize the durabil-
ity of wear parts in the massive
primary gyratory crusher
TEXT amp PHOTOS Eero Haumlmaumllaumlinen
Chrome ore is fed into Metsorsquos
Superiorreg 50-65 primary
gyratory crusher by three
different vibrating feeders
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983122983141983152983151983154983156983145983150983143 983154983141983155
Up until now the entire production of the
chrome mine totaling about 13 million
tons annually has been transported to the
Tornio ferrochrome plant for processing
and on to the Tornio stainless steel plant
The increase in production which will
begin in autumn 2012 is intended also to
enable Outokumpu to sell ferrochrome tocompanies outside the Group The produc-
tion target for 2013 is 27 million tons of
ore and of the ferrochrome produced from
the ore nearly a half (gt 200000 tons) is to
be sold outside
Underground expansion
work almost complete
About 500 meters underground the
majority of the work involved in increasing
the capacity the F3 project has already
been completed Doubling the production
is no problem for the Superiorreg primarygyratory crusher delivered to the mine
by Metso in 2002 which can digest more
than 2700 tons of feed material per hour if
necessary
At the moment the primary gyratory
crusher can be fed by three different vibrat-
ing feeders The crusher currently runs for
less than one-fifth of the production time
The increase in ore production will increase
the effective crushing time to about one-
third of the production time
A lot of work has been done for orestorage after the primary crusher The
two currently used storage silos are now
accompanied by two new 8000-ton silos
The number of Metso feeders transporting
the ore from the primary crusher has also
been doubled
Optimization of wear parts under way
Chrome ore has been a challenge to the
primary gyratory crusherrsquos wear parts The
wear is contributed to by the pulsating
feed which rarely fills the entire crushing
chamber There are also great differences inore type since brittle feed material prone
to chalking is occasionally replaced by hard
ore that requires a lot of crushing power
before it is crushed with a bang gt
Mika Saari (right) Foreman of ore line technicians at Outokumpursquos chrome mine in conversation with
Mikko Malkamaumlki Metsorsquos crusher wear parts specialist
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
last did in July for the replacement of the
crusherrsquos wear parts Our work is also facili-
tated by product development like the
addition of maintenance hatches to the
feedersrdquo he continues
Lasting technology
According to Mika Saarirsquos calculations the
Superiorreg primary gyratory crusher has so
far crushed more than six million tons of
ore in totalldquoThe factory polishing marks still show
on the bottom thrust bearing so we
believe that the bearing will last the entire
remaining service life of the crusher which
is about ten years and 30 million tons
Metsorsquos feeders have been equally reliablerdquo
Saari says
After the next 30 million tons of ore
it will be time to deepen the mine
More info
Jukka Raumlisaumlnen
Tel +358 50 317 1787 jukkaraisanenmetsocom
Mikko Malkamaumlki
Tel + 358 40 827 8223
mikkomalkamakimetsocom
The Kemi mine and Metso are currently
carrying out a development project to
increase the service life of the mantle and
outer concave and thus minimize down-
time due to replacement While the modu-
lar feed hopper enables quick replacement
of the mantle replacing the outer concave
can easily take more than a week The cooperation between the Kemi
mine and Metsorsquos wear parts team in
Tampere aims to extend the service life
of the parts to at least 4 million crushed
tons Durability is sought by optimizing the
chamber structure and selecting the r ight
materials for the outer concave
ldquoSmooth cooperationrdquo
Mika Saari Foreman of ore line technicians
working in the underground mainte-
nance of the Kemi mine leads a small but
experienced team of technicians The tidymodern offi ce spaces are located close to
the action at a depth of 500 meters
ldquoCooperation with Metso has been
smooth Increasing our own crushing
expertise takes time so all know-how
shared by the manufacturer is very wel-
come to usrdquo Mika Saari says
ldquoWe can also use Metsorsquos profession-
als for servicing when necessary like we
The Superiorreg 50-65 has provided reliable
crushing performance at a depth of 500 metres
in the Kemi chrome mine
Technicians Sari Kulju (left) and Marko Jaako ensure that the primary gyratory crusherrsquos hydraulicand electrical unit remains very tidy which contributes to trouble-free operation of the crusher
Outokumpu Oyrsquos Kemi
chrome mine
LOCATION Keminmaa northern
Finland
ORE TYPE chrome oxide (26)
ORE ESTIMATE ON 1 JANUARY 2011
ndash ore reserves 36 million tons
ndash mineral resources 87 million
tons
MINING METHOD bench and cut fillFEED MATERIAL SIZE 0ndash1000 mm
METSO EQUIPMENT IN THE MINE
bull 1 Superiorreg 50-65 primary
gyratory crusher
ndash open side setting 152 cm (6rdquo)
bull 8 VMOU 25-125 feeders
bull 1 VMOU 30-16 feeder
bull 1 VMOU 40125 feeder
bull 2 Symons cone crushers
bull 1 C80 jaw crusher
bull 4 HM75 pumps
bull 11HM100 pumps
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983122983141983152983151983154983156983145983150983143 983154983141983155
Metso was responsible for the design
development and construction of the
entire secondary and tertiary arrangement
The primary station will be the subject of a
subsequent investment
Latest environmental protection used
This installation has been designed in strict
compliance with the environmental quality
approach developed by Metso and its
partners using the latest technologies
in dust control including confinement
technology as well as dust encapsulation
technology for screens
To ensure an annual capacity of 15 mil-lion tons for a nominal output of 560th of
02 mm and 220 mm the clientrsquos choice
for the secondary stage naturally fell upon
the NP 1520 impact crusher
A complete impact crusher solution for Lafarge The Lafarge Group has entrusted Metso with the implementation of its new aggregates installation in southern France
It comprises a new secondary crushing stage equipped with an NP1520 impact crusher featuring a power range of2 x 250kW and equipped with hydraulic adjustment
TEXT amp PHOTO Gilles Dombey
The NP 1520 crusher has long proved
its performance not only in terms of capac-
ity and reduction rate but also quality of
the finished product and durability
More info
Arnaud Bertucat
Tel +33 (0)6 81 44 68 26
arnaudbertucatmetsocom
About 15 million tons of aggregates feed will be crushed with the NP1520 impact crusher at Lafargersquos stationary installation in southern France
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Multi-stage Lokotrack process a success in Senegal
A multi-stage crushing and screening process has proven its effi ciency in the production of concrete aggregates in
Senegal Western Africa With the mobile process Xewell Cimenteries SA now exploits its quarry better has reduced
its operating costs and can meet strict environmental requirements
TEXT Elisabetta Cataluffi PHOTOS Carlo Rinolfi
Senegal is a rapidly developing country
offering a good deal of potential activities
for crushing companies too At the sametime the country has several areas of high
environmental value Therefore contractors
must opt for state-of-the-art equipment that
offers reduced environmental emissions
The company Xewell Cimenteries SA
was founded in 2008 as a partnership
between Italian Swiss and Senegalesecontractors Xewell operates a limestone
quarry located in the Pout area east of the
capital city of Dakar
According to Alessandro Crestani Technical
Director of the Pout quarry a mobile process
was selected to better exploit the quarry and
reduce costsLokotrack process drawing made by Bruno simulation software
After assembling the Lokotrack units the process was tested by Xewell Cimenteries
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983122983141983152983151983154983156983145983150983143 983154983141983155
Owned by Freeport-McMoRan Copper amp
Gold (51) and CODELCO (49) the ElAbra mine has leachable oxide and sulfide
mineralization The minersquos processing facil-
ity has an annual capacity of 226000 tons
of copper cathode
Smaller size matters
Reducing the size of the crushed oxide
ore from the present 15 mm to 12 mm
was the main target of the mine and the
Metso team The changes that were carried
out in the process included a size varia-
tion change in the cut of the tertiary sieve
installation of rate-level sensors in thesecondary crushers and enabling speed
variables in the conveyor belt feeders of
the secondary crushing circuit
ldquoGoing from 15mm to 12mm may seem
small but the operational impact is very
important and significant for usrdquo explains
Juan Torres Carvajal Metallurgical Engi-
neer at the El Abra mine
ldquoOur goal is to reach 115000 tons with
a minimum of 80 of 12-mm-sized ore permonth The record to date is 105000 tons
and we will increase it until we reach our
project goalrdquo he adds
New design for cone liners
In addition to the work mentioned above
Metso is currently carrying out a project to
design the lining profiles for the secondary
and tertiary crushers of the plant which
will affect the smaller size of the material
In cooperation with Nelson Mella from
Metso and Rodolfo Navarro Crushing
Superintendent at the El Abra mine testswere carried out in July on the re-designed
Metso linings One set was tested for sec-
ondary crushing and two sets for tertiary
crushing
More info
Nelson Mella
Tel +56 99158 0576
nelsonmellametsocom
Finer ore through wear pro1047297lestudy at El Abra mine in ChileEl Abra is a porphyry copper open-pit mine and processing facility located in
Chile near the city of Calama some 4000 meters above sea level With the helpof Metsorsquos technical support the mine was able to achieve finer ore throughoutthe crushing process
TEXT amp PHOTOS Macarena Vallejo
Xewell Cimenteries produces a selec-
tion of dry processed aggregates for con-
crete Operations started at the end of 2009
with the aim of reaching 150000 metric
tons produced per year
Lokotracks chosen to reduce costs
To build up their tracked mobile processXewell Cimenteries decided to buy three
mobile plants from Metso two impactor
plants the Lokotrack LT1110 and LT1213
feeding a three-deck mobile screen the
ST620 The machines were sold by SCAI
SpA Metsorsquos Lokotrack distributor in Italy
ldquoWe chose tracked machines to bet-
ter exploit our quarry and to reduce
costs Mobile plants have low initial costs
because they donrsquot need any special foun-
dations or supply of electricity This obvi-
ously gives us a quicker process set-up and
better uptimerdquo says Alessandro Crestani Technical Director of the Pout quarry
ldquoThe mobile plant can also follow the
quarry face as the exploitation proceeds
reducing the transport costs of raw materi-
als in the same jobsite We chose Metso
because they ensured us the best cost-per-
ton ratiordquo he adds
Good customer service is crucial
According to Alessandro Crestani good
customer service also played a major role
when choosing the manufacturer of the
mobile equipmentldquoMetsorsquos distributor SCAI SpA was able
to provide us with a complete product
support and customer service package
Obviously service is a very important
aspect for us in a country like Senegal Any
downtime represents a clear loss of pro-
ductivity for usrdquo
The average level of productivity of the
mobile Lokotrack process is 200 metric
tons per hour
More info
Carlo Rinolfi Tel +39 335 1253159
crinolfiscaispacom
Example of the development of the Metso study
on the crusher lining profiles
Liner change for smaller ore size in the
MP1000 cone crusher
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Services success in Surabaya The Metso Surabaya workshop and offi ce complex opened in April 2008 provides Life Cycle Services and maintenance
solutions for Metso equipment in the Indonesia region The facility is strategically located in an industrial precinct on theouter rim of Surabaya the second largest city in Indonesia Its close proximity to an international airport major shipping
port and several engineering companies simplifies support for the regionrsquos key customers which include PT Newmont
and PT Freeport
TEXT amp PHOTOS David LeRoy amp Gary Whittred
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The Surabaya site operates through Metso
in Australia with assistance from key sales
and technical staff Handling regional ser-vice and repair business in-house allows
Metso to manage intellectual property and
closely control quality
It also enables the development of a
team of skilled service personnel who can
be utilized both internally and at key cus-
tomer sites as is common with the backup
service the workshop provides for screen
contracts
Innovation at work
Since 2008 the Surabaya facility has suc-
cessfully refurbished a wide variety ofcomponents Recently two ball mill heads
weighing 22 tons each were modified in
order to strengthen the 1047298ange of the ball
mill shell The modification included tap-
ping out existing 1047298ange holes and drilling
new ones so that finger plates could be
installed and welded to the 1047298anges
Positioning the head borer to properly
align the new 1047298ange holes proved diffi cult
Four roller support frames were manufac-
tured to support the heads and allow them
to be rotated easily Each hole was then
drilled and tapped at the correct angleusing the CNC five axis head The job had a
tight delivery as it was required for a shut-
down but with advance planning and inno-
vation it was completed ahead of schedule
MP1000 mainframe on
CNC vertical borer
Well equipped for fabricating and machin-
ing heavy components the Surabaya
The Surabaya facility has proven to be
a success for Metso The workshop offers a
wide variety of services in the region Qual-ity products and competitive pricing and
delivery times have led to strong customer
relationships
Turnover and customer service levels
have increased annually since the open-
ing and between 2008 and 2010 sales
increased 450 These excellent trends
are expected to continue as the operation
expands and the customer base grows
Since 2008 the Surabaya facility has
successfully refurbished
bull MP1000 counter shaft boxes headassemblies mainframes bowls adjust-
ment rings counterweights sockets and
tramp release cylinders
bull 7rsquo Symons bowls heads and countershaft
boxes
bull Vertimill screw and drive shafts
bull Ball mill heads
bull Ball mill trommel
bull VPA cylinders
bull Eaton clutches
bull Exciter screen mechanisms
bull 42x65 main shafts and eccentrics
More info
Gary Whittred
Tel +62 31 8430349
garywhittredmetsocom
workshop handles the majority of Metsorsquos
refurbishment work with ease But when
necessary PT PAL ndash a government facilitywith shipbuilding and heavy engineering
capabilities ndash offers a ldquoone stop shoprdquo Spe-
cially trained PT PAL staff ensures that the
work they perform complies with all Metso
specifications and quality standards
PT PAL also demonstrated their innova-
tive ability with the first MP1000 main-
frame refurbishment they completed The
mainframersquos shaft location bore needed
to be re-machined However the distance
from the top of the mainframe to the
tapered bore made it very hard to achieve
an accurate surface finish with the correctstandoff
To overcome this the shop decided to
machine the mainframe upside down and
elevated on support beams They posi-
tioned a new shaft under the mainframe in
a custom-made cradle Using an overhead
crane they could then lsquotrial fitrsquo the shaft in
the bore to make sure it seated correctly
and the mating tapers met specification
The method worked so well it has since
been used for four more mainframe refur-
bishments
Diversity and growth
Today Metso Surabaya continues to invest
in additional equipment in order to diver-
sify its service offering A new hydraulic
power pack which allows the facility to test
refurbished components to Metso specifi-
cations was recently used in the refurbish-
ment and testing of several VPA cylinders
for PT Freeport
Refurbished MP1000 mainframe dispatched by truck to
PT Freeport mine
Machining of MP1000 upper frame
at Metsorsquos Surabaya workshop
Mainframe at vertical CNC machining
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Creating Value with Metso in Hong KongIn Hong Kong the aggregates needed for construction are mostly supplied by two local quarries KWP Quarry Company
Limitedrsquos Anderson Road Quarry accounts for 60ndash70 making it the pillar of Hong Kongrsquos construction materials industry
TEXT amp PHOTOS Ou He
When arriving at the Anderson Road
Quarry the most impressive view at the850000 square-meter facility is the Metso
machines including equipment from the
primary secondary and tertiary crushing
circuits and the screens I t is Metsorsquos equip-
ment that secures the supply of aggregates
for Hong Kong
KWP Quarry Company Limited has been
working with Metso since its establishment
in 1997
Due to Hong Kongrsquos stringent dust and noise control standards Metso has paid special attention to the related suppression systems
ldquoOur quarry mainly lies on granite and
volcanic rock which are so hard they canonly be processed by equipment with
strong durability and stabilityrdquo explains
Mr Eddie Hung Manager of KWP ldquoWith a
long history of and experience in quarry-
ing we are very familiar with the equip-
ment of different brands Comparatively
Metsorsquos products are better than others in
terms of durability stability and effi ciency
Besides this the reason we selected Metso
is because of the simple maintenance of
their equipment and the easy access tomaintenance informationrdquo
Flexible modular solution
Based on extensive experience in crushing
and screening worldwide Metso presented
the Anderson Road Quarry with a modu-
lar solution and delivered it as a turn-key
project Through a four-stage crushing
circuit which contains three Metso C160
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jaw crushers for primary crushing two
Omnicone 1560SX crushers for secondary
crushing two HP 500SX cone crushers for
tertiary crushing and one HP500SX cone
crusher for extra-fine crushing the plant
was able to produce aggregates of optimal
shape with minimal 1047298akiness
The fine products include three sizes
0 to 5 mm 5 to 10 mm and 10 to 20mm
Since the employment of this system in
2000 production has reached 1250 th
which is far beyond the design capacityAccording to Mr Hung ldquoThe machines
always run effi ciently and seldom malfunc-
tion The occasional shutdown of some
machines does not affect production very
much the plant still could reach 60-70
of its normal production It gives us the
best 1047298exibility for the plant rsquos operation and
I believe this is the best feature of Metsorsquos
solution
Eddie Hung
Manager of KWPrsquos
Anderson Road
Quarry is happy with
the product quality
and service provided
by Metso
ldquoMetsorsquos equipment is expensive com-
paratively but in the long run you will find
that the investment is worthwhile on the
whole Metso secures superior stability reli-
ability and fewer downtimes and it guaran-
tees continuous operation and brings us
greater valuerdquo
Great service team
Metso sent a group of service engineers
to the plant within the warranty period
not only to provide service but to train theoperators Mr Hung speaks highly of Met-
sorsquos service team he is impressed with its
experienced experts and with their strong
sense of responsibility and customer-
oriented ways of working
ldquoMetsorsquos service team never fails to find
hidden problems and helps us to prevent
any mechanical failures And they are
available whenever we need them they
work closely with us to solve the problem
effi cientlyrdquo he said
Excellent environment-friendly designIn order to achieve the worldrsquos most strin-
gent noise and dust control standards
developed by the Environment Protection
Department of Hong Kong Metso has
incorporated a dust and noise suppression
system into the plant This includes the
infrared-triggered spray systems at feed
points encapsulation of individual crush-
ers and conveyors and the ability to select
specific sectors of the system for treatment
depending on feed and operating condi-
tions encapsulation of equipment and the
enclosure of all major sections of the plant
With these advanced environment-
friendly solutions Anderson Road Quarry
has won numerous safety and environmen-
tal awards In 2003 it was presented with a
silver medal in the prestigious Environmen-
tal Performance Awards in recognition of
its commitment to the environment and
community In 2004 KWP achieved certifi-cation of ISO 14001 it is the first quarry site
to have achieved this in Hong Kong and
southern China
ldquoA reliable partnerrdquo
The promulgation of the top ten infrastruc-
ture policies in Hong Kong boosted the
market for aggregates and demand will
keep rising over the next five to six years
ldquoWersquoll definitely keep our cooperation with
Metso once we have a need for expansion
because we regard Metso as a reliable part-
ner With their highly effi cient equipmentsatisfying service and great efforts in help-
ing us to achieve our environmental pro-
tection targets Metso is our best choicerdquo
says Hung
More info
Ziqiang Li
Tel +86 13601289027
ziqianglimetsocom
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The sturdy Metso C160
jaw crushers are fed
using huge feed chutes
and feeders
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Similar to hundreds of mine sites world-
wide Zinkgruvan is being operated on a
non-stop 247 basis with just a few main-
tenance breaks during the year Crusher
availability is crucial because 100 of the
ore has to pass through the jaws before
being hoisted up for further processing
In addition to the zinc- lead- copper-
and silver-containing ore the C jaws chop
all the host rock extracted along the min-
ing process With a sturdy design Metsorsquos
proven C jaws can easily reduce even the
hardest type of rock Every year more thanone million tons are crushed with the jaws
ldquoMinimal service neededrdquo
Crushing with the first C160B jaw crusher
began at Zinkgruvanrsquos -800 meter level in
2000 with the primary crushing of zinc-lead
ore The second jaw was installed in 2008
for the new copper process gt
The sight and sound of two C160 jaw crushers operating side by side in the underground
crushing station of the Swedish Zinkgruvan mine is impressive Good proactive service
secures good uptime and reliable continuous operation of Metsorsquos second-largest
C160 series jaw crushers and prepares the way for the ongoing plans to expand the
production of zinc concentrate
TEXT amp PHOTOS Eero Haumlmaumllaumlinen
New PolyMet liners are being tested with the grinding mill delivered by Metso
Zinkgruvanrsquos twin C160
jaws secure good uptime
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Blasted ore is taken from the presently
operated -850 meter level with normal
trucks as an outsourced process One full
truckload is fed to the C160s every
10 minutes
ldquoWe are happy with the high reliability
of the C jaws They only require some minor
service therefore providing us with good
uptime and steady continuous feed to our
secondary and tertiary crushing and grind-ing circuitsrdquo says Mine Manager Jan Klaumlre
ldquoBasic crusher service and wear part
changes are made by our own staff using
Metsorsquos partsrdquo he adds
Service contract with grinding
mills and conveyors
Zinkgruvan and Metso Sweden have more
than 11 yearsrsquo experience with a service
contract that contains grinding mills and
conveyors At the mine site two Metso
service people and one contractor take
care of all the related service jobs Man-
power can also be borrowed from Metsorsquos
Graumlngesberg mine service team of 20
people
Presently Zinkgruvan is testing Metsorsquos
new PolyMet mill linings in its big grinding
mills With previously used rubber partsthe linings had to be changed in the shell
every 9 to 11 months and in the feed head
every 6 months
ldquoWe expect a better lifetime with Poly-
Met linings Longer change intervals mean
a lot to our productivity because lining
changes takes two full working daysrdquo Mine
Manager Jan Klaumlre says
New mine goes deeper
With an expected mine life of more than 10
years Zinkgruvan is actively mapping new
ore reserves Experimental holes are being
drilled at the new mine section at the
-1110 meter level
More info
Fredrik Wennberg
Tel +46 70 657 00 08fredrikwennbergmetsocom
Mine Manager Jan Klaumlre (left) with Backfilling Manager Kjell Tillman at the underground -800 meter level mine cafeteria
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The Zinkgruvan mine located approxi-
mately 200 km southwest of Stockholm
Sweden is one of the oldest underground
mines in Northern Europe The mine has
been in production since 1857
The mining methods used are panel
stoping and benching The processing
facilities include a zinc concentrating plant
with a 11 mtpa and a copper plant with a04 mtpa capacity Tailings are recycled in
an impounding basin and host rock in the
backfill plant
Continuous mining since 1857
Even as one of the oldest mines in Northern
Europe Zinkgruvan exploits modern mining
and minerals processing installations
Zinkgruvan mine
OWNER Lundin Mining
PRODUCTION PER YEAR 1 million tons
ORE TYPE sedimentary exhalative
zinc lead copper and silver
NUMBER OF EMPLOYEES 320
2011 PRODUCTION TARGETS 78000 tonsof zinc 36000 tons of lead and
3400 tons of copper concentrate
METSO EQUIPMENT ON SITE
bull 1 extra long VF feeder
bull 2 C160 jaw crushers
ndash zinc process css 220ndash240 mm
ndash copper process css 150 mm
bull 1 GP300S cone crusher
ndash css 45mm
bull 1 HP4 cone crusher
ndash css 18 mm
bull 1 DS screen
bull 1 FS402 screenbull 1 grinding mill
bull Pumps VPAs
A normal truck feeds the C jaws with ore coming from the lower production levels
983122983141983152983151983154983156983145983150983143 983154983141983155
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Cost-per-ton wear agreements deepencustomer relationshipsCrusher wear parts are traditionally marketed purely based on transactional sales and mainly depend on
the weight of manganese Metso has recently introduced a new type of wear agreement based on thecost-per-ton crushed and the wear occurred Thus far the experience has been very positive increasing
transparency and deepening the operational relationship between the manufacturer and the customer
TEXT Olli Kellokumpu and Eero Haumlmaumllaumlinen PHOTOS Eero Haumlmaumllaumlinen
Arto Hiedanniemi (left)
Hannu Heman and Juha
Laukka of Metsorsquos Finnish
Service team checking the
cone crusher mantles shipped
for a cost-per-ton customer
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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156
Wear parts and parts changes
can be included
The structure of a cost-per-ton wearcontract is based on the number of tons
crushed and the estimated wear occurred
The amount and monetary value of the
wear is calculated per crushed ton
ldquoEither plain wear parts or parts changes
carried out by Metsorsquos service personnel
can be included in the contract In the latter
case we ask our Finnish customers to inform
us about an upcoming wear change opera-
tion one week in advancerdquo Heman explains
ldquoWe see good opportunities to market
cost-per-ton contracts further in Finland
and also abroad It really develops therelationship of Metso and our customers
towards a trusted partnershiprdquo he notes
Perfect tool for accurate planning
Soraliike Ikola Oy is a mid-sized contrac-
tor with three Metso two- and three-
stage mobile and portable crushing and
screening plants operating in Central and
Since 2002 Metsorsquos sales team in Finland
has developed the cost-per-ton-based
service offeringldquoOur aim has been to seek through
a cost-per-ton offering possibilities to
serve our customers better to differentiate
Metso from the other players as an OEM
manufacturer and to offer deeper profes-
sionalism and know-howrdquo says Hannu
Heman General Manager of service
operations
ldquoUntil now both our experience and
that of our customers has been quite posi-
tive When properly prepared cost-per-ton
contracts seem to create a win-win situa-
tionrdquo Heman adds Today Metso has operational cost-per-
ton agreements with several Finnish cus-
tomers The first contract was concluded
with a customer operating a stationary
plant Based on the results gathered new
cost-per-ton contracts have been signed
with customers operating wheeled and
tracked equipment too
Eastern Finland Because of the size of the
contracts up to 50 equipment moves are
made during the yearEntrepreneur Pasi Ikola has had a cost-
per-ton contract with Metso for nearly
two years and he is quite happy with the
outcome
ldquoThe cost-per-ton contract has provided
me with a perfect tool for accurate financial
planning Now I know in detail my actual
future wear parts costs This helps a lot
when calculating bidsrdquo
ldquoEarlier I used to buy a big batch of
Metso wear parts in one go and had to
reserve a reasonable amount of money for
that Today all wear costs are evenly sharedwhich gives us a welcomed 1047298exibility to
our cost structure Now we just pay Metso
afterwards based on our crushed tonsrdquo
he adds
More info
Olli Kellokumpu
Tel +358 50 354 1189
ollikellokumpumetsocom
According to crushing contractor Pasi Ikola the cost-per-ton contract with Metso has provided the entrepreneur with better economical 1047298exibility
and more accurate calculating of bids
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Pleasant Gap is owned and operated by
Glenn O Hawbaker Inc of State College
Pennsylvania This family-owned company
began in 1952 as a small excavation busi-
ness founded by Glenn O Hawbaker and
his wife Thelma Over the years the com-
pany grew by adding an integrated mix ofproducts and services and taking on larger
projects
In 1983 Hawbaker acquired Pleasant
Gap Quarry and built its first aggregates
processing plant Today Glenn O Haw-
baker Inc operates 21 quarries and eight
asphalt production facilities across Penn-
sylvania and southern New York as well as
five regional operation centers
Primary
challenge atPleasant GapQuarryA good part of what makes for a successful crushing
operation is the willingness to tackle challenges and to do
whatrsquos necessary to meet demand The team at Pleasant
Gap Quarry in central Pennsylvania recently met the chal-
lenge when they successfully addressed problems with
the plantrsquos primary crushing plant First they purchased
a new Metso C160 jaw to replace the existing primary
impact crusher Then they devised an innovative plan to
get the primary plant back in operation while awaitingdelivery of the new jaw crusher
TEXT Linda Bergmann PHOTOS John Rickinger
983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Time for a change
With the goal of increasing reliability and
output the management at Pleasant Gap
Quarry recently decided it was time to
replace the plantrsquos primary impact crusher
Following a thorough search they chose a
new Metso C160 jaw According to ScottReck Plant Manager it no longer made
sense to repair and rebuild the existing
impactor
ldquoBefore we purchased the Metso C160
we had a few other impact crushers and
they served us well but as our custom-
ersrsquo needs increased our plant production
had to match that demand We found our
formerly reliable unit was being overcome
by our demands for output and creative
work-around solutions We continued to
need more but there was only so much we
could do until we hit the breaking point ndash
literallyrdquo
In addition to performance improve-
ments the new crusher also needed to fitinto Pleasant Gaprsquos unique infrastructure
As Plant Project ManagerEngineer Jeremy
Fahr explains ldquoOur height restraint was 274
meters (108rdquo) This height was the distance
from the feed lip of the existing 6x12 scalp-
ing screen and the existing structure that
the crusher rests onrdquo
The normal C160 crusher is 307
meters (121rdquo) tall but Metso gave GOH
Scott Reck Plant Manager (left) and
Jeremy Fahr Plant Project Manager
Engineer at Pleasant Gap Quarry
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983122983141983152983151983154983156983145983150983143 983154983141983155
a 10-degree mounting option (which is
normally used on their portable crushers)
to overcome the height restraint Reck and
Fahr worked with Dave Rhoa of Cleveland
Brothers Equipment Metsorsquos crushing and
screening distributor in Pennsylvania to
pull everything together and fit the newcrusher into their plant
The C160 crusher selected for Pleasant
Gap is one of the latest models in Metsorsquos
C Series of jaws These jaw crushers feature
a large throw and steep toggle plate angle
resulting in a higher crusher output In
addition the C Series has a compact foot-
print that makes it an ideal choice for the
replacement of existing machines
According to Reck ldquoWe had heard about
the new Metso C160 and started doing our
own research and found Metso not only
had developed the output capacity we
needed but fit the uniqueness of our oper-
ationsrdquo The new Metso crusher will allow
the plant to increase tons per hour andgive them the 1047298exibility to meet demands
for varying products on short notice
Mobile solution
Purchasing the new primary jaw addressed
the long-term issues but still left Pleasant
Gap without a functioning primary plant
Reck continues ldquoOur main line was still
down leaving us with a big hole in hitting
customer needs but knowing that our new
Metso C160 was on its wayhellipwe needed an
immediate solution to keep our produc-
tion demands with an out-of-commission
crusherrdquo
The team at Pleasant Gap brainstormed
the problem and came up with a plan toget the primary plant back in operation
Their solution was to use the Lokotrack
LT1213 impactor plant and another mobile
unit to keep the main line crushing To do
this they removed the guts on the existing
impact crusher essentially turning it into a
rock chute They then moved the LT1213
and another manufacturerrsquos mobile unit
over to the existing dump hopper gt
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
ldquoWe had our haul trucks drop off mate-
rial while two excavators fed the two
mobile unitsrdquo Reck explains ldquoFor two-and-
a-half months the Lokotrack LT1213 unit
was producing 254 cm (10rdquo) minus at
700 tons per hour The other similar-sized
mobile unit was doing 400 tons an hour
maxed out The difference was unbeliev-
able to say the least Our unique solution
using the two mobile units especially the
LT1213 helped Glenn O Hawbaker achieve
a record output in 2010rdquoAccording to Fahr ldquoWe were not new to
Metsorsquos quality and supportrdquo because GOH
had been using Metsorsquos portable crushing
equipment for 3 years prior to the primary
plantrsquos impact crusher failure In another
part of our operation we have a system that
our team relies on every day a Lokotrack
LT1213 and ST272 working in tandem with
two portable conveyorsrdquo This highly effi -
cient mobile processing system turns out
300 tons of specialized blended material
per hour GOH has been so impressed with
Metso equipment its last two purchaseswere an LT106 tracked jaw plant and a
second ST272 mobile screen in 2010
Maintaining high productivity
The Metso C160 jaw was delivered to Pleas-
ant Gap Quarry in January of 2011 and
since start-up it has more than met expec-
tations The crusher is fed minus 910 mm
(36rdquo) limestone with the jaw set at 140 mm
(5 12rdquo) According to Reck ldquoFrom moment
we started up we knew we had a winner
Not only were we kicking out as much
product as our previous units without even
breathing hard but we immediately had a
2-cent per ton savings to the bottom line
without having to run a second 350 HP
motor as required by other units Plus by
adding on the new automatic lube system
the maintenance team had more time to
devote to keeping other areas of the com-
plex running more effi cientlyrdquoReck says ldquoThe Metso unit was a perfect
fit and with the improved features it pre-
sented it had it all We just turn it on load
it up and we are moving 600 tons per hour
through the crusher without any effort and
we know it can do so much morerdquo With
the primary crushing plant back in opera-
tion the entire team at Pleasant Gap will
continue to do what they do best produce
and sell high-quality products and meet
their customersrsquo expectations
More info
Scott Yablonsky Tel +1 262 717 793
scottyablonskymetsocom
The Metso C160 jaw
was installed at a 10deg
angle to fit Pleasant
Gaprsquos existing
infrastructure
The Lokotrack LT1213 impactor plant and ST272 mobile screen operate in tandem with two
portable conveyors at Pleasant Gap
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983149983141983156983155983151 983150
Paper amp fiberNew OptiConcept M paper
and board making line
The new OptiConcept M paper and board
making line stands for economy safety and
usability
Metso has launched a new modular paper
and board making line called OptiConceptM A member of the proven OptiConcept
production line family the new OptiCon-
cept M optimizes machine investment in
line with each millrsquos capacity needs
Savings in operating costs are achieved
through precise dimensioning of pro-
cesses proven technological solutions
optimal running parameters effective
maintenance operations and fully inte-
grated automation solutions
Optimized processes innovations
smart controls and accurate dimensioning
decrease the use of steam gas electricitywater chemicals and other raw materials
and reduce emission levels
OptiConcept M has been designed
both visually and physically with the
requirements of users in mind For exam-
ple the design of the machinery allows for
easy and safe changing of rolls and wear
parts thus reducing the total duration and
cost of maintenance shutdowns
RecyclingGreen energy technology to
Elektrociepłownia Białystok in Poland
Metso will convert a coal-fired boiler to
a biomass-fired Bubbling Fluidized Bed
boiler for Elektrociepłownia Białystok SArsquos
combined heat and power plant (CHP) in
Białystok Poland The new boiler system
will cut the power plantrsquos CO2 emissions
significantly by partly replacing the coal
fuel supply with biomass fuel
ldquoPoland is one of the largest countries
in Europe to have such a high depend-ence on energy derived from coal to
meet national electricity needs This is an
important incentive for us to reduce future
CO2 emissions and produce more green
electricity and with Metso technology
we are certain to accomplish our goalrdquo
states Mr Andrzej Schroeder President of
Elektrociepłownia Białystok SA
Since 2000 Metso has received a total
of 7 biomass boiler conversion orders in
Poland and the renewable energy share
in Poland is only 75 (2010) compared to
the target of 20 by 2020 set by the EUApproximately 80 of the current energy
boilers turbines and generators installed in
Polish power plants are over 20 years old In
order to meet the strict EU environmental
requirements modernization of existing
installations is necessary
Automation
Metso DNA automation system expands
to mining and construction
Using Metsorsquos control room automation
an entire crushing and screening plant can
be effi ciently managed
Metso is a leading supplier of mining and
construction machinery This expertise has
now been combined with a scalable Metso
DNA automation system that adapts to
the range of industry needs from single
machine controls to plant-wide automation
and information management systems
An example of Metsorsquos new offering is a
new crushing plant control room solution
that connects crushers and screens ensur-
ing the effective management of the entire
plant from a pleasant and safe control
room The Metso DNA user interface pro-vides the production information to ensure
a proper and rapid response to plant
events Automatic controls stabilize the
process and allow the operators to monitor
the plant as a whole
ldquoThe benefits of automation for the min-
ing and construction industry are signifi-
cant As an example of the services we offer
performance studies to crushing plants
utilizing Metsorsquos multi-disciplinary teams of
experts to determine the present level of
the plant and process effi ciency and to esti-
mate the improvement potential and thebenefits of optimization and automation
including ROI calculationsrdquo says Mikko Maumlki-
nen Product Manager of minerals applica-
tions in Metsorsquos Automation business line
ldquoAs another example our machine
condition monitoring solutions can reduce
plant and machine downtimes as well as
help to avoid safety and environmental
hazardsrdquo he adds
Metso around the world
Aerial view of the Elektrociepłownia Białystok combined heat and power plant in Poland
8202019 Metso Minerals Aggregates 3 2011
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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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The construction budget of EUR 534 billion
for projects in Sochi includes three major
sites the Olympic Park along the shore of
Black Sea the Olympic Village residences
for the athletes and the Krasnaya Polyana
ski resort in the Caucasus Mountains
These three sites will be interconnected
by numerous new highways roads bridges
Construction projects at a total budget of EUR 534 billion
983110983141983137983156983157983154983141983140 983137983154983156
The companyrsquos sand-gravel-mix
resources are expected to last upwards of
20 years Upon the completion of mining
and once the territory has been rehabili-
tated the quarry will be transformed into
an artificial lake for recreation and fishing
for the residents of the City of Maykop
More info
Alexey Shevyakhov
Tel +7 495 915 29 30
alexeyshevyakhovmetsocom
LOCATION City of Maykop Republic of
Adygea southern Russia
RAW MATERIAL hard rock sand-gravel mixhardness 40 kN
CAPACITY 250 th with increase up to 550
th in 2012
RESOURCES over 10 million cubic meters
END PRODUCTS Washed building sand 0ndash5
mm and crushed aggregates 5ndash10 mm
10ndash20 mm 5ndash20 mm 20ndash40 mm
ON-SITE MЕTSО EQUIPMENT
bull 1 Lokotrack LT106 jaw plant
bull 1 Lokotrack LT200HP cone plantbull 1 Lokotrack ST35 mobile screen
bull 1 Nordberg CVB 2060-4 inclined
screen
bull 1 Nordberg SF2870 sand trap
EQUIPMENT BEING INSTALLED WITH
COMMISSIONING IN 2ND QUARTER OF 2012
bull 1 Nordberg C80 jaw crusherbull 2 Nordberg HP4 cone crushers
bull 2 Nordberg CVB2060-4 inclined
screens
bull 1 Nordberg SF2360 sand trap
bull 1 Nordberg SF2870 sand trap
Maykop quarry owned by the Maykop Nerud Company
and tunnels Essentially the entire infra-
structure within and around the 110-km-
long Sochi will be renewed
More than 155000 workers are involved
in the construction projects In total more
than 300000 cubic meters of concrete
will be used for shotcreting and for the
solid cladding of the tunnels A consider-
able proportion of that concrete will be
prepared using the aggregates and sand of
Maykop Nerud
The company Severstroy is producing
concrete elements for lining 23 kilometers
of various tunnels All of the washed aggre-
gates and sand for those projects is also
being supplied by Maykop Nerud
Metsorsquos sand trap is a critical component of the washing complex
In August 2011 construction of the new ice stadium in Olympic Park was at full speed
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The new Metso C120 jaw crusher combines effi ciency versatility and safety
Metsorsquos new C120 jaw crusher made its worldwide debut at the Steinexpo exhibition in Germany
New products
Metso is proud to announce that we have developed the first fully
recyclable modular screening media ndash Metso Trellex LS-Eco
In response to customer requests for sustainable and environ-
mentally friendly screening media solutions and in line with our
own sustainability program we have taken the acclaimed Metso Trellex LS rubber modular screening media systems and success-
fully replaced the traditional steel reinforcement with an environ-
mentally friendly composite material This unique solution makes it
possible to effectively recycle our customersrsquo screening media
In the past screening media modules that were no longer
suitable for production were treated as waste and could not be
recycled Metso has introduced a new future for the product and a
sustainable solution
Sustainable solution for screening media
Metso has launched the
first fully recyclable
modular screening
media ndash Metso
Trellex LS-Eco
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Metsorsquos Mining and Construction Technology has introduced the
Metso C120 jaw crusher ndash the 13th member of the field-proven
C-series range of crushers The C120 combines uncompromising
reliability crushing effi ciency and versatility in both stationary and
mobile applications with safety and ease of use
Even at first glance it is clear that Metso has paid special atten-
tion to the C120rsquos new durable and user-friendly design start-
ing with the casting the design of which is based on thorough
FEA analysis and casting simulations Every detail of the C120 is
engineered for reliable operation and long life resulting in high
constant crushing capacity and uptime
ldquoWhen starting the C120 project we listened closely to our cus-
tomers and collected field data from a number of sites Based onthat information we decided to design the crusher cavity and kin-
ematics first As a result Metso can now offer aggregates produc-
ers large-scale contractors and mining companies a new crusher
that meets all the standards set for any demanding applicationrdquo
says Ilkka Somero Metsorsquos Product Manager for jaw crushers
New design brings outstanding productivity
The outstanding productivity of the C120 is guaranteed thanks
to several new design elements The crusher features a long and
aggressively directed stroke and a fixed jaw die longer than previ-
ously seen in this crusher size class The C120 has a large feed
opening of 1200 x 870 mm (34 x 47rsquorsquo) and an aggressive cavity cross
section securing a high per formance and reduction ratioIn terms of cavity volume and crusher weight the C120 is posi-
tioned between the existing Metso C116 and C125 jaw crusher
models
The Metso C120rsquos nominal power is 160 kW (200 HP) operating
speed 230 rpm closed side setting between 70 ndash 200 mm (2 34rsquorsquo
ndash 8rsquorsquo) The operational weight is 26000 kg (57200 lbs) excluding
options
More infoIlkka Somero
Tel + 358 50 317 0769
Ilkkasomerometsocom
The optional robust composite 1047298ywheel guards allow quick and safe
access to the service points
983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156
In addition to providing environmentally friendly screening
media panels Metso will implement a unique program to provide
its customers with a suitable range of recycling services
The Metso Trellex LS-Eco offers a wide range of health safety
and environmental benefits Each screening media panel is up to40 lighter than standard steel reinforced Trellex LS panels This
makes handling easier and the working environment safer Lighter
panels also help to reduce the overall stress on the entire screening
installation
Compared to steel-reinforced panels the composite-reinforced
panels of the Metso Trellex LS-Eco are more 1047298exible and will reduce
the effects of pegging and blinding during screening operations
The Metso Trellex LS-Eco promises reduced downtime and
increased productivity
The Trellex 300LS and Trellex 305LS rubber and polyurethane
panels are already acclaimed worldwide as being among the most
versatile modular screening media solutions They can be attached
to most screening media systems and can handle all types of
screening applications ndash fine and coarse wet and dry In the futurewhen Metso customers need new screening media panels for
their existing system they can choose Metso Trellex LS-Eco and be
assured that their panels will be safely and effectively recycled
More info
Claes Larsson
Tel +46 410 525 73
claeslarssonmetsocom
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The new Lokotrack LT120 with its world premiere at the Steinexpo
exhibition in Germany combines crushing performance and user-
friendly design in a new revolutionary way For the first time the
same Lokotrack model is now available in a hydraulically or electri-
cally driven version to meet customer needs
New Lokotrack LT120 jaw plant introduced
Lokotrack LT120 is the latest and most advanced of Metsorsquos track-mounted jaw crusher plants
Lokotrack LT120 combines user-friendly design and good crushing
performance in a new way
power supply or a 420-kV onboard diesel generator Having the
possibility to use an external power supply enables a highly eco-
nomical and ecological crushing process
The Lokotrack LT120 is built around the new C120 jaw crusher
See page 10 for information about the C120
Safe to use move and service
Safety is the highest priority for Metso when designing new equip-ment The Lokotrack LT120 is designed to be safe to operate move
and service
ldquoA safe operating environment is created by practical solutions
When service points can be reached easily the possibility of dan-
gerous situations diminishesrdquo says Product Manager Timo Nakari
ldquoGood examples of safety built in to the Lokotrack LT120 include
sturdy easy-to-open composite 1047298ywheel guards and hydraulically
folding and locking feed hopper sidesrdquo Nakari adds
The Lokotrack LT120 can be fine-tuned to suit the customerrsquos
application by selecting the required options from a long main
conveyor and hammer and boom to a water spraying system and
rubber lining for the feeder and hopper for example
The Lokotrack LT120 features a Caterpillar C13 310 kW (415 hp)engine Its transport dimensions are length 16 m (52rsquo 6rdquo) width 3 m
(9rsquo10rdquo) height 39 m (12rsquo 10rdquo) and weight 57 tons (114000 lbs) The
LT120E version weighs 63 tons (126000 lbs)
More info
Timo Nakari
Tel + 358 40 701 6143
timonakarimetsocom
983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155
The Lokotrack LT120 uses the same field-proven technology
seen in Metsorsquos tracked units for over 26 years Every detail of thenew jaw plant has been thoroughly designed for reliability and
long life The main targets when designing the unit have been
energy effi ciency good performance reliability and product safety
Field tests have demonstrated its good fuel economy and high
crushing capacity
Environment-friendly economy
The Lokotrack LT120 is also available as an electrically driven unit
ndash the Lokotrack LT120E ndash which can take energy from an external
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The TS range of screens is characterized by its innovative design
comprising two technologies combined multi-variable slopes with
a variable elliptical motion This proven range is being comple-
mented with the new TS63 screen
The TS63rsquos unique combination increases both the screenrsquos effi -
ciency and its capacity Material speed is high at the feed end and
slows down at the discharge end
Metso TS series screens offer more space between decks mak-
ing maintenance easier and improving service conditions for the
operators as well as meeting all safety requirements
Metso has recently sold several 25-m2 multi-slope screens for
mining applications such as a TS63 for Ferrostaal in Mauritania andalso for the construction industry for example Holcim in Lynwood
Australia Georyt in Poland Apaxco in Mexico and Newmont in
Peru
More info
Denis Pradon
Tel +33 680 64 39 67
denispradonmetsocom
New TS63 screen ndash the largest three-deck banana screen on the market
The new Metso TS63 banana screen features a 25-m2 screening area
Following the success of the HP4 and HP5 Metso has broadened
the product range with the new HP3 cone crusher This mid-range
cone crusher benefits from 70+ years of experience in crushing
technology while specifically addressing customer requirements
for large capacity ease of operation and a high reduction ratio
The HP3 responds to market demands for increased productionquality reduced maintenance time and low operating costs The
new generation HP models are comparable to their predecessors
but offer increased versatility
The HP3 features the size of an HP200 with the output of an
HP300 The power performance and robustness of the new gen-
eration models allow in certain cases two crushers to be replaced
with just one so investment production and operation costs are
greatly reduced
The HP3 has been tested at two different quarry sites in France
over the past seven months ndash at a gravel pit and a rock quarry
The Metso factory in France began production of the HP3
series in September Several orders have already been received for
secondary and tertiary applications Since 2009 nearly 300 HP newgeneration cone crushers have been commissioned The HP3 mar-
ket will be primarily centered on gravel pit applications (70)
The HP3 has a nominal feed opening of 220 mm (865rsquorsquo) a
motor size of up to 220 kW (300 hp) and a weight of 13280 kg
(29277 lbs)
More info
Carlos Padin
Tel +33 6 0727 2002
carlospadinmetsocomMetso HP3 at a stationary installation in France
HP3 cone ndash another new-generation cone crusher
983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
First modular plant to NepalMetso delivered its first modular crushing and screening plant to MS Palchowke Mai Roda Dunga Udyog Limited (PMRD)
in Melamchi Nepal The modular plant solution offers PMRD a fast and effective response to productivity and qualityrequirements
TEXT amp PHOTOS Atoshi Nayak Ghosh
The diversity of operations at a typical con-
struction site involves quick decision-mak-
ing and often a lot of pressure to ensure a
timely execution
High performance guaranteed
Considering todayrsquos volatile market sce-
nario business partners must maintainpace with their customersrsquo ever-changing
requirements Understanding custom-
ersrsquo strategic business needs is of utmost
importance PMRDrsquos plant was commis-
sioned in January 2011 and has logged
about 1200 hours of operation to date
The plant is much more compact than
the traditional skid-mounted plant and
provides space for free movement of utility
equipment within the plant area One of
the key features of the plant is the totally
bolted structure It can be easily disman-
tled into sub-assemblies transported and
re-assembled effortlessly at a new location
which is one of the biggest advantages in
helping to meet new market demand
Due to the use of pre-assembled mod-ules for each crushing station the instal-
lation work on site takes less time thus
decreasing the plantrsquos installation lead time
The plant also includes a foldable conveyor
for maintenance of the cone crushers
Stepping up with Metso
PMRD operates a two-stage plant compris-
ing a C80 jaw crusher an HP200 high-
performance cone crusher and a CVB1845
screen with circular motion MV2 vibra-
tory mechanism for final product recovery
resulting in an aggregate plant of 150 tph
capacity for producing size fractions of 0-40
mm The plant is an example of world-class
craftsmanship and excellent material han-
dling capacityModular and non-welded construction
supported by durable pitman assembly sin-
gle-piece cast steel frame bearing housings
with repairable crusher construction and
the right cavity design results in aggressive
kinematics and high power that best suits
the requirements of the customer
PMRD has immense pride in the plant
ldquoThe performance has been astounding
A drawing of typical modular plant
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983122983141983152983151983154983156983145983150983143 983154983141983155
with applications ranging from road aggre-
gates commercial sand production to
ready-mix concretes The modular plant is
almost set to create a new niche in aggre-
gates processing in Nepalrsquos construction
industry It is one of a kind and we are sur-
prised at the plant rsquos production capacity
It is easy to operate and requires minimalmanpower Our cost per ton has signifi-
cantly gone down and so has the cost of
productionrdquo says Mr Sandeep K Agarwal
Director PMRD
Safety as a key issue
Health safety and environmental solutions
are key concerns for Metso and they are
addressed with the same sense of responsi-
bility as quality productivity and cost-
effi ciency issues Metso is responsible for
conducting operations in an environmen-
tally sound way and offers products and
services that can help customers fulfill their
environmental responsibilities
Metso provides the plant offi ce and site
with operation and maintenance manu-als for each and every piece of equipment
including safety issues which are entrusted
to all the operators
All conveyors are equipped with pull-
cord safety switches along with emergency
stop buttons The working area and walk-
ways are all equipped with safety hand rails
and checkered plates for anti-skidding The
entire plant is equipped with earth pits for
electrical current earth leakage prevention
Metso has ensured all possible measures
to maintain high safety standards for all
operation and maintenance personnel
More info
Suhen Agarwal
Tel +91 124 2351566suhenagarwalmetsocom
Nepalrsquos first modularcrushing and screening plant deliv ered by Metso
E ffi cien t C VB1845 inclined screen wi th
an M V2 vibra tor y mechanism handles
the classi fica tion o f crushed ma terials
A s turd y f eeder dis tribu tes the ma terials to be crushed to
a
Me tso C80 ja w crusher
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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155
Outokumpursquos Kemi
mine set to doubleproduction The only mine unit owned by Outokumpu
the chrome mine in Kemi northern Finland
is busy making preparations to double its
production set to begin next year In co-
operation with Metso Outokumpu willincrease the number of underground
feeders and optimize the durabil-
ity of wear parts in the massive
primary gyratory crusher
TEXT amp PHOTOS Eero Haumlmaumllaumlinen
Chrome ore is fed into Metsorsquos
Superiorreg 50-65 primary
gyratory crusher by three
different vibrating feeders
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983122983141983152983151983154983156983145983150983143 983154983141983155
Up until now the entire production of the
chrome mine totaling about 13 million
tons annually has been transported to the
Tornio ferrochrome plant for processing
and on to the Tornio stainless steel plant
The increase in production which will
begin in autumn 2012 is intended also to
enable Outokumpu to sell ferrochrome tocompanies outside the Group The produc-
tion target for 2013 is 27 million tons of
ore and of the ferrochrome produced from
the ore nearly a half (gt 200000 tons) is to
be sold outside
Underground expansion
work almost complete
About 500 meters underground the
majority of the work involved in increasing
the capacity the F3 project has already
been completed Doubling the production
is no problem for the Superiorreg primarygyratory crusher delivered to the mine
by Metso in 2002 which can digest more
than 2700 tons of feed material per hour if
necessary
At the moment the primary gyratory
crusher can be fed by three different vibrat-
ing feeders The crusher currently runs for
less than one-fifth of the production time
The increase in ore production will increase
the effective crushing time to about one-
third of the production time
A lot of work has been done for orestorage after the primary crusher The
two currently used storage silos are now
accompanied by two new 8000-ton silos
The number of Metso feeders transporting
the ore from the primary crusher has also
been doubled
Optimization of wear parts under way
Chrome ore has been a challenge to the
primary gyratory crusherrsquos wear parts The
wear is contributed to by the pulsating
feed which rarely fills the entire crushing
chamber There are also great differences inore type since brittle feed material prone
to chalking is occasionally replaced by hard
ore that requires a lot of crushing power
before it is crushed with a bang gt
Mika Saari (right) Foreman of ore line technicians at Outokumpursquos chrome mine in conversation with
Mikko Malkamaumlki Metsorsquos crusher wear parts specialist
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
last did in July for the replacement of the
crusherrsquos wear parts Our work is also facili-
tated by product development like the
addition of maintenance hatches to the
feedersrdquo he continues
Lasting technology
According to Mika Saarirsquos calculations the
Superiorreg primary gyratory crusher has so
far crushed more than six million tons of
ore in totalldquoThe factory polishing marks still show
on the bottom thrust bearing so we
believe that the bearing will last the entire
remaining service life of the crusher which
is about ten years and 30 million tons
Metsorsquos feeders have been equally reliablerdquo
Saari says
After the next 30 million tons of ore
it will be time to deepen the mine
More info
Jukka Raumlisaumlnen
Tel +358 50 317 1787 jukkaraisanenmetsocom
Mikko Malkamaumlki
Tel + 358 40 827 8223
mikkomalkamakimetsocom
The Kemi mine and Metso are currently
carrying out a development project to
increase the service life of the mantle and
outer concave and thus minimize down-
time due to replacement While the modu-
lar feed hopper enables quick replacement
of the mantle replacing the outer concave
can easily take more than a week The cooperation between the Kemi
mine and Metsorsquos wear parts team in
Tampere aims to extend the service life
of the parts to at least 4 million crushed
tons Durability is sought by optimizing the
chamber structure and selecting the r ight
materials for the outer concave
ldquoSmooth cooperationrdquo
Mika Saari Foreman of ore line technicians
working in the underground mainte-
nance of the Kemi mine leads a small but
experienced team of technicians The tidymodern offi ce spaces are located close to
the action at a depth of 500 meters
ldquoCooperation with Metso has been
smooth Increasing our own crushing
expertise takes time so all know-how
shared by the manufacturer is very wel-
come to usrdquo Mika Saari says
ldquoWe can also use Metsorsquos profession-
als for servicing when necessary like we
The Superiorreg 50-65 has provided reliable
crushing performance at a depth of 500 metres
in the Kemi chrome mine
Technicians Sari Kulju (left) and Marko Jaako ensure that the primary gyratory crusherrsquos hydraulicand electrical unit remains very tidy which contributes to trouble-free operation of the crusher
Outokumpu Oyrsquos Kemi
chrome mine
LOCATION Keminmaa northern
Finland
ORE TYPE chrome oxide (26)
ORE ESTIMATE ON 1 JANUARY 2011
ndash ore reserves 36 million tons
ndash mineral resources 87 million
tons
MINING METHOD bench and cut fillFEED MATERIAL SIZE 0ndash1000 mm
METSO EQUIPMENT IN THE MINE
bull 1 Superiorreg 50-65 primary
gyratory crusher
ndash open side setting 152 cm (6rdquo)
bull 8 VMOU 25-125 feeders
bull 1 VMOU 30-16 feeder
bull 1 VMOU 40125 feeder
bull 2 Symons cone crushers
bull 1 C80 jaw crusher
bull 4 HM75 pumps
bull 11HM100 pumps
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983122983141983152983151983154983156983145983150983143 983154983141983155
Metso was responsible for the design
development and construction of the
entire secondary and tertiary arrangement
The primary station will be the subject of a
subsequent investment
Latest environmental protection used
This installation has been designed in strict
compliance with the environmental quality
approach developed by Metso and its
partners using the latest technologies
in dust control including confinement
technology as well as dust encapsulation
technology for screens
To ensure an annual capacity of 15 mil-lion tons for a nominal output of 560th of
02 mm and 220 mm the clientrsquos choice
for the secondary stage naturally fell upon
the NP 1520 impact crusher
A complete impact crusher solution for Lafarge The Lafarge Group has entrusted Metso with the implementation of its new aggregates installation in southern France
It comprises a new secondary crushing stage equipped with an NP1520 impact crusher featuring a power range of2 x 250kW and equipped with hydraulic adjustment
TEXT amp PHOTO Gilles Dombey
The NP 1520 crusher has long proved
its performance not only in terms of capac-
ity and reduction rate but also quality of
the finished product and durability
More info
Arnaud Bertucat
Tel +33 (0)6 81 44 68 26
arnaudbertucatmetsocom
About 15 million tons of aggregates feed will be crushed with the NP1520 impact crusher at Lafargersquos stationary installation in southern France
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Multi-stage Lokotrack process a success in Senegal
A multi-stage crushing and screening process has proven its effi ciency in the production of concrete aggregates in
Senegal Western Africa With the mobile process Xewell Cimenteries SA now exploits its quarry better has reduced
its operating costs and can meet strict environmental requirements
TEXT Elisabetta Cataluffi PHOTOS Carlo Rinolfi
Senegal is a rapidly developing country
offering a good deal of potential activities
for crushing companies too At the sametime the country has several areas of high
environmental value Therefore contractors
must opt for state-of-the-art equipment that
offers reduced environmental emissions
The company Xewell Cimenteries SA
was founded in 2008 as a partnership
between Italian Swiss and Senegalesecontractors Xewell operates a limestone
quarry located in the Pout area east of the
capital city of Dakar
According to Alessandro Crestani Technical
Director of the Pout quarry a mobile process
was selected to better exploit the quarry and
reduce costsLokotrack process drawing made by Bruno simulation software
After assembling the Lokotrack units the process was tested by Xewell Cimenteries
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983122983141983152983151983154983156983145983150983143 983154983141983155
Owned by Freeport-McMoRan Copper amp
Gold (51) and CODELCO (49) the ElAbra mine has leachable oxide and sulfide
mineralization The minersquos processing facil-
ity has an annual capacity of 226000 tons
of copper cathode
Smaller size matters
Reducing the size of the crushed oxide
ore from the present 15 mm to 12 mm
was the main target of the mine and the
Metso team The changes that were carried
out in the process included a size varia-
tion change in the cut of the tertiary sieve
installation of rate-level sensors in thesecondary crushers and enabling speed
variables in the conveyor belt feeders of
the secondary crushing circuit
ldquoGoing from 15mm to 12mm may seem
small but the operational impact is very
important and significant for usrdquo explains
Juan Torres Carvajal Metallurgical Engi-
neer at the El Abra mine
ldquoOur goal is to reach 115000 tons with
a minimum of 80 of 12-mm-sized ore permonth The record to date is 105000 tons
and we will increase it until we reach our
project goalrdquo he adds
New design for cone liners
In addition to the work mentioned above
Metso is currently carrying out a project to
design the lining profiles for the secondary
and tertiary crushers of the plant which
will affect the smaller size of the material
In cooperation with Nelson Mella from
Metso and Rodolfo Navarro Crushing
Superintendent at the El Abra mine testswere carried out in July on the re-designed
Metso linings One set was tested for sec-
ondary crushing and two sets for tertiary
crushing
More info
Nelson Mella
Tel +56 99158 0576
nelsonmellametsocom
Finer ore through wear pro1047297lestudy at El Abra mine in ChileEl Abra is a porphyry copper open-pit mine and processing facility located in
Chile near the city of Calama some 4000 meters above sea level With the helpof Metsorsquos technical support the mine was able to achieve finer ore throughoutthe crushing process
TEXT amp PHOTOS Macarena Vallejo
Xewell Cimenteries produces a selec-
tion of dry processed aggregates for con-
crete Operations started at the end of 2009
with the aim of reaching 150000 metric
tons produced per year
Lokotracks chosen to reduce costs
To build up their tracked mobile processXewell Cimenteries decided to buy three
mobile plants from Metso two impactor
plants the Lokotrack LT1110 and LT1213
feeding a three-deck mobile screen the
ST620 The machines were sold by SCAI
SpA Metsorsquos Lokotrack distributor in Italy
ldquoWe chose tracked machines to bet-
ter exploit our quarry and to reduce
costs Mobile plants have low initial costs
because they donrsquot need any special foun-
dations or supply of electricity This obvi-
ously gives us a quicker process set-up and
better uptimerdquo says Alessandro Crestani Technical Director of the Pout quarry
ldquoThe mobile plant can also follow the
quarry face as the exploitation proceeds
reducing the transport costs of raw materi-
als in the same jobsite We chose Metso
because they ensured us the best cost-per-
ton ratiordquo he adds
Good customer service is crucial
According to Alessandro Crestani good
customer service also played a major role
when choosing the manufacturer of the
mobile equipmentldquoMetsorsquos distributor SCAI SpA was able
to provide us with a complete product
support and customer service package
Obviously service is a very important
aspect for us in a country like Senegal Any
downtime represents a clear loss of pro-
ductivity for usrdquo
The average level of productivity of the
mobile Lokotrack process is 200 metric
tons per hour
More info
Carlo Rinolfi Tel +39 335 1253159
crinolfiscaispacom
Example of the development of the Metso study
on the crusher lining profiles
Liner change for smaller ore size in the
MP1000 cone crusher
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Services success in Surabaya The Metso Surabaya workshop and offi ce complex opened in April 2008 provides Life Cycle Services and maintenance
solutions for Metso equipment in the Indonesia region The facility is strategically located in an industrial precinct on theouter rim of Surabaya the second largest city in Indonesia Its close proximity to an international airport major shipping
port and several engineering companies simplifies support for the regionrsquos key customers which include PT Newmont
and PT Freeport
TEXT amp PHOTOS David LeRoy amp Gary Whittred
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983122983141983152983151983154983156983145983150983143 983154983141983155
The Surabaya site operates through Metso
in Australia with assistance from key sales
and technical staff Handling regional ser-vice and repair business in-house allows
Metso to manage intellectual property and
closely control quality
It also enables the development of a
team of skilled service personnel who can
be utilized both internally and at key cus-
tomer sites as is common with the backup
service the workshop provides for screen
contracts
Innovation at work
Since 2008 the Surabaya facility has suc-
cessfully refurbished a wide variety ofcomponents Recently two ball mill heads
weighing 22 tons each were modified in
order to strengthen the 1047298ange of the ball
mill shell The modification included tap-
ping out existing 1047298ange holes and drilling
new ones so that finger plates could be
installed and welded to the 1047298anges
Positioning the head borer to properly
align the new 1047298ange holes proved diffi cult
Four roller support frames were manufac-
tured to support the heads and allow them
to be rotated easily Each hole was then
drilled and tapped at the correct angleusing the CNC five axis head The job had a
tight delivery as it was required for a shut-
down but with advance planning and inno-
vation it was completed ahead of schedule
MP1000 mainframe on
CNC vertical borer
Well equipped for fabricating and machin-
ing heavy components the Surabaya
The Surabaya facility has proven to be
a success for Metso The workshop offers a
wide variety of services in the region Qual-ity products and competitive pricing and
delivery times have led to strong customer
relationships
Turnover and customer service levels
have increased annually since the open-
ing and between 2008 and 2010 sales
increased 450 These excellent trends
are expected to continue as the operation
expands and the customer base grows
Since 2008 the Surabaya facility has
successfully refurbished
bull MP1000 counter shaft boxes headassemblies mainframes bowls adjust-
ment rings counterweights sockets and
tramp release cylinders
bull 7rsquo Symons bowls heads and countershaft
boxes
bull Vertimill screw and drive shafts
bull Ball mill heads
bull Ball mill trommel
bull VPA cylinders
bull Eaton clutches
bull Exciter screen mechanisms
bull 42x65 main shafts and eccentrics
More info
Gary Whittred
Tel +62 31 8430349
garywhittredmetsocom
workshop handles the majority of Metsorsquos
refurbishment work with ease But when
necessary PT PAL ndash a government facilitywith shipbuilding and heavy engineering
capabilities ndash offers a ldquoone stop shoprdquo Spe-
cially trained PT PAL staff ensures that the
work they perform complies with all Metso
specifications and quality standards
PT PAL also demonstrated their innova-
tive ability with the first MP1000 main-
frame refurbishment they completed The
mainframersquos shaft location bore needed
to be re-machined However the distance
from the top of the mainframe to the
tapered bore made it very hard to achieve
an accurate surface finish with the correctstandoff
To overcome this the shop decided to
machine the mainframe upside down and
elevated on support beams They posi-
tioned a new shaft under the mainframe in
a custom-made cradle Using an overhead
crane they could then lsquotrial fitrsquo the shaft in
the bore to make sure it seated correctly
and the mating tapers met specification
The method worked so well it has since
been used for four more mainframe refur-
bishments
Diversity and growth
Today Metso Surabaya continues to invest
in additional equipment in order to diver-
sify its service offering A new hydraulic
power pack which allows the facility to test
refurbished components to Metso specifi-
cations was recently used in the refurbish-
ment and testing of several VPA cylinders
for PT Freeport
Refurbished MP1000 mainframe dispatched by truck to
PT Freeport mine
Machining of MP1000 upper frame
at Metsorsquos Surabaya workshop
Mainframe at vertical CNC machining
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Creating Value with Metso in Hong KongIn Hong Kong the aggregates needed for construction are mostly supplied by two local quarries KWP Quarry Company
Limitedrsquos Anderson Road Quarry accounts for 60ndash70 making it the pillar of Hong Kongrsquos construction materials industry
TEXT amp PHOTOS Ou He
When arriving at the Anderson Road
Quarry the most impressive view at the850000 square-meter facility is the Metso
machines including equipment from the
primary secondary and tertiary crushing
circuits and the screens I t is Metsorsquos equip-
ment that secures the supply of aggregates
for Hong Kong
KWP Quarry Company Limited has been
working with Metso since its establishment
in 1997
Due to Hong Kongrsquos stringent dust and noise control standards Metso has paid special attention to the related suppression systems
ldquoOur quarry mainly lies on granite and
volcanic rock which are so hard they canonly be processed by equipment with
strong durability and stabilityrdquo explains
Mr Eddie Hung Manager of KWP ldquoWith a
long history of and experience in quarry-
ing we are very familiar with the equip-
ment of different brands Comparatively
Metsorsquos products are better than others in
terms of durability stability and effi ciency
Besides this the reason we selected Metso
is because of the simple maintenance of
their equipment and the easy access tomaintenance informationrdquo
Flexible modular solution
Based on extensive experience in crushing
and screening worldwide Metso presented
the Anderson Road Quarry with a modu-
lar solution and delivered it as a turn-key
project Through a four-stage crushing
circuit which contains three Metso C160
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jaw crushers for primary crushing two
Omnicone 1560SX crushers for secondary
crushing two HP 500SX cone crushers for
tertiary crushing and one HP500SX cone
crusher for extra-fine crushing the plant
was able to produce aggregates of optimal
shape with minimal 1047298akiness
The fine products include three sizes
0 to 5 mm 5 to 10 mm and 10 to 20mm
Since the employment of this system in
2000 production has reached 1250 th
which is far beyond the design capacityAccording to Mr Hung ldquoThe machines
always run effi ciently and seldom malfunc-
tion The occasional shutdown of some
machines does not affect production very
much the plant still could reach 60-70
of its normal production It gives us the
best 1047298exibility for the plant rsquos operation and
I believe this is the best feature of Metsorsquos
solution
Eddie Hung
Manager of KWPrsquos
Anderson Road
Quarry is happy with
the product quality
and service provided
by Metso
ldquoMetsorsquos equipment is expensive com-
paratively but in the long run you will find
that the investment is worthwhile on the
whole Metso secures superior stability reli-
ability and fewer downtimes and it guaran-
tees continuous operation and brings us
greater valuerdquo
Great service team
Metso sent a group of service engineers
to the plant within the warranty period
not only to provide service but to train theoperators Mr Hung speaks highly of Met-
sorsquos service team he is impressed with its
experienced experts and with their strong
sense of responsibility and customer-
oriented ways of working
ldquoMetsorsquos service team never fails to find
hidden problems and helps us to prevent
any mechanical failures And they are
available whenever we need them they
work closely with us to solve the problem
effi cientlyrdquo he said
Excellent environment-friendly designIn order to achieve the worldrsquos most strin-
gent noise and dust control standards
developed by the Environment Protection
Department of Hong Kong Metso has
incorporated a dust and noise suppression
system into the plant This includes the
infrared-triggered spray systems at feed
points encapsulation of individual crush-
ers and conveyors and the ability to select
specific sectors of the system for treatment
depending on feed and operating condi-
tions encapsulation of equipment and the
enclosure of all major sections of the plant
With these advanced environment-
friendly solutions Anderson Road Quarry
has won numerous safety and environmen-
tal awards In 2003 it was presented with a
silver medal in the prestigious Environmen-
tal Performance Awards in recognition of
its commitment to the environment and
community In 2004 KWP achieved certifi-cation of ISO 14001 it is the first quarry site
to have achieved this in Hong Kong and
southern China
ldquoA reliable partnerrdquo
The promulgation of the top ten infrastruc-
ture policies in Hong Kong boosted the
market for aggregates and demand will
keep rising over the next five to six years
ldquoWersquoll definitely keep our cooperation with
Metso once we have a need for expansion
because we regard Metso as a reliable part-
ner With their highly effi cient equipmentsatisfying service and great efforts in help-
ing us to achieve our environmental pro-
tection targets Metso is our best choicerdquo
says Hung
More info
Ziqiang Li
Tel +86 13601289027
ziqianglimetsocom
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
The sturdy Metso C160
jaw crushers are fed
using huge feed chutes
and feeders
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983122983141983152983151983154983156983145983150983143 983154983141983155
Similar to hundreds of mine sites world-
wide Zinkgruvan is being operated on a
non-stop 247 basis with just a few main-
tenance breaks during the year Crusher
availability is crucial because 100 of the
ore has to pass through the jaws before
being hoisted up for further processing
In addition to the zinc- lead- copper-
and silver-containing ore the C jaws chop
all the host rock extracted along the min-
ing process With a sturdy design Metsorsquos
proven C jaws can easily reduce even the
hardest type of rock Every year more thanone million tons are crushed with the jaws
ldquoMinimal service neededrdquo
Crushing with the first C160B jaw crusher
began at Zinkgruvanrsquos -800 meter level in
2000 with the primary crushing of zinc-lead
ore The second jaw was installed in 2008
for the new copper process gt
The sight and sound of two C160 jaw crushers operating side by side in the underground
crushing station of the Swedish Zinkgruvan mine is impressive Good proactive service
secures good uptime and reliable continuous operation of Metsorsquos second-largest
C160 series jaw crushers and prepares the way for the ongoing plans to expand the
production of zinc concentrate
TEXT amp PHOTOS Eero Haumlmaumllaumlinen
New PolyMet liners are being tested with the grinding mill delivered by Metso
Zinkgruvanrsquos twin C160
jaws secure good uptime
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Blasted ore is taken from the presently
operated -850 meter level with normal
trucks as an outsourced process One full
truckload is fed to the C160s every
10 minutes
ldquoWe are happy with the high reliability
of the C jaws They only require some minor
service therefore providing us with good
uptime and steady continuous feed to our
secondary and tertiary crushing and grind-ing circuitsrdquo says Mine Manager Jan Klaumlre
ldquoBasic crusher service and wear part
changes are made by our own staff using
Metsorsquos partsrdquo he adds
Service contract with grinding
mills and conveyors
Zinkgruvan and Metso Sweden have more
than 11 yearsrsquo experience with a service
contract that contains grinding mills and
conveyors At the mine site two Metso
service people and one contractor take
care of all the related service jobs Man-
power can also be borrowed from Metsorsquos
Graumlngesberg mine service team of 20
people
Presently Zinkgruvan is testing Metsorsquos
new PolyMet mill linings in its big grinding
mills With previously used rubber partsthe linings had to be changed in the shell
every 9 to 11 months and in the feed head
every 6 months
ldquoWe expect a better lifetime with Poly-
Met linings Longer change intervals mean
a lot to our productivity because lining
changes takes two full working daysrdquo Mine
Manager Jan Klaumlre says
New mine goes deeper
With an expected mine life of more than 10
years Zinkgruvan is actively mapping new
ore reserves Experimental holes are being
drilled at the new mine section at the
-1110 meter level
More info
Fredrik Wennberg
Tel +46 70 657 00 08fredrikwennbergmetsocom
Mine Manager Jan Klaumlre (left) with Backfilling Manager Kjell Tillman at the underground -800 meter level mine cafeteria
983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
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The Zinkgruvan mine located approxi-
mately 200 km southwest of Stockholm
Sweden is one of the oldest underground
mines in Northern Europe The mine has
been in production since 1857
The mining methods used are panel
stoping and benching The processing
facilities include a zinc concentrating plant
with a 11 mtpa and a copper plant with a04 mtpa capacity Tailings are recycled in
an impounding basin and host rock in the
backfill plant
Continuous mining since 1857
Even as one of the oldest mines in Northern
Europe Zinkgruvan exploits modern mining
and minerals processing installations
Zinkgruvan mine
OWNER Lundin Mining
PRODUCTION PER YEAR 1 million tons
ORE TYPE sedimentary exhalative
zinc lead copper and silver
NUMBER OF EMPLOYEES 320
2011 PRODUCTION TARGETS 78000 tonsof zinc 36000 tons of lead and
3400 tons of copper concentrate
METSO EQUIPMENT ON SITE
bull 1 extra long VF feeder
bull 2 C160 jaw crushers
ndash zinc process css 220ndash240 mm
ndash copper process css 150 mm
bull 1 GP300S cone crusher
ndash css 45mm
bull 1 HP4 cone crusher
ndash css 18 mm
bull 1 DS screen
bull 1 FS402 screenbull 1 grinding mill
bull Pumps VPAs
A normal truck feeds the C jaws with ore coming from the lower production levels
983122983141983152983151983154983156983145983150983143 983154983141983155
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Cost-per-ton wear agreements deepencustomer relationshipsCrusher wear parts are traditionally marketed purely based on transactional sales and mainly depend on
the weight of manganese Metso has recently introduced a new type of wear agreement based on thecost-per-ton crushed and the wear occurred Thus far the experience has been very positive increasing
transparency and deepening the operational relationship between the manufacturer and the customer
TEXT Olli Kellokumpu and Eero Haumlmaumllaumlinen PHOTOS Eero Haumlmaumllaumlinen
Arto Hiedanniemi (left)
Hannu Heman and Juha
Laukka of Metsorsquos Finnish
Service team checking the
cone crusher mantles shipped
for a cost-per-ton customer
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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156
Wear parts and parts changes
can be included
The structure of a cost-per-ton wearcontract is based on the number of tons
crushed and the estimated wear occurred
The amount and monetary value of the
wear is calculated per crushed ton
ldquoEither plain wear parts or parts changes
carried out by Metsorsquos service personnel
can be included in the contract In the latter
case we ask our Finnish customers to inform
us about an upcoming wear change opera-
tion one week in advancerdquo Heman explains
ldquoWe see good opportunities to market
cost-per-ton contracts further in Finland
and also abroad It really develops therelationship of Metso and our customers
towards a trusted partnershiprdquo he notes
Perfect tool for accurate planning
Soraliike Ikola Oy is a mid-sized contrac-
tor with three Metso two- and three-
stage mobile and portable crushing and
screening plants operating in Central and
Since 2002 Metsorsquos sales team in Finland
has developed the cost-per-ton-based
service offeringldquoOur aim has been to seek through
a cost-per-ton offering possibilities to
serve our customers better to differentiate
Metso from the other players as an OEM
manufacturer and to offer deeper profes-
sionalism and know-howrdquo says Hannu
Heman General Manager of service
operations
ldquoUntil now both our experience and
that of our customers has been quite posi-
tive When properly prepared cost-per-ton
contracts seem to create a win-win situa-
tionrdquo Heman adds Today Metso has operational cost-per-
ton agreements with several Finnish cus-
tomers The first contract was concluded
with a customer operating a stationary
plant Based on the results gathered new
cost-per-ton contracts have been signed
with customers operating wheeled and
tracked equipment too
Eastern Finland Because of the size of the
contracts up to 50 equipment moves are
made during the yearEntrepreneur Pasi Ikola has had a cost-
per-ton contract with Metso for nearly
two years and he is quite happy with the
outcome
ldquoThe cost-per-ton contract has provided
me with a perfect tool for accurate financial
planning Now I know in detail my actual
future wear parts costs This helps a lot
when calculating bidsrdquo
ldquoEarlier I used to buy a big batch of
Metso wear parts in one go and had to
reserve a reasonable amount of money for
that Today all wear costs are evenly sharedwhich gives us a welcomed 1047298exibility to
our cost structure Now we just pay Metso
afterwards based on our crushed tonsrdquo
he adds
More info
Olli Kellokumpu
Tel +358 50 354 1189
ollikellokumpumetsocom
According to crushing contractor Pasi Ikola the cost-per-ton contract with Metso has provided the entrepreneur with better economical 1047298exibility
and more accurate calculating of bids
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Pleasant Gap is owned and operated by
Glenn O Hawbaker Inc of State College
Pennsylvania This family-owned company
began in 1952 as a small excavation busi-
ness founded by Glenn O Hawbaker and
his wife Thelma Over the years the com-
pany grew by adding an integrated mix ofproducts and services and taking on larger
projects
In 1983 Hawbaker acquired Pleasant
Gap Quarry and built its first aggregates
processing plant Today Glenn O Haw-
baker Inc operates 21 quarries and eight
asphalt production facilities across Penn-
sylvania and southern New York as well as
five regional operation centers
Primary
challenge atPleasant GapQuarryA good part of what makes for a successful crushing
operation is the willingness to tackle challenges and to do
whatrsquos necessary to meet demand The team at Pleasant
Gap Quarry in central Pennsylvania recently met the chal-
lenge when they successfully addressed problems with
the plantrsquos primary crushing plant First they purchased
a new Metso C160 jaw to replace the existing primary
impact crusher Then they devised an innovative plan to
get the primary plant back in operation while awaitingdelivery of the new jaw crusher
TEXT Linda Bergmann PHOTOS John Rickinger
983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Time for a change
With the goal of increasing reliability and
output the management at Pleasant Gap
Quarry recently decided it was time to
replace the plantrsquos primary impact crusher
Following a thorough search they chose a
new Metso C160 jaw According to ScottReck Plant Manager it no longer made
sense to repair and rebuild the existing
impactor
ldquoBefore we purchased the Metso C160
we had a few other impact crushers and
they served us well but as our custom-
ersrsquo needs increased our plant production
had to match that demand We found our
formerly reliable unit was being overcome
by our demands for output and creative
work-around solutions We continued to
need more but there was only so much we
could do until we hit the breaking point ndash
literallyrdquo
In addition to performance improve-
ments the new crusher also needed to fitinto Pleasant Gaprsquos unique infrastructure
As Plant Project ManagerEngineer Jeremy
Fahr explains ldquoOur height restraint was 274
meters (108rdquo) This height was the distance
from the feed lip of the existing 6x12 scalp-
ing screen and the existing structure that
the crusher rests onrdquo
The normal C160 crusher is 307
meters (121rdquo) tall but Metso gave GOH
Scott Reck Plant Manager (left) and
Jeremy Fahr Plant Project Manager
Engineer at Pleasant Gap Quarry
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983122983141983152983151983154983156983145983150983143 983154983141983155
a 10-degree mounting option (which is
normally used on their portable crushers)
to overcome the height restraint Reck and
Fahr worked with Dave Rhoa of Cleveland
Brothers Equipment Metsorsquos crushing and
screening distributor in Pennsylvania to
pull everything together and fit the newcrusher into their plant
The C160 crusher selected for Pleasant
Gap is one of the latest models in Metsorsquos
C Series of jaws These jaw crushers feature
a large throw and steep toggle plate angle
resulting in a higher crusher output In
addition the C Series has a compact foot-
print that makes it an ideal choice for the
replacement of existing machines
According to Reck ldquoWe had heard about
the new Metso C160 and started doing our
own research and found Metso not only
had developed the output capacity we
needed but fit the uniqueness of our oper-
ationsrdquo The new Metso crusher will allow
the plant to increase tons per hour andgive them the 1047298exibility to meet demands
for varying products on short notice
Mobile solution
Purchasing the new primary jaw addressed
the long-term issues but still left Pleasant
Gap without a functioning primary plant
Reck continues ldquoOur main line was still
down leaving us with a big hole in hitting
customer needs but knowing that our new
Metso C160 was on its wayhellipwe needed an
immediate solution to keep our produc-
tion demands with an out-of-commission
crusherrdquo
The team at Pleasant Gap brainstormed
the problem and came up with a plan toget the primary plant back in operation
Their solution was to use the Lokotrack
LT1213 impactor plant and another mobile
unit to keep the main line crushing To do
this they removed the guts on the existing
impact crusher essentially turning it into a
rock chute They then moved the LT1213
and another manufacturerrsquos mobile unit
over to the existing dump hopper gt
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ldquoWe had our haul trucks drop off mate-
rial while two excavators fed the two
mobile unitsrdquo Reck explains ldquoFor two-and-
a-half months the Lokotrack LT1213 unit
was producing 254 cm (10rdquo) minus at
700 tons per hour The other similar-sized
mobile unit was doing 400 tons an hour
maxed out The difference was unbeliev-
able to say the least Our unique solution
using the two mobile units especially the
LT1213 helped Glenn O Hawbaker achieve
a record output in 2010rdquoAccording to Fahr ldquoWe were not new to
Metsorsquos quality and supportrdquo because GOH
had been using Metsorsquos portable crushing
equipment for 3 years prior to the primary
plantrsquos impact crusher failure In another
part of our operation we have a system that
our team relies on every day a Lokotrack
LT1213 and ST272 working in tandem with
two portable conveyorsrdquo This highly effi -
cient mobile processing system turns out
300 tons of specialized blended material
per hour GOH has been so impressed with
Metso equipment its last two purchaseswere an LT106 tracked jaw plant and a
second ST272 mobile screen in 2010
Maintaining high productivity
The Metso C160 jaw was delivered to Pleas-
ant Gap Quarry in January of 2011 and
since start-up it has more than met expec-
tations The crusher is fed minus 910 mm
(36rdquo) limestone with the jaw set at 140 mm
(5 12rdquo) According to Reck ldquoFrom moment
we started up we knew we had a winner
Not only were we kicking out as much
product as our previous units without even
breathing hard but we immediately had a
2-cent per ton savings to the bottom line
without having to run a second 350 HP
motor as required by other units Plus by
adding on the new automatic lube system
the maintenance team had more time to
devote to keeping other areas of the com-
plex running more effi cientlyrdquoReck says ldquoThe Metso unit was a perfect
fit and with the improved features it pre-
sented it had it all We just turn it on load
it up and we are moving 600 tons per hour
through the crusher without any effort and
we know it can do so much morerdquo With
the primary crushing plant back in opera-
tion the entire team at Pleasant Gap will
continue to do what they do best produce
and sell high-quality products and meet
their customersrsquo expectations
More info
Scott Yablonsky Tel +1 262 717 793
scottyablonskymetsocom
The Metso C160 jaw
was installed at a 10deg
angle to fit Pleasant
Gaprsquos existing
infrastructure
The Lokotrack LT1213 impactor plant and ST272 mobile screen operate in tandem with two
portable conveyors at Pleasant Gap
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983149983141983156983155983151 983150
Paper amp fiberNew OptiConcept M paper
and board making line
The new OptiConcept M paper and board
making line stands for economy safety and
usability
Metso has launched a new modular paper
and board making line called OptiConceptM A member of the proven OptiConcept
production line family the new OptiCon-
cept M optimizes machine investment in
line with each millrsquos capacity needs
Savings in operating costs are achieved
through precise dimensioning of pro-
cesses proven technological solutions
optimal running parameters effective
maintenance operations and fully inte-
grated automation solutions
Optimized processes innovations
smart controls and accurate dimensioning
decrease the use of steam gas electricitywater chemicals and other raw materials
and reduce emission levels
OptiConcept M has been designed
both visually and physically with the
requirements of users in mind For exam-
ple the design of the machinery allows for
easy and safe changing of rolls and wear
parts thus reducing the total duration and
cost of maintenance shutdowns
RecyclingGreen energy technology to
Elektrociepłownia Białystok in Poland
Metso will convert a coal-fired boiler to
a biomass-fired Bubbling Fluidized Bed
boiler for Elektrociepłownia Białystok SArsquos
combined heat and power plant (CHP) in
Białystok Poland The new boiler system
will cut the power plantrsquos CO2 emissions
significantly by partly replacing the coal
fuel supply with biomass fuel
ldquoPoland is one of the largest countries
in Europe to have such a high depend-ence on energy derived from coal to
meet national electricity needs This is an
important incentive for us to reduce future
CO2 emissions and produce more green
electricity and with Metso technology
we are certain to accomplish our goalrdquo
states Mr Andrzej Schroeder President of
Elektrociepłownia Białystok SA
Since 2000 Metso has received a total
of 7 biomass boiler conversion orders in
Poland and the renewable energy share
in Poland is only 75 (2010) compared to
the target of 20 by 2020 set by the EUApproximately 80 of the current energy
boilers turbines and generators installed in
Polish power plants are over 20 years old In
order to meet the strict EU environmental
requirements modernization of existing
installations is necessary
Automation
Metso DNA automation system expands
to mining and construction
Using Metsorsquos control room automation
an entire crushing and screening plant can
be effi ciently managed
Metso is a leading supplier of mining and
construction machinery This expertise has
now been combined with a scalable Metso
DNA automation system that adapts to
the range of industry needs from single
machine controls to plant-wide automation
and information management systems
An example of Metsorsquos new offering is a
new crushing plant control room solution
that connects crushers and screens ensur-
ing the effective management of the entire
plant from a pleasant and safe control
room The Metso DNA user interface pro-vides the production information to ensure
a proper and rapid response to plant
events Automatic controls stabilize the
process and allow the operators to monitor
the plant as a whole
ldquoThe benefits of automation for the min-
ing and construction industry are signifi-
cant As an example of the services we offer
performance studies to crushing plants
utilizing Metsorsquos multi-disciplinary teams of
experts to determine the present level of
the plant and process effi ciency and to esti-
mate the improvement potential and thebenefits of optimization and automation
including ROI calculationsrdquo says Mikko Maumlki-
nen Product Manager of minerals applica-
tions in Metsorsquos Automation business line
ldquoAs another example our machine
condition monitoring solutions can reduce
plant and machine downtimes as well as
help to avoid safety and environmental
hazardsrdquo he adds
Metso around the world
Aerial view of the Elektrociepłownia Białystok combined heat and power plant in Poland
8202019 Metso Minerals Aggregates 3 2011
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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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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155
The new Metso C120 jaw crusher combines effi ciency versatility and safety
Metsorsquos new C120 jaw crusher made its worldwide debut at the Steinexpo exhibition in Germany
New products
Metso is proud to announce that we have developed the first fully
recyclable modular screening media ndash Metso Trellex LS-Eco
In response to customer requests for sustainable and environ-
mentally friendly screening media solutions and in line with our
own sustainability program we have taken the acclaimed Metso Trellex LS rubber modular screening media systems and success-
fully replaced the traditional steel reinforcement with an environ-
mentally friendly composite material This unique solution makes it
possible to effectively recycle our customersrsquo screening media
In the past screening media modules that were no longer
suitable for production were treated as waste and could not be
recycled Metso has introduced a new future for the product and a
sustainable solution
Sustainable solution for screening media
Metso has launched the
first fully recyclable
modular screening
media ndash Metso
Trellex LS-Eco
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Metsorsquos Mining and Construction Technology has introduced the
Metso C120 jaw crusher ndash the 13th member of the field-proven
C-series range of crushers The C120 combines uncompromising
reliability crushing effi ciency and versatility in both stationary and
mobile applications with safety and ease of use
Even at first glance it is clear that Metso has paid special atten-
tion to the C120rsquos new durable and user-friendly design start-
ing with the casting the design of which is based on thorough
FEA analysis and casting simulations Every detail of the C120 is
engineered for reliable operation and long life resulting in high
constant crushing capacity and uptime
ldquoWhen starting the C120 project we listened closely to our cus-
tomers and collected field data from a number of sites Based onthat information we decided to design the crusher cavity and kin-
ematics first As a result Metso can now offer aggregates produc-
ers large-scale contractors and mining companies a new crusher
that meets all the standards set for any demanding applicationrdquo
says Ilkka Somero Metsorsquos Product Manager for jaw crushers
New design brings outstanding productivity
The outstanding productivity of the C120 is guaranteed thanks
to several new design elements The crusher features a long and
aggressively directed stroke and a fixed jaw die longer than previ-
ously seen in this crusher size class The C120 has a large feed
opening of 1200 x 870 mm (34 x 47rsquorsquo) and an aggressive cavity cross
section securing a high per formance and reduction ratioIn terms of cavity volume and crusher weight the C120 is posi-
tioned between the existing Metso C116 and C125 jaw crusher
models
The Metso C120rsquos nominal power is 160 kW (200 HP) operating
speed 230 rpm closed side setting between 70 ndash 200 mm (2 34rsquorsquo
ndash 8rsquorsquo) The operational weight is 26000 kg (57200 lbs) excluding
options
More infoIlkka Somero
Tel + 358 50 317 0769
Ilkkasomerometsocom
The optional robust composite 1047298ywheel guards allow quick and safe
access to the service points
983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156
In addition to providing environmentally friendly screening
media panels Metso will implement a unique program to provide
its customers with a suitable range of recycling services
The Metso Trellex LS-Eco offers a wide range of health safety
and environmental benefits Each screening media panel is up to40 lighter than standard steel reinforced Trellex LS panels This
makes handling easier and the working environment safer Lighter
panels also help to reduce the overall stress on the entire screening
installation
Compared to steel-reinforced panels the composite-reinforced
panels of the Metso Trellex LS-Eco are more 1047298exible and will reduce
the effects of pegging and blinding during screening operations
The Metso Trellex LS-Eco promises reduced downtime and
increased productivity
The Trellex 300LS and Trellex 305LS rubber and polyurethane
panels are already acclaimed worldwide as being among the most
versatile modular screening media solutions They can be attached
to most screening media systems and can handle all types of
screening applications ndash fine and coarse wet and dry In the futurewhen Metso customers need new screening media panels for
their existing system they can choose Metso Trellex LS-Eco and be
assured that their panels will be safely and effectively recycled
More info
Claes Larsson
Tel +46 410 525 73
claeslarssonmetsocom
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The new Lokotrack LT120 with its world premiere at the Steinexpo
exhibition in Germany combines crushing performance and user-
friendly design in a new revolutionary way For the first time the
same Lokotrack model is now available in a hydraulically or electri-
cally driven version to meet customer needs
New Lokotrack LT120 jaw plant introduced
Lokotrack LT120 is the latest and most advanced of Metsorsquos track-mounted jaw crusher plants
Lokotrack LT120 combines user-friendly design and good crushing
performance in a new way
power supply or a 420-kV onboard diesel generator Having the
possibility to use an external power supply enables a highly eco-
nomical and ecological crushing process
The Lokotrack LT120 is built around the new C120 jaw crusher
See page 10 for information about the C120
Safe to use move and service
Safety is the highest priority for Metso when designing new equip-ment The Lokotrack LT120 is designed to be safe to operate move
and service
ldquoA safe operating environment is created by practical solutions
When service points can be reached easily the possibility of dan-
gerous situations diminishesrdquo says Product Manager Timo Nakari
ldquoGood examples of safety built in to the Lokotrack LT120 include
sturdy easy-to-open composite 1047298ywheel guards and hydraulically
folding and locking feed hopper sidesrdquo Nakari adds
The Lokotrack LT120 can be fine-tuned to suit the customerrsquos
application by selecting the required options from a long main
conveyor and hammer and boom to a water spraying system and
rubber lining for the feeder and hopper for example
The Lokotrack LT120 features a Caterpillar C13 310 kW (415 hp)engine Its transport dimensions are length 16 m (52rsquo 6rdquo) width 3 m
(9rsquo10rdquo) height 39 m (12rsquo 10rdquo) and weight 57 tons (114000 lbs) The
LT120E version weighs 63 tons (126000 lbs)
More info
Timo Nakari
Tel + 358 40 701 6143
timonakarimetsocom
983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155
The Lokotrack LT120 uses the same field-proven technology
seen in Metsorsquos tracked units for over 26 years Every detail of thenew jaw plant has been thoroughly designed for reliability and
long life The main targets when designing the unit have been
energy effi ciency good performance reliability and product safety
Field tests have demonstrated its good fuel economy and high
crushing capacity
Environment-friendly economy
The Lokotrack LT120 is also available as an electrically driven unit
ndash the Lokotrack LT120E ndash which can take energy from an external
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The TS range of screens is characterized by its innovative design
comprising two technologies combined multi-variable slopes with
a variable elliptical motion This proven range is being comple-
mented with the new TS63 screen
The TS63rsquos unique combination increases both the screenrsquos effi -
ciency and its capacity Material speed is high at the feed end and
slows down at the discharge end
Metso TS series screens offer more space between decks mak-
ing maintenance easier and improving service conditions for the
operators as well as meeting all safety requirements
Metso has recently sold several 25-m2 multi-slope screens for
mining applications such as a TS63 for Ferrostaal in Mauritania andalso for the construction industry for example Holcim in Lynwood
Australia Georyt in Poland Apaxco in Mexico and Newmont in
Peru
More info
Denis Pradon
Tel +33 680 64 39 67
denispradonmetsocom
New TS63 screen ndash the largest three-deck banana screen on the market
The new Metso TS63 banana screen features a 25-m2 screening area
Following the success of the HP4 and HP5 Metso has broadened
the product range with the new HP3 cone crusher This mid-range
cone crusher benefits from 70+ years of experience in crushing
technology while specifically addressing customer requirements
for large capacity ease of operation and a high reduction ratio
The HP3 responds to market demands for increased productionquality reduced maintenance time and low operating costs The
new generation HP models are comparable to their predecessors
but offer increased versatility
The HP3 features the size of an HP200 with the output of an
HP300 The power performance and robustness of the new gen-
eration models allow in certain cases two crushers to be replaced
with just one so investment production and operation costs are
greatly reduced
The HP3 has been tested at two different quarry sites in France
over the past seven months ndash at a gravel pit and a rock quarry
The Metso factory in France began production of the HP3
series in September Several orders have already been received for
secondary and tertiary applications Since 2009 nearly 300 HP newgeneration cone crushers have been commissioned The HP3 mar-
ket will be primarily centered on gravel pit applications (70)
The HP3 has a nominal feed opening of 220 mm (865rsquorsquo) a
motor size of up to 220 kW (300 hp) and a weight of 13280 kg
(29277 lbs)
More info
Carlos Padin
Tel +33 6 0727 2002
carlospadinmetsocomMetso HP3 at a stationary installation in France
HP3 cone ndash another new-generation cone crusher
983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
First modular plant to NepalMetso delivered its first modular crushing and screening plant to MS Palchowke Mai Roda Dunga Udyog Limited (PMRD)
in Melamchi Nepal The modular plant solution offers PMRD a fast and effective response to productivity and qualityrequirements
TEXT amp PHOTOS Atoshi Nayak Ghosh
The diversity of operations at a typical con-
struction site involves quick decision-mak-
ing and often a lot of pressure to ensure a
timely execution
High performance guaranteed
Considering todayrsquos volatile market sce-
nario business partners must maintainpace with their customersrsquo ever-changing
requirements Understanding custom-
ersrsquo strategic business needs is of utmost
importance PMRDrsquos plant was commis-
sioned in January 2011 and has logged
about 1200 hours of operation to date
The plant is much more compact than
the traditional skid-mounted plant and
provides space for free movement of utility
equipment within the plant area One of
the key features of the plant is the totally
bolted structure It can be easily disman-
tled into sub-assemblies transported and
re-assembled effortlessly at a new location
which is one of the biggest advantages in
helping to meet new market demand
Due to the use of pre-assembled mod-ules for each crushing station the instal-
lation work on site takes less time thus
decreasing the plantrsquos installation lead time
The plant also includes a foldable conveyor
for maintenance of the cone crushers
Stepping up with Metso
PMRD operates a two-stage plant compris-
ing a C80 jaw crusher an HP200 high-
performance cone crusher and a CVB1845
screen with circular motion MV2 vibra-
tory mechanism for final product recovery
resulting in an aggregate plant of 150 tph
capacity for producing size fractions of 0-40
mm The plant is an example of world-class
craftsmanship and excellent material han-
dling capacityModular and non-welded construction
supported by durable pitman assembly sin-
gle-piece cast steel frame bearing housings
with repairable crusher construction and
the right cavity design results in aggressive
kinematics and high power that best suits
the requirements of the customer
PMRD has immense pride in the plant
ldquoThe performance has been astounding
A drawing of typical modular plant
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983122983141983152983151983154983156983145983150983143 983154983141983155
with applications ranging from road aggre-
gates commercial sand production to
ready-mix concretes The modular plant is
almost set to create a new niche in aggre-
gates processing in Nepalrsquos construction
industry It is one of a kind and we are sur-
prised at the plant rsquos production capacity
It is easy to operate and requires minimalmanpower Our cost per ton has signifi-
cantly gone down and so has the cost of
productionrdquo says Mr Sandeep K Agarwal
Director PMRD
Safety as a key issue
Health safety and environmental solutions
are key concerns for Metso and they are
addressed with the same sense of responsi-
bility as quality productivity and cost-
effi ciency issues Metso is responsible for
conducting operations in an environmen-
tally sound way and offers products and
services that can help customers fulfill their
environmental responsibilities
Metso provides the plant offi ce and site
with operation and maintenance manu-als for each and every piece of equipment
including safety issues which are entrusted
to all the operators
All conveyors are equipped with pull-
cord safety switches along with emergency
stop buttons The working area and walk-
ways are all equipped with safety hand rails
and checkered plates for anti-skidding The
entire plant is equipped with earth pits for
electrical current earth leakage prevention
Metso has ensured all possible measures
to maintain high safety standards for all
operation and maintenance personnel
More info
Suhen Agarwal
Tel +91 124 2351566suhenagarwalmetsocom
Nepalrsquos first modularcrushing and screening plant deliv ered by Metso
E ffi cien t C VB1845 inclined screen wi th
an M V2 vibra tor y mechanism handles
the classi fica tion o f crushed ma terials
A s turd y f eeder dis tribu tes the ma terials to be crushed to
a
Me tso C80 ja w crusher
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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155
Outokumpursquos Kemi
mine set to doubleproduction The only mine unit owned by Outokumpu
the chrome mine in Kemi northern Finland
is busy making preparations to double its
production set to begin next year In co-
operation with Metso Outokumpu willincrease the number of underground
feeders and optimize the durabil-
ity of wear parts in the massive
primary gyratory crusher
TEXT amp PHOTOS Eero Haumlmaumllaumlinen
Chrome ore is fed into Metsorsquos
Superiorreg 50-65 primary
gyratory crusher by three
different vibrating feeders
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Up until now the entire production of the
chrome mine totaling about 13 million
tons annually has been transported to the
Tornio ferrochrome plant for processing
and on to the Tornio stainless steel plant
The increase in production which will
begin in autumn 2012 is intended also to
enable Outokumpu to sell ferrochrome tocompanies outside the Group The produc-
tion target for 2013 is 27 million tons of
ore and of the ferrochrome produced from
the ore nearly a half (gt 200000 tons) is to
be sold outside
Underground expansion
work almost complete
About 500 meters underground the
majority of the work involved in increasing
the capacity the F3 project has already
been completed Doubling the production
is no problem for the Superiorreg primarygyratory crusher delivered to the mine
by Metso in 2002 which can digest more
than 2700 tons of feed material per hour if
necessary
At the moment the primary gyratory
crusher can be fed by three different vibrat-
ing feeders The crusher currently runs for
less than one-fifth of the production time
The increase in ore production will increase
the effective crushing time to about one-
third of the production time
A lot of work has been done for orestorage after the primary crusher The
two currently used storage silos are now
accompanied by two new 8000-ton silos
The number of Metso feeders transporting
the ore from the primary crusher has also
been doubled
Optimization of wear parts under way
Chrome ore has been a challenge to the
primary gyratory crusherrsquos wear parts The
wear is contributed to by the pulsating
feed which rarely fills the entire crushing
chamber There are also great differences inore type since brittle feed material prone
to chalking is occasionally replaced by hard
ore that requires a lot of crushing power
before it is crushed with a bang gt
Mika Saari (right) Foreman of ore line technicians at Outokumpursquos chrome mine in conversation with
Mikko Malkamaumlki Metsorsquos crusher wear parts specialist
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
last did in July for the replacement of the
crusherrsquos wear parts Our work is also facili-
tated by product development like the
addition of maintenance hatches to the
feedersrdquo he continues
Lasting technology
According to Mika Saarirsquos calculations the
Superiorreg primary gyratory crusher has so
far crushed more than six million tons of
ore in totalldquoThe factory polishing marks still show
on the bottom thrust bearing so we
believe that the bearing will last the entire
remaining service life of the crusher which
is about ten years and 30 million tons
Metsorsquos feeders have been equally reliablerdquo
Saari says
After the next 30 million tons of ore
it will be time to deepen the mine
More info
Jukka Raumlisaumlnen
Tel +358 50 317 1787 jukkaraisanenmetsocom
Mikko Malkamaumlki
Tel + 358 40 827 8223
mikkomalkamakimetsocom
The Kemi mine and Metso are currently
carrying out a development project to
increase the service life of the mantle and
outer concave and thus minimize down-
time due to replacement While the modu-
lar feed hopper enables quick replacement
of the mantle replacing the outer concave
can easily take more than a week The cooperation between the Kemi
mine and Metsorsquos wear parts team in
Tampere aims to extend the service life
of the parts to at least 4 million crushed
tons Durability is sought by optimizing the
chamber structure and selecting the r ight
materials for the outer concave
ldquoSmooth cooperationrdquo
Mika Saari Foreman of ore line technicians
working in the underground mainte-
nance of the Kemi mine leads a small but
experienced team of technicians The tidymodern offi ce spaces are located close to
the action at a depth of 500 meters
ldquoCooperation with Metso has been
smooth Increasing our own crushing
expertise takes time so all know-how
shared by the manufacturer is very wel-
come to usrdquo Mika Saari says
ldquoWe can also use Metsorsquos profession-
als for servicing when necessary like we
The Superiorreg 50-65 has provided reliable
crushing performance at a depth of 500 metres
in the Kemi chrome mine
Technicians Sari Kulju (left) and Marko Jaako ensure that the primary gyratory crusherrsquos hydraulicand electrical unit remains very tidy which contributes to trouble-free operation of the crusher
Outokumpu Oyrsquos Kemi
chrome mine
LOCATION Keminmaa northern
Finland
ORE TYPE chrome oxide (26)
ORE ESTIMATE ON 1 JANUARY 2011
ndash ore reserves 36 million tons
ndash mineral resources 87 million
tons
MINING METHOD bench and cut fillFEED MATERIAL SIZE 0ndash1000 mm
METSO EQUIPMENT IN THE MINE
bull 1 Superiorreg 50-65 primary
gyratory crusher
ndash open side setting 152 cm (6rdquo)
bull 8 VMOU 25-125 feeders
bull 1 VMOU 30-16 feeder
bull 1 VMOU 40125 feeder
bull 2 Symons cone crushers
bull 1 C80 jaw crusher
bull 4 HM75 pumps
bull 11HM100 pumps
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983122983141983152983151983154983156983145983150983143 983154983141983155
Metso was responsible for the design
development and construction of the
entire secondary and tertiary arrangement
The primary station will be the subject of a
subsequent investment
Latest environmental protection used
This installation has been designed in strict
compliance with the environmental quality
approach developed by Metso and its
partners using the latest technologies
in dust control including confinement
technology as well as dust encapsulation
technology for screens
To ensure an annual capacity of 15 mil-lion tons for a nominal output of 560th of
02 mm and 220 mm the clientrsquos choice
for the secondary stage naturally fell upon
the NP 1520 impact crusher
A complete impact crusher solution for Lafarge The Lafarge Group has entrusted Metso with the implementation of its new aggregates installation in southern France
It comprises a new secondary crushing stage equipped with an NP1520 impact crusher featuring a power range of2 x 250kW and equipped with hydraulic adjustment
TEXT amp PHOTO Gilles Dombey
The NP 1520 crusher has long proved
its performance not only in terms of capac-
ity and reduction rate but also quality of
the finished product and durability
More info
Arnaud Bertucat
Tel +33 (0)6 81 44 68 26
arnaudbertucatmetsocom
About 15 million tons of aggregates feed will be crushed with the NP1520 impact crusher at Lafargersquos stationary installation in southern France
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Multi-stage Lokotrack process a success in Senegal
A multi-stage crushing and screening process has proven its effi ciency in the production of concrete aggregates in
Senegal Western Africa With the mobile process Xewell Cimenteries SA now exploits its quarry better has reduced
its operating costs and can meet strict environmental requirements
TEXT Elisabetta Cataluffi PHOTOS Carlo Rinolfi
Senegal is a rapidly developing country
offering a good deal of potential activities
for crushing companies too At the sametime the country has several areas of high
environmental value Therefore contractors
must opt for state-of-the-art equipment that
offers reduced environmental emissions
The company Xewell Cimenteries SA
was founded in 2008 as a partnership
between Italian Swiss and Senegalesecontractors Xewell operates a limestone
quarry located in the Pout area east of the
capital city of Dakar
According to Alessandro Crestani Technical
Director of the Pout quarry a mobile process
was selected to better exploit the quarry and
reduce costsLokotrack process drawing made by Bruno simulation software
After assembling the Lokotrack units the process was tested by Xewell Cimenteries
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983122983141983152983151983154983156983145983150983143 983154983141983155
Owned by Freeport-McMoRan Copper amp
Gold (51) and CODELCO (49) the ElAbra mine has leachable oxide and sulfide
mineralization The minersquos processing facil-
ity has an annual capacity of 226000 tons
of copper cathode
Smaller size matters
Reducing the size of the crushed oxide
ore from the present 15 mm to 12 mm
was the main target of the mine and the
Metso team The changes that were carried
out in the process included a size varia-
tion change in the cut of the tertiary sieve
installation of rate-level sensors in thesecondary crushers and enabling speed
variables in the conveyor belt feeders of
the secondary crushing circuit
ldquoGoing from 15mm to 12mm may seem
small but the operational impact is very
important and significant for usrdquo explains
Juan Torres Carvajal Metallurgical Engi-
neer at the El Abra mine
ldquoOur goal is to reach 115000 tons with
a minimum of 80 of 12-mm-sized ore permonth The record to date is 105000 tons
and we will increase it until we reach our
project goalrdquo he adds
New design for cone liners
In addition to the work mentioned above
Metso is currently carrying out a project to
design the lining profiles for the secondary
and tertiary crushers of the plant which
will affect the smaller size of the material
In cooperation with Nelson Mella from
Metso and Rodolfo Navarro Crushing
Superintendent at the El Abra mine testswere carried out in July on the re-designed
Metso linings One set was tested for sec-
ondary crushing and two sets for tertiary
crushing
More info
Nelson Mella
Tel +56 99158 0576
nelsonmellametsocom
Finer ore through wear pro1047297lestudy at El Abra mine in ChileEl Abra is a porphyry copper open-pit mine and processing facility located in
Chile near the city of Calama some 4000 meters above sea level With the helpof Metsorsquos technical support the mine was able to achieve finer ore throughoutthe crushing process
TEXT amp PHOTOS Macarena Vallejo
Xewell Cimenteries produces a selec-
tion of dry processed aggregates for con-
crete Operations started at the end of 2009
with the aim of reaching 150000 metric
tons produced per year
Lokotracks chosen to reduce costs
To build up their tracked mobile processXewell Cimenteries decided to buy three
mobile plants from Metso two impactor
plants the Lokotrack LT1110 and LT1213
feeding a three-deck mobile screen the
ST620 The machines were sold by SCAI
SpA Metsorsquos Lokotrack distributor in Italy
ldquoWe chose tracked machines to bet-
ter exploit our quarry and to reduce
costs Mobile plants have low initial costs
because they donrsquot need any special foun-
dations or supply of electricity This obvi-
ously gives us a quicker process set-up and
better uptimerdquo says Alessandro Crestani Technical Director of the Pout quarry
ldquoThe mobile plant can also follow the
quarry face as the exploitation proceeds
reducing the transport costs of raw materi-
als in the same jobsite We chose Metso
because they ensured us the best cost-per-
ton ratiordquo he adds
Good customer service is crucial
According to Alessandro Crestani good
customer service also played a major role
when choosing the manufacturer of the
mobile equipmentldquoMetsorsquos distributor SCAI SpA was able
to provide us with a complete product
support and customer service package
Obviously service is a very important
aspect for us in a country like Senegal Any
downtime represents a clear loss of pro-
ductivity for usrdquo
The average level of productivity of the
mobile Lokotrack process is 200 metric
tons per hour
More info
Carlo Rinolfi Tel +39 335 1253159
crinolfiscaispacom
Example of the development of the Metso study
on the crusher lining profiles
Liner change for smaller ore size in the
MP1000 cone crusher
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Services success in Surabaya The Metso Surabaya workshop and offi ce complex opened in April 2008 provides Life Cycle Services and maintenance
solutions for Metso equipment in the Indonesia region The facility is strategically located in an industrial precinct on theouter rim of Surabaya the second largest city in Indonesia Its close proximity to an international airport major shipping
port and several engineering companies simplifies support for the regionrsquos key customers which include PT Newmont
and PT Freeport
TEXT amp PHOTOS David LeRoy amp Gary Whittred
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983122983141983152983151983154983156983145983150983143 983154983141983155
The Surabaya site operates through Metso
in Australia with assistance from key sales
and technical staff Handling regional ser-vice and repair business in-house allows
Metso to manage intellectual property and
closely control quality
It also enables the development of a
team of skilled service personnel who can
be utilized both internally and at key cus-
tomer sites as is common with the backup
service the workshop provides for screen
contracts
Innovation at work
Since 2008 the Surabaya facility has suc-
cessfully refurbished a wide variety ofcomponents Recently two ball mill heads
weighing 22 tons each were modified in
order to strengthen the 1047298ange of the ball
mill shell The modification included tap-
ping out existing 1047298ange holes and drilling
new ones so that finger plates could be
installed and welded to the 1047298anges
Positioning the head borer to properly
align the new 1047298ange holes proved diffi cult
Four roller support frames were manufac-
tured to support the heads and allow them
to be rotated easily Each hole was then
drilled and tapped at the correct angleusing the CNC five axis head The job had a
tight delivery as it was required for a shut-
down but with advance planning and inno-
vation it was completed ahead of schedule
MP1000 mainframe on
CNC vertical borer
Well equipped for fabricating and machin-
ing heavy components the Surabaya
The Surabaya facility has proven to be
a success for Metso The workshop offers a
wide variety of services in the region Qual-ity products and competitive pricing and
delivery times have led to strong customer
relationships
Turnover and customer service levels
have increased annually since the open-
ing and between 2008 and 2010 sales
increased 450 These excellent trends
are expected to continue as the operation
expands and the customer base grows
Since 2008 the Surabaya facility has
successfully refurbished
bull MP1000 counter shaft boxes headassemblies mainframes bowls adjust-
ment rings counterweights sockets and
tramp release cylinders
bull 7rsquo Symons bowls heads and countershaft
boxes
bull Vertimill screw and drive shafts
bull Ball mill heads
bull Ball mill trommel
bull VPA cylinders
bull Eaton clutches
bull Exciter screen mechanisms
bull 42x65 main shafts and eccentrics
More info
Gary Whittred
Tel +62 31 8430349
garywhittredmetsocom
workshop handles the majority of Metsorsquos
refurbishment work with ease But when
necessary PT PAL ndash a government facilitywith shipbuilding and heavy engineering
capabilities ndash offers a ldquoone stop shoprdquo Spe-
cially trained PT PAL staff ensures that the
work they perform complies with all Metso
specifications and quality standards
PT PAL also demonstrated their innova-
tive ability with the first MP1000 main-
frame refurbishment they completed The
mainframersquos shaft location bore needed
to be re-machined However the distance
from the top of the mainframe to the
tapered bore made it very hard to achieve
an accurate surface finish with the correctstandoff
To overcome this the shop decided to
machine the mainframe upside down and
elevated on support beams They posi-
tioned a new shaft under the mainframe in
a custom-made cradle Using an overhead
crane they could then lsquotrial fitrsquo the shaft in
the bore to make sure it seated correctly
and the mating tapers met specification
The method worked so well it has since
been used for four more mainframe refur-
bishments
Diversity and growth
Today Metso Surabaya continues to invest
in additional equipment in order to diver-
sify its service offering A new hydraulic
power pack which allows the facility to test
refurbished components to Metso specifi-
cations was recently used in the refurbish-
ment and testing of several VPA cylinders
for PT Freeport
Refurbished MP1000 mainframe dispatched by truck to
PT Freeport mine
Machining of MP1000 upper frame
at Metsorsquos Surabaya workshop
Mainframe at vertical CNC machining
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Creating Value with Metso in Hong KongIn Hong Kong the aggregates needed for construction are mostly supplied by two local quarries KWP Quarry Company
Limitedrsquos Anderson Road Quarry accounts for 60ndash70 making it the pillar of Hong Kongrsquos construction materials industry
TEXT amp PHOTOS Ou He
When arriving at the Anderson Road
Quarry the most impressive view at the850000 square-meter facility is the Metso
machines including equipment from the
primary secondary and tertiary crushing
circuits and the screens I t is Metsorsquos equip-
ment that secures the supply of aggregates
for Hong Kong
KWP Quarry Company Limited has been
working with Metso since its establishment
in 1997
Due to Hong Kongrsquos stringent dust and noise control standards Metso has paid special attention to the related suppression systems
ldquoOur quarry mainly lies on granite and
volcanic rock which are so hard they canonly be processed by equipment with
strong durability and stabilityrdquo explains
Mr Eddie Hung Manager of KWP ldquoWith a
long history of and experience in quarry-
ing we are very familiar with the equip-
ment of different brands Comparatively
Metsorsquos products are better than others in
terms of durability stability and effi ciency
Besides this the reason we selected Metso
is because of the simple maintenance of
their equipment and the easy access tomaintenance informationrdquo
Flexible modular solution
Based on extensive experience in crushing
and screening worldwide Metso presented
the Anderson Road Quarry with a modu-
lar solution and delivered it as a turn-key
project Through a four-stage crushing
circuit which contains three Metso C160
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983122983141983152983151983154983156983145983150983143 983154983141983155
jaw crushers for primary crushing two
Omnicone 1560SX crushers for secondary
crushing two HP 500SX cone crushers for
tertiary crushing and one HP500SX cone
crusher for extra-fine crushing the plant
was able to produce aggregates of optimal
shape with minimal 1047298akiness
The fine products include three sizes
0 to 5 mm 5 to 10 mm and 10 to 20mm
Since the employment of this system in
2000 production has reached 1250 th
which is far beyond the design capacityAccording to Mr Hung ldquoThe machines
always run effi ciently and seldom malfunc-
tion The occasional shutdown of some
machines does not affect production very
much the plant still could reach 60-70
of its normal production It gives us the
best 1047298exibility for the plant rsquos operation and
I believe this is the best feature of Metsorsquos
solution
Eddie Hung
Manager of KWPrsquos
Anderson Road
Quarry is happy with
the product quality
and service provided
by Metso
ldquoMetsorsquos equipment is expensive com-
paratively but in the long run you will find
that the investment is worthwhile on the
whole Metso secures superior stability reli-
ability and fewer downtimes and it guaran-
tees continuous operation and brings us
greater valuerdquo
Great service team
Metso sent a group of service engineers
to the plant within the warranty period
not only to provide service but to train theoperators Mr Hung speaks highly of Met-
sorsquos service team he is impressed with its
experienced experts and with their strong
sense of responsibility and customer-
oriented ways of working
ldquoMetsorsquos service team never fails to find
hidden problems and helps us to prevent
any mechanical failures And they are
available whenever we need them they
work closely with us to solve the problem
effi cientlyrdquo he said
Excellent environment-friendly designIn order to achieve the worldrsquos most strin-
gent noise and dust control standards
developed by the Environment Protection
Department of Hong Kong Metso has
incorporated a dust and noise suppression
system into the plant This includes the
infrared-triggered spray systems at feed
points encapsulation of individual crush-
ers and conveyors and the ability to select
specific sectors of the system for treatment
depending on feed and operating condi-
tions encapsulation of equipment and the
enclosure of all major sections of the plant
With these advanced environment-
friendly solutions Anderson Road Quarry
has won numerous safety and environmen-
tal awards In 2003 it was presented with a
silver medal in the prestigious Environmen-
tal Performance Awards in recognition of
its commitment to the environment and
community In 2004 KWP achieved certifi-cation of ISO 14001 it is the first quarry site
to have achieved this in Hong Kong and
southern China
ldquoA reliable partnerrdquo
The promulgation of the top ten infrastruc-
ture policies in Hong Kong boosted the
market for aggregates and demand will
keep rising over the next five to six years
ldquoWersquoll definitely keep our cooperation with
Metso once we have a need for expansion
because we regard Metso as a reliable part-
ner With their highly effi cient equipmentsatisfying service and great efforts in help-
ing us to achieve our environmental pro-
tection targets Metso is our best choicerdquo
says Hung
More info
Ziqiang Li
Tel +86 13601289027
ziqianglimetsocom
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
The sturdy Metso C160
jaw crushers are fed
using huge feed chutes
and feeders
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983122983141983152983151983154983156983145983150983143 983154983141983155
Similar to hundreds of mine sites world-
wide Zinkgruvan is being operated on a
non-stop 247 basis with just a few main-
tenance breaks during the year Crusher
availability is crucial because 100 of the
ore has to pass through the jaws before
being hoisted up for further processing
In addition to the zinc- lead- copper-
and silver-containing ore the C jaws chop
all the host rock extracted along the min-
ing process With a sturdy design Metsorsquos
proven C jaws can easily reduce even the
hardest type of rock Every year more thanone million tons are crushed with the jaws
ldquoMinimal service neededrdquo
Crushing with the first C160B jaw crusher
began at Zinkgruvanrsquos -800 meter level in
2000 with the primary crushing of zinc-lead
ore The second jaw was installed in 2008
for the new copper process gt
The sight and sound of two C160 jaw crushers operating side by side in the underground
crushing station of the Swedish Zinkgruvan mine is impressive Good proactive service
secures good uptime and reliable continuous operation of Metsorsquos second-largest
C160 series jaw crushers and prepares the way for the ongoing plans to expand the
production of zinc concentrate
TEXT amp PHOTOS Eero Haumlmaumllaumlinen
New PolyMet liners are being tested with the grinding mill delivered by Metso
Zinkgruvanrsquos twin C160
jaws secure good uptime
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Blasted ore is taken from the presently
operated -850 meter level with normal
trucks as an outsourced process One full
truckload is fed to the C160s every
10 minutes
ldquoWe are happy with the high reliability
of the C jaws They only require some minor
service therefore providing us with good
uptime and steady continuous feed to our
secondary and tertiary crushing and grind-ing circuitsrdquo says Mine Manager Jan Klaumlre
ldquoBasic crusher service and wear part
changes are made by our own staff using
Metsorsquos partsrdquo he adds
Service contract with grinding
mills and conveyors
Zinkgruvan and Metso Sweden have more
than 11 yearsrsquo experience with a service
contract that contains grinding mills and
conveyors At the mine site two Metso
service people and one contractor take
care of all the related service jobs Man-
power can also be borrowed from Metsorsquos
Graumlngesberg mine service team of 20
people
Presently Zinkgruvan is testing Metsorsquos
new PolyMet mill linings in its big grinding
mills With previously used rubber partsthe linings had to be changed in the shell
every 9 to 11 months and in the feed head
every 6 months
ldquoWe expect a better lifetime with Poly-
Met linings Longer change intervals mean
a lot to our productivity because lining
changes takes two full working daysrdquo Mine
Manager Jan Klaumlre says
New mine goes deeper
With an expected mine life of more than 10
years Zinkgruvan is actively mapping new
ore reserves Experimental holes are being
drilled at the new mine section at the
-1110 meter level
More info
Fredrik Wennberg
Tel +46 70 657 00 08fredrikwennbergmetsocom
Mine Manager Jan Klaumlre (left) with Backfilling Manager Kjell Tillman at the underground -800 meter level mine cafeteria
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The Zinkgruvan mine located approxi-
mately 200 km southwest of Stockholm
Sweden is one of the oldest underground
mines in Northern Europe The mine has
been in production since 1857
The mining methods used are panel
stoping and benching The processing
facilities include a zinc concentrating plant
with a 11 mtpa and a copper plant with a04 mtpa capacity Tailings are recycled in
an impounding basin and host rock in the
backfill plant
Continuous mining since 1857
Even as one of the oldest mines in Northern
Europe Zinkgruvan exploits modern mining
and minerals processing installations
Zinkgruvan mine
OWNER Lundin Mining
PRODUCTION PER YEAR 1 million tons
ORE TYPE sedimentary exhalative
zinc lead copper and silver
NUMBER OF EMPLOYEES 320
2011 PRODUCTION TARGETS 78000 tonsof zinc 36000 tons of lead and
3400 tons of copper concentrate
METSO EQUIPMENT ON SITE
bull 1 extra long VF feeder
bull 2 C160 jaw crushers
ndash zinc process css 220ndash240 mm
ndash copper process css 150 mm
bull 1 GP300S cone crusher
ndash css 45mm
bull 1 HP4 cone crusher
ndash css 18 mm
bull 1 DS screen
bull 1 FS402 screenbull 1 grinding mill
bull Pumps VPAs
A normal truck feeds the C jaws with ore coming from the lower production levels
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Cost-per-ton wear agreements deepencustomer relationshipsCrusher wear parts are traditionally marketed purely based on transactional sales and mainly depend on
the weight of manganese Metso has recently introduced a new type of wear agreement based on thecost-per-ton crushed and the wear occurred Thus far the experience has been very positive increasing
transparency and deepening the operational relationship between the manufacturer and the customer
TEXT Olli Kellokumpu and Eero Haumlmaumllaumlinen PHOTOS Eero Haumlmaumllaumlinen
Arto Hiedanniemi (left)
Hannu Heman and Juha
Laukka of Metsorsquos Finnish
Service team checking the
cone crusher mantles shipped
for a cost-per-ton customer
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Wear parts and parts changes
can be included
The structure of a cost-per-ton wearcontract is based on the number of tons
crushed and the estimated wear occurred
The amount and monetary value of the
wear is calculated per crushed ton
ldquoEither plain wear parts or parts changes
carried out by Metsorsquos service personnel
can be included in the contract In the latter
case we ask our Finnish customers to inform
us about an upcoming wear change opera-
tion one week in advancerdquo Heman explains
ldquoWe see good opportunities to market
cost-per-ton contracts further in Finland
and also abroad It really develops therelationship of Metso and our customers
towards a trusted partnershiprdquo he notes
Perfect tool for accurate planning
Soraliike Ikola Oy is a mid-sized contrac-
tor with three Metso two- and three-
stage mobile and portable crushing and
screening plants operating in Central and
Since 2002 Metsorsquos sales team in Finland
has developed the cost-per-ton-based
service offeringldquoOur aim has been to seek through
a cost-per-ton offering possibilities to
serve our customers better to differentiate
Metso from the other players as an OEM
manufacturer and to offer deeper profes-
sionalism and know-howrdquo says Hannu
Heman General Manager of service
operations
ldquoUntil now both our experience and
that of our customers has been quite posi-
tive When properly prepared cost-per-ton
contracts seem to create a win-win situa-
tionrdquo Heman adds Today Metso has operational cost-per-
ton agreements with several Finnish cus-
tomers The first contract was concluded
with a customer operating a stationary
plant Based on the results gathered new
cost-per-ton contracts have been signed
with customers operating wheeled and
tracked equipment too
Eastern Finland Because of the size of the
contracts up to 50 equipment moves are
made during the yearEntrepreneur Pasi Ikola has had a cost-
per-ton contract with Metso for nearly
two years and he is quite happy with the
outcome
ldquoThe cost-per-ton contract has provided
me with a perfect tool for accurate financial
planning Now I know in detail my actual
future wear parts costs This helps a lot
when calculating bidsrdquo
ldquoEarlier I used to buy a big batch of
Metso wear parts in one go and had to
reserve a reasonable amount of money for
that Today all wear costs are evenly sharedwhich gives us a welcomed 1047298exibility to
our cost structure Now we just pay Metso
afterwards based on our crushed tonsrdquo
he adds
More info
Olli Kellokumpu
Tel +358 50 354 1189
ollikellokumpumetsocom
According to crushing contractor Pasi Ikola the cost-per-ton contract with Metso has provided the entrepreneur with better economical 1047298exibility
and more accurate calculating of bids
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Pleasant Gap is owned and operated by
Glenn O Hawbaker Inc of State College
Pennsylvania This family-owned company
began in 1952 as a small excavation busi-
ness founded by Glenn O Hawbaker and
his wife Thelma Over the years the com-
pany grew by adding an integrated mix ofproducts and services and taking on larger
projects
In 1983 Hawbaker acquired Pleasant
Gap Quarry and built its first aggregates
processing plant Today Glenn O Haw-
baker Inc operates 21 quarries and eight
asphalt production facilities across Penn-
sylvania and southern New York as well as
five regional operation centers
Primary
challenge atPleasant GapQuarryA good part of what makes for a successful crushing
operation is the willingness to tackle challenges and to do
whatrsquos necessary to meet demand The team at Pleasant
Gap Quarry in central Pennsylvania recently met the chal-
lenge when they successfully addressed problems with
the plantrsquos primary crushing plant First they purchased
a new Metso C160 jaw to replace the existing primary
impact crusher Then they devised an innovative plan to
get the primary plant back in operation while awaitingdelivery of the new jaw crusher
TEXT Linda Bergmann PHOTOS John Rickinger
983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Time for a change
With the goal of increasing reliability and
output the management at Pleasant Gap
Quarry recently decided it was time to
replace the plantrsquos primary impact crusher
Following a thorough search they chose a
new Metso C160 jaw According to ScottReck Plant Manager it no longer made
sense to repair and rebuild the existing
impactor
ldquoBefore we purchased the Metso C160
we had a few other impact crushers and
they served us well but as our custom-
ersrsquo needs increased our plant production
had to match that demand We found our
formerly reliable unit was being overcome
by our demands for output and creative
work-around solutions We continued to
need more but there was only so much we
could do until we hit the breaking point ndash
literallyrdquo
In addition to performance improve-
ments the new crusher also needed to fitinto Pleasant Gaprsquos unique infrastructure
As Plant Project ManagerEngineer Jeremy
Fahr explains ldquoOur height restraint was 274
meters (108rdquo) This height was the distance
from the feed lip of the existing 6x12 scalp-
ing screen and the existing structure that
the crusher rests onrdquo
The normal C160 crusher is 307
meters (121rdquo) tall but Metso gave GOH
Scott Reck Plant Manager (left) and
Jeremy Fahr Plant Project Manager
Engineer at Pleasant Gap Quarry
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983122983141983152983151983154983156983145983150983143 983154983141983155
a 10-degree mounting option (which is
normally used on their portable crushers)
to overcome the height restraint Reck and
Fahr worked with Dave Rhoa of Cleveland
Brothers Equipment Metsorsquos crushing and
screening distributor in Pennsylvania to
pull everything together and fit the newcrusher into their plant
The C160 crusher selected for Pleasant
Gap is one of the latest models in Metsorsquos
C Series of jaws These jaw crushers feature
a large throw and steep toggle plate angle
resulting in a higher crusher output In
addition the C Series has a compact foot-
print that makes it an ideal choice for the
replacement of existing machines
According to Reck ldquoWe had heard about
the new Metso C160 and started doing our
own research and found Metso not only
had developed the output capacity we
needed but fit the uniqueness of our oper-
ationsrdquo The new Metso crusher will allow
the plant to increase tons per hour andgive them the 1047298exibility to meet demands
for varying products on short notice
Mobile solution
Purchasing the new primary jaw addressed
the long-term issues but still left Pleasant
Gap without a functioning primary plant
Reck continues ldquoOur main line was still
down leaving us with a big hole in hitting
customer needs but knowing that our new
Metso C160 was on its wayhellipwe needed an
immediate solution to keep our produc-
tion demands with an out-of-commission
crusherrdquo
The team at Pleasant Gap brainstormed
the problem and came up with a plan toget the primary plant back in operation
Their solution was to use the Lokotrack
LT1213 impactor plant and another mobile
unit to keep the main line crushing To do
this they removed the guts on the existing
impact crusher essentially turning it into a
rock chute They then moved the LT1213
and another manufacturerrsquos mobile unit
over to the existing dump hopper gt
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ldquoWe had our haul trucks drop off mate-
rial while two excavators fed the two
mobile unitsrdquo Reck explains ldquoFor two-and-
a-half months the Lokotrack LT1213 unit
was producing 254 cm (10rdquo) minus at
700 tons per hour The other similar-sized
mobile unit was doing 400 tons an hour
maxed out The difference was unbeliev-
able to say the least Our unique solution
using the two mobile units especially the
LT1213 helped Glenn O Hawbaker achieve
a record output in 2010rdquoAccording to Fahr ldquoWe were not new to
Metsorsquos quality and supportrdquo because GOH
had been using Metsorsquos portable crushing
equipment for 3 years prior to the primary
plantrsquos impact crusher failure In another
part of our operation we have a system that
our team relies on every day a Lokotrack
LT1213 and ST272 working in tandem with
two portable conveyorsrdquo This highly effi -
cient mobile processing system turns out
300 tons of specialized blended material
per hour GOH has been so impressed with
Metso equipment its last two purchaseswere an LT106 tracked jaw plant and a
second ST272 mobile screen in 2010
Maintaining high productivity
The Metso C160 jaw was delivered to Pleas-
ant Gap Quarry in January of 2011 and
since start-up it has more than met expec-
tations The crusher is fed minus 910 mm
(36rdquo) limestone with the jaw set at 140 mm
(5 12rdquo) According to Reck ldquoFrom moment
we started up we knew we had a winner
Not only were we kicking out as much
product as our previous units without even
breathing hard but we immediately had a
2-cent per ton savings to the bottom line
without having to run a second 350 HP
motor as required by other units Plus by
adding on the new automatic lube system
the maintenance team had more time to
devote to keeping other areas of the com-
plex running more effi cientlyrdquoReck says ldquoThe Metso unit was a perfect
fit and with the improved features it pre-
sented it had it all We just turn it on load
it up and we are moving 600 tons per hour
through the crusher without any effort and
we know it can do so much morerdquo With
the primary crushing plant back in opera-
tion the entire team at Pleasant Gap will
continue to do what they do best produce
and sell high-quality products and meet
their customersrsquo expectations
More info
Scott Yablonsky Tel +1 262 717 793
scottyablonskymetsocom
The Metso C160 jaw
was installed at a 10deg
angle to fit Pleasant
Gaprsquos existing
infrastructure
The Lokotrack LT1213 impactor plant and ST272 mobile screen operate in tandem with two
portable conveyors at Pleasant Gap
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983149983141983156983155983151 983150
Paper amp fiberNew OptiConcept M paper
and board making line
The new OptiConcept M paper and board
making line stands for economy safety and
usability
Metso has launched a new modular paper
and board making line called OptiConceptM A member of the proven OptiConcept
production line family the new OptiCon-
cept M optimizes machine investment in
line with each millrsquos capacity needs
Savings in operating costs are achieved
through precise dimensioning of pro-
cesses proven technological solutions
optimal running parameters effective
maintenance operations and fully inte-
grated automation solutions
Optimized processes innovations
smart controls and accurate dimensioning
decrease the use of steam gas electricitywater chemicals and other raw materials
and reduce emission levels
OptiConcept M has been designed
both visually and physically with the
requirements of users in mind For exam-
ple the design of the machinery allows for
easy and safe changing of rolls and wear
parts thus reducing the total duration and
cost of maintenance shutdowns
RecyclingGreen energy technology to
Elektrociepłownia Białystok in Poland
Metso will convert a coal-fired boiler to
a biomass-fired Bubbling Fluidized Bed
boiler for Elektrociepłownia Białystok SArsquos
combined heat and power plant (CHP) in
Białystok Poland The new boiler system
will cut the power plantrsquos CO2 emissions
significantly by partly replacing the coal
fuel supply with biomass fuel
ldquoPoland is one of the largest countries
in Europe to have such a high depend-ence on energy derived from coal to
meet national electricity needs This is an
important incentive for us to reduce future
CO2 emissions and produce more green
electricity and with Metso technology
we are certain to accomplish our goalrdquo
states Mr Andrzej Schroeder President of
Elektrociepłownia Białystok SA
Since 2000 Metso has received a total
of 7 biomass boiler conversion orders in
Poland and the renewable energy share
in Poland is only 75 (2010) compared to
the target of 20 by 2020 set by the EUApproximately 80 of the current energy
boilers turbines and generators installed in
Polish power plants are over 20 years old In
order to meet the strict EU environmental
requirements modernization of existing
installations is necessary
Automation
Metso DNA automation system expands
to mining and construction
Using Metsorsquos control room automation
an entire crushing and screening plant can
be effi ciently managed
Metso is a leading supplier of mining and
construction machinery This expertise has
now been combined with a scalable Metso
DNA automation system that adapts to
the range of industry needs from single
machine controls to plant-wide automation
and information management systems
An example of Metsorsquos new offering is a
new crushing plant control room solution
that connects crushers and screens ensur-
ing the effective management of the entire
plant from a pleasant and safe control
room The Metso DNA user interface pro-vides the production information to ensure
a proper and rapid response to plant
events Automatic controls stabilize the
process and allow the operators to monitor
the plant as a whole
ldquoThe benefits of automation for the min-
ing and construction industry are signifi-
cant As an example of the services we offer
performance studies to crushing plants
utilizing Metsorsquos multi-disciplinary teams of
experts to determine the present level of
the plant and process effi ciency and to esti-
mate the improvement potential and thebenefits of optimization and automation
including ROI calculationsrdquo says Mikko Maumlki-
nen Product Manager of minerals applica-
tions in Metsorsquos Automation business line
ldquoAs another example our machine
condition monitoring solutions can reduce
plant and machine downtimes as well as
help to avoid safety and environmental
hazardsrdquo he adds
Metso around the world
Aerial view of the Elektrociepłownia Białystok combined heat and power plant in Poland
8202019 Metso Minerals Aggregates 3 2011
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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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Metsorsquos Mining and Construction Technology has introduced the
Metso C120 jaw crusher ndash the 13th member of the field-proven
C-series range of crushers The C120 combines uncompromising
reliability crushing effi ciency and versatility in both stationary and
mobile applications with safety and ease of use
Even at first glance it is clear that Metso has paid special atten-
tion to the C120rsquos new durable and user-friendly design start-
ing with the casting the design of which is based on thorough
FEA analysis and casting simulations Every detail of the C120 is
engineered for reliable operation and long life resulting in high
constant crushing capacity and uptime
ldquoWhen starting the C120 project we listened closely to our cus-
tomers and collected field data from a number of sites Based onthat information we decided to design the crusher cavity and kin-
ematics first As a result Metso can now offer aggregates produc-
ers large-scale contractors and mining companies a new crusher
that meets all the standards set for any demanding applicationrdquo
says Ilkka Somero Metsorsquos Product Manager for jaw crushers
New design brings outstanding productivity
The outstanding productivity of the C120 is guaranteed thanks
to several new design elements The crusher features a long and
aggressively directed stroke and a fixed jaw die longer than previ-
ously seen in this crusher size class The C120 has a large feed
opening of 1200 x 870 mm (34 x 47rsquorsquo) and an aggressive cavity cross
section securing a high per formance and reduction ratioIn terms of cavity volume and crusher weight the C120 is posi-
tioned between the existing Metso C116 and C125 jaw crusher
models
The Metso C120rsquos nominal power is 160 kW (200 HP) operating
speed 230 rpm closed side setting between 70 ndash 200 mm (2 34rsquorsquo
ndash 8rsquorsquo) The operational weight is 26000 kg (57200 lbs) excluding
options
More infoIlkka Somero
Tel + 358 50 317 0769
Ilkkasomerometsocom
The optional robust composite 1047298ywheel guards allow quick and safe
access to the service points
983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156
In addition to providing environmentally friendly screening
media panels Metso will implement a unique program to provide
its customers with a suitable range of recycling services
The Metso Trellex LS-Eco offers a wide range of health safety
and environmental benefits Each screening media panel is up to40 lighter than standard steel reinforced Trellex LS panels This
makes handling easier and the working environment safer Lighter
panels also help to reduce the overall stress on the entire screening
installation
Compared to steel-reinforced panels the composite-reinforced
panels of the Metso Trellex LS-Eco are more 1047298exible and will reduce
the effects of pegging and blinding during screening operations
The Metso Trellex LS-Eco promises reduced downtime and
increased productivity
The Trellex 300LS and Trellex 305LS rubber and polyurethane
panels are already acclaimed worldwide as being among the most
versatile modular screening media solutions They can be attached
to most screening media systems and can handle all types of
screening applications ndash fine and coarse wet and dry In the futurewhen Metso customers need new screening media panels for
their existing system they can choose Metso Trellex LS-Eco and be
assured that their panels will be safely and effectively recycled
More info
Claes Larsson
Tel +46 410 525 73
claeslarssonmetsocom
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The new Lokotrack LT120 with its world premiere at the Steinexpo
exhibition in Germany combines crushing performance and user-
friendly design in a new revolutionary way For the first time the
same Lokotrack model is now available in a hydraulically or electri-
cally driven version to meet customer needs
New Lokotrack LT120 jaw plant introduced
Lokotrack LT120 is the latest and most advanced of Metsorsquos track-mounted jaw crusher plants
Lokotrack LT120 combines user-friendly design and good crushing
performance in a new way
power supply or a 420-kV onboard diesel generator Having the
possibility to use an external power supply enables a highly eco-
nomical and ecological crushing process
The Lokotrack LT120 is built around the new C120 jaw crusher
See page 10 for information about the C120
Safe to use move and service
Safety is the highest priority for Metso when designing new equip-ment The Lokotrack LT120 is designed to be safe to operate move
and service
ldquoA safe operating environment is created by practical solutions
When service points can be reached easily the possibility of dan-
gerous situations diminishesrdquo says Product Manager Timo Nakari
ldquoGood examples of safety built in to the Lokotrack LT120 include
sturdy easy-to-open composite 1047298ywheel guards and hydraulically
folding and locking feed hopper sidesrdquo Nakari adds
The Lokotrack LT120 can be fine-tuned to suit the customerrsquos
application by selecting the required options from a long main
conveyor and hammer and boom to a water spraying system and
rubber lining for the feeder and hopper for example
The Lokotrack LT120 features a Caterpillar C13 310 kW (415 hp)engine Its transport dimensions are length 16 m (52rsquo 6rdquo) width 3 m
(9rsquo10rdquo) height 39 m (12rsquo 10rdquo) and weight 57 tons (114000 lbs) The
LT120E version weighs 63 tons (126000 lbs)
More info
Timo Nakari
Tel + 358 40 701 6143
timonakarimetsocom
983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155
The Lokotrack LT120 uses the same field-proven technology
seen in Metsorsquos tracked units for over 26 years Every detail of thenew jaw plant has been thoroughly designed for reliability and
long life The main targets when designing the unit have been
energy effi ciency good performance reliability and product safety
Field tests have demonstrated its good fuel economy and high
crushing capacity
Environment-friendly economy
The Lokotrack LT120 is also available as an electrically driven unit
ndash the Lokotrack LT120E ndash which can take energy from an external
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The TS range of screens is characterized by its innovative design
comprising two technologies combined multi-variable slopes with
a variable elliptical motion This proven range is being comple-
mented with the new TS63 screen
The TS63rsquos unique combination increases both the screenrsquos effi -
ciency and its capacity Material speed is high at the feed end and
slows down at the discharge end
Metso TS series screens offer more space between decks mak-
ing maintenance easier and improving service conditions for the
operators as well as meeting all safety requirements
Metso has recently sold several 25-m2 multi-slope screens for
mining applications such as a TS63 for Ferrostaal in Mauritania andalso for the construction industry for example Holcim in Lynwood
Australia Georyt in Poland Apaxco in Mexico and Newmont in
Peru
More info
Denis Pradon
Tel +33 680 64 39 67
denispradonmetsocom
New TS63 screen ndash the largest three-deck banana screen on the market
The new Metso TS63 banana screen features a 25-m2 screening area
Following the success of the HP4 and HP5 Metso has broadened
the product range with the new HP3 cone crusher This mid-range
cone crusher benefits from 70+ years of experience in crushing
technology while specifically addressing customer requirements
for large capacity ease of operation and a high reduction ratio
The HP3 responds to market demands for increased productionquality reduced maintenance time and low operating costs The
new generation HP models are comparable to their predecessors
but offer increased versatility
The HP3 features the size of an HP200 with the output of an
HP300 The power performance and robustness of the new gen-
eration models allow in certain cases two crushers to be replaced
with just one so investment production and operation costs are
greatly reduced
The HP3 has been tested at two different quarry sites in France
over the past seven months ndash at a gravel pit and a rock quarry
The Metso factory in France began production of the HP3
series in September Several orders have already been received for
secondary and tertiary applications Since 2009 nearly 300 HP newgeneration cone crushers have been commissioned The HP3 mar-
ket will be primarily centered on gravel pit applications (70)
The HP3 has a nominal feed opening of 220 mm (865rsquorsquo) a
motor size of up to 220 kW (300 hp) and a weight of 13280 kg
(29277 lbs)
More info
Carlos Padin
Tel +33 6 0727 2002
carlospadinmetsocomMetso HP3 at a stationary installation in France
HP3 cone ndash another new-generation cone crusher
983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156
8202019 Metso Minerals Aggregates 3 2011
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
First modular plant to NepalMetso delivered its first modular crushing and screening plant to MS Palchowke Mai Roda Dunga Udyog Limited (PMRD)
in Melamchi Nepal The modular plant solution offers PMRD a fast and effective response to productivity and qualityrequirements
TEXT amp PHOTOS Atoshi Nayak Ghosh
The diversity of operations at a typical con-
struction site involves quick decision-mak-
ing and often a lot of pressure to ensure a
timely execution
High performance guaranteed
Considering todayrsquos volatile market sce-
nario business partners must maintainpace with their customersrsquo ever-changing
requirements Understanding custom-
ersrsquo strategic business needs is of utmost
importance PMRDrsquos plant was commis-
sioned in January 2011 and has logged
about 1200 hours of operation to date
The plant is much more compact than
the traditional skid-mounted plant and
provides space for free movement of utility
equipment within the plant area One of
the key features of the plant is the totally
bolted structure It can be easily disman-
tled into sub-assemblies transported and
re-assembled effortlessly at a new location
which is one of the biggest advantages in
helping to meet new market demand
Due to the use of pre-assembled mod-ules for each crushing station the instal-
lation work on site takes less time thus
decreasing the plantrsquos installation lead time
The plant also includes a foldable conveyor
for maintenance of the cone crushers
Stepping up with Metso
PMRD operates a two-stage plant compris-
ing a C80 jaw crusher an HP200 high-
performance cone crusher and a CVB1845
screen with circular motion MV2 vibra-
tory mechanism for final product recovery
resulting in an aggregate plant of 150 tph
capacity for producing size fractions of 0-40
mm The plant is an example of world-class
craftsmanship and excellent material han-
dling capacityModular and non-welded construction
supported by durable pitman assembly sin-
gle-piece cast steel frame bearing housings
with repairable crusher construction and
the right cavity design results in aggressive
kinematics and high power that best suits
the requirements of the customer
PMRD has immense pride in the plant
ldquoThe performance has been astounding
A drawing of typical modular plant
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983122983141983152983151983154983156983145983150983143 983154983141983155
with applications ranging from road aggre-
gates commercial sand production to
ready-mix concretes The modular plant is
almost set to create a new niche in aggre-
gates processing in Nepalrsquos construction
industry It is one of a kind and we are sur-
prised at the plant rsquos production capacity
It is easy to operate and requires minimalmanpower Our cost per ton has signifi-
cantly gone down and so has the cost of
productionrdquo says Mr Sandeep K Agarwal
Director PMRD
Safety as a key issue
Health safety and environmental solutions
are key concerns for Metso and they are
addressed with the same sense of responsi-
bility as quality productivity and cost-
effi ciency issues Metso is responsible for
conducting operations in an environmen-
tally sound way and offers products and
services that can help customers fulfill their
environmental responsibilities
Metso provides the plant offi ce and site
with operation and maintenance manu-als for each and every piece of equipment
including safety issues which are entrusted
to all the operators
All conveyors are equipped with pull-
cord safety switches along with emergency
stop buttons The working area and walk-
ways are all equipped with safety hand rails
and checkered plates for anti-skidding The
entire plant is equipped with earth pits for
electrical current earth leakage prevention
Metso has ensured all possible measures
to maintain high safety standards for all
operation and maintenance personnel
More info
Suhen Agarwal
Tel +91 124 2351566suhenagarwalmetsocom
Nepalrsquos first modularcrushing and screening plant deliv ered by Metso
E ffi cien t C VB1845 inclined screen wi th
an M V2 vibra tor y mechanism handles
the classi fica tion o f crushed ma terials
A s turd y f eeder dis tribu tes the ma terials to be crushed to
a
Me tso C80 ja w crusher
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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155
Outokumpursquos Kemi
mine set to doubleproduction The only mine unit owned by Outokumpu
the chrome mine in Kemi northern Finland
is busy making preparations to double its
production set to begin next year In co-
operation with Metso Outokumpu willincrease the number of underground
feeders and optimize the durabil-
ity of wear parts in the massive
primary gyratory crusher
TEXT amp PHOTOS Eero Haumlmaumllaumlinen
Chrome ore is fed into Metsorsquos
Superiorreg 50-65 primary
gyratory crusher by three
different vibrating feeders
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983122983141983152983151983154983156983145983150983143 983154983141983155
Up until now the entire production of the
chrome mine totaling about 13 million
tons annually has been transported to the
Tornio ferrochrome plant for processing
and on to the Tornio stainless steel plant
The increase in production which will
begin in autumn 2012 is intended also to
enable Outokumpu to sell ferrochrome tocompanies outside the Group The produc-
tion target for 2013 is 27 million tons of
ore and of the ferrochrome produced from
the ore nearly a half (gt 200000 tons) is to
be sold outside
Underground expansion
work almost complete
About 500 meters underground the
majority of the work involved in increasing
the capacity the F3 project has already
been completed Doubling the production
is no problem for the Superiorreg primarygyratory crusher delivered to the mine
by Metso in 2002 which can digest more
than 2700 tons of feed material per hour if
necessary
At the moment the primary gyratory
crusher can be fed by three different vibrat-
ing feeders The crusher currently runs for
less than one-fifth of the production time
The increase in ore production will increase
the effective crushing time to about one-
third of the production time
A lot of work has been done for orestorage after the primary crusher The
two currently used storage silos are now
accompanied by two new 8000-ton silos
The number of Metso feeders transporting
the ore from the primary crusher has also
been doubled
Optimization of wear parts under way
Chrome ore has been a challenge to the
primary gyratory crusherrsquos wear parts The
wear is contributed to by the pulsating
feed which rarely fills the entire crushing
chamber There are also great differences inore type since brittle feed material prone
to chalking is occasionally replaced by hard
ore that requires a lot of crushing power
before it is crushed with a bang gt
Mika Saari (right) Foreman of ore line technicians at Outokumpursquos chrome mine in conversation with
Mikko Malkamaumlki Metsorsquos crusher wear parts specialist
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
last did in July for the replacement of the
crusherrsquos wear parts Our work is also facili-
tated by product development like the
addition of maintenance hatches to the
feedersrdquo he continues
Lasting technology
According to Mika Saarirsquos calculations the
Superiorreg primary gyratory crusher has so
far crushed more than six million tons of
ore in totalldquoThe factory polishing marks still show
on the bottom thrust bearing so we
believe that the bearing will last the entire
remaining service life of the crusher which
is about ten years and 30 million tons
Metsorsquos feeders have been equally reliablerdquo
Saari says
After the next 30 million tons of ore
it will be time to deepen the mine
More info
Jukka Raumlisaumlnen
Tel +358 50 317 1787 jukkaraisanenmetsocom
Mikko Malkamaumlki
Tel + 358 40 827 8223
mikkomalkamakimetsocom
The Kemi mine and Metso are currently
carrying out a development project to
increase the service life of the mantle and
outer concave and thus minimize down-
time due to replacement While the modu-
lar feed hopper enables quick replacement
of the mantle replacing the outer concave
can easily take more than a week The cooperation between the Kemi
mine and Metsorsquos wear parts team in
Tampere aims to extend the service life
of the parts to at least 4 million crushed
tons Durability is sought by optimizing the
chamber structure and selecting the r ight
materials for the outer concave
ldquoSmooth cooperationrdquo
Mika Saari Foreman of ore line technicians
working in the underground mainte-
nance of the Kemi mine leads a small but
experienced team of technicians The tidymodern offi ce spaces are located close to
the action at a depth of 500 meters
ldquoCooperation with Metso has been
smooth Increasing our own crushing
expertise takes time so all know-how
shared by the manufacturer is very wel-
come to usrdquo Mika Saari says
ldquoWe can also use Metsorsquos profession-
als for servicing when necessary like we
The Superiorreg 50-65 has provided reliable
crushing performance at a depth of 500 metres
in the Kemi chrome mine
Technicians Sari Kulju (left) and Marko Jaako ensure that the primary gyratory crusherrsquos hydraulicand electrical unit remains very tidy which contributes to trouble-free operation of the crusher
Outokumpu Oyrsquos Kemi
chrome mine
LOCATION Keminmaa northern
Finland
ORE TYPE chrome oxide (26)
ORE ESTIMATE ON 1 JANUARY 2011
ndash ore reserves 36 million tons
ndash mineral resources 87 million
tons
MINING METHOD bench and cut fillFEED MATERIAL SIZE 0ndash1000 mm
METSO EQUIPMENT IN THE MINE
bull 1 Superiorreg 50-65 primary
gyratory crusher
ndash open side setting 152 cm (6rdquo)
bull 8 VMOU 25-125 feeders
bull 1 VMOU 30-16 feeder
bull 1 VMOU 40125 feeder
bull 2 Symons cone crushers
bull 1 C80 jaw crusher
bull 4 HM75 pumps
bull 11HM100 pumps
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983122983141983152983151983154983156983145983150983143 983154983141983155
Metso was responsible for the design
development and construction of the
entire secondary and tertiary arrangement
The primary station will be the subject of a
subsequent investment
Latest environmental protection used
This installation has been designed in strict
compliance with the environmental quality
approach developed by Metso and its
partners using the latest technologies
in dust control including confinement
technology as well as dust encapsulation
technology for screens
To ensure an annual capacity of 15 mil-lion tons for a nominal output of 560th of
02 mm and 220 mm the clientrsquos choice
for the secondary stage naturally fell upon
the NP 1520 impact crusher
A complete impact crusher solution for Lafarge The Lafarge Group has entrusted Metso with the implementation of its new aggregates installation in southern France
It comprises a new secondary crushing stage equipped with an NP1520 impact crusher featuring a power range of2 x 250kW and equipped with hydraulic adjustment
TEXT amp PHOTO Gilles Dombey
The NP 1520 crusher has long proved
its performance not only in terms of capac-
ity and reduction rate but also quality of
the finished product and durability
More info
Arnaud Bertucat
Tel +33 (0)6 81 44 68 26
arnaudbertucatmetsocom
About 15 million tons of aggregates feed will be crushed with the NP1520 impact crusher at Lafargersquos stationary installation in southern France
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Multi-stage Lokotrack process a success in Senegal
A multi-stage crushing and screening process has proven its effi ciency in the production of concrete aggregates in
Senegal Western Africa With the mobile process Xewell Cimenteries SA now exploits its quarry better has reduced
its operating costs and can meet strict environmental requirements
TEXT Elisabetta Cataluffi PHOTOS Carlo Rinolfi
Senegal is a rapidly developing country
offering a good deal of potential activities
for crushing companies too At the sametime the country has several areas of high
environmental value Therefore contractors
must opt for state-of-the-art equipment that
offers reduced environmental emissions
The company Xewell Cimenteries SA
was founded in 2008 as a partnership
between Italian Swiss and Senegalesecontractors Xewell operates a limestone
quarry located in the Pout area east of the
capital city of Dakar
According to Alessandro Crestani Technical
Director of the Pout quarry a mobile process
was selected to better exploit the quarry and
reduce costsLokotrack process drawing made by Bruno simulation software
After assembling the Lokotrack units the process was tested by Xewell Cimenteries
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983122983141983152983151983154983156983145983150983143 983154983141983155
Owned by Freeport-McMoRan Copper amp
Gold (51) and CODELCO (49) the ElAbra mine has leachable oxide and sulfide
mineralization The minersquos processing facil-
ity has an annual capacity of 226000 tons
of copper cathode
Smaller size matters
Reducing the size of the crushed oxide
ore from the present 15 mm to 12 mm
was the main target of the mine and the
Metso team The changes that were carried
out in the process included a size varia-
tion change in the cut of the tertiary sieve
installation of rate-level sensors in thesecondary crushers and enabling speed
variables in the conveyor belt feeders of
the secondary crushing circuit
ldquoGoing from 15mm to 12mm may seem
small but the operational impact is very
important and significant for usrdquo explains
Juan Torres Carvajal Metallurgical Engi-
neer at the El Abra mine
ldquoOur goal is to reach 115000 tons with
a minimum of 80 of 12-mm-sized ore permonth The record to date is 105000 tons
and we will increase it until we reach our
project goalrdquo he adds
New design for cone liners
In addition to the work mentioned above
Metso is currently carrying out a project to
design the lining profiles for the secondary
and tertiary crushers of the plant which
will affect the smaller size of the material
In cooperation with Nelson Mella from
Metso and Rodolfo Navarro Crushing
Superintendent at the El Abra mine testswere carried out in July on the re-designed
Metso linings One set was tested for sec-
ondary crushing and two sets for tertiary
crushing
More info
Nelson Mella
Tel +56 99158 0576
nelsonmellametsocom
Finer ore through wear pro1047297lestudy at El Abra mine in ChileEl Abra is a porphyry copper open-pit mine and processing facility located in
Chile near the city of Calama some 4000 meters above sea level With the helpof Metsorsquos technical support the mine was able to achieve finer ore throughoutthe crushing process
TEXT amp PHOTOS Macarena Vallejo
Xewell Cimenteries produces a selec-
tion of dry processed aggregates for con-
crete Operations started at the end of 2009
with the aim of reaching 150000 metric
tons produced per year
Lokotracks chosen to reduce costs
To build up their tracked mobile processXewell Cimenteries decided to buy three
mobile plants from Metso two impactor
plants the Lokotrack LT1110 and LT1213
feeding a three-deck mobile screen the
ST620 The machines were sold by SCAI
SpA Metsorsquos Lokotrack distributor in Italy
ldquoWe chose tracked machines to bet-
ter exploit our quarry and to reduce
costs Mobile plants have low initial costs
because they donrsquot need any special foun-
dations or supply of electricity This obvi-
ously gives us a quicker process set-up and
better uptimerdquo says Alessandro Crestani Technical Director of the Pout quarry
ldquoThe mobile plant can also follow the
quarry face as the exploitation proceeds
reducing the transport costs of raw materi-
als in the same jobsite We chose Metso
because they ensured us the best cost-per-
ton ratiordquo he adds
Good customer service is crucial
According to Alessandro Crestani good
customer service also played a major role
when choosing the manufacturer of the
mobile equipmentldquoMetsorsquos distributor SCAI SpA was able
to provide us with a complete product
support and customer service package
Obviously service is a very important
aspect for us in a country like Senegal Any
downtime represents a clear loss of pro-
ductivity for usrdquo
The average level of productivity of the
mobile Lokotrack process is 200 metric
tons per hour
More info
Carlo Rinolfi Tel +39 335 1253159
crinolfiscaispacom
Example of the development of the Metso study
on the crusher lining profiles
Liner change for smaller ore size in the
MP1000 cone crusher
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Services success in Surabaya The Metso Surabaya workshop and offi ce complex opened in April 2008 provides Life Cycle Services and maintenance
solutions for Metso equipment in the Indonesia region The facility is strategically located in an industrial precinct on theouter rim of Surabaya the second largest city in Indonesia Its close proximity to an international airport major shipping
port and several engineering companies simplifies support for the regionrsquos key customers which include PT Newmont
and PT Freeport
TEXT amp PHOTOS David LeRoy amp Gary Whittred
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983122983141983152983151983154983156983145983150983143 983154983141983155
The Surabaya site operates through Metso
in Australia with assistance from key sales
and technical staff Handling regional ser-vice and repair business in-house allows
Metso to manage intellectual property and
closely control quality
It also enables the development of a
team of skilled service personnel who can
be utilized both internally and at key cus-
tomer sites as is common with the backup
service the workshop provides for screen
contracts
Innovation at work
Since 2008 the Surabaya facility has suc-
cessfully refurbished a wide variety ofcomponents Recently two ball mill heads
weighing 22 tons each were modified in
order to strengthen the 1047298ange of the ball
mill shell The modification included tap-
ping out existing 1047298ange holes and drilling
new ones so that finger plates could be
installed and welded to the 1047298anges
Positioning the head borer to properly
align the new 1047298ange holes proved diffi cult
Four roller support frames were manufac-
tured to support the heads and allow them
to be rotated easily Each hole was then
drilled and tapped at the correct angleusing the CNC five axis head The job had a
tight delivery as it was required for a shut-
down but with advance planning and inno-
vation it was completed ahead of schedule
MP1000 mainframe on
CNC vertical borer
Well equipped for fabricating and machin-
ing heavy components the Surabaya
The Surabaya facility has proven to be
a success for Metso The workshop offers a
wide variety of services in the region Qual-ity products and competitive pricing and
delivery times have led to strong customer
relationships
Turnover and customer service levels
have increased annually since the open-
ing and between 2008 and 2010 sales
increased 450 These excellent trends
are expected to continue as the operation
expands and the customer base grows
Since 2008 the Surabaya facility has
successfully refurbished
bull MP1000 counter shaft boxes headassemblies mainframes bowls adjust-
ment rings counterweights sockets and
tramp release cylinders
bull 7rsquo Symons bowls heads and countershaft
boxes
bull Vertimill screw and drive shafts
bull Ball mill heads
bull Ball mill trommel
bull VPA cylinders
bull Eaton clutches
bull Exciter screen mechanisms
bull 42x65 main shafts and eccentrics
More info
Gary Whittred
Tel +62 31 8430349
garywhittredmetsocom
workshop handles the majority of Metsorsquos
refurbishment work with ease But when
necessary PT PAL ndash a government facilitywith shipbuilding and heavy engineering
capabilities ndash offers a ldquoone stop shoprdquo Spe-
cially trained PT PAL staff ensures that the
work they perform complies with all Metso
specifications and quality standards
PT PAL also demonstrated their innova-
tive ability with the first MP1000 main-
frame refurbishment they completed The
mainframersquos shaft location bore needed
to be re-machined However the distance
from the top of the mainframe to the
tapered bore made it very hard to achieve
an accurate surface finish with the correctstandoff
To overcome this the shop decided to
machine the mainframe upside down and
elevated on support beams They posi-
tioned a new shaft under the mainframe in
a custom-made cradle Using an overhead
crane they could then lsquotrial fitrsquo the shaft in
the bore to make sure it seated correctly
and the mating tapers met specification
The method worked so well it has since
been used for four more mainframe refur-
bishments
Diversity and growth
Today Metso Surabaya continues to invest
in additional equipment in order to diver-
sify its service offering A new hydraulic
power pack which allows the facility to test
refurbished components to Metso specifi-
cations was recently used in the refurbish-
ment and testing of several VPA cylinders
for PT Freeport
Refurbished MP1000 mainframe dispatched by truck to
PT Freeport mine
Machining of MP1000 upper frame
at Metsorsquos Surabaya workshop
Mainframe at vertical CNC machining
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Creating Value with Metso in Hong KongIn Hong Kong the aggregates needed for construction are mostly supplied by two local quarries KWP Quarry Company
Limitedrsquos Anderson Road Quarry accounts for 60ndash70 making it the pillar of Hong Kongrsquos construction materials industry
TEXT amp PHOTOS Ou He
When arriving at the Anderson Road
Quarry the most impressive view at the850000 square-meter facility is the Metso
machines including equipment from the
primary secondary and tertiary crushing
circuits and the screens I t is Metsorsquos equip-
ment that secures the supply of aggregates
for Hong Kong
KWP Quarry Company Limited has been
working with Metso since its establishment
in 1997
Due to Hong Kongrsquos stringent dust and noise control standards Metso has paid special attention to the related suppression systems
ldquoOur quarry mainly lies on granite and
volcanic rock which are so hard they canonly be processed by equipment with
strong durability and stabilityrdquo explains
Mr Eddie Hung Manager of KWP ldquoWith a
long history of and experience in quarry-
ing we are very familiar with the equip-
ment of different brands Comparatively
Metsorsquos products are better than others in
terms of durability stability and effi ciency
Besides this the reason we selected Metso
is because of the simple maintenance of
their equipment and the easy access tomaintenance informationrdquo
Flexible modular solution
Based on extensive experience in crushing
and screening worldwide Metso presented
the Anderson Road Quarry with a modu-
lar solution and delivered it as a turn-key
project Through a four-stage crushing
circuit which contains three Metso C160
8202019 Metso Minerals Aggregates 3 2011
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jaw crushers for primary crushing two
Omnicone 1560SX crushers for secondary
crushing two HP 500SX cone crushers for
tertiary crushing and one HP500SX cone
crusher for extra-fine crushing the plant
was able to produce aggregates of optimal
shape with minimal 1047298akiness
The fine products include three sizes
0 to 5 mm 5 to 10 mm and 10 to 20mm
Since the employment of this system in
2000 production has reached 1250 th
which is far beyond the design capacityAccording to Mr Hung ldquoThe machines
always run effi ciently and seldom malfunc-
tion The occasional shutdown of some
machines does not affect production very
much the plant still could reach 60-70
of its normal production It gives us the
best 1047298exibility for the plant rsquos operation and
I believe this is the best feature of Metsorsquos
solution
Eddie Hung
Manager of KWPrsquos
Anderson Road
Quarry is happy with
the product quality
and service provided
by Metso
ldquoMetsorsquos equipment is expensive com-
paratively but in the long run you will find
that the investment is worthwhile on the
whole Metso secures superior stability reli-
ability and fewer downtimes and it guaran-
tees continuous operation and brings us
greater valuerdquo
Great service team
Metso sent a group of service engineers
to the plant within the warranty period
not only to provide service but to train theoperators Mr Hung speaks highly of Met-
sorsquos service team he is impressed with its
experienced experts and with their strong
sense of responsibility and customer-
oriented ways of working
ldquoMetsorsquos service team never fails to find
hidden problems and helps us to prevent
any mechanical failures And they are
available whenever we need them they
work closely with us to solve the problem
effi cientlyrdquo he said
Excellent environment-friendly designIn order to achieve the worldrsquos most strin-
gent noise and dust control standards
developed by the Environment Protection
Department of Hong Kong Metso has
incorporated a dust and noise suppression
system into the plant This includes the
infrared-triggered spray systems at feed
points encapsulation of individual crush-
ers and conveyors and the ability to select
specific sectors of the system for treatment
depending on feed and operating condi-
tions encapsulation of equipment and the
enclosure of all major sections of the plant
With these advanced environment-
friendly solutions Anderson Road Quarry
has won numerous safety and environmen-
tal awards In 2003 it was presented with a
silver medal in the prestigious Environmen-
tal Performance Awards in recognition of
its commitment to the environment and
community In 2004 KWP achieved certifi-cation of ISO 14001 it is the first quarry site
to have achieved this in Hong Kong and
southern China
ldquoA reliable partnerrdquo
The promulgation of the top ten infrastruc-
ture policies in Hong Kong boosted the
market for aggregates and demand will
keep rising over the next five to six years
ldquoWersquoll definitely keep our cooperation with
Metso once we have a need for expansion
because we regard Metso as a reliable part-
ner With their highly effi cient equipmentsatisfying service and great efforts in help-
ing us to achieve our environmental pro-
tection targets Metso is our best choicerdquo
says Hung
More info
Ziqiang Li
Tel +86 13601289027
ziqianglimetsocom
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The sturdy Metso C160
jaw crushers are fed
using huge feed chutes
and feeders
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Similar to hundreds of mine sites world-
wide Zinkgruvan is being operated on a
non-stop 247 basis with just a few main-
tenance breaks during the year Crusher
availability is crucial because 100 of the
ore has to pass through the jaws before
being hoisted up for further processing
In addition to the zinc- lead- copper-
and silver-containing ore the C jaws chop
all the host rock extracted along the min-
ing process With a sturdy design Metsorsquos
proven C jaws can easily reduce even the
hardest type of rock Every year more thanone million tons are crushed with the jaws
ldquoMinimal service neededrdquo
Crushing with the first C160B jaw crusher
began at Zinkgruvanrsquos -800 meter level in
2000 with the primary crushing of zinc-lead
ore The second jaw was installed in 2008
for the new copper process gt
The sight and sound of two C160 jaw crushers operating side by side in the underground
crushing station of the Swedish Zinkgruvan mine is impressive Good proactive service
secures good uptime and reliable continuous operation of Metsorsquos second-largest
C160 series jaw crushers and prepares the way for the ongoing plans to expand the
production of zinc concentrate
TEXT amp PHOTOS Eero Haumlmaumllaumlinen
New PolyMet liners are being tested with the grinding mill delivered by Metso
Zinkgruvanrsquos twin C160
jaws secure good uptime
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Blasted ore is taken from the presently
operated -850 meter level with normal
trucks as an outsourced process One full
truckload is fed to the C160s every
10 minutes
ldquoWe are happy with the high reliability
of the C jaws They only require some minor
service therefore providing us with good
uptime and steady continuous feed to our
secondary and tertiary crushing and grind-ing circuitsrdquo says Mine Manager Jan Klaumlre
ldquoBasic crusher service and wear part
changes are made by our own staff using
Metsorsquos partsrdquo he adds
Service contract with grinding
mills and conveyors
Zinkgruvan and Metso Sweden have more
than 11 yearsrsquo experience with a service
contract that contains grinding mills and
conveyors At the mine site two Metso
service people and one contractor take
care of all the related service jobs Man-
power can also be borrowed from Metsorsquos
Graumlngesberg mine service team of 20
people
Presently Zinkgruvan is testing Metsorsquos
new PolyMet mill linings in its big grinding
mills With previously used rubber partsthe linings had to be changed in the shell
every 9 to 11 months and in the feed head
every 6 months
ldquoWe expect a better lifetime with Poly-
Met linings Longer change intervals mean
a lot to our productivity because lining
changes takes two full working daysrdquo Mine
Manager Jan Klaumlre says
New mine goes deeper
With an expected mine life of more than 10
years Zinkgruvan is actively mapping new
ore reserves Experimental holes are being
drilled at the new mine section at the
-1110 meter level
More info
Fredrik Wennberg
Tel +46 70 657 00 08fredrikwennbergmetsocom
Mine Manager Jan Klaumlre (left) with Backfilling Manager Kjell Tillman at the underground -800 meter level mine cafeteria
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The Zinkgruvan mine located approxi-
mately 200 km southwest of Stockholm
Sweden is one of the oldest underground
mines in Northern Europe The mine has
been in production since 1857
The mining methods used are panel
stoping and benching The processing
facilities include a zinc concentrating plant
with a 11 mtpa and a copper plant with a04 mtpa capacity Tailings are recycled in
an impounding basin and host rock in the
backfill plant
Continuous mining since 1857
Even as one of the oldest mines in Northern
Europe Zinkgruvan exploits modern mining
and minerals processing installations
Zinkgruvan mine
OWNER Lundin Mining
PRODUCTION PER YEAR 1 million tons
ORE TYPE sedimentary exhalative
zinc lead copper and silver
NUMBER OF EMPLOYEES 320
2011 PRODUCTION TARGETS 78000 tonsof zinc 36000 tons of lead and
3400 tons of copper concentrate
METSO EQUIPMENT ON SITE
bull 1 extra long VF feeder
bull 2 C160 jaw crushers
ndash zinc process css 220ndash240 mm
ndash copper process css 150 mm
bull 1 GP300S cone crusher
ndash css 45mm
bull 1 HP4 cone crusher
ndash css 18 mm
bull 1 DS screen
bull 1 FS402 screenbull 1 grinding mill
bull Pumps VPAs
A normal truck feeds the C jaws with ore coming from the lower production levels
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Cost-per-ton wear agreements deepencustomer relationshipsCrusher wear parts are traditionally marketed purely based on transactional sales and mainly depend on
the weight of manganese Metso has recently introduced a new type of wear agreement based on thecost-per-ton crushed and the wear occurred Thus far the experience has been very positive increasing
transparency and deepening the operational relationship between the manufacturer and the customer
TEXT Olli Kellokumpu and Eero Haumlmaumllaumlinen PHOTOS Eero Haumlmaumllaumlinen
Arto Hiedanniemi (left)
Hannu Heman and Juha
Laukka of Metsorsquos Finnish
Service team checking the
cone crusher mantles shipped
for a cost-per-ton customer
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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156
Wear parts and parts changes
can be included
The structure of a cost-per-ton wearcontract is based on the number of tons
crushed and the estimated wear occurred
The amount and monetary value of the
wear is calculated per crushed ton
ldquoEither plain wear parts or parts changes
carried out by Metsorsquos service personnel
can be included in the contract In the latter
case we ask our Finnish customers to inform
us about an upcoming wear change opera-
tion one week in advancerdquo Heman explains
ldquoWe see good opportunities to market
cost-per-ton contracts further in Finland
and also abroad It really develops therelationship of Metso and our customers
towards a trusted partnershiprdquo he notes
Perfect tool for accurate planning
Soraliike Ikola Oy is a mid-sized contrac-
tor with three Metso two- and three-
stage mobile and portable crushing and
screening plants operating in Central and
Since 2002 Metsorsquos sales team in Finland
has developed the cost-per-ton-based
service offeringldquoOur aim has been to seek through
a cost-per-ton offering possibilities to
serve our customers better to differentiate
Metso from the other players as an OEM
manufacturer and to offer deeper profes-
sionalism and know-howrdquo says Hannu
Heman General Manager of service
operations
ldquoUntil now both our experience and
that of our customers has been quite posi-
tive When properly prepared cost-per-ton
contracts seem to create a win-win situa-
tionrdquo Heman adds Today Metso has operational cost-per-
ton agreements with several Finnish cus-
tomers The first contract was concluded
with a customer operating a stationary
plant Based on the results gathered new
cost-per-ton contracts have been signed
with customers operating wheeled and
tracked equipment too
Eastern Finland Because of the size of the
contracts up to 50 equipment moves are
made during the yearEntrepreneur Pasi Ikola has had a cost-
per-ton contract with Metso for nearly
two years and he is quite happy with the
outcome
ldquoThe cost-per-ton contract has provided
me with a perfect tool for accurate financial
planning Now I know in detail my actual
future wear parts costs This helps a lot
when calculating bidsrdquo
ldquoEarlier I used to buy a big batch of
Metso wear parts in one go and had to
reserve a reasonable amount of money for
that Today all wear costs are evenly sharedwhich gives us a welcomed 1047298exibility to
our cost structure Now we just pay Metso
afterwards based on our crushed tonsrdquo
he adds
More info
Olli Kellokumpu
Tel +358 50 354 1189
ollikellokumpumetsocom
According to crushing contractor Pasi Ikola the cost-per-ton contract with Metso has provided the entrepreneur with better economical 1047298exibility
and more accurate calculating of bids
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Pleasant Gap is owned and operated by
Glenn O Hawbaker Inc of State College
Pennsylvania This family-owned company
began in 1952 as a small excavation busi-
ness founded by Glenn O Hawbaker and
his wife Thelma Over the years the com-
pany grew by adding an integrated mix ofproducts and services and taking on larger
projects
In 1983 Hawbaker acquired Pleasant
Gap Quarry and built its first aggregates
processing plant Today Glenn O Haw-
baker Inc operates 21 quarries and eight
asphalt production facilities across Penn-
sylvania and southern New York as well as
five regional operation centers
Primary
challenge atPleasant GapQuarryA good part of what makes for a successful crushing
operation is the willingness to tackle challenges and to do
whatrsquos necessary to meet demand The team at Pleasant
Gap Quarry in central Pennsylvania recently met the chal-
lenge when they successfully addressed problems with
the plantrsquos primary crushing plant First they purchased
a new Metso C160 jaw to replace the existing primary
impact crusher Then they devised an innovative plan to
get the primary plant back in operation while awaitingdelivery of the new jaw crusher
TEXT Linda Bergmann PHOTOS John Rickinger
983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Time for a change
With the goal of increasing reliability and
output the management at Pleasant Gap
Quarry recently decided it was time to
replace the plantrsquos primary impact crusher
Following a thorough search they chose a
new Metso C160 jaw According to ScottReck Plant Manager it no longer made
sense to repair and rebuild the existing
impactor
ldquoBefore we purchased the Metso C160
we had a few other impact crushers and
they served us well but as our custom-
ersrsquo needs increased our plant production
had to match that demand We found our
formerly reliable unit was being overcome
by our demands for output and creative
work-around solutions We continued to
need more but there was only so much we
could do until we hit the breaking point ndash
literallyrdquo
In addition to performance improve-
ments the new crusher also needed to fitinto Pleasant Gaprsquos unique infrastructure
As Plant Project ManagerEngineer Jeremy
Fahr explains ldquoOur height restraint was 274
meters (108rdquo) This height was the distance
from the feed lip of the existing 6x12 scalp-
ing screen and the existing structure that
the crusher rests onrdquo
The normal C160 crusher is 307
meters (121rdquo) tall but Metso gave GOH
Scott Reck Plant Manager (left) and
Jeremy Fahr Plant Project Manager
Engineer at Pleasant Gap Quarry
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983122983141983152983151983154983156983145983150983143 983154983141983155
a 10-degree mounting option (which is
normally used on their portable crushers)
to overcome the height restraint Reck and
Fahr worked with Dave Rhoa of Cleveland
Brothers Equipment Metsorsquos crushing and
screening distributor in Pennsylvania to
pull everything together and fit the newcrusher into their plant
The C160 crusher selected for Pleasant
Gap is one of the latest models in Metsorsquos
C Series of jaws These jaw crushers feature
a large throw and steep toggle plate angle
resulting in a higher crusher output In
addition the C Series has a compact foot-
print that makes it an ideal choice for the
replacement of existing machines
According to Reck ldquoWe had heard about
the new Metso C160 and started doing our
own research and found Metso not only
had developed the output capacity we
needed but fit the uniqueness of our oper-
ationsrdquo The new Metso crusher will allow
the plant to increase tons per hour andgive them the 1047298exibility to meet demands
for varying products on short notice
Mobile solution
Purchasing the new primary jaw addressed
the long-term issues but still left Pleasant
Gap without a functioning primary plant
Reck continues ldquoOur main line was still
down leaving us with a big hole in hitting
customer needs but knowing that our new
Metso C160 was on its wayhellipwe needed an
immediate solution to keep our produc-
tion demands with an out-of-commission
crusherrdquo
The team at Pleasant Gap brainstormed
the problem and came up with a plan toget the primary plant back in operation
Their solution was to use the Lokotrack
LT1213 impactor plant and another mobile
unit to keep the main line crushing To do
this they removed the guts on the existing
impact crusher essentially turning it into a
rock chute They then moved the LT1213
and another manufacturerrsquos mobile unit
over to the existing dump hopper gt
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
ldquoWe had our haul trucks drop off mate-
rial while two excavators fed the two
mobile unitsrdquo Reck explains ldquoFor two-and-
a-half months the Lokotrack LT1213 unit
was producing 254 cm (10rdquo) minus at
700 tons per hour The other similar-sized
mobile unit was doing 400 tons an hour
maxed out The difference was unbeliev-
able to say the least Our unique solution
using the two mobile units especially the
LT1213 helped Glenn O Hawbaker achieve
a record output in 2010rdquoAccording to Fahr ldquoWe were not new to
Metsorsquos quality and supportrdquo because GOH
had been using Metsorsquos portable crushing
equipment for 3 years prior to the primary
plantrsquos impact crusher failure In another
part of our operation we have a system that
our team relies on every day a Lokotrack
LT1213 and ST272 working in tandem with
two portable conveyorsrdquo This highly effi -
cient mobile processing system turns out
300 tons of specialized blended material
per hour GOH has been so impressed with
Metso equipment its last two purchaseswere an LT106 tracked jaw plant and a
second ST272 mobile screen in 2010
Maintaining high productivity
The Metso C160 jaw was delivered to Pleas-
ant Gap Quarry in January of 2011 and
since start-up it has more than met expec-
tations The crusher is fed minus 910 mm
(36rdquo) limestone with the jaw set at 140 mm
(5 12rdquo) According to Reck ldquoFrom moment
we started up we knew we had a winner
Not only were we kicking out as much
product as our previous units without even
breathing hard but we immediately had a
2-cent per ton savings to the bottom line
without having to run a second 350 HP
motor as required by other units Plus by
adding on the new automatic lube system
the maintenance team had more time to
devote to keeping other areas of the com-
plex running more effi cientlyrdquoReck says ldquoThe Metso unit was a perfect
fit and with the improved features it pre-
sented it had it all We just turn it on load
it up and we are moving 600 tons per hour
through the crusher without any effort and
we know it can do so much morerdquo With
the primary crushing plant back in opera-
tion the entire team at Pleasant Gap will
continue to do what they do best produce
and sell high-quality products and meet
their customersrsquo expectations
More info
Scott Yablonsky Tel +1 262 717 793
scottyablonskymetsocom
The Metso C160 jaw
was installed at a 10deg
angle to fit Pleasant
Gaprsquos existing
infrastructure
The Lokotrack LT1213 impactor plant and ST272 mobile screen operate in tandem with two
portable conveyors at Pleasant Gap
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983149983141983156983155983151 983150
Paper amp fiberNew OptiConcept M paper
and board making line
The new OptiConcept M paper and board
making line stands for economy safety and
usability
Metso has launched a new modular paper
and board making line called OptiConceptM A member of the proven OptiConcept
production line family the new OptiCon-
cept M optimizes machine investment in
line with each millrsquos capacity needs
Savings in operating costs are achieved
through precise dimensioning of pro-
cesses proven technological solutions
optimal running parameters effective
maintenance operations and fully inte-
grated automation solutions
Optimized processes innovations
smart controls and accurate dimensioning
decrease the use of steam gas electricitywater chemicals and other raw materials
and reduce emission levels
OptiConcept M has been designed
both visually and physically with the
requirements of users in mind For exam-
ple the design of the machinery allows for
easy and safe changing of rolls and wear
parts thus reducing the total duration and
cost of maintenance shutdowns
RecyclingGreen energy technology to
Elektrociepłownia Białystok in Poland
Metso will convert a coal-fired boiler to
a biomass-fired Bubbling Fluidized Bed
boiler for Elektrociepłownia Białystok SArsquos
combined heat and power plant (CHP) in
Białystok Poland The new boiler system
will cut the power plantrsquos CO2 emissions
significantly by partly replacing the coal
fuel supply with biomass fuel
ldquoPoland is one of the largest countries
in Europe to have such a high depend-ence on energy derived from coal to
meet national electricity needs This is an
important incentive for us to reduce future
CO2 emissions and produce more green
electricity and with Metso technology
we are certain to accomplish our goalrdquo
states Mr Andrzej Schroeder President of
Elektrociepłownia Białystok SA
Since 2000 Metso has received a total
of 7 biomass boiler conversion orders in
Poland and the renewable energy share
in Poland is only 75 (2010) compared to
the target of 20 by 2020 set by the EUApproximately 80 of the current energy
boilers turbines and generators installed in
Polish power plants are over 20 years old In
order to meet the strict EU environmental
requirements modernization of existing
installations is necessary
Automation
Metso DNA automation system expands
to mining and construction
Using Metsorsquos control room automation
an entire crushing and screening plant can
be effi ciently managed
Metso is a leading supplier of mining and
construction machinery This expertise has
now been combined with a scalable Metso
DNA automation system that adapts to
the range of industry needs from single
machine controls to plant-wide automation
and information management systems
An example of Metsorsquos new offering is a
new crushing plant control room solution
that connects crushers and screens ensur-
ing the effective management of the entire
plant from a pleasant and safe control
room The Metso DNA user interface pro-vides the production information to ensure
a proper and rapid response to plant
events Automatic controls stabilize the
process and allow the operators to monitor
the plant as a whole
ldquoThe benefits of automation for the min-
ing and construction industry are signifi-
cant As an example of the services we offer
performance studies to crushing plants
utilizing Metsorsquos multi-disciplinary teams of
experts to determine the present level of
the plant and process effi ciency and to esti-
mate the improvement potential and thebenefits of optimization and automation
including ROI calculationsrdquo says Mikko Maumlki-
nen Product Manager of minerals applica-
tions in Metsorsquos Automation business line
ldquoAs another example our machine
condition monitoring solutions can reduce
plant and machine downtimes as well as
help to avoid safety and environmental
hazardsrdquo he adds
Metso around the world
Aerial view of the Elektrociepłownia Białystok combined heat and power plant in Poland
8202019 Metso Minerals Aggregates 3 2011
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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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The new Lokotrack LT120 with its world premiere at the Steinexpo
exhibition in Germany combines crushing performance and user-
friendly design in a new revolutionary way For the first time the
same Lokotrack model is now available in a hydraulically or electri-
cally driven version to meet customer needs
New Lokotrack LT120 jaw plant introduced
Lokotrack LT120 is the latest and most advanced of Metsorsquos track-mounted jaw crusher plants
Lokotrack LT120 combines user-friendly design and good crushing
performance in a new way
power supply or a 420-kV onboard diesel generator Having the
possibility to use an external power supply enables a highly eco-
nomical and ecological crushing process
The Lokotrack LT120 is built around the new C120 jaw crusher
See page 10 for information about the C120
Safe to use move and service
Safety is the highest priority for Metso when designing new equip-ment The Lokotrack LT120 is designed to be safe to operate move
and service
ldquoA safe operating environment is created by practical solutions
When service points can be reached easily the possibility of dan-
gerous situations diminishesrdquo says Product Manager Timo Nakari
ldquoGood examples of safety built in to the Lokotrack LT120 include
sturdy easy-to-open composite 1047298ywheel guards and hydraulically
folding and locking feed hopper sidesrdquo Nakari adds
The Lokotrack LT120 can be fine-tuned to suit the customerrsquos
application by selecting the required options from a long main
conveyor and hammer and boom to a water spraying system and
rubber lining for the feeder and hopper for example
The Lokotrack LT120 features a Caterpillar C13 310 kW (415 hp)engine Its transport dimensions are length 16 m (52rsquo 6rdquo) width 3 m
(9rsquo10rdquo) height 39 m (12rsquo 10rdquo) and weight 57 tons (114000 lbs) The
LT120E version weighs 63 tons (126000 lbs)
More info
Timo Nakari
Tel + 358 40 701 6143
timonakarimetsocom
983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155
The Lokotrack LT120 uses the same field-proven technology
seen in Metsorsquos tracked units for over 26 years Every detail of thenew jaw plant has been thoroughly designed for reliability and
long life The main targets when designing the unit have been
energy effi ciency good performance reliability and product safety
Field tests have demonstrated its good fuel economy and high
crushing capacity
Environment-friendly economy
The Lokotrack LT120 is also available as an electrically driven unit
ndash the Lokotrack LT120E ndash which can take energy from an external
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The TS range of screens is characterized by its innovative design
comprising two technologies combined multi-variable slopes with
a variable elliptical motion This proven range is being comple-
mented with the new TS63 screen
The TS63rsquos unique combination increases both the screenrsquos effi -
ciency and its capacity Material speed is high at the feed end and
slows down at the discharge end
Metso TS series screens offer more space between decks mak-
ing maintenance easier and improving service conditions for the
operators as well as meeting all safety requirements
Metso has recently sold several 25-m2 multi-slope screens for
mining applications such as a TS63 for Ferrostaal in Mauritania andalso for the construction industry for example Holcim in Lynwood
Australia Georyt in Poland Apaxco in Mexico and Newmont in
Peru
More info
Denis Pradon
Tel +33 680 64 39 67
denispradonmetsocom
New TS63 screen ndash the largest three-deck banana screen on the market
The new Metso TS63 banana screen features a 25-m2 screening area
Following the success of the HP4 and HP5 Metso has broadened
the product range with the new HP3 cone crusher This mid-range
cone crusher benefits from 70+ years of experience in crushing
technology while specifically addressing customer requirements
for large capacity ease of operation and a high reduction ratio
The HP3 responds to market demands for increased productionquality reduced maintenance time and low operating costs The
new generation HP models are comparable to their predecessors
but offer increased versatility
The HP3 features the size of an HP200 with the output of an
HP300 The power performance and robustness of the new gen-
eration models allow in certain cases two crushers to be replaced
with just one so investment production and operation costs are
greatly reduced
The HP3 has been tested at two different quarry sites in France
over the past seven months ndash at a gravel pit and a rock quarry
The Metso factory in France began production of the HP3
series in September Several orders have already been received for
secondary and tertiary applications Since 2009 nearly 300 HP newgeneration cone crushers have been commissioned The HP3 mar-
ket will be primarily centered on gravel pit applications (70)
The HP3 has a nominal feed opening of 220 mm (865rsquorsquo) a
motor size of up to 220 kW (300 hp) and a weight of 13280 kg
(29277 lbs)
More info
Carlos Padin
Tel +33 6 0727 2002
carlospadinmetsocomMetso HP3 at a stationary installation in France
HP3 cone ndash another new-generation cone crusher
983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
First modular plant to NepalMetso delivered its first modular crushing and screening plant to MS Palchowke Mai Roda Dunga Udyog Limited (PMRD)
in Melamchi Nepal The modular plant solution offers PMRD a fast and effective response to productivity and qualityrequirements
TEXT amp PHOTOS Atoshi Nayak Ghosh
The diversity of operations at a typical con-
struction site involves quick decision-mak-
ing and often a lot of pressure to ensure a
timely execution
High performance guaranteed
Considering todayrsquos volatile market sce-
nario business partners must maintainpace with their customersrsquo ever-changing
requirements Understanding custom-
ersrsquo strategic business needs is of utmost
importance PMRDrsquos plant was commis-
sioned in January 2011 and has logged
about 1200 hours of operation to date
The plant is much more compact than
the traditional skid-mounted plant and
provides space for free movement of utility
equipment within the plant area One of
the key features of the plant is the totally
bolted structure It can be easily disman-
tled into sub-assemblies transported and
re-assembled effortlessly at a new location
which is one of the biggest advantages in
helping to meet new market demand
Due to the use of pre-assembled mod-ules for each crushing station the instal-
lation work on site takes less time thus
decreasing the plantrsquos installation lead time
The plant also includes a foldable conveyor
for maintenance of the cone crushers
Stepping up with Metso
PMRD operates a two-stage plant compris-
ing a C80 jaw crusher an HP200 high-
performance cone crusher and a CVB1845
screen with circular motion MV2 vibra-
tory mechanism for final product recovery
resulting in an aggregate plant of 150 tph
capacity for producing size fractions of 0-40
mm The plant is an example of world-class
craftsmanship and excellent material han-
dling capacityModular and non-welded construction
supported by durable pitman assembly sin-
gle-piece cast steel frame bearing housings
with repairable crusher construction and
the right cavity design results in aggressive
kinematics and high power that best suits
the requirements of the customer
PMRD has immense pride in the plant
ldquoThe performance has been astounding
A drawing of typical modular plant
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983122983141983152983151983154983156983145983150983143 983154983141983155
with applications ranging from road aggre-
gates commercial sand production to
ready-mix concretes The modular plant is
almost set to create a new niche in aggre-
gates processing in Nepalrsquos construction
industry It is one of a kind and we are sur-
prised at the plant rsquos production capacity
It is easy to operate and requires minimalmanpower Our cost per ton has signifi-
cantly gone down and so has the cost of
productionrdquo says Mr Sandeep K Agarwal
Director PMRD
Safety as a key issue
Health safety and environmental solutions
are key concerns for Metso and they are
addressed with the same sense of responsi-
bility as quality productivity and cost-
effi ciency issues Metso is responsible for
conducting operations in an environmen-
tally sound way and offers products and
services that can help customers fulfill their
environmental responsibilities
Metso provides the plant offi ce and site
with operation and maintenance manu-als for each and every piece of equipment
including safety issues which are entrusted
to all the operators
All conveyors are equipped with pull-
cord safety switches along with emergency
stop buttons The working area and walk-
ways are all equipped with safety hand rails
and checkered plates for anti-skidding The
entire plant is equipped with earth pits for
electrical current earth leakage prevention
Metso has ensured all possible measures
to maintain high safety standards for all
operation and maintenance personnel
More info
Suhen Agarwal
Tel +91 124 2351566suhenagarwalmetsocom
Nepalrsquos first modularcrushing and screening plant deliv ered by Metso
E ffi cien t C VB1845 inclined screen wi th
an M V2 vibra tor y mechanism handles
the classi fica tion o f crushed ma terials
A s turd y f eeder dis tribu tes the ma terials to be crushed to
a
Me tso C80 ja w crusher
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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155
Outokumpursquos Kemi
mine set to doubleproduction The only mine unit owned by Outokumpu
the chrome mine in Kemi northern Finland
is busy making preparations to double its
production set to begin next year In co-
operation with Metso Outokumpu willincrease the number of underground
feeders and optimize the durabil-
ity of wear parts in the massive
primary gyratory crusher
TEXT amp PHOTOS Eero Haumlmaumllaumlinen
Chrome ore is fed into Metsorsquos
Superiorreg 50-65 primary
gyratory crusher by three
different vibrating feeders
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Up until now the entire production of the
chrome mine totaling about 13 million
tons annually has been transported to the
Tornio ferrochrome plant for processing
and on to the Tornio stainless steel plant
The increase in production which will
begin in autumn 2012 is intended also to
enable Outokumpu to sell ferrochrome tocompanies outside the Group The produc-
tion target for 2013 is 27 million tons of
ore and of the ferrochrome produced from
the ore nearly a half (gt 200000 tons) is to
be sold outside
Underground expansion
work almost complete
About 500 meters underground the
majority of the work involved in increasing
the capacity the F3 project has already
been completed Doubling the production
is no problem for the Superiorreg primarygyratory crusher delivered to the mine
by Metso in 2002 which can digest more
than 2700 tons of feed material per hour if
necessary
At the moment the primary gyratory
crusher can be fed by three different vibrat-
ing feeders The crusher currently runs for
less than one-fifth of the production time
The increase in ore production will increase
the effective crushing time to about one-
third of the production time
A lot of work has been done for orestorage after the primary crusher The
two currently used storage silos are now
accompanied by two new 8000-ton silos
The number of Metso feeders transporting
the ore from the primary crusher has also
been doubled
Optimization of wear parts under way
Chrome ore has been a challenge to the
primary gyratory crusherrsquos wear parts The
wear is contributed to by the pulsating
feed which rarely fills the entire crushing
chamber There are also great differences inore type since brittle feed material prone
to chalking is occasionally replaced by hard
ore that requires a lot of crushing power
before it is crushed with a bang gt
Mika Saari (right) Foreman of ore line technicians at Outokumpursquos chrome mine in conversation with
Mikko Malkamaumlki Metsorsquos crusher wear parts specialist
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
last did in July for the replacement of the
crusherrsquos wear parts Our work is also facili-
tated by product development like the
addition of maintenance hatches to the
feedersrdquo he continues
Lasting technology
According to Mika Saarirsquos calculations the
Superiorreg primary gyratory crusher has so
far crushed more than six million tons of
ore in totalldquoThe factory polishing marks still show
on the bottom thrust bearing so we
believe that the bearing will last the entire
remaining service life of the crusher which
is about ten years and 30 million tons
Metsorsquos feeders have been equally reliablerdquo
Saari says
After the next 30 million tons of ore
it will be time to deepen the mine
More info
Jukka Raumlisaumlnen
Tel +358 50 317 1787 jukkaraisanenmetsocom
Mikko Malkamaumlki
Tel + 358 40 827 8223
mikkomalkamakimetsocom
The Kemi mine and Metso are currently
carrying out a development project to
increase the service life of the mantle and
outer concave and thus minimize down-
time due to replacement While the modu-
lar feed hopper enables quick replacement
of the mantle replacing the outer concave
can easily take more than a week The cooperation between the Kemi
mine and Metsorsquos wear parts team in
Tampere aims to extend the service life
of the parts to at least 4 million crushed
tons Durability is sought by optimizing the
chamber structure and selecting the r ight
materials for the outer concave
ldquoSmooth cooperationrdquo
Mika Saari Foreman of ore line technicians
working in the underground mainte-
nance of the Kemi mine leads a small but
experienced team of technicians The tidymodern offi ce spaces are located close to
the action at a depth of 500 meters
ldquoCooperation with Metso has been
smooth Increasing our own crushing
expertise takes time so all know-how
shared by the manufacturer is very wel-
come to usrdquo Mika Saari says
ldquoWe can also use Metsorsquos profession-
als for servicing when necessary like we
The Superiorreg 50-65 has provided reliable
crushing performance at a depth of 500 metres
in the Kemi chrome mine
Technicians Sari Kulju (left) and Marko Jaako ensure that the primary gyratory crusherrsquos hydraulicand electrical unit remains very tidy which contributes to trouble-free operation of the crusher
Outokumpu Oyrsquos Kemi
chrome mine
LOCATION Keminmaa northern
Finland
ORE TYPE chrome oxide (26)
ORE ESTIMATE ON 1 JANUARY 2011
ndash ore reserves 36 million tons
ndash mineral resources 87 million
tons
MINING METHOD bench and cut fillFEED MATERIAL SIZE 0ndash1000 mm
METSO EQUIPMENT IN THE MINE
bull 1 Superiorreg 50-65 primary
gyratory crusher
ndash open side setting 152 cm (6rdquo)
bull 8 VMOU 25-125 feeders
bull 1 VMOU 30-16 feeder
bull 1 VMOU 40125 feeder
bull 2 Symons cone crushers
bull 1 C80 jaw crusher
bull 4 HM75 pumps
bull 11HM100 pumps
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983122983141983152983151983154983156983145983150983143 983154983141983155
Metso was responsible for the design
development and construction of the
entire secondary and tertiary arrangement
The primary station will be the subject of a
subsequent investment
Latest environmental protection used
This installation has been designed in strict
compliance with the environmental quality
approach developed by Metso and its
partners using the latest technologies
in dust control including confinement
technology as well as dust encapsulation
technology for screens
To ensure an annual capacity of 15 mil-lion tons for a nominal output of 560th of
02 mm and 220 mm the clientrsquos choice
for the secondary stage naturally fell upon
the NP 1520 impact crusher
A complete impact crusher solution for Lafarge The Lafarge Group has entrusted Metso with the implementation of its new aggregates installation in southern France
It comprises a new secondary crushing stage equipped with an NP1520 impact crusher featuring a power range of2 x 250kW and equipped with hydraulic adjustment
TEXT amp PHOTO Gilles Dombey
The NP 1520 crusher has long proved
its performance not only in terms of capac-
ity and reduction rate but also quality of
the finished product and durability
More info
Arnaud Bertucat
Tel +33 (0)6 81 44 68 26
arnaudbertucatmetsocom
About 15 million tons of aggregates feed will be crushed with the NP1520 impact crusher at Lafargersquos stationary installation in southern France
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Multi-stage Lokotrack process a success in Senegal
A multi-stage crushing and screening process has proven its effi ciency in the production of concrete aggregates in
Senegal Western Africa With the mobile process Xewell Cimenteries SA now exploits its quarry better has reduced
its operating costs and can meet strict environmental requirements
TEXT Elisabetta Cataluffi PHOTOS Carlo Rinolfi
Senegal is a rapidly developing country
offering a good deal of potential activities
for crushing companies too At the sametime the country has several areas of high
environmental value Therefore contractors
must opt for state-of-the-art equipment that
offers reduced environmental emissions
The company Xewell Cimenteries SA
was founded in 2008 as a partnership
between Italian Swiss and Senegalesecontractors Xewell operates a limestone
quarry located in the Pout area east of the
capital city of Dakar
According to Alessandro Crestani Technical
Director of the Pout quarry a mobile process
was selected to better exploit the quarry and
reduce costsLokotrack process drawing made by Bruno simulation software
After assembling the Lokotrack units the process was tested by Xewell Cimenteries
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983122983141983152983151983154983156983145983150983143 983154983141983155
Owned by Freeport-McMoRan Copper amp
Gold (51) and CODELCO (49) the ElAbra mine has leachable oxide and sulfide
mineralization The minersquos processing facil-
ity has an annual capacity of 226000 tons
of copper cathode
Smaller size matters
Reducing the size of the crushed oxide
ore from the present 15 mm to 12 mm
was the main target of the mine and the
Metso team The changes that were carried
out in the process included a size varia-
tion change in the cut of the tertiary sieve
installation of rate-level sensors in thesecondary crushers and enabling speed
variables in the conveyor belt feeders of
the secondary crushing circuit
ldquoGoing from 15mm to 12mm may seem
small but the operational impact is very
important and significant for usrdquo explains
Juan Torres Carvajal Metallurgical Engi-
neer at the El Abra mine
ldquoOur goal is to reach 115000 tons with
a minimum of 80 of 12-mm-sized ore permonth The record to date is 105000 tons
and we will increase it until we reach our
project goalrdquo he adds
New design for cone liners
In addition to the work mentioned above
Metso is currently carrying out a project to
design the lining profiles for the secondary
and tertiary crushers of the plant which
will affect the smaller size of the material
In cooperation with Nelson Mella from
Metso and Rodolfo Navarro Crushing
Superintendent at the El Abra mine testswere carried out in July on the re-designed
Metso linings One set was tested for sec-
ondary crushing and two sets for tertiary
crushing
More info
Nelson Mella
Tel +56 99158 0576
nelsonmellametsocom
Finer ore through wear pro1047297lestudy at El Abra mine in ChileEl Abra is a porphyry copper open-pit mine and processing facility located in
Chile near the city of Calama some 4000 meters above sea level With the helpof Metsorsquos technical support the mine was able to achieve finer ore throughoutthe crushing process
TEXT amp PHOTOS Macarena Vallejo
Xewell Cimenteries produces a selec-
tion of dry processed aggregates for con-
crete Operations started at the end of 2009
with the aim of reaching 150000 metric
tons produced per year
Lokotracks chosen to reduce costs
To build up their tracked mobile processXewell Cimenteries decided to buy three
mobile plants from Metso two impactor
plants the Lokotrack LT1110 and LT1213
feeding a three-deck mobile screen the
ST620 The machines were sold by SCAI
SpA Metsorsquos Lokotrack distributor in Italy
ldquoWe chose tracked machines to bet-
ter exploit our quarry and to reduce
costs Mobile plants have low initial costs
because they donrsquot need any special foun-
dations or supply of electricity This obvi-
ously gives us a quicker process set-up and
better uptimerdquo says Alessandro Crestani Technical Director of the Pout quarry
ldquoThe mobile plant can also follow the
quarry face as the exploitation proceeds
reducing the transport costs of raw materi-
als in the same jobsite We chose Metso
because they ensured us the best cost-per-
ton ratiordquo he adds
Good customer service is crucial
According to Alessandro Crestani good
customer service also played a major role
when choosing the manufacturer of the
mobile equipmentldquoMetsorsquos distributor SCAI SpA was able
to provide us with a complete product
support and customer service package
Obviously service is a very important
aspect for us in a country like Senegal Any
downtime represents a clear loss of pro-
ductivity for usrdquo
The average level of productivity of the
mobile Lokotrack process is 200 metric
tons per hour
More info
Carlo Rinolfi Tel +39 335 1253159
crinolfiscaispacom
Example of the development of the Metso study
on the crusher lining profiles
Liner change for smaller ore size in the
MP1000 cone crusher
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Services success in Surabaya The Metso Surabaya workshop and offi ce complex opened in April 2008 provides Life Cycle Services and maintenance
solutions for Metso equipment in the Indonesia region The facility is strategically located in an industrial precinct on theouter rim of Surabaya the second largest city in Indonesia Its close proximity to an international airport major shipping
port and several engineering companies simplifies support for the regionrsquos key customers which include PT Newmont
and PT Freeport
TEXT amp PHOTOS David LeRoy amp Gary Whittred
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983122983141983152983151983154983156983145983150983143 983154983141983155
The Surabaya site operates through Metso
in Australia with assistance from key sales
and technical staff Handling regional ser-vice and repair business in-house allows
Metso to manage intellectual property and
closely control quality
It also enables the development of a
team of skilled service personnel who can
be utilized both internally and at key cus-
tomer sites as is common with the backup
service the workshop provides for screen
contracts
Innovation at work
Since 2008 the Surabaya facility has suc-
cessfully refurbished a wide variety ofcomponents Recently two ball mill heads
weighing 22 tons each were modified in
order to strengthen the 1047298ange of the ball
mill shell The modification included tap-
ping out existing 1047298ange holes and drilling
new ones so that finger plates could be
installed and welded to the 1047298anges
Positioning the head borer to properly
align the new 1047298ange holes proved diffi cult
Four roller support frames were manufac-
tured to support the heads and allow them
to be rotated easily Each hole was then
drilled and tapped at the correct angleusing the CNC five axis head The job had a
tight delivery as it was required for a shut-
down but with advance planning and inno-
vation it was completed ahead of schedule
MP1000 mainframe on
CNC vertical borer
Well equipped for fabricating and machin-
ing heavy components the Surabaya
The Surabaya facility has proven to be
a success for Metso The workshop offers a
wide variety of services in the region Qual-ity products and competitive pricing and
delivery times have led to strong customer
relationships
Turnover and customer service levels
have increased annually since the open-
ing and between 2008 and 2010 sales
increased 450 These excellent trends
are expected to continue as the operation
expands and the customer base grows
Since 2008 the Surabaya facility has
successfully refurbished
bull MP1000 counter shaft boxes headassemblies mainframes bowls adjust-
ment rings counterweights sockets and
tramp release cylinders
bull 7rsquo Symons bowls heads and countershaft
boxes
bull Vertimill screw and drive shafts
bull Ball mill heads
bull Ball mill trommel
bull VPA cylinders
bull Eaton clutches
bull Exciter screen mechanisms
bull 42x65 main shafts and eccentrics
More info
Gary Whittred
Tel +62 31 8430349
garywhittredmetsocom
workshop handles the majority of Metsorsquos
refurbishment work with ease But when
necessary PT PAL ndash a government facilitywith shipbuilding and heavy engineering
capabilities ndash offers a ldquoone stop shoprdquo Spe-
cially trained PT PAL staff ensures that the
work they perform complies with all Metso
specifications and quality standards
PT PAL also demonstrated their innova-
tive ability with the first MP1000 main-
frame refurbishment they completed The
mainframersquos shaft location bore needed
to be re-machined However the distance
from the top of the mainframe to the
tapered bore made it very hard to achieve
an accurate surface finish with the correctstandoff
To overcome this the shop decided to
machine the mainframe upside down and
elevated on support beams They posi-
tioned a new shaft under the mainframe in
a custom-made cradle Using an overhead
crane they could then lsquotrial fitrsquo the shaft in
the bore to make sure it seated correctly
and the mating tapers met specification
The method worked so well it has since
been used for four more mainframe refur-
bishments
Diversity and growth
Today Metso Surabaya continues to invest
in additional equipment in order to diver-
sify its service offering A new hydraulic
power pack which allows the facility to test
refurbished components to Metso specifi-
cations was recently used in the refurbish-
ment and testing of several VPA cylinders
for PT Freeport
Refurbished MP1000 mainframe dispatched by truck to
PT Freeport mine
Machining of MP1000 upper frame
at Metsorsquos Surabaya workshop
Mainframe at vertical CNC machining
8202019 Metso Minerals Aggregates 3 2011
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Creating Value with Metso in Hong KongIn Hong Kong the aggregates needed for construction are mostly supplied by two local quarries KWP Quarry Company
Limitedrsquos Anderson Road Quarry accounts for 60ndash70 making it the pillar of Hong Kongrsquos construction materials industry
TEXT amp PHOTOS Ou He
When arriving at the Anderson Road
Quarry the most impressive view at the850000 square-meter facility is the Metso
machines including equipment from the
primary secondary and tertiary crushing
circuits and the screens I t is Metsorsquos equip-
ment that secures the supply of aggregates
for Hong Kong
KWP Quarry Company Limited has been
working with Metso since its establishment
in 1997
Due to Hong Kongrsquos stringent dust and noise control standards Metso has paid special attention to the related suppression systems
ldquoOur quarry mainly lies on granite and
volcanic rock which are so hard they canonly be processed by equipment with
strong durability and stabilityrdquo explains
Mr Eddie Hung Manager of KWP ldquoWith a
long history of and experience in quarry-
ing we are very familiar with the equip-
ment of different brands Comparatively
Metsorsquos products are better than others in
terms of durability stability and effi ciency
Besides this the reason we selected Metso
is because of the simple maintenance of
their equipment and the easy access tomaintenance informationrdquo
Flexible modular solution
Based on extensive experience in crushing
and screening worldwide Metso presented
the Anderson Road Quarry with a modu-
lar solution and delivered it as a turn-key
project Through a four-stage crushing
circuit which contains three Metso C160
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jaw crushers for primary crushing two
Omnicone 1560SX crushers for secondary
crushing two HP 500SX cone crushers for
tertiary crushing and one HP500SX cone
crusher for extra-fine crushing the plant
was able to produce aggregates of optimal
shape with minimal 1047298akiness
The fine products include three sizes
0 to 5 mm 5 to 10 mm and 10 to 20mm
Since the employment of this system in
2000 production has reached 1250 th
which is far beyond the design capacityAccording to Mr Hung ldquoThe machines
always run effi ciently and seldom malfunc-
tion The occasional shutdown of some
machines does not affect production very
much the plant still could reach 60-70
of its normal production It gives us the
best 1047298exibility for the plant rsquos operation and
I believe this is the best feature of Metsorsquos
solution
Eddie Hung
Manager of KWPrsquos
Anderson Road
Quarry is happy with
the product quality
and service provided
by Metso
ldquoMetsorsquos equipment is expensive com-
paratively but in the long run you will find
that the investment is worthwhile on the
whole Metso secures superior stability reli-
ability and fewer downtimes and it guaran-
tees continuous operation and brings us
greater valuerdquo
Great service team
Metso sent a group of service engineers
to the plant within the warranty period
not only to provide service but to train theoperators Mr Hung speaks highly of Met-
sorsquos service team he is impressed with its
experienced experts and with their strong
sense of responsibility and customer-
oriented ways of working
ldquoMetsorsquos service team never fails to find
hidden problems and helps us to prevent
any mechanical failures And they are
available whenever we need them they
work closely with us to solve the problem
effi cientlyrdquo he said
Excellent environment-friendly designIn order to achieve the worldrsquos most strin-
gent noise and dust control standards
developed by the Environment Protection
Department of Hong Kong Metso has
incorporated a dust and noise suppression
system into the plant This includes the
infrared-triggered spray systems at feed
points encapsulation of individual crush-
ers and conveyors and the ability to select
specific sectors of the system for treatment
depending on feed and operating condi-
tions encapsulation of equipment and the
enclosure of all major sections of the plant
With these advanced environment-
friendly solutions Anderson Road Quarry
has won numerous safety and environmen-
tal awards In 2003 it was presented with a
silver medal in the prestigious Environmen-
tal Performance Awards in recognition of
its commitment to the environment and
community In 2004 KWP achieved certifi-cation of ISO 14001 it is the first quarry site
to have achieved this in Hong Kong and
southern China
ldquoA reliable partnerrdquo
The promulgation of the top ten infrastruc-
ture policies in Hong Kong boosted the
market for aggregates and demand will
keep rising over the next five to six years
ldquoWersquoll definitely keep our cooperation with
Metso once we have a need for expansion
because we regard Metso as a reliable part-
ner With their highly effi cient equipmentsatisfying service and great efforts in help-
ing us to achieve our environmental pro-
tection targets Metso is our best choicerdquo
says Hung
More info
Ziqiang Li
Tel +86 13601289027
ziqianglimetsocom
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The sturdy Metso C160
jaw crushers are fed
using huge feed chutes
and feeders
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Similar to hundreds of mine sites world-
wide Zinkgruvan is being operated on a
non-stop 247 basis with just a few main-
tenance breaks during the year Crusher
availability is crucial because 100 of the
ore has to pass through the jaws before
being hoisted up for further processing
In addition to the zinc- lead- copper-
and silver-containing ore the C jaws chop
all the host rock extracted along the min-
ing process With a sturdy design Metsorsquos
proven C jaws can easily reduce even the
hardest type of rock Every year more thanone million tons are crushed with the jaws
ldquoMinimal service neededrdquo
Crushing with the first C160B jaw crusher
began at Zinkgruvanrsquos -800 meter level in
2000 with the primary crushing of zinc-lead
ore The second jaw was installed in 2008
for the new copper process gt
The sight and sound of two C160 jaw crushers operating side by side in the underground
crushing station of the Swedish Zinkgruvan mine is impressive Good proactive service
secures good uptime and reliable continuous operation of Metsorsquos second-largest
C160 series jaw crushers and prepares the way for the ongoing plans to expand the
production of zinc concentrate
TEXT amp PHOTOS Eero Haumlmaumllaumlinen
New PolyMet liners are being tested with the grinding mill delivered by Metso
Zinkgruvanrsquos twin C160
jaws secure good uptime
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Blasted ore is taken from the presently
operated -850 meter level with normal
trucks as an outsourced process One full
truckload is fed to the C160s every
10 minutes
ldquoWe are happy with the high reliability
of the C jaws They only require some minor
service therefore providing us with good
uptime and steady continuous feed to our
secondary and tertiary crushing and grind-ing circuitsrdquo says Mine Manager Jan Klaumlre
ldquoBasic crusher service and wear part
changes are made by our own staff using
Metsorsquos partsrdquo he adds
Service contract with grinding
mills and conveyors
Zinkgruvan and Metso Sweden have more
than 11 yearsrsquo experience with a service
contract that contains grinding mills and
conveyors At the mine site two Metso
service people and one contractor take
care of all the related service jobs Man-
power can also be borrowed from Metsorsquos
Graumlngesberg mine service team of 20
people
Presently Zinkgruvan is testing Metsorsquos
new PolyMet mill linings in its big grinding
mills With previously used rubber partsthe linings had to be changed in the shell
every 9 to 11 months and in the feed head
every 6 months
ldquoWe expect a better lifetime with Poly-
Met linings Longer change intervals mean
a lot to our productivity because lining
changes takes two full working daysrdquo Mine
Manager Jan Klaumlre says
New mine goes deeper
With an expected mine life of more than 10
years Zinkgruvan is actively mapping new
ore reserves Experimental holes are being
drilled at the new mine section at the
-1110 meter level
More info
Fredrik Wennberg
Tel +46 70 657 00 08fredrikwennbergmetsocom
Mine Manager Jan Klaumlre (left) with Backfilling Manager Kjell Tillman at the underground -800 meter level mine cafeteria
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The Zinkgruvan mine located approxi-
mately 200 km southwest of Stockholm
Sweden is one of the oldest underground
mines in Northern Europe The mine has
been in production since 1857
The mining methods used are panel
stoping and benching The processing
facilities include a zinc concentrating plant
with a 11 mtpa and a copper plant with a04 mtpa capacity Tailings are recycled in
an impounding basin and host rock in the
backfill plant
Continuous mining since 1857
Even as one of the oldest mines in Northern
Europe Zinkgruvan exploits modern mining
and minerals processing installations
Zinkgruvan mine
OWNER Lundin Mining
PRODUCTION PER YEAR 1 million tons
ORE TYPE sedimentary exhalative
zinc lead copper and silver
NUMBER OF EMPLOYEES 320
2011 PRODUCTION TARGETS 78000 tonsof zinc 36000 tons of lead and
3400 tons of copper concentrate
METSO EQUIPMENT ON SITE
bull 1 extra long VF feeder
bull 2 C160 jaw crushers
ndash zinc process css 220ndash240 mm
ndash copper process css 150 mm
bull 1 GP300S cone crusher
ndash css 45mm
bull 1 HP4 cone crusher
ndash css 18 mm
bull 1 DS screen
bull 1 FS402 screenbull 1 grinding mill
bull Pumps VPAs
A normal truck feeds the C jaws with ore coming from the lower production levels
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Cost-per-ton wear agreements deepencustomer relationshipsCrusher wear parts are traditionally marketed purely based on transactional sales and mainly depend on
the weight of manganese Metso has recently introduced a new type of wear agreement based on thecost-per-ton crushed and the wear occurred Thus far the experience has been very positive increasing
transparency and deepening the operational relationship between the manufacturer and the customer
TEXT Olli Kellokumpu and Eero Haumlmaumllaumlinen PHOTOS Eero Haumlmaumllaumlinen
Arto Hiedanniemi (left)
Hannu Heman and Juha
Laukka of Metsorsquos Finnish
Service team checking the
cone crusher mantles shipped
for a cost-per-ton customer
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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156
Wear parts and parts changes
can be included
The structure of a cost-per-ton wearcontract is based on the number of tons
crushed and the estimated wear occurred
The amount and monetary value of the
wear is calculated per crushed ton
ldquoEither plain wear parts or parts changes
carried out by Metsorsquos service personnel
can be included in the contract In the latter
case we ask our Finnish customers to inform
us about an upcoming wear change opera-
tion one week in advancerdquo Heman explains
ldquoWe see good opportunities to market
cost-per-ton contracts further in Finland
and also abroad It really develops therelationship of Metso and our customers
towards a trusted partnershiprdquo he notes
Perfect tool for accurate planning
Soraliike Ikola Oy is a mid-sized contrac-
tor with three Metso two- and three-
stage mobile and portable crushing and
screening plants operating in Central and
Since 2002 Metsorsquos sales team in Finland
has developed the cost-per-ton-based
service offeringldquoOur aim has been to seek through
a cost-per-ton offering possibilities to
serve our customers better to differentiate
Metso from the other players as an OEM
manufacturer and to offer deeper profes-
sionalism and know-howrdquo says Hannu
Heman General Manager of service
operations
ldquoUntil now both our experience and
that of our customers has been quite posi-
tive When properly prepared cost-per-ton
contracts seem to create a win-win situa-
tionrdquo Heman adds Today Metso has operational cost-per-
ton agreements with several Finnish cus-
tomers The first contract was concluded
with a customer operating a stationary
plant Based on the results gathered new
cost-per-ton contracts have been signed
with customers operating wheeled and
tracked equipment too
Eastern Finland Because of the size of the
contracts up to 50 equipment moves are
made during the yearEntrepreneur Pasi Ikola has had a cost-
per-ton contract with Metso for nearly
two years and he is quite happy with the
outcome
ldquoThe cost-per-ton contract has provided
me with a perfect tool for accurate financial
planning Now I know in detail my actual
future wear parts costs This helps a lot
when calculating bidsrdquo
ldquoEarlier I used to buy a big batch of
Metso wear parts in one go and had to
reserve a reasonable amount of money for
that Today all wear costs are evenly sharedwhich gives us a welcomed 1047298exibility to
our cost structure Now we just pay Metso
afterwards based on our crushed tonsrdquo
he adds
More info
Olli Kellokumpu
Tel +358 50 354 1189
ollikellokumpumetsocom
According to crushing contractor Pasi Ikola the cost-per-ton contract with Metso has provided the entrepreneur with better economical 1047298exibility
and more accurate calculating of bids
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Pleasant Gap is owned and operated by
Glenn O Hawbaker Inc of State College
Pennsylvania This family-owned company
began in 1952 as a small excavation busi-
ness founded by Glenn O Hawbaker and
his wife Thelma Over the years the com-
pany grew by adding an integrated mix ofproducts and services and taking on larger
projects
In 1983 Hawbaker acquired Pleasant
Gap Quarry and built its first aggregates
processing plant Today Glenn O Haw-
baker Inc operates 21 quarries and eight
asphalt production facilities across Penn-
sylvania and southern New York as well as
five regional operation centers
Primary
challenge atPleasant GapQuarryA good part of what makes for a successful crushing
operation is the willingness to tackle challenges and to do
whatrsquos necessary to meet demand The team at Pleasant
Gap Quarry in central Pennsylvania recently met the chal-
lenge when they successfully addressed problems with
the plantrsquos primary crushing plant First they purchased
a new Metso C160 jaw to replace the existing primary
impact crusher Then they devised an innovative plan to
get the primary plant back in operation while awaitingdelivery of the new jaw crusher
TEXT Linda Bergmann PHOTOS John Rickinger
983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Time for a change
With the goal of increasing reliability and
output the management at Pleasant Gap
Quarry recently decided it was time to
replace the plantrsquos primary impact crusher
Following a thorough search they chose a
new Metso C160 jaw According to ScottReck Plant Manager it no longer made
sense to repair and rebuild the existing
impactor
ldquoBefore we purchased the Metso C160
we had a few other impact crushers and
they served us well but as our custom-
ersrsquo needs increased our plant production
had to match that demand We found our
formerly reliable unit was being overcome
by our demands for output and creative
work-around solutions We continued to
need more but there was only so much we
could do until we hit the breaking point ndash
literallyrdquo
In addition to performance improve-
ments the new crusher also needed to fitinto Pleasant Gaprsquos unique infrastructure
As Plant Project ManagerEngineer Jeremy
Fahr explains ldquoOur height restraint was 274
meters (108rdquo) This height was the distance
from the feed lip of the existing 6x12 scalp-
ing screen and the existing structure that
the crusher rests onrdquo
The normal C160 crusher is 307
meters (121rdquo) tall but Metso gave GOH
Scott Reck Plant Manager (left) and
Jeremy Fahr Plant Project Manager
Engineer at Pleasant Gap Quarry
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983122983141983152983151983154983156983145983150983143 983154983141983155
a 10-degree mounting option (which is
normally used on their portable crushers)
to overcome the height restraint Reck and
Fahr worked with Dave Rhoa of Cleveland
Brothers Equipment Metsorsquos crushing and
screening distributor in Pennsylvania to
pull everything together and fit the newcrusher into their plant
The C160 crusher selected for Pleasant
Gap is one of the latest models in Metsorsquos
C Series of jaws These jaw crushers feature
a large throw and steep toggle plate angle
resulting in a higher crusher output In
addition the C Series has a compact foot-
print that makes it an ideal choice for the
replacement of existing machines
According to Reck ldquoWe had heard about
the new Metso C160 and started doing our
own research and found Metso not only
had developed the output capacity we
needed but fit the uniqueness of our oper-
ationsrdquo The new Metso crusher will allow
the plant to increase tons per hour andgive them the 1047298exibility to meet demands
for varying products on short notice
Mobile solution
Purchasing the new primary jaw addressed
the long-term issues but still left Pleasant
Gap without a functioning primary plant
Reck continues ldquoOur main line was still
down leaving us with a big hole in hitting
customer needs but knowing that our new
Metso C160 was on its wayhellipwe needed an
immediate solution to keep our produc-
tion demands with an out-of-commission
crusherrdquo
The team at Pleasant Gap brainstormed
the problem and came up with a plan toget the primary plant back in operation
Their solution was to use the Lokotrack
LT1213 impactor plant and another mobile
unit to keep the main line crushing To do
this they removed the guts on the existing
impact crusher essentially turning it into a
rock chute They then moved the LT1213
and another manufacturerrsquos mobile unit
over to the existing dump hopper gt
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
ldquoWe had our haul trucks drop off mate-
rial while two excavators fed the two
mobile unitsrdquo Reck explains ldquoFor two-and-
a-half months the Lokotrack LT1213 unit
was producing 254 cm (10rdquo) minus at
700 tons per hour The other similar-sized
mobile unit was doing 400 tons an hour
maxed out The difference was unbeliev-
able to say the least Our unique solution
using the two mobile units especially the
LT1213 helped Glenn O Hawbaker achieve
a record output in 2010rdquoAccording to Fahr ldquoWe were not new to
Metsorsquos quality and supportrdquo because GOH
had been using Metsorsquos portable crushing
equipment for 3 years prior to the primary
plantrsquos impact crusher failure In another
part of our operation we have a system that
our team relies on every day a Lokotrack
LT1213 and ST272 working in tandem with
two portable conveyorsrdquo This highly effi -
cient mobile processing system turns out
300 tons of specialized blended material
per hour GOH has been so impressed with
Metso equipment its last two purchaseswere an LT106 tracked jaw plant and a
second ST272 mobile screen in 2010
Maintaining high productivity
The Metso C160 jaw was delivered to Pleas-
ant Gap Quarry in January of 2011 and
since start-up it has more than met expec-
tations The crusher is fed minus 910 mm
(36rdquo) limestone with the jaw set at 140 mm
(5 12rdquo) According to Reck ldquoFrom moment
we started up we knew we had a winner
Not only were we kicking out as much
product as our previous units without even
breathing hard but we immediately had a
2-cent per ton savings to the bottom line
without having to run a second 350 HP
motor as required by other units Plus by
adding on the new automatic lube system
the maintenance team had more time to
devote to keeping other areas of the com-
plex running more effi cientlyrdquoReck says ldquoThe Metso unit was a perfect
fit and with the improved features it pre-
sented it had it all We just turn it on load
it up and we are moving 600 tons per hour
through the crusher without any effort and
we know it can do so much morerdquo With
the primary crushing plant back in opera-
tion the entire team at Pleasant Gap will
continue to do what they do best produce
and sell high-quality products and meet
their customersrsquo expectations
More info
Scott Yablonsky Tel +1 262 717 793
scottyablonskymetsocom
The Metso C160 jaw
was installed at a 10deg
angle to fit Pleasant
Gaprsquos existing
infrastructure
The Lokotrack LT1213 impactor plant and ST272 mobile screen operate in tandem with two
portable conveyors at Pleasant Gap
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983149983141983156983155983151 983150
Paper amp fiberNew OptiConcept M paper
and board making line
The new OptiConcept M paper and board
making line stands for economy safety and
usability
Metso has launched a new modular paper
and board making line called OptiConceptM A member of the proven OptiConcept
production line family the new OptiCon-
cept M optimizes machine investment in
line with each millrsquos capacity needs
Savings in operating costs are achieved
through precise dimensioning of pro-
cesses proven technological solutions
optimal running parameters effective
maintenance operations and fully inte-
grated automation solutions
Optimized processes innovations
smart controls and accurate dimensioning
decrease the use of steam gas electricitywater chemicals and other raw materials
and reduce emission levels
OptiConcept M has been designed
both visually and physically with the
requirements of users in mind For exam-
ple the design of the machinery allows for
easy and safe changing of rolls and wear
parts thus reducing the total duration and
cost of maintenance shutdowns
RecyclingGreen energy technology to
Elektrociepłownia Białystok in Poland
Metso will convert a coal-fired boiler to
a biomass-fired Bubbling Fluidized Bed
boiler for Elektrociepłownia Białystok SArsquos
combined heat and power plant (CHP) in
Białystok Poland The new boiler system
will cut the power plantrsquos CO2 emissions
significantly by partly replacing the coal
fuel supply with biomass fuel
ldquoPoland is one of the largest countries
in Europe to have such a high depend-ence on energy derived from coal to
meet national electricity needs This is an
important incentive for us to reduce future
CO2 emissions and produce more green
electricity and with Metso technology
we are certain to accomplish our goalrdquo
states Mr Andrzej Schroeder President of
Elektrociepłownia Białystok SA
Since 2000 Metso has received a total
of 7 biomass boiler conversion orders in
Poland and the renewable energy share
in Poland is only 75 (2010) compared to
the target of 20 by 2020 set by the EUApproximately 80 of the current energy
boilers turbines and generators installed in
Polish power plants are over 20 years old In
order to meet the strict EU environmental
requirements modernization of existing
installations is necessary
Automation
Metso DNA automation system expands
to mining and construction
Using Metsorsquos control room automation
an entire crushing and screening plant can
be effi ciently managed
Metso is a leading supplier of mining and
construction machinery This expertise has
now been combined with a scalable Metso
DNA automation system that adapts to
the range of industry needs from single
machine controls to plant-wide automation
and information management systems
An example of Metsorsquos new offering is a
new crushing plant control room solution
that connects crushers and screens ensur-
ing the effective management of the entire
plant from a pleasant and safe control
room The Metso DNA user interface pro-vides the production information to ensure
a proper and rapid response to plant
events Automatic controls stabilize the
process and allow the operators to monitor
the plant as a whole
ldquoThe benefits of automation for the min-
ing and construction industry are signifi-
cant As an example of the services we offer
performance studies to crushing plants
utilizing Metsorsquos multi-disciplinary teams of
experts to determine the present level of
the plant and process effi ciency and to esti-
mate the improvement potential and thebenefits of optimization and automation
including ROI calculationsrdquo says Mikko Maumlki-
nen Product Manager of minerals applica-
tions in Metsorsquos Automation business line
ldquoAs another example our machine
condition monitoring solutions can reduce
plant and machine downtimes as well as
help to avoid safety and environmental
hazardsrdquo he adds
Metso around the world
Aerial view of the Elektrociepłownia Białystok combined heat and power plant in Poland
8202019 Metso Minerals Aggregates 3 2011
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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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The TS range of screens is characterized by its innovative design
comprising two technologies combined multi-variable slopes with
a variable elliptical motion This proven range is being comple-
mented with the new TS63 screen
The TS63rsquos unique combination increases both the screenrsquos effi -
ciency and its capacity Material speed is high at the feed end and
slows down at the discharge end
Metso TS series screens offer more space between decks mak-
ing maintenance easier and improving service conditions for the
operators as well as meeting all safety requirements
Metso has recently sold several 25-m2 multi-slope screens for
mining applications such as a TS63 for Ferrostaal in Mauritania andalso for the construction industry for example Holcim in Lynwood
Australia Georyt in Poland Apaxco in Mexico and Newmont in
Peru
More info
Denis Pradon
Tel +33 680 64 39 67
denispradonmetsocom
New TS63 screen ndash the largest three-deck banana screen on the market
The new Metso TS63 banana screen features a 25-m2 screening area
Following the success of the HP4 and HP5 Metso has broadened
the product range with the new HP3 cone crusher This mid-range
cone crusher benefits from 70+ years of experience in crushing
technology while specifically addressing customer requirements
for large capacity ease of operation and a high reduction ratio
The HP3 responds to market demands for increased productionquality reduced maintenance time and low operating costs The
new generation HP models are comparable to their predecessors
but offer increased versatility
The HP3 features the size of an HP200 with the output of an
HP300 The power performance and robustness of the new gen-
eration models allow in certain cases two crushers to be replaced
with just one so investment production and operation costs are
greatly reduced
The HP3 has been tested at two different quarry sites in France
over the past seven months ndash at a gravel pit and a rock quarry
The Metso factory in France began production of the HP3
series in September Several orders have already been received for
secondary and tertiary applications Since 2009 nearly 300 HP newgeneration cone crushers have been commissioned The HP3 mar-
ket will be primarily centered on gravel pit applications (70)
The HP3 has a nominal feed opening of 220 mm (865rsquorsquo) a
motor size of up to 220 kW (300 hp) and a weight of 13280 kg
(29277 lbs)
More info
Carlos Padin
Tel +33 6 0727 2002
carlospadinmetsocomMetso HP3 at a stationary installation in France
HP3 cone ndash another new-generation cone crusher
983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156
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First modular plant to NepalMetso delivered its first modular crushing and screening plant to MS Palchowke Mai Roda Dunga Udyog Limited (PMRD)
in Melamchi Nepal The modular plant solution offers PMRD a fast and effective response to productivity and qualityrequirements
TEXT amp PHOTOS Atoshi Nayak Ghosh
The diversity of operations at a typical con-
struction site involves quick decision-mak-
ing and often a lot of pressure to ensure a
timely execution
High performance guaranteed
Considering todayrsquos volatile market sce-
nario business partners must maintainpace with their customersrsquo ever-changing
requirements Understanding custom-
ersrsquo strategic business needs is of utmost
importance PMRDrsquos plant was commis-
sioned in January 2011 and has logged
about 1200 hours of operation to date
The plant is much more compact than
the traditional skid-mounted plant and
provides space for free movement of utility
equipment within the plant area One of
the key features of the plant is the totally
bolted structure It can be easily disman-
tled into sub-assemblies transported and
re-assembled effortlessly at a new location
which is one of the biggest advantages in
helping to meet new market demand
Due to the use of pre-assembled mod-ules for each crushing station the instal-
lation work on site takes less time thus
decreasing the plantrsquos installation lead time
The plant also includes a foldable conveyor
for maintenance of the cone crushers
Stepping up with Metso
PMRD operates a two-stage plant compris-
ing a C80 jaw crusher an HP200 high-
performance cone crusher and a CVB1845
screen with circular motion MV2 vibra-
tory mechanism for final product recovery
resulting in an aggregate plant of 150 tph
capacity for producing size fractions of 0-40
mm The plant is an example of world-class
craftsmanship and excellent material han-
dling capacityModular and non-welded construction
supported by durable pitman assembly sin-
gle-piece cast steel frame bearing housings
with repairable crusher construction and
the right cavity design results in aggressive
kinematics and high power that best suits
the requirements of the customer
PMRD has immense pride in the plant
ldquoThe performance has been astounding
A drawing of typical modular plant
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with applications ranging from road aggre-
gates commercial sand production to
ready-mix concretes The modular plant is
almost set to create a new niche in aggre-
gates processing in Nepalrsquos construction
industry It is one of a kind and we are sur-
prised at the plant rsquos production capacity
It is easy to operate and requires minimalmanpower Our cost per ton has signifi-
cantly gone down and so has the cost of
productionrdquo says Mr Sandeep K Agarwal
Director PMRD
Safety as a key issue
Health safety and environmental solutions
are key concerns for Metso and they are
addressed with the same sense of responsi-
bility as quality productivity and cost-
effi ciency issues Metso is responsible for
conducting operations in an environmen-
tally sound way and offers products and
services that can help customers fulfill their
environmental responsibilities
Metso provides the plant offi ce and site
with operation and maintenance manu-als for each and every piece of equipment
including safety issues which are entrusted
to all the operators
All conveyors are equipped with pull-
cord safety switches along with emergency
stop buttons The working area and walk-
ways are all equipped with safety hand rails
and checkered plates for anti-skidding The
entire plant is equipped with earth pits for
electrical current earth leakage prevention
Metso has ensured all possible measures
to maintain high safety standards for all
operation and maintenance personnel
More info
Suhen Agarwal
Tel +91 124 2351566suhenagarwalmetsocom
Nepalrsquos first modularcrushing and screening plant deliv ered by Metso
E ffi cien t C VB1845 inclined screen wi th
an M V2 vibra tor y mechanism handles
the classi fica tion o f crushed ma terials
A s turd y f eeder dis tribu tes the ma terials to be crushed to
a
Me tso C80 ja w crusher
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Outokumpursquos Kemi
mine set to doubleproduction The only mine unit owned by Outokumpu
the chrome mine in Kemi northern Finland
is busy making preparations to double its
production set to begin next year In co-
operation with Metso Outokumpu willincrease the number of underground
feeders and optimize the durabil-
ity of wear parts in the massive
primary gyratory crusher
TEXT amp PHOTOS Eero Haumlmaumllaumlinen
Chrome ore is fed into Metsorsquos
Superiorreg 50-65 primary
gyratory crusher by three
different vibrating feeders
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Up until now the entire production of the
chrome mine totaling about 13 million
tons annually has been transported to the
Tornio ferrochrome plant for processing
and on to the Tornio stainless steel plant
The increase in production which will
begin in autumn 2012 is intended also to
enable Outokumpu to sell ferrochrome tocompanies outside the Group The produc-
tion target for 2013 is 27 million tons of
ore and of the ferrochrome produced from
the ore nearly a half (gt 200000 tons) is to
be sold outside
Underground expansion
work almost complete
About 500 meters underground the
majority of the work involved in increasing
the capacity the F3 project has already
been completed Doubling the production
is no problem for the Superiorreg primarygyratory crusher delivered to the mine
by Metso in 2002 which can digest more
than 2700 tons of feed material per hour if
necessary
At the moment the primary gyratory
crusher can be fed by three different vibrat-
ing feeders The crusher currently runs for
less than one-fifth of the production time
The increase in ore production will increase
the effective crushing time to about one-
third of the production time
A lot of work has been done for orestorage after the primary crusher The
two currently used storage silos are now
accompanied by two new 8000-ton silos
The number of Metso feeders transporting
the ore from the primary crusher has also
been doubled
Optimization of wear parts under way
Chrome ore has been a challenge to the
primary gyratory crusherrsquos wear parts The
wear is contributed to by the pulsating
feed which rarely fills the entire crushing
chamber There are also great differences inore type since brittle feed material prone
to chalking is occasionally replaced by hard
ore that requires a lot of crushing power
before it is crushed with a bang gt
Mika Saari (right) Foreman of ore line technicians at Outokumpursquos chrome mine in conversation with
Mikko Malkamaumlki Metsorsquos crusher wear parts specialist
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
last did in July for the replacement of the
crusherrsquos wear parts Our work is also facili-
tated by product development like the
addition of maintenance hatches to the
feedersrdquo he continues
Lasting technology
According to Mika Saarirsquos calculations the
Superiorreg primary gyratory crusher has so
far crushed more than six million tons of
ore in totalldquoThe factory polishing marks still show
on the bottom thrust bearing so we
believe that the bearing will last the entire
remaining service life of the crusher which
is about ten years and 30 million tons
Metsorsquos feeders have been equally reliablerdquo
Saari says
After the next 30 million tons of ore
it will be time to deepen the mine
More info
Jukka Raumlisaumlnen
Tel +358 50 317 1787 jukkaraisanenmetsocom
Mikko Malkamaumlki
Tel + 358 40 827 8223
mikkomalkamakimetsocom
The Kemi mine and Metso are currently
carrying out a development project to
increase the service life of the mantle and
outer concave and thus minimize down-
time due to replacement While the modu-
lar feed hopper enables quick replacement
of the mantle replacing the outer concave
can easily take more than a week The cooperation between the Kemi
mine and Metsorsquos wear parts team in
Tampere aims to extend the service life
of the parts to at least 4 million crushed
tons Durability is sought by optimizing the
chamber structure and selecting the r ight
materials for the outer concave
ldquoSmooth cooperationrdquo
Mika Saari Foreman of ore line technicians
working in the underground mainte-
nance of the Kemi mine leads a small but
experienced team of technicians The tidymodern offi ce spaces are located close to
the action at a depth of 500 meters
ldquoCooperation with Metso has been
smooth Increasing our own crushing
expertise takes time so all know-how
shared by the manufacturer is very wel-
come to usrdquo Mika Saari says
ldquoWe can also use Metsorsquos profession-
als for servicing when necessary like we
The Superiorreg 50-65 has provided reliable
crushing performance at a depth of 500 metres
in the Kemi chrome mine
Technicians Sari Kulju (left) and Marko Jaako ensure that the primary gyratory crusherrsquos hydraulicand electrical unit remains very tidy which contributes to trouble-free operation of the crusher
Outokumpu Oyrsquos Kemi
chrome mine
LOCATION Keminmaa northern
Finland
ORE TYPE chrome oxide (26)
ORE ESTIMATE ON 1 JANUARY 2011
ndash ore reserves 36 million tons
ndash mineral resources 87 million
tons
MINING METHOD bench and cut fillFEED MATERIAL SIZE 0ndash1000 mm
METSO EQUIPMENT IN THE MINE
bull 1 Superiorreg 50-65 primary
gyratory crusher
ndash open side setting 152 cm (6rdquo)
bull 8 VMOU 25-125 feeders
bull 1 VMOU 30-16 feeder
bull 1 VMOU 40125 feeder
bull 2 Symons cone crushers
bull 1 C80 jaw crusher
bull 4 HM75 pumps
bull 11HM100 pumps
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Metso was responsible for the design
development and construction of the
entire secondary and tertiary arrangement
The primary station will be the subject of a
subsequent investment
Latest environmental protection used
This installation has been designed in strict
compliance with the environmental quality
approach developed by Metso and its
partners using the latest technologies
in dust control including confinement
technology as well as dust encapsulation
technology for screens
To ensure an annual capacity of 15 mil-lion tons for a nominal output of 560th of
02 mm and 220 mm the clientrsquos choice
for the secondary stage naturally fell upon
the NP 1520 impact crusher
A complete impact crusher solution for Lafarge The Lafarge Group has entrusted Metso with the implementation of its new aggregates installation in southern France
It comprises a new secondary crushing stage equipped with an NP1520 impact crusher featuring a power range of2 x 250kW and equipped with hydraulic adjustment
TEXT amp PHOTO Gilles Dombey
The NP 1520 crusher has long proved
its performance not only in terms of capac-
ity and reduction rate but also quality of
the finished product and durability
More info
Arnaud Bertucat
Tel +33 (0)6 81 44 68 26
arnaudbertucatmetsocom
About 15 million tons of aggregates feed will be crushed with the NP1520 impact crusher at Lafargersquos stationary installation in southern France
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Multi-stage Lokotrack process a success in Senegal
A multi-stage crushing and screening process has proven its effi ciency in the production of concrete aggregates in
Senegal Western Africa With the mobile process Xewell Cimenteries SA now exploits its quarry better has reduced
its operating costs and can meet strict environmental requirements
TEXT Elisabetta Cataluffi PHOTOS Carlo Rinolfi
Senegal is a rapidly developing country
offering a good deal of potential activities
for crushing companies too At the sametime the country has several areas of high
environmental value Therefore contractors
must opt for state-of-the-art equipment that
offers reduced environmental emissions
The company Xewell Cimenteries SA
was founded in 2008 as a partnership
between Italian Swiss and Senegalesecontractors Xewell operates a limestone
quarry located in the Pout area east of the
capital city of Dakar
According to Alessandro Crestani Technical
Director of the Pout quarry a mobile process
was selected to better exploit the quarry and
reduce costsLokotrack process drawing made by Bruno simulation software
After assembling the Lokotrack units the process was tested by Xewell Cimenteries
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983122983141983152983151983154983156983145983150983143 983154983141983155
Owned by Freeport-McMoRan Copper amp
Gold (51) and CODELCO (49) the ElAbra mine has leachable oxide and sulfide
mineralization The minersquos processing facil-
ity has an annual capacity of 226000 tons
of copper cathode
Smaller size matters
Reducing the size of the crushed oxide
ore from the present 15 mm to 12 mm
was the main target of the mine and the
Metso team The changes that were carried
out in the process included a size varia-
tion change in the cut of the tertiary sieve
installation of rate-level sensors in thesecondary crushers and enabling speed
variables in the conveyor belt feeders of
the secondary crushing circuit
ldquoGoing from 15mm to 12mm may seem
small but the operational impact is very
important and significant for usrdquo explains
Juan Torres Carvajal Metallurgical Engi-
neer at the El Abra mine
ldquoOur goal is to reach 115000 tons with
a minimum of 80 of 12-mm-sized ore permonth The record to date is 105000 tons
and we will increase it until we reach our
project goalrdquo he adds
New design for cone liners
In addition to the work mentioned above
Metso is currently carrying out a project to
design the lining profiles for the secondary
and tertiary crushers of the plant which
will affect the smaller size of the material
In cooperation with Nelson Mella from
Metso and Rodolfo Navarro Crushing
Superintendent at the El Abra mine testswere carried out in July on the re-designed
Metso linings One set was tested for sec-
ondary crushing and two sets for tertiary
crushing
More info
Nelson Mella
Tel +56 99158 0576
nelsonmellametsocom
Finer ore through wear pro1047297lestudy at El Abra mine in ChileEl Abra is a porphyry copper open-pit mine and processing facility located in
Chile near the city of Calama some 4000 meters above sea level With the helpof Metsorsquos technical support the mine was able to achieve finer ore throughoutthe crushing process
TEXT amp PHOTOS Macarena Vallejo
Xewell Cimenteries produces a selec-
tion of dry processed aggregates for con-
crete Operations started at the end of 2009
with the aim of reaching 150000 metric
tons produced per year
Lokotracks chosen to reduce costs
To build up their tracked mobile processXewell Cimenteries decided to buy three
mobile plants from Metso two impactor
plants the Lokotrack LT1110 and LT1213
feeding a three-deck mobile screen the
ST620 The machines were sold by SCAI
SpA Metsorsquos Lokotrack distributor in Italy
ldquoWe chose tracked machines to bet-
ter exploit our quarry and to reduce
costs Mobile plants have low initial costs
because they donrsquot need any special foun-
dations or supply of electricity This obvi-
ously gives us a quicker process set-up and
better uptimerdquo says Alessandro Crestani Technical Director of the Pout quarry
ldquoThe mobile plant can also follow the
quarry face as the exploitation proceeds
reducing the transport costs of raw materi-
als in the same jobsite We chose Metso
because they ensured us the best cost-per-
ton ratiordquo he adds
Good customer service is crucial
According to Alessandro Crestani good
customer service also played a major role
when choosing the manufacturer of the
mobile equipmentldquoMetsorsquos distributor SCAI SpA was able
to provide us with a complete product
support and customer service package
Obviously service is a very important
aspect for us in a country like Senegal Any
downtime represents a clear loss of pro-
ductivity for usrdquo
The average level of productivity of the
mobile Lokotrack process is 200 metric
tons per hour
More info
Carlo Rinolfi Tel +39 335 1253159
crinolfiscaispacom
Example of the development of the Metso study
on the crusher lining profiles
Liner change for smaller ore size in the
MP1000 cone crusher
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Services success in Surabaya The Metso Surabaya workshop and offi ce complex opened in April 2008 provides Life Cycle Services and maintenance
solutions for Metso equipment in the Indonesia region The facility is strategically located in an industrial precinct on theouter rim of Surabaya the second largest city in Indonesia Its close proximity to an international airport major shipping
port and several engineering companies simplifies support for the regionrsquos key customers which include PT Newmont
and PT Freeport
TEXT amp PHOTOS David LeRoy amp Gary Whittred
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983122983141983152983151983154983156983145983150983143 983154983141983155
The Surabaya site operates through Metso
in Australia with assistance from key sales
and technical staff Handling regional ser-vice and repair business in-house allows
Metso to manage intellectual property and
closely control quality
It also enables the development of a
team of skilled service personnel who can
be utilized both internally and at key cus-
tomer sites as is common with the backup
service the workshop provides for screen
contracts
Innovation at work
Since 2008 the Surabaya facility has suc-
cessfully refurbished a wide variety ofcomponents Recently two ball mill heads
weighing 22 tons each were modified in
order to strengthen the 1047298ange of the ball
mill shell The modification included tap-
ping out existing 1047298ange holes and drilling
new ones so that finger plates could be
installed and welded to the 1047298anges
Positioning the head borer to properly
align the new 1047298ange holes proved diffi cult
Four roller support frames were manufac-
tured to support the heads and allow them
to be rotated easily Each hole was then
drilled and tapped at the correct angleusing the CNC five axis head The job had a
tight delivery as it was required for a shut-
down but with advance planning and inno-
vation it was completed ahead of schedule
MP1000 mainframe on
CNC vertical borer
Well equipped for fabricating and machin-
ing heavy components the Surabaya
The Surabaya facility has proven to be
a success for Metso The workshop offers a
wide variety of services in the region Qual-ity products and competitive pricing and
delivery times have led to strong customer
relationships
Turnover and customer service levels
have increased annually since the open-
ing and between 2008 and 2010 sales
increased 450 These excellent trends
are expected to continue as the operation
expands and the customer base grows
Since 2008 the Surabaya facility has
successfully refurbished
bull MP1000 counter shaft boxes headassemblies mainframes bowls adjust-
ment rings counterweights sockets and
tramp release cylinders
bull 7rsquo Symons bowls heads and countershaft
boxes
bull Vertimill screw and drive shafts
bull Ball mill heads
bull Ball mill trommel
bull VPA cylinders
bull Eaton clutches
bull Exciter screen mechanisms
bull 42x65 main shafts and eccentrics
More info
Gary Whittred
Tel +62 31 8430349
garywhittredmetsocom
workshop handles the majority of Metsorsquos
refurbishment work with ease But when
necessary PT PAL ndash a government facilitywith shipbuilding and heavy engineering
capabilities ndash offers a ldquoone stop shoprdquo Spe-
cially trained PT PAL staff ensures that the
work they perform complies with all Metso
specifications and quality standards
PT PAL also demonstrated their innova-
tive ability with the first MP1000 main-
frame refurbishment they completed The
mainframersquos shaft location bore needed
to be re-machined However the distance
from the top of the mainframe to the
tapered bore made it very hard to achieve
an accurate surface finish with the correctstandoff
To overcome this the shop decided to
machine the mainframe upside down and
elevated on support beams They posi-
tioned a new shaft under the mainframe in
a custom-made cradle Using an overhead
crane they could then lsquotrial fitrsquo the shaft in
the bore to make sure it seated correctly
and the mating tapers met specification
The method worked so well it has since
been used for four more mainframe refur-
bishments
Diversity and growth
Today Metso Surabaya continues to invest
in additional equipment in order to diver-
sify its service offering A new hydraulic
power pack which allows the facility to test
refurbished components to Metso specifi-
cations was recently used in the refurbish-
ment and testing of several VPA cylinders
for PT Freeport
Refurbished MP1000 mainframe dispatched by truck to
PT Freeport mine
Machining of MP1000 upper frame
at Metsorsquos Surabaya workshop
Mainframe at vertical CNC machining
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Creating Value with Metso in Hong KongIn Hong Kong the aggregates needed for construction are mostly supplied by two local quarries KWP Quarry Company
Limitedrsquos Anderson Road Quarry accounts for 60ndash70 making it the pillar of Hong Kongrsquos construction materials industry
TEXT amp PHOTOS Ou He
When arriving at the Anderson Road
Quarry the most impressive view at the850000 square-meter facility is the Metso
machines including equipment from the
primary secondary and tertiary crushing
circuits and the screens I t is Metsorsquos equip-
ment that secures the supply of aggregates
for Hong Kong
KWP Quarry Company Limited has been
working with Metso since its establishment
in 1997
Due to Hong Kongrsquos stringent dust and noise control standards Metso has paid special attention to the related suppression systems
ldquoOur quarry mainly lies on granite and
volcanic rock which are so hard they canonly be processed by equipment with
strong durability and stabilityrdquo explains
Mr Eddie Hung Manager of KWP ldquoWith a
long history of and experience in quarry-
ing we are very familiar with the equip-
ment of different brands Comparatively
Metsorsquos products are better than others in
terms of durability stability and effi ciency
Besides this the reason we selected Metso
is because of the simple maintenance of
their equipment and the easy access tomaintenance informationrdquo
Flexible modular solution
Based on extensive experience in crushing
and screening worldwide Metso presented
the Anderson Road Quarry with a modu-
lar solution and delivered it as a turn-key
project Through a four-stage crushing
circuit which contains three Metso C160
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jaw crushers for primary crushing two
Omnicone 1560SX crushers for secondary
crushing two HP 500SX cone crushers for
tertiary crushing and one HP500SX cone
crusher for extra-fine crushing the plant
was able to produce aggregates of optimal
shape with minimal 1047298akiness
The fine products include three sizes
0 to 5 mm 5 to 10 mm and 10 to 20mm
Since the employment of this system in
2000 production has reached 1250 th
which is far beyond the design capacityAccording to Mr Hung ldquoThe machines
always run effi ciently and seldom malfunc-
tion The occasional shutdown of some
machines does not affect production very
much the plant still could reach 60-70
of its normal production It gives us the
best 1047298exibility for the plant rsquos operation and
I believe this is the best feature of Metsorsquos
solution
Eddie Hung
Manager of KWPrsquos
Anderson Road
Quarry is happy with
the product quality
and service provided
by Metso
ldquoMetsorsquos equipment is expensive com-
paratively but in the long run you will find
that the investment is worthwhile on the
whole Metso secures superior stability reli-
ability and fewer downtimes and it guaran-
tees continuous operation and brings us
greater valuerdquo
Great service team
Metso sent a group of service engineers
to the plant within the warranty period
not only to provide service but to train theoperators Mr Hung speaks highly of Met-
sorsquos service team he is impressed with its
experienced experts and with their strong
sense of responsibility and customer-
oriented ways of working
ldquoMetsorsquos service team never fails to find
hidden problems and helps us to prevent
any mechanical failures And they are
available whenever we need them they
work closely with us to solve the problem
effi cientlyrdquo he said
Excellent environment-friendly designIn order to achieve the worldrsquos most strin-
gent noise and dust control standards
developed by the Environment Protection
Department of Hong Kong Metso has
incorporated a dust and noise suppression
system into the plant This includes the
infrared-triggered spray systems at feed
points encapsulation of individual crush-
ers and conveyors and the ability to select
specific sectors of the system for treatment
depending on feed and operating condi-
tions encapsulation of equipment and the
enclosure of all major sections of the plant
With these advanced environment-
friendly solutions Anderson Road Quarry
has won numerous safety and environmen-
tal awards In 2003 it was presented with a
silver medal in the prestigious Environmen-
tal Performance Awards in recognition of
its commitment to the environment and
community In 2004 KWP achieved certifi-cation of ISO 14001 it is the first quarry site
to have achieved this in Hong Kong and
southern China
ldquoA reliable partnerrdquo
The promulgation of the top ten infrastruc-
ture policies in Hong Kong boosted the
market for aggregates and demand will
keep rising over the next five to six years
ldquoWersquoll definitely keep our cooperation with
Metso once we have a need for expansion
because we regard Metso as a reliable part-
ner With their highly effi cient equipmentsatisfying service and great efforts in help-
ing us to achieve our environmental pro-
tection targets Metso is our best choicerdquo
says Hung
More info
Ziqiang Li
Tel +86 13601289027
ziqianglimetsocom
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The sturdy Metso C160
jaw crushers are fed
using huge feed chutes
and feeders
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Similar to hundreds of mine sites world-
wide Zinkgruvan is being operated on a
non-stop 247 basis with just a few main-
tenance breaks during the year Crusher
availability is crucial because 100 of the
ore has to pass through the jaws before
being hoisted up for further processing
In addition to the zinc- lead- copper-
and silver-containing ore the C jaws chop
all the host rock extracted along the min-
ing process With a sturdy design Metsorsquos
proven C jaws can easily reduce even the
hardest type of rock Every year more thanone million tons are crushed with the jaws
ldquoMinimal service neededrdquo
Crushing with the first C160B jaw crusher
began at Zinkgruvanrsquos -800 meter level in
2000 with the primary crushing of zinc-lead
ore The second jaw was installed in 2008
for the new copper process gt
The sight and sound of two C160 jaw crushers operating side by side in the underground
crushing station of the Swedish Zinkgruvan mine is impressive Good proactive service
secures good uptime and reliable continuous operation of Metsorsquos second-largest
C160 series jaw crushers and prepares the way for the ongoing plans to expand the
production of zinc concentrate
TEXT amp PHOTOS Eero Haumlmaumllaumlinen
New PolyMet liners are being tested with the grinding mill delivered by Metso
Zinkgruvanrsquos twin C160
jaws secure good uptime
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Blasted ore is taken from the presently
operated -850 meter level with normal
trucks as an outsourced process One full
truckload is fed to the C160s every
10 minutes
ldquoWe are happy with the high reliability
of the C jaws They only require some minor
service therefore providing us with good
uptime and steady continuous feed to our
secondary and tertiary crushing and grind-ing circuitsrdquo says Mine Manager Jan Klaumlre
ldquoBasic crusher service and wear part
changes are made by our own staff using
Metsorsquos partsrdquo he adds
Service contract with grinding
mills and conveyors
Zinkgruvan and Metso Sweden have more
than 11 yearsrsquo experience with a service
contract that contains grinding mills and
conveyors At the mine site two Metso
service people and one contractor take
care of all the related service jobs Man-
power can also be borrowed from Metsorsquos
Graumlngesberg mine service team of 20
people
Presently Zinkgruvan is testing Metsorsquos
new PolyMet mill linings in its big grinding
mills With previously used rubber partsthe linings had to be changed in the shell
every 9 to 11 months and in the feed head
every 6 months
ldquoWe expect a better lifetime with Poly-
Met linings Longer change intervals mean
a lot to our productivity because lining
changes takes two full working daysrdquo Mine
Manager Jan Klaumlre says
New mine goes deeper
With an expected mine life of more than 10
years Zinkgruvan is actively mapping new
ore reserves Experimental holes are being
drilled at the new mine section at the
-1110 meter level
More info
Fredrik Wennberg
Tel +46 70 657 00 08fredrikwennbergmetsocom
Mine Manager Jan Klaumlre (left) with Backfilling Manager Kjell Tillman at the underground -800 meter level mine cafeteria
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The Zinkgruvan mine located approxi-
mately 200 km southwest of Stockholm
Sweden is one of the oldest underground
mines in Northern Europe The mine has
been in production since 1857
The mining methods used are panel
stoping and benching The processing
facilities include a zinc concentrating plant
with a 11 mtpa and a copper plant with a04 mtpa capacity Tailings are recycled in
an impounding basin and host rock in the
backfill plant
Continuous mining since 1857
Even as one of the oldest mines in Northern
Europe Zinkgruvan exploits modern mining
and minerals processing installations
Zinkgruvan mine
OWNER Lundin Mining
PRODUCTION PER YEAR 1 million tons
ORE TYPE sedimentary exhalative
zinc lead copper and silver
NUMBER OF EMPLOYEES 320
2011 PRODUCTION TARGETS 78000 tonsof zinc 36000 tons of lead and
3400 tons of copper concentrate
METSO EQUIPMENT ON SITE
bull 1 extra long VF feeder
bull 2 C160 jaw crushers
ndash zinc process css 220ndash240 mm
ndash copper process css 150 mm
bull 1 GP300S cone crusher
ndash css 45mm
bull 1 HP4 cone crusher
ndash css 18 mm
bull 1 DS screen
bull 1 FS402 screenbull 1 grinding mill
bull Pumps VPAs
A normal truck feeds the C jaws with ore coming from the lower production levels
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Cost-per-ton wear agreements deepencustomer relationshipsCrusher wear parts are traditionally marketed purely based on transactional sales and mainly depend on
the weight of manganese Metso has recently introduced a new type of wear agreement based on thecost-per-ton crushed and the wear occurred Thus far the experience has been very positive increasing
transparency and deepening the operational relationship between the manufacturer and the customer
TEXT Olli Kellokumpu and Eero Haumlmaumllaumlinen PHOTOS Eero Haumlmaumllaumlinen
Arto Hiedanniemi (left)
Hannu Heman and Juha
Laukka of Metsorsquos Finnish
Service team checking the
cone crusher mantles shipped
for a cost-per-ton customer
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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156
Wear parts and parts changes
can be included
The structure of a cost-per-ton wearcontract is based on the number of tons
crushed and the estimated wear occurred
The amount and monetary value of the
wear is calculated per crushed ton
ldquoEither plain wear parts or parts changes
carried out by Metsorsquos service personnel
can be included in the contract In the latter
case we ask our Finnish customers to inform
us about an upcoming wear change opera-
tion one week in advancerdquo Heman explains
ldquoWe see good opportunities to market
cost-per-ton contracts further in Finland
and also abroad It really develops therelationship of Metso and our customers
towards a trusted partnershiprdquo he notes
Perfect tool for accurate planning
Soraliike Ikola Oy is a mid-sized contrac-
tor with three Metso two- and three-
stage mobile and portable crushing and
screening plants operating in Central and
Since 2002 Metsorsquos sales team in Finland
has developed the cost-per-ton-based
service offeringldquoOur aim has been to seek through
a cost-per-ton offering possibilities to
serve our customers better to differentiate
Metso from the other players as an OEM
manufacturer and to offer deeper profes-
sionalism and know-howrdquo says Hannu
Heman General Manager of service
operations
ldquoUntil now both our experience and
that of our customers has been quite posi-
tive When properly prepared cost-per-ton
contracts seem to create a win-win situa-
tionrdquo Heman adds Today Metso has operational cost-per-
ton agreements with several Finnish cus-
tomers The first contract was concluded
with a customer operating a stationary
plant Based on the results gathered new
cost-per-ton contracts have been signed
with customers operating wheeled and
tracked equipment too
Eastern Finland Because of the size of the
contracts up to 50 equipment moves are
made during the yearEntrepreneur Pasi Ikola has had a cost-
per-ton contract with Metso for nearly
two years and he is quite happy with the
outcome
ldquoThe cost-per-ton contract has provided
me with a perfect tool for accurate financial
planning Now I know in detail my actual
future wear parts costs This helps a lot
when calculating bidsrdquo
ldquoEarlier I used to buy a big batch of
Metso wear parts in one go and had to
reserve a reasonable amount of money for
that Today all wear costs are evenly sharedwhich gives us a welcomed 1047298exibility to
our cost structure Now we just pay Metso
afterwards based on our crushed tonsrdquo
he adds
More info
Olli Kellokumpu
Tel +358 50 354 1189
ollikellokumpumetsocom
According to crushing contractor Pasi Ikola the cost-per-ton contract with Metso has provided the entrepreneur with better economical 1047298exibility
and more accurate calculating of bids
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Pleasant Gap is owned and operated by
Glenn O Hawbaker Inc of State College
Pennsylvania This family-owned company
began in 1952 as a small excavation busi-
ness founded by Glenn O Hawbaker and
his wife Thelma Over the years the com-
pany grew by adding an integrated mix ofproducts and services and taking on larger
projects
In 1983 Hawbaker acquired Pleasant
Gap Quarry and built its first aggregates
processing plant Today Glenn O Haw-
baker Inc operates 21 quarries and eight
asphalt production facilities across Penn-
sylvania and southern New York as well as
five regional operation centers
Primary
challenge atPleasant GapQuarryA good part of what makes for a successful crushing
operation is the willingness to tackle challenges and to do
whatrsquos necessary to meet demand The team at Pleasant
Gap Quarry in central Pennsylvania recently met the chal-
lenge when they successfully addressed problems with
the plantrsquos primary crushing plant First they purchased
a new Metso C160 jaw to replace the existing primary
impact crusher Then they devised an innovative plan to
get the primary plant back in operation while awaitingdelivery of the new jaw crusher
TEXT Linda Bergmann PHOTOS John Rickinger
983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Time for a change
With the goal of increasing reliability and
output the management at Pleasant Gap
Quarry recently decided it was time to
replace the plantrsquos primary impact crusher
Following a thorough search they chose a
new Metso C160 jaw According to ScottReck Plant Manager it no longer made
sense to repair and rebuild the existing
impactor
ldquoBefore we purchased the Metso C160
we had a few other impact crushers and
they served us well but as our custom-
ersrsquo needs increased our plant production
had to match that demand We found our
formerly reliable unit was being overcome
by our demands for output and creative
work-around solutions We continued to
need more but there was only so much we
could do until we hit the breaking point ndash
literallyrdquo
In addition to performance improve-
ments the new crusher also needed to fitinto Pleasant Gaprsquos unique infrastructure
As Plant Project ManagerEngineer Jeremy
Fahr explains ldquoOur height restraint was 274
meters (108rdquo) This height was the distance
from the feed lip of the existing 6x12 scalp-
ing screen and the existing structure that
the crusher rests onrdquo
The normal C160 crusher is 307
meters (121rdquo) tall but Metso gave GOH
Scott Reck Plant Manager (left) and
Jeremy Fahr Plant Project Manager
Engineer at Pleasant Gap Quarry
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983122983141983152983151983154983156983145983150983143 983154983141983155
a 10-degree mounting option (which is
normally used on their portable crushers)
to overcome the height restraint Reck and
Fahr worked with Dave Rhoa of Cleveland
Brothers Equipment Metsorsquos crushing and
screening distributor in Pennsylvania to
pull everything together and fit the newcrusher into their plant
The C160 crusher selected for Pleasant
Gap is one of the latest models in Metsorsquos
C Series of jaws These jaw crushers feature
a large throw and steep toggle plate angle
resulting in a higher crusher output In
addition the C Series has a compact foot-
print that makes it an ideal choice for the
replacement of existing machines
According to Reck ldquoWe had heard about
the new Metso C160 and started doing our
own research and found Metso not only
had developed the output capacity we
needed but fit the uniqueness of our oper-
ationsrdquo The new Metso crusher will allow
the plant to increase tons per hour andgive them the 1047298exibility to meet demands
for varying products on short notice
Mobile solution
Purchasing the new primary jaw addressed
the long-term issues but still left Pleasant
Gap without a functioning primary plant
Reck continues ldquoOur main line was still
down leaving us with a big hole in hitting
customer needs but knowing that our new
Metso C160 was on its wayhellipwe needed an
immediate solution to keep our produc-
tion demands with an out-of-commission
crusherrdquo
The team at Pleasant Gap brainstormed
the problem and came up with a plan toget the primary plant back in operation
Their solution was to use the Lokotrack
LT1213 impactor plant and another mobile
unit to keep the main line crushing To do
this they removed the guts on the existing
impact crusher essentially turning it into a
rock chute They then moved the LT1213
and another manufacturerrsquos mobile unit
over to the existing dump hopper gt
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
ldquoWe had our haul trucks drop off mate-
rial while two excavators fed the two
mobile unitsrdquo Reck explains ldquoFor two-and-
a-half months the Lokotrack LT1213 unit
was producing 254 cm (10rdquo) minus at
700 tons per hour The other similar-sized
mobile unit was doing 400 tons an hour
maxed out The difference was unbeliev-
able to say the least Our unique solution
using the two mobile units especially the
LT1213 helped Glenn O Hawbaker achieve
a record output in 2010rdquoAccording to Fahr ldquoWe were not new to
Metsorsquos quality and supportrdquo because GOH
had been using Metsorsquos portable crushing
equipment for 3 years prior to the primary
plantrsquos impact crusher failure In another
part of our operation we have a system that
our team relies on every day a Lokotrack
LT1213 and ST272 working in tandem with
two portable conveyorsrdquo This highly effi -
cient mobile processing system turns out
300 tons of specialized blended material
per hour GOH has been so impressed with
Metso equipment its last two purchaseswere an LT106 tracked jaw plant and a
second ST272 mobile screen in 2010
Maintaining high productivity
The Metso C160 jaw was delivered to Pleas-
ant Gap Quarry in January of 2011 and
since start-up it has more than met expec-
tations The crusher is fed minus 910 mm
(36rdquo) limestone with the jaw set at 140 mm
(5 12rdquo) According to Reck ldquoFrom moment
we started up we knew we had a winner
Not only were we kicking out as much
product as our previous units without even
breathing hard but we immediately had a
2-cent per ton savings to the bottom line
without having to run a second 350 HP
motor as required by other units Plus by
adding on the new automatic lube system
the maintenance team had more time to
devote to keeping other areas of the com-
plex running more effi cientlyrdquoReck says ldquoThe Metso unit was a perfect
fit and with the improved features it pre-
sented it had it all We just turn it on load
it up and we are moving 600 tons per hour
through the crusher without any effort and
we know it can do so much morerdquo With
the primary crushing plant back in opera-
tion the entire team at Pleasant Gap will
continue to do what they do best produce
and sell high-quality products and meet
their customersrsquo expectations
More info
Scott Yablonsky Tel +1 262 717 793
scottyablonskymetsocom
The Metso C160 jaw
was installed at a 10deg
angle to fit Pleasant
Gaprsquos existing
infrastructure
The Lokotrack LT1213 impactor plant and ST272 mobile screen operate in tandem with two
portable conveyors at Pleasant Gap
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983149983141983156983155983151 983150
Paper amp fiberNew OptiConcept M paper
and board making line
The new OptiConcept M paper and board
making line stands for economy safety and
usability
Metso has launched a new modular paper
and board making line called OptiConceptM A member of the proven OptiConcept
production line family the new OptiCon-
cept M optimizes machine investment in
line with each millrsquos capacity needs
Savings in operating costs are achieved
through precise dimensioning of pro-
cesses proven technological solutions
optimal running parameters effective
maintenance operations and fully inte-
grated automation solutions
Optimized processes innovations
smart controls and accurate dimensioning
decrease the use of steam gas electricitywater chemicals and other raw materials
and reduce emission levels
OptiConcept M has been designed
both visually and physically with the
requirements of users in mind For exam-
ple the design of the machinery allows for
easy and safe changing of rolls and wear
parts thus reducing the total duration and
cost of maintenance shutdowns
RecyclingGreen energy technology to
Elektrociepłownia Białystok in Poland
Metso will convert a coal-fired boiler to
a biomass-fired Bubbling Fluidized Bed
boiler for Elektrociepłownia Białystok SArsquos
combined heat and power plant (CHP) in
Białystok Poland The new boiler system
will cut the power plantrsquos CO2 emissions
significantly by partly replacing the coal
fuel supply with biomass fuel
ldquoPoland is one of the largest countries
in Europe to have such a high depend-ence on energy derived from coal to
meet national electricity needs This is an
important incentive for us to reduce future
CO2 emissions and produce more green
electricity and with Metso technology
we are certain to accomplish our goalrdquo
states Mr Andrzej Schroeder President of
Elektrociepłownia Białystok SA
Since 2000 Metso has received a total
of 7 biomass boiler conversion orders in
Poland and the renewable energy share
in Poland is only 75 (2010) compared to
the target of 20 by 2020 set by the EUApproximately 80 of the current energy
boilers turbines and generators installed in
Polish power plants are over 20 years old In
order to meet the strict EU environmental
requirements modernization of existing
installations is necessary
Automation
Metso DNA automation system expands
to mining and construction
Using Metsorsquos control room automation
an entire crushing and screening plant can
be effi ciently managed
Metso is a leading supplier of mining and
construction machinery This expertise has
now been combined with a scalable Metso
DNA automation system that adapts to
the range of industry needs from single
machine controls to plant-wide automation
and information management systems
An example of Metsorsquos new offering is a
new crushing plant control room solution
that connects crushers and screens ensur-
ing the effective management of the entire
plant from a pleasant and safe control
room The Metso DNA user interface pro-vides the production information to ensure
a proper and rapid response to plant
events Automatic controls stabilize the
process and allow the operators to monitor
the plant as a whole
ldquoThe benefits of automation for the min-
ing and construction industry are signifi-
cant As an example of the services we offer
performance studies to crushing plants
utilizing Metsorsquos multi-disciplinary teams of
experts to determine the present level of
the plant and process effi ciency and to esti-
mate the improvement potential and thebenefits of optimization and automation
including ROI calculationsrdquo says Mikko Maumlki-
nen Product Manager of minerals applica-
tions in Metsorsquos Automation business line
ldquoAs another example our machine
condition monitoring solutions can reduce
plant and machine downtimes as well as
help to avoid safety and environmental
hazardsrdquo he adds
Metso around the world
Aerial view of the Elektrociepłownia Białystok combined heat and power plant in Poland
8202019 Metso Minerals Aggregates 3 2011
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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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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
First modular plant to NepalMetso delivered its first modular crushing and screening plant to MS Palchowke Mai Roda Dunga Udyog Limited (PMRD)
in Melamchi Nepal The modular plant solution offers PMRD a fast and effective response to productivity and qualityrequirements
TEXT amp PHOTOS Atoshi Nayak Ghosh
The diversity of operations at a typical con-
struction site involves quick decision-mak-
ing and often a lot of pressure to ensure a
timely execution
High performance guaranteed
Considering todayrsquos volatile market sce-
nario business partners must maintainpace with their customersrsquo ever-changing
requirements Understanding custom-
ersrsquo strategic business needs is of utmost
importance PMRDrsquos plant was commis-
sioned in January 2011 and has logged
about 1200 hours of operation to date
The plant is much more compact than
the traditional skid-mounted plant and
provides space for free movement of utility
equipment within the plant area One of
the key features of the plant is the totally
bolted structure It can be easily disman-
tled into sub-assemblies transported and
re-assembled effortlessly at a new location
which is one of the biggest advantages in
helping to meet new market demand
Due to the use of pre-assembled mod-ules for each crushing station the instal-
lation work on site takes less time thus
decreasing the plantrsquos installation lead time
The plant also includes a foldable conveyor
for maintenance of the cone crushers
Stepping up with Metso
PMRD operates a two-stage plant compris-
ing a C80 jaw crusher an HP200 high-
performance cone crusher and a CVB1845
screen with circular motion MV2 vibra-
tory mechanism for final product recovery
resulting in an aggregate plant of 150 tph
capacity for producing size fractions of 0-40
mm The plant is an example of world-class
craftsmanship and excellent material han-
dling capacityModular and non-welded construction
supported by durable pitman assembly sin-
gle-piece cast steel frame bearing housings
with repairable crusher construction and
the right cavity design results in aggressive
kinematics and high power that best suits
the requirements of the customer
PMRD has immense pride in the plant
ldquoThe performance has been astounding
A drawing of typical modular plant
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983122983141983152983151983154983156983145983150983143 983154983141983155
with applications ranging from road aggre-
gates commercial sand production to
ready-mix concretes The modular plant is
almost set to create a new niche in aggre-
gates processing in Nepalrsquos construction
industry It is one of a kind and we are sur-
prised at the plant rsquos production capacity
It is easy to operate and requires minimalmanpower Our cost per ton has signifi-
cantly gone down and so has the cost of
productionrdquo says Mr Sandeep K Agarwal
Director PMRD
Safety as a key issue
Health safety and environmental solutions
are key concerns for Metso and they are
addressed with the same sense of responsi-
bility as quality productivity and cost-
effi ciency issues Metso is responsible for
conducting operations in an environmen-
tally sound way and offers products and
services that can help customers fulfill their
environmental responsibilities
Metso provides the plant offi ce and site
with operation and maintenance manu-als for each and every piece of equipment
including safety issues which are entrusted
to all the operators
All conveyors are equipped with pull-
cord safety switches along with emergency
stop buttons The working area and walk-
ways are all equipped with safety hand rails
and checkered plates for anti-skidding The
entire plant is equipped with earth pits for
electrical current earth leakage prevention
Metso has ensured all possible measures
to maintain high safety standards for all
operation and maintenance personnel
More info
Suhen Agarwal
Tel +91 124 2351566suhenagarwalmetsocom
Nepalrsquos first modularcrushing and screening plant deliv ered by Metso
E ffi cien t C VB1845 inclined screen wi th
an M V2 vibra tor y mechanism handles
the classi fica tion o f crushed ma terials
A s turd y f eeder dis tribu tes the ma terials to be crushed to
a
Me tso C80 ja w crusher
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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155
Outokumpursquos Kemi
mine set to doubleproduction The only mine unit owned by Outokumpu
the chrome mine in Kemi northern Finland
is busy making preparations to double its
production set to begin next year In co-
operation with Metso Outokumpu willincrease the number of underground
feeders and optimize the durabil-
ity of wear parts in the massive
primary gyratory crusher
TEXT amp PHOTOS Eero Haumlmaumllaumlinen
Chrome ore is fed into Metsorsquos
Superiorreg 50-65 primary
gyratory crusher by three
different vibrating feeders
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Up until now the entire production of the
chrome mine totaling about 13 million
tons annually has been transported to the
Tornio ferrochrome plant for processing
and on to the Tornio stainless steel plant
The increase in production which will
begin in autumn 2012 is intended also to
enable Outokumpu to sell ferrochrome tocompanies outside the Group The produc-
tion target for 2013 is 27 million tons of
ore and of the ferrochrome produced from
the ore nearly a half (gt 200000 tons) is to
be sold outside
Underground expansion
work almost complete
About 500 meters underground the
majority of the work involved in increasing
the capacity the F3 project has already
been completed Doubling the production
is no problem for the Superiorreg primarygyratory crusher delivered to the mine
by Metso in 2002 which can digest more
than 2700 tons of feed material per hour if
necessary
At the moment the primary gyratory
crusher can be fed by three different vibrat-
ing feeders The crusher currently runs for
less than one-fifth of the production time
The increase in ore production will increase
the effective crushing time to about one-
third of the production time
A lot of work has been done for orestorage after the primary crusher The
two currently used storage silos are now
accompanied by two new 8000-ton silos
The number of Metso feeders transporting
the ore from the primary crusher has also
been doubled
Optimization of wear parts under way
Chrome ore has been a challenge to the
primary gyratory crusherrsquos wear parts The
wear is contributed to by the pulsating
feed which rarely fills the entire crushing
chamber There are also great differences inore type since brittle feed material prone
to chalking is occasionally replaced by hard
ore that requires a lot of crushing power
before it is crushed with a bang gt
Mika Saari (right) Foreman of ore line technicians at Outokumpursquos chrome mine in conversation with
Mikko Malkamaumlki Metsorsquos crusher wear parts specialist
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
last did in July for the replacement of the
crusherrsquos wear parts Our work is also facili-
tated by product development like the
addition of maintenance hatches to the
feedersrdquo he continues
Lasting technology
According to Mika Saarirsquos calculations the
Superiorreg primary gyratory crusher has so
far crushed more than six million tons of
ore in totalldquoThe factory polishing marks still show
on the bottom thrust bearing so we
believe that the bearing will last the entire
remaining service life of the crusher which
is about ten years and 30 million tons
Metsorsquos feeders have been equally reliablerdquo
Saari says
After the next 30 million tons of ore
it will be time to deepen the mine
More info
Jukka Raumlisaumlnen
Tel +358 50 317 1787 jukkaraisanenmetsocom
Mikko Malkamaumlki
Tel + 358 40 827 8223
mikkomalkamakimetsocom
The Kemi mine and Metso are currently
carrying out a development project to
increase the service life of the mantle and
outer concave and thus minimize down-
time due to replacement While the modu-
lar feed hopper enables quick replacement
of the mantle replacing the outer concave
can easily take more than a week The cooperation between the Kemi
mine and Metsorsquos wear parts team in
Tampere aims to extend the service life
of the parts to at least 4 million crushed
tons Durability is sought by optimizing the
chamber structure and selecting the r ight
materials for the outer concave
ldquoSmooth cooperationrdquo
Mika Saari Foreman of ore line technicians
working in the underground mainte-
nance of the Kemi mine leads a small but
experienced team of technicians The tidymodern offi ce spaces are located close to
the action at a depth of 500 meters
ldquoCooperation with Metso has been
smooth Increasing our own crushing
expertise takes time so all know-how
shared by the manufacturer is very wel-
come to usrdquo Mika Saari says
ldquoWe can also use Metsorsquos profession-
als for servicing when necessary like we
The Superiorreg 50-65 has provided reliable
crushing performance at a depth of 500 metres
in the Kemi chrome mine
Technicians Sari Kulju (left) and Marko Jaako ensure that the primary gyratory crusherrsquos hydraulicand electrical unit remains very tidy which contributes to trouble-free operation of the crusher
Outokumpu Oyrsquos Kemi
chrome mine
LOCATION Keminmaa northern
Finland
ORE TYPE chrome oxide (26)
ORE ESTIMATE ON 1 JANUARY 2011
ndash ore reserves 36 million tons
ndash mineral resources 87 million
tons
MINING METHOD bench and cut fillFEED MATERIAL SIZE 0ndash1000 mm
METSO EQUIPMENT IN THE MINE
bull 1 Superiorreg 50-65 primary
gyratory crusher
ndash open side setting 152 cm (6rdquo)
bull 8 VMOU 25-125 feeders
bull 1 VMOU 30-16 feeder
bull 1 VMOU 40125 feeder
bull 2 Symons cone crushers
bull 1 C80 jaw crusher
bull 4 HM75 pumps
bull 11HM100 pumps
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983122983141983152983151983154983156983145983150983143 983154983141983155
Metso was responsible for the design
development and construction of the
entire secondary and tertiary arrangement
The primary station will be the subject of a
subsequent investment
Latest environmental protection used
This installation has been designed in strict
compliance with the environmental quality
approach developed by Metso and its
partners using the latest technologies
in dust control including confinement
technology as well as dust encapsulation
technology for screens
To ensure an annual capacity of 15 mil-lion tons for a nominal output of 560th of
02 mm and 220 mm the clientrsquos choice
for the secondary stage naturally fell upon
the NP 1520 impact crusher
A complete impact crusher solution for Lafarge The Lafarge Group has entrusted Metso with the implementation of its new aggregates installation in southern France
It comprises a new secondary crushing stage equipped with an NP1520 impact crusher featuring a power range of2 x 250kW and equipped with hydraulic adjustment
TEXT amp PHOTO Gilles Dombey
The NP 1520 crusher has long proved
its performance not only in terms of capac-
ity and reduction rate but also quality of
the finished product and durability
More info
Arnaud Bertucat
Tel +33 (0)6 81 44 68 26
arnaudbertucatmetsocom
About 15 million tons of aggregates feed will be crushed with the NP1520 impact crusher at Lafargersquos stationary installation in southern France
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Multi-stage Lokotrack process a success in Senegal
A multi-stage crushing and screening process has proven its effi ciency in the production of concrete aggregates in
Senegal Western Africa With the mobile process Xewell Cimenteries SA now exploits its quarry better has reduced
its operating costs and can meet strict environmental requirements
TEXT Elisabetta Cataluffi PHOTOS Carlo Rinolfi
Senegal is a rapidly developing country
offering a good deal of potential activities
for crushing companies too At the sametime the country has several areas of high
environmental value Therefore contractors
must opt for state-of-the-art equipment that
offers reduced environmental emissions
The company Xewell Cimenteries SA
was founded in 2008 as a partnership
between Italian Swiss and Senegalesecontractors Xewell operates a limestone
quarry located in the Pout area east of the
capital city of Dakar
According to Alessandro Crestani Technical
Director of the Pout quarry a mobile process
was selected to better exploit the quarry and
reduce costsLokotrack process drawing made by Bruno simulation software
After assembling the Lokotrack units the process was tested by Xewell Cimenteries
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983122983141983152983151983154983156983145983150983143 983154983141983155
Owned by Freeport-McMoRan Copper amp
Gold (51) and CODELCO (49) the ElAbra mine has leachable oxide and sulfide
mineralization The minersquos processing facil-
ity has an annual capacity of 226000 tons
of copper cathode
Smaller size matters
Reducing the size of the crushed oxide
ore from the present 15 mm to 12 mm
was the main target of the mine and the
Metso team The changes that were carried
out in the process included a size varia-
tion change in the cut of the tertiary sieve
installation of rate-level sensors in thesecondary crushers and enabling speed
variables in the conveyor belt feeders of
the secondary crushing circuit
ldquoGoing from 15mm to 12mm may seem
small but the operational impact is very
important and significant for usrdquo explains
Juan Torres Carvajal Metallurgical Engi-
neer at the El Abra mine
ldquoOur goal is to reach 115000 tons with
a minimum of 80 of 12-mm-sized ore permonth The record to date is 105000 tons
and we will increase it until we reach our
project goalrdquo he adds
New design for cone liners
In addition to the work mentioned above
Metso is currently carrying out a project to
design the lining profiles for the secondary
and tertiary crushers of the plant which
will affect the smaller size of the material
In cooperation with Nelson Mella from
Metso and Rodolfo Navarro Crushing
Superintendent at the El Abra mine testswere carried out in July on the re-designed
Metso linings One set was tested for sec-
ondary crushing and two sets for tertiary
crushing
More info
Nelson Mella
Tel +56 99158 0576
nelsonmellametsocom
Finer ore through wear pro1047297lestudy at El Abra mine in ChileEl Abra is a porphyry copper open-pit mine and processing facility located in
Chile near the city of Calama some 4000 meters above sea level With the helpof Metsorsquos technical support the mine was able to achieve finer ore throughoutthe crushing process
TEXT amp PHOTOS Macarena Vallejo
Xewell Cimenteries produces a selec-
tion of dry processed aggregates for con-
crete Operations started at the end of 2009
with the aim of reaching 150000 metric
tons produced per year
Lokotracks chosen to reduce costs
To build up their tracked mobile processXewell Cimenteries decided to buy three
mobile plants from Metso two impactor
plants the Lokotrack LT1110 and LT1213
feeding a three-deck mobile screen the
ST620 The machines were sold by SCAI
SpA Metsorsquos Lokotrack distributor in Italy
ldquoWe chose tracked machines to bet-
ter exploit our quarry and to reduce
costs Mobile plants have low initial costs
because they donrsquot need any special foun-
dations or supply of electricity This obvi-
ously gives us a quicker process set-up and
better uptimerdquo says Alessandro Crestani Technical Director of the Pout quarry
ldquoThe mobile plant can also follow the
quarry face as the exploitation proceeds
reducing the transport costs of raw materi-
als in the same jobsite We chose Metso
because they ensured us the best cost-per-
ton ratiordquo he adds
Good customer service is crucial
According to Alessandro Crestani good
customer service also played a major role
when choosing the manufacturer of the
mobile equipmentldquoMetsorsquos distributor SCAI SpA was able
to provide us with a complete product
support and customer service package
Obviously service is a very important
aspect for us in a country like Senegal Any
downtime represents a clear loss of pro-
ductivity for usrdquo
The average level of productivity of the
mobile Lokotrack process is 200 metric
tons per hour
More info
Carlo Rinolfi Tel +39 335 1253159
crinolfiscaispacom
Example of the development of the Metso study
on the crusher lining profiles
Liner change for smaller ore size in the
MP1000 cone crusher
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Services success in Surabaya The Metso Surabaya workshop and offi ce complex opened in April 2008 provides Life Cycle Services and maintenance
solutions for Metso equipment in the Indonesia region The facility is strategically located in an industrial precinct on theouter rim of Surabaya the second largest city in Indonesia Its close proximity to an international airport major shipping
port and several engineering companies simplifies support for the regionrsquos key customers which include PT Newmont
and PT Freeport
TEXT amp PHOTOS David LeRoy amp Gary Whittred
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983122983141983152983151983154983156983145983150983143 983154983141983155
The Surabaya site operates through Metso
in Australia with assistance from key sales
and technical staff Handling regional ser-vice and repair business in-house allows
Metso to manage intellectual property and
closely control quality
It also enables the development of a
team of skilled service personnel who can
be utilized both internally and at key cus-
tomer sites as is common with the backup
service the workshop provides for screen
contracts
Innovation at work
Since 2008 the Surabaya facility has suc-
cessfully refurbished a wide variety ofcomponents Recently two ball mill heads
weighing 22 tons each were modified in
order to strengthen the 1047298ange of the ball
mill shell The modification included tap-
ping out existing 1047298ange holes and drilling
new ones so that finger plates could be
installed and welded to the 1047298anges
Positioning the head borer to properly
align the new 1047298ange holes proved diffi cult
Four roller support frames were manufac-
tured to support the heads and allow them
to be rotated easily Each hole was then
drilled and tapped at the correct angleusing the CNC five axis head The job had a
tight delivery as it was required for a shut-
down but with advance planning and inno-
vation it was completed ahead of schedule
MP1000 mainframe on
CNC vertical borer
Well equipped for fabricating and machin-
ing heavy components the Surabaya
The Surabaya facility has proven to be
a success for Metso The workshop offers a
wide variety of services in the region Qual-ity products and competitive pricing and
delivery times have led to strong customer
relationships
Turnover and customer service levels
have increased annually since the open-
ing and between 2008 and 2010 sales
increased 450 These excellent trends
are expected to continue as the operation
expands and the customer base grows
Since 2008 the Surabaya facility has
successfully refurbished
bull MP1000 counter shaft boxes headassemblies mainframes bowls adjust-
ment rings counterweights sockets and
tramp release cylinders
bull 7rsquo Symons bowls heads and countershaft
boxes
bull Vertimill screw and drive shafts
bull Ball mill heads
bull Ball mill trommel
bull VPA cylinders
bull Eaton clutches
bull Exciter screen mechanisms
bull 42x65 main shafts and eccentrics
More info
Gary Whittred
Tel +62 31 8430349
garywhittredmetsocom
workshop handles the majority of Metsorsquos
refurbishment work with ease But when
necessary PT PAL ndash a government facilitywith shipbuilding and heavy engineering
capabilities ndash offers a ldquoone stop shoprdquo Spe-
cially trained PT PAL staff ensures that the
work they perform complies with all Metso
specifications and quality standards
PT PAL also demonstrated their innova-
tive ability with the first MP1000 main-
frame refurbishment they completed The
mainframersquos shaft location bore needed
to be re-machined However the distance
from the top of the mainframe to the
tapered bore made it very hard to achieve
an accurate surface finish with the correctstandoff
To overcome this the shop decided to
machine the mainframe upside down and
elevated on support beams They posi-
tioned a new shaft under the mainframe in
a custom-made cradle Using an overhead
crane they could then lsquotrial fitrsquo the shaft in
the bore to make sure it seated correctly
and the mating tapers met specification
The method worked so well it has since
been used for four more mainframe refur-
bishments
Diversity and growth
Today Metso Surabaya continues to invest
in additional equipment in order to diver-
sify its service offering A new hydraulic
power pack which allows the facility to test
refurbished components to Metso specifi-
cations was recently used in the refurbish-
ment and testing of several VPA cylinders
for PT Freeport
Refurbished MP1000 mainframe dispatched by truck to
PT Freeport mine
Machining of MP1000 upper frame
at Metsorsquos Surabaya workshop
Mainframe at vertical CNC machining
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Creating Value with Metso in Hong KongIn Hong Kong the aggregates needed for construction are mostly supplied by two local quarries KWP Quarry Company
Limitedrsquos Anderson Road Quarry accounts for 60ndash70 making it the pillar of Hong Kongrsquos construction materials industry
TEXT amp PHOTOS Ou He
When arriving at the Anderson Road
Quarry the most impressive view at the850000 square-meter facility is the Metso
machines including equipment from the
primary secondary and tertiary crushing
circuits and the screens I t is Metsorsquos equip-
ment that secures the supply of aggregates
for Hong Kong
KWP Quarry Company Limited has been
working with Metso since its establishment
in 1997
Due to Hong Kongrsquos stringent dust and noise control standards Metso has paid special attention to the related suppression systems
ldquoOur quarry mainly lies on granite and
volcanic rock which are so hard they canonly be processed by equipment with
strong durability and stabilityrdquo explains
Mr Eddie Hung Manager of KWP ldquoWith a
long history of and experience in quarry-
ing we are very familiar with the equip-
ment of different brands Comparatively
Metsorsquos products are better than others in
terms of durability stability and effi ciency
Besides this the reason we selected Metso
is because of the simple maintenance of
their equipment and the easy access tomaintenance informationrdquo
Flexible modular solution
Based on extensive experience in crushing
and screening worldwide Metso presented
the Anderson Road Quarry with a modu-
lar solution and delivered it as a turn-key
project Through a four-stage crushing
circuit which contains three Metso C160
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983122983141983152983151983154983156983145983150983143 983154983141983155
jaw crushers for primary crushing two
Omnicone 1560SX crushers for secondary
crushing two HP 500SX cone crushers for
tertiary crushing and one HP500SX cone
crusher for extra-fine crushing the plant
was able to produce aggregates of optimal
shape with minimal 1047298akiness
The fine products include three sizes
0 to 5 mm 5 to 10 mm and 10 to 20mm
Since the employment of this system in
2000 production has reached 1250 th
which is far beyond the design capacityAccording to Mr Hung ldquoThe machines
always run effi ciently and seldom malfunc-
tion The occasional shutdown of some
machines does not affect production very
much the plant still could reach 60-70
of its normal production It gives us the
best 1047298exibility for the plant rsquos operation and
I believe this is the best feature of Metsorsquos
solution
Eddie Hung
Manager of KWPrsquos
Anderson Road
Quarry is happy with
the product quality
and service provided
by Metso
ldquoMetsorsquos equipment is expensive com-
paratively but in the long run you will find
that the investment is worthwhile on the
whole Metso secures superior stability reli-
ability and fewer downtimes and it guaran-
tees continuous operation and brings us
greater valuerdquo
Great service team
Metso sent a group of service engineers
to the plant within the warranty period
not only to provide service but to train theoperators Mr Hung speaks highly of Met-
sorsquos service team he is impressed with its
experienced experts and with their strong
sense of responsibility and customer-
oriented ways of working
ldquoMetsorsquos service team never fails to find
hidden problems and helps us to prevent
any mechanical failures And they are
available whenever we need them they
work closely with us to solve the problem
effi cientlyrdquo he said
Excellent environment-friendly designIn order to achieve the worldrsquos most strin-
gent noise and dust control standards
developed by the Environment Protection
Department of Hong Kong Metso has
incorporated a dust and noise suppression
system into the plant This includes the
infrared-triggered spray systems at feed
points encapsulation of individual crush-
ers and conveyors and the ability to select
specific sectors of the system for treatment
depending on feed and operating condi-
tions encapsulation of equipment and the
enclosure of all major sections of the plant
With these advanced environment-
friendly solutions Anderson Road Quarry
has won numerous safety and environmen-
tal awards In 2003 it was presented with a
silver medal in the prestigious Environmen-
tal Performance Awards in recognition of
its commitment to the environment and
community In 2004 KWP achieved certifi-cation of ISO 14001 it is the first quarry site
to have achieved this in Hong Kong and
southern China
ldquoA reliable partnerrdquo
The promulgation of the top ten infrastruc-
ture policies in Hong Kong boosted the
market for aggregates and demand will
keep rising over the next five to six years
ldquoWersquoll definitely keep our cooperation with
Metso once we have a need for expansion
because we regard Metso as a reliable part-
ner With their highly effi cient equipmentsatisfying service and great efforts in help-
ing us to achieve our environmental pro-
tection targets Metso is our best choicerdquo
says Hung
More info
Ziqiang Li
Tel +86 13601289027
ziqianglimetsocom
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The sturdy Metso C160
jaw crushers are fed
using huge feed chutes
and feeders
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Similar to hundreds of mine sites world-
wide Zinkgruvan is being operated on a
non-stop 247 basis with just a few main-
tenance breaks during the year Crusher
availability is crucial because 100 of the
ore has to pass through the jaws before
being hoisted up for further processing
In addition to the zinc- lead- copper-
and silver-containing ore the C jaws chop
all the host rock extracted along the min-
ing process With a sturdy design Metsorsquos
proven C jaws can easily reduce even the
hardest type of rock Every year more thanone million tons are crushed with the jaws
ldquoMinimal service neededrdquo
Crushing with the first C160B jaw crusher
began at Zinkgruvanrsquos -800 meter level in
2000 with the primary crushing of zinc-lead
ore The second jaw was installed in 2008
for the new copper process gt
The sight and sound of two C160 jaw crushers operating side by side in the underground
crushing station of the Swedish Zinkgruvan mine is impressive Good proactive service
secures good uptime and reliable continuous operation of Metsorsquos second-largest
C160 series jaw crushers and prepares the way for the ongoing plans to expand the
production of zinc concentrate
TEXT amp PHOTOS Eero Haumlmaumllaumlinen
New PolyMet liners are being tested with the grinding mill delivered by Metso
Zinkgruvanrsquos twin C160
jaws secure good uptime
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Blasted ore is taken from the presently
operated -850 meter level with normal
trucks as an outsourced process One full
truckload is fed to the C160s every
10 minutes
ldquoWe are happy with the high reliability
of the C jaws They only require some minor
service therefore providing us with good
uptime and steady continuous feed to our
secondary and tertiary crushing and grind-ing circuitsrdquo says Mine Manager Jan Klaumlre
ldquoBasic crusher service and wear part
changes are made by our own staff using
Metsorsquos partsrdquo he adds
Service contract with grinding
mills and conveyors
Zinkgruvan and Metso Sweden have more
than 11 yearsrsquo experience with a service
contract that contains grinding mills and
conveyors At the mine site two Metso
service people and one contractor take
care of all the related service jobs Man-
power can also be borrowed from Metsorsquos
Graumlngesberg mine service team of 20
people
Presently Zinkgruvan is testing Metsorsquos
new PolyMet mill linings in its big grinding
mills With previously used rubber partsthe linings had to be changed in the shell
every 9 to 11 months and in the feed head
every 6 months
ldquoWe expect a better lifetime with Poly-
Met linings Longer change intervals mean
a lot to our productivity because lining
changes takes two full working daysrdquo Mine
Manager Jan Klaumlre says
New mine goes deeper
With an expected mine life of more than 10
years Zinkgruvan is actively mapping new
ore reserves Experimental holes are being
drilled at the new mine section at the
-1110 meter level
More info
Fredrik Wennberg
Tel +46 70 657 00 08fredrikwennbergmetsocom
Mine Manager Jan Klaumlre (left) with Backfilling Manager Kjell Tillman at the underground -800 meter level mine cafeteria
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The Zinkgruvan mine located approxi-
mately 200 km southwest of Stockholm
Sweden is one of the oldest underground
mines in Northern Europe The mine has
been in production since 1857
The mining methods used are panel
stoping and benching The processing
facilities include a zinc concentrating plant
with a 11 mtpa and a copper plant with a04 mtpa capacity Tailings are recycled in
an impounding basin and host rock in the
backfill plant
Continuous mining since 1857
Even as one of the oldest mines in Northern
Europe Zinkgruvan exploits modern mining
and minerals processing installations
Zinkgruvan mine
OWNER Lundin Mining
PRODUCTION PER YEAR 1 million tons
ORE TYPE sedimentary exhalative
zinc lead copper and silver
NUMBER OF EMPLOYEES 320
2011 PRODUCTION TARGETS 78000 tonsof zinc 36000 tons of lead and
3400 tons of copper concentrate
METSO EQUIPMENT ON SITE
bull 1 extra long VF feeder
bull 2 C160 jaw crushers
ndash zinc process css 220ndash240 mm
ndash copper process css 150 mm
bull 1 GP300S cone crusher
ndash css 45mm
bull 1 HP4 cone crusher
ndash css 18 mm
bull 1 DS screen
bull 1 FS402 screenbull 1 grinding mill
bull Pumps VPAs
A normal truck feeds the C jaws with ore coming from the lower production levels
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Cost-per-ton wear agreements deepencustomer relationshipsCrusher wear parts are traditionally marketed purely based on transactional sales and mainly depend on
the weight of manganese Metso has recently introduced a new type of wear agreement based on thecost-per-ton crushed and the wear occurred Thus far the experience has been very positive increasing
transparency and deepening the operational relationship between the manufacturer and the customer
TEXT Olli Kellokumpu and Eero Haumlmaumllaumlinen PHOTOS Eero Haumlmaumllaumlinen
Arto Hiedanniemi (left)
Hannu Heman and Juha
Laukka of Metsorsquos Finnish
Service team checking the
cone crusher mantles shipped
for a cost-per-ton customer
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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156
Wear parts and parts changes
can be included
The structure of a cost-per-ton wearcontract is based on the number of tons
crushed and the estimated wear occurred
The amount and monetary value of the
wear is calculated per crushed ton
ldquoEither plain wear parts or parts changes
carried out by Metsorsquos service personnel
can be included in the contract In the latter
case we ask our Finnish customers to inform
us about an upcoming wear change opera-
tion one week in advancerdquo Heman explains
ldquoWe see good opportunities to market
cost-per-ton contracts further in Finland
and also abroad It really develops therelationship of Metso and our customers
towards a trusted partnershiprdquo he notes
Perfect tool for accurate planning
Soraliike Ikola Oy is a mid-sized contrac-
tor with three Metso two- and three-
stage mobile and portable crushing and
screening plants operating in Central and
Since 2002 Metsorsquos sales team in Finland
has developed the cost-per-ton-based
service offeringldquoOur aim has been to seek through
a cost-per-ton offering possibilities to
serve our customers better to differentiate
Metso from the other players as an OEM
manufacturer and to offer deeper profes-
sionalism and know-howrdquo says Hannu
Heman General Manager of service
operations
ldquoUntil now both our experience and
that of our customers has been quite posi-
tive When properly prepared cost-per-ton
contracts seem to create a win-win situa-
tionrdquo Heman adds Today Metso has operational cost-per-
ton agreements with several Finnish cus-
tomers The first contract was concluded
with a customer operating a stationary
plant Based on the results gathered new
cost-per-ton contracts have been signed
with customers operating wheeled and
tracked equipment too
Eastern Finland Because of the size of the
contracts up to 50 equipment moves are
made during the yearEntrepreneur Pasi Ikola has had a cost-
per-ton contract with Metso for nearly
two years and he is quite happy with the
outcome
ldquoThe cost-per-ton contract has provided
me with a perfect tool for accurate financial
planning Now I know in detail my actual
future wear parts costs This helps a lot
when calculating bidsrdquo
ldquoEarlier I used to buy a big batch of
Metso wear parts in one go and had to
reserve a reasonable amount of money for
that Today all wear costs are evenly sharedwhich gives us a welcomed 1047298exibility to
our cost structure Now we just pay Metso
afterwards based on our crushed tonsrdquo
he adds
More info
Olli Kellokumpu
Tel +358 50 354 1189
ollikellokumpumetsocom
According to crushing contractor Pasi Ikola the cost-per-ton contract with Metso has provided the entrepreneur with better economical 1047298exibility
and more accurate calculating of bids
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Pleasant Gap is owned and operated by
Glenn O Hawbaker Inc of State College
Pennsylvania This family-owned company
began in 1952 as a small excavation busi-
ness founded by Glenn O Hawbaker and
his wife Thelma Over the years the com-
pany grew by adding an integrated mix ofproducts and services and taking on larger
projects
In 1983 Hawbaker acquired Pleasant
Gap Quarry and built its first aggregates
processing plant Today Glenn O Haw-
baker Inc operates 21 quarries and eight
asphalt production facilities across Penn-
sylvania and southern New York as well as
five regional operation centers
Primary
challenge atPleasant GapQuarryA good part of what makes for a successful crushing
operation is the willingness to tackle challenges and to do
whatrsquos necessary to meet demand The team at Pleasant
Gap Quarry in central Pennsylvania recently met the chal-
lenge when they successfully addressed problems with
the plantrsquos primary crushing plant First they purchased
a new Metso C160 jaw to replace the existing primary
impact crusher Then they devised an innovative plan to
get the primary plant back in operation while awaitingdelivery of the new jaw crusher
TEXT Linda Bergmann PHOTOS John Rickinger
983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Time for a change
With the goal of increasing reliability and
output the management at Pleasant Gap
Quarry recently decided it was time to
replace the plantrsquos primary impact crusher
Following a thorough search they chose a
new Metso C160 jaw According to ScottReck Plant Manager it no longer made
sense to repair and rebuild the existing
impactor
ldquoBefore we purchased the Metso C160
we had a few other impact crushers and
they served us well but as our custom-
ersrsquo needs increased our plant production
had to match that demand We found our
formerly reliable unit was being overcome
by our demands for output and creative
work-around solutions We continued to
need more but there was only so much we
could do until we hit the breaking point ndash
literallyrdquo
In addition to performance improve-
ments the new crusher also needed to fitinto Pleasant Gaprsquos unique infrastructure
As Plant Project ManagerEngineer Jeremy
Fahr explains ldquoOur height restraint was 274
meters (108rdquo) This height was the distance
from the feed lip of the existing 6x12 scalp-
ing screen and the existing structure that
the crusher rests onrdquo
The normal C160 crusher is 307
meters (121rdquo) tall but Metso gave GOH
Scott Reck Plant Manager (left) and
Jeremy Fahr Plant Project Manager
Engineer at Pleasant Gap Quarry
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983122983141983152983151983154983156983145983150983143 983154983141983155
a 10-degree mounting option (which is
normally used on their portable crushers)
to overcome the height restraint Reck and
Fahr worked with Dave Rhoa of Cleveland
Brothers Equipment Metsorsquos crushing and
screening distributor in Pennsylvania to
pull everything together and fit the newcrusher into their plant
The C160 crusher selected for Pleasant
Gap is one of the latest models in Metsorsquos
C Series of jaws These jaw crushers feature
a large throw and steep toggle plate angle
resulting in a higher crusher output In
addition the C Series has a compact foot-
print that makes it an ideal choice for the
replacement of existing machines
According to Reck ldquoWe had heard about
the new Metso C160 and started doing our
own research and found Metso not only
had developed the output capacity we
needed but fit the uniqueness of our oper-
ationsrdquo The new Metso crusher will allow
the plant to increase tons per hour andgive them the 1047298exibility to meet demands
for varying products on short notice
Mobile solution
Purchasing the new primary jaw addressed
the long-term issues but still left Pleasant
Gap without a functioning primary plant
Reck continues ldquoOur main line was still
down leaving us with a big hole in hitting
customer needs but knowing that our new
Metso C160 was on its wayhellipwe needed an
immediate solution to keep our produc-
tion demands with an out-of-commission
crusherrdquo
The team at Pleasant Gap brainstormed
the problem and came up with a plan toget the primary plant back in operation
Their solution was to use the Lokotrack
LT1213 impactor plant and another mobile
unit to keep the main line crushing To do
this they removed the guts on the existing
impact crusher essentially turning it into a
rock chute They then moved the LT1213
and another manufacturerrsquos mobile unit
over to the existing dump hopper gt
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ldquoWe had our haul trucks drop off mate-
rial while two excavators fed the two
mobile unitsrdquo Reck explains ldquoFor two-and-
a-half months the Lokotrack LT1213 unit
was producing 254 cm (10rdquo) minus at
700 tons per hour The other similar-sized
mobile unit was doing 400 tons an hour
maxed out The difference was unbeliev-
able to say the least Our unique solution
using the two mobile units especially the
LT1213 helped Glenn O Hawbaker achieve
a record output in 2010rdquoAccording to Fahr ldquoWe were not new to
Metsorsquos quality and supportrdquo because GOH
had been using Metsorsquos portable crushing
equipment for 3 years prior to the primary
plantrsquos impact crusher failure In another
part of our operation we have a system that
our team relies on every day a Lokotrack
LT1213 and ST272 working in tandem with
two portable conveyorsrdquo This highly effi -
cient mobile processing system turns out
300 tons of specialized blended material
per hour GOH has been so impressed with
Metso equipment its last two purchaseswere an LT106 tracked jaw plant and a
second ST272 mobile screen in 2010
Maintaining high productivity
The Metso C160 jaw was delivered to Pleas-
ant Gap Quarry in January of 2011 and
since start-up it has more than met expec-
tations The crusher is fed minus 910 mm
(36rdquo) limestone with the jaw set at 140 mm
(5 12rdquo) According to Reck ldquoFrom moment
we started up we knew we had a winner
Not only were we kicking out as much
product as our previous units without even
breathing hard but we immediately had a
2-cent per ton savings to the bottom line
without having to run a second 350 HP
motor as required by other units Plus by
adding on the new automatic lube system
the maintenance team had more time to
devote to keeping other areas of the com-
plex running more effi cientlyrdquoReck says ldquoThe Metso unit was a perfect
fit and with the improved features it pre-
sented it had it all We just turn it on load
it up and we are moving 600 tons per hour
through the crusher without any effort and
we know it can do so much morerdquo With
the primary crushing plant back in opera-
tion the entire team at Pleasant Gap will
continue to do what they do best produce
and sell high-quality products and meet
their customersrsquo expectations
More info
Scott Yablonsky Tel +1 262 717 793
scottyablonskymetsocom
The Metso C160 jaw
was installed at a 10deg
angle to fit Pleasant
Gaprsquos existing
infrastructure
The Lokotrack LT1213 impactor plant and ST272 mobile screen operate in tandem with two
portable conveyors at Pleasant Gap
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983149983141983156983155983151 983150
Paper amp fiberNew OptiConcept M paper
and board making line
The new OptiConcept M paper and board
making line stands for economy safety and
usability
Metso has launched a new modular paper
and board making line called OptiConceptM A member of the proven OptiConcept
production line family the new OptiCon-
cept M optimizes machine investment in
line with each millrsquos capacity needs
Savings in operating costs are achieved
through precise dimensioning of pro-
cesses proven technological solutions
optimal running parameters effective
maintenance operations and fully inte-
grated automation solutions
Optimized processes innovations
smart controls and accurate dimensioning
decrease the use of steam gas electricitywater chemicals and other raw materials
and reduce emission levels
OptiConcept M has been designed
both visually and physically with the
requirements of users in mind For exam-
ple the design of the machinery allows for
easy and safe changing of rolls and wear
parts thus reducing the total duration and
cost of maintenance shutdowns
RecyclingGreen energy technology to
Elektrociepłownia Białystok in Poland
Metso will convert a coal-fired boiler to
a biomass-fired Bubbling Fluidized Bed
boiler for Elektrociepłownia Białystok SArsquos
combined heat and power plant (CHP) in
Białystok Poland The new boiler system
will cut the power plantrsquos CO2 emissions
significantly by partly replacing the coal
fuel supply with biomass fuel
ldquoPoland is one of the largest countries
in Europe to have such a high depend-ence on energy derived from coal to
meet national electricity needs This is an
important incentive for us to reduce future
CO2 emissions and produce more green
electricity and with Metso technology
we are certain to accomplish our goalrdquo
states Mr Andrzej Schroeder President of
Elektrociepłownia Białystok SA
Since 2000 Metso has received a total
of 7 biomass boiler conversion orders in
Poland and the renewable energy share
in Poland is only 75 (2010) compared to
the target of 20 by 2020 set by the EUApproximately 80 of the current energy
boilers turbines and generators installed in
Polish power plants are over 20 years old In
order to meet the strict EU environmental
requirements modernization of existing
installations is necessary
Automation
Metso DNA automation system expands
to mining and construction
Using Metsorsquos control room automation
an entire crushing and screening plant can
be effi ciently managed
Metso is a leading supplier of mining and
construction machinery This expertise has
now been combined with a scalable Metso
DNA automation system that adapts to
the range of industry needs from single
machine controls to plant-wide automation
and information management systems
An example of Metsorsquos new offering is a
new crushing plant control room solution
that connects crushers and screens ensur-
ing the effective management of the entire
plant from a pleasant and safe control
room The Metso DNA user interface pro-vides the production information to ensure
a proper and rapid response to plant
events Automatic controls stabilize the
process and allow the operators to monitor
the plant as a whole
ldquoThe benefits of automation for the min-
ing and construction industry are signifi-
cant As an example of the services we offer
performance studies to crushing plants
utilizing Metsorsquos multi-disciplinary teams of
experts to determine the present level of
the plant and process effi ciency and to esti-
mate the improvement potential and thebenefits of optimization and automation
including ROI calculationsrdquo says Mikko Maumlki-
nen Product Manager of minerals applica-
tions in Metsorsquos Automation business line
ldquoAs another example our machine
condition monitoring solutions can reduce
plant and machine downtimes as well as
help to avoid safety and environmental
hazardsrdquo he adds
Metso around the world
Aerial view of the Elektrociepłownia Białystok combined heat and power plant in Poland
8202019 Metso Minerals Aggregates 3 2011
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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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983122983141983152983151983154983156983145983150983143 983154983141983155
with applications ranging from road aggre-
gates commercial sand production to
ready-mix concretes The modular plant is
almost set to create a new niche in aggre-
gates processing in Nepalrsquos construction
industry It is one of a kind and we are sur-
prised at the plant rsquos production capacity
It is easy to operate and requires minimalmanpower Our cost per ton has signifi-
cantly gone down and so has the cost of
productionrdquo says Mr Sandeep K Agarwal
Director PMRD
Safety as a key issue
Health safety and environmental solutions
are key concerns for Metso and they are
addressed with the same sense of responsi-
bility as quality productivity and cost-
effi ciency issues Metso is responsible for
conducting operations in an environmen-
tally sound way and offers products and
services that can help customers fulfill their
environmental responsibilities
Metso provides the plant offi ce and site
with operation and maintenance manu-als for each and every piece of equipment
including safety issues which are entrusted
to all the operators
All conveyors are equipped with pull-
cord safety switches along with emergency
stop buttons The working area and walk-
ways are all equipped with safety hand rails
and checkered plates for anti-skidding The
entire plant is equipped with earth pits for
electrical current earth leakage prevention
Metso has ensured all possible measures
to maintain high safety standards for all
operation and maintenance personnel
More info
Suhen Agarwal
Tel +91 124 2351566suhenagarwalmetsocom
Nepalrsquos first modularcrushing and screening plant deliv ered by Metso
E ffi cien t C VB1845 inclined screen wi th
an M V2 vibra tor y mechanism handles
the classi fica tion o f crushed ma terials
A s turd y f eeder dis tribu tes the ma terials to be crushed to
a
Me tso C80 ja w crusher
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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155
Outokumpursquos Kemi
mine set to doubleproduction The only mine unit owned by Outokumpu
the chrome mine in Kemi northern Finland
is busy making preparations to double its
production set to begin next year In co-
operation with Metso Outokumpu willincrease the number of underground
feeders and optimize the durabil-
ity of wear parts in the massive
primary gyratory crusher
TEXT amp PHOTOS Eero Haumlmaumllaumlinen
Chrome ore is fed into Metsorsquos
Superiorreg 50-65 primary
gyratory crusher by three
different vibrating feeders
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983122983141983152983151983154983156983145983150983143 983154983141983155
Up until now the entire production of the
chrome mine totaling about 13 million
tons annually has been transported to the
Tornio ferrochrome plant for processing
and on to the Tornio stainless steel plant
The increase in production which will
begin in autumn 2012 is intended also to
enable Outokumpu to sell ferrochrome tocompanies outside the Group The produc-
tion target for 2013 is 27 million tons of
ore and of the ferrochrome produced from
the ore nearly a half (gt 200000 tons) is to
be sold outside
Underground expansion
work almost complete
About 500 meters underground the
majority of the work involved in increasing
the capacity the F3 project has already
been completed Doubling the production
is no problem for the Superiorreg primarygyratory crusher delivered to the mine
by Metso in 2002 which can digest more
than 2700 tons of feed material per hour if
necessary
At the moment the primary gyratory
crusher can be fed by three different vibrat-
ing feeders The crusher currently runs for
less than one-fifth of the production time
The increase in ore production will increase
the effective crushing time to about one-
third of the production time
A lot of work has been done for orestorage after the primary crusher The
two currently used storage silos are now
accompanied by two new 8000-ton silos
The number of Metso feeders transporting
the ore from the primary crusher has also
been doubled
Optimization of wear parts under way
Chrome ore has been a challenge to the
primary gyratory crusherrsquos wear parts The
wear is contributed to by the pulsating
feed which rarely fills the entire crushing
chamber There are also great differences inore type since brittle feed material prone
to chalking is occasionally replaced by hard
ore that requires a lot of crushing power
before it is crushed with a bang gt
Mika Saari (right) Foreman of ore line technicians at Outokumpursquos chrome mine in conversation with
Mikko Malkamaumlki Metsorsquos crusher wear parts specialist
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last did in July for the replacement of the
crusherrsquos wear parts Our work is also facili-
tated by product development like the
addition of maintenance hatches to the
feedersrdquo he continues
Lasting technology
According to Mika Saarirsquos calculations the
Superiorreg primary gyratory crusher has so
far crushed more than six million tons of
ore in totalldquoThe factory polishing marks still show
on the bottom thrust bearing so we
believe that the bearing will last the entire
remaining service life of the crusher which
is about ten years and 30 million tons
Metsorsquos feeders have been equally reliablerdquo
Saari says
After the next 30 million tons of ore
it will be time to deepen the mine
More info
Jukka Raumlisaumlnen
Tel +358 50 317 1787 jukkaraisanenmetsocom
Mikko Malkamaumlki
Tel + 358 40 827 8223
mikkomalkamakimetsocom
The Kemi mine and Metso are currently
carrying out a development project to
increase the service life of the mantle and
outer concave and thus minimize down-
time due to replacement While the modu-
lar feed hopper enables quick replacement
of the mantle replacing the outer concave
can easily take more than a week The cooperation between the Kemi
mine and Metsorsquos wear parts team in
Tampere aims to extend the service life
of the parts to at least 4 million crushed
tons Durability is sought by optimizing the
chamber structure and selecting the r ight
materials for the outer concave
ldquoSmooth cooperationrdquo
Mika Saari Foreman of ore line technicians
working in the underground mainte-
nance of the Kemi mine leads a small but
experienced team of technicians The tidymodern offi ce spaces are located close to
the action at a depth of 500 meters
ldquoCooperation with Metso has been
smooth Increasing our own crushing
expertise takes time so all know-how
shared by the manufacturer is very wel-
come to usrdquo Mika Saari says
ldquoWe can also use Metsorsquos profession-
als for servicing when necessary like we
The Superiorreg 50-65 has provided reliable
crushing performance at a depth of 500 metres
in the Kemi chrome mine
Technicians Sari Kulju (left) and Marko Jaako ensure that the primary gyratory crusherrsquos hydraulicand electrical unit remains very tidy which contributes to trouble-free operation of the crusher
Outokumpu Oyrsquos Kemi
chrome mine
LOCATION Keminmaa northern
Finland
ORE TYPE chrome oxide (26)
ORE ESTIMATE ON 1 JANUARY 2011
ndash ore reserves 36 million tons
ndash mineral resources 87 million
tons
MINING METHOD bench and cut fillFEED MATERIAL SIZE 0ndash1000 mm
METSO EQUIPMENT IN THE MINE
bull 1 Superiorreg 50-65 primary
gyratory crusher
ndash open side setting 152 cm (6rdquo)
bull 8 VMOU 25-125 feeders
bull 1 VMOU 30-16 feeder
bull 1 VMOU 40125 feeder
bull 2 Symons cone crushers
bull 1 C80 jaw crusher
bull 4 HM75 pumps
bull 11HM100 pumps
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Metso was responsible for the design
development and construction of the
entire secondary and tertiary arrangement
The primary station will be the subject of a
subsequent investment
Latest environmental protection used
This installation has been designed in strict
compliance with the environmental quality
approach developed by Metso and its
partners using the latest technologies
in dust control including confinement
technology as well as dust encapsulation
technology for screens
To ensure an annual capacity of 15 mil-lion tons for a nominal output of 560th of
02 mm and 220 mm the clientrsquos choice
for the secondary stage naturally fell upon
the NP 1520 impact crusher
A complete impact crusher solution for Lafarge The Lafarge Group has entrusted Metso with the implementation of its new aggregates installation in southern France
It comprises a new secondary crushing stage equipped with an NP1520 impact crusher featuring a power range of2 x 250kW and equipped with hydraulic adjustment
TEXT amp PHOTO Gilles Dombey
The NP 1520 crusher has long proved
its performance not only in terms of capac-
ity and reduction rate but also quality of
the finished product and durability
More info
Arnaud Bertucat
Tel +33 (0)6 81 44 68 26
arnaudbertucatmetsocom
About 15 million tons of aggregates feed will be crushed with the NP1520 impact crusher at Lafargersquos stationary installation in southern France
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Multi-stage Lokotrack process a success in Senegal
A multi-stage crushing and screening process has proven its effi ciency in the production of concrete aggregates in
Senegal Western Africa With the mobile process Xewell Cimenteries SA now exploits its quarry better has reduced
its operating costs and can meet strict environmental requirements
TEXT Elisabetta Cataluffi PHOTOS Carlo Rinolfi
Senegal is a rapidly developing country
offering a good deal of potential activities
for crushing companies too At the sametime the country has several areas of high
environmental value Therefore contractors
must opt for state-of-the-art equipment that
offers reduced environmental emissions
The company Xewell Cimenteries SA
was founded in 2008 as a partnership
between Italian Swiss and Senegalesecontractors Xewell operates a limestone
quarry located in the Pout area east of the
capital city of Dakar
According to Alessandro Crestani Technical
Director of the Pout quarry a mobile process
was selected to better exploit the quarry and
reduce costsLokotrack process drawing made by Bruno simulation software
After assembling the Lokotrack units the process was tested by Xewell Cimenteries
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983122983141983152983151983154983156983145983150983143 983154983141983155
Owned by Freeport-McMoRan Copper amp
Gold (51) and CODELCO (49) the ElAbra mine has leachable oxide and sulfide
mineralization The minersquos processing facil-
ity has an annual capacity of 226000 tons
of copper cathode
Smaller size matters
Reducing the size of the crushed oxide
ore from the present 15 mm to 12 mm
was the main target of the mine and the
Metso team The changes that were carried
out in the process included a size varia-
tion change in the cut of the tertiary sieve
installation of rate-level sensors in thesecondary crushers and enabling speed
variables in the conveyor belt feeders of
the secondary crushing circuit
ldquoGoing from 15mm to 12mm may seem
small but the operational impact is very
important and significant for usrdquo explains
Juan Torres Carvajal Metallurgical Engi-
neer at the El Abra mine
ldquoOur goal is to reach 115000 tons with
a minimum of 80 of 12-mm-sized ore permonth The record to date is 105000 tons
and we will increase it until we reach our
project goalrdquo he adds
New design for cone liners
In addition to the work mentioned above
Metso is currently carrying out a project to
design the lining profiles for the secondary
and tertiary crushers of the plant which
will affect the smaller size of the material
In cooperation with Nelson Mella from
Metso and Rodolfo Navarro Crushing
Superintendent at the El Abra mine testswere carried out in July on the re-designed
Metso linings One set was tested for sec-
ondary crushing and two sets for tertiary
crushing
More info
Nelson Mella
Tel +56 99158 0576
nelsonmellametsocom
Finer ore through wear pro1047297lestudy at El Abra mine in ChileEl Abra is a porphyry copper open-pit mine and processing facility located in
Chile near the city of Calama some 4000 meters above sea level With the helpof Metsorsquos technical support the mine was able to achieve finer ore throughoutthe crushing process
TEXT amp PHOTOS Macarena Vallejo
Xewell Cimenteries produces a selec-
tion of dry processed aggregates for con-
crete Operations started at the end of 2009
with the aim of reaching 150000 metric
tons produced per year
Lokotracks chosen to reduce costs
To build up their tracked mobile processXewell Cimenteries decided to buy three
mobile plants from Metso two impactor
plants the Lokotrack LT1110 and LT1213
feeding a three-deck mobile screen the
ST620 The machines were sold by SCAI
SpA Metsorsquos Lokotrack distributor in Italy
ldquoWe chose tracked machines to bet-
ter exploit our quarry and to reduce
costs Mobile plants have low initial costs
because they donrsquot need any special foun-
dations or supply of electricity This obvi-
ously gives us a quicker process set-up and
better uptimerdquo says Alessandro Crestani Technical Director of the Pout quarry
ldquoThe mobile plant can also follow the
quarry face as the exploitation proceeds
reducing the transport costs of raw materi-
als in the same jobsite We chose Metso
because they ensured us the best cost-per-
ton ratiordquo he adds
Good customer service is crucial
According to Alessandro Crestani good
customer service also played a major role
when choosing the manufacturer of the
mobile equipmentldquoMetsorsquos distributor SCAI SpA was able
to provide us with a complete product
support and customer service package
Obviously service is a very important
aspect for us in a country like Senegal Any
downtime represents a clear loss of pro-
ductivity for usrdquo
The average level of productivity of the
mobile Lokotrack process is 200 metric
tons per hour
More info
Carlo Rinolfi Tel +39 335 1253159
crinolfiscaispacom
Example of the development of the Metso study
on the crusher lining profiles
Liner change for smaller ore size in the
MP1000 cone crusher
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Services success in Surabaya The Metso Surabaya workshop and offi ce complex opened in April 2008 provides Life Cycle Services and maintenance
solutions for Metso equipment in the Indonesia region The facility is strategically located in an industrial precinct on theouter rim of Surabaya the second largest city in Indonesia Its close proximity to an international airport major shipping
port and several engineering companies simplifies support for the regionrsquos key customers which include PT Newmont
and PT Freeport
TEXT amp PHOTOS David LeRoy amp Gary Whittred
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983122983141983152983151983154983156983145983150983143 983154983141983155
The Surabaya site operates through Metso
in Australia with assistance from key sales
and technical staff Handling regional ser-vice and repair business in-house allows
Metso to manage intellectual property and
closely control quality
It also enables the development of a
team of skilled service personnel who can
be utilized both internally and at key cus-
tomer sites as is common with the backup
service the workshop provides for screen
contracts
Innovation at work
Since 2008 the Surabaya facility has suc-
cessfully refurbished a wide variety ofcomponents Recently two ball mill heads
weighing 22 tons each were modified in
order to strengthen the 1047298ange of the ball
mill shell The modification included tap-
ping out existing 1047298ange holes and drilling
new ones so that finger plates could be
installed and welded to the 1047298anges
Positioning the head borer to properly
align the new 1047298ange holes proved diffi cult
Four roller support frames were manufac-
tured to support the heads and allow them
to be rotated easily Each hole was then
drilled and tapped at the correct angleusing the CNC five axis head The job had a
tight delivery as it was required for a shut-
down but with advance planning and inno-
vation it was completed ahead of schedule
MP1000 mainframe on
CNC vertical borer
Well equipped for fabricating and machin-
ing heavy components the Surabaya
The Surabaya facility has proven to be
a success for Metso The workshop offers a
wide variety of services in the region Qual-ity products and competitive pricing and
delivery times have led to strong customer
relationships
Turnover and customer service levels
have increased annually since the open-
ing and between 2008 and 2010 sales
increased 450 These excellent trends
are expected to continue as the operation
expands and the customer base grows
Since 2008 the Surabaya facility has
successfully refurbished
bull MP1000 counter shaft boxes headassemblies mainframes bowls adjust-
ment rings counterweights sockets and
tramp release cylinders
bull 7rsquo Symons bowls heads and countershaft
boxes
bull Vertimill screw and drive shafts
bull Ball mill heads
bull Ball mill trommel
bull VPA cylinders
bull Eaton clutches
bull Exciter screen mechanisms
bull 42x65 main shafts and eccentrics
More info
Gary Whittred
Tel +62 31 8430349
garywhittredmetsocom
workshop handles the majority of Metsorsquos
refurbishment work with ease But when
necessary PT PAL ndash a government facilitywith shipbuilding and heavy engineering
capabilities ndash offers a ldquoone stop shoprdquo Spe-
cially trained PT PAL staff ensures that the
work they perform complies with all Metso
specifications and quality standards
PT PAL also demonstrated their innova-
tive ability with the first MP1000 main-
frame refurbishment they completed The
mainframersquos shaft location bore needed
to be re-machined However the distance
from the top of the mainframe to the
tapered bore made it very hard to achieve
an accurate surface finish with the correctstandoff
To overcome this the shop decided to
machine the mainframe upside down and
elevated on support beams They posi-
tioned a new shaft under the mainframe in
a custom-made cradle Using an overhead
crane they could then lsquotrial fitrsquo the shaft in
the bore to make sure it seated correctly
and the mating tapers met specification
The method worked so well it has since
been used for four more mainframe refur-
bishments
Diversity and growth
Today Metso Surabaya continues to invest
in additional equipment in order to diver-
sify its service offering A new hydraulic
power pack which allows the facility to test
refurbished components to Metso specifi-
cations was recently used in the refurbish-
ment and testing of several VPA cylinders
for PT Freeport
Refurbished MP1000 mainframe dispatched by truck to
PT Freeport mine
Machining of MP1000 upper frame
at Metsorsquos Surabaya workshop
Mainframe at vertical CNC machining
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Creating Value with Metso in Hong KongIn Hong Kong the aggregates needed for construction are mostly supplied by two local quarries KWP Quarry Company
Limitedrsquos Anderson Road Quarry accounts for 60ndash70 making it the pillar of Hong Kongrsquos construction materials industry
TEXT amp PHOTOS Ou He
When arriving at the Anderson Road
Quarry the most impressive view at the850000 square-meter facility is the Metso
machines including equipment from the
primary secondary and tertiary crushing
circuits and the screens I t is Metsorsquos equip-
ment that secures the supply of aggregates
for Hong Kong
KWP Quarry Company Limited has been
working with Metso since its establishment
in 1997
Due to Hong Kongrsquos stringent dust and noise control standards Metso has paid special attention to the related suppression systems
ldquoOur quarry mainly lies on granite and
volcanic rock which are so hard they canonly be processed by equipment with
strong durability and stabilityrdquo explains
Mr Eddie Hung Manager of KWP ldquoWith a
long history of and experience in quarry-
ing we are very familiar with the equip-
ment of different brands Comparatively
Metsorsquos products are better than others in
terms of durability stability and effi ciency
Besides this the reason we selected Metso
is because of the simple maintenance of
their equipment and the easy access tomaintenance informationrdquo
Flexible modular solution
Based on extensive experience in crushing
and screening worldwide Metso presented
the Anderson Road Quarry with a modu-
lar solution and delivered it as a turn-key
project Through a four-stage crushing
circuit which contains three Metso C160
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jaw crushers for primary crushing two
Omnicone 1560SX crushers for secondary
crushing two HP 500SX cone crushers for
tertiary crushing and one HP500SX cone
crusher for extra-fine crushing the plant
was able to produce aggregates of optimal
shape with minimal 1047298akiness
The fine products include three sizes
0 to 5 mm 5 to 10 mm and 10 to 20mm
Since the employment of this system in
2000 production has reached 1250 th
which is far beyond the design capacityAccording to Mr Hung ldquoThe machines
always run effi ciently and seldom malfunc-
tion The occasional shutdown of some
machines does not affect production very
much the plant still could reach 60-70
of its normal production It gives us the
best 1047298exibility for the plant rsquos operation and
I believe this is the best feature of Metsorsquos
solution
Eddie Hung
Manager of KWPrsquos
Anderson Road
Quarry is happy with
the product quality
and service provided
by Metso
ldquoMetsorsquos equipment is expensive com-
paratively but in the long run you will find
that the investment is worthwhile on the
whole Metso secures superior stability reli-
ability and fewer downtimes and it guaran-
tees continuous operation and brings us
greater valuerdquo
Great service team
Metso sent a group of service engineers
to the plant within the warranty period
not only to provide service but to train theoperators Mr Hung speaks highly of Met-
sorsquos service team he is impressed with its
experienced experts and with their strong
sense of responsibility and customer-
oriented ways of working
ldquoMetsorsquos service team never fails to find
hidden problems and helps us to prevent
any mechanical failures And they are
available whenever we need them they
work closely with us to solve the problem
effi cientlyrdquo he said
Excellent environment-friendly designIn order to achieve the worldrsquos most strin-
gent noise and dust control standards
developed by the Environment Protection
Department of Hong Kong Metso has
incorporated a dust and noise suppression
system into the plant This includes the
infrared-triggered spray systems at feed
points encapsulation of individual crush-
ers and conveyors and the ability to select
specific sectors of the system for treatment
depending on feed and operating condi-
tions encapsulation of equipment and the
enclosure of all major sections of the plant
With these advanced environment-
friendly solutions Anderson Road Quarry
has won numerous safety and environmen-
tal awards In 2003 it was presented with a
silver medal in the prestigious Environmen-
tal Performance Awards in recognition of
its commitment to the environment and
community In 2004 KWP achieved certifi-cation of ISO 14001 it is the first quarry site
to have achieved this in Hong Kong and
southern China
ldquoA reliable partnerrdquo
The promulgation of the top ten infrastruc-
ture policies in Hong Kong boosted the
market for aggregates and demand will
keep rising over the next five to six years
ldquoWersquoll definitely keep our cooperation with
Metso once we have a need for expansion
because we regard Metso as a reliable part-
ner With their highly effi cient equipmentsatisfying service and great efforts in help-
ing us to achieve our environmental pro-
tection targets Metso is our best choicerdquo
says Hung
More info
Ziqiang Li
Tel +86 13601289027
ziqianglimetsocom
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
The sturdy Metso C160
jaw crushers are fed
using huge feed chutes
and feeders
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983122983141983152983151983154983156983145983150983143 983154983141983155
Similar to hundreds of mine sites world-
wide Zinkgruvan is being operated on a
non-stop 247 basis with just a few main-
tenance breaks during the year Crusher
availability is crucial because 100 of the
ore has to pass through the jaws before
being hoisted up for further processing
In addition to the zinc- lead- copper-
and silver-containing ore the C jaws chop
all the host rock extracted along the min-
ing process With a sturdy design Metsorsquos
proven C jaws can easily reduce even the
hardest type of rock Every year more thanone million tons are crushed with the jaws
ldquoMinimal service neededrdquo
Crushing with the first C160B jaw crusher
began at Zinkgruvanrsquos -800 meter level in
2000 with the primary crushing of zinc-lead
ore The second jaw was installed in 2008
for the new copper process gt
The sight and sound of two C160 jaw crushers operating side by side in the underground
crushing station of the Swedish Zinkgruvan mine is impressive Good proactive service
secures good uptime and reliable continuous operation of Metsorsquos second-largest
C160 series jaw crushers and prepares the way for the ongoing plans to expand the
production of zinc concentrate
TEXT amp PHOTOS Eero Haumlmaumllaumlinen
New PolyMet liners are being tested with the grinding mill delivered by Metso
Zinkgruvanrsquos twin C160
jaws secure good uptime
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Blasted ore is taken from the presently
operated -850 meter level with normal
trucks as an outsourced process One full
truckload is fed to the C160s every
10 minutes
ldquoWe are happy with the high reliability
of the C jaws They only require some minor
service therefore providing us with good
uptime and steady continuous feed to our
secondary and tertiary crushing and grind-ing circuitsrdquo says Mine Manager Jan Klaumlre
ldquoBasic crusher service and wear part
changes are made by our own staff using
Metsorsquos partsrdquo he adds
Service contract with grinding
mills and conveyors
Zinkgruvan and Metso Sweden have more
than 11 yearsrsquo experience with a service
contract that contains grinding mills and
conveyors At the mine site two Metso
service people and one contractor take
care of all the related service jobs Man-
power can also be borrowed from Metsorsquos
Graumlngesberg mine service team of 20
people
Presently Zinkgruvan is testing Metsorsquos
new PolyMet mill linings in its big grinding
mills With previously used rubber partsthe linings had to be changed in the shell
every 9 to 11 months and in the feed head
every 6 months
ldquoWe expect a better lifetime with Poly-
Met linings Longer change intervals mean
a lot to our productivity because lining
changes takes two full working daysrdquo Mine
Manager Jan Klaumlre says
New mine goes deeper
With an expected mine life of more than 10
years Zinkgruvan is actively mapping new
ore reserves Experimental holes are being
drilled at the new mine section at the
-1110 meter level
More info
Fredrik Wennberg
Tel +46 70 657 00 08fredrikwennbergmetsocom
Mine Manager Jan Klaumlre (left) with Backfilling Manager Kjell Tillman at the underground -800 meter level mine cafeteria
983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
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The Zinkgruvan mine located approxi-
mately 200 km southwest of Stockholm
Sweden is one of the oldest underground
mines in Northern Europe The mine has
been in production since 1857
The mining methods used are panel
stoping and benching The processing
facilities include a zinc concentrating plant
with a 11 mtpa and a copper plant with a04 mtpa capacity Tailings are recycled in
an impounding basin and host rock in the
backfill plant
Continuous mining since 1857
Even as one of the oldest mines in Northern
Europe Zinkgruvan exploits modern mining
and minerals processing installations
Zinkgruvan mine
OWNER Lundin Mining
PRODUCTION PER YEAR 1 million tons
ORE TYPE sedimentary exhalative
zinc lead copper and silver
NUMBER OF EMPLOYEES 320
2011 PRODUCTION TARGETS 78000 tonsof zinc 36000 tons of lead and
3400 tons of copper concentrate
METSO EQUIPMENT ON SITE
bull 1 extra long VF feeder
bull 2 C160 jaw crushers
ndash zinc process css 220ndash240 mm
ndash copper process css 150 mm
bull 1 GP300S cone crusher
ndash css 45mm
bull 1 HP4 cone crusher
ndash css 18 mm
bull 1 DS screen
bull 1 FS402 screenbull 1 grinding mill
bull Pumps VPAs
A normal truck feeds the C jaws with ore coming from the lower production levels
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Cost-per-ton wear agreements deepencustomer relationshipsCrusher wear parts are traditionally marketed purely based on transactional sales and mainly depend on
the weight of manganese Metso has recently introduced a new type of wear agreement based on thecost-per-ton crushed and the wear occurred Thus far the experience has been very positive increasing
transparency and deepening the operational relationship between the manufacturer and the customer
TEXT Olli Kellokumpu and Eero Haumlmaumllaumlinen PHOTOS Eero Haumlmaumllaumlinen
Arto Hiedanniemi (left)
Hannu Heman and Juha
Laukka of Metsorsquos Finnish
Service team checking the
cone crusher mantles shipped
for a cost-per-ton customer
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Wear parts and parts changes
can be included
The structure of a cost-per-ton wearcontract is based on the number of tons
crushed and the estimated wear occurred
The amount and monetary value of the
wear is calculated per crushed ton
ldquoEither plain wear parts or parts changes
carried out by Metsorsquos service personnel
can be included in the contract In the latter
case we ask our Finnish customers to inform
us about an upcoming wear change opera-
tion one week in advancerdquo Heman explains
ldquoWe see good opportunities to market
cost-per-ton contracts further in Finland
and also abroad It really develops therelationship of Metso and our customers
towards a trusted partnershiprdquo he notes
Perfect tool for accurate planning
Soraliike Ikola Oy is a mid-sized contrac-
tor with three Metso two- and three-
stage mobile and portable crushing and
screening plants operating in Central and
Since 2002 Metsorsquos sales team in Finland
has developed the cost-per-ton-based
service offeringldquoOur aim has been to seek through
a cost-per-ton offering possibilities to
serve our customers better to differentiate
Metso from the other players as an OEM
manufacturer and to offer deeper profes-
sionalism and know-howrdquo says Hannu
Heman General Manager of service
operations
ldquoUntil now both our experience and
that of our customers has been quite posi-
tive When properly prepared cost-per-ton
contracts seem to create a win-win situa-
tionrdquo Heman adds Today Metso has operational cost-per-
ton agreements with several Finnish cus-
tomers The first contract was concluded
with a customer operating a stationary
plant Based on the results gathered new
cost-per-ton contracts have been signed
with customers operating wheeled and
tracked equipment too
Eastern Finland Because of the size of the
contracts up to 50 equipment moves are
made during the yearEntrepreneur Pasi Ikola has had a cost-
per-ton contract with Metso for nearly
two years and he is quite happy with the
outcome
ldquoThe cost-per-ton contract has provided
me with a perfect tool for accurate financial
planning Now I know in detail my actual
future wear parts costs This helps a lot
when calculating bidsrdquo
ldquoEarlier I used to buy a big batch of
Metso wear parts in one go and had to
reserve a reasonable amount of money for
that Today all wear costs are evenly sharedwhich gives us a welcomed 1047298exibility to
our cost structure Now we just pay Metso
afterwards based on our crushed tonsrdquo
he adds
More info
Olli Kellokumpu
Tel +358 50 354 1189
ollikellokumpumetsocom
According to crushing contractor Pasi Ikola the cost-per-ton contract with Metso has provided the entrepreneur with better economical 1047298exibility
and more accurate calculating of bids
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Pleasant Gap is owned and operated by
Glenn O Hawbaker Inc of State College
Pennsylvania This family-owned company
began in 1952 as a small excavation busi-
ness founded by Glenn O Hawbaker and
his wife Thelma Over the years the com-
pany grew by adding an integrated mix ofproducts and services and taking on larger
projects
In 1983 Hawbaker acquired Pleasant
Gap Quarry and built its first aggregates
processing plant Today Glenn O Haw-
baker Inc operates 21 quarries and eight
asphalt production facilities across Penn-
sylvania and southern New York as well as
five regional operation centers
Primary
challenge atPleasant GapQuarryA good part of what makes for a successful crushing
operation is the willingness to tackle challenges and to do
whatrsquos necessary to meet demand The team at Pleasant
Gap Quarry in central Pennsylvania recently met the chal-
lenge when they successfully addressed problems with
the plantrsquos primary crushing plant First they purchased
a new Metso C160 jaw to replace the existing primary
impact crusher Then they devised an innovative plan to
get the primary plant back in operation while awaitingdelivery of the new jaw crusher
TEXT Linda Bergmann PHOTOS John Rickinger
983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Time for a change
With the goal of increasing reliability and
output the management at Pleasant Gap
Quarry recently decided it was time to
replace the plantrsquos primary impact crusher
Following a thorough search they chose a
new Metso C160 jaw According to ScottReck Plant Manager it no longer made
sense to repair and rebuild the existing
impactor
ldquoBefore we purchased the Metso C160
we had a few other impact crushers and
they served us well but as our custom-
ersrsquo needs increased our plant production
had to match that demand We found our
formerly reliable unit was being overcome
by our demands for output and creative
work-around solutions We continued to
need more but there was only so much we
could do until we hit the breaking point ndash
literallyrdquo
In addition to performance improve-
ments the new crusher also needed to fitinto Pleasant Gaprsquos unique infrastructure
As Plant Project ManagerEngineer Jeremy
Fahr explains ldquoOur height restraint was 274
meters (108rdquo) This height was the distance
from the feed lip of the existing 6x12 scalp-
ing screen and the existing structure that
the crusher rests onrdquo
The normal C160 crusher is 307
meters (121rdquo) tall but Metso gave GOH
Scott Reck Plant Manager (left) and
Jeremy Fahr Plant Project Manager
Engineer at Pleasant Gap Quarry
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983122983141983152983151983154983156983145983150983143 983154983141983155
a 10-degree mounting option (which is
normally used on their portable crushers)
to overcome the height restraint Reck and
Fahr worked with Dave Rhoa of Cleveland
Brothers Equipment Metsorsquos crushing and
screening distributor in Pennsylvania to
pull everything together and fit the newcrusher into their plant
The C160 crusher selected for Pleasant
Gap is one of the latest models in Metsorsquos
C Series of jaws These jaw crushers feature
a large throw and steep toggle plate angle
resulting in a higher crusher output In
addition the C Series has a compact foot-
print that makes it an ideal choice for the
replacement of existing machines
According to Reck ldquoWe had heard about
the new Metso C160 and started doing our
own research and found Metso not only
had developed the output capacity we
needed but fit the uniqueness of our oper-
ationsrdquo The new Metso crusher will allow
the plant to increase tons per hour andgive them the 1047298exibility to meet demands
for varying products on short notice
Mobile solution
Purchasing the new primary jaw addressed
the long-term issues but still left Pleasant
Gap without a functioning primary plant
Reck continues ldquoOur main line was still
down leaving us with a big hole in hitting
customer needs but knowing that our new
Metso C160 was on its wayhellipwe needed an
immediate solution to keep our produc-
tion demands with an out-of-commission
crusherrdquo
The team at Pleasant Gap brainstormed
the problem and came up with a plan toget the primary plant back in operation
Their solution was to use the Lokotrack
LT1213 impactor plant and another mobile
unit to keep the main line crushing To do
this they removed the guts on the existing
impact crusher essentially turning it into a
rock chute They then moved the LT1213
and another manufacturerrsquos mobile unit
over to the existing dump hopper gt
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ldquoWe had our haul trucks drop off mate-
rial while two excavators fed the two
mobile unitsrdquo Reck explains ldquoFor two-and-
a-half months the Lokotrack LT1213 unit
was producing 254 cm (10rdquo) minus at
700 tons per hour The other similar-sized
mobile unit was doing 400 tons an hour
maxed out The difference was unbeliev-
able to say the least Our unique solution
using the two mobile units especially the
LT1213 helped Glenn O Hawbaker achieve
a record output in 2010rdquoAccording to Fahr ldquoWe were not new to
Metsorsquos quality and supportrdquo because GOH
had been using Metsorsquos portable crushing
equipment for 3 years prior to the primary
plantrsquos impact crusher failure In another
part of our operation we have a system that
our team relies on every day a Lokotrack
LT1213 and ST272 working in tandem with
two portable conveyorsrdquo This highly effi -
cient mobile processing system turns out
300 tons of specialized blended material
per hour GOH has been so impressed with
Metso equipment its last two purchaseswere an LT106 tracked jaw plant and a
second ST272 mobile screen in 2010
Maintaining high productivity
The Metso C160 jaw was delivered to Pleas-
ant Gap Quarry in January of 2011 and
since start-up it has more than met expec-
tations The crusher is fed minus 910 mm
(36rdquo) limestone with the jaw set at 140 mm
(5 12rdquo) According to Reck ldquoFrom moment
we started up we knew we had a winner
Not only were we kicking out as much
product as our previous units without even
breathing hard but we immediately had a
2-cent per ton savings to the bottom line
without having to run a second 350 HP
motor as required by other units Plus by
adding on the new automatic lube system
the maintenance team had more time to
devote to keeping other areas of the com-
plex running more effi cientlyrdquoReck says ldquoThe Metso unit was a perfect
fit and with the improved features it pre-
sented it had it all We just turn it on load
it up and we are moving 600 tons per hour
through the crusher without any effort and
we know it can do so much morerdquo With
the primary crushing plant back in opera-
tion the entire team at Pleasant Gap will
continue to do what they do best produce
and sell high-quality products and meet
their customersrsquo expectations
More info
Scott Yablonsky Tel +1 262 717 793
scottyablonskymetsocom
The Metso C160 jaw
was installed at a 10deg
angle to fit Pleasant
Gaprsquos existing
infrastructure
The Lokotrack LT1213 impactor plant and ST272 mobile screen operate in tandem with two
portable conveyors at Pleasant Gap
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983149983141983156983155983151 983150
Paper amp fiberNew OptiConcept M paper
and board making line
The new OptiConcept M paper and board
making line stands for economy safety and
usability
Metso has launched a new modular paper
and board making line called OptiConceptM A member of the proven OptiConcept
production line family the new OptiCon-
cept M optimizes machine investment in
line with each millrsquos capacity needs
Savings in operating costs are achieved
through precise dimensioning of pro-
cesses proven technological solutions
optimal running parameters effective
maintenance operations and fully inte-
grated automation solutions
Optimized processes innovations
smart controls and accurate dimensioning
decrease the use of steam gas electricitywater chemicals and other raw materials
and reduce emission levels
OptiConcept M has been designed
both visually and physically with the
requirements of users in mind For exam-
ple the design of the machinery allows for
easy and safe changing of rolls and wear
parts thus reducing the total duration and
cost of maintenance shutdowns
RecyclingGreen energy technology to
Elektrociepłownia Białystok in Poland
Metso will convert a coal-fired boiler to
a biomass-fired Bubbling Fluidized Bed
boiler for Elektrociepłownia Białystok SArsquos
combined heat and power plant (CHP) in
Białystok Poland The new boiler system
will cut the power plantrsquos CO2 emissions
significantly by partly replacing the coal
fuel supply with biomass fuel
ldquoPoland is one of the largest countries
in Europe to have such a high depend-ence on energy derived from coal to
meet national electricity needs This is an
important incentive for us to reduce future
CO2 emissions and produce more green
electricity and with Metso technology
we are certain to accomplish our goalrdquo
states Mr Andrzej Schroeder President of
Elektrociepłownia Białystok SA
Since 2000 Metso has received a total
of 7 biomass boiler conversion orders in
Poland and the renewable energy share
in Poland is only 75 (2010) compared to
the target of 20 by 2020 set by the EUApproximately 80 of the current energy
boilers turbines and generators installed in
Polish power plants are over 20 years old In
order to meet the strict EU environmental
requirements modernization of existing
installations is necessary
Automation
Metso DNA automation system expands
to mining and construction
Using Metsorsquos control room automation
an entire crushing and screening plant can
be effi ciently managed
Metso is a leading supplier of mining and
construction machinery This expertise has
now been combined with a scalable Metso
DNA automation system that adapts to
the range of industry needs from single
machine controls to plant-wide automation
and information management systems
An example of Metsorsquos new offering is a
new crushing plant control room solution
that connects crushers and screens ensur-
ing the effective management of the entire
plant from a pleasant and safe control
room The Metso DNA user interface pro-vides the production information to ensure
a proper and rapid response to plant
events Automatic controls stabilize the
process and allow the operators to monitor
the plant as a whole
ldquoThe benefits of automation for the min-
ing and construction industry are signifi-
cant As an example of the services we offer
performance studies to crushing plants
utilizing Metsorsquos multi-disciplinary teams of
experts to determine the present level of
the plant and process effi ciency and to esti-
mate the improvement potential and thebenefits of optimization and automation
including ROI calculationsrdquo says Mikko Maumlki-
nen Product Manager of minerals applica-
tions in Metsorsquos Automation business line
ldquoAs another example our machine
condition monitoring solutions can reduce
plant and machine downtimes as well as
help to avoid safety and environmental
hazardsrdquo he adds
Metso around the world
Aerial view of the Elektrociepłownia Białystok combined heat and power plant in Poland
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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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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155
Outokumpursquos Kemi
mine set to doubleproduction The only mine unit owned by Outokumpu
the chrome mine in Kemi northern Finland
is busy making preparations to double its
production set to begin next year In co-
operation with Metso Outokumpu willincrease the number of underground
feeders and optimize the durabil-
ity of wear parts in the massive
primary gyratory crusher
TEXT amp PHOTOS Eero Haumlmaumllaumlinen
Chrome ore is fed into Metsorsquos
Superiorreg 50-65 primary
gyratory crusher by three
different vibrating feeders
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Up until now the entire production of the
chrome mine totaling about 13 million
tons annually has been transported to the
Tornio ferrochrome plant for processing
and on to the Tornio stainless steel plant
The increase in production which will
begin in autumn 2012 is intended also to
enable Outokumpu to sell ferrochrome tocompanies outside the Group The produc-
tion target for 2013 is 27 million tons of
ore and of the ferrochrome produced from
the ore nearly a half (gt 200000 tons) is to
be sold outside
Underground expansion
work almost complete
About 500 meters underground the
majority of the work involved in increasing
the capacity the F3 project has already
been completed Doubling the production
is no problem for the Superiorreg primarygyratory crusher delivered to the mine
by Metso in 2002 which can digest more
than 2700 tons of feed material per hour if
necessary
At the moment the primary gyratory
crusher can be fed by three different vibrat-
ing feeders The crusher currently runs for
less than one-fifth of the production time
The increase in ore production will increase
the effective crushing time to about one-
third of the production time
A lot of work has been done for orestorage after the primary crusher The
two currently used storage silos are now
accompanied by two new 8000-ton silos
The number of Metso feeders transporting
the ore from the primary crusher has also
been doubled
Optimization of wear parts under way
Chrome ore has been a challenge to the
primary gyratory crusherrsquos wear parts The
wear is contributed to by the pulsating
feed which rarely fills the entire crushing
chamber There are also great differences inore type since brittle feed material prone
to chalking is occasionally replaced by hard
ore that requires a lot of crushing power
before it is crushed with a bang gt
Mika Saari (right) Foreman of ore line technicians at Outokumpursquos chrome mine in conversation with
Mikko Malkamaumlki Metsorsquos crusher wear parts specialist
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
last did in July for the replacement of the
crusherrsquos wear parts Our work is also facili-
tated by product development like the
addition of maintenance hatches to the
feedersrdquo he continues
Lasting technology
According to Mika Saarirsquos calculations the
Superiorreg primary gyratory crusher has so
far crushed more than six million tons of
ore in totalldquoThe factory polishing marks still show
on the bottom thrust bearing so we
believe that the bearing will last the entire
remaining service life of the crusher which
is about ten years and 30 million tons
Metsorsquos feeders have been equally reliablerdquo
Saari says
After the next 30 million tons of ore
it will be time to deepen the mine
More info
Jukka Raumlisaumlnen
Tel +358 50 317 1787 jukkaraisanenmetsocom
Mikko Malkamaumlki
Tel + 358 40 827 8223
mikkomalkamakimetsocom
The Kemi mine and Metso are currently
carrying out a development project to
increase the service life of the mantle and
outer concave and thus minimize down-
time due to replacement While the modu-
lar feed hopper enables quick replacement
of the mantle replacing the outer concave
can easily take more than a week The cooperation between the Kemi
mine and Metsorsquos wear parts team in
Tampere aims to extend the service life
of the parts to at least 4 million crushed
tons Durability is sought by optimizing the
chamber structure and selecting the r ight
materials for the outer concave
ldquoSmooth cooperationrdquo
Mika Saari Foreman of ore line technicians
working in the underground mainte-
nance of the Kemi mine leads a small but
experienced team of technicians The tidymodern offi ce spaces are located close to
the action at a depth of 500 meters
ldquoCooperation with Metso has been
smooth Increasing our own crushing
expertise takes time so all know-how
shared by the manufacturer is very wel-
come to usrdquo Mika Saari says
ldquoWe can also use Metsorsquos profession-
als for servicing when necessary like we
The Superiorreg 50-65 has provided reliable
crushing performance at a depth of 500 metres
in the Kemi chrome mine
Technicians Sari Kulju (left) and Marko Jaako ensure that the primary gyratory crusherrsquos hydraulicand electrical unit remains very tidy which contributes to trouble-free operation of the crusher
Outokumpu Oyrsquos Kemi
chrome mine
LOCATION Keminmaa northern
Finland
ORE TYPE chrome oxide (26)
ORE ESTIMATE ON 1 JANUARY 2011
ndash ore reserves 36 million tons
ndash mineral resources 87 million
tons
MINING METHOD bench and cut fillFEED MATERIAL SIZE 0ndash1000 mm
METSO EQUIPMENT IN THE MINE
bull 1 Superiorreg 50-65 primary
gyratory crusher
ndash open side setting 152 cm (6rdquo)
bull 8 VMOU 25-125 feeders
bull 1 VMOU 30-16 feeder
bull 1 VMOU 40125 feeder
bull 2 Symons cone crushers
bull 1 C80 jaw crusher
bull 4 HM75 pumps
bull 11HM100 pumps
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983122983141983152983151983154983156983145983150983143 983154983141983155
Metso was responsible for the design
development and construction of the
entire secondary and tertiary arrangement
The primary station will be the subject of a
subsequent investment
Latest environmental protection used
This installation has been designed in strict
compliance with the environmental quality
approach developed by Metso and its
partners using the latest technologies
in dust control including confinement
technology as well as dust encapsulation
technology for screens
To ensure an annual capacity of 15 mil-lion tons for a nominal output of 560th of
02 mm and 220 mm the clientrsquos choice
for the secondary stage naturally fell upon
the NP 1520 impact crusher
A complete impact crusher solution for Lafarge The Lafarge Group has entrusted Metso with the implementation of its new aggregates installation in southern France
It comprises a new secondary crushing stage equipped with an NP1520 impact crusher featuring a power range of2 x 250kW and equipped with hydraulic adjustment
TEXT amp PHOTO Gilles Dombey
The NP 1520 crusher has long proved
its performance not only in terms of capac-
ity and reduction rate but also quality of
the finished product and durability
More info
Arnaud Bertucat
Tel +33 (0)6 81 44 68 26
arnaudbertucatmetsocom
About 15 million tons of aggregates feed will be crushed with the NP1520 impact crusher at Lafargersquos stationary installation in southern France
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Multi-stage Lokotrack process a success in Senegal
A multi-stage crushing and screening process has proven its effi ciency in the production of concrete aggregates in
Senegal Western Africa With the mobile process Xewell Cimenteries SA now exploits its quarry better has reduced
its operating costs and can meet strict environmental requirements
TEXT Elisabetta Cataluffi PHOTOS Carlo Rinolfi
Senegal is a rapidly developing country
offering a good deal of potential activities
for crushing companies too At the sametime the country has several areas of high
environmental value Therefore contractors
must opt for state-of-the-art equipment that
offers reduced environmental emissions
The company Xewell Cimenteries SA
was founded in 2008 as a partnership
between Italian Swiss and Senegalesecontractors Xewell operates a limestone
quarry located in the Pout area east of the
capital city of Dakar
According to Alessandro Crestani Technical
Director of the Pout quarry a mobile process
was selected to better exploit the quarry and
reduce costsLokotrack process drawing made by Bruno simulation software
After assembling the Lokotrack units the process was tested by Xewell Cimenteries
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983122983141983152983151983154983156983145983150983143 983154983141983155
Owned by Freeport-McMoRan Copper amp
Gold (51) and CODELCO (49) the ElAbra mine has leachable oxide and sulfide
mineralization The minersquos processing facil-
ity has an annual capacity of 226000 tons
of copper cathode
Smaller size matters
Reducing the size of the crushed oxide
ore from the present 15 mm to 12 mm
was the main target of the mine and the
Metso team The changes that were carried
out in the process included a size varia-
tion change in the cut of the tertiary sieve
installation of rate-level sensors in thesecondary crushers and enabling speed
variables in the conveyor belt feeders of
the secondary crushing circuit
ldquoGoing from 15mm to 12mm may seem
small but the operational impact is very
important and significant for usrdquo explains
Juan Torres Carvajal Metallurgical Engi-
neer at the El Abra mine
ldquoOur goal is to reach 115000 tons with
a minimum of 80 of 12-mm-sized ore permonth The record to date is 105000 tons
and we will increase it until we reach our
project goalrdquo he adds
New design for cone liners
In addition to the work mentioned above
Metso is currently carrying out a project to
design the lining profiles for the secondary
and tertiary crushers of the plant which
will affect the smaller size of the material
In cooperation with Nelson Mella from
Metso and Rodolfo Navarro Crushing
Superintendent at the El Abra mine testswere carried out in July on the re-designed
Metso linings One set was tested for sec-
ondary crushing and two sets for tertiary
crushing
More info
Nelson Mella
Tel +56 99158 0576
nelsonmellametsocom
Finer ore through wear pro1047297lestudy at El Abra mine in ChileEl Abra is a porphyry copper open-pit mine and processing facility located in
Chile near the city of Calama some 4000 meters above sea level With the helpof Metsorsquos technical support the mine was able to achieve finer ore throughoutthe crushing process
TEXT amp PHOTOS Macarena Vallejo
Xewell Cimenteries produces a selec-
tion of dry processed aggregates for con-
crete Operations started at the end of 2009
with the aim of reaching 150000 metric
tons produced per year
Lokotracks chosen to reduce costs
To build up their tracked mobile processXewell Cimenteries decided to buy three
mobile plants from Metso two impactor
plants the Lokotrack LT1110 and LT1213
feeding a three-deck mobile screen the
ST620 The machines were sold by SCAI
SpA Metsorsquos Lokotrack distributor in Italy
ldquoWe chose tracked machines to bet-
ter exploit our quarry and to reduce
costs Mobile plants have low initial costs
because they donrsquot need any special foun-
dations or supply of electricity This obvi-
ously gives us a quicker process set-up and
better uptimerdquo says Alessandro Crestani Technical Director of the Pout quarry
ldquoThe mobile plant can also follow the
quarry face as the exploitation proceeds
reducing the transport costs of raw materi-
als in the same jobsite We chose Metso
because they ensured us the best cost-per-
ton ratiordquo he adds
Good customer service is crucial
According to Alessandro Crestani good
customer service also played a major role
when choosing the manufacturer of the
mobile equipmentldquoMetsorsquos distributor SCAI SpA was able
to provide us with a complete product
support and customer service package
Obviously service is a very important
aspect for us in a country like Senegal Any
downtime represents a clear loss of pro-
ductivity for usrdquo
The average level of productivity of the
mobile Lokotrack process is 200 metric
tons per hour
More info
Carlo Rinolfi Tel +39 335 1253159
crinolfiscaispacom
Example of the development of the Metso study
on the crusher lining profiles
Liner change for smaller ore size in the
MP1000 cone crusher
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Services success in Surabaya The Metso Surabaya workshop and offi ce complex opened in April 2008 provides Life Cycle Services and maintenance
solutions for Metso equipment in the Indonesia region The facility is strategically located in an industrial precinct on theouter rim of Surabaya the second largest city in Indonesia Its close proximity to an international airport major shipping
port and several engineering companies simplifies support for the regionrsquos key customers which include PT Newmont
and PT Freeport
TEXT amp PHOTOS David LeRoy amp Gary Whittred
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The Surabaya site operates through Metso
in Australia with assistance from key sales
and technical staff Handling regional ser-vice and repair business in-house allows
Metso to manage intellectual property and
closely control quality
It also enables the development of a
team of skilled service personnel who can
be utilized both internally and at key cus-
tomer sites as is common with the backup
service the workshop provides for screen
contracts
Innovation at work
Since 2008 the Surabaya facility has suc-
cessfully refurbished a wide variety ofcomponents Recently two ball mill heads
weighing 22 tons each were modified in
order to strengthen the 1047298ange of the ball
mill shell The modification included tap-
ping out existing 1047298ange holes and drilling
new ones so that finger plates could be
installed and welded to the 1047298anges
Positioning the head borer to properly
align the new 1047298ange holes proved diffi cult
Four roller support frames were manufac-
tured to support the heads and allow them
to be rotated easily Each hole was then
drilled and tapped at the correct angleusing the CNC five axis head The job had a
tight delivery as it was required for a shut-
down but with advance planning and inno-
vation it was completed ahead of schedule
MP1000 mainframe on
CNC vertical borer
Well equipped for fabricating and machin-
ing heavy components the Surabaya
The Surabaya facility has proven to be
a success for Metso The workshop offers a
wide variety of services in the region Qual-ity products and competitive pricing and
delivery times have led to strong customer
relationships
Turnover and customer service levels
have increased annually since the open-
ing and between 2008 and 2010 sales
increased 450 These excellent trends
are expected to continue as the operation
expands and the customer base grows
Since 2008 the Surabaya facility has
successfully refurbished
bull MP1000 counter shaft boxes headassemblies mainframes bowls adjust-
ment rings counterweights sockets and
tramp release cylinders
bull 7rsquo Symons bowls heads and countershaft
boxes
bull Vertimill screw and drive shafts
bull Ball mill heads
bull Ball mill trommel
bull VPA cylinders
bull Eaton clutches
bull Exciter screen mechanisms
bull 42x65 main shafts and eccentrics
More info
Gary Whittred
Tel +62 31 8430349
garywhittredmetsocom
workshop handles the majority of Metsorsquos
refurbishment work with ease But when
necessary PT PAL ndash a government facilitywith shipbuilding and heavy engineering
capabilities ndash offers a ldquoone stop shoprdquo Spe-
cially trained PT PAL staff ensures that the
work they perform complies with all Metso
specifications and quality standards
PT PAL also demonstrated their innova-
tive ability with the first MP1000 main-
frame refurbishment they completed The
mainframersquos shaft location bore needed
to be re-machined However the distance
from the top of the mainframe to the
tapered bore made it very hard to achieve
an accurate surface finish with the correctstandoff
To overcome this the shop decided to
machine the mainframe upside down and
elevated on support beams They posi-
tioned a new shaft under the mainframe in
a custom-made cradle Using an overhead
crane they could then lsquotrial fitrsquo the shaft in
the bore to make sure it seated correctly
and the mating tapers met specification
The method worked so well it has since
been used for four more mainframe refur-
bishments
Diversity and growth
Today Metso Surabaya continues to invest
in additional equipment in order to diver-
sify its service offering A new hydraulic
power pack which allows the facility to test
refurbished components to Metso specifi-
cations was recently used in the refurbish-
ment and testing of several VPA cylinders
for PT Freeport
Refurbished MP1000 mainframe dispatched by truck to
PT Freeport mine
Machining of MP1000 upper frame
at Metsorsquos Surabaya workshop
Mainframe at vertical CNC machining
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Creating Value with Metso in Hong KongIn Hong Kong the aggregates needed for construction are mostly supplied by two local quarries KWP Quarry Company
Limitedrsquos Anderson Road Quarry accounts for 60ndash70 making it the pillar of Hong Kongrsquos construction materials industry
TEXT amp PHOTOS Ou He
When arriving at the Anderson Road
Quarry the most impressive view at the850000 square-meter facility is the Metso
machines including equipment from the
primary secondary and tertiary crushing
circuits and the screens I t is Metsorsquos equip-
ment that secures the supply of aggregates
for Hong Kong
KWP Quarry Company Limited has been
working with Metso since its establishment
in 1997
Due to Hong Kongrsquos stringent dust and noise control standards Metso has paid special attention to the related suppression systems
ldquoOur quarry mainly lies on granite and
volcanic rock which are so hard they canonly be processed by equipment with
strong durability and stabilityrdquo explains
Mr Eddie Hung Manager of KWP ldquoWith a
long history of and experience in quarry-
ing we are very familiar with the equip-
ment of different brands Comparatively
Metsorsquos products are better than others in
terms of durability stability and effi ciency
Besides this the reason we selected Metso
is because of the simple maintenance of
their equipment and the easy access tomaintenance informationrdquo
Flexible modular solution
Based on extensive experience in crushing
and screening worldwide Metso presented
the Anderson Road Quarry with a modu-
lar solution and delivered it as a turn-key
project Through a four-stage crushing
circuit which contains three Metso C160
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jaw crushers for primary crushing two
Omnicone 1560SX crushers for secondary
crushing two HP 500SX cone crushers for
tertiary crushing and one HP500SX cone
crusher for extra-fine crushing the plant
was able to produce aggregates of optimal
shape with minimal 1047298akiness
The fine products include three sizes
0 to 5 mm 5 to 10 mm and 10 to 20mm
Since the employment of this system in
2000 production has reached 1250 th
which is far beyond the design capacityAccording to Mr Hung ldquoThe machines
always run effi ciently and seldom malfunc-
tion The occasional shutdown of some
machines does not affect production very
much the plant still could reach 60-70
of its normal production It gives us the
best 1047298exibility for the plant rsquos operation and
I believe this is the best feature of Metsorsquos
solution
Eddie Hung
Manager of KWPrsquos
Anderson Road
Quarry is happy with
the product quality
and service provided
by Metso
ldquoMetsorsquos equipment is expensive com-
paratively but in the long run you will find
that the investment is worthwhile on the
whole Metso secures superior stability reli-
ability and fewer downtimes and it guaran-
tees continuous operation and brings us
greater valuerdquo
Great service team
Metso sent a group of service engineers
to the plant within the warranty period
not only to provide service but to train theoperators Mr Hung speaks highly of Met-
sorsquos service team he is impressed with its
experienced experts and with their strong
sense of responsibility and customer-
oriented ways of working
ldquoMetsorsquos service team never fails to find
hidden problems and helps us to prevent
any mechanical failures And they are
available whenever we need them they
work closely with us to solve the problem
effi cientlyrdquo he said
Excellent environment-friendly designIn order to achieve the worldrsquos most strin-
gent noise and dust control standards
developed by the Environment Protection
Department of Hong Kong Metso has
incorporated a dust and noise suppression
system into the plant This includes the
infrared-triggered spray systems at feed
points encapsulation of individual crush-
ers and conveyors and the ability to select
specific sectors of the system for treatment
depending on feed and operating condi-
tions encapsulation of equipment and the
enclosure of all major sections of the plant
With these advanced environment-
friendly solutions Anderson Road Quarry
has won numerous safety and environmen-
tal awards In 2003 it was presented with a
silver medal in the prestigious Environmen-
tal Performance Awards in recognition of
its commitment to the environment and
community In 2004 KWP achieved certifi-cation of ISO 14001 it is the first quarry site
to have achieved this in Hong Kong and
southern China
ldquoA reliable partnerrdquo
The promulgation of the top ten infrastruc-
ture policies in Hong Kong boosted the
market for aggregates and demand will
keep rising over the next five to six years
ldquoWersquoll definitely keep our cooperation with
Metso once we have a need for expansion
because we regard Metso as a reliable part-
ner With their highly effi cient equipmentsatisfying service and great efforts in help-
ing us to achieve our environmental pro-
tection targets Metso is our best choicerdquo
says Hung
More info
Ziqiang Li
Tel +86 13601289027
ziqianglimetsocom
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The sturdy Metso C160
jaw crushers are fed
using huge feed chutes
and feeders
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983122983141983152983151983154983156983145983150983143 983154983141983155
Similar to hundreds of mine sites world-
wide Zinkgruvan is being operated on a
non-stop 247 basis with just a few main-
tenance breaks during the year Crusher
availability is crucial because 100 of the
ore has to pass through the jaws before
being hoisted up for further processing
In addition to the zinc- lead- copper-
and silver-containing ore the C jaws chop
all the host rock extracted along the min-
ing process With a sturdy design Metsorsquos
proven C jaws can easily reduce even the
hardest type of rock Every year more thanone million tons are crushed with the jaws
ldquoMinimal service neededrdquo
Crushing with the first C160B jaw crusher
began at Zinkgruvanrsquos -800 meter level in
2000 with the primary crushing of zinc-lead
ore The second jaw was installed in 2008
for the new copper process gt
The sight and sound of two C160 jaw crushers operating side by side in the underground
crushing station of the Swedish Zinkgruvan mine is impressive Good proactive service
secures good uptime and reliable continuous operation of Metsorsquos second-largest
C160 series jaw crushers and prepares the way for the ongoing plans to expand the
production of zinc concentrate
TEXT amp PHOTOS Eero Haumlmaumllaumlinen
New PolyMet liners are being tested with the grinding mill delivered by Metso
Zinkgruvanrsquos twin C160
jaws secure good uptime
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Blasted ore is taken from the presently
operated -850 meter level with normal
trucks as an outsourced process One full
truckload is fed to the C160s every
10 minutes
ldquoWe are happy with the high reliability
of the C jaws They only require some minor
service therefore providing us with good
uptime and steady continuous feed to our
secondary and tertiary crushing and grind-ing circuitsrdquo says Mine Manager Jan Klaumlre
ldquoBasic crusher service and wear part
changes are made by our own staff using
Metsorsquos partsrdquo he adds
Service contract with grinding
mills and conveyors
Zinkgruvan and Metso Sweden have more
than 11 yearsrsquo experience with a service
contract that contains grinding mills and
conveyors At the mine site two Metso
service people and one contractor take
care of all the related service jobs Man-
power can also be borrowed from Metsorsquos
Graumlngesberg mine service team of 20
people
Presently Zinkgruvan is testing Metsorsquos
new PolyMet mill linings in its big grinding
mills With previously used rubber partsthe linings had to be changed in the shell
every 9 to 11 months and in the feed head
every 6 months
ldquoWe expect a better lifetime with Poly-
Met linings Longer change intervals mean
a lot to our productivity because lining
changes takes two full working daysrdquo Mine
Manager Jan Klaumlre says
New mine goes deeper
With an expected mine life of more than 10
years Zinkgruvan is actively mapping new
ore reserves Experimental holes are being
drilled at the new mine section at the
-1110 meter level
More info
Fredrik Wennberg
Tel +46 70 657 00 08fredrikwennbergmetsocom
Mine Manager Jan Klaumlre (left) with Backfilling Manager Kjell Tillman at the underground -800 meter level mine cafeteria
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The Zinkgruvan mine located approxi-
mately 200 km southwest of Stockholm
Sweden is one of the oldest underground
mines in Northern Europe The mine has
been in production since 1857
The mining methods used are panel
stoping and benching The processing
facilities include a zinc concentrating plant
with a 11 mtpa and a copper plant with a04 mtpa capacity Tailings are recycled in
an impounding basin and host rock in the
backfill plant
Continuous mining since 1857
Even as one of the oldest mines in Northern
Europe Zinkgruvan exploits modern mining
and minerals processing installations
Zinkgruvan mine
OWNER Lundin Mining
PRODUCTION PER YEAR 1 million tons
ORE TYPE sedimentary exhalative
zinc lead copper and silver
NUMBER OF EMPLOYEES 320
2011 PRODUCTION TARGETS 78000 tonsof zinc 36000 tons of lead and
3400 tons of copper concentrate
METSO EQUIPMENT ON SITE
bull 1 extra long VF feeder
bull 2 C160 jaw crushers
ndash zinc process css 220ndash240 mm
ndash copper process css 150 mm
bull 1 GP300S cone crusher
ndash css 45mm
bull 1 HP4 cone crusher
ndash css 18 mm
bull 1 DS screen
bull 1 FS402 screenbull 1 grinding mill
bull Pumps VPAs
A normal truck feeds the C jaws with ore coming from the lower production levels
983122983141983152983151983154983156983145983150983143 983154983141983155
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Cost-per-ton wear agreements deepencustomer relationshipsCrusher wear parts are traditionally marketed purely based on transactional sales and mainly depend on
the weight of manganese Metso has recently introduced a new type of wear agreement based on thecost-per-ton crushed and the wear occurred Thus far the experience has been very positive increasing
transparency and deepening the operational relationship between the manufacturer and the customer
TEXT Olli Kellokumpu and Eero Haumlmaumllaumlinen PHOTOS Eero Haumlmaumllaumlinen
Arto Hiedanniemi (left)
Hannu Heman and Juha
Laukka of Metsorsquos Finnish
Service team checking the
cone crusher mantles shipped
for a cost-per-ton customer
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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156
Wear parts and parts changes
can be included
The structure of a cost-per-ton wearcontract is based on the number of tons
crushed and the estimated wear occurred
The amount and monetary value of the
wear is calculated per crushed ton
ldquoEither plain wear parts or parts changes
carried out by Metsorsquos service personnel
can be included in the contract In the latter
case we ask our Finnish customers to inform
us about an upcoming wear change opera-
tion one week in advancerdquo Heman explains
ldquoWe see good opportunities to market
cost-per-ton contracts further in Finland
and also abroad It really develops therelationship of Metso and our customers
towards a trusted partnershiprdquo he notes
Perfect tool for accurate planning
Soraliike Ikola Oy is a mid-sized contrac-
tor with three Metso two- and three-
stage mobile and portable crushing and
screening plants operating in Central and
Since 2002 Metsorsquos sales team in Finland
has developed the cost-per-ton-based
service offeringldquoOur aim has been to seek through
a cost-per-ton offering possibilities to
serve our customers better to differentiate
Metso from the other players as an OEM
manufacturer and to offer deeper profes-
sionalism and know-howrdquo says Hannu
Heman General Manager of service
operations
ldquoUntil now both our experience and
that of our customers has been quite posi-
tive When properly prepared cost-per-ton
contracts seem to create a win-win situa-
tionrdquo Heman adds Today Metso has operational cost-per-
ton agreements with several Finnish cus-
tomers The first contract was concluded
with a customer operating a stationary
plant Based on the results gathered new
cost-per-ton contracts have been signed
with customers operating wheeled and
tracked equipment too
Eastern Finland Because of the size of the
contracts up to 50 equipment moves are
made during the yearEntrepreneur Pasi Ikola has had a cost-
per-ton contract with Metso for nearly
two years and he is quite happy with the
outcome
ldquoThe cost-per-ton contract has provided
me with a perfect tool for accurate financial
planning Now I know in detail my actual
future wear parts costs This helps a lot
when calculating bidsrdquo
ldquoEarlier I used to buy a big batch of
Metso wear parts in one go and had to
reserve a reasonable amount of money for
that Today all wear costs are evenly sharedwhich gives us a welcomed 1047298exibility to
our cost structure Now we just pay Metso
afterwards based on our crushed tonsrdquo
he adds
More info
Olli Kellokumpu
Tel +358 50 354 1189
ollikellokumpumetsocom
According to crushing contractor Pasi Ikola the cost-per-ton contract with Metso has provided the entrepreneur with better economical 1047298exibility
and more accurate calculating of bids
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Pleasant Gap is owned and operated by
Glenn O Hawbaker Inc of State College
Pennsylvania This family-owned company
began in 1952 as a small excavation busi-
ness founded by Glenn O Hawbaker and
his wife Thelma Over the years the com-
pany grew by adding an integrated mix ofproducts and services and taking on larger
projects
In 1983 Hawbaker acquired Pleasant
Gap Quarry and built its first aggregates
processing plant Today Glenn O Haw-
baker Inc operates 21 quarries and eight
asphalt production facilities across Penn-
sylvania and southern New York as well as
five regional operation centers
Primary
challenge atPleasant GapQuarryA good part of what makes for a successful crushing
operation is the willingness to tackle challenges and to do
whatrsquos necessary to meet demand The team at Pleasant
Gap Quarry in central Pennsylvania recently met the chal-
lenge when they successfully addressed problems with
the plantrsquos primary crushing plant First they purchased
a new Metso C160 jaw to replace the existing primary
impact crusher Then they devised an innovative plan to
get the primary plant back in operation while awaitingdelivery of the new jaw crusher
TEXT Linda Bergmann PHOTOS John Rickinger
983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Time for a change
With the goal of increasing reliability and
output the management at Pleasant Gap
Quarry recently decided it was time to
replace the plantrsquos primary impact crusher
Following a thorough search they chose a
new Metso C160 jaw According to ScottReck Plant Manager it no longer made
sense to repair and rebuild the existing
impactor
ldquoBefore we purchased the Metso C160
we had a few other impact crushers and
they served us well but as our custom-
ersrsquo needs increased our plant production
had to match that demand We found our
formerly reliable unit was being overcome
by our demands for output and creative
work-around solutions We continued to
need more but there was only so much we
could do until we hit the breaking point ndash
literallyrdquo
In addition to performance improve-
ments the new crusher also needed to fitinto Pleasant Gaprsquos unique infrastructure
As Plant Project ManagerEngineer Jeremy
Fahr explains ldquoOur height restraint was 274
meters (108rdquo) This height was the distance
from the feed lip of the existing 6x12 scalp-
ing screen and the existing structure that
the crusher rests onrdquo
The normal C160 crusher is 307
meters (121rdquo) tall but Metso gave GOH
Scott Reck Plant Manager (left) and
Jeremy Fahr Plant Project Manager
Engineer at Pleasant Gap Quarry
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983122983141983152983151983154983156983145983150983143 983154983141983155
a 10-degree mounting option (which is
normally used on their portable crushers)
to overcome the height restraint Reck and
Fahr worked with Dave Rhoa of Cleveland
Brothers Equipment Metsorsquos crushing and
screening distributor in Pennsylvania to
pull everything together and fit the newcrusher into their plant
The C160 crusher selected for Pleasant
Gap is one of the latest models in Metsorsquos
C Series of jaws These jaw crushers feature
a large throw and steep toggle plate angle
resulting in a higher crusher output In
addition the C Series has a compact foot-
print that makes it an ideal choice for the
replacement of existing machines
According to Reck ldquoWe had heard about
the new Metso C160 and started doing our
own research and found Metso not only
had developed the output capacity we
needed but fit the uniqueness of our oper-
ationsrdquo The new Metso crusher will allow
the plant to increase tons per hour andgive them the 1047298exibility to meet demands
for varying products on short notice
Mobile solution
Purchasing the new primary jaw addressed
the long-term issues but still left Pleasant
Gap without a functioning primary plant
Reck continues ldquoOur main line was still
down leaving us with a big hole in hitting
customer needs but knowing that our new
Metso C160 was on its wayhellipwe needed an
immediate solution to keep our produc-
tion demands with an out-of-commission
crusherrdquo
The team at Pleasant Gap brainstormed
the problem and came up with a plan toget the primary plant back in operation
Their solution was to use the Lokotrack
LT1213 impactor plant and another mobile
unit to keep the main line crushing To do
this they removed the guts on the existing
impact crusher essentially turning it into a
rock chute They then moved the LT1213
and another manufacturerrsquos mobile unit
over to the existing dump hopper gt
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ldquoWe had our haul trucks drop off mate-
rial while two excavators fed the two
mobile unitsrdquo Reck explains ldquoFor two-and-
a-half months the Lokotrack LT1213 unit
was producing 254 cm (10rdquo) minus at
700 tons per hour The other similar-sized
mobile unit was doing 400 tons an hour
maxed out The difference was unbeliev-
able to say the least Our unique solution
using the two mobile units especially the
LT1213 helped Glenn O Hawbaker achieve
a record output in 2010rdquoAccording to Fahr ldquoWe were not new to
Metsorsquos quality and supportrdquo because GOH
had been using Metsorsquos portable crushing
equipment for 3 years prior to the primary
plantrsquos impact crusher failure In another
part of our operation we have a system that
our team relies on every day a Lokotrack
LT1213 and ST272 working in tandem with
two portable conveyorsrdquo This highly effi -
cient mobile processing system turns out
300 tons of specialized blended material
per hour GOH has been so impressed with
Metso equipment its last two purchaseswere an LT106 tracked jaw plant and a
second ST272 mobile screen in 2010
Maintaining high productivity
The Metso C160 jaw was delivered to Pleas-
ant Gap Quarry in January of 2011 and
since start-up it has more than met expec-
tations The crusher is fed minus 910 mm
(36rdquo) limestone with the jaw set at 140 mm
(5 12rdquo) According to Reck ldquoFrom moment
we started up we knew we had a winner
Not only were we kicking out as much
product as our previous units without even
breathing hard but we immediately had a
2-cent per ton savings to the bottom line
without having to run a second 350 HP
motor as required by other units Plus by
adding on the new automatic lube system
the maintenance team had more time to
devote to keeping other areas of the com-
plex running more effi cientlyrdquoReck says ldquoThe Metso unit was a perfect
fit and with the improved features it pre-
sented it had it all We just turn it on load
it up and we are moving 600 tons per hour
through the crusher without any effort and
we know it can do so much morerdquo With
the primary crushing plant back in opera-
tion the entire team at Pleasant Gap will
continue to do what they do best produce
and sell high-quality products and meet
their customersrsquo expectations
More info
Scott Yablonsky Tel +1 262 717 793
scottyablonskymetsocom
The Metso C160 jaw
was installed at a 10deg
angle to fit Pleasant
Gaprsquos existing
infrastructure
The Lokotrack LT1213 impactor plant and ST272 mobile screen operate in tandem with two
portable conveyors at Pleasant Gap
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983149983141983156983155983151 983150
Paper amp fiberNew OptiConcept M paper
and board making line
The new OptiConcept M paper and board
making line stands for economy safety and
usability
Metso has launched a new modular paper
and board making line called OptiConceptM A member of the proven OptiConcept
production line family the new OptiCon-
cept M optimizes machine investment in
line with each millrsquos capacity needs
Savings in operating costs are achieved
through precise dimensioning of pro-
cesses proven technological solutions
optimal running parameters effective
maintenance operations and fully inte-
grated automation solutions
Optimized processes innovations
smart controls and accurate dimensioning
decrease the use of steam gas electricitywater chemicals and other raw materials
and reduce emission levels
OptiConcept M has been designed
both visually and physically with the
requirements of users in mind For exam-
ple the design of the machinery allows for
easy and safe changing of rolls and wear
parts thus reducing the total duration and
cost of maintenance shutdowns
RecyclingGreen energy technology to
Elektrociepłownia Białystok in Poland
Metso will convert a coal-fired boiler to
a biomass-fired Bubbling Fluidized Bed
boiler for Elektrociepłownia Białystok SArsquos
combined heat and power plant (CHP) in
Białystok Poland The new boiler system
will cut the power plantrsquos CO2 emissions
significantly by partly replacing the coal
fuel supply with biomass fuel
ldquoPoland is one of the largest countries
in Europe to have such a high depend-ence on energy derived from coal to
meet national electricity needs This is an
important incentive for us to reduce future
CO2 emissions and produce more green
electricity and with Metso technology
we are certain to accomplish our goalrdquo
states Mr Andrzej Schroeder President of
Elektrociepłownia Białystok SA
Since 2000 Metso has received a total
of 7 biomass boiler conversion orders in
Poland and the renewable energy share
in Poland is only 75 (2010) compared to
the target of 20 by 2020 set by the EUApproximately 80 of the current energy
boilers turbines and generators installed in
Polish power plants are over 20 years old In
order to meet the strict EU environmental
requirements modernization of existing
installations is necessary
Automation
Metso DNA automation system expands
to mining and construction
Using Metsorsquos control room automation
an entire crushing and screening plant can
be effi ciently managed
Metso is a leading supplier of mining and
construction machinery This expertise has
now been combined with a scalable Metso
DNA automation system that adapts to
the range of industry needs from single
machine controls to plant-wide automation
and information management systems
An example of Metsorsquos new offering is a
new crushing plant control room solution
that connects crushers and screens ensur-
ing the effective management of the entire
plant from a pleasant and safe control
room The Metso DNA user interface pro-vides the production information to ensure
a proper and rapid response to plant
events Automatic controls stabilize the
process and allow the operators to monitor
the plant as a whole
ldquoThe benefits of automation for the min-
ing and construction industry are signifi-
cant As an example of the services we offer
performance studies to crushing plants
utilizing Metsorsquos multi-disciplinary teams of
experts to determine the present level of
the plant and process effi ciency and to esti-
mate the improvement potential and thebenefits of optimization and automation
including ROI calculationsrdquo says Mikko Maumlki-
nen Product Manager of minerals applica-
tions in Metsorsquos Automation business line
ldquoAs another example our machine
condition monitoring solutions can reduce
plant and machine downtimes as well as
help to avoid safety and environmental
hazardsrdquo he adds
Metso around the world
Aerial view of the Elektrociepłownia Białystok combined heat and power plant in Poland
8202019 Metso Minerals Aggregates 3 2011
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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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983122983141983152983151983154983156983145983150983143 983154983141983155
Up until now the entire production of the
chrome mine totaling about 13 million
tons annually has been transported to the
Tornio ferrochrome plant for processing
and on to the Tornio stainless steel plant
The increase in production which will
begin in autumn 2012 is intended also to
enable Outokumpu to sell ferrochrome tocompanies outside the Group The produc-
tion target for 2013 is 27 million tons of
ore and of the ferrochrome produced from
the ore nearly a half (gt 200000 tons) is to
be sold outside
Underground expansion
work almost complete
About 500 meters underground the
majority of the work involved in increasing
the capacity the F3 project has already
been completed Doubling the production
is no problem for the Superiorreg primarygyratory crusher delivered to the mine
by Metso in 2002 which can digest more
than 2700 tons of feed material per hour if
necessary
At the moment the primary gyratory
crusher can be fed by three different vibrat-
ing feeders The crusher currently runs for
less than one-fifth of the production time
The increase in ore production will increase
the effective crushing time to about one-
third of the production time
A lot of work has been done for orestorage after the primary crusher The
two currently used storage silos are now
accompanied by two new 8000-ton silos
The number of Metso feeders transporting
the ore from the primary crusher has also
been doubled
Optimization of wear parts under way
Chrome ore has been a challenge to the
primary gyratory crusherrsquos wear parts The
wear is contributed to by the pulsating
feed which rarely fills the entire crushing
chamber There are also great differences inore type since brittle feed material prone
to chalking is occasionally replaced by hard
ore that requires a lot of crushing power
before it is crushed with a bang gt
Mika Saari (right) Foreman of ore line technicians at Outokumpursquos chrome mine in conversation with
Mikko Malkamaumlki Metsorsquos crusher wear parts specialist
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
last did in July for the replacement of the
crusherrsquos wear parts Our work is also facili-
tated by product development like the
addition of maintenance hatches to the
feedersrdquo he continues
Lasting technology
According to Mika Saarirsquos calculations the
Superiorreg primary gyratory crusher has so
far crushed more than six million tons of
ore in totalldquoThe factory polishing marks still show
on the bottom thrust bearing so we
believe that the bearing will last the entire
remaining service life of the crusher which
is about ten years and 30 million tons
Metsorsquos feeders have been equally reliablerdquo
Saari says
After the next 30 million tons of ore
it will be time to deepen the mine
More info
Jukka Raumlisaumlnen
Tel +358 50 317 1787 jukkaraisanenmetsocom
Mikko Malkamaumlki
Tel + 358 40 827 8223
mikkomalkamakimetsocom
The Kemi mine and Metso are currently
carrying out a development project to
increase the service life of the mantle and
outer concave and thus minimize down-
time due to replacement While the modu-
lar feed hopper enables quick replacement
of the mantle replacing the outer concave
can easily take more than a week The cooperation between the Kemi
mine and Metsorsquos wear parts team in
Tampere aims to extend the service life
of the parts to at least 4 million crushed
tons Durability is sought by optimizing the
chamber structure and selecting the r ight
materials for the outer concave
ldquoSmooth cooperationrdquo
Mika Saari Foreman of ore line technicians
working in the underground mainte-
nance of the Kemi mine leads a small but
experienced team of technicians The tidymodern offi ce spaces are located close to
the action at a depth of 500 meters
ldquoCooperation with Metso has been
smooth Increasing our own crushing
expertise takes time so all know-how
shared by the manufacturer is very wel-
come to usrdquo Mika Saari says
ldquoWe can also use Metsorsquos profession-
als for servicing when necessary like we
The Superiorreg 50-65 has provided reliable
crushing performance at a depth of 500 metres
in the Kemi chrome mine
Technicians Sari Kulju (left) and Marko Jaako ensure that the primary gyratory crusherrsquos hydraulicand electrical unit remains very tidy which contributes to trouble-free operation of the crusher
Outokumpu Oyrsquos Kemi
chrome mine
LOCATION Keminmaa northern
Finland
ORE TYPE chrome oxide (26)
ORE ESTIMATE ON 1 JANUARY 2011
ndash ore reserves 36 million tons
ndash mineral resources 87 million
tons
MINING METHOD bench and cut fillFEED MATERIAL SIZE 0ndash1000 mm
METSO EQUIPMENT IN THE MINE
bull 1 Superiorreg 50-65 primary
gyratory crusher
ndash open side setting 152 cm (6rdquo)
bull 8 VMOU 25-125 feeders
bull 1 VMOU 30-16 feeder
bull 1 VMOU 40125 feeder
bull 2 Symons cone crushers
bull 1 C80 jaw crusher
bull 4 HM75 pumps
bull 11HM100 pumps
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983122983141983152983151983154983156983145983150983143 983154983141983155
Metso was responsible for the design
development and construction of the
entire secondary and tertiary arrangement
The primary station will be the subject of a
subsequent investment
Latest environmental protection used
This installation has been designed in strict
compliance with the environmental quality
approach developed by Metso and its
partners using the latest technologies
in dust control including confinement
technology as well as dust encapsulation
technology for screens
To ensure an annual capacity of 15 mil-lion tons for a nominal output of 560th of
02 mm and 220 mm the clientrsquos choice
for the secondary stage naturally fell upon
the NP 1520 impact crusher
A complete impact crusher solution for Lafarge The Lafarge Group has entrusted Metso with the implementation of its new aggregates installation in southern France
It comprises a new secondary crushing stage equipped with an NP1520 impact crusher featuring a power range of2 x 250kW and equipped with hydraulic adjustment
TEXT amp PHOTO Gilles Dombey
The NP 1520 crusher has long proved
its performance not only in terms of capac-
ity and reduction rate but also quality of
the finished product and durability
More info
Arnaud Bertucat
Tel +33 (0)6 81 44 68 26
arnaudbertucatmetsocom
About 15 million tons of aggregates feed will be crushed with the NP1520 impact crusher at Lafargersquos stationary installation in southern France
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Multi-stage Lokotrack process a success in Senegal
A multi-stage crushing and screening process has proven its effi ciency in the production of concrete aggregates in
Senegal Western Africa With the mobile process Xewell Cimenteries SA now exploits its quarry better has reduced
its operating costs and can meet strict environmental requirements
TEXT Elisabetta Cataluffi PHOTOS Carlo Rinolfi
Senegal is a rapidly developing country
offering a good deal of potential activities
for crushing companies too At the sametime the country has several areas of high
environmental value Therefore contractors
must opt for state-of-the-art equipment that
offers reduced environmental emissions
The company Xewell Cimenteries SA
was founded in 2008 as a partnership
between Italian Swiss and Senegalesecontractors Xewell operates a limestone
quarry located in the Pout area east of the
capital city of Dakar
According to Alessandro Crestani Technical
Director of the Pout quarry a mobile process
was selected to better exploit the quarry and
reduce costsLokotrack process drawing made by Bruno simulation software
After assembling the Lokotrack units the process was tested by Xewell Cimenteries
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983122983141983152983151983154983156983145983150983143 983154983141983155
Owned by Freeport-McMoRan Copper amp
Gold (51) and CODELCO (49) the ElAbra mine has leachable oxide and sulfide
mineralization The minersquos processing facil-
ity has an annual capacity of 226000 tons
of copper cathode
Smaller size matters
Reducing the size of the crushed oxide
ore from the present 15 mm to 12 mm
was the main target of the mine and the
Metso team The changes that were carried
out in the process included a size varia-
tion change in the cut of the tertiary sieve
installation of rate-level sensors in thesecondary crushers and enabling speed
variables in the conveyor belt feeders of
the secondary crushing circuit
ldquoGoing from 15mm to 12mm may seem
small but the operational impact is very
important and significant for usrdquo explains
Juan Torres Carvajal Metallurgical Engi-
neer at the El Abra mine
ldquoOur goal is to reach 115000 tons with
a minimum of 80 of 12-mm-sized ore permonth The record to date is 105000 tons
and we will increase it until we reach our
project goalrdquo he adds
New design for cone liners
In addition to the work mentioned above
Metso is currently carrying out a project to
design the lining profiles for the secondary
and tertiary crushers of the plant which
will affect the smaller size of the material
In cooperation with Nelson Mella from
Metso and Rodolfo Navarro Crushing
Superintendent at the El Abra mine testswere carried out in July on the re-designed
Metso linings One set was tested for sec-
ondary crushing and two sets for tertiary
crushing
More info
Nelson Mella
Tel +56 99158 0576
nelsonmellametsocom
Finer ore through wear pro1047297lestudy at El Abra mine in ChileEl Abra is a porphyry copper open-pit mine and processing facility located in
Chile near the city of Calama some 4000 meters above sea level With the helpof Metsorsquos technical support the mine was able to achieve finer ore throughoutthe crushing process
TEXT amp PHOTOS Macarena Vallejo
Xewell Cimenteries produces a selec-
tion of dry processed aggregates for con-
crete Operations started at the end of 2009
with the aim of reaching 150000 metric
tons produced per year
Lokotracks chosen to reduce costs
To build up their tracked mobile processXewell Cimenteries decided to buy three
mobile plants from Metso two impactor
plants the Lokotrack LT1110 and LT1213
feeding a three-deck mobile screen the
ST620 The machines were sold by SCAI
SpA Metsorsquos Lokotrack distributor in Italy
ldquoWe chose tracked machines to bet-
ter exploit our quarry and to reduce
costs Mobile plants have low initial costs
because they donrsquot need any special foun-
dations or supply of electricity This obvi-
ously gives us a quicker process set-up and
better uptimerdquo says Alessandro Crestani Technical Director of the Pout quarry
ldquoThe mobile plant can also follow the
quarry face as the exploitation proceeds
reducing the transport costs of raw materi-
als in the same jobsite We chose Metso
because they ensured us the best cost-per-
ton ratiordquo he adds
Good customer service is crucial
According to Alessandro Crestani good
customer service also played a major role
when choosing the manufacturer of the
mobile equipmentldquoMetsorsquos distributor SCAI SpA was able
to provide us with a complete product
support and customer service package
Obviously service is a very important
aspect for us in a country like Senegal Any
downtime represents a clear loss of pro-
ductivity for usrdquo
The average level of productivity of the
mobile Lokotrack process is 200 metric
tons per hour
More info
Carlo Rinolfi Tel +39 335 1253159
crinolfiscaispacom
Example of the development of the Metso study
on the crusher lining profiles
Liner change for smaller ore size in the
MP1000 cone crusher
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Services success in Surabaya The Metso Surabaya workshop and offi ce complex opened in April 2008 provides Life Cycle Services and maintenance
solutions for Metso equipment in the Indonesia region The facility is strategically located in an industrial precinct on theouter rim of Surabaya the second largest city in Indonesia Its close proximity to an international airport major shipping
port and several engineering companies simplifies support for the regionrsquos key customers which include PT Newmont
and PT Freeport
TEXT amp PHOTOS David LeRoy amp Gary Whittred
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983122983141983152983151983154983156983145983150983143 983154983141983155
The Surabaya site operates through Metso
in Australia with assistance from key sales
and technical staff Handling regional ser-vice and repair business in-house allows
Metso to manage intellectual property and
closely control quality
It also enables the development of a
team of skilled service personnel who can
be utilized both internally and at key cus-
tomer sites as is common with the backup
service the workshop provides for screen
contracts
Innovation at work
Since 2008 the Surabaya facility has suc-
cessfully refurbished a wide variety ofcomponents Recently two ball mill heads
weighing 22 tons each were modified in
order to strengthen the 1047298ange of the ball
mill shell The modification included tap-
ping out existing 1047298ange holes and drilling
new ones so that finger plates could be
installed and welded to the 1047298anges
Positioning the head borer to properly
align the new 1047298ange holes proved diffi cult
Four roller support frames were manufac-
tured to support the heads and allow them
to be rotated easily Each hole was then
drilled and tapped at the correct angleusing the CNC five axis head The job had a
tight delivery as it was required for a shut-
down but with advance planning and inno-
vation it was completed ahead of schedule
MP1000 mainframe on
CNC vertical borer
Well equipped for fabricating and machin-
ing heavy components the Surabaya
The Surabaya facility has proven to be
a success for Metso The workshop offers a
wide variety of services in the region Qual-ity products and competitive pricing and
delivery times have led to strong customer
relationships
Turnover and customer service levels
have increased annually since the open-
ing and between 2008 and 2010 sales
increased 450 These excellent trends
are expected to continue as the operation
expands and the customer base grows
Since 2008 the Surabaya facility has
successfully refurbished
bull MP1000 counter shaft boxes headassemblies mainframes bowls adjust-
ment rings counterweights sockets and
tramp release cylinders
bull 7rsquo Symons bowls heads and countershaft
boxes
bull Vertimill screw and drive shafts
bull Ball mill heads
bull Ball mill trommel
bull VPA cylinders
bull Eaton clutches
bull Exciter screen mechanisms
bull 42x65 main shafts and eccentrics
More info
Gary Whittred
Tel +62 31 8430349
garywhittredmetsocom
workshop handles the majority of Metsorsquos
refurbishment work with ease But when
necessary PT PAL ndash a government facilitywith shipbuilding and heavy engineering
capabilities ndash offers a ldquoone stop shoprdquo Spe-
cially trained PT PAL staff ensures that the
work they perform complies with all Metso
specifications and quality standards
PT PAL also demonstrated their innova-
tive ability with the first MP1000 main-
frame refurbishment they completed The
mainframersquos shaft location bore needed
to be re-machined However the distance
from the top of the mainframe to the
tapered bore made it very hard to achieve
an accurate surface finish with the correctstandoff
To overcome this the shop decided to
machine the mainframe upside down and
elevated on support beams They posi-
tioned a new shaft under the mainframe in
a custom-made cradle Using an overhead
crane they could then lsquotrial fitrsquo the shaft in
the bore to make sure it seated correctly
and the mating tapers met specification
The method worked so well it has since
been used for four more mainframe refur-
bishments
Diversity and growth
Today Metso Surabaya continues to invest
in additional equipment in order to diver-
sify its service offering A new hydraulic
power pack which allows the facility to test
refurbished components to Metso specifi-
cations was recently used in the refurbish-
ment and testing of several VPA cylinders
for PT Freeport
Refurbished MP1000 mainframe dispatched by truck to
PT Freeport mine
Machining of MP1000 upper frame
at Metsorsquos Surabaya workshop
Mainframe at vertical CNC machining
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Creating Value with Metso in Hong KongIn Hong Kong the aggregates needed for construction are mostly supplied by two local quarries KWP Quarry Company
Limitedrsquos Anderson Road Quarry accounts for 60ndash70 making it the pillar of Hong Kongrsquos construction materials industry
TEXT amp PHOTOS Ou He
When arriving at the Anderson Road
Quarry the most impressive view at the850000 square-meter facility is the Metso
machines including equipment from the
primary secondary and tertiary crushing
circuits and the screens I t is Metsorsquos equip-
ment that secures the supply of aggregates
for Hong Kong
KWP Quarry Company Limited has been
working with Metso since its establishment
in 1997
Due to Hong Kongrsquos stringent dust and noise control standards Metso has paid special attention to the related suppression systems
ldquoOur quarry mainly lies on granite and
volcanic rock which are so hard they canonly be processed by equipment with
strong durability and stabilityrdquo explains
Mr Eddie Hung Manager of KWP ldquoWith a
long history of and experience in quarry-
ing we are very familiar with the equip-
ment of different brands Comparatively
Metsorsquos products are better than others in
terms of durability stability and effi ciency
Besides this the reason we selected Metso
is because of the simple maintenance of
their equipment and the easy access tomaintenance informationrdquo
Flexible modular solution
Based on extensive experience in crushing
and screening worldwide Metso presented
the Anderson Road Quarry with a modu-
lar solution and delivered it as a turn-key
project Through a four-stage crushing
circuit which contains three Metso C160
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jaw crushers for primary crushing two
Omnicone 1560SX crushers for secondary
crushing two HP 500SX cone crushers for
tertiary crushing and one HP500SX cone
crusher for extra-fine crushing the plant
was able to produce aggregates of optimal
shape with minimal 1047298akiness
The fine products include three sizes
0 to 5 mm 5 to 10 mm and 10 to 20mm
Since the employment of this system in
2000 production has reached 1250 th
which is far beyond the design capacityAccording to Mr Hung ldquoThe machines
always run effi ciently and seldom malfunc-
tion The occasional shutdown of some
machines does not affect production very
much the plant still could reach 60-70
of its normal production It gives us the
best 1047298exibility for the plant rsquos operation and
I believe this is the best feature of Metsorsquos
solution
Eddie Hung
Manager of KWPrsquos
Anderson Road
Quarry is happy with
the product quality
and service provided
by Metso
ldquoMetsorsquos equipment is expensive com-
paratively but in the long run you will find
that the investment is worthwhile on the
whole Metso secures superior stability reli-
ability and fewer downtimes and it guaran-
tees continuous operation and brings us
greater valuerdquo
Great service team
Metso sent a group of service engineers
to the plant within the warranty period
not only to provide service but to train theoperators Mr Hung speaks highly of Met-
sorsquos service team he is impressed with its
experienced experts and with their strong
sense of responsibility and customer-
oriented ways of working
ldquoMetsorsquos service team never fails to find
hidden problems and helps us to prevent
any mechanical failures And they are
available whenever we need them they
work closely with us to solve the problem
effi cientlyrdquo he said
Excellent environment-friendly designIn order to achieve the worldrsquos most strin-
gent noise and dust control standards
developed by the Environment Protection
Department of Hong Kong Metso has
incorporated a dust and noise suppression
system into the plant This includes the
infrared-triggered spray systems at feed
points encapsulation of individual crush-
ers and conveyors and the ability to select
specific sectors of the system for treatment
depending on feed and operating condi-
tions encapsulation of equipment and the
enclosure of all major sections of the plant
With these advanced environment-
friendly solutions Anderson Road Quarry
has won numerous safety and environmen-
tal awards In 2003 it was presented with a
silver medal in the prestigious Environmen-
tal Performance Awards in recognition of
its commitment to the environment and
community In 2004 KWP achieved certifi-cation of ISO 14001 it is the first quarry site
to have achieved this in Hong Kong and
southern China
ldquoA reliable partnerrdquo
The promulgation of the top ten infrastruc-
ture policies in Hong Kong boosted the
market for aggregates and demand will
keep rising over the next five to six years
ldquoWersquoll definitely keep our cooperation with
Metso once we have a need for expansion
because we regard Metso as a reliable part-
ner With their highly effi cient equipmentsatisfying service and great efforts in help-
ing us to achieve our environmental pro-
tection targets Metso is our best choicerdquo
says Hung
More info
Ziqiang Li
Tel +86 13601289027
ziqianglimetsocom
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The sturdy Metso C160
jaw crushers are fed
using huge feed chutes
and feeders
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Similar to hundreds of mine sites world-
wide Zinkgruvan is being operated on a
non-stop 247 basis with just a few main-
tenance breaks during the year Crusher
availability is crucial because 100 of the
ore has to pass through the jaws before
being hoisted up for further processing
In addition to the zinc- lead- copper-
and silver-containing ore the C jaws chop
all the host rock extracted along the min-
ing process With a sturdy design Metsorsquos
proven C jaws can easily reduce even the
hardest type of rock Every year more thanone million tons are crushed with the jaws
ldquoMinimal service neededrdquo
Crushing with the first C160B jaw crusher
began at Zinkgruvanrsquos -800 meter level in
2000 with the primary crushing of zinc-lead
ore The second jaw was installed in 2008
for the new copper process gt
The sight and sound of two C160 jaw crushers operating side by side in the underground
crushing station of the Swedish Zinkgruvan mine is impressive Good proactive service
secures good uptime and reliable continuous operation of Metsorsquos second-largest
C160 series jaw crushers and prepares the way for the ongoing plans to expand the
production of zinc concentrate
TEXT amp PHOTOS Eero Haumlmaumllaumlinen
New PolyMet liners are being tested with the grinding mill delivered by Metso
Zinkgruvanrsquos twin C160
jaws secure good uptime
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Blasted ore is taken from the presently
operated -850 meter level with normal
trucks as an outsourced process One full
truckload is fed to the C160s every
10 minutes
ldquoWe are happy with the high reliability
of the C jaws They only require some minor
service therefore providing us with good
uptime and steady continuous feed to our
secondary and tertiary crushing and grind-ing circuitsrdquo says Mine Manager Jan Klaumlre
ldquoBasic crusher service and wear part
changes are made by our own staff using
Metsorsquos partsrdquo he adds
Service contract with grinding
mills and conveyors
Zinkgruvan and Metso Sweden have more
than 11 yearsrsquo experience with a service
contract that contains grinding mills and
conveyors At the mine site two Metso
service people and one contractor take
care of all the related service jobs Man-
power can also be borrowed from Metsorsquos
Graumlngesberg mine service team of 20
people
Presently Zinkgruvan is testing Metsorsquos
new PolyMet mill linings in its big grinding
mills With previously used rubber partsthe linings had to be changed in the shell
every 9 to 11 months and in the feed head
every 6 months
ldquoWe expect a better lifetime with Poly-
Met linings Longer change intervals mean
a lot to our productivity because lining
changes takes two full working daysrdquo Mine
Manager Jan Klaumlre says
New mine goes deeper
With an expected mine life of more than 10
years Zinkgruvan is actively mapping new
ore reserves Experimental holes are being
drilled at the new mine section at the
-1110 meter level
More info
Fredrik Wennberg
Tel +46 70 657 00 08fredrikwennbergmetsocom
Mine Manager Jan Klaumlre (left) with Backfilling Manager Kjell Tillman at the underground -800 meter level mine cafeteria
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The Zinkgruvan mine located approxi-
mately 200 km southwest of Stockholm
Sweden is one of the oldest underground
mines in Northern Europe The mine has
been in production since 1857
The mining methods used are panel
stoping and benching The processing
facilities include a zinc concentrating plant
with a 11 mtpa and a copper plant with a04 mtpa capacity Tailings are recycled in
an impounding basin and host rock in the
backfill plant
Continuous mining since 1857
Even as one of the oldest mines in Northern
Europe Zinkgruvan exploits modern mining
and minerals processing installations
Zinkgruvan mine
OWNER Lundin Mining
PRODUCTION PER YEAR 1 million tons
ORE TYPE sedimentary exhalative
zinc lead copper and silver
NUMBER OF EMPLOYEES 320
2011 PRODUCTION TARGETS 78000 tonsof zinc 36000 tons of lead and
3400 tons of copper concentrate
METSO EQUIPMENT ON SITE
bull 1 extra long VF feeder
bull 2 C160 jaw crushers
ndash zinc process css 220ndash240 mm
ndash copper process css 150 mm
bull 1 GP300S cone crusher
ndash css 45mm
bull 1 HP4 cone crusher
ndash css 18 mm
bull 1 DS screen
bull 1 FS402 screenbull 1 grinding mill
bull Pumps VPAs
A normal truck feeds the C jaws with ore coming from the lower production levels
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Cost-per-ton wear agreements deepencustomer relationshipsCrusher wear parts are traditionally marketed purely based on transactional sales and mainly depend on
the weight of manganese Metso has recently introduced a new type of wear agreement based on thecost-per-ton crushed and the wear occurred Thus far the experience has been very positive increasing
transparency and deepening the operational relationship between the manufacturer and the customer
TEXT Olli Kellokumpu and Eero Haumlmaumllaumlinen PHOTOS Eero Haumlmaumllaumlinen
Arto Hiedanniemi (left)
Hannu Heman and Juha
Laukka of Metsorsquos Finnish
Service team checking the
cone crusher mantles shipped
for a cost-per-ton customer
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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156
Wear parts and parts changes
can be included
The structure of a cost-per-ton wearcontract is based on the number of tons
crushed and the estimated wear occurred
The amount and monetary value of the
wear is calculated per crushed ton
ldquoEither plain wear parts or parts changes
carried out by Metsorsquos service personnel
can be included in the contract In the latter
case we ask our Finnish customers to inform
us about an upcoming wear change opera-
tion one week in advancerdquo Heman explains
ldquoWe see good opportunities to market
cost-per-ton contracts further in Finland
and also abroad It really develops therelationship of Metso and our customers
towards a trusted partnershiprdquo he notes
Perfect tool for accurate planning
Soraliike Ikola Oy is a mid-sized contrac-
tor with three Metso two- and three-
stage mobile and portable crushing and
screening plants operating in Central and
Since 2002 Metsorsquos sales team in Finland
has developed the cost-per-ton-based
service offeringldquoOur aim has been to seek through
a cost-per-ton offering possibilities to
serve our customers better to differentiate
Metso from the other players as an OEM
manufacturer and to offer deeper profes-
sionalism and know-howrdquo says Hannu
Heman General Manager of service
operations
ldquoUntil now both our experience and
that of our customers has been quite posi-
tive When properly prepared cost-per-ton
contracts seem to create a win-win situa-
tionrdquo Heman adds Today Metso has operational cost-per-
ton agreements with several Finnish cus-
tomers The first contract was concluded
with a customer operating a stationary
plant Based on the results gathered new
cost-per-ton contracts have been signed
with customers operating wheeled and
tracked equipment too
Eastern Finland Because of the size of the
contracts up to 50 equipment moves are
made during the yearEntrepreneur Pasi Ikola has had a cost-
per-ton contract with Metso for nearly
two years and he is quite happy with the
outcome
ldquoThe cost-per-ton contract has provided
me with a perfect tool for accurate financial
planning Now I know in detail my actual
future wear parts costs This helps a lot
when calculating bidsrdquo
ldquoEarlier I used to buy a big batch of
Metso wear parts in one go and had to
reserve a reasonable amount of money for
that Today all wear costs are evenly sharedwhich gives us a welcomed 1047298exibility to
our cost structure Now we just pay Metso
afterwards based on our crushed tonsrdquo
he adds
More info
Olli Kellokumpu
Tel +358 50 354 1189
ollikellokumpumetsocom
According to crushing contractor Pasi Ikola the cost-per-ton contract with Metso has provided the entrepreneur with better economical 1047298exibility
and more accurate calculating of bids
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Pleasant Gap is owned and operated by
Glenn O Hawbaker Inc of State College
Pennsylvania This family-owned company
began in 1952 as a small excavation busi-
ness founded by Glenn O Hawbaker and
his wife Thelma Over the years the com-
pany grew by adding an integrated mix ofproducts and services and taking on larger
projects
In 1983 Hawbaker acquired Pleasant
Gap Quarry and built its first aggregates
processing plant Today Glenn O Haw-
baker Inc operates 21 quarries and eight
asphalt production facilities across Penn-
sylvania and southern New York as well as
five regional operation centers
Primary
challenge atPleasant GapQuarryA good part of what makes for a successful crushing
operation is the willingness to tackle challenges and to do
whatrsquos necessary to meet demand The team at Pleasant
Gap Quarry in central Pennsylvania recently met the chal-
lenge when they successfully addressed problems with
the plantrsquos primary crushing plant First they purchased
a new Metso C160 jaw to replace the existing primary
impact crusher Then they devised an innovative plan to
get the primary plant back in operation while awaitingdelivery of the new jaw crusher
TEXT Linda Bergmann PHOTOS John Rickinger
983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Time for a change
With the goal of increasing reliability and
output the management at Pleasant Gap
Quarry recently decided it was time to
replace the plantrsquos primary impact crusher
Following a thorough search they chose a
new Metso C160 jaw According to ScottReck Plant Manager it no longer made
sense to repair and rebuild the existing
impactor
ldquoBefore we purchased the Metso C160
we had a few other impact crushers and
they served us well but as our custom-
ersrsquo needs increased our plant production
had to match that demand We found our
formerly reliable unit was being overcome
by our demands for output and creative
work-around solutions We continued to
need more but there was only so much we
could do until we hit the breaking point ndash
literallyrdquo
In addition to performance improve-
ments the new crusher also needed to fitinto Pleasant Gaprsquos unique infrastructure
As Plant Project ManagerEngineer Jeremy
Fahr explains ldquoOur height restraint was 274
meters (108rdquo) This height was the distance
from the feed lip of the existing 6x12 scalp-
ing screen and the existing structure that
the crusher rests onrdquo
The normal C160 crusher is 307
meters (121rdquo) tall but Metso gave GOH
Scott Reck Plant Manager (left) and
Jeremy Fahr Plant Project Manager
Engineer at Pleasant Gap Quarry
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983122983141983152983151983154983156983145983150983143 983154983141983155
a 10-degree mounting option (which is
normally used on their portable crushers)
to overcome the height restraint Reck and
Fahr worked with Dave Rhoa of Cleveland
Brothers Equipment Metsorsquos crushing and
screening distributor in Pennsylvania to
pull everything together and fit the newcrusher into their plant
The C160 crusher selected for Pleasant
Gap is one of the latest models in Metsorsquos
C Series of jaws These jaw crushers feature
a large throw and steep toggle plate angle
resulting in a higher crusher output In
addition the C Series has a compact foot-
print that makes it an ideal choice for the
replacement of existing machines
According to Reck ldquoWe had heard about
the new Metso C160 and started doing our
own research and found Metso not only
had developed the output capacity we
needed but fit the uniqueness of our oper-
ationsrdquo The new Metso crusher will allow
the plant to increase tons per hour andgive them the 1047298exibility to meet demands
for varying products on short notice
Mobile solution
Purchasing the new primary jaw addressed
the long-term issues but still left Pleasant
Gap without a functioning primary plant
Reck continues ldquoOur main line was still
down leaving us with a big hole in hitting
customer needs but knowing that our new
Metso C160 was on its wayhellipwe needed an
immediate solution to keep our produc-
tion demands with an out-of-commission
crusherrdquo
The team at Pleasant Gap brainstormed
the problem and came up with a plan toget the primary plant back in operation
Their solution was to use the Lokotrack
LT1213 impactor plant and another mobile
unit to keep the main line crushing To do
this they removed the guts on the existing
impact crusher essentially turning it into a
rock chute They then moved the LT1213
and another manufacturerrsquos mobile unit
over to the existing dump hopper gt
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
ldquoWe had our haul trucks drop off mate-
rial while two excavators fed the two
mobile unitsrdquo Reck explains ldquoFor two-and-
a-half months the Lokotrack LT1213 unit
was producing 254 cm (10rdquo) minus at
700 tons per hour The other similar-sized
mobile unit was doing 400 tons an hour
maxed out The difference was unbeliev-
able to say the least Our unique solution
using the two mobile units especially the
LT1213 helped Glenn O Hawbaker achieve
a record output in 2010rdquoAccording to Fahr ldquoWe were not new to
Metsorsquos quality and supportrdquo because GOH
had been using Metsorsquos portable crushing
equipment for 3 years prior to the primary
plantrsquos impact crusher failure In another
part of our operation we have a system that
our team relies on every day a Lokotrack
LT1213 and ST272 working in tandem with
two portable conveyorsrdquo This highly effi -
cient mobile processing system turns out
300 tons of specialized blended material
per hour GOH has been so impressed with
Metso equipment its last two purchaseswere an LT106 tracked jaw plant and a
second ST272 mobile screen in 2010
Maintaining high productivity
The Metso C160 jaw was delivered to Pleas-
ant Gap Quarry in January of 2011 and
since start-up it has more than met expec-
tations The crusher is fed minus 910 mm
(36rdquo) limestone with the jaw set at 140 mm
(5 12rdquo) According to Reck ldquoFrom moment
we started up we knew we had a winner
Not only were we kicking out as much
product as our previous units without even
breathing hard but we immediately had a
2-cent per ton savings to the bottom line
without having to run a second 350 HP
motor as required by other units Plus by
adding on the new automatic lube system
the maintenance team had more time to
devote to keeping other areas of the com-
plex running more effi cientlyrdquoReck says ldquoThe Metso unit was a perfect
fit and with the improved features it pre-
sented it had it all We just turn it on load
it up and we are moving 600 tons per hour
through the crusher without any effort and
we know it can do so much morerdquo With
the primary crushing plant back in opera-
tion the entire team at Pleasant Gap will
continue to do what they do best produce
and sell high-quality products and meet
their customersrsquo expectations
More info
Scott Yablonsky Tel +1 262 717 793
scottyablonskymetsocom
The Metso C160 jaw
was installed at a 10deg
angle to fit Pleasant
Gaprsquos existing
infrastructure
The Lokotrack LT1213 impactor plant and ST272 mobile screen operate in tandem with two
portable conveyors at Pleasant Gap
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983149983141983156983155983151 983150
Paper amp fiberNew OptiConcept M paper
and board making line
The new OptiConcept M paper and board
making line stands for economy safety and
usability
Metso has launched a new modular paper
and board making line called OptiConceptM A member of the proven OptiConcept
production line family the new OptiCon-
cept M optimizes machine investment in
line with each millrsquos capacity needs
Savings in operating costs are achieved
through precise dimensioning of pro-
cesses proven technological solutions
optimal running parameters effective
maintenance operations and fully inte-
grated automation solutions
Optimized processes innovations
smart controls and accurate dimensioning
decrease the use of steam gas electricitywater chemicals and other raw materials
and reduce emission levels
OptiConcept M has been designed
both visually and physically with the
requirements of users in mind For exam-
ple the design of the machinery allows for
easy and safe changing of rolls and wear
parts thus reducing the total duration and
cost of maintenance shutdowns
RecyclingGreen energy technology to
Elektrociepłownia Białystok in Poland
Metso will convert a coal-fired boiler to
a biomass-fired Bubbling Fluidized Bed
boiler for Elektrociepłownia Białystok SArsquos
combined heat and power plant (CHP) in
Białystok Poland The new boiler system
will cut the power plantrsquos CO2 emissions
significantly by partly replacing the coal
fuel supply with biomass fuel
ldquoPoland is one of the largest countries
in Europe to have such a high depend-ence on energy derived from coal to
meet national electricity needs This is an
important incentive for us to reduce future
CO2 emissions and produce more green
electricity and with Metso technology
we are certain to accomplish our goalrdquo
states Mr Andrzej Schroeder President of
Elektrociepłownia Białystok SA
Since 2000 Metso has received a total
of 7 biomass boiler conversion orders in
Poland and the renewable energy share
in Poland is only 75 (2010) compared to
the target of 20 by 2020 set by the EUApproximately 80 of the current energy
boilers turbines and generators installed in
Polish power plants are over 20 years old In
order to meet the strict EU environmental
requirements modernization of existing
installations is necessary
Automation
Metso DNA automation system expands
to mining and construction
Using Metsorsquos control room automation
an entire crushing and screening plant can
be effi ciently managed
Metso is a leading supplier of mining and
construction machinery This expertise has
now been combined with a scalable Metso
DNA automation system that adapts to
the range of industry needs from single
machine controls to plant-wide automation
and information management systems
An example of Metsorsquos new offering is a
new crushing plant control room solution
that connects crushers and screens ensur-
ing the effective management of the entire
plant from a pleasant and safe control
room The Metso DNA user interface pro-vides the production information to ensure
a proper and rapid response to plant
events Automatic controls stabilize the
process and allow the operators to monitor
the plant as a whole
ldquoThe benefits of automation for the min-
ing and construction industry are signifi-
cant As an example of the services we offer
performance studies to crushing plants
utilizing Metsorsquos multi-disciplinary teams of
experts to determine the present level of
the plant and process effi ciency and to esti-
mate the improvement potential and thebenefits of optimization and automation
including ROI calculationsrdquo says Mikko Maumlki-
nen Product Manager of minerals applica-
tions in Metsorsquos Automation business line
ldquoAs another example our machine
condition monitoring solutions can reduce
plant and machine downtimes as well as
help to avoid safety and environmental
hazardsrdquo he adds
Metso around the world
Aerial view of the Elektrociepłownia Białystok combined heat and power plant in Poland
8202019 Metso Minerals Aggregates 3 2011
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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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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
last did in July for the replacement of the
crusherrsquos wear parts Our work is also facili-
tated by product development like the
addition of maintenance hatches to the
feedersrdquo he continues
Lasting technology
According to Mika Saarirsquos calculations the
Superiorreg primary gyratory crusher has so
far crushed more than six million tons of
ore in totalldquoThe factory polishing marks still show
on the bottom thrust bearing so we
believe that the bearing will last the entire
remaining service life of the crusher which
is about ten years and 30 million tons
Metsorsquos feeders have been equally reliablerdquo
Saari says
After the next 30 million tons of ore
it will be time to deepen the mine
More info
Jukka Raumlisaumlnen
Tel +358 50 317 1787 jukkaraisanenmetsocom
Mikko Malkamaumlki
Tel + 358 40 827 8223
mikkomalkamakimetsocom
The Kemi mine and Metso are currently
carrying out a development project to
increase the service life of the mantle and
outer concave and thus minimize down-
time due to replacement While the modu-
lar feed hopper enables quick replacement
of the mantle replacing the outer concave
can easily take more than a week The cooperation between the Kemi
mine and Metsorsquos wear parts team in
Tampere aims to extend the service life
of the parts to at least 4 million crushed
tons Durability is sought by optimizing the
chamber structure and selecting the r ight
materials for the outer concave
ldquoSmooth cooperationrdquo
Mika Saari Foreman of ore line technicians
working in the underground mainte-
nance of the Kemi mine leads a small but
experienced team of technicians The tidymodern offi ce spaces are located close to
the action at a depth of 500 meters
ldquoCooperation with Metso has been
smooth Increasing our own crushing
expertise takes time so all know-how
shared by the manufacturer is very wel-
come to usrdquo Mika Saari says
ldquoWe can also use Metsorsquos profession-
als for servicing when necessary like we
The Superiorreg 50-65 has provided reliable
crushing performance at a depth of 500 metres
in the Kemi chrome mine
Technicians Sari Kulju (left) and Marko Jaako ensure that the primary gyratory crusherrsquos hydraulicand electrical unit remains very tidy which contributes to trouble-free operation of the crusher
Outokumpu Oyrsquos Kemi
chrome mine
LOCATION Keminmaa northern
Finland
ORE TYPE chrome oxide (26)
ORE ESTIMATE ON 1 JANUARY 2011
ndash ore reserves 36 million tons
ndash mineral resources 87 million
tons
MINING METHOD bench and cut fillFEED MATERIAL SIZE 0ndash1000 mm
METSO EQUIPMENT IN THE MINE
bull 1 Superiorreg 50-65 primary
gyratory crusher
ndash open side setting 152 cm (6rdquo)
bull 8 VMOU 25-125 feeders
bull 1 VMOU 30-16 feeder
bull 1 VMOU 40125 feeder
bull 2 Symons cone crushers
bull 1 C80 jaw crusher
bull 4 HM75 pumps
bull 11HM100 pumps
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983122983141983152983151983154983156983145983150983143 983154983141983155
Metso was responsible for the design
development and construction of the
entire secondary and tertiary arrangement
The primary station will be the subject of a
subsequent investment
Latest environmental protection used
This installation has been designed in strict
compliance with the environmental quality
approach developed by Metso and its
partners using the latest technologies
in dust control including confinement
technology as well as dust encapsulation
technology for screens
To ensure an annual capacity of 15 mil-lion tons for a nominal output of 560th of
02 mm and 220 mm the clientrsquos choice
for the secondary stage naturally fell upon
the NP 1520 impact crusher
A complete impact crusher solution for Lafarge The Lafarge Group has entrusted Metso with the implementation of its new aggregates installation in southern France
It comprises a new secondary crushing stage equipped with an NP1520 impact crusher featuring a power range of2 x 250kW and equipped with hydraulic adjustment
TEXT amp PHOTO Gilles Dombey
The NP 1520 crusher has long proved
its performance not only in terms of capac-
ity and reduction rate but also quality of
the finished product and durability
More info
Arnaud Bertucat
Tel +33 (0)6 81 44 68 26
arnaudbertucatmetsocom
About 15 million tons of aggregates feed will be crushed with the NP1520 impact crusher at Lafargersquos stationary installation in southern France
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Multi-stage Lokotrack process a success in Senegal
A multi-stage crushing and screening process has proven its effi ciency in the production of concrete aggregates in
Senegal Western Africa With the mobile process Xewell Cimenteries SA now exploits its quarry better has reduced
its operating costs and can meet strict environmental requirements
TEXT Elisabetta Cataluffi PHOTOS Carlo Rinolfi
Senegal is a rapidly developing country
offering a good deal of potential activities
for crushing companies too At the sametime the country has several areas of high
environmental value Therefore contractors
must opt for state-of-the-art equipment that
offers reduced environmental emissions
The company Xewell Cimenteries SA
was founded in 2008 as a partnership
between Italian Swiss and Senegalesecontractors Xewell operates a limestone
quarry located in the Pout area east of the
capital city of Dakar
According to Alessandro Crestani Technical
Director of the Pout quarry a mobile process
was selected to better exploit the quarry and
reduce costsLokotrack process drawing made by Bruno simulation software
After assembling the Lokotrack units the process was tested by Xewell Cimenteries
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983122983141983152983151983154983156983145983150983143 983154983141983155
Owned by Freeport-McMoRan Copper amp
Gold (51) and CODELCO (49) the ElAbra mine has leachable oxide and sulfide
mineralization The minersquos processing facil-
ity has an annual capacity of 226000 tons
of copper cathode
Smaller size matters
Reducing the size of the crushed oxide
ore from the present 15 mm to 12 mm
was the main target of the mine and the
Metso team The changes that were carried
out in the process included a size varia-
tion change in the cut of the tertiary sieve
installation of rate-level sensors in thesecondary crushers and enabling speed
variables in the conveyor belt feeders of
the secondary crushing circuit
ldquoGoing from 15mm to 12mm may seem
small but the operational impact is very
important and significant for usrdquo explains
Juan Torres Carvajal Metallurgical Engi-
neer at the El Abra mine
ldquoOur goal is to reach 115000 tons with
a minimum of 80 of 12-mm-sized ore permonth The record to date is 105000 tons
and we will increase it until we reach our
project goalrdquo he adds
New design for cone liners
In addition to the work mentioned above
Metso is currently carrying out a project to
design the lining profiles for the secondary
and tertiary crushers of the plant which
will affect the smaller size of the material
In cooperation with Nelson Mella from
Metso and Rodolfo Navarro Crushing
Superintendent at the El Abra mine testswere carried out in July on the re-designed
Metso linings One set was tested for sec-
ondary crushing and two sets for tertiary
crushing
More info
Nelson Mella
Tel +56 99158 0576
nelsonmellametsocom
Finer ore through wear pro1047297lestudy at El Abra mine in ChileEl Abra is a porphyry copper open-pit mine and processing facility located in
Chile near the city of Calama some 4000 meters above sea level With the helpof Metsorsquos technical support the mine was able to achieve finer ore throughoutthe crushing process
TEXT amp PHOTOS Macarena Vallejo
Xewell Cimenteries produces a selec-
tion of dry processed aggregates for con-
crete Operations started at the end of 2009
with the aim of reaching 150000 metric
tons produced per year
Lokotracks chosen to reduce costs
To build up their tracked mobile processXewell Cimenteries decided to buy three
mobile plants from Metso two impactor
plants the Lokotrack LT1110 and LT1213
feeding a three-deck mobile screen the
ST620 The machines were sold by SCAI
SpA Metsorsquos Lokotrack distributor in Italy
ldquoWe chose tracked machines to bet-
ter exploit our quarry and to reduce
costs Mobile plants have low initial costs
because they donrsquot need any special foun-
dations or supply of electricity This obvi-
ously gives us a quicker process set-up and
better uptimerdquo says Alessandro Crestani Technical Director of the Pout quarry
ldquoThe mobile plant can also follow the
quarry face as the exploitation proceeds
reducing the transport costs of raw materi-
als in the same jobsite We chose Metso
because they ensured us the best cost-per-
ton ratiordquo he adds
Good customer service is crucial
According to Alessandro Crestani good
customer service also played a major role
when choosing the manufacturer of the
mobile equipmentldquoMetsorsquos distributor SCAI SpA was able
to provide us with a complete product
support and customer service package
Obviously service is a very important
aspect for us in a country like Senegal Any
downtime represents a clear loss of pro-
ductivity for usrdquo
The average level of productivity of the
mobile Lokotrack process is 200 metric
tons per hour
More info
Carlo Rinolfi Tel +39 335 1253159
crinolfiscaispacom
Example of the development of the Metso study
on the crusher lining profiles
Liner change for smaller ore size in the
MP1000 cone crusher
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Services success in Surabaya The Metso Surabaya workshop and offi ce complex opened in April 2008 provides Life Cycle Services and maintenance
solutions for Metso equipment in the Indonesia region The facility is strategically located in an industrial precinct on theouter rim of Surabaya the second largest city in Indonesia Its close proximity to an international airport major shipping
port and several engineering companies simplifies support for the regionrsquos key customers which include PT Newmont
and PT Freeport
TEXT amp PHOTOS David LeRoy amp Gary Whittred
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983122983141983152983151983154983156983145983150983143 983154983141983155
The Surabaya site operates through Metso
in Australia with assistance from key sales
and technical staff Handling regional ser-vice and repair business in-house allows
Metso to manage intellectual property and
closely control quality
It also enables the development of a
team of skilled service personnel who can
be utilized both internally and at key cus-
tomer sites as is common with the backup
service the workshop provides for screen
contracts
Innovation at work
Since 2008 the Surabaya facility has suc-
cessfully refurbished a wide variety ofcomponents Recently two ball mill heads
weighing 22 tons each were modified in
order to strengthen the 1047298ange of the ball
mill shell The modification included tap-
ping out existing 1047298ange holes and drilling
new ones so that finger plates could be
installed and welded to the 1047298anges
Positioning the head borer to properly
align the new 1047298ange holes proved diffi cult
Four roller support frames were manufac-
tured to support the heads and allow them
to be rotated easily Each hole was then
drilled and tapped at the correct angleusing the CNC five axis head The job had a
tight delivery as it was required for a shut-
down but with advance planning and inno-
vation it was completed ahead of schedule
MP1000 mainframe on
CNC vertical borer
Well equipped for fabricating and machin-
ing heavy components the Surabaya
The Surabaya facility has proven to be
a success for Metso The workshop offers a
wide variety of services in the region Qual-ity products and competitive pricing and
delivery times have led to strong customer
relationships
Turnover and customer service levels
have increased annually since the open-
ing and between 2008 and 2010 sales
increased 450 These excellent trends
are expected to continue as the operation
expands and the customer base grows
Since 2008 the Surabaya facility has
successfully refurbished
bull MP1000 counter shaft boxes headassemblies mainframes bowls adjust-
ment rings counterweights sockets and
tramp release cylinders
bull 7rsquo Symons bowls heads and countershaft
boxes
bull Vertimill screw and drive shafts
bull Ball mill heads
bull Ball mill trommel
bull VPA cylinders
bull Eaton clutches
bull Exciter screen mechanisms
bull 42x65 main shafts and eccentrics
More info
Gary Whittred
Tel +62 31 8430349
garywhittredmetsocom
workshop handles the majority of Metsorsquos
refurbishment work with ease But when
necessary PT PAL ndash a government facilitywith shipbuilding and heavy engineering
capabilities ndash offers a ldquoone stop shoprdquo Spe-
cially trained PT PAL staff ensures that the
work they perform complies with all Metso
specifications and quality standards
PT PAL also demonstrated their innova-
tive ability with the first MP1000 main-
frame refurbishment they completed The
mainframersquos shaft location bore needed
to be re-machined However the distance
from the top of the mainframe to the
tapered bore made it very hard to achieve
an accurate surface finish with the correctstandoff
To overcome this the shop decided to
machine the mainframe upside down and
elevated on support beams They posi-
tioned a new shaft under the mainframe in
a custom-made cradle Using an overhead
crane they could then lsquotrial fitrsquo the shaft in
the bore to make sure it seated correctly
and the mating tapers met specification
The method worked so well it has since
been used for four more mainframe refur-
bishments
Diversity and growth
Today Metso Surabaya continues to invest
in additional equipment in order to diver-
sify its service offering A new hydraulic
power pack which allows the facility to test
refurbished components to Metso specifi-
cations was recently used in the refurbish-
ment and testing of several VPA cylinders
for PT Freeport
Refurbished MP1000 mainframe dispatched by truck to
PT Freeport mine
Machining of MP1000 upper frame
at Metsorsquos Surabaya workshop
Mainframe at vertical CNC machining
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Creating Value with Metso in Hong KongIn Hong Kong the aggregates needed for construction are mostly supplied by two local quarries KWP Quarry Company
Limitedrsquos Anderson Road Quarry accounts for 60ndash70 making it the pillar of Hong Kongrsquos construction materials industry
TEXT amp PHOTOS Ou He
When arriving at the Anderson Road
Quarry the most impressive view at the850000 square-meter facility is the Metso
machines including equipment from the
primary secondary and tertiary crushing
circuits and the screens I t is Metsorsquos equip-
ment that secures the supply of aggregates
for Hong Kong
KWP Quarry Company Limited has been
working with Metso since its establishment
in 1997
Due to Hong Kongrsquos stringent dust and noise control standards Metso has paid special attention to the related suppression systems
ldquoOur quarry mainly lies on granite and
volcanic rock which are so hard they canonly be processed by equipment with
strong durability and stabilityrdquo explains
Mr Eddie Hung Manager of KWP ldquoWith a
long history of and experience in quarry-
ing we are very familiar with the equip-
ment of different brands Comparatively
Metsorsquos products are better than others in
terms of durability stability and effi ciency
Besides this the reason we selected Metso
is because of the simple maintenance of
their equipment and the easy access tomaintenance informationrdquo
Flexible modular solution
Based on extensive experience in crushing
and screening worldwide Metso presented
the Anderson Road Quarry with a modu-
lar solution and delivered it as a turn-key
project Through a four-stage crushing
circuit which contains three Metso C160
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jaw crushers for primary crushing two
Omnicone 1560SX crushers for secondary
crushing two HP 500SX cone crushers for
tertiary crushing and one HP500SX cone
crusher for extra-fine crushing the plant
was able to produce aggregates of optimal
shape with minimal 1047298akiness
The fine products include three sizes
0 to 5 mm 5 to 10 mm and 10 to 20mm
Since the employment of this system in
2000 production has reached 1250 th
which is far beyond the design capacityAccording to Mr Hung ldquoThe machines
always run effi ciently and seldom malfunc-
tion The occasional shutdown of some
machines does not affect production very
much the plant still could reach 60-70
of its normal production It gives us the
best 1047298exibility for the plant rsquos operation and
I believe this is the best feature of Metsorsquos
solution
Eddie Hung
Manager of KWPrsquos
Anderson Road
Quarry is happy with
the product quality
and service provided
by Metso
ldquoMetsorsquos equipment is expensive com-
paratively but in the long run you will find
that the investment is worthwhile on the
whole Metso secures superior stability reli-
ability and fewer downtimes and it guaran-
tees continuous operation and brings us
greater valuerdquo
Great service team
Metso sent a group of service engineers
to the plant within the warranty period
not only to provide service but to train theoperators Mr Hung speaks highly of Met-
sorsquos service team he is impressed with its
experienced experts and with their strong
sense of responsibility and customer-
oriented ways of working
ldquoMetsorsquos service team never fails to find
hidden problems and helps us to prevent
any mechanical failures And they are
available whenever we need them they
work closely with us to solve the problem
effi cientlyrdquo he said
Excellent environment-friendly designIn order to achieve the worldrsquos most strin-
gent noise and dust control standards
developed by the Environment Protection
Department of Hong Kong Metso has
incorporated a dust and noise suppression
system into the plant This includes the
infrared-triggered spray systems at feed
points encapsulation of individual crush-
ers and conveyors and the ability to select
specific sectors of the system for treatment
depending on feed and operating condi-
tions encapsulation of equipment and the
enclosure of all major sections of the plant
With these advanced environment-
friendly solutions Anderson Road Quarry
has won numerous safety and environmen-
tal awards In 2003 it was presented with a
silver medal in the prestigious Environmen-
tal Performance Awards in recognition of
its commitment to the environment and
community In 2004 KWP achieved certifi-cation of ISO 14001 it is the first quarry site
to have achieved this in Hong Kong and
southern China
ldquoA reliable partnerrdquo
The promulgation of the top ten infrastruc-
ture policies in Hong Kong boosted the
market for aggregates and demand will
keep rising over the next five to six years
ldquoWersquoll definitely keep our cooperation with
Metso once we have a need for expansion
because we regard Metso as a reliable part-
ner With their highly effi cient equipmentsatisfying service and great efforts in help-
ing us to achieve our environmental pro-
tection targets Metso is our best choicerdquo
says Hung
More info
Ziqiang Li
Tel +86 13601289027
ziqianglimetsocom
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
The sturdy Metso C160
jaw crushers are fed
using huge feed chutes
and feeders
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983122983141983152983151983154983156983145983150983143 983154983141983155
Similar to hundreds of mine sites world-
wide Zinkgruvan is being operated on a
non-stop 247 basis with just a few main-
tenance breaks during the year Crusher
availability is crucial because 100 of the
ore has to pass through the jaws before
being hoisted up for further processing
In addition to the zinc- lead- copper-
and silver-containing ore the C jaws chop
all the host rock extracted along the min-
ing process With a sturdy design Metsorsquos
proven C jaws can easily reduce even the
hardest type of rock Every year more thanone million tons are crushed with the jaws
ldquoMinimal service neededrdquo
Crushing with the first C160B jaw crusher
began at Zinkgruvanrsquos -800 meter level in
2000 with the primary crushing of zinc-lead
ore The second jaw was installed in 2008
for the new copper process gt
The sight and sound of two C160 jaw crushers operating side by side in the underground
crushing station of the Swedish Zinkgruvan mine is impressive Good proactive service
secures good uptime and reliable continuous operation of Metsorsquos second-largest
C160 series jaw crushers and prepares the way for the ongoing plans to expand the
production of zinc concentrate
TEXT amp PHOTOS Eero Haumlmaumllaumlinen
New PolyMet liners are being tested with the grinding mill delivered by Metso
Zinkgruvanrsquos twin C160
jaws secure good uptime
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Blasted ore is taken from the presently
operated -850 meter level with normal
trucks as an outsourced process One full
truckload is fed to the C160s every
10 minutes
ldquoWe are happy with the high reliability
of the C jaws They only require some minor
service therefore providing us with good
uptime and steady continuous feed to our
secondary and tertiary crushing and grind-ing circuitsrdquo says Mine Manager Jan Klaumlre
ldquoBasic crusher service and wear part
changes are made by our own staff using
Metsorsquos partsrdquo he adds
Service contract with grinding
mills and conveyors
Zinkgruvan and Metso Sweden have more
than 11 yearsrsquo experience with a service
contract that contains grinding mills and
conveyors At the mine site two Metso
service people and one contractor take
care of all the related service jobs Man-
power can also be borrowed from Metsorsquos
Graumlngesberg mine service team of 20
people
Presently Zinkgruvan is testing Metsorsquos
new PolyMet mill linings in its big grinding
mills With previously used rubber partsthe linings had to be changed in the shell
every 9 to 11 months and in the feed head
every 6 months
ldquoWe expect a better lifetime with Poly-
Met linings Longer change intervals mean
a lot to our productivity because lining
changes takes two full working daysrdquo Mine
Manager Jan Klaumlre says
New mine goes deeper
With an expected mine life of more than 10
years Zinkgruvan is actively mapping new
ore reserves Experimental holes are being
drilled at the new mine section at the
-1110 meter level
More info
Fredrik Wennberg
Tel +46 70 657 00 08fredrikwennbergmetsocom
Mine Manager Jan Klaumlre (left) with Backfilling Manager Kjell Tillman at the underground -800 meter level mine cafeteria
983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
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The Zinkgruvan mine located approxi-
mately 200 km southwest of Stockholm
Sweden is one of the oldest underground
mines in Northern Europe The mine has
been in production since 1857
The mining methods used are panel
stoping and benching The processing
facilities include a zinc concentrating plant
with a 11 mtpa and a copper plant with a04 mtpa capacity Tailings are recycled in
an impounding basin and host rock in the
backfill plant
Continuous mining since 1857
Even as one of the oldest mines in Northern
Europe Zinkgruvan exploits modern mining
and minerals processing installations
Zinkgruvan mine
OWNER Lundin Mining
PRODUCTION PER YEAR 1 million tons
ORE TYPE sedimentary exhalative
zinc lead copper and silver
NUMBER OF EMPLOYEES 320
2011 PRODUCTION TARGETS 78000 tonsof zinc 36000 tons of lead and
3400 tons of copper concentrate
METSO EQUIPMENT ON SITE
bull 1 extra long VF feeder
bull 2 C160 jaw crushers
ndash zinc process css 220ndash240 mm
ndash copper process css 150 mm
bull 1 GP300S cone crusher
ndash css 45mm
bull 1 HP4 cone crusher
ndash css 18 mm
bull 1 DS screen
bull 1 FS402 screenbull 1 grinding mill
bull Pumps VPAs
A normal truck feeds the C jaws with ore coming from the lower production levels
983122983141983152983151983154983156983145983150983143 983154983141983155
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Cost-per-ton wear agreements deepencustomer relationshipsCrusher wear parts are traditionally marketed purely based on transactional sales and mainly depend on
the weight of manganese Metso has recently introduced a new type of wear agreement based on thecost-per-ton crushed and the wear occurred Thus far the experience has been very positive increasing
transparency and deepening the operational relationship between the manufacturer and the customer
TEXT Olli Kellokumpu and Eero Haumlmaumllaumlinen PHOTOS Eero Haumlmaumllaumlinen
Arto Hiedanniemi (left)
Hannu Heman and Juha
Laukka of Metsorsquos Finnish
Service team checking the
cone crusher mantles shipped
for a cost-per-ton customer
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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156
Wear parts and parts changes
can be included
The structure of a cost-per-ton wearcontract is based on the number of tons
crushed and the estimated wear occurred
The amount and monetary value of the
wear is calculated per crushed ton
ldquoEither plain wear parts or parts changes
carried out by Metsorsquos service personnel
can be included in the contract In the latter
case we ask our Finnish customers to inform
us about an upcoming wear change opera-
tion one week in advancerdquo Heman explains
ldquoWe see good opportunities to market
cost-per-ton contracts further in Finland
and also abroad It really develops therelationship of Metso and our customers
towards a trusted partnershiprdquo he notes
Perfect tool for accurate planning
Soraliike Ikola Oy is a mid-sized contrac-
tor with three Metso two- and three-
stage mobile and portable crushing and
screening plants operating in Central and
Since 2002 Metsorsquos sales team in Finland
has developed the cost-per-ton-based
service offeringldquoOur aim has been to seek through
a cost-per-ton offering possibilities to
serve our customers better to differentiate
Metso from the other players as an OEM
manufacturer and to offer deeper profes-
sionalism and know-howrdquo says Hannu
Heman General Manager of service
operations
ldquoUntil now both our experience and
that of our customers has been quite posi-
tive When properly prepared cost-per-ton
contracts seem to create a win-win situa-
tionrdquo Heman adds Today Metso has operational cost-per-
ton agreements with several Finnish cus-
tomers The first contract was concluded
with a customer operating a stationary
plant Based on the results gathered new
cost-per-ton contracts have been signed
with customers operating wheeled and
tracked equipment too
Eastern Finland Because of the size of the
contracts up to 50 equipment moves are
made during the yearEntrepreneur Pasi Ikola has had a cost-
per-ton contract with Metso for nearly
two years and he is quite happy with the
outcome
ldquoThe cost-per-ton contract has provided
me with a perfect tool for accurate financial
planning Now I know in detail my actual
future wear parts costs This helps a lot
when calculating bidsrdquo
ldquoEarlier I used to buy a big batch of
Metso wear parts in one go and had to
reserve a reasonable amount of money for
that Today all wear costs are evenly sharedwhich gives us a welcomed 1047298exibility to
our cost structure Now we just pay Metso
afterwards based on our crushed tonsrdquo
he adds
More info
Olli Kellokumpu
Tel +358 50 354 1189
ollikellokumpumetsocom
According to crushing contractor Pasi Ikola the cost-per-ton contract with Metso has provided the entrepreneur with better economical 1047298exibility
and more accurate calculating of bids
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Pleasant Gap is owned and operated by
Glenn O Hawbaker Inc of State College
Pennsylvania This family-owned company
began in 1952 as a small excavation busi-
ness founded by Glenn O Hawbaker and
his wife Thelma Over the years the com-
pany grew by adding an integrated mix ofproducts and services and taking on larger
projects
In 1983 Hawbaker acquired Pleasant
Gap Quarry and built its first aggregates
processing plant Today Glenn O Haw-
baker Inc operates 21 quarries and eight
asphalt production facilities across Penn-
sylvania and southern New York as well as
five regional operation centers
Primary
challenge atPleasant GapQuarryA good part of what makes for a successful crushing
operation is the willingness to tackle challenges and to do
whatrsquos necessary to meet demand The team at Pleasant
Gap Quarry in central Pennsylvania recently met the chal-
lenge when they successfully addressed problems with
the plantrsquos primary crushing plant First they purchased
a new Metso C160 jaw to replace the existing primary
impact crusher Then they devised an innovative plan to
get the primary plant back in operation while awaitingdelivery of the new jaw crusher
TEXT Linda Bergmann PHOTOS John Rickinger
983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Time for a change
With the goal of increasing reliability and
output the management at Pleasant Gap
Quarry recently decided it was time to
replace the plantrsquos primary impact crusher
Following a thorough search they chose a
new Metso C160 jaw According to ScottReck Plant Manager it no longer made
sense to repair and rebuild the existing
impactor
ldquoBefore we purchased the Metso C160
we had a few other impact crushers and
they served us well but as our custom-
ersrsquo needs increased our plant production
had to match that demand We found our
formerly reliable unit was being overcome
by our demands for output and creative
work-around solutions We continued to
need more but there was only so much we
could do until we hit the breaking point ndash
literallyrdquo
In addition to performance improve-
ments the new crusher also needed to fitinto Pleasant Gaprsquos unique infrastructure
As Plant Project ManagerEngineer Jeremy
Fahr explains ldquoOur height restraint was 274
meters (108rdquo) This height was the distance
from the feed lip of the existing 6x12 scalp-
ing screen and the existing structure that
the crusher rests onrdquo
The normal C160 crusher is 307
meters (121rdquo) tall but Metso gave GOH
Scott Reck Plant Manager (left) and
Jeremy Fahr Plant Project Manager
Engineer at Pleasant Gap Quarry
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983122983141983152983151983154983156983145983150983143 983154983141983155
a 10-degree mounting option (which is
normally used on their portable crushers)
to overcome the height restraint Reck and
Fahr worked with Dave Rhoa of Cleveland
Brothers Equipment Metsorsquos crushing and
screening distributor in Pennsylvania to
pull everything together and fit the newcrusher into their plant
The C160 crusher selected for Pleasant
Gap is one of the latest models in Metsorsquos
C Series of jaws These jaw crushers feature
a large throw and steep toggle plate angle
resulting in a higher crusher output In
addition the C Series has a compact foot-
print that makes it an ideal choice for the
replacement of existing machines
According to Reck ldquoWe had heard about
the new Metso C160 and started doing our
own research and found Metso not only
had developed the output capacity we
needed but fit the uniqueness of our oper-
ationsrdquo The new Metso crusher will allow
the plant to increase tons per hour andgive them the 1047298exibility to meet demands
for varying products on short notice
Mobile solution
Purchasing the new primary jaw addressed
the long-term issues but still left Pleasant
Gap without a functioning primary plant
Reck continues ldquoOur main line was still
down leaving us with a big hole in hitting
customer needs but knowing that our new
Metso C160 was on its wayhellipwe needed an
immediate solution to keep our produc-
tion demands with an out-of-commission
crusherrdquo
The team at Pleasant Gap brainstormed
the problem and came up with a plan toget the primary plant back in operation
Their solution was to use the Lokotrack
LT1213 impactor plant and another mobile
unit to keep the main line crushing To do
this they removed the guts on the existing
impact crusher essentially turning it into a
rock chute They then moved the LT1213
and another manufacturerrsquos mobile unit
over to the existing dump hopper gt
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ldquoWe had our haul trucks drop off mate-
rial while two excavators fed the two
mobile unitsrdquo Reck explains ldquoFor two-and-
a-half months the Lokotrack LT1213 unit
was producing 254 cm (10rdquo) minus at
700 tons per hour The other similar-sized
mobile unit was doing 400 tons an hour
maxed out The difference was unbeliev-
able to say the least Our unique solution
using the two mobile units especially the
LT1213 helped Glenn O Hawbaker achieve
a record output in 2010rdquoAccording to Fahr ldquoWe were not new to
Metsorsquos quality and supportrdquo because GOH
had been using Metsorsquos portable crushing
equipment for 3 years prior to the primary
plantrsquos impact crusher failure In another
part of our operation we have a system that
our team relies on every day a Lokotrack
LT1213 and ST272 working in tandem with
two portable conveyorsrdquo This highly effi -
cient mobile processing system turns out
300 tons of specialized blended material
per hour GOH has been so impressed with
Metso equipment its last two purchaseswere an LT106 tracked jaw plant and a
second ST272 mobile screen in 2010
Maintaining high productivity
The Metso C160 jaw was delivered to Pleas-
ant Gap Quarry in January of 2011 and
since start-up it has more than met expec-
tations The crusher is fed minus 910 mm
(36rdquo) limestone with the jaw set at 140 mm
(5 12rdquo) According to Reck ldquoFrom moment
we started up we knew we had a winner
Not only were we kicking out as much
product as our previous units without even
breathing hard but we immediately had a
2-cent per ton savings to the bottom line
without having to run a second 350 HP
motor as required by other units Plus by
adding on the new automatic lube system
the maintenance team had more time to
devote to keeping other areas of the com-
plex running more effi cientlyrdquoReck says ldquoThe Metso unit was a perfect
fit and with the improved features it pre-
sented it had it all We just turn it on load
it up and we are moving 600 tons per hour
through the crusher without any effort and
we know it can do so much morerdquo With
the primary crushing plant back in opera-
tion the entire team at Pleasant Gap will
continue to do what they do best produce
and sell high-quality products and meet
their customersrsquo expectations
More info
Scott Yablonsky Tel +1 262 717 793
scottyablonskymetsocom
The Metso C160 jaw
was installed at a 10deg
angle to fit Pleasant
Gaprsquos existing
infrastructure
The Lokotrack LT1213 impactor plant and ST272 mobile screen operate in tandem with two
portable conveyors at Pleasant Gap
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983149983141983156983155983151 983150
Paper amp fiberNew OptiConcept M paper
and board making line
The new OptiConcept M paper and board
making line stands for economy safety and
usability
Metso has launched a new modular paper
and board making line called OptiConceptM A member of the proven OptiConcept
production line family the new OptiCon-
cept M optimizes machine investment in
line with each millrsquos capacity needs
Savings in operating costs are achieved
through precise dimensioning of pro-
cesses proven technological solutions
optimal running parameters effective
maintenance operations and fully inte-
grated automation solutions
Optimized processes innovations
smart controls and accurate dimensioning
decrease the use of steam gas electricitywater chemicals and other raw materials
and reduce emission levels
OptiConcept M has been designed
both visually and physically with the
requirements of users in mind For exam-
ple the design of the machinery allows for
easy and safe changing of rolls and wear
parts thus reducing the total duration and
cost of maintenance shutdowns
RecyclingGreen energy technology to
Elektrociepłownia Białystok in Poland
Metso will convert a coal-fired boiler to
a biomass-fired Bubbling Fluidized Bed
boiler for Elektrociepłownia Białystok SArsquos
combined heat and power plant (CHP) in
Białystok Poland The new boiler system
will cut the power plantrsquos CO2 emissions
significantly by partly replacing the coal
fuel supply with biomass fuel
ldquoPoland is one of the largest countries
in Europe to have such a high depend-ence on energy derived from coal to
meet national electricity needs This is an
important incentive for us to reduce future
CO2 emissions and produce more green
electricity and with Metso technology
we are certain to accomplish our goalrdquo
states Mr Andrzej Schroeder President of
Elektrociepłownia Białystok SA
Since 2000 Metso has received a total
of 7 biomass boiler conversion orders in
Poland and the renewable energy share
in Poland is only 75 (2010) compared to
the target of 20 by 2020 set by the EUApproximately 80 of the current energy
boilers turbines and generators installed in
Polish power plants are over 20 years old In
order to meet the strict EU environmental
requirements modernization of existing
installations is necessary
Automation
Metso DNA automation system expands
to mining and construction
Using Metsorsquos control room automation
an entire crushing and screening plant can
be effi ciently managed
Metso is a leading supplier of mining and
construction machinery This expertise has
now been combined with a scalable Metso
DNA automation system that adapts to
the range of industry needs from single
machine controls to plant-wide automation
and information management systems
An example of Metsorsquos new offering is a
new crushing plant control room solution
that connects crushers and screens ensur-
ing the effective management of the entire
plant from a pleasant and safe control
room The Metso DNA user interface pro-vides the production information to ensure
a proper and rapid response to plant
events Automatic controls stabilize the
process and allow the operators to monitor
the plant as a whole
ldquoThe benefits of automation for the min-
ing and construction industry are signifi-
cant As an example of the services we offer
performance studies to crushing plants
utilizing Metsorsquos multi-disciplinary teams of
experts to determine the present level of
the plant and process effi ciency and to esti-
mate the improvement potential and thebenefits of optimization and automation
including ROI calculationsrdquo says Mikko Maumlki-
nen Product Manager of minerals applica-
tions in Metsorsquos Automation business line
ldquoAs another example our machine
condition monitoring solutions can reduce
plant and machine downtimes as well as
help to avoid safety and environmental
hazardsrdquo he adds
Metso around the world
Aerial view of the Elektrociepłownia Białystok combined heat and power plant in Poland
8202019 Metso Minerals Aggregates 3 2011
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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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Metso was responsible for the design
development and construction of the
entire secondary and tertiary arrangement
The primary station will be the subject of a
subsequent investment
Latest environmental protection used
This installation has been designed in strict
compliance with the environmental quality
approach developed by Metso and its
partners using the latest technologies
in dust control including confinement
technology as well as dust encapsulation
technology for screens
To ensure an annual capacity of 15 mil-lion tons for a nominal output of 560th of
02 mm and 220 mm the clientrsquos choice
for the secondary stage naturally fell upon
the NP 1520 impact crusher
A complete impact crusher solution for Lafarge The Lafarge Group has entrusted Metso with the implementation of its new aggregates installation in southern France
It comprises a new secondary crushing stage equipped with an NP1520 impact crusher featuring a power range of2 x 250kW and equipped with hydraulic adjustment
TEXT amp PHOTO Gilles Dombey
The NP 1520 crusher has long proved
its performance not only in terms of capac-
ity and reduction rate but also quality of
the finished product and durability
More info
Arnaud Bertucat
Tel +33 (0)6 81 44 68 26
arnaudbertucatmetsocom
About 15 million tons of aggregates feed will be crushed with the NP1520 impact crusher at Lafargersquos stationary installation in southern France
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Multi-stage Lokotrack process a success in Senegal
A multi-stage crushing and screening process has proven its effi ciency in the production of concrete aggregates in
Senegal Western Africa With the mobile process Xewell Cimenteries SA now exploits its quarry better has reduced
its operating costs and can meet strict environmental requirements
TEXT Elisabetta Cataluffi PHOTOS Carlo Rinolfi
Senegal is a rapidly developing country
offering a good deal of potential activities
for crushing companies too At the sametime the country has several areas of high
environmental value Therefore contractors
must opt for state-of-the-art equipment that
offers reduced environmental emissions
The company Xewell Cimenteries SA
was founded in 2008 as a partnership
between Italian Swiss and Senegalesecontractors Xewell operates a limestone
quarry located in the Pout area east of the
capital city of Dakar
According to Alessandro Crestani Technical
Director of the Pout quarry a mobile process
was selected to better exploit the quarry and
reduce costsLokotrack process drawing made by Bruno simulation software
After assembling the Lokotrack units the process was tested by Xewell Cimenteries
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983122983141983152983151983154983156983145983150983143 983154983141983155
Owned by Freeport-McMoRan Copper amp
Gold (51) and CODELCO (49) the ElAbra mine has leachable oxide and sulfide
mineralization The minersquos processing facil-
ity has an annual capacity of 226000 tons
of copper cathode
Smaller size matters
Reducing the size of the crushed oxide
ore from the present 15 mm to 12 mm
was the main target of the mine and the
Metso team The changes that were carried
out in the process included a size varia-
tion change in the cut of the tertiary sieve
installation of rate-level sensors in thesecondary crushers and enabling speed
variables in the conveyor belt feeders of
the secondary crushing circuit
ldquoGoing from 15mm to 12mm may seem
small but the operational impact is very
important and significant for usrdquo explains
Juan Torres Carvajal Metallurgical Engi-
neer at the El Abra mine
ldquoOur goal is to reach 115000 tons with
a minimum of 80 of 12-mm-sized ore permonth The record to date is 105000 tons
and we will increase it until we reach our
project goalrdquo he adds
New design for cone liners
In addition to the work mentioned above
Metso is currently carrying out a project to
design the lining profiles for the secondary
and tertiary crushers of the plant which
will affect the smaller size of the material
In cooperation with Nelson Mella from
Metso and Rodolfo Navarro Crushing
Superintendent at the El Abra mine testswere carried out in July on the re-designed
Metso linings One set was tested for sec-
ondary crushing and two sets for tertiary
crushing
More info
Nelson Mella
Tel +56 99158 0576
nelsonmellametsocom
Finer ore through wear pro1047297lestudy at El Abra mine in ChileEl Abra is a porphyry copper open-pit mine and processing facility located in
Chile near the city of Calama some 4000 meters above sea level With the helpof Metsorsquos technical support the mine was able to achieve finer ore throughoutthe crushing process
TEXT amp PHOTOS Macarena Vallejo
Xewell Cimenteries produces a selec-
tion of dry processed aggregates for con-
crete Operations started at the end of 2009
with the aim of reaching 150000 metric
tons produced per year
Lokotracks chosen to reduce costs
To build up their tracked mobile processXewell Cimenteries decided to buy three
mobile plants from Metso two impactor
plants the Lokotrack LT1110 and LT1213
feeding a three-deck mobile screen the
ST620 The machines were sold by SCAI
SpA Metsorsquos Lokotrack distributor in Italy
ldquoWe chose tracked machines to bet-
ter exploit our quarry and to reduce
costs Mobile plants have low initial costs
because they donrsquot need any special foun-
dations or supply of electricity This obvi-
ously gives us a quicker process set-up and
better uptimerdquo says Alessandro Crestani Technical Director of the Pout quarry
ldquoThe mobile plant can also follow the
quarry face as the exploitation proceeds
reducing the transport costs of raw materi-
als in the same jobsite We chose Metso
because they ensured us the best cost-per-
ton ratiordquo he adds
Good customer service is crucial
According to Alessandro Crestani good
customer service also played a major role
when choosing the manufacturer of the
mobile equipmentldquoMetsorsquos distributor SCAI SpA was able
to provide us with a complete product
support and customer service package
Obviously service is a very important
aspect for us in a country like Senegal Any
downtime represents a clear loss of pro-
ductivity for usrdquo
The average level of productivity of the
mobile Lokotrack process is 200 metric
tons per hour
More info
Carlo Rinolfi Tel +39 335 1253159
crinolfiscaispacom
Example of the development of the Metso study
on the crusher lining profiles
Liner change for smaller ore size in the
MP1000 cone crusher
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Services success in Surabaya The Metso Surabaya workshop and offi ce complex opened in April 2008 provides Life Cycle Services and maintenance
solutions for Metso equipment in the Indonesia region The facility is strategically located in an industrial precinct on theouter rim of Surabaya the second largest city in Indonesia Its close proximity to an international airport major shipping
port and several engineering companies simplifies support for the regionrsquos key customers which include PT Newmont
and PT Freeport
TEXT amp PHOTOS David LeRoy amp Gary Whittred
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983122983141983152983151983154983156983145983150983143 983154983141983155
The Surabaya site operates through Metso
in Australia with assistance from key sales
and technical staff Handling regional ser-vice and repair business in-house allows
Metso to manage intellectual property and
closely control quality
It also enables the development of a
team of skilled service personnel who can
be utilized both internally and at key cus-
tomer sites as is common with the backup
service the workshop provides for screen
contracts
Innovation at work
Since 2008 the Surabaya facility has suc-
cessfully refurbished a wide variety ofcomponents Recently two ball mill heads
weighing 22 tons each were modified in
order to strengthen the 1047298ange of the ball
mill shell The modification included tap-
ping out existing 1047298ange holes and drilling
new ones so that finger plates could be
installed and welded to the 1047298anges
Positioning the head borer to properly
align the new 1047298ange holes proved diffi cult
Four roller support frames were manufac-
tured to support the heads and allow them
to be rotated easily Each hole was then
drilled and tapped at the correct angleusing the CNC five axis head The job had a
tight delivery as it was required for a shut-
down but with advance planning and inno-
vation it was completed ahead of schedule
MP1000 mainframe on
CNC vertical borer
Well equipped for fabricating and machin-
ing heavy components the Surabaya
The Surabaya facility has proven to be
a success for Metso The workshop offers a
wide variety of services in the region Qual-ity products and competitive pricing and
delivery times have led to strong customer
relationships
Turnover and customer service levels
have increased annually since the open-
ing and between 2008 and 2010 sales
increased 450 These excellent trends
are expected to continue as the operation
expands and the customer base grows
Since 2008 the Surabaya facility has
successfully refurbished
bull MP1000 counter shaft boxes headassemblies mainframes bowls adjust-
ment rings counterweights sockets and
tramp release cylinders
bull 7rsquo Symons bowls heads and countershaft
boxes
bull Vertimill screw and drive shafts
bull Ball mill heads
bull Ball mill trommel
bull VPA cylinders
bull Eaton clutches
bull Exciter screen mechanisms
bull 42x65 main shafts and eccentrics
More info
Gary Whittred
Tel +62 31 8430349
garywhittredmetsocom
workshop handles the majority of Metsorsquos
refurbishment work with ease But when
necessary PT PAL ndash a government facilitywith shipbuilding and heavy engineering
capabilities ndash offers a ldquoone stop shoprdquo Spe-
cially trained PT PAL staff ensures that the
work they perform complies with all Metso
specifications and quality standards
PT PAL also demonstrated their innova-
tive ability with the first MP1000 main-
frame refurbishment they completed The
mainframersquos shaft location bore needed
to be re-machined However the distance
from the top of the mainframe to the
tapered bore made it very hard to achieve
an accurate surface finish with the correctstandoff
To overcome this the shop decided to
machine the mainframe upside down and
elevated on support beams They posi-
tioned a new shaft under the mainframe in
a custom-made cradle Using an overhead
crane they could then lsquotrial fitrsquo the shaft in
the bore to make sure it seated correctly
and the mating tapers met specification
The method worked so well it has since
been used for four more mainframe refur-
bishments
Diversity and growth
Today Metso Surabaya continues to invest
in additional equipment in order to diver-
sify its service offering A new hydraulic
power pack which allows the facility to test
refurbished components to Metso specifi-
cations was recently used in the refurbish-
ment and testing of several VPA cylinders
for PT Freeport
Refurbished MP1000 mainframe dispatched by truck to
PT Freeport mine
Machining of MP1000 upper frame
at Metsorsquos Surabaya workshop
Mainframe at vertical CNC machining
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Creating Value with Metso in Hong KongIn Hong Kong the aggregates needed for construction are mostly supplied by two local quarries KWP Quarry Company
Limitedrsquos Anderson Road Quarry accounts for 60ndash70 making it the pillar of Hong Kongrsquos construction materials industry
TEXT amp PHOTOS Ou He
When arriving at the Anderson Road
Quarry the most impressive view at the850000 square-meter facility is the Metso
machines including equipment from the
primary secondary and tertiary crushing
circuits and the screens I t is Metsorsquos equip-
ment that secures the supply of aggregates
for Hong Kong
KWP Quarry Company Limited has been
working with Metso since its establishment
in 1997
Due to Hong Kongrsquos stringent dust and noise control standards Metso has paid special attention to the related suppression systems
ldquoOur quarry mainly lies on granite and
volcanic rock which are so hard they canonly be processed by equipment with
strong durability and stabilityrdquo explains
Mr Eddie Hung Manager of KWP ldquoWith a
long history of and experience in quarry-
ing we are very familiar with the equip-
ment of different brands Comparatively
Metsorsquos products are better than others in
terms of durability stability and effi ciency
Besides this the reason we selected Metso
is because of the simple maintenance of
their equipment and the easy access tomaintenance informationrdquo
Flexible modular solution
Based on extensive experience in crushing
and screening worldwide Metso presented
the Anderson Road Quarry with a modu-
lar solution and delivered it as a turn-key
project Through a four-stage crushing
circuit which contains three Metso C160
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jaw crushers for primary crushing two
Omnicone 1560SX crushers for secondary
crushing two HP 500SX cone crushers for
tertiary crushing and one HP500SX cone
crusher for extra-fine crushing the plant
was able to produce aggregates of optimal
shape with minimal 1047298akiness
The fine products include three sizes
0 to 5 mm 5 to 10 mm and 10 to 20mm
Since the employment of this system in
2000 production has reached 1250 th
which is far beyond the design capacityAccording to Mr Hung ldquoThe machines
always run effi ciently and seldom malfunc-
tion The occasional shutdown of some
machines does not affect production very
much the plant still could reach 60-70
of its normal production It gives us the
best 1047298exibility for the plant rsquos operation and
I believe this is the best feature of Metsorsquos
solution
Eddie Hung
Manager of KWPrsquos
Anderson Road
Quarry is happy with
the product quality
and service provided
by Metso
ldquoMetsorsquos equipment is expensive com-
paratively but in the long run you will find
that the investment is worthwhile on the
whole Metso secures superior stability reli-
ability and fewer downtimes and it guaran-
tees continuous operation and brings us
greater valuerdquo
Great service team
Metso sent a group of service engineers
to the plant within the warranty period
not only to provide service but to train theoperators Mr Hung speaks highly of Met-
sorsquos service team he is impressed with its
experienced experts and with their strong
sense of responsibility and customer-
oriented ways of working
ldquoMetsorsquos service team never fails to find
hidden problems and helps us to prevent
any mechanical failures And they are
available whenever we need them they
work closely with us to solve the problem
effi cientlyrdquo he said
Excellent environment-friendly designIn order to achieve the worldrsquos most strin-
gent noise and dust control standards
developed by the Environment Protection
Department of Hong Kong Metso has
incorporated a dust and noise suppression
system into the plant This includes the
infrared-triggered spray systems at feed
points encapsulation of individual crush-
ers and conveyors and the ability to select
specific sectors of the system for treatment
depending on feed and operating condi-
tions encapsulation of equipment and the
enclosure of all major sections of the plant
With these advanced environment-
friendly solutions Anderson Road Quarry
has won numerous safety and environmen-
tal awards In 2003 it was presented with a
silver medal in the prestigious Environmen-
tal Performance Awards in recognition of
its commitment to the environment and
community In 2004 KWP achieved certifi-cation of ISO 14001 it is the first quarry site
to have achieved this in Hong Kong and
southern China
ldquoA reliable partnerrdquo
The promulgation of the top ten infrastruc-
ture policies in Hong Kong boosted the
market for aggregates and demand will
keep rising over the next five to six years
ldquoWersquoll definitely keep our cooperation with
Metso once we have a need for expansion
because we regard Metso as a reliable part-
ner With their highly effi cient equipmentsatisfying service and great efforts in help-
ing us to achieve our environmental pro-
tection targets Metso is our best choicerdquo
says Hung
More info
Ziqiang Li
Tel +86 13601289027
ziqianglimetsocom
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The sturdy Metso C160
jaw crushers are fed
using huge feed chutes
and feeders
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Similar to hundreds of mine sites world-
wide Zinkgruvan is being operated on a
non-stop 247 basis with just a few main-
tenance breaks during the year Crusher
availability is crucial because 100 of the
ore has to pass through the jaws before
being hoisted up for further processing
In addition to the zinc- lead- copper-
and silver-containing ore the C jaws chop
all the host rock extracted along the min-
ing process With a sturdy design Metsorsquos
proven C jaws can easily reduce even the
hardest type of rock Every year more thanone million tons are crushed with the jaws
ldquoMinimal service neededrdquo
Crushing with the first C160B jaw crusher
began at Zinkgruvanrsquos -800 meter level in
2000 with the primary crushing of zinc-lead
ore The second jaw was installed in 2008
for the new copper process gt
The sight and sound of two C160 jaw crushers operating side by side in the underground
crushing station of the Swedish Zinkgruvan mine is impressive Good proactive service
secures good uptime and reliable continuous operation of Metsorsquos second-largest
C160 series jaw crushers and prepares the way for the ongoing plans to expand the
production of zinc concentrate
TEXT amp PHOTOS Eero Haumlmaumllaumlinen
New PolyMet liners are being tested with the grinding mill delivered by Metso
Zinkgruvanrsquos twin C160
jaws secure good uptime
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Blasted ore is taken from the presently
operated -850 meter level with normal
trucks as an outsourced process One full
truckload is fed to the C160s every
10 minutes
ldquoWe are happy with the high reliability
of the C jaws They only require some minor
service therefore providing us with good
uptime and steady continuous feed to our
secondary and tertiary crushing and grind-ing circuitsrdquo says Mine Manager Jan Klaumlre
ldquoBasic crusher service and wear part
changes are made by our own staff using
Metsorsquos partsrdquo he adds
Service contract with grinding
mills and conveyors
Zinkgruvan and Metso Sweden have more
than 11 yearsrsquo experience with a service
contract that contains grinding mills and
conveyors At the mine site two Metso
service people and one contractor take
care of all the related service jobs Man-
power can also be borrowed from Metsorsquos
Graumlngesberg mine service team of 20
people
Presently Zinkgruvan is testing Metsorsquos
new PolyMet mill linings in its big grinding
mills With previously used rubber partsthe linings had to be changed in the shell
every 9 to 11 months and in the feed head
every 6 months
ldquoWe expect a better lifetime with Poly-
Met linings Longer change intervals mean
a lot to our productivity because lining
changes takes two full working daysrdquo Mine
Manager Jan Klaumlre says
New mine goes deeper
With an expected mine life of more than 10
years Zinkgruvan is actively mapping new
ore reserves Experimental holes are being
drilled at the new mine section at the
-1110 meter level
More info
Fredrik Wennberg
Tel +46 70 657 00 08fredrikwennbergmetsocom
Mine Manager Jan Klaumlre (left) with Backfilling Manager Kjell Tillman at the underground -800 meter level mine cafeteria
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The Zinkgruvan mine located approxi-
mately 200 km southwest of Stockholm
Sweden is one of the oldest underground
mines in Northern Europe The mine has
been in production since 1857
The mining methods used are panel
stoping and benching The processing
facilities include a zinc concentrating plant
with a 11 mtpa and a copper plant with a04 mtpa capacity Tailings are recycled in
an impounding basin and host rock in the
backfill plant
Continuous mining since 1857
Even as one of the oldest mines in Northern
Europe Zinkgruvan exploits modern mining
and minerals processing installations
Zinkgruvan mine
OWNER Lundin Mining
PRODUCTION PER YEAR 1 million tons
ORE TYPE sedimentary exhalative
zinc lead copper and silver
NUMBER OF EMPLOYEES 320
2011 PRODUCTION TARGETS 78000 tonsof zinc 36000 tons of lead and
3400 tons of copper concentrate
METSO EQUIPMENT ON SITE
bull 1 extra long VF feeder
bull 2 C160 jaw crushers
ndash zinc process css 220ndash240 mm
ndash copper process css 150 mm
bull 1 GP300S cone crusher
ndash css 45mm
bull 1 HP4 cone crusher
ndash css 18 mm
bull 1 DS screen
bull 1 FS402 screenbull 1 grinding mill
bull Pumps VPAs
A normal truck feeds the C jaws with ore coming from the lower production levels
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Cost-per-ton wear agreements deepencustomer relationshipsCrusher wear parts are traditionally marketed purely based on transactional sales and mainly depend on
the weight of manganese Metso has recently introduced a new type of wear agreement based on thecost-per-ton crushed and the wear occurred Thus far the experience has been very positive increasing
transparency and deepening the operational relationship between the manufacturer and the customer
TEXT Olli Kellokumpu and Eero Haumlmaumllaumlinen PHOTOS Eero Haumlmaumllaumlinen
Arto Hiedanniemi (left)
Hannu Heman and Juha
Laukka of Metsorsquos Finnish
Service team checking the
cone crusher mantles shipped
for a cost-per-ton customer
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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156
Wear parts and parts changes
can be included
The structure of a cost-per-ton wearcontract is based on the number of tons
crushed and the estimated wear occurred
The amount and monetary value of the
wear is calculated per crushed ton
ldquoEither plain wear parts or parts changes
carried out by Metsorsquos service personnel
can be included in the contract In the latter
case we ask our Finnish customers to inform
us about an upcoming wear change opera-
tion one week in advancerdquo Heman explains
ldquoWe see good opportunities to market
cost-per-ton contracts further in Finland
and also abroad It really develops therelationship of Metso and our customers
towards a trusted partnershiprdquo he notes
Perfect tool for accurate planning
Soraliike Ikola Oy is a mid-sized contrac-
tor with three Metso two- and three-
stage mobile and portable crushing and
screening plants operating in Central and
Since 2002 Metsorsquos sales team in Finland
has developed the cost-per-ton-based
service offeringldquoOur aim has been to seek through
a cost-per-ton offering possibilities to
serve our customers better to differentiate
Metso from the other players as an OEM
manufacturer and to offer deeper profes-
sionalism and know-howrdquo says Hannu
Heman General Manager of service
operations
ldquoUntil now both our experience and
that of our customers has been quite posi-
tive When properly prepared cost-per-ton
contracts seem to create a win-win situa-
tionrdquo Heman adds Today Metso has operational cost-per-
ton agreements with several Finnish cus-
tomers The first contract was concluded
with a customer operating a stationary
plant Based on the results gathered new
cost-per-ton contracts have been signed
with customers operating wheeled and
tracked equipment too
Eastern Finland Because of the size of the
contracts up to 50 equipment moves are
made during the yearEntrepreneur Pasi Ikola has had a cost-
per-ton contract with Metso for nearly
two years and he is quite happy with the
outcome
ldquoThe cost-per-ton contract has provided
me with a perfect tool for accurate financial
planning Now I know in detail my actual
future wear parts costs This helps a lot
when calculating bidsrdquo
ldquoEarlier I used to buy a big batch of
Metso wear parts in one go and had to
reserve a reasonable amount of money for
that Today all wear costs are evenly sharedwhich gives us a welcomed 1047298exibility to
our cost structure Now we just pay Metso
afterwards based on our crushed tonsrdquo
he adds
More info
Olli Kellokumpu
Tel +358 50 354 1189
ollikellokumpumetsocom
According to crushing contractor Pasi Ikola the cost-per-ton contract with Metso has provided the entrepreneur with better economical 1047298exibility
and more accurate calculating of bids
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Pleasant Gap is owned and operated by
Glenn O Hawbaker Inc of State College
Pennsylvania This family-owned company
began in 1952 as a small excavation busi-
ness founded by Glenn O Hawbaker and
his wife Thelma Over the years the com-
pany grew by adding an integrated mix ofproducts and services and taking on larger
projects
In 1983 Hawbaker acquired Pleasant
Gap Quarry and built its first aggregates
processing plant Today Glenn O Haw-
baker Inc operates 21 quarries and eight
asphalt production facilities across Penn-
sylvania and southern New York as well as
five regional operation centers
Primary
challenge atPleasant GapQuarryA good part of what makes for a successful crushing
operation is the willingness to tackle challenges and to do
whatrsquos necessary to meet demand The team at Pleasant
Gap Quarry in central Pennsylvania recently met the chal-
lenge when they successfully addressed problems with
the plantrsquos primary crushing plant First they purchased
a new Metso C160 jaw to replace the existing primary
impact crusher Then they devised an innovative plan to
get the primary plant back in operation while awaitingdelivery of the new jaw crusher
TEXT Linda Bergmann PHOTOS John Rickinger
983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Time for a change
With the goal of increasing reliability and
output the management at Pleasant Gap
Quarry recently decided it was time to
replace the plantrsquos primary impact crusher
Following a thorough search they chose a
new Metso C160 jaw According to ScottReck Plant Manager it no longer made
sense to repair and rebuild the existing
impactor
ldquoBefore we purchased the Metso C160
we had a few other impact crushers and
they served us well but as our custom-
ersrsquo needs increased our plant production
had to match that demand We found our
formerly reliable unit was being overcome
by our demands for output and creative
work-around solutions We continued to
need more but there was only so much we
could do until we hit the breaking point ndash
literallyrdquo
In addition to performance improve-
ments the new crusher also needed to fitinto Pleasant Gaprsquos unique infrastructure
As Plant Project ManagerEngineer Jeremy
Fahr explains ldquoOur height restraint was 274
meters (108rdquo) This height was the distance
from the feed lip of the existing 6x12 scalp-
ing screen and the existing structure that
the crusher rests onrdquo
The normal C160 crusher is 307
meters (121rdquo) tall but Metso gave GOH
Scott Reck Plant Manager (left) and
Jeremy Fahr Plant Project Manager
Engineer at Pleasant Gap Quarry
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983122983141983152983151983154983156983145983150983143 983154983141983155
a 10-degree mounting option (which is
normally used on their portable crushers)
to overcome the height restraint Reck and
Fahr worked with Dave Rhoa of Cleveland
Brothers Equipment Metsorsquos crushing and
screening distributor in Pennsylvania to
pull everything together and fit the newcrusher into their plant
The C160 crusher selected for Pleasant
Gap is one of the latest models in Metsorsquos
C Series of jaws These jaw crushers feature
a large throw and steep toggle plate angle
resulting in a higher crusher output In
addition the C Series has a compact foot-
print that makes it an ideal choice for the
replacement of existing machines
According to Reck ldquoWe had heard about
the new Metso C160 and started doing our
own research and found Metso not only
had developed the output capacity we
needed but fit the uniqueness of our oper-
ationsrdquo The new Metso crusher will allow
the plant to increase tons per hour andgive them the 1047298exibility to meet demands
for varying products on short notice
Mobile solution
Purchasing the new primary jaw addressed
the long-term issues but still left Pleasant
Gap without a functioning primary plant
Reck continues ldquoOur main line was still
down leaving us with a big hole in hitting
customer needs but knowing that our new
Metso C160 was on its wayhellipwe needed an
immediate solution to keep our produc-
tion demands with an out-of-commission
crusherrdquo
The team at Pleasant Gap brainstormed
the problem and came up with a plan toget the primary plant back in operation
Their solution was to use the Lokotrack
LT1213 impactor plant and another mobile
unit to keep the main line crushing To do
this they removed the guts on the existing
impact crusher essentially turning it into a
rock chute They then moved the LT1213
and another manufacturerrsquos mobile unit
over to the existing dump hopper gt
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
ldquoWe had our haul trucks drop off mate-
rial while two excavators fed the two
mobile unitsrdquo Reck explains ldquoFor two-and-
a-half months the Lokotrack LT1213 unit
was producing 254 cm (10rdquo) minus at
700 tons per hour The other similar-sized
mobile unit was doing 400 tons an hour
maxed out The difference was unbeliev-
able to say the least Our unique solution
using the two mobile units especially the
LT1213 helped Glenn O Hawbaker achieve
a record output in 2010rdquoAccording to Fahr ldquoWe were not new to
Metsorsquos quality and supportrdquo because GOH
had been using Metsorsquos portable crushing
equipment for 3 years prior to the primary
plantrsquos impact crusher failure In another
part of our operation we have a system that
our team relies on every day a Lokotrack
LT1213 and ST272 working in tandem with
two portable conveyorsrdquo This highly effi -
cient mobile processing system turns out
300 tons of specialized blended material
per hour GOH has been so impressed with
Metso equipment its last two purchaseswere an LT106 tracked jaw plant and a
second ST272 mobile screen in 2010
Maintaining high productivity
The Metso C160 jaw was delivered to Pleas-
ant Gap Quarry in January of 2011 and
since start-up it has more than met expec-
tations The crusher is fed minus 910 mm
(36rdquo) limestone with the jaw set at 140 mm
(5 12rdquo) According to Reck ldquoFrom moment
we started up we knew we had a winner
Not only were we kicking out as much
product as our previous units without even
breathing hard but we immediately had a
2-cent per ton savings to the bottom line
without having to run a second 350 HP
motor as required by other units Plus by
adding on the new automatic lube system
the maintenance team had more time to
devote to keeping other areas of the com-
plex running more effi cientlyrdquoReck says ldquoThe Metso unit was a perfect
fit and with the improved features it pre-
sented it had it all We just turn it on load
it up and we are moving 600 tons per hour
through the crusher without any effort and
we know it can do so much morerdquo With
the primary crushing plant back in opera-
tion the entire team at Pleasant Gap will
continue to do what they do best produce
and sell high-quality products and meet
their customersrsquo expectations
More info
Scott Yablonsky Tel +1 262 717 793
scottyablonskymetsocom
The Metso C160 jaw
was installed at a 10deg
angle to fit Pleasant
Gaprsquos existing
infrastructure
The Lokotrack LT1213 impactor plant and ST272 mobile screen operate in tandem with two
portable conveyors at Pleasant Gap
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983149983141983156983155983151 983150
Paper amp fiberNew OptiConcept M paper
and board making line
The new OptiConcept M paper and board
making line stands for economy safety and
usability
Metso has launched a new modular paper
and board making line called OptiConceptM A member of the proven OptiConcept
production line family the new OptiCon-
cept M optimizes machine investment in
line with each millrsquos capacity needs
Savings in operating costs are achieved
through precise dimensioning of pro-
cesses proven technological solutions
optimal running parameters effective
maintenance operations and fully inte-
grated automation solutions
Optimized processes innovations
smart controls and accurate dimensioning
decrease the use of steam gas electricitywater chemicals and other raw materials
and reduce emission levels
OptiConcept M has been designed
both visually and physically with the
requirements of users in mind For exam-
ple the design of the machinery allows for
easy and safe changing of rolls and wear
parts thus reducing the total duration and
cost of maintenance shutdowns
RecyclingGreen energy technology to
Elektrociepłownia Białystok in Poland
Metso will convert a coal-fired boiler to
a biomass-fired Bubbling Fluidized Bed
boiler for Elektrociepłownia Białystok SArsquos
combined heat and power plant (CHP) in
Białystok Poland The new boiler system
will cut the power plantrsquos CO2 emissions
significantly by partly replacing the coal
fuel supply with biomass fuel
ldquoPoland is one of the largest countries
in Europe to have such a high depend-ence on energy derived from coal to
meet national electricity needs This is an
important incentive for us to reduce future
CO2 emissions and produce more green
electricity and with Metso technology
we are certain to accomplish our goalrdquo
states Mr Andrzej Schroeder President of
Elektrociepłownia Białystok SA
Since 2000 Metso has received a total
of 7 biomass boiler conversion orders in
Poland and the renewable energy share
in Poland is only 75 (2010) compared to
the target of 20 by 2020 set by the EUApproximately 80 of the current energy
boilers turbines and generators installed in
Polish power plants are over 20 years old In
order to meet the strict EU environmental
requirements modernization of existing
installations is necessary
Automation
Metso DNA automation system expands
to mining and construction
Using Metsorsquos control room automation
an entire crushing and screening plant can
be effi ciently managed
Metso is a leading supplier of mining and
construction machinery This expertise has
now been combined with a scalable Metso
DNA automation system that adapts to
the range of industry needs from single
machine controls to plant-wide automation
and information management systems
An example of Metsorsquos new offering is a
new crushing plant control room solution
that connects crushers and screens ensur-
ing the effective management of the entire
plant from a pleasant and safe control
room The Metso DNA user interface pro-vides the production information to ensure
a proper and rapid response to plant
events Automatic controls stabilize the
process and allow the operators to monitor
the plant as a whole
ldquoThe benefits of automation for the min-
ing and construction industry are signifi-
cant As an example of the services we offer
performance studies to crushing plants
utilizing Metsorsquos multi-disciplinary teams of
experts to determine the present level of
the plant and process effi ciency and to esti-
mate the improvement potential and thebenefits of optimization and automation
including ROI calculationsrdquo says Mikko Maumlki-
nen Product Manager of minerals applica-
tions in Metsorsquos Automation business line
ldquoAs another example our machine
condition monitoring solutions can reduce
plant and machine downtimes as well as
help to avoid safety and environmental
hazardsrdquo he adds
Metso around the world
Aerial view of the Elektrociepłownia Białystok combined heat and power plant in Poland
8202019 Metso Minerals Aggregates 3 2011
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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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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Multi-stage Lokotrack process a success in Senegal
A multi-stage crushing and screening process has proven its effi ciency in the production of concrete aggregates in
Senegal Western Africa With the mobile process Xewell Cimenteries SA now exploits its quarry better has reduced
its operating costs and can meet strict environmental requirements
TEXT Elisabetta Cataluffi PHOTOS Carlo Rinolfi
Senegal is a rapidly developing country
offering a good deal of potential activities
for crushing companies too At the sametime the country has several areas of high
environmental value Therefore contractors
must opt for state-of-the-art equipment that
offers reduced environmental emissions
The company Xewell Cimenteries SA
was founded in 2008 as a partnership
between Italian Swiss and Senegalesecontractors Xewell operates a limestone
quarry located in the Pout area east of the
capital city of Dakar
According to Alessandro Crestani Technical
Director of the Pout quarry a mobile process
was selected to better exploit the quarry and
reduce costsLokotrack process drawing made by Bruno simulation software
After assembling the Lokotrack units the process was tested by Xewell Cimenteries
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Owned by Freeport-McMoRan Copper amp
Gold (51) and CODELCO (49) the ElAbra mine has leachable oxide and sulfide
mineralization The minersquos processing facil-
ity has an annual capacity of 226000 tons
of copper cathode
Smaller size matters
Reducing the size of the crushed oxide
ore from the present 15 mm to 12 mm
was the main target of the mine and the
Metso team The changes that were carried
out in the process included a size varia-
tion change in the cut of the tertiary sieve
installation of rate-level sensors in thesecondary crushers and enabling speed
variables in the conveyor belt feeders of
the secondary crushing circuit
ldquoGoing from 15mm to 12mm may seem
small but the operational impact is very
important and significant for usrdquo explains
Juan Torres Carvajal Metallurgical Engi-
neer at the El Abra mine
ldquoOur goal is to reach 115000 tons with
a minimum of 80 of 12-mm-sized ore permonth The record to date is 105000 tons
and we will increase it until we reach our
project goalrdquo he adds
New design for cone liners
In addition to the work mentioned above
Metso is currently carrying out a project to
design the lining profiles for the secondary
and tertiary crushers of the plant which
will affect the smaller size of the material
In cooperation with Nelson Mella from
Metso and Rodolfo Navarro Crushing
Superintendent at the El Abra mine testswere carried out in July on the re-designed
Metso linings One set was tested for sec-
ondary crushing and two sets for tertiary
crushing
More info
Nelson Mella
Tel +56 99158 0576
nelsonmellametsocom
Finer ore through wear pro1047297lestudy at El Abra mine in ChileEl Abra is a porphyry copper open-pit mine and processing facility located in
Chile near the city of Calama some 4000 meters above sea level With the helpof Metsorsquos technical support the mine was able to achieve finer ore throughoutthe crushing process
TEXT amp PHOTOS Macarena Vallejo
Xewell Cimenteries produces a selec-
tion of dry processed aggregates for con-
crete Operations started at the end of 2009
with the aim of reaching 150000 metric
tons produced per year
Lokotracks chosen to reduce costs
To build up their tracked mobile processXewell Cimenteries decided to buy three
mobile plants from Metso two impactor
plants the Lokotrack LT1110 and LT1213
feeding a three-deck mobile screen the
ST620 The machines were sold by SCAI
SpA Metsorsquos Lokotrack distributor in Italy
ldquoWe chose tracked machines to bet-
ter exploit our quarry and to reduce
costs Mobile plants have low initial costs
because they donrsquot need any special foun-
dations or supply of electricity This obvi-
ously gives us a quicker process set-up and
better uptimerdquo says Alessandro Crestani Technical Director of the Pout quarry
ldquoThe mobile plant can also follow the
quarry face as the exploitation proceeds
reducing the transport costs of raw materi-
als in the same jobsite We chose Metso
because they ensured us the best cost-per-
ton ratiordquo he adds
Good customer service is crucial
According to Alessandro Crestani good
customer service also played a major role
when choosing the manufacturer of the
mobile equipmentldquoMetsorsquos distributor SCAI SpA was able
to provide us with a complete product
support and customer service package
Obviously service is a very important
aspect for us in a country like Senegal Any
downtime represents a clear loss of pro-
ductivity for usrdquo
The average level of productivity of the
mobile Lokotrack process is 200 metric
tons per hour
More info
Carlo Rinolfi Tel +39 335 1253159
crinolfiscaispacom
Example of the development of the Metso study
on the crusher lining profiles
Liner change for smaller ore size in the
MP1000 cone crusher
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Services success in Surabaya The Metso Surabaya workshop and offi ce complex opened in April 2008 provides Life Cycle Services and maintenance
solutions for Metso equipment in the Indonesia region The facility is strategically located in an industrial precinct on theouter rim of Surabaya the second largest city in Indonesia Its close proximity to an international airport major shipping
port and several engineering companies simplifies support for the regionrsquos key customers which include PT Newmont
and PT Freeport
TEXT amp PHOTOS David LeRoy amp Gary Whittred
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The Surabaya site operates through Metso
in Australia with assistance from key sales
and technical staff Handling regional ser-vice and repair business in-house allows
Metso to manage intellectual property and
closely control quality
It also enables the development of a
team of skilled service personnel who can
be utilized both internally and at key cus-
tomer sites as is common with the backup
service the workshop provides for screen
contracts
Innovation at work
Since 2008 the Surabaya facility has suc-
cessfully refurbished a wide variety ofcomponents Recently two ball mill heads
weighing 22 tons each were modified in
order to strengthen the 1047298ange of the ball
mill shell The modification included tap-
ping out existing 1047298ange holes and drilling
new ones so that finger plates could be
installed and welded to the 1047298anges
Positioning the head borer to properly
align the new 1047298ange holes proved diffi cult
Four roller support frames were manufac-
tured to support the heads and allow them
to be rotated easily Each hole was then
drilled and tapped at the correct angleusing the CNC five axis head The job had a
tight delivery as it was required for a shut-
down but with advance planning and inno-
vation it was completed ahead of schedule
MP1000 mainframe on
CNC vertical borer
Well equipped for fabricating and machin-
ing heavy components the Surabaya
The Surabaya facility has proven to be
a success for Metso The workshop offers a
wide variety of services in the region Qual-ity products and competitive pricing and
delivery times have led to strong customer
relationships
Turnover and customer service levels
have increased annually since the open-
ing and between 2008 and 2010 sales
increased 450 These excellent trends
are expected to continue as the operation
expands and the customer base grows
Since 2008 the Surabaya facility has
successfully refurbished
bull MP1000 counter shaft boxes headassemblies mainframes bowls adjust-
ment rings counterweights sockets and
tramp release cylinders
bull 7rsquo Symons bowls heads and countershaft
boxes
bull Vertimill screw and drive shafts
bull Ball mill heads
bull Ball mill trommel
bull VPA cylinders
bull Eaton clutches
bull Exciter screen mechanisms
bull 42x65 main shafts and eccentrics
More info
Gary Whittred
Tel +62 31 8430349
garywhittredmetsocom
workshop handles the majority of Metsorsquos
refurbishment work with ease But when
necessary PT PAL ndash a government facilitywith shipbuilding and heavy engineering
capabilities ndash offers a ldquoone stop shoprdquo Spe-
cially trained PT PAL staff ensures that the
work they perform complies with all Metso
specifications and quality standards
PT PAL also demonstrated their innova-
tive ability with the first MP1000 main-
frame refurbishment they completed The
mainframersquos shaft location bore needed
to be re-machined However the distance
from the top of the mainframe to the
tapered bore made it very hard to achieve
an accurate surface finish with the correctstandoff
To overcome this the shop decided to
machine the mainframe upside down and
elevated on support beams They posi-
tioned a new shaft under the mainframe in
a custom-made cradle Using an overhead
crane they could then lsquotrial fitrsquo the shaft in
the bore to make sure it seated correctly
and the mating tapers met specification
The method worked so well it has since
been used for four more mainframe refur-
bishments
Diversity and growth
Today Metso Surabaya continues to invest
in additional equipment in order to diver-
sify its service offering A new hydraulic
power pack which allows the facility to test
refurbished components to Metso specifi-
cations was recently used in the refurbish-
ment and testing of several VPA cylinders
for PT Freeport
Refurbished MP1000 mainframe dispatched by truck to
PT Freeport mine
Machining of MP1000 upper frame
at Metsorsquos Surabaya workshop
Mainframe at vertical CNC machining
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Creating Value with Metso in Hong KongIn Hong Kong the aggregates needed for construction are mostly supplied by two local quarries KWP Quarry Company
Limitedrsquos Anderson Road Quarry accounts for 60ndash70 making it the pillar of Hong Kongrsquos construction materials industry
TEXT amp PHOTOS Ou He
When arriving at the Anderson Road
Quarry the most impressive view at the850000 square-meter facility is the Metso
machines including equipment from the
primary secondary and tertiary crushing
circuits and the screens I t is Metsorsquos equip-
ment that secures the supply of aggregates
for Hong Kong
KWP Quarry Company Limited has been
working with Metso since its establishment
in 1997
Due to Hong Kongrsquos stringent dust and noise control standards Metso has paid special attention to the related suppression systems
ldquoOur quarry mainly lies on granite and
volcanic rock which are so hard they canonly be processed by equipment with
strong durability and stabilityrdquo explains
Mr Eddie Hung Manager of KWP ldquoWith a
long history of and experience in quarry-
ing we are very familiar with the equip-
ment of different brands Comparatively
Metsorsquos products are better than others in
terms of durability stability and effi ciency
Besides this the reason we selected Metso
is because of the simple maintenance of
their equipment and the easy access tomaintenance informationrdquo
Flexible modular solution
Based on extensive experience in crushing
and screening worldwide Metso presented
the Anderson Road Quarry with a modu-
lar solution and delivered it as a turn-key
project Through a four-stage crushing
circuit which contains three Metso C160
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jaw crushers for primary crushing two
Omnicone 1560SX crushers for secondary
crushing two HP 500SX cone crushers for
tertiary crushing and one HP500SX cone
crusher for extra-fine crushing the plant
was able to produce aggregates of optimal
shape with minimal 1047298akiness
The fine products include three sizes
0 to 5 mm 5 to 10 mm and 10 to 20mm
Since the employment of this system in
2000 production has reached 1250 th
which is far beyond the design capacityAccording to Mr Hung ldquoThe machines
always run effi ciently and seldom malfunc-
tion The occasional shutdown of some
machines does not affect production very
much the plant still could reach 60-70
of its normal production It gives us the
best 1047298exibility for the plant rsquos operation and
I believe this is the best feature of Metsorsquos
solution
Eddie Hung
Manager of KWPrsquos
Anderson Road
Quarry is happy with
the product quality
and service provided
by Metso
ldquoMetsorsquos equipment is expensive com-
paratively but in the long run you will find
that the investment is worthwhile on the
whole Metso secures superior stability reli-
ability and fewer downtimes and it guaran-
tees continuous operation and brings us
greater valuerdquo
Great service team
Metso sent a group of service engineers
to the plant within the warranty period
not only to provide service but to train theoperators Mr Hung speaks highly of Met-
sorsquos service team he is impressed with its
experienced experts and with their strong
sense of responsibility and customer-
oriented ways of working
ldquoMetsorsquos service team never fails to find
hidden problems and helps us to prevent
any mechanical failures And they are
available whenever we need them they
work closely with us to solve the problem
effi cientlyrdquo he said
Excellent environment-friendly designIn order to achieve the worldrsquos most strin-
gent noise and dust control standards
developed by the Environment Protection
Department of Hong Kong Metso has
incorporated a dust and noise suppression
system into the plant This includes the
infrared-triggered spray systems at feed
points encapsulation of individual crush-
ers and conveyors and the ability to select
specific sectors of the system for treatment
depending on feed and operating condi-
tions encapsulation of equipment and the
enclosure of all major sections of the plant
With these advanced environment-
friendly solutions Anderson Road Quarry
has won numerous safety and environmen-
tal awards In 2003 it was presented with a
silver medal in the prestigious Environmen-
tal Performance Awards in recognition of
its commitment to the environment and
community In 2004 KWP achieved certifi-cation of ISO 14001 it is the first quarry site
to have achieved this in Hong Kong and
southern China
ldquoA reliable partnerrdquo
The promulgation of the top ten infrastruc-
ture policies in Hong Kong boosted the
market for aggregates and demand will
keep rising over the next five to six years
ldquoWersquoll definitely keep our cooperation with
Metso once we have a need for expansion
because we regard Metso as a reliable part-
ner With their highly effi cient equipmentsatisfying service and great efforts in help-
ing us to achieve our environmental pro-
tection targets Metso is our best choicerdquo
says Hung
More info
Ziqiang Li
Tel +86 13601289027
ziqianglimetsocom
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The sturdy Metso C160
jaw crushers are fed
using huge feed chutes
and feeders
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983122983141983152983151983154983156983145983150983143 983154983141983155
Similar to hundreds of mine sites world-
wide Zinkgruvan is being operated on a
non-stop 247 basis with just a few main-
tenance breaks during the year Crusher
availability is crucial because 100 of the
ore has to pass through the jaws before
being hoisted up for further processing
In addition to the zinc- lead- copper-
and silver-containing ore the C jaws chop
all the host rock extracted along the min-
ing process With a sturdy design Metsorsquos
proven C jaws can easily reduce even the
hardest type of rock Every year more thanone million tons are crushed with the jaws
ldquoMinimal service neededrdquo
Crushing with the first C160B jaw crusher
began at Zinkgruvanrsquos -800 meter level in
2000 with the primary crushing of zinc-lead
ore The second jaw was installed in 2008
for the new copper process gt
The sight and sound of two C160 jaw crushers operating side by side in the underground
crushing station of the Swedish Zinkgruvan mine is impressive Good proactive service
secures good uptime and reliable continuous operation of Metsorsquos second-largest
C160 series jaw crushers and prepares the way for the ongoing plans to expand the
production of zinc concentrate
TEXT amp PHOTOS Eero Haumlmaumllaumlinen
New PolyMet liners are being tested with the grinding mill delivered by Metso
Zinkgruvanrsquos twin C160
jaws secure good uptime
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Blasted ore is taken from the presently
operated -850 meter level with normal
trucks as an outsourced process One full
truckload is fed to the C160s every
10 minutes
ldquoWe are happy with the high reliability
of the C jaws They only require some minor
service therefore providing us with good
uptime and steady continuous feed to our
secondary and tertiary crushing and grind-ing circuitsrdquo says Mine Manager Jan Klaumlre
ldquoBasic crusher service and wear part
changes are made by our own staff using
Metsorsquos partsrdquo he adds
Service contract with grinding
mills and conveyors
Zinkgruvan and Metso Sweden have more
than 11 yearsrsquo experience with a service
contract that contains grinding mills and
conveyors At the mine site two Metso
service people and one contractor take
care of all the related service jobs Man-
power can also be borrowed from Metsorsquos
Graumlngesberg mine service team of 20
people
Presently Zinkgruvan is testing Metsorsquos
new PolyMet mill linings in its big grinding
mills With previously used rubber partsthe linings had to be changed in the shell
every 9 to 11 months and in the feed head
every 6 months
ldquoWe expect a better lifetime with Poly-
Met linings Longer change intervals mean
a lot to our productivity because lining
changes takes two full working daysrdquo Mine
Manager Jan Klaumlre says
New mine goes deeper
With an expected mine life of more than 10
years Zinkgruvan is actively mapping new
ore reserves Experimental holes are being
drilled at the new mine section at the
-1110 meter level
More info
Fredrik Wennberg
Tel +46 70 657 00 08fredrikwennbergmetsocom
Mine Manager Jan Klaumlre (left) with Backfilling Manager Kjell Tillman at the underground -800 meter level mine cafeteria
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The Zinkgruvan mine located approxi-
mately 200 km southwest of Stockholm
Sweden is one of the oldest underground
mines in Northern Europe The mine has
been in production since 1857
The mining methods used are panel
stoping and benching The processing
facilities include a zinc concentrating plant
with a 11 mtpa and a copper plant with a04 mtpa capacity Tailings are recycled in
an impounding basin and host rock in the
backfill plant
Continuous mining since 1857
Even as one of the oldest mines in Northern
Europe Zinkgruvan exploits modern mining
and minerals processing installations
Zinkgruvan mine
OWNER Lundin Mining
PRODUCTION PER YEAR 1 million tons
ORE TYPE sedimentary exhalative
zinc lead copper and silver
NUMBER OF EMPLOYEES 320
2011 PRODUCTION TARGETS 78000 tonsof zinc 36000 tons of lead and
3400 tons of copper concentrate
METSO EQUIPMENT ON SITE
bull 1 extra long VF feeder
bull 2 C160 jaw crushers
ndash zinc process css 220ndash240 mm
ndash copper process css 150 mm
bull 1 GP300S cone crusher
ndash css 45mm
bull 1 HP4 cone crusher
ndash css 18 mm
bull 1 DS screen
bull 1 FS402 screenbull 1 grinding mill
bull Pumps VPAs
A normal truck feeds the C jaws with ore coming from the lower production levels
983122983141983152983151983154983156983145983150983143 983154983141983155
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Cost-per-ton wear agreements deepencustomer relationshipsCrusher wear parts are traditionally marketed purely based on transactional sales and mainly depend on
the weight of manganese Metso has recently introduced a new type of wear agreement based on thecost-per-ton crushed and the wear occurred Thus far the experience has been very positive increasing
transparency and deepening the operational relationship between the manufacturer and the customer
TEXT Olli Kellokumpu and Eero Haumlmaumllaumlinen PHOTOS Eero Haumlmaumllaumlinen
Arto Hiedanniemi (left)
Hannu Heman and Juha
Laukka of Metsorsquos Finnish
Service team checking the
cone crusher mantles shipped
for a cost-per-ton customer
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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156
Wear parts and parts changes
can be included
The structure of a cost-per-ton wearcontract is based on the number of tons
crushed and the estimated wear occurred
The amount and monetary value of the
wear is calculated per crushed ton
ldquoEither plain wear parts or parts changes
carried out by Metsorsquos service personnel
can be included in the contract In the latter
case we ask our Finnish customers to inform
us about an upcoming wear change opera-
tion one week in advancerdquo Heman explains
ldquoWe see good opportunities to market
cost-per-ton contracts further in Finland
and also abroad It really develops therelationship of Metso and our customers
towards a trusted partnershiprdquo he notes
Perfect tool for accurate planning
Soraliike Ikola Oy is a mid-sized contrac-
tor with three Metso two- and three-
stage mobile and portable crushing and
screening plants operating in Central and
Since 2002 Metsorsquos sales team in Finland
has developed the cost-per-ton-based
service offeringldquoOur aim has been to seek through
a cost-per-ton offering possibilities to
serve our customers better to differentiate
Metso from the other players as an OEM
manufacturer and to offer deeper profes-
sionalism and know-howrdquo says Hannu
Heman General Manager of service
operations
ldquoUntil now both our experience and
that of our customers has been quite posi-
tive When properly prepared cost-per-ton
contracts seem to create a win-win situa-
tionrdquo Heman adds Today Metso has operational cost-per-
ton agreements with several Finnish cus-
tomers The first contract was concluded
with a customer operating a stationary
plant Based on the results gathered new
cost-per-ton contracts have been signed
with customers operating wheeled and
tracked equipment too
Eastern Finland Because of the size of the
contracts up to 50 equipment moves are
made during the yearEntrepreneur Pasi Ikola has had a cost-
per-ton contract with Metso for nearly
two years and he is quite happy with the
outcome
ldquoThe cost-per-ton contract has provided
me with a perfect tool for accurate financial
planning Now I know in detail my actual
future wear parts costs This helps a lot
when calculating bidsrdquo
ldquoEarlier I used to buy a big batch of
Metso wear parts in one go and had to
reserve a reasonable amount of money for
that Today all wear costs are evenly sharedwhich gives us a welcomed 1047298exibility to
our cost structure Now we just pay Metso
afterwards based on our crushed tonsrdquo
he adds
More info
Olli Kellokumpu
Tel +358 50 354 1189
ollikellokumpumetsocom
According to crushing contractor Pasi Ikola the cost-per-ton contract with Metso has provided the entrepreneur with better economical 1047298exibility
and more accurate calculating of bids
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Pleasant Gap is owned and operated by
Glenn O Hawbaker Inc of State College
Pennsylvania This family-owned company
began in 1952 as a small excavation busi-
ness founded by Glenn O Hawbaker and
his wife Thelma Over the years the com-
pany grew by adding an integrated mix ofproducts and services and taking on larger
projects
In 1983 Hawbaker acquired Pleasant
Gap Quarry and built its first aggregates
processing plant Today Glenn O Haw-
baker Inc operates 21 quarries and eight
asphalt production facilities across Penn-
sylvania and southern New York as well as
five regional operation centers
Primary
challenge atPleasant GapQuarryA good part of what makes for a successful crushing
operation is the willingness to tackle challenges and to do
whatrsquos necessary to meet demand The team at Pleasant
Gap Quarry in central Pennsylvania recently met the chal-
lenge when they successfully addressed problems with
the plantrsquos primary crushing plant First they purchased
a new Metso C160 jaw to replace the existing primary
impact crusher Then they devised an innovative plan to
get the primary plant back in operation while awaitingdelivery of the new jaw crusher
TEXT Linda Bergmann PHOTOS John Rickinger
983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Time for a change
With the goal of increasing reliability and
output the management at Pleasant Gap
Quarry recently decided it was time to
replace the plantrsquos primary impact crusher
Following a thorough search they chose a
new Metso C160 jaw According to ScottReck Plant Manager it no longer made
sense to repair and rebuild the existing
impactor
ldquoBefore we purchased the Metso C160
we had a few other impact crushers and
they served us well but as our custom-
ersrsquo needs increased our plant production
had to match that demand We found our
formerly reliable unit was being overcome
by our demands for output and creative
work-around solutions We continued to
need more but there was only so much we
could do until we hit the breaking point ndash
literallyrdquo
In addition to performance improve-
ments the new crusher also needed to fitinto Pleasant Gaprsquos unique infrastructure
As Plant Project ManagerEngineer Jeremy
Fahr explains ldquoOur height restraint was 274
meters (108rdquo) This height was the distance
from the feed lip of the existing 6x12 scalp-
ing screen and the existing structure that
the crusher rests onrdquo
The normal C160 crusher is 307
meters (121rdquo) tall but Metso gave GOH
Scott Reck Plant Manager (left) and
Jeremy Fahr Plant Project Manager
Engineer at Pleasant Gap Quarry
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a 10-degree mounting option (which is
normally used on their portable crushers)
to overcome the height restraint Reck and
Fahr worked with Dave Rhoa of Cleveland
Brothers Equipment Metsorsquos crushing and
screening distributor in Pennsylvania to
pull everything together and fit the newcrusher into their plant
The C160 crusher selected for Pleasant
Gap is one of the latest models in Metsorsquos
C Series of jaws These jaw crushers feature
a large throw and steep toggle plate angle
resulting in a higher crusher output In
addition the C Series has a compact foot-
print that makes it an ideal choice for the
replacement of existing machines
According to Reck ldquoWe had heard about
the new Metso C160 and started doing our
own research and found Metso not only
had developed the output capacity we
needed but fit the uniqueness of our oper-
ationsrdquo The new Metso crusher will allow
the plant to increase tons per hour andgive them the 1047298exibility to meet demands
for varying products on short notice
Mobile solution
Purchasing the new primary jaw addressed
the long-term issues but still left Pleasant
Gap without a functioning primary plant
Reck continues ldquoOur main line was still
down leaving us with a big hole in hitting
customer needs but knowing that our new
Metso C160 was on its wayhellipwe needed an
immediate solution to keep our produc-
tion demands with an out-of-commission
crusherrdquo
The team at Pleasant Gap brainstormed
the problem and came up with a plan toget the primary plant back in operation
Their solution was to use the Lokotrack
LT1213 impactor plant and another mobile
unit to keep the main line crushing To do
this they removed the guts on the existing
impact crusher essentially turning it into a
rock chute They then moved the LT1213
and another manufacturerrsquos mobile unit
over to the existing dump hopper gt
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ldquoWe had our haul trucks drop off mate-
rial while two excavators fed the two
mobile unitsrdquo Reck explains ldquoFor two-and-
a-half months the Lokotrack LT1213 unit
was producing 254 cm (10rdquo) minus at
700 tons per hour The other similar-sized
mobile unit was doing 400 tons an hour
maxed out The difference was unbeliev-
able to say the least Our unique solution
using the two mobile units especially the
LT1213 helped Glenn O Hawbaker achieve
a record output in 2010rdquoAccording to Fahr ldquoWe were not new to
Metsorsquos quality and supportrdquo because GOH
had been using Metsorsquos portable crushing
equipment for 3 years prior to the primary
plantrsquos impact crusher failure In another
part of our operation we have a system that
our team relies on every day a Lokotrack
LT1213 and ST272 working in tandem with
two portable conveyorsrdquo This highly effi -
cient mobile processing system turns out
300 tons of specialized blended material
per hour GOH has been so impressed with
Metso equipment its last two purchaseswere an LT106 tracked jaw plant and a
second ST272 mobile screen in 2010
Maintaining high productivity
The Metso C160 jaw was delivered to Pleas-
ant Gap Quarry in January of 2011 and
since start-up it has more than met expec-
tations The crusher is fed minus 910 mm
(36rdquo) limestone with the jaw set at 140 mm
(5 12rdquo) According to Reck ldquoFrom moment
we started up we knew we had a winner
Not only were we kicking out as much
product as our previous units without even
breathing hard but we immediately had a
2-cent per ton savings to the bottom line
without having to run a second 350 HP
motor as required by other units Plus by
adding on the new automatic lube system
the maintenance team had more time to
devote to keeping other areas of the com-
plex running more effi cientlyrdquoReck says ldquoThe Metso unit was a perfect
fit and with the improved features it pre-
sented it had it all We just turn it on load
it up and we are moving 600 tons per hour
through the crusher without any effort and
we know it can do so much morerdquo With
the primary crushing plant back in opera-
tion the entire team at Pleasant Gap will
continue to do what they do best produce
and sell high-quality products and meet
their customersrsquo expectations
More info
Scott Yablonsky Tel +1 262 717 793
scottyablonskymetsocom
The Metso C160 jaw
was installed at a 10deg
angle to fit Pleasant
Gaprsquos existing
infrastructure
The Lokotrack LT1213 impactor plant and ST272 mobile screen operate in tandem with two
portable conveyors at Pleasant Gap
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983149983141983156983155983151 983150
Paper amp fiberNew OptiConcept M paper
and board making line
The new OptiConcept M paper and board
making line stands for economy safety and
usability
Metso has launched a new modular paper
and board making line called OptiConceptM A member of the proven OptiConcept
production line family the new OptiCon-
cept M optimizes machine investment in
line with each millrsquos capacity needs
Savings in operating costs are achieved
through precise dimensioning of pro-
cesses proven technological solutions
optimal running parameters effective
maintenance operations and fully inte-
grated automation solutions
Optimized processes innovations
smart controls and accurate dimensioning
decrease the use of steam gas electricitywater chemicals and other raw materials
and reduce emission levels
OptiConcept M has been designed
both visually and physically with the
requirements of users in mind For exam-
ple the design of the machinery allows for
easy and safe changing of rolls and wear
parts thus reducing the total duration and
cost of maintenance shutdowns
RecyclingGreen energy technology to
Elektrociepłownia Białystok in Poland
Metso will convert a coal-fired boiler to
a biomass-fired Bubbling Fluidized Bed
boiler for Elektrociepłownia Białystok SArsquos
combined heat and power plant (CHP) in
Białystok Poland The new boiler system
will cut the power plantrsquos CO2 emissions
significantly by partly replacing the coal
fuel supply with biomass fuel
ldquoPoland is one of the largest countries
in Europe to have such a high depend-ence on energy derived from coal to
meet national electricity needs This is an
important incentive for us to reduce future
CO2 emissions and produce more green
electricity and with Metso technology
we are certain to accomplish our goalrdquo
states Mr Andrzej Schroeder President of
Elektrociepłownia Białystok SA
Since 2000 Metso has received a total
of 7 biomass boiler conversion orders in
Poland and the renewable energy share
in Poland is only 75 (2010) compared to
the target of 20 by 2020 set by the EUApproximately 80 of the current energy
boilers turbines and generators installed in
Polish power plants are over 20 years old In
order to meet the strict EU environmental
requirements modernization of existing
installations is necessary
Automation
Metso DNA automation system expands
to mining and construction
Using Metsorsquos control room automation
an entire crushing and screening plant can
be effi ciently managed
Metso is a leading supplier of mining and
construction machinery This expertise has
now been combined with a scalable Metso
DNA automation system that adapts to
the range of industry needs from single
machine controls to plant-wide automation
and information management systems
An example of Metsorsquos new offering is a
new crushing plant control room solution
that connects crushers and screens ensur-
ing the effective management of the entire
plant from a pleasant and safe control
room The Metso DNA user interface pro-vides the production information to ensure
a proper and rapid response to plant
events Automatic controls stabilize the
process and allow the operators to monitor
the plant as a whole
ldquoThe benefits of automation for the min-
ing and construction industry are signifi-
cant As an example of the services we offer
performance studies to crushing plants
utilizing Metsorsquos multi-disciplinary teams of
experts to determine the present level of
the plant and process effi ciency and to esti-
mate the improvement potential and thebenefits of optimization and automation
including ROI calculationsrdquo says Mikko Maumlki-
nen Product Manager of minerals applica-
tions in Metsorsquos Automation business line
ldquoAs another example our machine
condition monitoring solutions can reduce
plant and machine downtimes as well as
help to avoid safety and environmental
hazardsrdquo he adds
Metso around the world
Aerial view of the Elektrociepłownia Białystok combined heat and power plant in Poland
8202019 Metso Minerals Aggregates 3 2011
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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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983122983141983152983151983154983156983145983150983143 983154983141983155
Owned by Freeport-McMoRan Copper amp
Gold (51) and CODELCO (49) the ElAbra mine has leachable oxide and sulfide
mineralization The minersquos processing facil-
ity has an annual capacity of 226000 tons
of copper cathode
Smaller size matters
Reducing the size of the crushed oxide
ore from the present 15 mm to 12 mm
was the main target of the mine and the
Metso team The changes that were carried
out in the process included a size varia-
tion change in the cut of the tertiary sieve
installation of rate-level sensors in thesecondary crushers and enabling speed
variables in the conveyor belt feeders of
the secondary crushing circuit
ldquoGoing from 15mm to 12mm may seem
small but the operational impact is very
important and significant for usrdquo explains
Juan Torres Carvajal Metallurgical Engi-
neer at the El Abra mine
ldquoOur goal is to reach 115000 tons with
a minimum of 80 of 12-mm-sized ore permonth The record to date is 105000 tons
and we will increase it until we reach our
project goalrdquo he adds
New design for cone liners
In addition to the work mentioned above
Metso is currently carrying out a project to
design the lining profiles for the secondary
and tertiary crushers of the plant which
will affect the smaller size of the material
In cooperation with Nelson Mella from
Metso and Rodolfo Navarro Crushing
Superintendent at the El Abra mine testswere carried out in July on the re-designed
Metso linings One set was tested for sec-
ondary crushing and two sets for tertiary
crushing
More info
Nelson Mella
Tel +56 99158 0576
nelsonmellametsocom
Finer ore through wear pro1047297lestudy at El Abra mine in ChileEl Abra is a porphyry copper open-pit mine and processing facility located in
Chile near the city of Calama some 4000 meters above sea level With the helpof Metsorsquos technical support the mine was able to achieve finer ore throughoutthe crushing process
TEXT amp PHOTOS Macarena Vallejo
Xewell Cimenteries produces a selec-
tion of dry processed aggregates for con-
crete Operations started at the end of 2009
with the aim of reaching 150000 metric
tons produced per year
Lokotracks chosen to reduce costs
To build up their tracked mobile processXewell Cimenteries decided to buy three
mobile plants from Metso two impactor
plants the Lokotrack LT1110 and LT1213
feeding a three-deck mobile screen the
ST620 The machines were sold by SCAI
SpA Metsorsquos Lokotrack distributor in Italy
ldquoWe chose tracked machines to bet-
ter exploit our quarry and to reduce
costs Mobile plants have low initial costs
because they donrsquot need any special foun-
dations or supply of electricity This obvi-
ously gives us a quicker process set-up and
better uptimerdquo says Alessandro Crestani Technical Director of the Pout quarry
ldquoThe mobile plant can also follow the
quarry face as the exploitation proceeds
reducing the transport costs of raw materi-
als in the same jobsite We chose Metso
because they ensured us the best cost-per-
ton ratiordquo he adds
Good customer service is crucial
According to Alessandro Crestani good
customer service also played a major role
when choosing the manufacturer of the
mobile equipmentldquoMetsorsquos distributor SCAI SpA was able
to provide us with a complete product
support and customer service package
Obviously service is a very important
aspect for us in a country like Senegal Any
downtime represents a clear loss of pro-
ductivity for usrdquo
The average level of productivity of the
mobile Lokotrack process is 200 metric
tons per hour
More info
Carlo Rinolfi Tel +39 335 1253159
crinolfiscaispacom
Example of the development of the Metso study
on the crusher lining profiles
Liner change for smaller ore size in the
MP1000 cone crusher
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Services success in Surabaya The Metso Surabaya workshop and offi ce complex opened in April 2008 provides Life Cycle Services and maintenance
solutions for Metso equipment in the Indonesia region The facility is strategically located in an industrial precinct on theouter rim of Surabaya the second largest city in Indonesia Its close proximity to an international airport major shipping
port and several engineering companies simplifies support for the regionrsquos key customers which include PT Newmont
and PT Freeport
TEXT amp PHOTOS David LeRoy amp Gary Whittred
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983122983141983152983151983154983156983145983150983143 983154983141983155
The Surabaya site operates through Metso
in Australia with assistance from key sales
and technical staff Handling regional ser-vice and repair business in-house allows
Metso to manage intellectual property and
closely control quality
It also enables the development of a
team of skilled service personnel who can
be utilized both internally and at key cus-
tomer sites as is common with the backup
service the workshop provides for screen
contracts
Innovation at work
Since 2008 the Surabaya facility has suc-
cessfully refurbished a wide variety ofcomponents Recently two ball mill heads
weighing 22 tons each were modified in
order to strengthen the 1047298ange of the ball
mill shell The modification included tap-
ping out existing 1047298ange holes and drilling
new ones so that finger plates could be
installed and welded to the 1047298anges
Positioning the head borer to properly
align the new 1047298ange holes proved diffi cult
Four roller support frames were manufac-
tured to support the heads and allow them
to be rotated easily Each hole was then
drilled and tapped at the correct angleusing the CNC five axis head The job had a
tight delivery as it was required for a shut-
down but with advance planning and inno-
vation it was completed ahead of schedule
MP1000 mainframe on
CNC vertical borer
Well equipped for fabricating and machin-
ing heavy components the Surabaya
The Surabaya facility has proven to be
a success for Metso The workshop offers a
wide variety of services in the region Qual-ity products and competitive pricing and
delivery times have led to strong customer
relationships
Turnover and customer service levels
have increased annually since the open-
ing and between 2008 and 2010 sales
increased 450 These excellent trends
are expected to continue as the operation
expands and the customer base grows
Since 2008 the Surabaya facility has
successfully refurbished
bull MP1000 counter shaft boxes headassemblies mainframes bowls adjust-
ment rings counterweights sockets and
tramp release cylinders
bull 7rsquo Symons bowls heads and countershaft
boxes
bull Vertimill screw and drive shafts
bull Ball mill heads
bull Ball mill trommel
bull VPA cylinders
bull Eaton clutches
bull Exciter screen mechanisms
bull 42x65 main shafts and eccentrics
More info
Gary Whittred
Tel +62 31 8430349
garywhittredmetsocom
workshop handles the majority of Metsorsquos
refurbishment work with ease But when
necessary PT PAL ndash a government facilitywith shipbuilding and heavy engineering
capabilities ndash offers a ldquoone stop shoprdquo Spe-
cially trained PT PAL staff ensures that the
work they perform complies with all Metso
specifications and quality standards
PT PAL also demonstrated their innova-
tive ability with the first MP1000 main-
frame refurbishment they completed The
mainframersquos shaft location bore needed
to be re-machined However the distance
from the top of the mainframe to the
tapered bore made it very hard to achieve
an accurate surface finish with the correctstandoff
To overcome this the shop decided to
machine the mainframe upside down and
elevated on support beams They posi-
tioned a new shaft under the mainframe in
a custom-made cradle Using an overhead
crane they could then lsquotrial fitrsquo the shaft in
the bore to make sure it seated correctly
and the mating tapers met specification
The method worked so well it has since
been used for four more mainframe refur-
bishments
Diversity and growth
Today Metso Surabaya continues to invest
in additional equipment in order to diver-
sify its service offering A new hydraulic
power pack which allows the facility to test
refurbished components to Metso specifi-
cations was recently used in the refurbish-
ment and testing of several VPA cylinders
for PT Freeport
Refurbished MP1000 mainframe dispatched by truck to
PT Freeport mine
Machining of MP1000 upper frame
at Metsorsquos Surabaya workshop
Mainframe at vertical CNC machining
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Creating Value with Metso in Hong KongIn Hong Kong the aggregates needed for construction are mostly supplied by two local quarries KWP Quarry Company
Limitedrsquos Anderson Road Quarry accounts for 60ndash70 making it the pillar of Hong Kongrsquos construction materials industry
TEXT amp PHOTOS Ou He
When arriving at the Anderson Road
Quarry the most impressive view at the850000 square-meter facility is the Metso
machines including equipment from the
primary secondary and tertiary crushing
circuits and the screens I t is Metsorsquos equip-
ment that secures the supply of aggregates
for Hong Kong
KWP Quarry Company Limited has been
working with Metso since its establishment
in 1997
Due to Hong Kongrsquos stringent dust and noise control standards Metso has paid special attention to the related suppression systems
ldquoOur quarry mainly lies on granite and
volcanic rock which are so hard they canonly be processed by equipment with
strong durability and stabilityrdquo explains
Mr Eddie Hung Manager of KWP ldquoWith a
long history of and experience in quarry-
ing we are very familiar with the equip-
ment of different brands Comparatively
Metsorsquos products are better than others in
terms of durability stability and effi ciency
Besides this the reason we selected Metso
is because of the simple maintenance of
their equipment and the easy access tomaintenance informationrdquo
Flexible modular solution
Based on extensive experience in crushing
and screening worldwide Metso presented
the Anderson Road Quarry with a modu-
lar solution and delivered it as a turn-key
project Through a four-stage crushing
circuit which contains three Metso C160
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983122983141983152983151983154983156983145983150983143 983154983141983155
jaw crushers for primary crushing two
Omnicone 1560SX crushers for secondary
crushing two HP 500SX cone crushers for
tertiary crushing and one HP500SX cone
crusher for extra-fine crushing the plant
was able to produce aggregates of optimal
shape with minimal 1047298akiness
The fine products include three sizes
0 to 5 mm 5 to 10 mm and 10 to 20mm
Since the employment of this system in
2000 production has reached 1250 th
which is far beyond the design capacityAccording to Mr Hung ldquoThe machines
always run effi ciently and seldom malfunc-
tion The occasional shutdown of some
machines does not affect production very
much the plant still could reach 60-70
of its normal production It gives us the
best 1047298exibility for the plant rsquos operation and
I believe this is the best feature of Metsorsquos
solution
Eddie Hung
Manager of KWPrsquos
Anderson Road
Quarry is happy with
the product quality
and service provided
by Metso
ldquoMetsorsquos equipment is expensive com-
paratively but in the long run you will find
that the investment is worthwhile on the
whole Metso secures superior stability reli-
ability and fewer downtimes and it guaran-
tees continuous operation and brings us
greater valuerdquo
Great service team
Metso sent a group of service engineers
to the plant within the warranty period
not only to provide service but to train theoperators Mr Hung speaks highly of Met-
sorsquos service team he is impressed with its
experienced experts and with their strong
sense of responsibility and customer-
oriented ways of working
ldquoMetsorsquos service team never fails to find
hidden problems and helps us to prevent
any mechanical failures And they are
available whenever we need them they
work closely with us to solve the problem
effi cientlyrdquo he said
Excellent environment-friendly designIn order to achieve the worldrsquos most strin-
gent noise and dust control standards
developed by the Environment Protection
Department of Hong Kong Metso has
incorporated a dust and noise suppression
system into the plant This includes the
infrared-triggered spray systems at feed
points encapsulation of individual crush-
ers and conveyors and the ability to select
specific sectors of the system for treatment
depending on feed and operating condi-
tions encapsulation of equipment and the
enclosure of all major sections of the plant
With these advanced environment-
friendly solutions Anderson Road Quarry
has won numerous safety and environmen-
tal awards In 2003 it was presented with a
silver medal in the prestigious Environmen-
tal Performance Awards in recognition of
its commitment to the environment and
community In 2004 KWP achieved certifi-cation of ISO 14001 it is the first quarry site
to have achieved this in Hong Kong and
southern China
ldquoA reliable partnerrdquo
The promulgation of the top ten infrastruc-
ture policies in Hong Kong boosted the
market for aggregates and demand will
keep rising over the next five to six years
ldquoWersquoll definitely keep our cooperation with
Metso once we have a need for expansion
because we regard Metso as a reliable part-
ner With their highly effi cient equipmentsatisfying service and great efforts in help-
ing us to achieve our environmental pro-
tection targets Metso is our best choicerdquo
says Hung
More info
Ziqiang Li
Tel +86 13601289027
ziqianglimetsocom
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
The sturdy Metso C160
jaw crushers are fed
using huge feed chutes
and feeders
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983122983141983152983151983154983156983145983150983143 983154983141983155
Similar to hundreds of mine sites world-
wide Zinkgruvan is being operated on a
non-stop 247 basis with just a few main-
tenance breaks during the year Crusher
availability is crucial because 100 of the
ore has to pass through the jaws before
being hoisted up for further processing
In addition to the zinc- lead- copper-
and silver-containing ore the C jaws chop
all the host rock extracted along the min-
ing process With a sturdy design Metsorsquos
proven C jaws can easily reduce even the
hardest type of rock Every year more thanone million tons are crushed with the jaws
ldquoMinimal service neededrdquo
Crushing with the first C160B jaw crusher
began at Zinkgruvanrsquos -800 meter level in
2000 with the primary crushing of zinc-lead
ore The second jaw was installed in 2008
for the new copper process gt
The sight and sound of two C160 jaw crushers operating side by side in the underground
crushing station of the Swedish Zinkgruvan mine is impressive Good proactive service
secures good uptime and reliable continuous operation of Metsorsquos second-largest
C160 series jaw crushers and prepares the way for the ongoing plans to expand the
production of zinc concentrate
TEXT amp PHOTOS Eero Haumlmaumllaumlinen
New PolyMet liners are being tested with the grinding mill delivered by Metso
Zinkgruvanrsquos twin C160
jaws secure good uptime
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Blasted ore is taken from the presently
operated -850 meter level with normal
trucks as an outsourced process One full
truckload is fed to the C160s every
10 minutes
ldquoWe are happy with the high reliability
of the C jaws They only require some minor
service therefore providing us with good
uptime and steady continuous feed to our
secondary and tertiary crushing and grind-ing circuitsrdquo says Mine Manager Jan Klaumlre
ldquoBasic crusher service and wear part
changes are made by our own staff using
Metsorsquos partsrdquo he adds
Service contract with grinding
mills and conveyors
Zinkgruvan and Metso Sweden have more
than 11 yearsrsquo experience with a service
contract that contains grinding mills and
conveyors At the mine site two Metso
service people and one contractor take
care of all the related service jobs Man-
power can also be borrowed from Metsorsquos
Graumlngesberg mine service team of 20
people
Presently Zinkgruvan is testing Metsorsquos
new PolyMet mill linings in its big grinding
mills With previously used rubber partsthe linings had to be changed in the shell
every 9 to 11 months and in the feed head
every 6 months
ldquoWe expect a better lifetime with Poly-
Met linings Longer change intervals mean
a lot to our productivity because lining
changes takes two full working daysrdquo Mine
Manager Jan Klaumlre says
New mine goes deeper
With an expected mine life of more than 10
years Zinkgruvan is actively mapping new
ore reserves Experimental holes are being
drilled at the new mine section at the
-1110 meter level
More info
Fredrik Wennberg
Tel +46 70 657 00 08fredrikwennbergmetsocom
Mine Manager Jan Klaumlre (left) with Backfilling Manager Kjell Tillman at the underground -800 meter level mine cafeteria
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The Zinkgruvan mine located approxi-
mately 200 km southwest of Stockholm
Sweden is one of the oldest underground
mines in Northern Europe The mine has
been in production since 1857
The mining methods used are panel
stoping and benching The processing
facilities include a zinc concentrating plant
with a 11 mtpa and a copper plant with a04 mtpa capacity Tailings are recycled in
an impounding basin and host rock in the
backfill plant
Continuous mining since 1857
Even as one of the oldest mines in Northern
Europe Zinkgruvan exploits modern mining
and minerals processing installations
Zinkgruvan mine
OWNER Lundin Mining
PRODUCTION PER YEAR 1 million tons
ORE TYPE sedimentary exhalative
zinc lead copper and silver
NUMBER OF EMPLOYEES 320
2011 PRODUCTION TARGETS 78000 tonsof zinc 36000 tons of lead and
3400 tons of copper concentrate
METSO EQUIPMENT ON SITE
bull 1 extra long VF feeder
bull 2 C160 jaw crushers
ndash zinc process css 220ndash240 mm
ndash copper process css 150 mm
bull 1 GP300S cone crusher
ndash css 45mm
bull 1 HP4 cone crusher
ndash css 18 mm
bull 1 DS screen
bull 1 FS402 screenbull 1 grinding mill
bull Pumps VPAs
A normal truck feeds the C jaws with ore coming from the lower production levels
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Cost-per-ton wear agreements deepencustomer relationshipsCrusher wear parts are traditionally marketed purely based on transactional sales and mainly depend on
the weight of manganese Metso has recently introduced a new type of wear agreement based on thecost-per-ton crushed and the wear occurred Thus far the experience has been very positive increasing
transparency and deepening the operational relationship between the manufacturer and the customer
TEXT Olli Kellokumpu and Eero Haumlmaumllaumlinen PHOTOS Eero Haumlmaumllaumlinen
Arto Hiedanniemi (left)
Hannu Heman and Juha
Laukka of Metsorsquos Finnish
Service team checking the
cone crusher mantles shipped
for a cost-per-ton customer
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Wear parts and parts changes
can be included
The structure of a cost-per-ton wearcontract is based on the number of tons
crushed and the estimated wear occurred
The amount and monetary value of the
wear is calculated per crushed ton
ldquoEither plain wear parts or parts changes
carried out by Metsorsquos service personnel
can be included in the contract In the latter
case we ask our Finnish customers to inform
us about an upcoming wear change opera-
tion one week in advancerdquo Heman explains
ldquoWe see good opportunities to market
cost-per-ton contracts further in Finland
and also abroad It really develops therelationship of Metso and our customers
towards a trusted partnershiprdquo he notes
Perfect tool for accurate planning
Soraliike Ikola Oy is a mid-sized contrac-
tor with three Metso two- and three-
stage mobile and portable crushing and
screening plants operating in Central and
Since 2002 Metsorsquos sales team in Finland
has developed the cost-per-ton-based
service offeringldquoOur aim has been to seek through
a cost-per-ton offering possibilities to
serve our customers better to differentiate
Metso from the other players as an OEM
manufacturer and to offer deeper profes-
sionalism and know-howrdquo says Hannu
Heman General Manager of service
operations
ldquoUntil now both our experience and
that of our customers has been quite posi-
tive When properly prepared cost-per-ton
contracts seem to create a win-win situa-
tionrdquo Heman adds Today Metso has operational cost-per-
ton agreements with several Finnish cus-
tomers The first contract was concluded
with a customer operating a stationary
plant Based on the results gathered new
cost-per-ton contracts have been signed
with customers operating wheeled and
tracked equipment too
Eastern Finland Because of the size of the
contracts up to 50 equipment moves are
made during the yearEntrepreneur Pasi Ikola has had a cost-
per-ton contract with Metso for nearly
two years and he is quite happy with the
outcome
ldquoThe cost-per-ton contract has provided
me with a perfect tool for accurate financial
planning Now I know in detail my actual
future wear parts costs This helps a lot
when calculating bidsrdquo
ldquoEarlier I used to buy a big batch of
Metso wear parts in one go and had to
reserve a reasonable amount of money for
that Today all wear costs are evenly sharedwhich gives us a welcomed 1047298exibility to
our cost structure Now we just pay Metso
afterwards based on our crushed tonsrdquo
he adds
More info
Olli Kellokumpu
Tel +358 50 354 1189
ollikellokumpumetsocom
According to crushing contractor Pasi Ikola the cost-per-ton contract with Metso has provided the entrepreneur with better economical 1047298exibility
and more accurate calculating of bids
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Pleasant Gap is owned and operated by
Glenn O Hawbaker Inc of State College
Pennsylvania This family-owned company
began in 1952 as a small excavation busi-
ness founded by Glenn O Hawbaker and
his wife Thelma Over the years the com-
pany grew by adding an integrated mix ofproducts and services and taking on larger
projects
In 1983 Hawbaker acquired Pleasant
Gap Quarry and built its first aggregates
processing plant Today Glenn O Haw-
baker Inc operates 21 quarries and eight
asphalt production facilities across Penn-
sylvania and southern New York as well as
five regional operation centers
Primary
challenge atPleasant GapQuarryA good part of what makes for a successful crushing
operation is the willingness to tackle challenges and to do
whatrsquos necessary to meet demand The team at Pleasant
Gap Quarry in central Pennsylvania recently met the chal-
lenge when they successfully addressed problems with
the plantrsquos primary crushing plant First they purchased
a new Metso C160 jaw to replace the existing primary
impact crusher Then they devised an innovative plan to
get the primary plant back in operation while awaitingdelivery of the new jaw crusher
TEXT Linda Bergmann PHOTOS John Rickinger
983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Time for a change
With the goal of increasing reliability and
output the management at Pleasant Gap
Quarry recently decided it was time to
replace the plantrsquos primary impact crusher
Following a thorough search they chose a
new Metso C160 jaw According to ScottReck Plant Manager it no longer made
sense to repair and rebuild the existing
impactor
ldquoBefore we purchased the Metso C160
we had a few other impact crushers and
they served us well but as our custom-
ersrsquo needs increased our plant production
had to match that demand We found our
formerly reliable unit was being overcome
by our demands for output and creative
work-around solutions We continued to
need more but there was only so much we
could do until we hit the breaking point ndash
literallyrdquo
In addition to performance improve-
ments the new crusher also needed to fitinto Pleasant Gaprsquos unique infrastructure
As Plant Project ManagerEngineer Jeremy
Fahr explains ldquoOur height restraint was 274
meters (108rdquo) This height was the distance
from the feed lip of the existing 6x12 scalp-
ing screen and the existing structure that
the crusher rests onrdquo
The normal C160 crusher is 307
meters (121rdquo) tall but Metso gave GOH
Scott Reck Plant Manager (left) and
Jeremy Fahr Plant Project Manager
Engineer at Pleasant Gap Quarry
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983122983141983152983151983154983156983145983150983143 983154983141983155
a 10-degree mounting option (which is
normally used on their portable crushers)
to overcome the height restraint Reck and
Fahr worked with Dave Rhoa of Cleveland
Brothers Equipment Metsorsquos crushing and
screening distributor in Pennsylvania to
pull everything together and fit the newcrusher into their plant
The C160 crusher selected for Pleasant
Gap is one of the latest models in Metsorsquos
C Series of jaws These jaw crushers feature
a large throw and steep toggle plate angle
resulting in a higher crusher output In
addition the C Series has a compact foot-
print that makes it an ideal choice for the
replacement of existing machines
According to Reck ldquoWe had heard about
the new Metso C160 and started doing our
own research and found Metso not only
had developed the output capacity we
needed but fit the uniqueness of our oper-
ationsrdquo The new Metso crusher will allow
the plant to increase tons per hour andgive them the 1047298exibility to meet demands
for varying products on short notice
Mobile solution
Purchasing the new primary jaw addressed
the long-term issues but still left Pleasant
Gap without a functioning primary plant
Reck continues ldquoOur main line was still
down leaving us with a big hole in hitting
customer needs but knowing that our new
Metso C160 was on its wayhellipwe needed an
immediate solution to keep our produc-
tion demands with an out-of-commission
crusherrdquo
The team at Pleasant Gap brainstormed
the problem and came up with a plan toget the primary plant back in operation
Their solution was to use the Lokotrack
LT1213 impactor plant and another mobile
unit to keep the main line crushing To do
this they removed the guts on the existing
impact crusher essentially turning it into a
rock chute They then moved the LT1213
and another manufacturerrsquos mobile unit
over to the existing dump hopper gt
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
ldquoWe had our haul trucks drop off mate-
rial while two excavators fed the two
mobile unitsrdquo Reck explains ldquoFor two-and-
a-half months the Lokotrack LT1213 unit
was producing 254 cm (10rdquo) minus at
700 tons per hour The other similar-sized
mobile unit was doing 400 tons an hour
maxed out The difference was unbeliev-
able to say the least Our unique solution
using the two mobile units especially the
LT1213 helped Glenn O Hawbaker achieve
a record output in 2010rdquoAccording to Fahr ldquoWe were not new to
Metsorsquos quality and supportrdquo because GOH
had been using Metsorsquos portable crushing
equipment for 3 years prior to the primary
plantrsquos impact crusher failure In another
part of our operation we have a system that
our team relies on every day a Lokotrack
LT1213 and ST272 working in tandem with
two portable conveyorsrdquo This highly effi -
cient mobile processing system turns out
300 tons of specialized blended material
per hour GOH has been so impressed with
Metso equipment its last two purchaseswere an LT106 tracked jaw plant and a
second ST272 mobile screen in 2010
Maintaining high productivity
The Metso C160 jaw was delivered to Pleas-
ant Gap Quarry in January of 2011 and
since start-up it has more than met expec-
tations The crusher is fed minus 910 mm
(36rdquo) limestone with the jaw set at 140 mm
(5 12rdquo) According to Reck ldquoFrom moment
we started up we knew we had a winner
Not only were we kicking out as much
product as our previous units without even
breathing hard but we immediately had a
2-cent per ton savings to the bottom line
without having to run a second 350 HP
motor as required by other units Plus by
adding on the new automatic lube system
the maintenance team had more time to
devote to keeping other areas of the com-
plex running more effi cientlyrdquoReck says ldquoThe Metso unit was a perfect
fit and with the improved features it pre-
sented it had it all We just turn it on load
it up and we are moving 600 tons per hour
through the crusher without any effort and
we know it can do so much morerdquo With
the primary crushing plant back in opera-
tion the entire team at Pleasant Gap will
continue to do what they do best produce
and sell high-quality products and meet
their customersrsquo expectations
More info
Scott Yablonsky Tel +1 262 717 793
scottyablonskymetsocom
The Metso C160 jaw
was installed at a 10deg
angle to fit Pleasant
Gaprsquos existing
infrastructure
The Lokotrack LT1213 impactor plant and ST272 mobile screen operate in tandem with two
portable conveyors at Pleasant Gap
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983149983141983156983155983151 983150
Paper amp fiberNew OptiConcept M paper
and board making line
The new OptiConcept M paper and board
making line stands for economy safety and
usability
Metso has launched a new modular paper
and board making line called OptiConceptM A member of the proven OptiConcept
production line family the new OptiCon-
cept M optimizes machine investment in
line with each millrsquos capacity needs
Savings in operating costs are achieved
through precise dimensioning of pro-
cesses proven technological solutions
optimal running parameters effective
maintenance operations and fully inte-
grated automation solutions
Optimized processes innovations
smart controls and accurate dimensioning
decrease the use of steam gas electricitywater chemicals and other raw materials
and reduce emission levels
OptiConcept M has been designed
both visually and physically with the
requirements of users in mind For exam-
ple the design of the machinery allows for
easy and safe changing of rolls and wear
parts thus reducing the total duration and
cost of maintenance shutdowns
RecyclingGreen energy technology to
Elektrociepłownia Białystok in Poland
Metso will convert a coal-fired boiler to
a biomass-fired Bubbling Fluidized Bed
boiler for Elektrociepłownia Białystok SArsquos
combined heat and power plant (CHP) in
Białystok Poland The new boiler system
will cut the power plantrsquos CO2 emissions
significantly by partly replacing the coal
fuel supply with biomass fuel
ldquoPoland is one of the largest countries
in Europe to have such a high depend-ence on energy derived from coal to
meet national electricity needs This is an
important incentive for us to reduce future
CO2 emissions and produce more green
electricity and with Metso technology
we are certain to accomplish our goalrdquo
states Mr Andrzej Schroeder President of
Elektrociepłownia Białystok SA
Since 2000 Metso has received a total
of 7 biomass boiler conversion orders in
Poland and the renewable energy share
in Poland is only 75 (2010) compared to
the target of 20 by 2020 set by the EUApproximately 80 of the current energy
boilers turbines and generators installed in
Polish power plants are over 20 years old In
order to meet the strict EU environmental
requirements modernization of existing
installations is necessary
Automation
Metso DNA automation system expands
to mining and construction
Using Metsorsquos control room automation
an entire crushing and screening plant can
be effi ciently managed
Metso is a leading supplier of mining and
construction machinery This expertise has
now been combined with a scalable Metso
DNA automation system that adapts to
the range of industry needs from single
machine controls to plant-wide automation
and information management systems
An example of Metsorsquos new offering is a
new crushing plant control room solution
that connects crushers and screens ensur-
ing the effective management of the entire
plant from a pleasant and safe control
room The Metso DNA user interface pro-vides the production information to ensure
a proper and rapid response to plant
events Automatic controls stabilize the
process and allow the operators to monitor
the plant as a whole
ldquoThe benefits of automation for the min-
ing and construction industry are signifi-
cant As an example of the services we offer
performance studies to crushing plants
utilizing Metsorsquos multi-disciplinary teams of
experts to determine the present level of
the plant and process effi ciency and to esti-
mate the improvement potential and thebenefits of optimization and automation
including ROI calculationsrdquo says Mikko Maumlki-
nen Product Manager of minerals applica-
tions in Metsorsquos Automation business line
ldquoAs another example our machine
condition monitoring solutions can reduce
plant and machine downtimes as well as
help to avoid safety and environmental
hazardsrdquo he adds
Metso around the world
Aerial view of the Elektrociepłownia Białystok combined heat and power plant in Poland
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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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Services success in Surabaya The Metso Surabaya workshop and offi ce complex opened in April 2008 provides Life Cycle Services and maintenance
solutions for Metso equipment in the Indonesia region The facility is strategically located in an industrial precinct on theouter rim of Surabaya the second largest city in Indonesia Its close proximity to an international airport major shipping
port and several engineering companies simplifies support for the regionrsquos key customers which include PT Newmont
and PT Freeport
TEXT amp PHOTOS David LeRoy amp Gary Whittred
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983122983141983152983151983154983156983145983150983143 983154983141983155
The Surabaya site operates through Metso
in Australia with assistance from key sales
and technical staff Handling regional ser-vice and repair business in-house allows
Metso to manage intellectual property and
closely control quality
It also enables the development of a
team of skilled service personnel who can
be utilized both internally and at key cus-
tomer sites as is common with the backup
service the workshop provides for screen
contracts
Innovation at work
Since 2008 the Surabaya facility has suc-
cessfully refurbished a wide variety ofcomponents Recently two ball mill heads
weighing 22 tons each were modified in
order to strengthen the 1047298ange of the ball
mill shell The modification included tap-
ping out existing 1047298ange holes and drilling
new ones so that finger plates could be
installed and welded to the 1047298anges
Positioning the head borer to properly
align the new 1047298ange holes proved diffi cult
Four roller support frames were manufac-
tured to support the heads and allow them
to be rotated easily Each hole was then
drilled and tapped at the correct angleusing the CNC five axis head The job had a
tight delivery as it was required for a shut-
down but with advance planning and inno-
vation it was completed ahead of schedule
MP1000 mainframe on
CNC vertical borer
Well equipped for fabricating and machin-
ing heavy components the Surabaya
The Surabaya facility has proven to be
a success for Metso The workshop offers a
wide variety of services in the region Qual-ity products and competitive pricing and
delivery times have led to strong customer
relationships
Turnover and customer service levels
have increased annually since the open-
ing and between 2008 and 2010 sales
increased 450 These excellent trends
are expected to continue as the operation
expands and the customer base grows
Since 2008 the Surabaya facility has
successfully refurbished
bull MP1000 counter shaft boxes headassemblies mainframes bowls adjust-
ment rings counterweights sockets and
tramp release cylinders
bull 7rsquo Symons bowls heads and countershaft
boxes
bull Vertimill screw and drive shafts
bull Ball mill heads
bull Ball mill trommel
bull VPA cylinders
bull Eaton clutches
bull Exciter screen mechanisms
bull 42x65 main shafts and eccentrics
More info
Gary Whittred
Tel +62 31 8430349
garywhittredmetsocom
workshop handles the majority of Metsorsquos
refurbishment work with ease But when
necessary PT PAL ndash a government facilitywith shipbuilding and heavy engineering
capabilities ndash offers a ldquoone stop shoprdquo Spe-
cially trained PT PAL staff ensures that the
work they perform complies with all Metso
specifications and quality standards
PT PAL also demonstrated their innova-
tive ability with the first MP1000 main-
frame refurbishment they completed The
mainframersquos shaft location bore needed
to be re-machined However the distance
from the top of the mainframe to the
tapered bore made it very hard to achieve
an accurate surface finish with the correctstandoff
To overcome this the shop decided to
machine the mainframe upside down and
elevated on support beams They posi-
tioned a new shaft under the mainframe in
a custom-made cradle Using an overhead
crane they could then lsquotrial fitrsquo the shaft in
the bore to make sure it seated correctly
and the mating tapers met specification
The method worked so well it has since
been used for four more mainframe refur-
bishments
Diversity and growth
Today Metso Surabaya continues to invest
in additional equipment in order to diver-
sify its service offering A new hydraulic
power pack which allows the facility to test
refurbished components to Metso specifi-
cations was recently used in the refurbish-
ment and testing of several VPA cylinders
for PT Freeport
Refurbished MP1000 mainframe dispatched by truck to
PT Freeport mine
Machining of MP1000 upper frame
at Metsorsquos Surabaya workshop
Mainframe at vertical CNC machining
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Creating Value with Metso in Hong KongIn Hong Kong the aggregates needed for construction are mostly supplied by two local quarries KWP Quarry Company
Limitedrsquos Anderson Road Quarry accounts for 60ndash70 making it the pillar of Hong Kongrsquos construction materials industry
TEXT amp PHOTOS Ou He
When arriving at the Anderson Road
Quarry the most impressive view at the850000 square-meter facility is the Metso
machines including equipment from the
primary secondary and tertiary crushing
circuits and the screens I t is Metsorsquos equip-
ment that secures the supply of aggregates
for Hong Kong
KWP Quarry Company Limited has been
working with Metso since its establishment
in 1997
Due to Hong Kongrsquos stringent dust and noise control standards Metso has paid special attention to the related suppression systems
ldquoOur quarry mainly lies on granite and
volcanic rock which are so hard they canonly be processed by equipment with
strong durability and stabilityrdquo explains
Mr Eddie Hung Manager of KWP ldquoWith a
long history of and experience in quarry-
ing we are very familiar with the equip-
ment of different brands Comparatively
Metsorsquos products are better than others in
terms of durability stability and effi ciency
Besides this the reason we selected Metso
is because of the simple maintenance of
their equipment and the easy access tomaintenance informationrdquo
Flexible modular solution
Based on extensive experience in crushing
and screening worldwide Metso presented
the Anderson Road Quarry with a modu-
lar solution and delivered it as a turn-key
project Through a four-stage crushing
circuit which contains three Metso C160
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983122983141983152983151983154983156983145983150983143 983154983141983155
jaw crushers for primary crushing two
Omnicone 1560SX crushers for secondary
crushing two HP 500SX cone crushers for
tertiary crushing and one HP500SX cone
crusher for extra-fine crushing the plant
was able to produce aggregates of optimal
shape with minimal 1047298akiness
The fine products include three sizes
0 to 5 mm 5 to 10 mm and 10 to 20mm
Since the employment of this system in
2000 production has reached 1250 th
which is far beyond the design capacityAccording to Mr Hung ldquoThe machines
always run effi ciently and seldom malfunc-
tion The occasional shutdown of some
machines does not affect production very
much the plant still could reach 60-70
of its normal production It gives us the
best 1047298exibility for the plant rsquos operation and
I believe this is the best feature of Metsorsquos
solution
Eddie Hung
Manager of KWPrsquos
Anderson Road
Quarry is happy with
the product quality
and service provided
by Metso
ldquoMetsorsquos equipment is expensive com-
paratively but in the long run you will find
that the investment is worthwhile on the
whole Metso secures superior stability reli-
ability and fewer downtimes and it guaran-
tees continuous operation and brings us
greater valuerdquo
Great service team
Metso sent a group of service engineers
to the plant within the warranty period
not only to provide service but to train theoperators Mr Hung speaks highly of Met-
sorsquos service team he is impressed with its
experienced experts and with their strong
sense of responsibility and customer-
oriented ways of working
ldquoMetsorsquos service team never fails to find
hidden problems and helps us to prevent
any mechanical failures And they are
available whenever we need them they
work closely with us to solve the problem
effi cientlyrdquo he said
Excellent environment-friendly designIn order to achieve the worldrsquos most strin-
gent noise and dust control standards
developed by the Environment Protection
Department of Hong Kong Metso has
incorporated a dust and noise suppression
system into the plant This includes the
infrared-triggered spray systems at feed
points encapsulation of individual crush-
ers and conveyors and the ability to select
specific sectors of the system for treatment
depending on feed and operating condi-
tions encapsulation of equipment and the
enclosure of all major sections of the plant
With these advanced environment-
friendly solutions Anderson Road Quarry
has won numerous safety and environmen-
tal awards In 2003 it was presented with a
silver medal in the prestigious Environmen-
tal Performance Awards in recognition of
its commitment to the environment and
community In 2004 KWP achieved certifi-cation of ISO 14001 it is the first quarry site
to have achieved this in Hong Kong and
southern China
ldquoA reliable partnerrdquo
The promulgation of the top ten infrastruc-
ture policies in Hong Kong boosted the
market for aggregates and demand will
keep rising over the next five to six years
ldquoWersquoll definitely keep our cooperation with
Metso once we have a need for expansion
because we regard Metso as a reliable part-
ner With their highly effi cient equipmentsatisfying service and great efforts in help-
ing us to achieve our environmental pro-
tection targets Metso is our best choicerdquo
says Hung
More info
Ziqiang Li
Tel +86 13601289027
ziqianglimetsocom
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The sturdy Metso C160
jaw crushers are fed
using huge feed chutes
and feeders
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Similar to hundreds of mine sites world-
wide Zinkgruvan is being operated on a
non-stop 247 basis with just a few main-
tenance breaks during the year Crusher
availability is crucial because 100 of the
ore has to pass through the jaws before
being hoisted up for further processing
In addition to the zinc- lead- copper-
and silver-containing ore the C jaws chop
all the host rock extracted along the min-
ing process With a sturdy design Metsorsquos
proven C jaws can easily reduce even the
hardest type of rock Every year more thanone million tons are crushed with the jaws
ldquoMinimal service neededrdquo
Crushing with the first C160B jaw crusher
began at Zinkgruvanrsquos -800 meter level in
2000 with the primary crushing of zinc-lead
ore The second jaw was installed in 2008
for the new copper process gt
The sight and sound of two C160 jaw crushers operating side by side in the underground
crushing station of the Swedish Zinkgruvan mine is impressive Good proactive service
secures good uptime and reliable continuous operation of Metsorsquos second-largest
C160 series jaw crushers and prepares the way for the ongoing plans to expand the
production of zinc concentrate
TEXT amp PHOTOS Eero Haumlmaumllaumlinen
New PolyMet liners are being tested with the grinding mill delivered by Metso
Zinkgruvanrsquos twin C160
jaws secure good uptime
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Blasted ore is taken from the presently
operated -850 meter level with normal
trucks as an outsourced process One full
truckload is fed to the C160s every
10 minutes
ldquoWe are happy with the high reliability
of the C jaws They only require some minor
service therefore providing us with good
uptime and steady continuous feed to our
secondary and tertiary crushing and grind-ing circuitsrdquo says Mine Manager Jan Klaumlre
ldquoBasic crusher service and wear part
changes are made by our own staff using
Metsorsquos partsrdquo he adds
Service contract with grinding
mills and conveyors
Zinkgruvan and Metso Sweden have more
than 11 yearsrsquo experience with a service
contract that contains grinding mills and
conveyors At the mine site two Metso
service people and one contractor take
care of all the related service jobs Man-
power can also be borrowed from Metsorsquos
Graumlngesberg mine service team of 20
people
Presently Zinkgruvan is testing Metsorsquos
new PolyMet mill linings in its big grinding
mills With previously used rubber partsthe linings had to be changed in the shell
every 9 to 11 months and in the feed head
every 6 months
ldquoWe expect a better lifetime with Poly-
Met linings Longer change intervals mean
a lot to our productivity because lining
changes takes two full working daysrdquo Mine
Manager Jan Klaumlre says
New mine goes deeper
With an expected mine life of more than 10
years Zinkgruvan is actively mapping new
ore reserves Experimental holes are being
drilled at the new mine section at the
-1110 meter level
More info
Fredrik Wennberg
Tel +46 70 657 00 08fredrikwennbergmetsocom
Mine Manager Jan Klaumlre (left) with Backfilling Manager Kjell Tillman at the underground -800 meter level mine cafeteria
983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
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The Zinkgruvan mine located approxi-
mately 200 km southwest of Stockholm
Sweden is one of the oldest underground
mines in Northern Europe The mine has
been in production since 1857
The mining methods used are panel
stoping and benching The processing
facilities include a zinc concentrating plant
with a 11 mtpa and a copper plant with a04 mtpa capacity Tailings are recycled in
an impounding basin and host rock in the
backfill plant
Continuous mining since 1857
Even as one of the oldest mines in Northern
Europe Zinkgruvan exploits modern mining
and minerals processing installations
Zinkgruvan mine
OWNER Lundin Mining
PRODUCTION PER YEAR 1 million tons
ORE TYPE sedimentary exhalative
zinc lead copper and silver
NUMBER OF EMPLOYEES 320
2011 PRODUCTION TARGETS 78000 tonsof zinc 36000 tons of lead and
3400 tons of copper concentrate
METSO EQUIPMENT ON SITE
bull 1 extra long VF feeder
bull 2 C160 jaw crushers
ndash zinc process css 220ndash240 mm
ndash copper process css 150 mm
bull 1 GP300S cone crusher
ndash css 45mm
bull 1 HP4 cone crusher
ndash css 18 mm
bull 1 DS screen
bull 1 FS402 screenbull 1 grinding mill
bull Pumps VPAs
A normal truck feeds the C jaws with ore coming from the lower production levels
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Cost-per-ton wear agreements deepencustomer relationshipsCrusher wear parts are traditionally marketed purely based on transactional sales and mainly depend on
the weight of manganese Metso has recently introduced a new type of wear agreement based on thecost-per-ton crushed and the wear occurred Thus far the experience has been very positive increasing
transparency and deepening the operational relationship between the manufacturer and the customer
TEXT Olli Kellokumpu and Eero Haumlmaumllaumlinen PHOTOS Eero Haumlmaumllaumlinen
Arto Hiedanniemi (left)
Hannu Heman and Juha
Laukka of Metsorsquos Finnish
Service team checking the
cone crusher mantles shipped
for a cost-per-ton customer
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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156
Wear parts and parts changes
can be included
The structure of a cost-per-ton wearcontract is based on the number of tons
crushed and the estimated wear occurred
The amount and monetary value of the
wear is calculated per crushed ton
ldquoEither plain wear parts or parts changes
carried out by Metsorsquos service personnel
can be included in the contract In the latter
case we ask our Finnish customers to inform
us about an upcoming wear change opera-
tion one week in advancerdquo Heman explains
ldquoWe see good opportunities to market
cost-per-ton contracts further in Finland
and also abroad It really develops therelationship of Metso and our customers
towards a trusted partnershiprdquo he notes
Perfect tool for accurate planning
Soraliike Ikola Oy is a mid-sized contrac-
tor with three Metso two- and three-
stage mobile and portable crushing and
screening plants operating in Central and
Since 2002 Metsorsquos sales team in Finland
has developed the cost-per-ton-based
service offeringldquoOur aim has been to seek through
a cost-per-ton offering possibilities to
serve our customers better to differentiate
Metso from the other players as an OEM
manufacturer and to offer deeper profes-
sionalism and know-howrdquo says Hannu
Heman General Manager of service
operations
ldquoUntil now both our experience and
that of our customers has been quite posi-
tive When properly prepared cost-per-ton
contracts seem to create a win-win situa-
tionrdquo Heman adds Today Metso has operational cost-per-
ton agreements with several Finnish cus-
tomers The first contract was concluded
with a customer operating a stationary
plant Based on the results gathered new
cost-per-ton contracts have been signed
with customers operating wheeled and
tracked equipment too
Eastern Finland Because of the size of the
contracts up to 50 equipment moves are
made during the yearEntrepreneur Pasi Ikola has had a cost-
per-ton contract with Metso for nearly
two years and he is quite happy with the
outcome
ldquoThe cost-per-ton contract has provided
me with a perfect tool for accurate financial
planning Now I know in detail my actual
future wear parts costs This helps a lot
when calculating bidsrdquo
ldquoEarlier I used to buy a big batch of
Metso wear parts in one go and had to
reserve a reasonable amount of money for
that Today all wear costs are evenly sharedwhich gives us a welcomed 1047298exibility to
our cost structure Now we just pay Metso
afterwards based on our crushed tonsrdquo
he adds
More info
Olli Kellokumpu
Tel +358 50 354 1189
ollikellokumpumetsocom
According to crushing contractor Pasi Ikola the cost-per-ton contract with Metso has provided the entrepreneur with better economical 1047298exibility
and more accurate calculating of bids
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Pleasant Gap is owned and operated by
Glenn O Hawbaker Inc of State College
Pennsylvania This family-owned company
began in 1952 as a small excavation busi-
ness founded by Glenn O Hawbaker and
his wife Thelma Over the years the com-
pany grew by adding an integrated mix ofproducts and services and taking on larger
projects
In 1983 Hawbaker acquired Pleasant
Gap Quarry and built its first aggregates
processing plant Today Glenn O Haw-
baker Inc operates 21 quarries and eight
asphalt production facilities across Penn-
sylvania and southern New York as well as
five regional operation centers
Primary
challenge atPleasant GapQuarryA good part of what makes for a successful crushing
operation is the willingness to tackle challenges and to do
whatrsquos necessary to meet demand The team at Pleasant
Gap Quarry in central Pennsylvania recently met the chal-
lenge when they successfully addressed problems with
the plantrsquos primary crushing plant First they purchased
a new Metso C160 jaw to replace the existing primary
impact crusher Then they devised an innovative plan to
get the primary plant back in operation while awaitingdelivery of the new jaw crusher
TEXT Linda Bergmann PHOTOS John Rickinger
983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Time for a change
With the goal of increasing reliability and
output the management at Pleasant Gap
Quarry recently decided it was time to
replace the plantrsquos primary impact crusher
Following a thorough search they chose a
new Metso C160 jaw According to ScottReck Plant Manager it no longer made
sense to repair and rebuild the existing
impactor
ldquoBefore we purchased the Metso C160
we had a few other impact crushers and
they served us well but as our custom-
ersrsquo needs increased our plant production
had to match that demand We found our
formerly reliable unit was being overcome
by our demands for output and creative
work-around solutions We continued to
need more but there was only so much we
could do until we hit the breaking point ndash
literallyrdquo
In addition to performance improve-
ments the new crusher also needed to fitinto Pleasant Gaprsquos unique infrastructure
As Plant Project ManagerEngineer Jeremy
Fahr explains ldquoOur height restraint was 274
meters (108rdquo) This height was the distance
from the feed lip of the existing 6x12 scalp-
ing screen and the existing structure that
the crusher rests onrdquo
The normal C160 crusher is 307
meters (121rdquo) tall but Metso gave GOH
Scott Reck Plant Manager (left) and
Jeremy Fahr Plant Project Manager
Engineer at Pleasant Gap Quarry
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983122983141983152983151983154983156983145983150983143 983154983141983155
a 10-degree mounting option (which is
normally used on their portable crushers)
to overcome the height restraint Reck and
Fahr worked with Dave Rhoa of Cleveland
Brothers Equipment Metsorsquos crushing and
screening distributor in Pennsylvania to
pull everything together and fit the newcrusher into their plant
The C160 crusher selected for Pleasant
Gap is one of the latest models in Metsorsquos
C Series of jaws These jaw crushers feature
a large throw and steep toggle plate angle
resulting in a higher crusher output In
addition the C Series has a compact foot-
print that makes it an ideal choice for the
replacement of existing machines
According to Reck ldquoWe had heard about
the new Metso C160 and started doing our
own research and found Metso not only
had developed the output capacity we
needed but fit the uniqueness of our oper-
ationsrdquo The new Metso crusher will allow
the plant to increase tons per hour andgive them the 1047298exibility to meet demands
for varying products on short notice
Mobile solution
Purchasing the new primary jaw addressed
the long-term issues but still left Pleasant
Gap without a functioning primary plant
Reck continues ldquoOur main line was still
down leaving us with a big hole in hitting
customer needs but knowing that our new
Metso C160 was on its wayhellipwe needed an
immediate solution to keep our produc-
tion demands with an out-of-commission
crusherrdquo
The team at Pleasant Gap brainstormed
the problem and came up with a plan toget the primary plant back in operation
Their solution was to use the Lokotrack
LT1213 impactor plant and another mobile
unit to keep the main line crushing To do
this they removed the guts on the existing
impact crusher essentially turning it into a
rock chute They then moved the LT1213
and another manufacturerrsquos mobile unit
over to the existing dump hopper gt
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
ldquoWe had our haul trucks drop off mate-
rial while two excavators fed the two
mobile unitsrdquo Reck explains ldquoFor two-and-
a-half months the Lokotrack LT1213 unit
was producing 254 cm (10rdquo) minus at
700 tons per hour The other similar-sized
mobile unit was doing 400 tons an hour
maxed out The difference was unbeliev-
able to say the least Our unique solution
using the two mobile units especially the
LT1213 helped Glenn O Hawbaker achieve
a record output in 2010rdquoAccording to Fahr ldquoWe were not new to
Metsorsquos quality and supportrdquo because GOH
had been using Metsorsquos portable crushing
equipment for 3 years prior to the primary
plantrsquos impact crusher failure In another
part of our operation we have a system that
our team relies on every day a Lokotrack
LT1213 and ST272 working in tandem with
two portable conveyorsrdquo This highly effi -
cient mobile processing system turns out
300 tons of specialized blended material
per hour GOH has been so impressed with
Metso equipment its last two purchaseswere an LT106 tracked jaw plant and a
second ST272 mobile screen in 2010
Maintaining high productivity
The Metso C160 jaw was delivered to Pleas-
ant Gap Quarry in January of 2011 and
since start-up it has more than met expec-
tations The crusher is fed minus 910 mm
(36rdquo) limestone with the jaw set at 140 mm
(5 12rdquo) According to Reck ldquoFrom moment
we started up we knew we had a winner
Not only were we kicking out as much
product as our previous units without even
breathing hard but we immediately had a
2-cent per ton savings to the bottom line
without having to run a second 350 HP
motor as required by other units Plus by
adding on the new automatic lube system
the maintenance team had more time to
devote to keeping other areas of the com-
plex running more effi cientlyrdquoReck says ldquoThe Metso unit was a perfect
fit and with the improved features it pre-
sented it had it all We just turn it on load
it up and we are moving 600 tons per hour
through the crusher without any effort and
we know it can do so much morerdquo With
the primary crushing plant back in opera-
tion the entire team at Pleasant Gap will
continue to do what they do best produce
and sell high-quality products and meet
their customersrsquo expectations
More info
Scott Yablonsky Tel +1 262 717 793
scottyablonskymetsocom
The Metso C160 jaw
was installed at a 10deg
angle to fit Pleasant
Gaprsquos existing
infrastructure
The Lokotrack LT1213 impactor plant and ST272 mobile screen operate in tandem with two
portable conveyors at Pleasant Gap
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983149983141983156983155983151 983150
Paper amp fiberNew OptiConcept M paper
and board making line
The new OptiConcept M paper and board
making line stands for economy safety and
usability
Metso has launched a new modular paper
and board making line called OptiConceptM A member of the proven OptiConcept
production line family the new OptiCon-
cept M optimizes machine investment in
line with each millrsquos capacity needs
Savings in operating costs are achieved
through precise dimensioning of pro-
cesses proven technological solutions
optimal running parameters effective
maintenance operations and fully inte-
grated automation solutions
Optimized processes innovations
smart controls and accurate dimensioning
decrease the use of steam gas electricitywater chemicals and other raw materials
and reduce emission levels
OptiConcept M has been designed
both visually and physically with the
requirements of users in mind For exam-
ple the design of the machinery allows for
easy and safe changing of rolls and wear
parts thus reducing the total duration and
cost of maintenance shutdowns
RecyclingGreen energy technology to
Elektrociepłownia Białystok in Poland
Metso will convert a coal-fired boiler to
a biomass-fired Bubbling Fluidized Bed
boiler for Elektrociepłownia Białystok SArsquos
combined heat and power plant (CHP) in
Białystok Poland The new boiler system
will cut the power plantrsquos CO2 emissions
significantly by partly replacing the coal
fuel supply with biomass fuel
ldquoPoland is one of the largest countries
in Europe to have such a high depend-ence on energy derived from coal to
meet national electricity needs This is an
important incentive for us to reduce future
CO2 emissions and produce more green
electricity and with Metso technology
we are certain to accomplish our goalrdquo
states Mr Andrzej Schroeder President of
Elektrociepłownia Białystok SA
Since 2000 Metso has received a total
of 7 biomass boiler conversion orders in
Poland and the renewable energy share
in Poland is only 75 (2010) compared to
the target of 20 by 2020 set by the EUApproximately 80 of the current energy
boilers turbines and generators installed in
Polish power plants are over 20 years old In
order to meet the strict EU environmental
requirements modernization of existing
installations is necessary
Automation
Metso DNA automation system expands
to mining and construction
Using Metsorsquos control room automation
an entire crushing and screening plant can
be effi ciently managed
Metso is a leading supplier of mining and
construction machinery This expertise has
now been combined with a scalable Metso
DNA automation system that adapts to
the range of industry needs from single
machine controls to plant-wide automation
and information management systems
An example of Metsorsquos new offering is a
new crushing plant control room solution
that connects crushers and screens ensur-
ing the effective management of the entire
plant from a pleasant and safe control
room The Metso DNA user interface pro-vides the production information to ensure
a proper and rapid response to plant
events Automatic controls stabilize the
process and allow the operators to monitor
the plant as a whole
ldquoThe benefits of automation for the min-
ing and construction industry are signifi-
cant As an example of the services we offer
performance studies to crushing plants
utilizing Metsorsquos multi-disciplinary teams of
experts to determine the present level of
the plant and process effi ciency and to esti-
mate the improvement potential and thebenefits of optimization and automation
including ROI calculationsrdquo says Mikko Maumlki-
nen Product Manager of minerals applica-
tions in Metsorsquos Automation business line
ldquoAs another example our machine
condition monitoring solutions can reduce
plant and machine downtimes as well as
help to avoid safety and environmental
hazardsrdquo he adds
Metso around the world
Aerial view of the Elektrociepłownia Białystok combined heat and power plant in Poland
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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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983122983141983152983151983154983156983145983150983143 983154983141983155
The Surabaya site operates through Metso
in Australia with assistance from key sales
and technical staff Handling regional ser-vice and repair business in-house allows
Metso to manage intellectual property and
closely control quality
It also enables the development of a
team of skilled service personnel who can
be utilized both internally and at key cus-
tomer sites as is common with the backup
service the workshop provides for screen
contracts
Innovation at work
Since 2008 the Surabaya facility has suc-
cessfully refurbished a wide variety ofcomponents Recently two ball mill heads
weighing 22 tons each were modified in
order to strengthen the 1047298ange of the ball
mill shell The modification included tap-
ping out existing 1047298ange holes and drilling
new ones so that finger plates could be
installed and welded to the 1047298anges
Positioning the head borer to properly
align the new 1047298ange holes proved diffi cult
Four roller support frames were manufac-
tured to support the heads and allow them
to be rotated easily Each hole was then
drilled and tapped at the correct angleusing the CNC five axis head The job had a
tight delivery as it was required for a shut-
down but with advance planning and inno-
vation it was completed ahead of schedule
MP1000 mainframe on
CNC vertical borer
Well equipped for fabricating and machin-
ing heavy components the Surabaya
The Surabaya facility has proven to be
a success for Metso The workshop offers a
wide variety of services in the region Qual-ity products and competitive pricing and
delivery times have led to strong customer
relationships
Turnover and customer service levels
have increased annually since the open-
ing and between 2008 and 2010 sales
increased 450 These excellent trends
are expected to continue as the operation
expands and the customer base grows
Since 2008 the Surabaya facility has
successfully refurbished
bull MP1000 counter shaft boxes headassemblies mainframes bowls adjust-
ment rings counterweights sockets and
tramp release cylinders
bull 7rsquo Symons bowls heads and countershaft
boxes
bull Vertimill screw and drive shafts
bull Ball mill heads
bull Ball mill trommel
bull VPA cylinders
bull Eaton clutches
bull Exciter screen mechanisms
bull 42x65 main shafts and eccentrics
More info
Gary Whittred
Tel +62 31 8430349
garywhittredmetsocom
workshop handles the majority of Metsorsquos
refurbishment work with ease But when
necessary PT PAL ndash a government facilitywith shipbuilding and heavy engineering
capabilities ndash offers a ldquoone stop shoprdquo Spe-
cially trained PT PAL staff ensures that the
work they perform complies with all Metso
specifications and quality standards
PT PAL also demonstrated their innova-
tive ability with the first MP1000 main-
frame refurbishment they completed The
mainframersquos shaft location bore needed
to be re-machined However the distance
from the top of the mainframe to the
tapered bore made it very hard to achieve
an accurate surface finish with the correctstandoff
To overcome this the shop decided to
machine the mainframe upside down and
elevated on support beams They posi-
tioned a new shaft under the mainframe in
a custom-made cradle Using an overhead
crane they could then lsquotrial fitrsquo the shaft in
the bore to make sure it seated correctly
and the mating tapers met specification
The method worked so well it has since
been used for four more mainframe refur-
bishments
Diversity and growth
Today Metso Surabaya continues to invest
in additional equipment in order to diver-
sify its service offering A new hydraulic
power pack which allows the facility to test
refurbished components to Metso specifi-
cations was recently used in the refurbish-
ment and testing of several VPA cylinders
for PT Freeport
Refurbished MP1000 mainframe dispatched by truck to
PT Freeport mine
Machining of MP1000 upper frame
at Metsorsquos Surabaya workshop
Mainframe at vertical CNC machining
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Creating Value with Metso in Hong KongIn Hong Kong the aggregates needed for construction are mostly supplied by two local quarries KWP Quarry Company
Limitedrsquos Anderson Road Quarry accounts for 60ndash70 making it the pillar of Hong Kongrsquos construction materials industry
TEXT amp PHOTOS Ou He
When arriving at the Anderson Road
Quarry the most impressive view at the850000 square-meter facility is the Metso
machines including equipment from the
primary secondary and tertiary crushing
circuits and the screens I t is Metsorsquos equip-
ment that secures the supply of aggregates
for Hong Kong
KWP Quarry Company Limited has been
working with Metso since its establishment
in 1997
Due to Hong Kongrsquos stringent dust and noise control standards Metso has paid special attention to the related suppression systems
ldquoOur quarry mainly lies on granite and
volcanic rock which are so hard they canonly be processed by equipment with
strong durability and stabilityrdquo explains
Mr Eddie Hung Manager of KWP ldquoWith a
long history of and experience in quarry-
ing we are very familiar with the equip-
ment of different brands Comparatively
Metsorsquos products are better than others in
terms of durability stability and effi ciency
Besides this the reason we selected Metso
is because of the simple maintenance of
their equipment and the easy access tomaintenance informationrdquo
Flexible modular solution
Based on extensive experience in crushing
and screening worldwide Metso presented
the Anderson Road Quarry with a modu-
lar solution and delivered it as a turn-key
project Through a four-stage crushing
circuit which contains three Metso C160
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jaw crushers for primary crushing two
Omnicone 1560SX crushers for secondary
crushing two HP 500SX cone crushers for
tertiary crushing and one HP500SX cone
crusher for extra-fine crushing the plant
was able to produce aggregates of optimal
shape with minimal 1047298akiness
The fine products include three sizes
0 to 5 mm 5 to 10 mm and 10 to 20mm
Since the employment of this system in
2000 production has reached 1250 th
which is far beyond the design capacityAccording to Mr Hung ldquoThe machines
always run effi ciently and seldom malfunc-
tion The occasional shutdown of some
machines does not affect production very
much the plant still could reach 60-70
of its normal production It gives us the
best 1047298exibility for the plant rsquos operation and
I believe this is the best feature of Metsorsquos
solution
Eddie Hung
Manager of KWPrsquos
Anderson Road
Quarry is happy with
the product quality
and service provided
by Metso
ldquoMetsorsquos equipment is expensive com-
paratively but in the long run you will find
that the investment is worthwhile on the
whole Metso secures superior stability reli-
ability and fewer downtimes and it guaran-
tees continuous operation and brings us
greater valuerdquo
Great service team
Metso sent a group of service engineers
to the plant within the warranty period
not only to provide service but to train theoperators Mr Hung speaks highly of Met-
sorsquos service team he is impressed with its
experienced experts and with their strong
sense of responsibility and customer-
oriented ways of working
ldquoMetsorsquos service team never fails to find
hidden problems and helps us to prevent
any mechanical failures And they are
available whenever we need them they
work closely with us to solve the problem
effi cientlyrdquo he said
Excellent environment-friendly designIn order to achieve the worldrsquos most strin-
gent noise and dust control standards
developed by the Environment Protection
Department of Hong Kong Metso has
incorporated a dust and noise suppression
system into the plant This includes the
infrared-triggered spray systems at feed
points encapsulation of individual crush-
ers and conveyors and the ability to select
specific sectors of the system for treatment
depending on feed and operating condi-
tions encapsulation of equipment and the
enclosure of all major sections of the plant
With these advanced environment-
friendly solutions Anderson Road Quarry
has won numerous safety and environmen-
tal awards In 2003 it was presented with a
silver medal in the prestigious Environmen-
tal Performance Awards in recognition of
its commitment to the environment and
community In 2004 KWP achieved certifi-cation of ISO 14001 it is the first quarry site
to have achieved this in Hong Kong and
southern China
ldquoA reliable partnerrdquo
The promulgation of the top ten infrastruc-
ture policies in Hong Kong boosted the
market for aggregates and demand will
keep rising over the next five to six years
ldquoWersquoll definitely keep our cooperation with
Metso once we have a need for expansion
because we regard Metso as a reliable part-
ner With their highly effi cient equipmentsatisfying service and great efforts in help-
ing us to achieve our environmental pro-
tection targets Metso is our best choicerdquo
says Hung
More info
Ziqiang Li
Tel +86 13601289027
ziqianglimetsocom
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The sturdy Metso C160
jaw crushers are fed
using huge feed chutes
and feeders
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Similar to hundreds of mine sites world-
wide Zinkgruvan is being operated on a
non-stop 247 basis with just a few main-
tenance breaks during the year Crusher
availability is crucial because 100 of the
ore has to pass through the jaws before
being hoisted up for further processing
In addition to the zinc- lead- copper-
and silver-containing ore the C jaws chop
all the host rock extracted along the min-
ing process With a sturdy design Metsorsquos
proven C jaws can easily reduce even the
hardest type of rock Every year more thanone million tons are crushed with the jaws
ldquoMinimal service neededrdquo
Crushing with the first C160B jaw crusher
began at Zinkgruvanrsquos -800 meter level in
2000 with the primary crushing of zinc-lead
ore The second jaw was installed in 2008
for the new copper process gt
The sight and sound of two C160 jaw crushers operating side by side in the underground
crushing station of the Swedish Zinkgruvan mine is impressive Good proactive service
secures good uptime and reliable continuous operation of Metsorsquos second-largest
C160 series jaw crushers and prepares the way for the ongoing plans to expand the
production of zinc concentrate
TEXT amp PHOTOS Eero Haumlmaumllaumlinen
New PolyMet liners are being tested with the grinding mill delivered by Metso
Zinkgruvanrsquos twin C160
jaws secure good uptime
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Blasted ore is taken from the presently
operated -850 meter level with normal
trucks as an outsourced process One full
truckload is fed to the C160s every
10 minutes
ldquoWe are happy with the high reliability
of the C jaws They only require some minor
service therefore providing us with good
uptime and steady continuous feed to our
secondary and tertiary crushing and grind-ing circuitsrdquo says Mine Manager Jan Klaumlre
ldquoBasic crusher service and wear part
changes are made by our own staff using
Metsorsquos partsrdquo he adds
Service contract with grinding
mills and conveyors
Zinkgruvan and Metso Sweden have more
than 11 yearsrsquo experience with a service
contract that contains grinding mills and
conveyors At the mine site two Metso
service people and one contractor take
care of all the related service jobs Man-
power can also be borrowed from Metsorsquos
Graumlngesberg mine service team of 20
people
Presently Zinkgruvan is testing Metsorsquos
new PolyMet mill linings in its big grinding
mills With previously used rubber partsthe linings had to be changed in the shell
every 9 to 11 months and in the feed head
every 6 months
ldquoWe expect a better lifetime with Poly-
Met linings Longer change intervals mean
a lot to our productivity because lining
changes takes two full working daysrdquo Mine
Manager Jan Klaumlre says
New mine goes deeper
With an expected mine life of more than 10
years Zinkgruvan is actively mapping new
ore reserves Experimental holes are being
drilled at the new mine section at the
-1110 meter level
More info
Fredrik Wennberg
Tel +46 70 657 00 08fredrikwennbergmetsocom
Mine Manager Jan Klaumlre (left) with Backfilling Manager Kjell Tillman at the underground -800 meter level mine cafeteria
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The Zinkgruvan mine located approxi-
mately 200 km southwest of Stockholm
Sweden is one of the oldest underground
mines in Northern Europe The mine has
been in production since 1857
The mining methods used are panel
stoping and benching The processing
facilities include a zinc concentrating plant
with a 11 mtpa and a copper plant with a04 mtpa capacity Tailings are recycled in
an impounding basin and host rock in the
backfill plant
Continuous mining since 1857
Even as one of the oldest mines in Northern
Europe Zinkgruvan exploits modern mining
and minerals processing installations
Zinkgruvan mine
OWNER Lundin Mining
PRODUCTION PER YEAR 1 million tons
ORE TYPE sedimentary exhalative
zinc lead copper and silver
NUMBER OF EMPLOYEES 320
2011 PRODUCTION TARGETS 78000 tonsof zinc 36000 tons of lead and
3400 tons of copper concentrate
METSO EQUIPMENT ON SITE
bull 1 extra long VF feeder
bull 2 C160 jaw crushers
ndash zinc process css 220ndash240 mm
ndash copper process css 150 mm
bull 1 GP300S cone crusher
ndash css 45mm
bull 1 HP4 cone crusher
ndash css 18 mm
bull 1 DS screen
bull 1 FS402 screenbull 1 grinding mill
bull Pumps VPAs
A normal truck feeds the C jaws with ore coming from the lower production levels
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Cost-per-ton wear agreements deepencustomer relationshipsCrusher wear parts are traditionally marketed purely based on transactional sales and mainly depend on
the weight of manganese Metso has recently introduced a new type of wear agreement based on thecost-per-ton crushed and the wear occurred Thus far the experience has been very positive increasing
transparency and deepening the operational relationship between the manufacturer and the customer
TEXT Olli Kellokumpu and Eero Haumlmaumllaumlinen PHOTOS Eero Haumlmaumllaumlinen
Arto Hiedanniemi (left)
Hannu Heman and Juha
Laukka of Metsorsquos Finnish
Service team checking the
cone crusher mantles shipped
for a cost-per-ton customer
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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156
Wear parts and parts changes
can be included
The structure of a cost-per-ton wearcontract is based on the number of tons
crushed and the estimated wear occurred
The amount and monetary value of the
wear is calculated per crushed ton
ldquoEither plain wear parts or parts changes
carried out by Metsorsquos service personnel
can be included in the contract In the latter
case we ask our Finnish customers to inform
us about an upcoming wear change opera-
tion one week in advancerdquo Heman explains
ldquoWe see good opportunities to market
cost-per-ton contracts further in Finland
and also abroad It really develops therelationship of Metso and our customers
towards a trusted partnershiprdquo he notes
Perfect tool for accurate planning
Soraliike Ikola Oy is a mid-sized contrac-
tor with three Metso two- and three-
stage mobile and portable crushing and
screening plants operating in Central and
Since 2002 Metsorsquos sales team in Finland
has developed the cost-per-ton-based
service offeringldquoOur aim has been to seek through
a cost-per-ton offering possibilities to
serve our customers better to differentiate
Metso from the other players as an OEM
manufacturer and to offer deeper profes-
sionalism and know-howrdquo says Hannu
Heman General Manager of service
operations
ldquoUntil now both our experience and
that of our customers has been quite posi-
tive When properly prepared cost-per-ton
contracts seem to create a win-win situa-
tionrdquo Heman adds Today Metso has operational cost-per-
ton agreements with several Finnish cus-
tomers The first contract was concluded
with a customer operating a stationary
plant Based on the results gathered new
cost-per-ton contracts have been signed
with customers operating wheeled and
tracked equipment too
Eastern Finland Because of the size of the
contracts up to 50 equipment moves are
made during the yearEntrepreneur Pasi Ikola has had a cost-
per-ton contract with Metso for nearly
two years and he is quite happy with the
outcome
ldquoThe cost-per-ton contract has provided
me with a perfect tool for accurate financial
planning Now I know in detail my actual
future wear parts costs This helps a lot
when calculating bidsrdquo
ldquoEarlier I used to buy a big batch of
Metso wear parts in one go and had to
reserve a reasonable amount of money for
that Today all wear costs are evenly sharedwhich gives us a welcomed 1047298exibility to
our cost structure Now we just pay Metso
afterwards based on our crushed tonsrdquo
he adds
More info
Olli Kellokumpu
Tel +358 50 354 1189
ollikellokumpumetsocom
According to crushing contractor Pasi Ikola the cost-per-ton contract with Metso has provided the entrepreneur with better economical 1047298exibility
and more accurate calculating of bids
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Pleasant Gap is owned and operated by
Glenn O Hawbaker Inc of State College
Pennsylvania This family-owned company
began in 1952 as a small excavation busi-
ness founded by Glenn O Hawbaker and
his wife Thelma Over the years the com-
pany grew by adding an integrated mix ofproducts and services and taking on larger
projects
In 1983 Hawbaker acquired Pleasant
Gap Quarry and built its first aggregates
processing plant Today Glenn O Haw-
baker Inc operates 21 quarries and eight
asphalt production facilities across Penn-
sylvania and southern New York as well as
five regional operation centers
Primary
challenge atPleasant GapQuarryA good part of what makes for a successful crushing
operation is the willingness to tackle challenges and to do
whatrsquos necessary to meet demand The team at Pleasant
Gap Quarry in central Pennsylvania recently met the chal-
lenge when they successfully addressed problems with
the plantrsquos primary crushing plant First they purchased
a new Metso C160 jaw to replace the existing primary
impact crusher Then they devised an innovative plan to
get the primary plant back in operation while awaitingdelivery of the new jaw crusher
TEXT Linda Bergmann PHOTOS John Rickinger
983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Time for a change
With the goal of increasing reliability and
output the management at Pleasant Gap
Quarry recently decided it was time to
replace the plantrsquos primary impact crusher
Following a thorough search they chose a
new Metso C160 jaw According to ScottReck Plant Manager it no longer made
sense to repair and rebuild the existing
impactor
ldquoBefore we purchased the Metso C160
we had a few other impact crushers and
they served us well but as our custom-
ersrsquo needs increased our plant production
had to match that demand We found our
formerly reliable unit was being overcome
by our demands for output and creative
work-around solutions We continued to
need more but there was only so much we
could do until we hit the breaking point ndash
literallyrdquo
In addition to performance improve-
ments the new crusher also needed to fitinto Pleasant Gaprsquos unique infrastructure
As Plant Project ManagerEngineer Jeremy
Fahr explains ldquoOur height restraint was 274
meters (108rdquo) This height was the distance
from the feed lip of the existing 6x12 scalp-
ing screen and the existing structure that
the crusher rests onrdquo
The normal C160 crusher is 307
meters (121rdquo) tall but Metso gave GOH
Scott Reck Plant Manager (left) and
Jeremy Fahr Plant Project Manager
Engineer at Pleasant Gap Quarry
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983122983141983152983151983154983156983145983150983143 983154983141983155
a 10-degree mounting option (which is
normally used on their portable crushers)
to overcome the height restraint Reck and
Fahr worked with Dave Rhoa of Cleveland
Brothers Equipment Metsorsquos crushing and
screening distributor in Pennsylvania to
pull everything together and fit the newcrusher into their plant
The C160 crusher selected for Pleasant
Gap is one of the latest models in Metsorsquos
C Series of jaws These jaw crushers feature
a large throw and steep toggle plate angle
resulting in a higher crusher output In
addition the C Series has a compact foot-
print that makes it an ideal choice for the
replacement of existing machines
According to Reck ldquoWe had heard about
the new Metso C160 and started doing our
own research and found Metso not only
had developed the output capacity we
needed but fit the uniqueness of our oper-
ationsrdquo The new Metso crusher will allow
the plant to increase tons per hour andgive them the 1047298exibility to meet demands
for varying products on short notice
Mobile solution
Purchasing the new primary jaw addressed
the long-term issues but still left Pleasant
Gap without a functioning primary plant
Reck continues ldquoOur main line was still
down leaving us with a big hole in hitting
customer needs but knowing that our new
Metso C160 was on its wayhellipwe needed an
immediate solution to keep our produc-
tion demands with an out-of-commission
crusherrdquo
The team at Pleasant Gap brainstormed
the problem and came up with a plan toget the primary plant back in operation
Their solution was to use the Lokotrack
LT1213 impactor plant and another mobile
unit to keep the main line crushing To do
this they removed the guts on the existing
impact crusher essentially turning it into a
rock chute They then moved the LT1213
and another manufacturerrsquos mobile unit
over to the existing dump hopper gt
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
ldquoWe had our haul trucks drop off mate-
rial while two excavators fed the two
mobile unitsrdquo Reck explains ldquoFor two-and-
a-half months the Lokotrack LT1213 unit
was producing 254 cm (10rdquo) minus at
700 tons per hour The other similar-sized
mobile unit was doing 400 tons an hour
maxed out The difference was unbeliev-
able to say the least Our unique solution
using the two mobile units especially the
LT1213 helped Glenn O Hawbaker achieve
a record output in 2010rdquoAccording to Fahr ldquoWe were not new to
Metsorsquos quality and supportrdquo because GOH
had been using Metsorsquos portable crushing
equipment for 3 years prior to the primary
plantrsquos impact crusher failure In another
part of our operation we have a system that
our team relies on every day a Lokotrack
LT1213 and ST272 working in tandem with
two portable conveyorsrdquo This highly effi -
cient mobile processing system turns out
300 tons of specialized blended material
per hour GOH has been so impressed with
Metso equipment its last two purchaseswere an LT106 tracked jaw plant and a
second ST272 mobile screen in 2010
Maintaining high productivity
The Metso C160 jaw was delivered to Pleas-
ant Gap Quarry in January of 2011 and
since start-up it has more than met expec-
tations The crusher is fed minus 910 mm
(36rdquo) limestone with the jaw set at 140 mm
(5 12rdquo) According to Reck ldquoFrom moment
we started up we knew we had a winner
Not only were we kicking out as much
product as our previous units without even
breathing hard but we immediately had a
2-cent per ton savings to the bottom line
without having to run a second 350 HP
motor as required by other units Plus by
adding on the new automatic lube system
the maintenance team had more time to
devote to keeping other areas of the com-
plex running more effi cientlyrdquoReck says ldquoThe Metso unit was a perfect
fit and with the improved features it pre-
sented it had it all We just turn it on load
it up and we are moving 600 tons per hour
through the crusher without any effort and
we know it can do so much morerdquo With
the primary crushing plant back in opera-
tion the entire team at Pleasant Gap will
continue to do what they do best produce
and sell high-quality products and meet
their customersrsquo expectations
More info
Scott Yablonsky Tel +1 262 717 793
scottyablonskymetsocom
The Metso C160 jaw
was installed at a 10deg
angle to fit Pleasant
Gaprsquos existing
infrastructure
The Lokotrack LT1213 impactor plant and ST272 mobile screen operate in tandem with two
portable conveyors at Pleasant Gap
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983149983141983156983155983151 983150
Paper amp fiberNew OptiConcept M paper
and board making line
The new OptiConcept M paper and board
making line stands for economy safety and
usability
Metso has launched a new modular paper
and board making line called OptiConceptM A member of the proven OptiConcept
production line family the new OptiCon-
cept M optimizes machine investment in
line with each millrsquos capacity needs
Savings in operating costs are achieved
through precise dimensioning of pro-
cesses proven technological solutions
optimal running parameters effective
maintenance operations and fully inte-
grated automation solutions
Optimized processes innovations
smart controls and accurate dimensioning
decrease the use of steam gas electricitywater chemicals and other raw materials
and reduce emission levels
OptiConcept M has been designed
both visually and physically with the
requirements of users in mind For exam-
ple the design of the machinery allows for
easy and safe changing of rolls and wear
parts thus reducing the total duration and
cost of maintenance shutdowns
RecyclingGreen energy technology to
Elektrociepłownia Białystok in Poland
Metso will convert a coal-fired boiler to
a biomass-fired Bubbling Fluidized Bed
boiler for Elektrociepłownia Białystok SArsquos
combined heat and power plant (CHP) in
Białystok Poland The new boiler system
will cut the power plantrsquos CO2 emissions
significantly by partly replacing the coal
fuel supply with biomass fuel
ldquoPoland is one of the largest countries
in Europe to have such a high depend-ence on energy derived from coal to
meet national electricity needs This is an
important incentive for us to reduce future
CO2 emissions and produce more green
electricity and with Metso technology
we are certain to accomplish our goalrdquo
states Mr Andrzej Schroeder President of
Elektrociepłownia Białystok SA
Since 2000 Metso has received a total
of 7 biomass boiler conversion orders in
Poland and the renewable energy share
in Poland is only 75 (2010) compared to
the target of 20 by 2020 set by the EUApproximately 80 of the current energy
boilers turbines and generators installed in
Polish power plants are over 20 years old In
order to meet the strict EU environmental
requirements modernization of existing
installations is necessary
Automation
Metso DNA automation system expands
to mining and construction
Using Metsorsquos control room automation
an entire crushing and screening plant can
be effi ciently managed
Metso is a leading supplier of mining and
construction machinery This expertise has
now been combined with a scalable Metso
DNA automation system that adapts to
the range of industry needs from single
machine controls to plant-wide automation
and information management systems
An example of Metsorsquos new offering is a
new crushing plant control room solution
that connects crushers and screens ensur-
ing the effective management of the entire
plant from a pleasant and safe control
room The Metso DNA user interface pro-vides the production information to ensure
a proper and rapid response to plant
events Automatic controls stabilize the
process and allow the operators to monitor
the plant as a whole
ldquoThe benefits of automation for the min-
ing and construction industry are signifi-
cant As an example of the services we offer
performance studies to crushing plants
utilizing Metsorsquos multi-disciplinary teams of
experts to determine the present level of
the plant and process effi ciency and to esti-
mate the improvement potential and thebenefits of optimization and automation
including ROI calculationsrdquo says Mikko Maumlki-
nen Product Manager of minerals applica-
tions in Metsorsquos Automation business line
ldquoAs another example our machine
condition monitoring solutions can reduce
plant and machine downtimes as well as
help to avoid safety and environmental
hazardsrdquo he adds
Metso around the world
Aerial view of the Elektrociepłownia Białystok combined heat and power plant in Poland
8202019 Metso Minerals Aggregates 3 2011
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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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Creating Value with Metso in Hong KongIn Hong Kong the aggregates needed for construction are mostly supplied by two local quarries KWP Quarry Company
Limitedrsquos Anderson Road Quarry accounts for 60ndash70 making it the pillar of Hong Kongrsquos construction materials industry
TEXT amp PHOTOS Ou He
When arriving at the Anderson Road
Quarry the most impressive view at the850000 square-meter facility is the Metso
machines including equipment from the
primary secondary and tertiary crushing
circuits and the screens I t is Metsorsquos equip-
ment that secures the supply of aggregates
for Hong Kong
KWP Quarry Company Limited has been
working with Metso since its establishment
in 1997
Due to Hong Kongrsquos stringent dust and noise control standards Metso has paid special attention to the related suppression systems
ldquoOur quarry mainly lies on granite and
volcanic rock which are so hard they canonly be processed by equipment with
strong durability and stabilityrdquo explains
Mr Eddie Hung Manager of KWP ldquoWith a
long history of and experience in quarry-
ing we are very familiar with the equip-
ment of different brands Comparatively
Metsorsquos products are better than others in
terms of durability stability and effi ciency
Besides this the reason we selected Metso
is because of the simple maintenance of
their equipment and the easy access tomaintenance informationrdquo
Flexible modular solution
Based on extensive experience in crushing
and screening worldwide Metso presented
the Anderson Road Quarry with a modu-
lar solution and delivered it as a turn-key
project Through a four-stage crushing
circuit which contains three Metso C160
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jaw crushers for primary crushing two
Omnicone 1560SX crushers for secondary
crushing two HP 500SX cone crushers for
tertiary crushing and one HP500SX cone
crusher for extra-fine crushing the plant
was able to produce aggregates of optimal
shape with minimal 1047298akiness
The fine products include three sizes
0 to 5 mm 5 to 10 mm and 10 to 20mm
Since the employment of this system in
2000 production has reached 1250 th
which is far beyond the design capacityAccording to Mr Hung ldquoThe machines
always run effi ciently and seldom malfunc-
tion The occasional shutdown of some
machines does not affect production very
much the plant still could reach 60-70
of its normal production It gives us the
best 1047298exibility for the plant rsquos operation and
I believe this is the best feature of Metsorsquos
solution
Eddie Hung
Manager of KWPrsquos
Anderson Road
Quarry is happy with
the product quality
and service provided
by Metso
ldquoMetsorsquos equipment is expensive com-
paratively but in the long run you will find
that the investment is worthwhile on the
whole Metso secures superior stability reli-
ability and fewer downtimes and it guaran-
tees continuous operation and brings us
greater valuerdquo
Great service team
Metso sent a group of service engineers
to the plant within the warranty period
not only to provide service but to train theoperators Mr Hung speaks highly of Met-
sorsquos service team he is impressed with its
experienced experts and with their strong
sense of responsibility and customer-
oriented ways of working
ldquoMetsorsquos service team never fails to find
hidden problems and helps us to prevent
any mechanical failures And they are
available whenever we need them they
work closely with us to solve the problem
effi cientlyrdquo he said
Excellent environment-friendly designIn order to achieve the worldrsquos most strin-
gent noise and dust control standards
developed by the Environment Protection
Department of Hong Kong Metso has
incorporated a dust and noise suppression
system into the plant This includes the
infrared-triggered spray systems at feed
points encapsulation of individual crush-
ers and conveyors and the ability to select
specific sectors of the system for treatment
depending on feed and operating condi-
tions encapsulation of equipment and the
enclosure of all major sections of the plant
With these advanced environment-
friendly solutions Anderson Road Quarry
has won numerous safety and environmen-
tal awards In 2003 it was presented with a
silver medal in the prestigious Environmen-
tal Performance Awards in recognition of
its commitment to the environment and
community In 2004 KWP achieved certifi-cation of ISO 14001 it is the first quarry site
to have achieved this in Hong Kong and
southern China
ldquoA reliable partnerrdquo
The promulgation of the top ten infrastruc-
ture policies in Hong Kong boosted the
market for aggregates and demand will
keep rising over the next five to six years
ldquoWersquoll definitely keep our cooperation with
Metso once we have a need for expansion
because we regard Metso as a reliable part-
ner With their highly effi cient equipmentsatisfying service and great efforts in help-
ing us to achieve our environmental pro-
tection targets Metso is our best choicerdquo
says Hung
More info
Ziqiang Li
Tel +86 13601289027
ziqianglimetsocom
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The sturdy Metso C160
jaw crushers are fed
using huge feed chutes
and feeders
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Similar to hundreds of mine sites world-
wide Zinkgruvan is being operated on a
non-stop 247 basis with just a few main-
tenance breaks during the year Crusher
availability is crucial because 100 of the
ore has to pass through the jaws before
being hoisted up for further processing
In addition to the zinc- lead- copper-
and silver-containing ore the C jaws chop
all the host rock extracted along the min-
ing process With a sturdy design Metsorsquos
proven C jaws can easily reduce even the
hardest type of rock Every year more thanone million tons are crushed with the jaws
ldquoMinimal service neededrdquo
Crushing with the first C160B jaw crusher
began at Zinkgruvanrsquos -800 meter level in
2000 with the primary crushing of zinc-lead
ore The second jaw was installed in 2008
for the new copper process gt
The sight and sound of two C160 jaw crushers operating side by side in the underground
crushing station of the Swedish Zinkgruvan mine is impressive Good proactive service
secures good uptime and reliable continuous operation of Metsorsquos second-largest
C160 series jaw crushers and prepares the way for the ongoing plans to expand the
production of zinc concentrate
TEXT amp PHOTOS Eero Haumlmaumllaumlinen
New PolyMet liners are being tested with the grinding mill delivered by Metso
Zinkgruvanrsquos twin C160
jaws secure good uptime
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Blasted ore is taken from the presently
operated -850 meter level with normal
trucks as an outsourced process One full
truckload is fed to the C160s every
10 minutes
ldquoWe are happy with the high reliability
of the C jaws They only require some minor
service therefore providing us with good
uptime and steady continuous feed to our
secondary and tertiary crushing and grind-ing circuitsrdquo says Mine Manager Jan Klaumlre
ldquoBasic crusher service and wear part
changes are made by our own staff using
Metsorsquos partsrdquo he adds
Service contract with grinding
mills and conveyors
Zinkgruvan and Metso Sweden have more
than 11 yearsrsquo experience with a service
contract that contains grinding mills and
conveyors At the mine site two Metso
service people and one contractor take
care of all the related service jobs Man-
power can also be borrowed from Metsorsquos
Graumlngesberg mine service team of 20
people
Presently Zinkgruvan is testing Metsorsquos
new PolyMet mill linings in its big grinding
mills With previously used rubber partsthe linings had to be changed in the shell
every 9 to 11 months and in the feed head
every 6 months
ldquoWe expect a better lifetime with Poly-
Met linings Longer change intervals mean
a lot to our productivity because lining
changes takes two full working daysrdquo Mine
Manager Jan Klaumlre says
New mine goes deeper
With an expected mine life of more than 10
years Zinkgruvan is actively mapping new
ore reserves Experimental holes are being
drilled at the new mine section at the
-1110 meter level
More info
Fredrik Wennberg
Tel +46 70 657 00 08fredrikwennbergmetsocom
Mine Manager Jan Klaumlre (left) with Backfilling Manager Kjell Tillman at the underground -800 meter level mine cafeteria
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The Zinkgruvan mine located approxi-
mately 200 km southwest of Stockholm
Sweden is one of the oldest underground
mines in Northern Europe The mine has
been in production since 1857
The mining methods used are panel
stoping and benching The processing
facilities include a zinc concentrating plant
with a 11 mtpa and a copper plant with a04 mtpa capacity Tailings are recycled in
an impounding basin and host rock in the
backfill plant
Continuous mining since 1857
Even as one of the oldest mines in Northern
Europe Zinkgruvan exploits modern mining
and minerals processing installations
Zinkgruvan mine
OWNER Lundin Mining
PRODUCTION PER YEAR 1 million tons
ORE TYPE sedimentary exhalative
zinc lead copper and silver
NUMBER OF EMPLOYEES 320
2011 PRODUCTION TARGETS 78000 tonsof zinc 36000 tons of lead and
3400 tons of copper concentrate
METSO EQUIPMENT ON SITE
bull 1 extra long VF feeder
bull 2 C160 jaw crushers
ndash zinc process css 220ndash240 mm
ndash copper process css 150 mm
bull 1 GP300S cone crusher
ndash css 45mm
bull 1 HP4 cone crusher
ndash css 18 mm
bull 1 DS screen
bull 1 FS402 screenbull 1 grinding mill
bull Pumps VPAs
A normal truck feeds the C jaws with ore coming from the lower production levels
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Cost-per-ton wear agreements deepencustomer relationshipsCrusher wear parts are traditionally marketed purely based on transactional sales and mainly depend on
the weight of manganese Metso has recently introduced a new type of wear agreement based on thecost-per-ton crushed and the wear occurred Thus far the experience has been very positive increasing
transparency and deepening the operational relationship between the manufacturer and the customer
TEXT Olli Kellokumpu and Eero Haumlmaumllaumlinen PHOTOS Eero Haumlmaumllaumlinen
Arto Hiedanniemi (left)
Hannu Heman and Juha
Laukka of Metsorsquos Finnish
Service team checking the
cone crusher mantles shipped
for a cost-per-ton customer
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Wear parts and parts changes
can be included
The structure of a cost-per-ton wearcontract is based on the number of tons
crushed and the estimated wear occurred
The amount and monetary value of the
wear is calculated per crushed ton
ldquoEither plain wear parts or parts changes
carried out by Metsorsquos service personnel
can be included in the contract In the latter
case we ask our Finnish customers to inform
us about an upcoming wear change opera-
tion one week in advancerdquo Heman explains
ldquoWe see good opportunities to market
cost-per-ton contracts further in Finland
and also abroad It really develops therelationship of Metso and our customers
towards a trusted partnershiprdquo he notes
Perfect tool for accurate planning
Soraliike Ikola Oy is a mid-sized contrac-
tor with three Metso two- and three-
stage mobile and portable crushing and
screening plants operating in Central and
Since 2002 Metsorsquos sales team in Finland
has developed the cost-per-ton-based
service offeringldquoOur aim has been to seek through
a cost-per-ton offering possibilities to
serve our customers better to differentiate
Metso from the other players as an OEM
manufacturer and to offer deeper profes-
sionalism and know-howrdquo says Hannu
Heman General Manager of service
operations
ldquoUntil now both our experience and
that of our customers has been quite posi-
tive When properly prepared cost-per-ton
contracts seem to create a win-win situa-
tionrdquo Heman adds Today Metso has operational cost-per-
ton agreements with several Finnish cus-
tomers The first contract was concluded
with a customer operating a stationary
plant Based on the results gathered new
cost-per-ton contracts have been signed
with customers operating wheeled and
tracked equipment too
Eastern Finland Because of the size of the
contracts up to 50 equipment moves are
made during the yearEntrepreneur Pasi Ikola has had a cost-
per-ton contract with Metso for nearly
two years and he is quite happy with the
outcome
ldquoThe cost-per-ton contract has provided
me with a perfect tool for accurate financial
planning Now I know in detail my actual
future wear parts costs This helps a lot
when calculating bidsrdquo
ldquoEarlier I used to buy a big batch of
Metso wear parts in one go and had to
reserve a reasonable amount of money for
that Today all wear costs are evenly sharedwhich gives us a welcomed 1047298exibility to
our cost structure Now we just pay Metso
afterwards based on our crushed tonsrdquo
he adds
More info
Olli Kellokumpu
Tel +358 50 354 1189
ollikellokumpumetsocom
According to crushing contractor Pasi Ikola the cost-per-ton contract with Metso has provided the entrepreneur with better economical 1047298exibility
and more accurate calculating of bids
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Pleasant Gap is owned and operated by
Glenn O Hawbaker Inc of State College
Pennsylvania This family-owned company
began in 1952 as a small excavation busi-
ness founded by Glenn O Hawbaker and
his wife Thelma Over the years the com-
pany grew by adding an integrated mix ofproducts and services and taking on larger
projects
In 1983 Hawbaker acquired Pleasant
Gap Quarry and built its first aggregates
processing plant Today Glenn O Haw-
baker Inc operates 21 quarries and eight
asphalt production facilities across Penn-
sylvania and southern New York as well as
five regional operation centers
Primary
challenge atPleasant GapQuarryA good part of what makes for a successful crushing
operation is the willingness to tackle challenges and to do
whatrsquos necessary to meet demand The team at Pleasant
Gap Quarry in central Pennsylvania recently met the chal-
lenge when they successfully addressed problems with
the plantrsquos primary crushing plant First they purchased
a new Metso C160 jaw to replace the existing primary
impact crusher Then they devised an innovative plan to
get the primary plant back in operation while awaitingdelivery of the new jaw crusher
TEXT Linda Bergmann PHOTOS John Rickinger
983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Time for a change
With the goal of increasing reliability and
output the management at Pleasant Gap
Quarry recently decided it was time to
replace the plantrsquos primary impact crusher
Following a thorough search they chose a
new Metso C160 jaw According to ScottReck Plant Manager it no longer made
sense to repair and rebuild the existing
impactor
ldquoBefore we purchased the Metso C160
we had a few other impact crushers and
they served us well but as our custom-
ersrsquo needs increased our plant production
had to match that demand We found our
formerly reliable unit was being overcome
by our demands for output and creative
work-around solutions We continued to
need more but there was only so much we
could do until we hit the breaking point ndash
literallyrdquo
In addition to performance improve-
ments the new crusher also needed to fitinto Pleasant Gaprsquos unique infrastructure
As Plant Project ManagerEngineer Jeremy
Fahr explains ldquoOur height restraint was 274
meters (108rdquo) This height was the distance
from the feed lip of the existing 6x12 scalp-
ing screen and the existing structure that
the crusher rests onrdquo
The normal C160 crusher is 307
meters (121rdquo) tall but Metso gave GOH
Scott Reck Plant Manager (left) and
Jeremy Fahr Plant Project Manager
Engineer at Pleasant Gap Quarry
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983122983141983152983151983154983156983145983150983143 983154983141983155
a 10-degree mounting option (which is
normally used on their portable crushers)
to overcome the height restraint Reck and
Fahr worked with Dave Rhoa of Cleveland
Brothers Equipment Metsorsquos crushing and
screening distributor in Pennsylvania to
pull everything together and fit the newcrusher into their plant
The C160 crusher selected for Pleasant
Gap is one of the latest models in Metsorsquos
C Series of jaws These jaw crushers feature
a large throw and steep toggle plate angle
resulting in a higher crusher output In
addition the C Series has a compact foot-
print that makes it an ideal choice for the
replacement of existing machines
According to Reck ldquoWe had heard about
the new Metso C160 and started doing our
own research and found Metso not only
had developed the output capacity we
needed but fit the uniqueness of our oper-
ationsrdquo The new Metso crusher will allow
the plant to increase tons per hour andgive them the 1047298exibility to meet demands
for varying products on short notice
Mobile solution
Purchasing the new primary jaw addressed
the long-term issues but still left Pleasant
Gap without a functioning primary plant
Reck continues ldquoOur main line was still
down leaving us with a big hole in hitting
customer needs but knowing that our new
Metso C160 was on its wayhellipwe needed an
immediate solution to keep our produc-
tion demands with an out-of-commission
crusherrdquo
The team at Pleasant Gap brainstormed
the problem and came up with a plan toget the primary plant back in operation
Their solution was to use the Lokotrack
LT1213 impactor plant and another mobile
unit to keep the main line crushing To do
this they removed the guts on the existing
impact crusher essentially turning it into a
rock chute They then moved the LT1213
and another manufacturerrsquos mobile unit
over to the existing dump hopper gt
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
ldquoWe had our haul trucks drop off mate-
rial while two excavators fed the two
mobile unitsrdquo Reck explains ldquoFor two-and-
a-half months the Lokotrack LT1213 unit
was producing 254 cm (10rdquo) minus at
700 tons per hour The other similar-sized
mobile unit was doing 400 tons an hour
maxed out The difference was unbeliev-
able to say the least Our unique solution
using the two mobile units especially the
LT1213 helped Glenn O Hawbaker achieve
a record output in 2010rdquoAccording to Fahr ldquoWe were not new to
Metsorsquos quality and supportrdquo because GOH
had been using Metsorsquos portable crushing
equipment for 3 years prior to the primary
plantrsquos impact crusher failure In another
part of our operation we have a system that
our team relies on every day a Lokotrack
LT1213 and ST272 working in tandem with
two portable conveyorsrdquo This highly effi -
cient mobile processing system turns out
300 tons of specialized blended material
per hour GOH has been so impressed with
Metso equipment its last two purchaseswere an LT106 tracked jaw plant and a
second ST272 mobile screen in 2010
Maintaining high productivity
The Metso C160 jaw was delivered to Pleas-
ant Gap Quarry in January of 2011 and
since start-up it has more than met expec-
tations The crusher is fed minus 910 mm
(36rdquo) limestone with the jaw set at 140 mm
(5 12rdquo) According to Reck ldquoFrom moment
we started up we knew we had a winner
Not only were we kicking out as much
product as our previous units without even
breathing hard but we immediately had a
2-cent per ton savings to the bottom line
without having to run a second 350 HP
motor as required by other units Plus by
adding on the new automatic lube system
the maintenance team had more time to
devote to keeping other areas of the com-
plex running more effi cientlyrdquoReck says ldquoThe Metso unit was a perfect
fit and with the improved features it pre-
sented it had it all We just turn it on load
it up and we are moving 600 tons per hour
through the crusher without any effort and
we know it can do so much morerdquo With
the primary crushing plant back in opera-
tion the entire team at Pleasant Gap will
continue to do what they do best produce
and sell high-quality products and meet
their customersrsquo expectations
More info
Scott Yablonsky Tel +1 262 717 793
scottyablonskymetsocom
The Metso C160 jaw
was installed at a 10deg
angle to fit Pleasant
Gaprsquos existing
infrastructure
The Lokotrack LT1213 impactor plant and ST272 mobile screen operate in tandem with two
portable conveyors at Pleasant Gap
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983149983141983156983155983151 983150
Paper amp fiberNew OptiConcept M paper
and board making line
The new OptiConcept M paper and board
making line stands for economy safety and
usability
Metso has launched a new modular paper
and board making line called OptiConceptM A member of the proven OptiConcept
production line family the new OptiCon-
cept M optimizes machine investment in
line with each millrsquos capacity needs
Savings in operating costs are achieved
through precise dimensioning of pro-
cesses proven technological solutions
optimal running parameters effective
maintenance operations and fully inte-
grated automation solutions
Optimized processes innovations
smart controls and accurate dimensioning
decrease the use of steam gas electricitywater chemicals and other raw materials
and reduce emission levels
OptiConcept M has been designed
both visually and physically with the
requirements of users in mind For exam-
ple the design of the machinery allows for
easy and safe changing of rolls and wear
parts thus reducing the total duration and
cost of maintenance shutdowns
RecyclingGreen energy technology to
Elektrociepłownia Białystok in Poland
Metso will convert a coal-fired boiler to
a biomass-fired Bubbling Fluidized Bed
boiler for Elektrociepłownia Białystok SArsquos
combined heat and power plant (CHP) in
Białystok Poland The new boiler system
will cut the power plantrsquos CO2 emissions
significantly by partly replacing the coal
fuel supply with biomass fuel
ldquoPoland is one of the largest countries
in Europe to have such a high depend-ence on energy derived from coal to
meet national electricity needs This is an
important incentive for us to reduce future
CO2 emissions and produce more green
electricity and with Metso technology
we are certain to accomplish our goalrdquo
states Mr Andrzej Schroeder President of
Elektrociepłownia Białystok SA
Since 2000 Metso has received a total
of 7 biomass boiler conversion orders in
Poland and the renewable energy share
in Poland is only 75 (2010) compared to
the target of 20 by 2020 set by the EUApproximately 80 of the current energy
boilers turbines and generators installed in
Polish power plants are over 20 years old In
order to meet the strict EU environmental
requirements modernization of existing
installations is necessary
Automation
Metso DNA automation system expands
to mining and construction
Using Metsorsquos control room automation
an entire crushing and screening plant can
be effi ciently managed
Metso is a leading supplier of mining and
construction machinery This expertise has
now been combined with a scalable Metso
DNA automation system that adapts to
the range of industry needs from single
machine controls to plant-wide automation
and information management systems
An example of Metsorsquos new offering is a
new crushing plant control room solution
that connects crushers and screens ensur-
ing the effective management of the entire
plant from a pleasant and safe control
room The Metso DNA user interface pro-vides the production information to ensure
a proper and rapid response to plant
events Automatic controls stabilize the
process and allow the operators to monitor
the plant as a whole
ldquoThe benefits of automation for the min-
ing and construction industry are signifi-
cant As an example of the services we offer
performance studies to crushing plants
utilizing Metsorsquos multi-disciplinary teams of
experts to determine the present level of
the plant and process effi ciency and to esti-
mate the improvement potential and thebenefits of optimization and automation
including ROI calculationsrdquo says Mikko Maumlki-
nen Product Manager of minerals applica-
tions in Metsorsquos Automation business line
ldquoAs another example our machine
condition monitoring solutions can reduce
plant and machine downtimes as well as
help to avoid safety and environmental
hazardsrdquo he adds
Metso around the world
Aerial view of the Elektrociepłownia Białystok combined heat and power plant in Poland
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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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jaw crushers for primary crushing two
Omnicone 1560SX crushers for secondary
crushing two HP 500SX cone crushers for
tertiary crushing and one HP500SX cone
crusher for extra-fine crushing the plant
was able to produce aggregates of optimal
shape with minimal 1047298akiness
The fine products include three sizes
0 to 5 mm 5 to 10 mm and 10 to 20mm
Since the employment of this system in
2000 production has reached 1250 th
which is far beyond the design capacityAccording to Mr Hung ldquoThe machines
always run effi ciently and seldom malfunc-
tion The occasional shutdown of some
machines does not affect production very
much the plant still could reach 60-70
of its normal production It gives us the
best 1047298exibility for the plant rsquos operation and
I believe this is the best feature of Metsorsquos
solution
Eddie Hung
Manager of KWPrsquos
Anderson Road
Quarry is happy with
the product quality
and service provided
by Metso
ldquoMetsorsquos equipment is expensive com-
paratively but in the long run you will find
that the investment is worthwhile on the
whole Metso secures superior stability reli-
ability and fewer downtimes and it guaran-
tees continuous operation and brings us
greater valuerdquo
Great service team
Metso sent a group of service engineers
to the plant within the warranty period
not only to provide service but to train theoperators Mr Hung speaks highly of Met-
sorsquos service team he is impressed with its
experienced experts and with their strong
sense of responsibility and customer-
oriented ways of working
ldquoMetsorsquos service team never fails to find
hidden problems and helps us to prevent
any mechanical failures And they are
available whenever we need them they
work closely with us to solve the problem
effi cientlyrdquo he said
Excellent environment-friendly designIn order to achieve the worldrsquos most strin-
gent noise and dust control standards
developed by the Environment Protection
Department of Hong Kong Metso has
incorporated a dust and noise suppression
system into the plant This includes the
infrared-triggered spray systems at feed
points encapsulation of individual crush-
ers and conveyors and the ability to select
specific sectors of the system for treatment
depending on feed and operating condi-
tions encapsulation of equipment and the
enclosure of all major sections of the plant
With these advanced environment-
friendly solutions Anderson Road Quarry
has won numerous safety and environmen-
tal awards In 2003 it was presented with a
silver medal in the prestigious Environmen-
tal Performance Awards in recognition of
its commitment to the environment and
community In 2004 KWP achieved certifi-cation of ISO 14001 it is the first quarry site
to have achieved this in Hong Kong and
southern China
ldquoA reliable partnerrdquo
The promulgation of the top ten infrastruc-
ture policies in Hong Kong boosted the
market for aggregates and demand will
keep rising over the next five to six years
ldquoWersquoll definitely keep our cooperation with
Metso once we have a need for expansion
because we regard Metso as a reliable part-
ner With their highly effi cient equipmentsatisfying service and great efforts in help-
ing us to achieve our environmental pro-
tection targets Metso is our best choicerdquo
says Hung
More info
Ziqiang Li
Tel +86 13601289027
ziqianglimetsocom
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The sturdy Metso C160
jaw crushers are fed
using huge feed chutes
and feeders
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Similar to hundreds of mine sites world-
wide Zinkgruvan is being operated on a
non-stop 247 basis with just a few main-
tenance breaks during the year Crusher
availability is crucial because 100 of the
ore has to pass through the jaws before
being hoisted up for further processing
In addition to the zinc- lead- copper-
and silver-containing ore the C jaws chop
all the host rock extracted along the min-
ing process With a sturdy design Metsorsquos
proven C jaws can easily reduce even the
hardest type of rock Every year more thanone million tons are crushed with the jaws
ldquoMinimal service neededrdquo
Crushing with the first C160B jaw crusher
began at Zinkgruvanrsquos -800 meter level in
2000 with the primary crushing of zinc-lead
ore The second jaw was installed in 2008
for the new copper process gt
The sight and sound of two C160 jaw crushers operating side by side in the underground
crushing station of the Swedish Zinkgruvan mine is impressive Good proactive service
secures good uptime and reliable continuous operation of Metsorsquos second-largest
C160 series jaw crushers and prepares the way for the ongoing plans to expand the
production of zinc concentrate
TEXT amp PHOTOS Eero Haumlmaumllaumlinen
New PolyMet liners are being tested with the grinding mill delivered by Metso
Zinkgruvanrsquos twin C160
jaws secure good uptime
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Blasted ore is taken from the presently
operated -850 meter level with normal
trucks as an outsourced process One full
truckload is fed to the C160s every
10 minutes
ldquoWe are happy with the high reliability
of the C jaws They only require some minor
service therefore providing us with good
uptime and steady continuous feed to our
secondary and tertiary crushing and grind-ing circuitsrdquo says Mine Manager Jan Klaumlre
ldquoBasic crusher service and wear part
changes are made by our own staff using
Metsorsquos partsrdquo he adds
Service contract with grinding
mills and conveyors
Zinkgruvan and Metso Sweden have more
than 11 yearsrsquo experience with a service
contract that contains grinding mills and
conveyors At the mine site two Metso
service people and one contractor take
care of all the related service jobs Man-
power can also be borrowed from Metsorsquos
Graumlngesberg mine service team of 20
people
Presently Zinkgruvan is testing Metsorsquos
new PolyMet mill linings in its big grinding
mills With previously used rubber partsthe linings had to be changed in the shell
every 9 to 11 months and in the feed head
every 6 months
ldquoWe expect a better lifetime with Poly-
Met linings Longer change intervals mean
a lot to our productivity because lining
changes takes two full working daysrdquo Mine
Manager Jan Klaumlre says
New mine goes deeper
With an expected mine life of more than 10
years Zinkgruvan is actively mapping new
ore reserves Experimental holes are being
drilled at the new mine section at the
-1110 meter level
More info
Fredrik Wennberg
Tel +46 70 657 00 08fredrikwennbergmetsocom
Mine Manager Jan Klaumlre (left) with Backfilling Manager Kjell Tillman at the underground -800 meter level mine cafeteria
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The Zinkgruvan mine located approxi-
mately 200 km southwest of Stockholm
Sweden is one of the oldest underground
mines in Northern Europe The mine has
been in production since 1857
The mining methods used are panel
stoping and benching The processing
facilities include a zinc concentrating plant
with a 11 mtpa and a copper plant with a04 mtpa capacity Tailings are recycled in
an impounding basin and host rock in the
backfill plant
Continuous mining since 1857
Even as one of the oldest mines in Northern
Europe Zinkgruvan exploits modern mining
and minerals processing installations
Zinkgruvan mine
OWNER Lundin Mining
PRODUCTION PER YEAR 1 million tons
ORE TYPE sedimentary exhalative
zinc lead copper and silver
NUMBER OF EMPLOYEES 320
2011 PRODUCTION TARGETS 78000 tonsof zinc 36000 tons of lead and
3400 tons of copper concentrate
METSO EQUIPMENT ON SITE
bull 1 extra long VF feeder
bull 2 C160 jaw crushers
ndash zinc process css 220ndash240 mm
ndash copper process css 150 mm
bull 1 GP300S cone crusher
ndash css 45mm
bull 1 HP4 cone crusher
ndash css 18 mm
bull 1 DS screen
bull 1 FS402 screenbull 1 grinding mill
bull Pumps VPAs
A normal truck feeds the C jaws with ore coming from the lower production levels
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Cost-per-ton wear agreements deepencustomer relationshipsCrusher wear parts are traditionally marketed purely based on transactional sales and mainly depend on
the weight of manganese Metso has recently introduced a new type of wear agreement based on thecost-per-ton crushed and the wear occurred Thus far the experience has been very positive increasing
transparency and deepening the operational relationship between the manufacturer and the customer
TEXT Olli Kellokumpu and Eero Haumlmaumllaumlinen PHOTOS Eero Haumlmaumllaumlinen
Arto Hiedanniemi (left)
Hannu Heman and Juha
Laukka of Metsorsquos Finnish
Service team checking the
cone crusher mantles shipped
for a cost-per-ton customer
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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156
Wear parts and parts changes
can be included
The structure of a cost-per-ton wearcontract is based on the number of tons
crushed and the estimated wear occurred
The amount and monetary value of the
wear is calculated per crushed ton
ldquoEither plain wear parts or parts changes
carried out by Metsorsquos service personnel
can be included in the contract In the latter
case we ask our Finnish customers to inform
us about an upcoming wear change opera-
tion one week in advancerdquo Heman explains
ldquoWe see good opportunities to market
cost-per-ton contracts further in Finland
and also abroad It really develops therelationship of Metso and our customers
towards a trusted partnershiprdquo he notes
Perfect tool for accurate planning
Soraliike Ikola Oy is a mid-sized contrac-
tor with three Metso two- and three-
stage mobile and portable crushing and
screening plants operating in Central and
Since 2002 Metsorsquos sales team in Finland
has developed the cost-per-ton-based
service offeringldquoOur aim has been to seek through
a cost-per-ton offering possibilities to
serve our customers better to differentiate
Metso from the other players as an OEM
manufacturer and to offer deeper profes-
sionalism and know-howrdquo says Hannu
Heman General Manager of service
operations
ldquoUntil now both our experience and
that of our customers has been quite posi-
tive When properly prepared cost-per-ton
contracts seem to create a win-win situa-
tionrdquo Heman adds Today Metso has operational cost-per-
ton agreements with several Finnish cus-
tomers The first contract was concluded
with a customer operating a stationary
plant Based on the results gathered new
cost-per-ton contracts have been signed
with customers operating wheeled and
tracked equipment too
Eastern Finland Because of the size of the
contracts up to 50 equipment moves are
made during the yearEntrepreneur Pasi Ikola has had a cost-
per-ton contract with Metso for nearly
two years and he is quite happy with the
outcome
ldquoThe cost-per-ton contract has provided
me with a perfect tool for accurate financial
planning Now I know in detail my actual
future wear parts costs This helps a lot
when calculating bidsrdquo
ldquoEarlier I used to buy a big batch of
Metso wear parts in one go and had to
reserve a reasonable amount of money for
that Today all wear costs are evenly sharedwhich gives us a welcomed 1047298exibility to
our cost structure Now we just pay Metso
afterwards based on our crushed tonsrdquo
he adds
More info
Olli Kellokumpu
Tel +358 50 354 1189
ollikellokumpumetsocom
According to crushing contractor Pasi Ikola the cost-per-ton contract with Metso has provided the entrepreneur with better economical 1047298exibility
and more accurate calculating of bids
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Pleasant Gap is owned and operated by
Glenn O Hawbaker Inc of State College
Pennsylvania This family-owned company
began in 1952 as a small excavation busi-
ness founded by Glenn O Hawbaker and
his wife Thelma Over the years the com-
pany grew by adding an integrated mix ofproducts and services and taking on larger
projects
In 1983 Hawbaker acquired Pleasant
Gap Quarry and built its first aggregates
processing plant Today Glenn O Haw-
baker Inc operates 21 quarries and eight
asphalt production facilities across Penn-
sylvania and southern New York as well as
five regional operation centers
Primary
challenge atPleasant GapQuarryA good part of what makes for a successful crushing
operation is the willingness to tackle challenges and to do
whatrsquos necessary to meet demand The team at Pleasant
Gap Quarry in central Pennsylvania recently met the chal-
lenge when they successfully addressed problems with
the plantrsquos primary crushing plant First they purchased
a new Metso C160 jaw to replace the existing primary
impact crusher Then they devised an innovative plan to
get the primary plant back in operation while awaitingdelivery of the new jaw crusher
TEXT Linda Bergmann PHOTOS John Rickinger
983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Time for a change
With the goal of increasing reliability and
output the management at Pleasant Gap
Quarry recently decided it was time to
replace the plantrsquos primary impact crusher
Following a thorough search they chose a
new Metso C160 jaw According to ScottReck Plant Manager it no longer made
sense to repair and rebuild the existing
impactor
ldquoBefore we purchased the Metso C160
we had a few other impact crushers and
they served us well but as our custom-
ersrsquo needs increased our plant production
had to match that demand We found our
formerly reliable unit was being overcome
by our demands for output and creative
work-around solutions We continued to
need more but there was only so much we
could do until we hit the breaking point ndash
literallyrdquo
In addition to performance improve-
ments the new crusher also needed to fitinto Pleasant Gaprsquos unique infrastructure
As Plant Project ManagerEngineer Jeremy
Fahr explains ldquoOur height restraint was 274
meters (108rdquo) This height was the distance
from the feed lip of the existing 6x12 scalp-
ing screen and the existing structure that
the crusher rests onrdquo
The normal C160 crusher is 307
meters (121rdquo) tall but Metso gave GOH
Scott Reck Plant Manager (left) and
Jeremy Fahr Plant Project Manager
Engineer at Pleasant Gap Quarry
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983122983141983152983151983154983156983145983150983143 983154983141983155
a 10-degree mounting option (which is
normally used on their portable crushers)
to overcome the height restraint Reck and
Fahr worked with Dave Rhoa of Cleveland
Brothers Equipment Metsorsquos crushing and
screening distributor in Pennsylvania to
pull everything together and fit the newcrusher into their plant
The C160 crusher selected for Pleasant
Gap is one of the latest models in Metsorsquos
C Series of jaws These jaw crushers feature
a large throw and steep toggle plate angle
resulting in a higher crusher output In
addition the C Series has a compact foot-
print that makes it an ideal choice for the
replacement of existing machines
According to Reck ldquoWe had heard about
the new Metso C160 and started doing our
own research and found Metso not only
had developed the output capacity we
needed but fit the uniqueness of our oper-
ationsrdquo The new Metso crusher will allow
the plant to increase tons per hour andgive them the 1047298exibility to meet demands
for varying products on short notice
Mobile solution
Purchasing the new primary jaw addressed
the long-term issues but still left Pleasant
Gap without a functioning primary plant
Reck continues ldquoOur main line was still
down leaving us with a big hole in hitting
customer needs but knowing that our new
Metso C160 was on its wayhellipwe needed an
immediate solution to keep our produc-
tion demands with an out-of-commission
crusherrdquo
The team at Pleasant Gap brainstormed
the problem and came up with a plan toget the primary plant back in operation
Their solution was to use the Lokotrack
LT1213 impactor plant and another mobile
unit to keep the main line crushing To do
this they removed the guts on the existing
impact crusher essentially turning it into a
rock chute They then moved the LT1213
and another manufacturerrsquos mobile unit
over to the existing dump hopper gt
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
ldquoWe had our haul trucks drop off mate-
rial while two excavators fed the two
mobile unitsrdquo Reck explains ldquoFor two-and-
a-half months the Lokotrack LT1213 unit
was producing 254 cm (10rdquo) minus at
700 tons per hour The other similar-sized
mobile unit was doing 400 tons an hour
maxed out The difference was unbeliev-
able to say the least Our unique solution
using the two mobile units especially the
LT1213 helped Glenn O Hawbaker achieve
a record output in 2010rdquoAccording to Fahr ldquoWe were not new to
Metsorsquos quality and supportrdquo because GOH
had been using Metsorsquos portable crushing
equipment for 3 years prior to the primary
plantrsquos impact crusher failure In another
part of our operation we have a system that
our team relies on every day a Lokotrack
LT1213 and ST272 working in tandem with
two portable conveyorsrdquo This highly effi -
cient mobile processing system turns out
300 tons of specialized blended material
per hour GOH has been so impressed with
Metso equipment its last two purchaseswere an LT106 tracked jaw plant and a
second ST272 mobile screen in 2010
Maintaining high productivity
The Metso C160 jaw was delivered to Pleas-
ant Gap Quarry in January of 2011 and
since start-up it has more than met expec-
tations The crusher is fed minus 910 mm
(36rdquo) limestone with the jaw set at 140 mm
(5 12rdquo) According to Reck ldquoFrom moment
we started up we knew we had a winner
Not only were we kicking out as much
product as our previous units without even
breathing hard but we immediately had a
2-cent per ton savings to the bottom line
without having to run a second 350 HP
motor as required by other units Plus by
adding on the new automatic lube system
the maintenance team had more time to
devote to keeping other areas of the com-
plex running more effi cientlyrdquoReck says ldquoThe Metso unit was a perfect
fit and with the improved features it pre-
sented it had it all We just turn it on load
it up and we are moving 600 tons per hour
through the crusher without any effort and
we know it can do so much morerdquo With
the primary crushing plant back in opera-
tion the entire team at Pleasant Gap will
continue to do what they do best produce
and sell high-quality products and meet
their customersrsquo expectations
More info
Scott Yablonsky Tel +1 262 717 793
scottyablonskymetsocom
The Metso C160 jaw
was installed at a 10deg
angle to fit Pleasant
Gaprsquos existing
infrastructure
The Lokotrack LT1213 impactor plant and ST272 mobile screen operate in tandem with two
portable conveyors at Pleasant Gap
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983149983141983156983155983151 983150
Paper amp fiberNew OptiConcept M paper
and board making line
The new OptiConcept M paper and board
making line stands for economy safety and
usability
Metso has launched a new modular paper
and board making line called OptiConceptM A member of the proven OptiConcept
production line family the new OptiCon-
cept M optimizes machine investment in
line with each millrsquos capacity needs
Savings in operating costs are achieved
through precise dimensioning of pro-
cesses proven technological solutions
optimal running parameters effective
maintenance operations and fully inte-
grated automation solutions
Optimized processes innovations
smart controls and accurate dimensioning
decrease the use of steam gas electricitywater chemicals and other raw materials
and reduce emission levels
OptiConcept M has been designed
both visually and physically with the
requirements of users in mind For exam-
ple the design of the machinery allows for
easy and safe changing of rolls and wear
parts thus reducing the total duration and
cost of maintenance shutdowns
RecyclingGreen energy technology to
Elektrociepłownia Białystok in Poland
Metso will convert a coal-fired boiler to
a biomass-fired Bubbling Fluidized Bed
boiler for Elektrociepłownia Białystok SArsquos
combined heat and power plant (CHP) in
Białystok Poland The new boiler system
will cut the power plantrsquos CO2 emissions
significantly by partly replacing the coal
fuel supply with biomass fuel
ldquoPoland is one of the largest countries
in Europe to have such a high depend-ence on energy derived from coal to
meet national electricity needs This is an
important incentive for us to reduce future
CO2 emissions and produce more green
electricity and with Metso technology
we are certain to accomplish our goalrdquo
states Mr Andrzej Schroeder President of
Elektrociepłownia Białystok SA
Since 2000 Metso has received a total
of 7 biomass boiler conversion orders in
Poland and the renewable energy share
in Poland is only 75 (2010) compared to
the target of 20 by 2020 set by the EUApproximately 80 of the current energy
boilers turbines and generators installed in
Polish power plants are over 20 years old In
order to meet the strict EU environmental
requirements modernization of existing
installations is necessary
Automation
Metso DNA automation system expands
to mining and construction
Using Metsorsquos control room automation
an entire crushing and screening plant can
be effi ciently managed
Metso is a leading supplier of mining and
construction machinery This expertise has
now been combined with a scalable Metso
DNA automation system that adapts to
the range of industry needs from single
machine controls to plant-wide automation
and information management systems
An example of Metsorsquos new offering is a
new crushing plant control room solution
that connects crushers and screens ensur-
ing the effective management of the entire
plant from a pleasant and safe control
room The Metso DNA user interface pro-vides the production information to ensure
a proper and rapid response to plant
events Automatic controls stabilize the
process and allow the operators to monitor
the plant as a whole
ldquoThe benefits of automation for the min-
ing and construction industry are signifi-
cant As an example of the services we offer
performance studies to crushing plants
utilizing Metsorsquos multi-disciplinary teams of
experts to determine the present level of
the plant and process effi ciency and to esti-
mate the improvement potential and thebenefits of optimization and automation
including ROI calculationsrdquo says Mikko Maumlki-
nen Product Manager of minerals applica-
tions in Metsorsquos Automation business line
ldquoAs another example our machine
condition monitoring solutions can reduce
plant and machine downtimes as well as
help to avoid safety and environmental
hazardsrdquo he adds
Metso around the world
Aerial view of the Elektrociepłownia Białystok combined heat and power plant in Poland
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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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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
The sturdy Metso C160
jaw crushers are fed
using huge feed chutes
and feeders
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983122983141983152983151983154983156983145983150983143 983154983141983155
Similar to hundreds of mine sites world-
wide Zinkgruvan is being operated on a
non-stop 247 basis with just a few main-
tenance breaks during the year Crusher
availability is crucial because 100 of the
ore has to pass through the jaws before
being hoisted up for further processing
In addition to the zinc- lead- copper-
and silver-containing ore the C jaws chop
all the host rock extracted along the min-
ing process With a sturdy design Metsorsquos
proven C jaws can easily reduce even the
hardest type of rock Every year more thanone million tons are crushed with the jaws
ldquoMinimal service neededrdquo
Crushing with the first C160B jaw crusher
began at Zinkgruvanrsquos -800 meter level in
2000 with the primary crushing of zinc-lead
ore The second jaw was installed in 2008
for the new copper process gt
The sight and sound of two C160 jaw crushers operating side by side in the underground
crushing station of the Swedish Zinkgruvan mine is impressive Good proactive service
secures good uptime and reliable continuous operation of Metsorsquos second-largest
C160 series jaw crushers and prepares the way for the ongoing plans to expand the
production of zinc concentrate
TEXT amp PHOTOS Eero Haumlmaumllaumlinen
New PolyMet liners are being tested with the grinding mill delivered by Metso
Zinkgruvanrsquos twin C160
jaws secure good uptime
8202019 Metso Minerals Aggregates 3 2011
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Blasted ore is taken from the presently
operated -850 meter level with normal
trucks as an outsourced process One full
truckload is fed to the C160s every
10 minutes
ldquoWe are happy with the high reliability
of the C jaws They only require some minor
service therefore providing us with good
uptime and steady continuous feed to our
secondary and tertiary crushing and grind-ing circuitsrdquo says Mine Manager Jan Klaumlre
ldquoBasic crusher service and wear part
changes are made by our own staff using
Metsorsquos partsrdquo he adds
Service contract with grinding
mills and conveyors
Zinkgruvan and Metso Sweden have more
than 11 yearsrsquo experience with a service
contract that contains grinding mills and
conveyors At the mine site two Metso
service people and one contractor take
care of all the related service jobs Man-
power can also be borrowed from Metsorsquos
Graumlngesberg mine service team of 20
people
Presently Zinkgruvan is testing Metsorsquos
new PolyMet mill linings in its big grinding
mills With previously used rubber partsthe linings had to be changed in the shell
every 9 to 11 months and in the feed head
every 6 months
ldquoWe expect a better lifetime with Poly-
Met linings Longer change intervals mean
a lot to our productivity because lining
changes takes two full working daysrdquo Mine
Manager Jan Klaumlre says
New mine goes deeper
With an expected mine life of more than 10
years Zinkgruvan is actively mapping new
ore reserves Experimental holes are being
drilled at the new mine section at the
-1110 meter level
More info
Fredrik Wennberg
Tel +46 70 657 00 08fredrikwennbergmetsocom
Mine Manager Jan Klaumlre (left) with Backfilling Manager Kjell Tillman at the underground -800 meter level mine cafeteria
983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
8202019 Metso Minerals Aggregates 3 2011
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The Zinkgruvan mine located approxi-
mately 200 km southwest of Stockholm
Sweden is one of the oldest underground
mines in Northern Europe The mine has
been in production since 1857
The mining methods used are panel
stoping and benching The processing
facilities include a zinc concentrating plant
with a 11 mtpa and a copper plant with a04 mtpa capacity Tailings are recycled in
an impounding basin and host rock in the
backfill plant
Continuous mining since 1857
Even as one of the oldest mines in Northern
Europe Zinkgruvan exploits modern mining
and minerals processing installations
Zinkgruvan mine
OWNER Lundin Mining
PRODUCTION PER YEAR 1 million tons
ORE TYPE sedimentary exhalative
zinc lead copper and silver
NUMBER OF EMPLOYEES 320
2011 PRODUCTION TARGETS 78000 tonsof zinc 36000 tons of lead and
3400 tons of copper concentrate
METSO EQUIPMENT ON SITE
bull 1 extra long VF feeder
bull 2 C160 jaw crushers
ndash zinc process css 220ndash240 mm
ndash copper process css 150 mm
bull 1 GP300S cone crusher
ndash css 45mm
bull 1 HP4 cone crusher
ndash css 18 mm
bull 1 DS screen
bull 1 FS402 screenbull 1 grinding mill
bull Pumps VPAs
A normal truck feeds the C jaws with ore coming from the lower production levels
983122983141983152983151983154983156983145983150983143 983154983141983155
8202019 Metso Minerals Aggregates 3 2011
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Cost-per-ton wear agreements deepencustomer relationshipsCrusher wear parts are traditionally marketed purely based on transactional sales and mainly depend on
the weight of manganese Metso has recently introduced a new type of wear agreement based on thecost-per-ton crushed and the wear occurred Thus far the experience has been very positive increasing
transparency and deepening the operational relationship between the manufacturer and the customer
TEXT Olli Kellokumpu and Eero Haumlmaumllaumlinen PHOTOS Eero Haumlmaumllaumlinen
Arto Hiedanniemi (left)
Hannu Heman and Juha
Laukka of Metsorsquos Finnish
Service team checking the
cone crusher mantles shipped
for a cost-per-ton customer
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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156
Wear parts and parts changes
can be included
The structure of a cost-per-ton wearcontract is based on the number of tons
crushed and the estimated wear occurred
The amount and monetary value of the
wear is calculated per crushed ton
ldquoEither plain wear parts or parts changes
carried out by Metsorsquos service personnel
can be included in the contract In the latter
case we ask our Finnish customers to inform
us about an upcoming wear change opera-
tion one week in advancerdquo Heman explains
ldquoWe see good opportunities to market
cost-per-ton contracts further in Finland
and also abroad It really develops therelationship of Metso and our customers
towards a trusted partnershiprdquo he notes
Perfect tool for accurate planning
Soraliike Ikola Oy is a mid-sized contrac-
tor with three Metso two- and three-
stage mobile and portable crushing and
screening plants operating in Central and
Since 2002 Metsorsquos sales team in Finland
has developed the cost-per-ton-based
service offeringldquoOur aim has been to seek through
a cost-per-ton offering possibilities to
serve our customers better to differentiate
Metso from the other players as an OEM
manufacturer and to offer deeper profes-
sionalism and know-howrdquo says Hannu
Heman General Manager of service
operations
ldquoUntil now both our experience and
that of our customers has been quite posi-
tive When properly prepared cost-per-ton
contracts seem to create a win-win situa-
tionrdquo Heman adds Today Metso has operational cost-per-
ton agreements with several Finnish cus-
tomers The first contract was concluded
with a customer operating a stationary
plant Based on the results gathered new
cost-per-ton contracts have been signed
with customers operating wheeled and
tracked equipment too
Eastern Finland Because of the size of the
contracts up to 50 equipment moves are
made during the yearEntrepreneur Pasi Ikola has had a cost-
per-ton contract with Metso for nearly
two years and he is quite happy with the
outcome
ldquoThe cost-per-ton contract has provided
me with a perfect tool for accurate financial
planning Now I know in detail my actual
future wear parts costs This helps a lot
when calculating bidsrdquo
ldquoEarlier I used to buy a big batch of
Metso wear parts in one go and had to
reserve a reasonable amount of money for
that Today all wear costs are evenly sharedwhich gives us a welcomed 1047298exibility to
our cost structure Now we just pay Metso
afterwards based on our crushed tonsrdquo
he adds
More info
Olli Kellokumpu
Tel +358 50 354 1189
ollikellokumpumetsocom
According to crushing contractor Pasi Ikola the cost-per-ton contract with Metso has provided the entrepreneur with better economical 1047298exibility
and more accurate calculating of bids
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Pleasant Gap is owned and operated by
Glenn O Hawbaker Inc of State College
Pennsylvania This family-owned company
began in 1952 as a small excavation busi-
ness founded by Glenn O Hawbaker and
his wife Thelma Over the years the com-
pany grew by adding an integrated mix ofproducts and services and taking on larger
projects
In 1983 Hawbaker acquired Pleasant
Gap Quarry and built its first aggregates
processing plant Today Glenn O Haw-
baker Inc operates 21 quarries and eight
asphalt production facilities across Penn-
sylvania and southern New York as well as
five regional operation centers
Primary
challenge atPleasant GapQuarryA good part of what makes for a successful crushing
operation is the willingness to tackle challenges and to do
whatrsquos necessary to meet demand The team at Pleasant
Gap Quarry in central Pennsylvania recently met the chal-
lenge when they successfully addressed problems with
the plantrsquos primary crushing plant First they purchased
a new Metso C160 jaw to replace the existing primary
impact crusher Then they devised an innovative plan to
get the primary plant back in operation while awaitingdelivery of the new jaw crusher
TEXT Linda Bergmann PHOTOS John Rickinger
983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Time for a change
With the goal of increasing reliability and
output the management at Pleasant Gap
Quarry recently decided it was time to
replace the plantrsquos primary impact crusher
Following a thorough search they chose a
new Metso C160 jaw According to ScottReck Plant Manager it no longer made
sense to repair and rebuild the existing
impactor
ldquoBefore we purchased the Metso C160
we had a few other impact crushers and
they served us well but as our custom-
ersrsquo needs increased our plant production
had to match that demand We found our
formerly reliable unit was being overcome
by our demands for output and creative
work-around solutions We continued to
need more but there was only so much we
could do until we hit the breaking point ndash
literallyrdquo
In addition to performance improve-
ments the new crusher also needed to fitinto Pleasant Gaprsquos unique infrastructure
As Plant Project ManagerEngineer Jeremy
Fahr explains ldquoOur height restraint was 274
meters (108rdquo) This height was the distance
from the feed lip of the existing 6x12 scalp-
ing screen and the existing structure that
the crusher rests onrdquo
The normal C160 crusher is 307
meters (121rdquo) tall but Metso gave GOH
Scott Reck Plant Manager (left) and
Jeremy Fahr Plant Project Manager
Engineer at Pleasant Gap Quarry
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983122983141983152983151983154983156983145983150983143 983154983141983155
a 10-degree mounting option (which is
normally used on their portable crushers)
to overcome the height restraint Reck and
Fahr worked with Dave Rhoa of Cleveland
Brothers Equipment Metsorsquos crushing and
screening distributor in Pennsylvania to
pull everything together and fit the newcrusher into their plant
The C160 crusher selected for Pleasant
Gap is one of the latest models in Metsorsquos
C Series of jaws These jaw crushers feature
a large throw and steep toggle plate angle
resulting in a higher crusher output In
addition the C Series has a compact foot-
print that makes it an ideal choice for the
replacement of existing machines
According to Reck ldquoWe had heard about
the new Metso C160 and started doing our
own research and found Metso not only
had developed the output capacity we
needed but fit the uniqueness of our oper-
ationsrdquo The new Metso crusher will allow
the plant to increase tons per hour andgive them the 1047298exibility to meet demands
for varying products on short notice
Mobile solution
Purchasing the new primary jaw addressed
the long-term issues but still left Pleasant
Gap without a functioning primary plant
Reck continues ldquoOur main line was still
down leaving us with a big hole in hitting
customer needs but knowing that our new
Metso C160 was on its wayhellipwe needed an
immediate solution to keep our produc-
tion demands with an out-of-commission
crusherrdquo
The team at Pleasant Gap brainstormed
the problem and came up with a plan toget the primary plant back in operation
Their solution was to use the Lokotrack
LT1213 impactor plant and another mobile
unit to keep the main line crushing To do
this they removed the guts on the existing
impact crusher essentially turning it into a
rock chute They then moved the LT1213
and another manufacturerrsquos mobile unit
over to the existing dump hopper gt
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
ldquoWe had our haul trucks drop off mate-
rial while two excavators fed the two
mobile unitsrdquo Reck explains ldquoFor two-and-
a-half months the Lokotrack LT1213 unit
was producing 254 cm (10rdquo) minus at
700 tons per hour The other similar-sized
mobile unit was doing 400 tons an hour
maxed out The difference was unbeliev-
able to say the least Our unique solution
using the two mobile units especially the
LT1213 helped Glenn O Hawbaker achieve
a record output in 2010rdquoAccording to Fahr ldquoWe were not new to
Metsorsquos quality and supportrdquo because GOH
had been using Metsorsquos portable crushing
equipment for 3 years prior to the primary
plantrsquos impact crusher failure In another
part of our operation we have a system that
our team relies on every day a Lokotrack
LT1213 and ST272 working in tandem with
two portable conveyorsrdquo This highly effi -
cient mobile processing system turns out
300 tons of specialized blended material
per hour GOH has been so impressed with
Metso equipment its last two purchaseswere an LT106 tracked jaw plant and a
second ST272 mobile screen in 2010
Maintaining high productivity
The Metso C160 jaw was delivered to Pleas-
ant Gap Quarry in January of 2011 and
since start-up it has more than met expec-
tations The crusher is fed minus 910 mm
(36rdquo) limestone with the jaw set at 140 mm
(5 12rdquo) According to Reck ldquoFrom moment
we started up we knew we had a winner
Not only were we kicking out as much
product as our previous units without even
breathing hard but we immediately had a
2-cent per ton savings to the bottom line
without having to run a second 350 HP
motor as required by other units Plus by
adding on the new automatic lube system
the maintenance team had more time to
devote to keeping other areas of the com-
plex running more effi cientlyrdquoReck says ldquoThe Metso unit was a perfect
fit and with the improved features it pre-
sented it had it all We just turn it on load
it up and we are moving 600 tons per hour
through the crusher without any effort and
we know it can do so much morerdquo With
the primary crushing plant back in opera-
tion the entire team at Pleasant Gap will
continue to do what they do best produce
and sell high-quality products and meet
their customersrsquo expectations
More info
Scott Yablonsky Tel +1 262 717 793
scottyablonskymetsocom
The Metso C160 jaw
was installed at a 10deg
angle to fit Pleasant
Gaprsquos existing
infrastructure
The Lokotrack LT1213 impactor plant and ST272 mobile screen operate in tandem with two
portable conveyors at Pleasant Gap
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983149983141983156983155983151 983150
Paper amp fiberNew OptiConcept M paper
and board making line
The new OptiConcept M paper and board
making line stands for economy safety and
usability
Metso has launched a new modular paper
and board making line called OptiConceptM A member of the proven OptiConcept
production line family the new OptiCon-
cept M optimizes machine investment in
line with each millrsquos capacity needs
Savings in operating costs are achieved
through precise dimensioning of pro-
cesses proven technological solutions
optimal running parameters effective
maintenance operations and fully inte-
grated automation solutions
Optimized processes innovations
smart controls and accurate dimensioning
decrease the use of steam gas electricitywater chemicals and other raw materials
and reduce emission levels
OptiConcept M has been designed
both visually and physically with the
requirements of users in mind For exam-
ple the design of the machinery allows for
easy and safe changing of rolls and wear
parts thus reducing the total duration and
cost of maintenance shutdowns
RecyclingGreen energy technology to
Elektrociepłownia Białystok in Poland
Metso will convert a coal-fired boiler to
a biomass-fired Bubbling Fluidized Bed
boiler for Elektrociepłownia Białystok SArsquos
combined heat and power plant (CHP) in
Białystok Poland The new boiler system
will cut the power plantrsquos CO2 emissions
significantly by partly replacing the coal
fuel supply with biomass fuel
ldquoPoland is one of the largest countries
in Europe to have such a high depend-ence on energy derived from coal to
meet national electricity needs This is an
important incentive for us to reduce future
CO2 emissions and produce more green
electricity and with Metso technology
we are certain to accomplish our goalrdquo
states Mr Andrzej Schroeder President of
Elektrociepłownia Białystok SA
Since 2000 Metso has received a total
of 7 biomass boiler conversion orders in
Poland and the renewable energy share
in Poland is only 75 (2010) compared to
the target of 20 by 2020 set by the EUApproximately 80 of the current energy
boilers turbines and generators installed in
Polish power plants are over 20 years old In
order to meet the strict EU environmental
requirements modernization of existing
installations is necessary
Automation
Metso DNA automation system expands
to mining and construction
Using Metsorsquos control room automation
an entire crushing and screening plant can
be effi ciently managed
Metso is a leading supplier of mining and
construction machinery This expertise has
now been combined with a scalable Metso
DNA automation system that adapts to
the range of industry needs from single
machine controls to plant-wide automation
and information management systems
An example of Metsorsquos new offering is a
new crushing plant control room solution
that connects crushers and screens ensur-
ing the effective management of the entire
plant from a pleasant and safe control
room The Metso DNA user interface pro-vides the production information to ensure
a proper and rapid response to plant
events Automatic controls stabilize the
process and allow the operators to monitor
the plant as a whole
ldquoThe benefits of automation for the min-
ing and construction industry are signifi-
cant As an example of the services we offer
performance studies to crushing plants
utilizing Metsorsquos multi-disciplinary teams of
experts to determine the present level of
the plant and process effi ciency and to esti-
mate the improvement potential and thebenefits of optimization and automation
including ROI calculationsrdquo says Mikko Maumlki-
nen Product Manager of minerals applica-
tions in Metsorsquos Automation business line
ldquoAs another example our machine
condition monitoring solutions can reduce
plant and machine downtimes as well as
help to avoid safety and environmental
hazardsrdquo he adds
Metso around the world
Aerial view of the Elektrociepłownia Białystok combined heat and power plant in Poland
8202019 Metso Minerals Aggregates 3 2011
httpslidepdfcomreaderfullmetso-minerals-aggregates-3-2011 3636
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
8202019 Metso Minerals Aggregates 3 2011
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983122983141983152983151983154983156983145983150983143 983154983141983155
Similar to hundreds of mine sites world-
wide Zinkgruvan is being operated on a
non-stop 247 basis with just a few main-
tenance breaks during the year Crusher
availability is crucial because 100 of the
ore has to pass through the jaws before
being hoisted up for further processing
In addition to the zinc- lead- copper-
and silver-containing ore the C jaws chop
all the host rock extracted along the min-
ing process With a sturdy design Metsorsquos
proven C jaws can easily reduce even the
hardest type of rock Every year more thanone million tons are crushed with the jaws
ldquoMinimal service neededrdquo
Crushing with the first C160B jaw crusher
began at Zinkgruvanrsquos -800 meter level in
2000 with the primary crushing of zinc-lead
ore The second jaw was installed in 2008
for the new copper process gt
The sight and sound of two C160 jaw crushers operating side by side in the underground
crushing station of the Swedish Zinkgruvan mine is impressive Good proactive service
secures good uptime and reliable continuous operation of Metsorsquos second-largest
C160 series jaw crushers and prepares the way for the ongoing plans to expand the
production of zinc concentrate
TEXT amp PHOTOS Eero Haumlmaumllaumlinen
New PolyMet liners are being tested with the grinding mill delivered by Metso
Zinkgruvanrsquos twin C160
jaws secure good uptime
8202019 Metso Minerals Aggregates 3 2011
httpslidepdfcomreaderfullmetso-minerals-aggregates-3-2011 28368983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983089
Blasted ore is taken from the presently
operated -850 meter level with normal
trucks as an outsourced process One full
truckload is fed to the C160s every
10 minutes
ldquoWe are happy with the high reliability
of the C jaws They only require some minor
service therefore providing us with good
uptime and steady continuous feed to our
secondary and tertiary crushing and grind-ing circuitsrdquo says Mine Manager Jan Klaumlre
ldquoBasic crusher service and wear part
changes are made by our own staff using
Metsorsquos partsrdquo he adds
Service contract with grinding
mills and conveyors
Zinkgruvan and Metso Sweden have more
than 11 yearsrsquo experience with a service
contract that contains grinding mills and
conveyors At the mine site two Metso
service people and one contractor take
care of all the related service jobs Man-
power can also be borrowed from Metsorsquos
Graumlngesberg mine service team of 20
people
Presently Zinkgruvan is testing Metsorsquos
new PolyMet mill linings in its big grinding
mills With previously used rubber partsthe linings had to be changed in the shell
every 9 to 11 months and in the feed head
every 6 months
ldquoWe expect a better lifetime with Poly-
Met linings Longer change intervals mean
a lot to our productivity because lining
changes takes two full working daysrdquo Mine
Manager Jan Klaumlre says
New mine goes deeper
With an expected mine life of more than 10
years Zinkgruvan is actively mapping new
ore reserves Experimental holes are being
drilled at the new mine section at the
-1110 meter level
More info
Fredrik Wennberg
Tel +46 70 657 00 08fredrikwennbergmetsocom
Mine Manager Jan Klaumlre (left) with Backfilling Manager Kjell Tillman at the underground -800 meter level mine cafeteria
983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
8202019 Metso Minerals Aggregates 3 2011
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The Zinkgruvan mine located approxi-
mately 200 km southwest of Stockholm
Sweden is one of the oldest underground
mines in Northern Europe The mine has
been in production since 1857
The mining methods used are panel
stoping and benching The processing
facilities include a zinc concentrating plant
with a 11 mtpa and a copper plant with a04 mtpa capacity Tailings are recycled in
an impounding basin and host rock in the
backfill plant
Continuous mining since 1857
Even as one of the oldest mines in Northern
Europe Zinkgruvan exploits modern mining
and minerals processing installations
Zinkgruvan mine
OWNER Lundin Mining
PRODUCTION PER YEAR 1 million tons
ORE TYPE sedimentary exhalative
zinc lead copper and silver
NUMBER OF EMPLOYEES 320
2011 PRODUCTION TARGETS 78000 tonsof zinc 36000 tons of lead and
3400 tons of copper concentrate
METSO EQUIPMENT ON SITE
bull 1 extra long VF feeder
bull 2 C160 jaw crushers
ndash zinc process css 220ndash240 mm
ndash copper process css 150 mm
bull 1 GP300S cone crusher
ndash css 45mm
bull 1 HP4 cone crusher
ndash css 18 mm
bull 1 DS screen
bull 1 FS402 screenbull 1 grinding mill
bull Pumps VPAs
A normal truck feeds the C jaws with ore coming from the lower production levels
983122983141983152983151983154983156983145983150983143 983154983141983155
8202019 Metso Minerals Aggregates 3 2011
httpslidepdfcomreaderfullmetso-minerals-aggregates-3-2011 30360983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983089
Cost-per-ton wear agreements deepencustomer relationshipsCrusher wear parts are traditionally marketed purely based on transactional sales and mainly depend on
the weight of manganese Metso has recently introduced a new type of wear agreement based on thecost-per-ton crushed and the wear occurred Thus far the experience has been very positive increasing
transparency and deepening the operational relationship between the manufacturer and the customer
TEXT Olli Kellokumpu and Eero Haumlmaumllaumlinen PHOTOS Eero Haumlmaumllaumlinen
Arto Hiedanniemi (left)
Hannu Heman and Juha
Laukka of Metsorsquos Finnish
Service team checking the
cone crusher mantles shipped
for a cost-per-ton customer
8202019 Metso Minerals Aggregates 3 2011
httpslidepdfcomreaderfullmetso-minerals-aggregates-3-2011 3136983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088
983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156
Wear parts and parts changes
can be included
The structure of a cost-per-ton wearcontract is based on the number of tons
crushed and the estimated wear occurred
The amount and monetary value of the
wear is calculated per crushed ton
ldquoEither plain wear parts or parts changes
carried out by Metsorsquos service personnel
can be included in the contract In the latter
case we ask our Finnish customers to inform
us about an upcoming wear change opera-
tion one week in advancerdquo Heman explains
ldquoWe see good opportunities to market
cost-per-ton contracts further in Finland
and also abroad It really develops therelationship of Metso and our customers
towards a trusted partnershiprdquo he notes
Perfect tool for accurate planning
Soraliike Ikola Oy is a mid-sized contrac-
tor with three Metso two- and three-
stage mobile and portable crushing and
screening plants operating in Central and
Since 2002 Metsorsquos sales team in Finland
has developed the cost-per-ton-based
service offeringldquoOur aim has been to seek through
a cost-per-ton offering possibilities to
serve our customers better to differentiate
Metso from the other players as an OEM
manufacturer and to offer deeper profes-
sionalism and know-howrdquo says Hannu
Heman General Manager of service
operations
ldquoUntil now both our experience and
that of our customers has been quite posi-
tive When properly prepared cost-per-ton
contracts seem to create a win-win situa-
tionrdquo Heman adds Today Metso has operational cost-per-
ton agreements with several Finnish cus-
tomers The first contract was concluded
with a customer operating a stationary
plant Based on the results gathered new
cost-per-ton contracts have been signed
with customers operating wheeled and
tracked equipment too
Eastern Finland Because of the size of the
contracts up to 50 equipment moves are
made during the yearEntrepreneur Pasi Ikola has had a cost-
per-ton contract with Metso for nearly
two years and he is quite happy with the
outcome
ldquoThe cost-per-ton contract has provided
me with a perfect tool for accurate financial
planning Now I know in detail my actual
future wear parts costs This helps a lot
when calculating bidsrdquo
ldquoEarlier I used to buy a big batch of
Metso wear parts in one go and had to
reserve a reasonable amount of money for
that Today all wear costs are evenly sharedwhich gives us a welcomed 1047298exibility to
our cost structure Now we just pay Metso
afterwards based on our crushed tonsrdquo
he adds
More info
Olli Kellokumpu
Tel +358 50 354 1189
ollikellokumpumetsocom
According to crushing contractor Pasi Ikola the cost-per-ton contract with Metso has provided the entrepreneur with better economical 1047298exibility
and more accurate calculating of bids
8202019 Metso Minerals Aggregates 3 2011
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Pleasant Gap is owned and operated by
Glenn O Hawbaker Inc of State College
Pennsylvania This family-owned company
began in 1952 as a small excavation busi-
ness founded by Glenn O Hawbaker and
his wife Thelma Over the years the com-
pany grew by adding an integrated mix ofproducts and services and taking on larger
projects
In 1983 Hawbaker acquired Pleasant
Gap Quarry and built its first aggregates
processing plant Today Glenn O Haw-
baker Inc operates 21 quarries and eight
asphalt production facilities across Penn-
sylvania and southern New York as well as
five regional operation centers
Primary
challenge atPleasant GapQuarryA good part of what makes for a successful crushing
operation is the willingness to tackle challenges and to do
whatrsquos necessary to meet demand The team at Pleasant
Gap Quarry in central Pennsylvania recently met the chal-
lenge when they successfully addressed problems with
the plantrsquos primary crushing plant First they purchased
a new Metso C160 jaw to replace the existing primary
impact crusher Then they devised an innovative plan to
get the primary plant back in operation while awaitingdelivery of the new jaw crusher
TEXT Linda Bergmann PHOTOS John Rickinger
983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Time for a change
With the goal of increasing reliability and
output the management at Pleasant Gap
Quarry recently decided it was time to
replace the plantrsquos primary impact crusher
Following a thorough search they chose a
new Metso C160 jaw According to ScottReck Plant Manager it no longer made
sense to repair and rebuild the existing
impactor
ldquoBefore we purchased the Metso C160
we had a few other impact crushers and
they served us well but as our custom-
ersrsquo needs increased our plant production
had to match that demand We found our
formerly reliable unit was being overcome
by our demands for output and creative
work-around solutions We continued to
need more but there was only so much we
could do until we hit the breaking point ndash
literallyrdquo
In addition to performance improve-
ments the new crusher also needed to fitinto Pleasant Gaprsquos unique infrastructure
As Plant Project ManagerEngineer Jeremy
Fahr explains ldquoOur height restraint was 274
meters (108rdquo) This height was the distance
from the feed lip of the existing 6x12 scalp-
ing screen and the existing structure that
the crusher rests onrdquo
The normal C160 crusher is 307
meters (121rdquo) tall but Metso gave GOH
Scott Reck Plant Manager (left) and
Jeremy Fahr Plant Project Manager
Engineer at Pleasant Gap Quarry
8202019 Metso Minerals Aggregates 3 2011
httpslidepdfcomreaderfullmetso-minerals-aggregates-3-2011 3336983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088
983122983141983152983151983154983156983145983150983143 983154983141983155
a 10-degree mounting option (which is
normally used on their portable crushers)
to overcome the height restraint Reck and
Fahr worked with Dave Rhoa of Cleveland
Brothers Equipment Metsorsquos crushing and
screening distributor in Pennsylvania to
pull everything together and fit the newcrusher into their plant
The C160 crusher selected for Pleasant
Gap is one of the latest models in Metsorsquos
C Series of jaws These jaw crushers feature
a large throw and steep toggle plate angle
resulting in a higher crusher output In
addition the C Series has a compact foot-
print that makes it an ideal choice for the
replacement of existing machines
According to Reck ldquoWe had heard about
the new Metso C160 and started doing our
own research and found Metso not only
had developed the output capacity we
needed but fit the uniqueness of our oper-
ationsrdquo The new Metso crusher will allow
the plant to increase tons per hour andgive them the 1047298exibility to meet demands
for varying products on short notice
Mobile solution
Purchasing the new primary jaw addressed
the long-term issues but still left Pleasant
Gap without a functioning primary plant
Reck continues ldquoOur main line was still
down leaving us with a big hole in hitting
customer needs but knowing that our new
Metso C160 was on its wayhellipwe needed an
immediate solution to keep our produc-
tion demands with an out-of-commission
crusherrdquo
The team at Pleasant Gap brainstormed
the problem and came up with a plan toget the primary plant back in operation
Their solution was to use the Lokotrack
LT1213 impactor plant and another mobile
unit to keep the main line crushing To do
this they removed the guts on the existing
impact crusher essentially turning it into a
rock chute They then moved the LT1213
and another manufacturerrsquos mobile unit
over to the existing dump hopper gt
8202019 Metso Minerals Aggregates 3 2011
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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
ldquoWe had our haul trucks drop off mate-
rial while two excavators fed the two
mobile unitsrdquo Reck explains ldquoFor two-and-
a-half months the Lokotrack LT1213 unit
was producing 254 cm (10rdquo) minus at
700 tons per hour The other similar-sized
mobile unit was doing 400 tons an hour
maxed out The difference was unbeliev-
able to say the least Our unique solution
using the two mobile units especially the
LT1213 helped Glenn O Hawbaker achieve
a record output in 2010rdquoAccording to Fahr ldquoWe were not new to
Metsorsquos quality and supportrdquo because GOH
had been using Metsorsquos portable crushing
equipment for 3 years prior to the primary
plantrsquos impact crusher failure In another
part of our operation we have a system that
our team relies on every day a Lokotrack
LT1213 and ST272 working in tandem with
two portable conveyorsrdquo This highly effi -
cient mobile processing system turns out
300 tons of specialized blended material
per hour GOH has been so impressed with
Metso equipment its last two purchaseswere an LT106 tracked jaw plant and a
second ST272 mobile screen in 2010
Maintaining high productivity
The Metso C160 jaw was delivered to Pleas-
ant Gap Quarry in January of 2011 and
since start-up it has more than met expec-
tations The crusher is fed minus 910 mm
(36rdquo) limestone with the jaw set at 140 mm
(5 12rdquo) According to Reck ldquoFrom moment
we started up we knew we had a winner
Not only were we kicking out as much
product as our previous units without even
breathing hard but we immediately had a
2-cent per ton savings to the bottom line
without having to run a second 350 HP
motor as required by other units Plus by
adding on the new automatic lube system
the maintenance team had more time to
devote to keeping other areas of the com-
plex running more effi cientlyrdquoReck says ldquoThe Metso unit was a perfect
fit and with the improved features it pre-
sented it had it all We just turn it on load
it up and we are moving 600 tons per hour
through the crusher without any effort and
we know it can do so much morerdquo With
the primary crushing plant back in opera-
tion the entire team at Pleasant Gap will
continue to do what they do best produce
and sell high-quality products and meet
their customersrsquo expectations
More info
Scott Yablonsky Tel +1 262 717 793
scottyablonskymetsocom
The Metso C160 jaw
was installed at a 10deg
angle to fit Pleasant
Gaprsquos existing
infrastructure
The Lokotrack LT1213 impactor plant and ST272 mobile screen operate in tandem with two
portable conveyors at Pleasant Gap
8202019 Metso Minerals Aggregates 3 2011
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983149983141983156983155983151 983150
Paper amp fiberNew OptiConcept M paper
and board making line
The new OptiConcept M paper and board
making line stands for economy safety and
usability
Metso has launched a new modular paper
and board making line called OptiConceptM A member of the proven OptiConcept
production line family the new OptiCon-
cept M optimizes machine investment in
line with each millrsquos capacity needs
Savings in operating costs are achieved
through precise dimensioning of pro-
cesses proven technological solutions
optimal running parameters effective
maintenance operations and fully inte-
grated automation solutions
Optimized processes innovations
smart controls and accurate dimensioning
decrease the use of steam gas electricitywater chemicals and other raw materials
and reduce emission levels
OptiConcept M has been designed
both visually and physically with the
requirements of users in mind For exam-
ple the design of the machinery allows for
easy and safe changing of rolls and wear
parts thus reducing the total duration and
cost of maintenance shutdowns
RecyclingGreen energy technology to
Elektrociepłownia Białystok in Poland
Metso will convert a coal-fired boiler to
a biomass-fired Bubbling Fluidized Bed
boiler for Elektrociepłownia Białystok SArsquos
combined heat and power plant (CHP) in
Białystok Poland The new boiler system
will cut the power plantrsquos CO2 emissions
significantly by partly replacing the coal
fuel supply with biomass fuel
ldquoPoland is one of the largest countries
in Europe to have such a high depend-ence on energy derived from coal to
meet national electricity needs This is an
important incentive for us to reduce future
CO2 emissions and produce more green
electricity and with Metso technology
we are certain to accomplish our goalrdquo
states Mr Andrzej Schroeder President of
Elektrociepłownia Białystok SA
Since 2000 Metso has received a total
of 7 biomass boiler conversion orders in
Poland and the renewable energy share
in Poland is only 75 (2010) compared to
the target of 20 by 2020 set by the EUApproximately 80 of the current energy
boilers turbines and generators installed in
Polish power plants are over 20 years old In
order to meet the strict EU environmental
requirements modernization of existing
installations is necessary
Automation
Metso DNA automation system expands
to mining and construction
Using Metsorsquos control room automation
an entire crushing and screening plant can
be effi ciently managed
Metso is a leading supplier of mining and
construction machinery This expertise has
now been combined with a scalable Metso
DNA automation system that adapts to
the range of industry needs from single
machine controls to plant-wide automation
and information management systems
An example of Metsorsquos new offering is a
new crushing plant control room solution
that connects crushers and screens ensur-
ing the effective management of the entire
plant from a pleasant and safe control
room The Metso DNA user interface pro-vides the production information to ensure
a proper and rapid response to plant
events Automatic controls stabilize the
process and allow the operators to monitor
the plant as a whole
ldquoThe benefits of automation for the min-
ing and construction industry are signifi-
cant As an example of the services we offer
performance studies to crushing plants
utilizing Metsorsquos multi-disciplinary teams of
experts to determine the present level of
the plant and process effi ciency and to esti-
mate the improvement potential and thebenefits of optimization and automation
including ROI calculationsrdquo says Mikko Maumlki-
nen Product Manager of minerals applica-
tions in Metsorsquos Automation business line
ldquoAs another example our machine
condition monitoring solutions can reduce
plant and machine downtimes as well as
help to avoid safety and environmental
hazardsrdquo he adds
Metso around the world
Aerial view of the Elektrociepłownia Białystok combined heat and power plant in Poland
8202019 Metso Minerals Aggregates 3 2011
httpslidepdfcomreaderfullmetso-minerals-aggregates-3-2011 3636
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
8202019 Metso Minerals Aggregates 3 2011
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Blasted ore is taken from the presently
operated -850 meter level with normal
trucks as an outsourced process One full
truckload is fed to the C160s every
10 minutes
ldquoWe are happy with the high reliability
of the C jaws They only require some minor
service therefore providing us with good
uptime and steady continuous feed to our
secondary and tertiary crushing and grind-ing circuitsrdquo says Mine Manager Jan Klaumlre
ldquoBasic crusher service and wear part
changes are made by our own staff using
Metsorsquos partsrdquo he adds
Service contract with grinding
mills and conveyors
Zinkgruvan and Metso Sweden have more
than 11 yearsrsquo experience with a service
contract that contains grinding mills and
conveyors At the mine site two Metso
service people and one contractor take
care of all the related service jobs Man-
power can also be borrowed from Metsorsquos
Graumlngesberg mine service team of 20
people
Presently Zinkgruvan is testing Metsorsquos
new PolyMet mill linings in its big grinding
mills With previously used rubber partsthe linings had to be changed in the shell
every 9 to 11 months and in the feed head
every 6 months
ldquoWe expect a better lifetime with Poly-
Met linings Longer change intervals mean
a lot to our productivity because lining
changes takes two full working daysrdquo Mine
Manager Jan Klaumlre says
New mine goes deeper
With an expected mine life of more than 10
years Zinkgruvan is actively mapping new
ore reserves Experimental holes are being
drilled at the new mine section at the
-1110 meter level
More info
Fredrik Wennberg
Tel +46 70 657 00 08fredrikwennbergmetsocom
Mine Manager Jan Klaumlre (left) with Backfilling Manager Kjell Tillman at the underground -800 meter level mine cafeteria
983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
8202019 Metso Minerals Aggregates 3 2011
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The Zinkgruvan mine located approxi-
mately 200 km southwest of Stockholm
Sweden is one of the oldest underground
mines in Northern Europe The mine has
been in production since 1857
The mining methods used are panel
stoping and benching The processing
facilities include a zinc concentrating plant
with a 11 mtpa and a copper plant with a04 mtpa capacity Tailings are recycled in
an impounding basin and host rock in the
backfill plant
Continuous mining since 1857
Even as one of the oldest mines in Northern
Europe Zinkgruvan exploits modern mining
and minerals processing installations
Zinkgruvan mine
OWNER Lundin Mining
PRODUCTION PER YEAR 1 million tons
ORE TYPE sedimentary exhalative
zinc lead copper and silver
NUMBER OF EMPLOYEES 320
2011 PRODUCTION TARGETS 78000 tonsof zinc 36000 tons of lead and
3400 tons of copper concentrate
METSO EQUIPMENT ON SITE
bull 1 extra long VF feeder
bull 2 C160 jaw crushers
ndash zinc process css 220ndash240 mm
ndash copper process css 150 mm
bull 1 GP300S cone crusher
ndash css 45mm
bull 1 HP4 cone crusher
ndash css 18 mm
bull 1 DS screen
bull 1 FS402 screenbull 1 grinding mill
bull Pumps VPAs
A normal truck feeds the C jaws with ore coming from the lower production levels
983122983141983152983151983154983156983145983150983143 983154983141983155
8202019 Metso Minerals Aggregates 3 2011
httpslidepdfcomreaderfullmetso-minerals-aggregates-3-2011 30360983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983089
Cost-per-ton wear agreements deepencustomer relationshipsCrusher wear parts are traditionally marketed purely based on transactional sales and mainly depend on
the weight of manganese Metso has recently introduced a new type of wear agreement based on thecost-per-ton crushed and the wear occurred Thus far the experience has been very positive increasing
transparency and deepening the operational relationship between the manufacturer and the customer
TEXT Olli Kellokumpu and Eero Haumlmaumllaumlinen PHOTOS Eero Haumlmaumllaumlinen
Arto Hiedanniemi (left)
Hannu Heman and Juha
Laukka of Metsorsquos Finnish
Service team checking the
cone crusher mantles shipped
for a cost-per-ton customer
8202019 Metso Minerals Aggregates 3 2011
httpslidepdfcomreaderfullmetso-minerals-aggregates-3-2011 3136983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088
983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156
Wear parts and parts changes
can be included
The structure of a cost-per-ton wearcontract is based on the number of tons
crushed and the estimated wear occurred
The amount and monetary value of the
wear is calculated per crushed ton
ldquoEither plain wear parts or parts changes
carried out by Metsorsquos service personnel
can be included in the contract In the latter
case we ask our Finnish customers to inform
us about an upcoming wear change opera-
tion one week in advancerdquo Heman explains
ldquoWe see good opportunities to market
cost-per-ton contracts further in Finland
and also abroad It really develops therelationship of Metso and our customers
towards a trusted partnershiprdquo he notes
Perfect tool for accurate planning
Soraliike Ikola Oy is a mid-sized contrac-
tor with three Metso two- and three-
stage mobile and portable crushing and
screening plants operating in Central and
Since 2002 Metsorsquos sales team in Finland
has developed the cost-per-ton-based
service offeringldquoOur aim has been to seek through
a cost-per-ton offering possibilities to
serve our customers better to differentiate
Metso from the other players as an OEM
manufacturer and to offer deeper profes-
sionalism and know-howrdquo says Hannu
Heman General Manager of service
operations
ldquoUntil now both our experience and
that of our customers has been quite posi-
tive When properly prepared cost-per-ton
contracts seem to create a win-win situa-
tionrdquo Heman adds Today Metso has operational cost-per-
ton agreements with several Finnish cus-
tomers The first contract was concluded
with a customer operating a stationary
plant Based on the results gathered new
cost-per-ton contracts have been signed
with customers operating wheeled and
tracked equipment too
Eastern Finland Because of the size of the
contracts up to 50 equipment moves are
made during the yearEntrepreneur Pasi Ikola has had a cost-
per-ton contract with Metso for nearly
two years and he is quite happy with the
outcome
ldquoThe cost-per-ton contract has provided
me with a perfect tool for accurate financial
planning Now I know in detail my actual
future wear parts costs This helps a lot
when calculating bidsrdquo
ldquoEarlier I used to buy a big batch of
Metso wear parts in one go and had to
reserve a reasonable amount of money for
that Today all wear costs are evenly sharedwhich gives us a welcomed 1047298exibility to
our cost structure Now we just pay Metso
afterwards based on our crushed tonsrdquo
he adds
More info
Olli Kellokumpu
Tel +358 50 354 1189
ollikellokumpumetsocom
According to crushing contractor Pasi Ikola the cost-per-ton contract with Metso has provided the entrepreneur with better economical 1047298exibility
and more accurate calculating of bids
8202019 Metso Minerals Aggregates 3 2011
httpslidepdfcomreaderfullmetso-minerals-aggregates-3-2011 32362983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983089
Pleasant Gap is owned and operated by
Glenn O Hawbaker Inc of State College
Pennsylvania This family-owned company
began in 1952 as a small excavation busi-
ness founded by Glenn O Hawbaker and
his wife Thelma Over the years the com-
pany grew by adding an integrated mix ofproducts and services and taking on larger
projects
In 1983 Hawbaker acquired Pleasant
Gap Quarry and built its first aggregates
processing plant Today Glenn O Haw-
baker Inc operates 21 quarries and eight
asphalt production facilities across Penn-
sylvania and southern New York as well as
five regional operation centers
Primary
challenge atPleasant GapQuarryA good part of what makes for a successful crushing
operation is the willingness to tackle challenges and to do
whatrsquos necessary to meet demand The team at Pleasant
Gap Quarry in central Pennsylvania recently met the chal-
lenge when they successfully addressed problems with
the plantrsquos primary crushing plant First they purchased
a new Metso C160 jaw to replace the existing primary
impact crusher Then they devised an innovative plan to
get the primary plant back in operation while awaitingdelivery of the new jaw crusher
TEXT Linda Bergmann PHOTOS John Rickinger
983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Time for a change
With the goal of increasing reliability and
output the management at Pleasant Gap
Quarry recently decided it was time to
replace the plantrsquos primary impact crusher
Following a thorough search they chose a
new Metso C160 jaw According to ScottReck Plant Manager it no longer made
sense to repair and rebuild the existing
impactor
ldquoBefore we purchased the Metso C160
we had a few other impact crushers and
they served us well but as our custom-
ersrsquo needs increased our plant production
had to match that demand We found our
formerly reliable unit was being overcome
by our demands for output and creative
work-around solutions We continued to
need more but there was only so much we
could do until we hit the breaking point ndash
literallyrdquo
In addition to performance improve-
ments the new crusher also needed to fitinto Pleasant Gaprsquos unique infrastructure
As Plant Project ManagerEngineer Jeremy
Fahr explains ldquoOur height restraint was 274
meters (108rdquo) This height was the distance
from the feed lip of the existing 6x12 scalp-
ing screen and the existing structure that
the crusher rests onrdquo
The normal C160 crusher is 307
meters (121rdquo) tall but Metso gave GOH
Scott Reck Plant Manager (left) and
Jeremy Fahr Plant Project Manager
Engineer at Pleasant Gap Quarry
8202019 Metso Minerals Aggregates 3 2011
httpslidepdfcomreaderfullmetso-minerals-aggregates-3-2011 3336983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088
983122983141983152983151983154983156983145983150983143 983154983141983155
a 10-degree mounting option (which is
normally used on their portable crushers)
to overcome the height restraint Reck and
Fahr worked with Dave Rhoa of Cleveland
Brothers Equipment Metsorsquos crushing and
screening distributor in Pennsylvania to
pull everything together and fit the newcrusher into their plant
The C160 crusher selected for Pleasant
Gap is one of the latest models in Metsorsquos
C Series of jaws These jaw crushers feature
a large throw and steep toggle plate angle
resulting in a higher crusher output In
addition the C Series has a compact foot-
print that makes it an ideal choice for the
replacement of existing machines
According to Reck ldquoWe had heard about
the new Metso C160 and started doing our
own research and found Metso not only
had developed the output capacity we
needed but fit the uniqueness of our oper-
ationsrdquo The new Metso crusher will allow
the plant to increase tons per hour andgive them the 1047298exibility to meet demands
for varying products on short notice
Mobile solution
Purchasing the new primary jaw addressed
the long-term issues but still left Pleasant
Gap without a functioning primary plant
Reck continues ldquoOur main line was still
down leaving us with a big hole in hitting
customer needs but knowing that our new
Metso C160 was on its wayhellipwe needed an
immediate solution to keep our produc-
tion demands with an out-of-commission
crusherrdquo
The team at Pleasant Gap brainstormed
the problem and came up with a plan toget the primary plant back in operation
Their solution was to use the Lokotrack
LT1213 impactor plant and another mobile
unit to keep the main line crushing To do
this they removed the guts on the existing
impact crusher essentially turning it into a
rock chute They then moved the LT1213
and another manufacturerrsquos mobile unit
over to the existing dump hopper gt
8202019 Metso Minerals Aggregates 3 2011
httpslidepdfcomreaderfullmetso-minerals-aggregates-3-2011 34364983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983089
983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
ldquoWe had our haul trucks drop off mate-
rial while two excavators fed the two
mobile unitsrdquo Reck explains ldquoFor two-and-
a-half months the Lokotrack LT1213 unit
was producing 254 cm (10rdquo) minus at
700 tons per hour The other similar-sized
mobile unit was doing 400 tons an hour
maxed out The difference was unbeliev-
able to say the least Our unique solution
using the two mobile units especially the
LT1213 helped Glenn O Hawbaker achieve
a record output in 2010rdquoAccording to Fahr ldquoWe were not new to
Metsorsquos quality and supportrdquo because GOH
had been using Metsorsquos portable crushing
equipment for 3 years prior to the primary
plantrsquos impact crusher failure In another
part of our operation we have a system that
our team relies on every day a Lokotrack
LT1213 and ST272 working in tandem with
two portable conveyorsrdquo This highly effi -
cient mobile processing system turns out
300 tons of specialized blended material
per hour GOH has been so impressed with
Metso equipment its last two purchaseswere an LT106 tracked jaw plant and a
second ST272 mobile screen in 2010
Maintaining high productivity
The Metso C160 jaw was delivered to Pleas-
ant Gap Quarry in January of 2011 and
since start-up it has more than met expec-
tations The crusher is fed minus 910 mm
(36rdquo) limestone with the jaw set at 140 mm
(5 12rdquo) According to Reck ldquoFrom moment
we started up we knew we had a winner
Not only were we kicking out as much
product as our previous units without even
breathing hard but we immediately had a
2-cent per ton savings to the bottom line
without having to run a second 350 HP
motor as required by other units Plus by
adding on the new automatic lube system
the maintenance team had more time to
devote to keeping other areas of the com-
plex running more effi cientlyrdquoReck says ldquoThe Metso unit was a perfect
fit and with the improved features it pre-
sented it had it all We just turn it on load
it up and we are moving 600 tons per hour
through the crusher without any effort and
we know it can do so much morerdquo With
the primary crushing plant back in opera-
tion the entire team at Pleasant Gap will
continue to do what they do best produce
and sell high-quality products and meet
their customersrsquo expectations
More info
Scott Yablonsky Tel +1 262 717 793
scottyablonskymetsocom
The Metso C160 jaw
was installed at a 10deg
angle to fit Pleasant
Gaprsquos existing
infrastructure
The Lokotrack LT1213 impactor plant and ST272 mobile screen operate in tandem with two
portable conveyors at Pleasant Gap
8202019 Metso Minerals Aggregates 3 2011
httpslidepdfcomreaderfullmetso-minerals-aggregates-3-2011 3536983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088
983149983141983156983155983151 983150
Paper amp fiberNew OptiConcept M paper
and board making line
The new OptiConcept M paper and board
making line stands for economy safety and
usability
Metso has launched a new modular paper
and board making line called OptiConceptM A member of the proven OptiConcept
production line family the new OptiCon-
cept M optimizes machine investment in
line with each millrsquos capacity needs
Savings in operating costs are achieved
through precise dimensioning of pro-
cesses proven technological solutions
optimal running parameters effective
maintenance operations and fully inte-
grated automation solutions
Optimized processes innovations
smart controls and accurate dimensioning
decrease the use of steam gas electricitywater chemicals and other raw materials
and reduce emission levels
OptiConcept M has been designed
both visually and physically with the
requirements of users in mind For exam-
ple the design of the machinery allows for
easy and safe changing of rolls and wear
parts thus reducing the total duration and
cost of maintenance shutdowns
RecyclingGreen energy technology to
Elektrociepłownia Białystok in Poland
Metso will convert a coal-fired boiler to
a biomass-fired Bubbling Fluidized Bed
boiler for Elektrociepłownia Białystok SArsquos
combined heat and power plant (CHP) in
Białystok Poland The new boiler system
will cut the power plantrsquos CO2 emissions
significantly by partly replacing the coal
fuel supply with biomass fuel
ldquoPoland is one of the largest countries
in Europe to have such a high depend-ence on energy derived from coal to
meet national electricity needs This is an
important incentive for us to reduce future
CO2 emissions and produce more green
electricity and with Metso technology
we are certain to accomplish our goalrdquo
states Mr Andrzej Schroeder President of
Elektrociepłownia Białystok SA
Since 2000 Metso has received a total
of 7 biomass boiler conversion orders in
Poland and the renewable energy share
in Poland is only 75 (2010) compared to
the target of 20 by 2020 set by the EUApproximately 80 of the current energy
boilers turbines and generators installed in
Polish power plants are over 20 years old In
order to meet the strict EU environmental
requirements modernization of existing
installations is necessary
Automation
Metso DNA automation system expands
to mining and construction
Using Metsorsquos control room automation
an entire crushing and screening plant can
be effi ciently managed
Metso is a leading supplier of mining and
construction machinery This expertise has
now been combined with a scalable Metso
DNA automation system that adapts to
the range of industry needs from single
machine controls to plant-wide automation
and information management systems
An example of Metsorsquos new offering is a
new crushing plant control room solution
that connects crushers and screens ensur-
ing the effective management of the entire
plant from a pleasant and safe control
room The Metso DNA user interface pro-vides the production information to ensure
a proper and rapid response to plant
events Automatic controls stabilize the
process and allow the operators to monitor
the plant as a whole
ldquoThe benefits of automation for the min-
ing and construction industry are signifi-
cant As an example of the services we offer
performance studies to crushing plants
utilizing Metsorsquos multi-disciplinary teams of
experts to determine the present level of
the plant and process effi ciency and to esti-
mate the improvement potential and thebenefits of optimization and automation
including ROI calculationsrdquo says Mikko Maumlki-
nen Product Manager of minerals applica-
tions in Metsorsquos Automation business line
ldquoAs another example our machine
condition monitoring solutions can reduce
plant and machine downtimes as well as
help to avoid safety and environmental
hazardsrdquo he adds
Metso around the world
Aerial view of the Elektrociepłownia Białystok combined heat and power plant in Poland
8202019 Metso Minerals Aggregates 3 2011
httpslidepdfcomreaderfullmetso-minerals-aggregates-3-2011 3636
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
8202019 Metso Minerals Aggregates 3 2011
httpslidepdfcomreaderfullmetso-minerals-aggregates-3-2011 2936983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088
The Zinkgruvan mine located approxi-
mately 200 km southwest of Stockholm
Sweden is one of the oldest underground
mines in Northern Europe The mine has
been in production since 1857
The mining methods used are panel
stoping and benching The processing
facilities include a zinc concentrating plant
with a 11 mtpa and a copper plant with a04 mtpa capacity Tailings are recycled in
an impounding basin and host rock in the
backfill plant
Continuous mining since 1857
Even as one of the oldest mines in Northern
Europe Zinkgruvan exploits modern mining
and minerals processing installations
Zinkgruvan mine
OWNER Lundin Mining
PRODUCTION PER YEAR 1 million tons
ORE TYPE sedimentary exhalative
zinc lead copper and silver
NUMBER OF EMPLOYEES 320
2011 PRODUCTION TARGETS 78000 tonsof zinc 36000 tons of lead and
3400 tons of copper concentrate
METSO EQUIPMENT ON SITE
bull 1 extra long VF feeder
bull 2 C160 jaw crushers
ndash zinc process css 220ndash240 mm
ndash copper process css 150 mm
bull 1 GP300S cone crusher
ndash css 45mm
bull 1 HP4 cone crusher
ndash css 18 mm
bull 1 DS screen
bull 1 FS402 screenbull 1 grinding mill
bull Pumps VPAs
A normal truck feeds the C jaws with ore coming from the lower production levels
983122983141983152983151983154983156983145983150983143 983154983141983155
8202019 Metso Minerals Aggregates 3 2011
httpslidepdfcomreaderfullmetso-minerals-aggregates-3-2011 30360983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983089
Cost-per-ton wear agreements deepencustomer relationshipsCrusher wear parts are traditionally marketed purely based on transactional sales and mainly depend on
the weight of manganese Metso has recently introduced a new type of wear agreement based on thecost-per-ton crushed and the wear occurred Thus far the experience has been very positive increasing
transparency and deepening the operational relationship between the manufacturer and the customer
TEXT Olli Kellokumpu and Eero Haumlmaumllaumlinen PHOTOS Eero Haumlmaumllaumlinen
Arto Hiedanniemi (left)
Hannu Heman and Juha
Laukka of Metsorsquos Finnish
Service team checking the
cone crusher mantles shipped
for a cost-per-ton customer
8202019 Metso Minerals Aggregates 3 2011
httpslidepdfcomreaderfullmetso-minerals-aggregates-3-2011 3136983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088
983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156
Wear parts and parts changes
can be included
The structure of a cost-per-ton wearcontract is based on the number of tons
crushed and the estimated wear occurred
The amount and monetary value of the
wear is calculated per crushed ton
ldquoEither plain wear parts or parts changes
carried out by Metsorsquos service personnel
can be included in the contract In the latter
case we ask our Finnish customers to inform
us about an upcoming wear change opera-
tion one week in advancerdquo Heman explains
ldquoWe see good opportunities to market
cost-per-ton contracts further in Finland
and also abroad It really develops therelationship of Metso and our customers
towards a trusted partnershiprdquo he notes
Perfect tool for accurate planning
Soraliike Ikola Oy is a mid-sized contrac-
tor with three Metso two- and three-
stage mobile and portable crushing and
screening plants operating in Central and
Since 2002 Metsorsquos sales team in Finland
has developed the cost-per-ton-based
service offeringldquoOur aim has been to seek through
a cost-per-ton offering possibilities to
serve our customers better to differentiate
Metso from the other players as an OEM
manufacturer and to offer deeper profes-
sionalism and know-howrdquo says Hannu
Heman General Manager of service
operations
ldquoUntil now both our experience and
that of our customers has been quite posi-
tive When properly prepared cost-per-ton
contracts seem to create a win-win situa-
tionrdquo Heman adds Today Metso has operational cost-per-
ton agreements with several Finnish cus-
tomers The first contract was concluded
with a customer operating a stationary
plant Based on the results gathered new
cost-per-ton contracts have been signed
with customers operating wheeled and
tracked equipment too
Eastern Finland Because of the size of the
contracts up to 50 equipment moves are
made during the yearEntrepreneur Pasi Ikola has had a cost-
per-ton contract with Metso for nearly
two years and he is quite happy with the
outcome
ldquoThe cost-per-ton contract has provided
me with a perfect tool for accurate financial
planning Now I know in detail my actual
future wear parts costs This helps a lot
when calculating bidsrdquo
ldquoEarlier I used to buy a big batch of
Metso wear parts in one go and had to
reserve a reasonable amount of money for
that Today all wear costs are evenly sharedwhich gives us a welcomed 1047298exibility to
our cost structure Now we just pay Metso
afterwards based on our crushed tonsrdquo
he adds
More info
Olli Kellokumpu
Tel +358 50 354 1189
ollikellokumpumetsocom
According to crushing contractor Pasi Ikola the cost-per-ton contract with Metso has provided the entrepreneur with better economical 1047298exibility
and more accurate calculating of bids
8202019 Metso Minerals Aggregates 3 2011
httpslidepdfcomreaderfullmetso-minerals-aggregates-3-2011 32362983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983089
Pleasant Gap is owned and operated by
Glenn O Hawbaker Inc of State College
Pennsylvania This family-owned company
began in 1952 as a small excavation busi-
ness founded by Glenn O Hawbaker and
his wife Thelma Over the years the com-
pany grew by adding an integrated mix ofproducts and services and taking on larger
projects
In 1983 Hawbaker acquired Pleasant
Gap Quarry and built its first aggregates
processing plant Today Glenn O Haw-
baker Inc operates 21 quarries and eight
asphalt production facilities across Penn-
sylvania and southern New York as well as
five regional operation centers
Primary
challenge atPleasant GapQuarryA good part of what makes for a successful crushing
operation is the willingness to tackle challenges and to do
whatrsquos necessary to meet demand The team at Pleasant
Gap Quarry in central Pennsylvania recently met the chal-
lenge when they successfully addressed problems with
the plantrsquos primary crushing plant First they purchased
a new Metso C160 jaw to replace the existing primary
impact crusher Then they devised an innovative plan to
get the primary plant back in operation while awaitingdelivery of the new jaw crusher
TEXT Linda Bergmann PHOTOS John Rickinger
983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Time for a change
With the goal of increasing reliability and
output the management at Pleasant Gap
Quarry recently decided it was time to
replace the plantrsquos primary impact crusher
Following a thorough search they chose a
new Metso C160 jaw According to ScottReck Plant Manager it no longer made
sense to repair and rebuild the existing
impactor
ldquoBefore we purchased the Metso C160
we had a few other impact crushers and
they served us well but as our custom-
ersrsquo needs increased our plant production
had to match that demand We found our
formerly reliable unit was being overcome
by our demands for output and creative
work-around solutions We continued to
need more but there was only so much we
could do until we hit the breaking point ndash
literallyrdquo
In addition to performance improve-
ments the new crusher also needed to fitinto Pleasant Gaprsquos unique infrastructure
As Plant Project ManagerEngineer Jeremy
Fahr explains ldquoOur height restraint was 274
meters (108rdquo) This height was the distance
from the feed lip of the existing 6x12 scalp-
ing screen and the existing structure that
the crusher rests onrdquo
The normal C160 crusher is 307
meters (121rdquo) tall but Metso gave GOH
Scott Reck Plant Manager (left) and
Jeremy Fahr Plant Project Manager
Engineer at Pleasant Gap Quarry
8202019 Metso Minerals Aggregates 3 2011
httpslidepdfcomreaderfullmetso-minerals-aggregates-3-2011 3336983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088
983122983141983152983151983154983156983145983150983143 983154983141983155
a 10-degree mounting option (which is
normally used on their portable crushers)
to overcome the height restraint Reck and
Fahr worked with Dave Rhoa of Cleveland
Brothers Equipment Metsorsquos crushing and
screening distributor in Pennsylvania to
pull everything together and fit the newcrusher into their plant
The C160 crusher selected for Pleasant
Gap is one of the latest models in Metsorsquos
C Series of jaws These jaw crushers feature
a large throw and steep toggle plate angle
resulting in a higher crusher output In
addition the C Series has a compact foot-
print that makes it an ideal choice for the
replacement of existing machines
According to Reck ldquoWe had heard about
the new Metso C160 and started doing our
own research and found Metso not only
had developed the output capacity we
needed but fit the uniqueness of our oper-
ationsrdquo The new Metso crusher will allow
the plant to increase tons per hour andgive them the 1047298exibility to meet demands
for varying products on short notice
Mobile solution
Purchasing the new primary jaw addressed
the long-term issues but still left Pleasant
Gap without a functioning primary plant
Reck continues ldquoOur main line was still
down leaving us with a big hole in hitting
customer needs but knowing that our new
Metso C160 was on its wayhellipwe needed an
immediate solution to keep our produc-
tion demands with an out-of-commission
crusherrdquo
The team at Pleasant Gap brainstormed
the problem and came up with a plan toget the primary plant back in operation
Their solution was to use the Lokotrack
LT1213 impactor plant and another mobile
unit to keep the main line crushing To do
this they removed the guts on the existing
impact crusher essentially turning it into a
rock chute They then moved the LT1213
and another manufacturerrsquos mobile unit
over to the existing dump hopper gt
8202019 Metso Minerals Aggregates 3 2011
httpslidepdfcomreaderfullmetso-minerals-aggregates-3-2011 34364983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983089
983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
ldquoWe had our haul trucks drop off mate-
rial while two excavators fed the two
mobile unitsrdquo Reck explains ldquoFor two-and-
a-half months the Lokotrack LT1213 unit
was producing 254 cm (10rdquo) minus at
700 tons per hour The other similar-sized
mobile unit was doing 400 tons an hour
maxed out The difference was unbeliev-
able to say the least Our unique solution
using the two mobile units especially the
LT1213 helped Glenn O Hawbaker achieve
a record output in 2010rdquoAccording to Fahr ldquoWe were not new to
Metsorsquos quality and supportrdquo because GOH
had been using Metsorsquos portable crushing
equipment for 3 years prior to the primary
plantrsquos impact crusher failure In another
part of our operation we have a system that
our team relies on every day a Lokotrack
LT1213 and ST272 working in tandem with
two portable conveyorsrdquo This highly effi -
cient mobile processing system turns out
300 tons of specialized blended material
per hour GOH has been so impressed with
Metso equipment its last two purchaseswere an LT106 tracked jaw plant and a
second ST272 mobile screen in 2010
Maintaining high productivity
The Metso C160 jaw was delivered to Pleas-
ant Gap Quarry in January of 2011 and
since start-up it has more than met expec-
tations The crusher is fed minus 910 mm
(36rdquo) limestone with the jaw set at 140 mm
(5 12rdquo) According to Reck ldquoFrom moment
we started up we knew we had a winner
Not only were we kicking out as much
product as our previous units without even
breathing hard but we immediately had a
2-cent per ton savings to the bottom line
without having to run a second 350 HP
motor as required by other units Plus by
adding on the new automatic lube system
the maintenance team had more time to
devote to keeping other areas of the com-
plex running more effi cientlyrdquoReck says ldquoThe Metso unit was a perfect
fit and with the improved features it pre-
sented it had it all We just turn it on load
it up and we are moving 600 tons per hour
through the crusher without any effort and
we know it can do so much morerdquo With
the primary crushing plant back in opera-
tion the entire team at Pleasant Gap will
continue to do what they do best produce
and sell high-quality products and meet
their customersrsquo expectations
More info
Scott Yablonsky Tel +1 262 717 793
scottyablonskymetsocom
The Metso C160 jaw
was installed at a 10deg
angle to fit Pleasant
Gaprsquos existing
infrastructure
The Lokotrack LT1213 impactor plant and ST272 mobile screen operate in tandem with two
portable conveyors at Pleasant Gap
8202019 Metso Minerals Aggregates 3 2011
httpslidepdfcomreaderfullmetso-minerals-aggregates-3-2011 3536983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088
983149983141983156983155983151 983150
Paper amp fiberNew OptiConcept M paper
and board making line
The new OptiConcept M paper and board
making line stands for economy safety and
usability
Metso has launched a new modular paper
and board making line called OptiConceptM A member of the proven OptiConcept
production line family the new OptiCon-
cept M optimizes machine investment in
line with each millrsquos capacity needs
Savings in operating costs are achieved
through precise dimensioning of pro-
cesses proven technological solutions
optimal running parameters effective
maintenance operations and fully inte-
grated automation solutions
Optimized processes innovations
smart controls and accurate dimensioning
decrease the use of steam gas electricitywater chemicals and other raw materials
and reduce emission levels
OptiConcept M has been designed
both visually and physically with the
requirements of users in mind For exam-
ple the design of the machinery allows for
easy and safe changing of rolls and wear
parts thus reducing the total duration and
cost of maintenance shutdowns
RecyclingGreen energy technology to
Elektrociepłownia Białystok in Poland
Metso will convert a coal-fired boiler to
a biomass-fired Bubbling Fluidized Bed
boiler for Elektrociepłownia Białystok SArsquos
combined heat and power plant (CHP) in
Białystok Poland The new boiler system
will cut the power plantrsquos CO2 emissions
significantly by partly replacing the coal
fuel supply with biomass fuel
ldquoPoland is one of the largest countries
in Europe to have such a high depend-ence on energy derived from coal to
meet national electricity needs This is an
important incentive for us to reduce future
CO2 emissions and produce more green
electricity and with Metso technology
we are certain to accomplish our goalrdquo
states Mr Andrzej Schroeder President of
Elektrociepłownia Białystok SA
Since 2000 Metso has received a total
of 7 biomass boiler conversion orders in
Poland and the renewable energy share
in Poland is only 75 (2010) compared to
the target of 20 by 2020 set by the EUApproximately 80 of the current energy
boilers turbines and generators installed in
Polish power plants are over 20 years old In
order to meet the strict EU environmental
requirements modernization of existing
installations is necessary
Automation
Metso DNA automation system expands
to mining and construction
Using Metsorsquos control room automation
an entire crushing and screening plant can
be effi ciently managed
Metso is a leading supplier of mining and
construction machinery This expertise has
now been combined with a scalable Metso
DNA automation system that adapts to
the range of industry needs from single
machine controls to plant-wide automation
and information management systems
An example of Metsorsquos new offering is a
new crushing plant control room solution
that connects crushers and screens ensur-
ing the effective management of the entire
plant from a pleasant and safe control
room The Metso DNA user interface pro-vides the production information to ensure
a proper and rapid response to plant
events Automatic controls stabilize the
process and allow the operators to monitor
the plant as a whole
ldquoThe benefits of automation for the min-
ing and construction industry are signifi-
cant As an example of the services we offer
performance studies to crushing plants
utilizing Metsorsquos multi-disciplinary teams of
experts to determine the present level of
the plant and process effi ciency and to esti-
mate the improvement potential and thebenefits of optimization and automation
including ROI calculationsrdquo says Mikko Maumlki-
nen Product Manager of minerals applica-
tions in Metsorsquos Automation business line
ldquoAs another example our machine
condition monitoring solutions can reduce
plant and machine downtimes as well as
help to avoid safety and environmental
hazardsrdquo he adds
Metso around the world
Aerial view of the Elektrociepłownia Białystok combined heat and power plant in Poland
8202019 Metso Minerals Aggregates 3 2011
httpslidepdfcomreaderfullmetso-minerals-aggregates-3-2011 3636
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
8202019 Metso Minerals Aggregates 3 2011
httpslidepdfcomreaderfullmetso-minerals-aggregates-3-2011 30360983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983089
Cost-per-ton wear agreements deepencustomer relationshipsCrusher wear parts are traditionally marketed purely based on transactional sales and mainly depend on
the weight of manganese Metso has recently introduced a new type of wear agreement based on thecost-per-ton crushed and the wear occurred Thus far the experience has been very positive increasing
transparency and deepening the operational relationship between the manufacturer and the customer
TEXT Olli Kellokumpu and Eero Haumlmaumllaumlinen PHOTOS Eero Haumlmaumllaumlinen
Arto Hiedanniemi (left)
Hannu Heman and Juha
Laukka of Metsorsquos Finnish
Service team checking the
cone crusher mantles shipped
for a cost-per-ton customer
8202019 Metso Minerals Aggregates 3 2011
httpslidepdfcomreaderfullmetso-minerals-aggregates-3-2011 3136983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088
983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156
Wear parts and parts changes
can be included
The structure of a cost-per-ton wearcontract is based on the number of tons
crushed and the estimated wear occurred
The amount and monetary value of the
wear is calculated per crushed ton
ldquoEither plain wear parts or parts changes
carried out by Metsorsquos service personnel
can be included in the contract In the latter
case we ask our Finnish customers to inform
us about an upcoming wear change opera-
tion one week in advancerdquo Heman explains
ldquoWe see good opportunities to market
cost-per-ton contracts further in Finland
and also abroad It really develops therelationship of Metso and our customers
towards a trusted partnershiprdquo he notes
Perfect tool for accurate planning
Soraliike Ikola Oy is a mid-sized contrac-
tor with three Metso two- and three-
stage mobile and portable crushing and
screening plants operating in Central and
Since 2002 Metsorsquos sales team in Finland
has developed the cost-per-ton-based
service offeringldquoOur aim has been to seek through
a cost-per-ton offering possibilities to
serve our customers better to differentiate
Metso from the other players as an OEM
manufacturer and to offer deeper profes-
sionalism and know-howrdquo says Hannu
Heman General Manager of service
operations
ldquoUntil now both our experience and
that of our customers has been quite posi-
tive When properly prepared cost-per-ton
contracts seem to create a win-win situa-
tionrdquo Heman adds Today Metso has operational cost-per-
ton agreements with several Finnish cus-
tomers The first contract was concluded
with a customer operating a stationary
plant Based on the results gathered new
cost-per-ton contracts have been signed
with customers operating wheeled and
tracked equipment too
Eastern Finland Because of the size of the
contracts up to 50 equipment moves are
made during the yearEntrepreneur Pasi Ikola has had a cost-
per-ton contract with Metso for nearly
two years and he is quite happy with the
outcome
ldquoThe cost-per-ton contract has provided
me with a perfect tool for accurate financial
planning Now I know in detail my actual
future wear parts costs This helps a lot
when calculating bidsrdquo
ldquoEarlier I used to buy a big batch of
Metso wear parts in one go and had to
reserve a reasonable amount of money for
that Today all wear costs are evenly sharedwhich gives us a welcomed 1047298exibility to
our cost structure Now we just pay Metso
afterwards based on our crushed tonsrdquo
he adds
More info
Olli Kellokumpu
Tel +358 50 354 1189
ollikellokumpumetsocom
According to crushing contractor Pasi Ikola the cost-per-ton contract with Metso has provided the entrepreneur with better economical 1047298exibility
and more accurate calculating of bids
8202019 Metso Minerals Aggregates 3 2011
httpslidepdfcomreaderfullmetso-minerals-aggregates-3-2011 32362983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983089
Pleasant Gap is owned and operated by
Glenn O Hawbaker Inc of State College
Pennsylvania This family-owned company
began in 1952 as a small excavation busi-
ness founded by Glenn O Hawbaker and
his wife Thelma Over the years the com-
pany grew by adding an integrated mix ofproducts and services and taking on larger
projects
In 1983 Hawbaker acquired Pleasant
Gap Quarry and built its first aggregates
processing plant Today Glenn O Haw-
baker Inc operates 21 quarries and eight
asphalt production facilities across Penn-
sylvania and southern New York as well as
five regional operation centers
Primary
challenge atPleasant GapQuarryA good part of what makes for a successful crushing
operation is the willingness to tackle challenges and to do
whatrsquos necessary to meet demand The team at Pleasant
Gap Quarry in central Pennsylvania recently met the chal-
lenge when they successfully addressed problems with
the plantrsquos primary crushing plant First they purchased
a new Metso C160 jaw to replace the existing primary
impact crusher Then they devised an innovative plan to
get the primary plant back in operation while awaitingdelivery of the new jaw crusher
TEXT Linda Bergmann PHOTOS John Rickinger
983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Time for a change
With the goal of increasing reliability and
output the management at Pleasant Gap
Quarry recently decided it was time to
replace the plantrsquos primary impact crusher
Following a thorough search they chose a
new Metso C160 jaw According to ScottReck Plant Manager it no longer made
sense to repair and rebuild the existing
impactor
ldquoBefore we purchased the Metso C160
we had a few other impact crushers and
they served us well but as our custom-
ersrsquo needs increased our plant production
had to match that demand We found our
formerly reliable unit was being overcome
by our demands for output and creative
work-around solutions We continued to
need more but there was only so much we
could do until we hit the breaking point ndash
literallyrdquo
In addition to performance improve-
ments the new crusher also needed to fitinto Pleasant Gaprsquos unique infrastructure
As Plant Project ManagerEngineer Jeremy
Fahr explains ldquoOur height restraint was 274
meters (108rdquo) This height was the distance
from the feed lip of the existing 6x12 scalp-
ing screen and the existing structure that
the crusher rests onrdquo
The normal C160 crusher is 307
meters (121rdquo) tall but Metso gave GOH
Scott Reck Plant Manager (left) and
Jeremy Fahr Plant Project Manager
Engineer at Pleasant Gap Quarry
8202019 Metso Minerals Aggregates 3 2011
httpslidepdfcomreaderfullmetso-minerals-aggregates-3-2011 3336983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088
983122983141983152983151983154983156983145983150983143 983154983141983155
a 10-degree mounting option (which is
normally used on their portable crushers)
to overcome the height restraint Reck and
Fahr worked with Dave Rhoa of Cleveland
Brothers Equipment Metsorsquos crushing and
screening distributor in Pennsylvania to
pull everything together and fit the newcrusher into their plant
The C160 crusher selected for Pleasant
Gap is one of the latest models in Metsorsquos
C Series of jaws These jaw crushers feature
a large throw and steep toggle plate angle
resulting in a higher crusher output In
addition the C Series has a compact foot-
print that makes it an ideal choice for the
replacement of existing machines
According to Reck ldquoWe had heard about
the new Metso C160 and started doing our
own research and found Metso not only
had developed the output capacity we
needed but fit the uniqueness of our oper-
ationsrdquo The new Metso crusher will allow
the plant to increase tons per hour andgive them the 1047298exibility to meet demands
for varying products on short notice
Mobile solution
Purchasing the new primary jaw addressed
the long-term issues but still left Pleasant
Gap without a functioning primary plant
Reck continues ldquoOur main line was still
down leaving us with a big hole in hitting
customer needs but knowing that our new
Metso C160 was on its wayhellipwe needed an
immediate solution to keep our produc-
tion demands with an out-of-commission
crusherrdquo
The team at Pleasant Gap brainstormed
the problem and came up with a plan toget the primary plant back in operation
Their solution was to use the Lokotrack
LT1213 impactor plant and another mobile
unit to keep the main line crushing To do
this they removed the guts on the existing
impact crusher essentially turning it into a
rock chute They then moved the LT1213
and another manufacturerrsquos mobile unit
over to the existing dump hopper gt
8202019 Metso Minerals Aggregates 3 2011
httpslidepdfcomreaderfullmetso-minerals-aggregates-3-2011 34364983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983089
983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
ldquoWe had our haul trucks drop off mate-
rial while two excavators fed the two
mobile unitsrdquo Reck explains ldquoFor two-and-
a-half months the Lokotrack LT1213 unit
was producing 254 cm (10rdquo) minus at
700 tons per hour The other similar-sized
mobile unit was doing 400 tons an hour
maxed out The difference was unbeliev-
able to say the least Our unique solution
using the two mobile units especially the
LT1213 helped Glenn O Hawbaker achieve
a record output in 2010rdquoAccording to Fahr ldquoWe were not new to
Metsorsquos quality and supportrdquo because GOH
had been using Metsorsquos portable crushing
equipment for 3 years prior to the primary
plantrsquos impact crusher failure In another
part of our operation we have a system that
our team relies on every day a Lokotrack
LT1213 and ST272 working in tandem with
two portable conveyorsrdquo This highly effi -
cient mobile processing system turns out
300 tons of specialized blended material
per hour GOH has been so impressed with
Metso equipment its last two purchaseswere an LT106 tracked jaw plant and a
second ST272 mobile screen in 2010
Maintaining high productivity
The Metso C160 jaw was delivered to Pleas-
ant Gap Quarry in January of 2011 and
since start-up it has more than met expec-
tations The crusher is fed minus 910 mm
(36rdquo) limestone with the jaw set at 140 mm
(5 12rdquo) According to Reck ldquoFrom moment
we started up we knew we had a winner
Not only were we kicking out as much
product as our previous units without even
breathing hard but we immediately had a
2-cent per ton savings to the bottom line
without having to run a second 350 HP
motor as required by other units Plus by
adding on the new automatic lube system
the maintenance team had more time to
devote to keeping other areas of the com-
plex running more effi cientlyrdquoReck says ldquoThe Metso unit was a perfect
fit and with the improved features it pre-
sented it had it all We just turn it on load
it up and we are moving 600 tons per hour
through the crusher without any effort and
we know it can do so much morerdquo With
the primary crushing plant back in opera-
tion the entire team at Pleasant Gap will
continue to do what they do best produce
and sell high-quality products and meet
their customersrsquo expectations
More info
Scott Yablonsky Tel +1 262 717 793
scottyablonskymetsocom
The Metso C160 jaw
was installed at a 10deg
angle to fit Pleasant
Gaprsquos existing
infrastructure
The Lokotrack LT1213 impactor plant and ST272 mobile screen operate in tandem with two
portable conveyors at Pleasant Gap
8202019 Metso Minerals Aggregates 3 2011
httpslidepdfcomreaderfullmetso-minerals-aggregates-3-2011 3536983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088
983149983141983156983155983151 983150
Paper amp fiberNew OptiConcept M paper
and board making line
The new OptiConcept M paper and board
making line stands for economy safety and
usability
Metso has launched a new modular paper
and board making line called OptiConceptM A member of the proven OptiConcept
production line family the new OptiCon-
cept M optimizes machine investment in
line with each millrsquos capacity needs
Savings in operating costs are achieved
through precise dimensioning of pro-
cesses proven technological solutions
optimal running parameters effective
maintenance operations and fully inte-
grated automation solutions
Optimized processes innovations
smart controls and accurate dimensioning
decrease the use of steam gas electricitywater chemicals and other raw materials
and reduce emission levels
OptiConcept M has been designed
both visually and physically with the
requirements of users in mind For exam-
ple the design of the machinery allows for
easy and safe changing of rolls and wear
parts thus reducing the total duration and
cost of maintenance shutdowns
RecyclingGreen energy technology to
Elektrociepłownia Białystok in Poland
Metso will convert a coal-fired boiler to
a biomass-fired Bubbling Fluidized Bed
boiler for Elektrociepłownia Białystok SArsquos
combined heat and power plant (CHP) in
Białystok Poland The new boiler system
will cut the power plantrsquos CO2 emissions
significantly by partly replacing the coal
fuel supply with biomass fuel
ldquoPoland is one of the largest countries
in Europe to have such a high depend-ence on energy derived from coal to
meet national electricity needs This is an
important incentive for us to reduce future
CO2 emissions and produce more green
electricity and with Metso technology
we are certain to accomplish our goalrdquo
states Mr Andrzej Schroeder President of
Elektrociepłownia Białystok SA
Since 2000 Metso has received a total
of 7 biomass boiler conversion orders in
Poland and the renewable energy share
in Poland is only 75 (2010) compared to
the target of 20 by 2020 set by the EUApproximately 80 of the current energy
boilers turbines and generators installed in
Polish power plants are over 20 years old In
order to meet the strict EU environmental
requirements modernization of existing
installations is necessary
Automation
Metso DNA automation system expands
to mining and construction
Using Metsorsquos control room automation
an entire crushing and screening plant can
be effi ciently managed
Metso is a leading supplier of mining and
construction machinery This expertise has
now been combined with a scalable Metso
DNA automation system that adapts to
the range of industry needs from single
machine controls to plant-wide automation
and information management systems
An example of Metsorsquos new offering is a
new crushing plant control room solution
that connects crushers and screens ensur-
ing the effective management of the entire
plant from a pleasant and safe control
room The Metso DNA user interface pro-vides the production information to ensure
a proper and rapid response to plant
events Automatic controls stabilize the
process and allow the operators to monitor
the plant as a whole
ldquoThe benefits of automation for the min-
ing and construction industry are signifi-
cant As an example of the services we offer
performance studies to crushing plants
utilizing Metsorsquos multi-disciplinary teams of
experts to determine the present level of
the plant and process effi ciency and to esti-
mate the improvement potential and thebenefits of optimization and automation
including ROI calculationsrdquo says Mikko Maumlki-
nen Product Manager of minerals applica-
tions in Metsorsquos Automation business line
ldquoAs another example our machine
condition monitoring solutions can reduce
plant and machine downtimes as well as
help to avoid safety and environmental
hazardsrdquo he adds
Metso around the world
Aerial view of the Elektrociepłownia Białystok combined heat and power plant in Poland
8202019 Metso Minerals Aggregates 3 2011
httpslidepdfcomreaderfullmetso-minerals-aggregates-3-2011 3636
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
8202019 Metso Minerals Aggregates 3 2011
httpslidepdfcomreaderfullmetso-minerals-aggregates-3-2011 3136983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088
983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156
Wear parts and parts changes
can be included
The structure of a cost-per-ton wearcontract is based on the number of tons
crushed and the estimated wear occurred
The amount and monetary value of the
wear is calculated per crushed ton
ldquoEither plain wear parts or parts changes
carried out by Metsorsquos service personnel
can be included in the contract In the latter
case we ask our Finnish customers to inform
us about an upcoming wear change opera-
tion one week in advancerdquo Heman explains
ldquoWe see good opportunities to market
cost-per-ton contracts further in Finland
and also abroad It really develops therelationship of Metso and our customers
towards a trusted partnershiprdquo he notes
Perfect tool for accurate planning
Soraliike Ikola Oy is a mid-sized contrac-
tor with three Metso two- and three-
stage mobile and portable crushing and
screening plants operating in Central and
Since 2002 Metsorsquos sales team in Finland
has developed the cost-per-ton-based
service offeringldquoOur aim has been to seek through
a cost-per-ton offering possibilities to
serve our customers better to differentiate
Metso from the other players as an OEM
manufacturer and to offer deeper profes-
sionalism and know-howrdquo says Hannu
Heman General Manager of service
operations
ldquoUntil now both our experience and
that of our customers has been quite posi-
tive When properly prepared cost-per-ton
contracts seem to create a win-win situa-
tionrdquo Heman adds Today Metso has operational cost-per-
ton agreements with several Finnish cus-
tomers The first contract was concluded
with a customer operating a stationary
plant Based on the results gathered new
cost-per-ton contracts have been signed
with customers operating wheeled and
tracked equipment too
Eastern Finland Because of the size of the
contracts up to 50 equipment moves are
made during the yearEntrepreneur Pasi Ikola has had a cost-
per-ton contract with Metso for nearly
two years and he is quite happy with the
outcome
ldquoThe cost-per-ton contract has provided
me with a perfect tool for accurate financial
planning Now I know in detail my actual
future wear parts costs This helps a lot
when calculating bidsrdquo
ldquoEarlier I used to buy a big batch of
Metso wear parts in one go and had to
reserve a reasonable amount of money for
that Today all wear costs are evenly sharedwhich gives us a welcomed 1047298exibility to
our cost structure Now we just pay Metso
afterwards based on our crushed tonsrdquo
he adds
More info
Olli Kellokumpu
Tel +358 50 354 1189
ollikellokumpumetsocom
According to crushing contractor Pasi Ikola the cost-per-ton contract with Metso has provided the entrepreneur with better economical 1047298exibility
and more accurate calculating of bids
8202019 Metso Minerals Aggregates 3 2011
httpslidepdfcomreaderfullmetso-minerals-aggregates-3-2011 32362983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983089
Pleasant Gap is owned and operated by
Glenn O Hawbaker Inc of State College
Pennsylvania This family-owned company
began in 1952 as a small excavation busi-
ness founded by Glenn O Hawbaker and
his wife Thelma Over the years the com-
pany grew by adding an integrated mix ofproducts and services and taking on larger
projects
In 1983 Hawbaker acquired Pleasant
Gap Quarry and built its first aggregates
processing plant Today Glenn O Haw-
baker Inc operates 21 quarries and eight
asphalt production facilities across Penn-
sylvania and southern New York as well as
five regional operation centers
Primary
challenge atPleasant GapQuarryA good part of what makes for a successful crushing
operation is the willingness to tackle challenges and to do
whatrsquos necessary to meet demand The team at Pleasant
Gap Quarry in central Pennsylvania recently met the chal-
lenge when they successfully addressed problems with
the plantrsquos primary crushing plant First they purchased
a new Metso C160 jaw to replace the existing primary
impact crusher Then they devised an innovative plan to
get the primary plant back in operation while awaitingdelivery of the new jaw crusher
TEXT Linda Bergmann PHOTOS John Rickinger
983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Time for a change
With the goal of increasing reliability and
output the management at Pleasant Gap
Quarry recently decided it was time to
replace the plantrsquos primary impact crusher
Following a thorough search they chose a
new Metso C160 jaw According to ScottReck Plant Manager it no longer made
sense to repair and rebuild the existing
impactor
ldquoBefore we purchased the Metso C160
we had a few other impact crushers and
they served us well but as our custom-
ersrsquo needs increased our plant production
had to match that demand We found our
formerly reliable unit was being overcome
by our demands for output and creative
work-around solutions We continued to
need more but there was only so much we
could do until we hit the breaking point ndash
literallyrdquo
In addition to performance improve-
ments the new crusher also needed to fitinto Pleasant Gaprsquos unique infrastructure
As Plant Project ManagerEngineer Jeremy
Fahr explains ldquoOur height restraint was 274
meters (108rdquo) This height was the distance
from the feed lip of the existing 6x12 scalp-
ing screen and the existing structure that
the crusher rests onrdquo
The normal C160 crusher is 307
meters (121rdquo) tall but Metso gave GOH
Scott Reck Plant Manager (left) and
Jeremy Fahr Plant Project Manager
Engineer at Pleasant Gap Quarry
8202019 Metso Minerals Aggregates 3 2011
httpslidepdfcomreaderfullmetso-minerals-aggregates-3-2011 3336983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088
983122983141983152983151983154983156983145983150983143 983154983141983155
a 10-degree mounting option (which is
normally used on their portable crushers)
to overcome the height restraint Reck and
Fahr worked with Dave Rhoa of Cleveland
Brothers Equipment Metsorsquos crushing and
screening distributor in Pennsylvania to
pull everything together and fit the newcrusher into their plant
The C160 crusher selected for Pleasant
Gap is one of the latest models in Metsorsquos
C Series of jaws These jaw crushers feature
a large throw and steep toggle plate angle
resulting in a higher crusher output In
addition the C Series has a compact foot-
print that makes it an ideal choice for the
replacement of existing machines
According to Reck ldquoWe had heard about
the new Metso C160 and started doing our
own research and found Metso not only
had developed the output capacity we
needed but fit the uniqueness of our oper-
ationsrdquo The new Metso crusher will allow
the plant to increase tons per hour andgive them the 1047298exibility to meet demands
for varying products on short notice
Mobile solution
Purchasing the new primary jaw addressed
the long-term issues but still left Pleasant
Gap without a functioning primary plant
Reck continues ldquoOur main line was still
down leaving us with a big hole in hitting
customer needs but knowing that our new
Metso C160 was on its wayhellipwe needed an
immediate solution to keep our produc-
tion demands with an out-of-commission
crusherrdquo
The team at Pleasant Gap brainstormed
the problem and came up with a plan toget the primary plant back in operation
Their solution was to use the Lokotrack
LT1213 impactor plant and another mobile
unit to keep the main line crushing To do
this they removed the guts on the existing
impact crusher essentially turning it into a
rock chute They then moved the LT1213
and another manufacturerrsquos mobile unit
over to the existing dump hopper gt
8202019 Metso Minerals Aggregates 3 2011
httpslidepdfcomreaderfullmetso-minerals-aggregates-3-2011 34364983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983089
983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
ldquoWe had our haul trucks drop off mate-
rial while two excavators fed the two
mobile unitsrdquo Reck explains ldquoFor two-and-
a-half months the Lokotrack LT1213 unit
was producing 254 cm (10rdquo) minus at
700 tons per hour The other similar-sized
mobile unit was doing 400 tons an hour
maxed out The difference was unbeliev-
able to say the least Our unique solution
using the two mobile units especially the
LT1213 helped Glenn O Hawbaker achieve
a record output in 2010rdquoAccording to Fahr ldquoWe were not new to
Metsorsquos quality and supportrdquo because GOH
had been using Metsorsquos portable crushing
equipment for 3 years prior to the primary
plantrsquos impact crusher failure In another
part of our operation we have a system that
our team relies on every day a Lokotrack
LT1213 and ST272 working in tandem with
two portable conveyorsrdquo This highly effi -
cient mobile processing system turns out
300 tons of specialized blended material
per hour GOH has been so impressed with
Metso equipment its last two purchaseswere an LT106 tracked jaw plant and a
second ST272 mobile screen in 2010
Maintaining high productivity
The Metso C160 jaw was delivered to Pleas-
ant Gap Quarry in January of 2011 and
since start-up it has more than met expec-
tations The crusher is fed minus 910 mm
(36rdquo) limestone with the jaw set at 140 mm
(5 12rdquo) According to Reck ldquoFrom moment
we started up we knew we had a winner
Not only were we kicking out as much
product as our previous units without even
breathing hard but we immediately had a
2-cent per ton savings to the bottom line
without having to run a second 350 HP
motor as required by other units Plus by
adding on the new automatic lube system
the maintenance team had more time to
devote to keeping other areas of the com-
plex running more effi cientlyrdquoReck says ldquoThe Metso unit was a perfect
fit and with the improved features it pre-
sented it had it all We just turn it on load
it up and we are moving 600 tons per hour
through the crusher without any effort and
we know it can do so much morerdquo With
the primary crushing plant back in opera-
tion the entire team at Pleasant Gap will
continue to do what they do best produce
and sell high-quality products and meet
their customersrsquo expectations
More info
Scott Yablonsky Tel +1 262 717 793
scottyablonskymetsocom
The Metso C160 jaw
was installed at a 10deg
angle to fit Pleasant
Gaprsquos existing
infrastructure
The Lokotrack LT1213 impactor plant and ST272 mobile screen operate in tandem with two
portable conveyors at Pleasant Gap
8202019 Metso Minerals Aggregates 3 2011
httpslidepdfcomreaderfullmetso-minerals-aggregates-3-2011 3536983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088
983149983141983156983155983151 983150
Paper amp fiberNew OptiConcept M paper
and board making line
The new OptiConcept M paper and board
making line stands for economy safety and
usability
Metso has launched a new modular paper
and board making line called OptiConceptM A member of the proven OptiConcept
production line family the new OptiCon-
cept M optimizes machine investment in
line with each millrsquos capacity needs
Savings in operating costs are achieved
through precise dimensioning of pro-
cesses proven technological solutions
optimal running parameters effective
maintenance operations and fully inte-
grated automation solutions
Optimized processes innovations
smart controls and accurate dimensioning
decrease the use of steam gas electricitywater chemicals and other raw materials
and reduce emission levels
OptiConcept M has been designed
both visually and physically with the
requirements of users in mind For exam-
ple the design of the machinery allows for
easy and safe changing of rolls and wear
parts thus reducing the total duration and
cost of maintenance shutdowns
RecyclingGreen energy technology to
Elektrociepłownia Białystok in Poland
Metso will convert a coal-fired boiler to
a biomass-fired Bubbling Fluidized Bed
boiler for Elektrociepłownia Białystok SArsquos
combined heat and power plant (CHP) in
Białystok Poland The new boiler system
will cut the power plantrsquos CO2 emissions
significantly by partly replacing the coal
fuel supply with biomass fuel
ldquoPoland is one of the largest countries
in Europe to have such a high depend-ence on energy derived from coal to
meet national electricity needs This is an
important incentive for us to reduce future
CO2 emissions and produce more green
electricity and with Metso technology
we are certain to accomplish our goalrdquo
states Mr Andrzej Schroeder President of
Elektrociepłownia Białystok SA
Since 2000 Metso has received a total
of 7 biomass boiler conversion orders in
Poland and the renewable energy share
in Poland is only 75 (2010) compared to
the target of 20 by 2020 set by the EUApproximately 80 of the current energy
boilers turbines and generators installed in
Polish power plants are over 20 years old In
order to meet the strict EU environmental
requirements modernization of existing
installations is necessary
Automation
Metso DNA automation system expands
to mining and construction
Using Metsorsquos control room automation
an entire crushing and screening plant can
be effi ciently managed
Metso is a leading supplier of mining and
construction machinery This expertise has
now been combined with a scalable Metso
DNA automation system that adapts to
the range of industry needs from single
machine controls to plant-wide automation
and information management systems
An example of Metsorsquos new offering is a
new crushing plant control room solution
that connects crushers and screens ensur-
ing the effective management of the entire
plant from a pleasant and safe control
room The Metso DNA user interface pro-vides the production information to ensure
a proper and rapid response to plant
events Automatic controls stabilize the
process and allow the operators to monitor
the plant as a whole
ldquoThe benefits of automation for the min-
ing and construction industry are signifi-
cant As an example of the services we offer
performance studies to crushing plants
utilizing Metsorsquos multi-disciplinary teams of
experts to determine the present level of
the plant and process effi ciency and to esti-
mate the improvement potential and thebenefits of optimization and automation
including ROI calculationsrdquo says Mikko Maumlki-
nen Product Manager of minerals applica-
tions in Metsorsquos Automation business line
ldquoAs another example our machine
condition monitoring solutions can reduce
plant and machine downtimes as well as
help to avoid safety and environmental
hazardsrdquo he adds
Metso around the world
Aerial view of the Elektrociepłownia Białystok combined heat and power plant in Poland
8202019 Metso Minerals Aggregates 3 2011
httpslidepdfcomreaderfullmetso-minerals-aggregates-3-2011 3636
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
8202019 Metso Minerals Aggregates 3 2011
httpslidepdfcomreaderfullmetso-minerals-aggregates-3-2011 32362983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983089
Pleasant Gap is owned and operated by
Glenn O Hawbaker Inc of State College
Pennsylvania This family-owned company
began in 1952 as a small excavation busi-
ness founded by Glenn O Hawbaker and
his wife Thelma Over the years the com-
pany grew by adding an integrated mix ofproducts and services and taking on larger
projects
In 1983 Hawbaker acquired Pleasant
Gap Quarry and built its first aggregates
processing plant Today Glenn O Haw-
baker Inc operates 21 quarries and eight
asphalt production facilities across Penn-
sylvania and southern New York as well as
five regional operation centers
Primary
challenge atPleasant GapQuarryA good part of what makes for a successful crushing
operation is the willingness to tackle challenges and to do
whatrsquos necessary to meet demand The team at Pleasant
Gap Quarry in central Pennsylvania recently met the chal-
lenge when they successfully addressed problems with
the plantrsquos primary crushing plant First they purchased
a new Metso C160 jaw to replace the existing primary
impact crusher Then they devised an innovative plan to
get the primary plant back in operation while awaitingdelivery of the new jaw crusher
TEXT Linda Bergmann PHOTOS John Rickinger
983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
Time for a change
With the goal of increasing reliability and
output the management at Pleasant Gap
Quarry recently decided it was time to
replace the plantrsquos primary impact crusher
Following a thorough search they chose a
new Metso C160 jaw According to ScottReck Plant Manager it no longer made
sense to repair and rebuild the existing
impactor
ldquoBefore we purchased the Metso C160
we had a few other impact crushers and
they served us well but as our custom-
ersrsquo needs increased our plant production
had to match that demand We found our
formerly reliable unit was being overcome
by our demands for output and creative
work-around solutions We continued to
need more but there was only so much we
could do until we hit the breaking point ndash
literallyrdquo
In addition to performance improve-
ments the new crusher also needed to fitinto Pleasant Gaprsquos unique infrastructure
As Plant Project ManagerEngineer Jeremy
Fahr explains ldquoOur height restraint was 274
meters (108rdquo) This height was the distance
from the feed lip of the existing 6x12 scalp-
ing screen and the existing structure that
the crusher rests onrdquo
The normal C160 crusher is 307
meters (121rdquo) tall but Metso gave GOH
Scott Reck Plant Manager (left) and
Jeremy Fahr Plant Project Manager
Engineer at Pleasant Gap Quarry
8202019 Metso Minerals Aggregates 3 2011
httpslidepdfcomreaderfullmetso-minerals-aggregates-3-2011 3336983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088
983122983141983152983151983154983156983145983150983143 983154983141983155
a 10-degree mounting option (which is
normally used on their portable crushers)
to overcome the height restraint Reck and
Fahr worked with Dave Rhoa of Cleveland
Brothers Equipment Metsorsquos crushing and
screening distributor in Pennsylvania to
pull everything together and fit the newcrusher into their plant
The C160 crusher selected for Pleasant
Gap is one of the latest models in Metsorsquos
C Series of jaws These jaw crushers feature
a large throw and steep toggle plate angle
resulting in a higher crusher output In
addition the C Series has a compact foot-
print that makes it an ideal choice for the
replacement of existing machines
According to Reck ldquoWe had heard about
the new Metso C160 and started doing our
own research and found Metso not only
had developed the output capacity we
needed but fit the uniqueness of our oper-
ationsrdquo The new Metso crusher will allow
the plant to increase tons per hour andgive them the 1047298exibility to meet demands
for varying products on short notice
Mobile solution
Purchasing the new primary jaw addressed
the long-term issues but still left Pleasant
Gap without a functioning primary plant
Reck continues ldquoOur main line was still
down leaving us with a big hole in hitting
customer needs but knowing that our new
Metso C160 was on its wayhellipwe needed an
immediate solution to keep our produc-
tion demands with an out-of-commission
crusherrdquo
The team at Pleasant Gap brainstormed
the problem and came up with a plan toget the primary plant back in operation
Their solution was to use the Lokotrack
LT1213 impactor plant and another mobile
unit to keep the main line crushing To do
this they removed the guts on the existing
impact crusher essentially turning it into a
rock chute They then moved the LT1213
and another manufacturerrsquos mobile unit
over to the existing dump hopper gt
8202019 Metso Minerals Aggregates 3 2011
httpslidepdfcomreaderfullmetso-minerals-aggregates-3-2011 34364983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983089
983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
ldquoWe had our haul trucks drop off mate-
rial while two excavators fed the two
mobile unitsrdquo Reck explains ldquoFor two-and-
a-half months the Lokotrack LT1213 unit
was producing 254 cm (10rdquo) minus at
700 tons per hour The other similar-sized
mobile unit was doing 400 tons an hour
maxed out The difference was unbeliev-
able to say the least Our unique solution
using the two mobile units especially the
LT1213 helped Glenn O Hawbaker achieve
a record output in 2010rdquoAccording to Fahr ldquoWe were not new to
Metsorsquos quality and supportrdquo because GOH
had been using Metsorsquos portable crushing
equipment for 3 years prior to the primary
plantrsquos impact crusher failure In another
part of our operation we have a system that
our team relies on every day a Lokotrack
LT1213 and ST272 working in tandem with
two portable conveyorsrdquo This highly effi -
cient mobile processing system turns out
300 tons of specialized blended material
per hour GOH has been so impressed with
Metso equipment its last two purchaseswere an LT106 tracked jaw plant and a
second ST272 mobile screen in 2010
Maintaining high productivity
The Metso C160 jaw was delivered to Pleas-
ant Gap Quarry in January of 2011 and
since start-up it has more than met expec-
tations The crusher is fed minus 910 mm
(36rdquo) limestone with the jaw set at 140 mm
(5 12rdquo) According to Reck ldquoFrom moment
we started up we knew we had a winner
Not only were we kicking out as much
product as our previous units without even
breathing hard but we immediately had a
2-cent per ton savings to the bottom line
without having to run a second 350 HP
motor as required by other units Plus by
adding on the new automatic lube system
the maintenance team had more time to
devote to keeping other areas of the com-
plex running more effi cientlyrdquoReck says ldquoThe Metso unit was a perfect
fit and with the improved features it pre-
sented it had it all We just turn it on load
it up and we are moving 600 tons per hour
through the crusher without any effort and
we know it can do so much morerdquo With
the primary crushing plant back in opera-
tion the entire team at Pleasant Gap will
continue to do what they do best produce
and sell high-quality products and meet
their customersrsquo expectations
More info
Scott Yablonsky Tel +1 262 717 793
scottyablonskymetsocom
The Metso C160 jaw
was installed at a 10deg
angle to fit Pleasant
Gaprsquos existing
infrastructure
The Lokotrack LT1213 impactor plant and ST272 mobile screen operate in tandem with two
portable conveyors at Pleasant Gap
8202019 Metso Minerals Aggregates 3 2011
httpslidepdfcomreaderfullmetso-minerals-aggregates-3-2011 3536983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088
983149983141983156983155983151 983150
Paper amp fiberNew OptiConcept M paper
and board making line
The new OptiConcept M paper and board
making line stands for economy safety and
usability
Metso has launched a new modular paper
and board making line called OptiConceptM A member of the proven OptiConcept
production line family the new OptiCon-
cept M optimizes machine investment in
line with each millrsquos capacity needs
Savings in operating costs are achieved
through precise dimensioning of pro-
cesses proven technological solutions
optimal running parameters effective
maintenance operations and fully inte-
grated automation solutions
Optimized processes innovations
smart controls and accurate dimensioning
decrease the use of steam gas electricitywater chemicals and other raw materials
and reduce emission levels
OptiConcept M has been designed
both visually and physically with the
requirements of users in mind For exam-
ple the design of the machinery allows for
easy and safe changing of rolls and wear
parts thus reducing the total duration and
cost of maintenance shutdowns
RecyclingGreen energy technology to
Elektrociepłownia Białystok in Poland
Metso will convert a coal-fired boiler to
a biomass-fired Bubbling Fluidized Bed
boiler for Elektrociepłownia Białystok SArsquos
combined heat and power plant (CHP) in
Białystok Poland The new boiler system
will cut the power plantrsquos CO2 emissions
significantly by partly replacing the coal
fuel supply with biomass fuel
ldquoPoland is one of the largest countries
in Europe to have such a high depend-ence on energy derived from coal to
meet national electricity needs This is an
important incentive for us to reduce future
CO2 emissions and produce more green
electricity and with Metso technology
we are certain to accomplish our goalrdquo
states Mr Andrzej Schroeder President of
Elektrociepłownia Białystok SA
Since 2000 Metso has received a total
of 7 biomass boiler conversion orders in
Poland and the renewable energy share
in Poland is only 75 (2010) compared to
the target of 20 by 2020 set by the EUApproximately 80 of the current energy
boilers turbines and generators installed in
Polish power plants are over 20 years old In
order to meet the strict EU environmental
requirements modernization of existing
installations is necessary
Automation
Metso DNA automation system expands
to mining and construction
Using Metsorsquos control room automation
an entire crushing and screening plant can
be effi ciently managed
Metso is a leading supplier of mining and
construction machinery This expertise has
now been combined with a scalable Metso
DNA automation system that adapts to
the range of industry needs from single
machine controls to plant-wide automation
and information management systems
An example of Metsorsquos new offering is a
new crushing plant control room solution
that connects crushers and screens ensur-
ing the effective management of the entire
plant from a pleasant and safe control
room The Metso DNA user interface pro-vides the production information to ensure
a proper and rapid response to plant
events Automatic controls stabilize the
process and allow the operators to monitor
the plant as a whole
ldquoThe benefits of automation for the min-
ing and construction industry are signifi-
cant As an example of the services we offer
performance studies to crushing plants
utilizing Metsorsquos multi-disciplinary teams of
experts to determine the present level of
the plant and process effi ciency and to esti-
mate the improvement potential and thebenefits of optimization and automation
including ROI calculationsrdquo says Mikko Maumlki-
nen Product Manager of minerals applica-
tions in Metsorsquos Automation business line
ldquoAs another example our machine
condition monitoring solutions can reduce
plant and machine downtimes as well as
help to avoid safety and environmental
hazardsrdquo he adds
Metso around the world
Aerial view of the Elektrociepłownia Białystok combined heat and power plant in Poland
8202019 Metso Minerals Aggregates 3 2011
httpslidepdfcomreaderfullmetso-minerals-aggregates-3-2011 3636
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
8202019 Metso Minerals Aggregates 3 2011
httpslidepdfcomreaderfullmetso-minerals-aggregates-3-2011 3336983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088
983122983141983152983151983154983156983145983150983143 983154983141983155
a 10-degree mounting option (which is
normally used on their portable crushers)
to overcome the height restraint Reck and
Fahr worked with Dave Rhoa of Cleveland
Brothers Equipment Metsorsquos crushing and
screening distributor in Pennsylvania to
pull everything together and fit the newcrusher into their plant
The C160 crusher selected for Pleasant
Gap is one of the latest models in Metsorsquos
C Series of jaws These jaw crushers feature
a large throw and steep toggle plate angle
resulting in a higher crusher output In
addition the C Series has a compact foot-
print that makes it an ideal choice for the
replacement of existing machines
According to Reck ldquoWe had heard about
the new Metso C160 and started doing our
own research and found Metso not only
had developed the output capacity we
needed but fit the uniqueness of our oper-
ationsrdquo The new Metso crusher will allow
the plant to increase tons per hour andgive them the 1047298exibility to meet demands
for varying products on short notice
Mobile solution
Purchasing the new primary jaw addressed
the long-term issues but still left Pleasant
Gap without a functioning primary plant
Reck continues ldquoOur main line was still
down leaving us with a big hole in hitting
customer needs but knowing that our new
Metso C160 was on its wayhellipwe needed an
immediate solution to keep our produc-
tion demands with an out-of-commission
crusherrdquo
The team at Pleasant Gap brainstormed
the problem and came up with a plan toget the primary plant back in operation
Their solution was to use the Lokotrack
LT1213 impactor plant and another mobile
unit to keep the main line crushing To do
this they removed the guts on the existing
impact crusher essentially turning it into a
rock chute They then moved the LT1213
and another manufacturerrsquos mobile unit
over to the existing dump hopper gt
8202019 Metso Minerals Aggregates 3 2011
httpslidepdfcomreaderfullmetso-minerals-aggregates-3-2011 34364983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983089
983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
ldquoWe had our haul trucks drop off mate-
rial while two excavators fed the two
mobile unitsrdquo Reck explains ldquoFor two-and-
a-half months the Lokotrack LT1213 unit
was producing 254 cm (10rdquo) minus at
700 tons per hour The other similar-sized
mobile unit was doing 400 tons an hour
maxed out The difference was unbeliev-
able to say the least Our unique solution
using the two mobile units especially the
LT1213 helped Glenn O Hawbaker achieve
a record output in 2010rdquoAccording to Fahr ldquoWe were not new to
Metsorsquos quality and supportrdquo because GOH
had been using Metsorsquos portable crushing
equipment for 3 years prior to the primary
plantrsquos impact crusher failure In another
part of our operation we have a system that
our team relies on every day a Lokotrack
LT1213 and ST272 working in tandem with
two portable conveyorsrdquo This highly effi -
cient mobile processing system turns out
300 tons of specialized blended material
per hour GOH has been so impressed with
Metso equipment its last two purchaseswere an LT106 tracked jaw plant and a
second ST272 mobile screen in 2010
Maintaining high productivity
The Metso C160 jaw was delivered to Pleas-
ant Gap Quarry in January of 2011 and
since start-up it has more than met expec-
tations The crusher is fed minus 910 mm
(36rdquo) limestone with the jaw set at 140 mm
(5 12rdquo) According to Reck ldquoFrom moment
we started up we knew we had a winner
Not only were we kicking out as much
product as our previous units without even
breathing hard but we immediately had a
2-cent per ton savings to the bottom line
without having to run a second 350 HP
motor as required by other units Plus by
adding on the new automatic lube system
the maintenance team had more time to
devote to keeping other areas of the com-
plex running more effi cientlyrdquoReck says ldquoThe Metso unit was a perfect
fit and with the improved features it pre-
sented it had it all We just turn it on load
it up and we are moving 600 tons per hour
through the crusher without any effort and
we know it can do so much morerdquo With
the primary crushing plant back in opera-
tion the entire team at Pleasant Gap will
continue to do what they do best produce
and sell high-quality products and meet
their customersrsquo expectations
More info
Scott Yablonsky Tel +1 262 717 793
scottyablonskymetsocom
The Metso C160 jaw
was installed at a 10deg
angle to fit Pleasant
Gaprsquos existing
infrastructure
The Lokotrack LT1213 impactor plant and ST272 mobile screen operate in tandem with two
portable conveyors at Pleasant Gap
8202019 Metso Minerals Aggregates 3 2011
httpslidepdfcomreaderfullmetso-minerals-aggregates-3-2011 3536983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088
983149983141983156983155983151 983150
Paper amp fiberNew OptiConcept M paper
and board making line
The new OptiConcept M paper and board
making line stands for economy safety and
usability
Metso has launched a new modular paper
and board making line called OptiConceptM A member of the proven OptiConcept
production line family the new OptiCon-
cept M optimizes machine investment in
line with each millrsquos capacity needs
Savings in operating costs are achieved
through precise dimensioning of pro-
cesses proven technological solutions
optimal running parameters effective
maintenance operations and fully inte-
grated automation solutions
Optimized processes innovations
smart controls and accurate dimensioning
decrease the use of steam gas electricitywater chemicals and other raw materials
and reduce emission levels
OptiConcept M has been designed
both visually and physically with the
requirements of users in mind For exam-
ple the design of the machinery allows for
easy and safe changing of rolls and wear
parts thus reducing the total duration and
cost of maintenance shutdowns
RecyclingGreen energy technology to
Elektrociepłownia Białystok in Poland
Metso will convert a coal-fired boiler to
a biomass-fired Bubbling Fluidized Bed
boiler for Elektrociepłownia Białystok SArsquos
combined heat and power plant (CHP) in
Białystok Poland The new boiler system
will cut the power plantrsquos CO2 emissions
significantly by partly replacing the coal
fuel supply with biomass fuel
ldquoPoland is one of the largest countries
in Europe to have such a high depend-ence on energy derived from coal to
meet national electricity needs This is an
important incentive for us to reduce future
CO2 emissions and produce more green
electricity and with Metso technology
we are certain to accomplish our goalrdquo
states Mr Andrzej Schroeder President of
Elektrociepłownia Białystok SA
Since 2000 Metso has received a total
of 7 biomass boiler conversion orders in
Poland and the renewable energy share
in Poland is only 75 (2010) compared to
the target of 20 by 2020 set by the EUApproximately 80 of the current energy
boilers turbines and generators installed in
Polish power plants are over 20 years old In
order to meet the strict EU environmental
requirements modernization of existing
installations is necessary
Automation
Metso DNA automation system expands
to mining and construction
Using Metsorsquos control room automation
an entire crushing and screening plant can
be effi ciently managed
Metso is a leading supplier of mining and
construction machinery This expertise has
now been combined with a scalable Metso
DNA automation system that adapts to
the range of industry needs from single
machine controls to plant-wide automation
and information management systems
An example of Metsorsquos new offering is a
new crushing plant control room solution
that connects crushers and screens ensur-
ing the effective management of the entire
plant from a pleasant and safe control
room The Metso DNA user interface pro-vides the production information to ensure
a proper and rapid response to plant
events Automatic controls stabilize the
process and allow the operators to monitor
the plant as a whole
ldquoThe benefits of automation for the min-
ing and construction industry are signifi-
cant As an example of the services we offer
performance studies to crushing plants
utilizing Metsorsquos multi-disciplinary teams of
experts to determine the present level of
the plant and process effi ciency and to esti-
mate the improvement potential and thebenefits of optimization and automation
including ROI calculationsrdquo says Mikko Maumlki-
nen Product Manager of minerals applica-
tions in Metsorsquos Automation business line
ldquoAs another example our machine
condition monitoring solutions can reduce
plant and machine downtimes as well as
help to avoid safety and environmental
hazardsrdquo he adds
Metso around the world
Aerial view of the Elektrociepłownia Białystok combined heat and power plant in Poland
8202019 Metso Minerals Aggregates 3 2011
httpslidepdfcomreaderfullmetso-minerals-aggregates-3-2011 3636
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
8202019 Metso Minerals Aggregates 3 2011
httpslidepdfcomreaderfullmetso-minerals-aggregates-3-2011 34364983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983089
983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155
ldquoWe had our haul trucks drop off mate-
rial while two excavators fed the two
mobile unitsrdquo Reck explains ldquoFor two-and-
a-half months the Lokotrack LT1213 unit
was producing 254 cm (10rdquo) minus at
700 tons per hour The other similar-sized
mobile unit was doing 400 tons an hour
maxed out The difference was unbeliev-
able to say the least Our unique solution
using the two mobile units especially the
LT1213 helped Glenn O Hawbaker achieve
a record output in 2010rdquoAccording to Fahr ldquoWe were not new to
Metsorsquos quality and supportrdquo because GOH
had been using Metsorsquos portable crushing
equipment for 3 years prior to the primary
plantrsquos impact crusher failure In another
part of our operation we have a system that
our team relies on every day a Lokotrack
LT1213 and ST272 working in tandem with
two portable conveyorsrdquo This highly effi -
cient mobile processing system turns out
300 tons of specialized blended material
per hour GOH has been so impressed with
Metso equipment its last two purchaseswere an LT106 tracked jaw plant and a
second ST272 mobile screen in 2010
Maintaining high productivity
The Metso C160 jaw was delivered to Pleas-
ant Gap Quarry in January of 2011 and
since start-up it has more than met expec-
tations The crusher is fed minus 910 mm
(36rdquo) limestone with the jaw set at 140 mm
(5 12rdquo) According to Reck ldquoFrom moment
we started up we knew we had a winner
Not only were we kicking out as much
product as our previous units without even
breathing hard but we immediately had a
2-cent per ton savings to the bottom line
without having to run a second 350 HP
motor as required by other units Plus by
adding on the new automatic lube system
the maintenance team had more time to
devote to keeping other areas of the com-
plex running more effi cientlyrdquoReck says ldquoThe Metso unit was a perfect
fit and with the improved features it pre-
sented it had it all We just turn it on load
it up and we are moving 600 tons per hour
through the crusher without any effort and
we know it can do so much morerdquo With
the primary crushing plant back in opera-
tion the entire team at Pleasant Gap will
continue to do what they do best produce
and sell high-quality products and meet
their customersrsquo expectations
More info
Scott Yablonsky Tel +1 262 717 793
scottyablonskymetsocom
The Metso C160 jaw
was installed at a 10deg
angle to fit Pleasant
Gaprsquos existing
infrastructure
The Lokotrack LT1213 impactor plant and ST272 mobile screen operate in tandem with two
portable conveyors at Pleasant Gap
8202019 Metso Minerals Aggregates 3 2011
httpslidepdfcomreaderfullmetso-minerals-aggregates-3-2011 3536983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088
983149983141983156983155983151 983150
Paper amp fiberNew OptiConcept M paper
and board making line
The new OptiConcept M paper and board
making line stands for economy safety and
usability
Metso has launched a new modular paper
and board making line called OptiConceptM A member of the proven OptiConcept
production line family the new OptiCon-
cept M optimizes machine investment in
line with each millrsquos capacity needs
Savings in operating costs are achieved
through precise dimensioning of pro-
cesses proven technological solutions
optimal running parameters effective
maintenance operations and fully inte-
grated automation solutions
Optimized processes innovations
smart controls and accurate dimensioning
decrease the use of steam gas electricitywater chemicals and other raw materials
and reduce emission levels
OptiConcept M has been designed
both visually and physically with the
requirements of users in mind For exam-
ple the design of the machinery allows for
easy and safe changing of rolls and wear
parts thus reducing the total duration and
cost of maintenance shutdowns
RecyclingGreen energy technology to
Elektrociepłownia Białystok in Poland
Metso will convert a coal-fired boiler to
a biomass-fired Bubbling Fluidized Bed
boiler for Elektrociepłownia Białystok SArsquos
combined heat and power plant (CHP) in
Białystok Poland The new boiler system
will cut the power plantrsquos CO2 emissions
significantly by partly replacing the coal
fuel supply with biomass fuel
ldquoPoland is one of the largest countries
in Europe to have such a high depend-ence on energy derived from coal to
meet national electricity needs This is an
important incentive for us to reduce future
CO2 emissions and produce more green
electricity and with Metso technology
we are certain to accomplish our goalrdquo
states Mr Andrzej Schroeder President of
Elektrociepłownia Białystok SA
Since 2000 Metso has received a total
of 7 biomass boiler conversion orders in
Poland and the renewable energy share
in Poland is only 75 (2010) compared to
the target of 20 by 2020 set by the EUApproximately 80 of the current energy
boilers turbines and generators installed in
Polish power plants are over 20 years old In
order to meet the strict EU environmental
requirements modernization of existing
installations is necessary
Automation
Metso DNA automation system expands
to mining and construction
Using Metsorsquos control room automation
an entire crushing and screening plant can
be effi ciently managed
Metso is a leading supplier of mining and
construction machinery This expertise has
now been combined with a scalable Metso
DNA automation system that adapts to
the range of industry needs from single
machine controls to plant-wide automation
and information management systems
An example of Metsorsquos new offering is a
new crushing plant control room solution
that connects crushers and screens ensur-
ing the effective management of the entire
plant from a pleasant and safe control
room The Metso DNA user interface pro-vides the production information to ensure
a proper and rapid response to plant
events Automatic controls stabilize the
process and allow the operators to monitor
the plant as a whole
ldquoThe benefits of automation for the min-
ing and construction industry are signifi-
cant As an example of the services we offer
performance studies to crushing plants
utilizing Metsorsquos multi-disciplinary teams of
experts to determine the present level of
the plant and process effi ciency and to esti-
mate the improvement potential and thebenefits of optimization and automation
including ROI calculationsrdquo says Mikko Maumlki-
nen Product Manager of minerals applica-
tions in Metsorsquos Automation business line
ldquoAs another example our machine
condition monitoring solutions can reduce
plant and machine downtimes as well as
help to avoid safety and environmental
hazardsrdquo he adds
Metso around the world
Aerial view of the Elektrociepłownia Białystok combined heat and power plant in Poland
8202019 Metso Minerals Aggregates 3 2011
httpslidepdfcomreaderfullmetso-minerals-aggregates-3-2011 3636
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
8202019 Metso Minerals Aggregates 3 2011
httpslidepdfcomreaderfullmetso-minerals-aggregates-3-2011 3536983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088
983149983141983156983155983151 983150
Paper amp fiberNew OptiConcept M paper
and board making line
The new OptiConcept M paper and board
making line stands for economy safety and
usability
Metso has launched a new modular paper
and board making line called OptiConceptM A member of the proven OptiConcept
production line family the new OptiCon-
cept M optimizes machine investment in
line with each millrsquos capacity needs
Savings in operating costs are achieved
through precise dimensioning of pro-
cesses proven technological solutions
optimal running parameters effective
maintenance operations and fully inte-
grated automation solutions
Optimized processes innovations
smart controls and accurate dimensioning
decrease the use of steam gas electricitywater chemicals and other raw materials
and reduce emission levels
OptiConcept M has been designed
both visually and physically with the
requirements of users in mind For exam-
ple the design of the machinery allows for
easy and safe changing of rolls and wear
parts thus reducing the total duration and
cost of maintenance shutdowns
RecyclingGreen energy technology to
Elektrociepłownia Białystok in Poland
Metso will convert a coal-fired boiler to
a biomass-fired Bubbling Fluidized Bed
boiler for Elektrociepłownia Białystok SArsquos
combined heat and power plant (CHP) in
Białystok Poland The new boiler system
will cut the power plantrsquos CO2 emissions
significantly by partly replacing the coal
fuel supply with biomass fuel
ldquoPoland is one of the largest countries
in Europe to have such a high depend-ence on energy derived from coal to
meet national electricity needs This is an
important incentive for us to reduce future
CO2 emissions and produce more green
electricity and with Metso technology
we are certain to accomplish our goalrdquo
states Mr Andrzej Schroeder President of
Elektrociepłownia Białystok SA
Since 2000 Metso has received a total
of 7 biomass boiler conversion orders in
Poland and the renewable energy share
in Poland is only 75 (2010) compared to
the target of 20 by 2020 set by the EUApproximately 80 of the current energy
boilers turbines and generators installed in
Polish power plants are over 20 years old In
order to meet the strict EU environmental
requirements modernization of existing
installations is necessary
Automation
Metso DNA automation system expands
to mining and construction
Using Metsorsquos control room automation
an entire crushing and screening plant can
be effi ciently managed
Metso is a leading supplier of mining and
construction machinery This expertise has
now been combined with a scalable Metso
DNA automation system that adapts to
the range of industry needs from single
machine controls to plant-wide automation
and information management systems
An example of Metsorsquos new offering is a
new crushing plant control room solution
that connects crushers and screens ensur-
ing the effective management of the entire
plant from a pleasant and safe control
room The Metso DNA user interface pro-vides the production information to ensure
a proper and rapid response to plant
events Automatic controls stabilize the
process and allow the operators to monitor
the plant as a whole
ldquoThe benefits of automation for the min-
ing and construction industry are signifi-
cant As an example of the services we offer
performance studies to crushing plants
utilizing Metsorsquos multi-disciplinary teams of
experts to determine the present level of
the plant and process effi ciency and to esti-
mate the improvement potential and thebenefits of optimization and automation
including ROI calculationsrdquo says Mikko Maumlki-
nen Product Manager of minerals applica-
tions in Metsorsquos Automation business line
ldquoAs another example our machine
condition monitoring solutions can reduce
plant and machine downtimes as well as
help to avoid safety and environmental
hazardsrdquo he adds
Metso around the world
Aerial view of the Elektrociepłownia Białystok combined heat and power plant in Poland
8202019 Metso Minerals Aggregates 3 2011
httpslidepdfcomreaderfullmetso-minerals-aggregates-3-2011 3636
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
8202019 Metso Minerals Aggregates 3 2011
httpslidepdfcomreaderfullmetso-minerals-aggregates-3-2011 3636
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