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8/20/2019 Metso Minerals Aggregates 3 2011 http://slidepdf.com/reader/full/metso-minerals-aggregates-3-2011 1/36 Clean, washed Metso sand to build Sochi Winter Olympics in Russia 6 minerals & aggregates METSO’S CUSTOMER MAGAZINE FOR THE MINING AND CONSTRUCTION INDUSTRIES No. / results

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Page 1: Metso Minerals Aggregates 3 2011

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

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

8202019 Metso Minerals Aggregates 3 2011

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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

Page 2: Metso Minerals Aggregates 3 2011

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

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

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

8202019 Metso Minerals Aggregates 3 2011

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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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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

Page 3: 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

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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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

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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

Page 4: Metso Minerals Aggregates 3 2011

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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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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

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

8202019 Metso Minerals Aggregates 3 2011

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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

8202019 Metso Minerals Aggregates 3 2011

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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

8202019 Metso Minerals Aggregates 3 2011

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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

8202019 Metso Minerals Aggregates 3 2011

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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

8202019 Metso Minerals Aggregates 3 2011

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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

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

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

Page 5: Metso Minerals Aggregates 3 2011

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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

8202019 Metso Minerals Aggregates 3 2011

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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

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

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

Page 6: Metso Minerals Aggregates 3 2011

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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

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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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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

Page 7: Metso Minerals Aggregates 3 2011

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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

8202019 Metso Minerals Aggregates 3 2011

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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

8202019 Metso Minerals Aggregates 3 2011

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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

8202019 Metso Minerals Aggregates 3 2011

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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

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

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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

Page 8: Metso Minerals Aggregates 3 2011

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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

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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

8202019 Metso Minerals Aggregates 3 2011

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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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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

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

Page 9: Metso Minerals Aggregates 3 2011

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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

8202019 Metso Minerals Aggregates 3 2011

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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

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

8202019 Metso Minerals Aggregates 3 2011

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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

8202019 Metso Minerals Aggregates 3 2011

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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

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

Page 10: Metso Minerals Aggregates 3 2011

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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

8202019 Metso Minerals Aggregates 3 2011

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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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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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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

Page 11: Metso Minerals Aggregates 3 2011

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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

8202019 Metso Minerals Aggregates 3 2011

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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

8202019 Metso Minerals Aggregates 3 2011

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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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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

Page 12: 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

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

8202019 Metso Minerals Aggregates 3 2011

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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

8202019 Metso Minerals Aggregates 3 2011

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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

Page 13: Metso Minerals Aggregates 3 2011

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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

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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

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

Page 14: Metso Minerals Aggregates 3 2011

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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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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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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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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

Page 15: Metso Minerals Aggregates 3 2011

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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

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

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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

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

Page 16: Metso Minerals Aggregates 3 2011

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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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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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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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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

Page 17: Metso Minerals Aggregates 3 2011

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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

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

Page 18: Metso Minerals Aggregates 3 2011

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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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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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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

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

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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

Page 19: Metso Minerals Aggregates 3 2011

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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

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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

Page 20: Metso Minerals Aggregates 3 2011

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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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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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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

Page 21: Metso Minerals Aggregates 3 2011

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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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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

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

Page 22: Metso Minerals Aggregates 3 2011

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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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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

Page 23: Metso Minerals Aggregates 3 2011

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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

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

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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

Page 24: 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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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

Page 25: Metso Minerals Aggregates 3 2011

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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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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

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

Page 26: Metso Minerals Aggregates 3 2011

8202019 Metso Minerals Aggregates 3 2011

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

The sturdy Metso C160

jaw crushers are fed

using huge feed chutes

and feeders

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

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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

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

Page 27: Metso Minerals Aggregates 3 2011

8202019 Metso Minerals Aggregates 3 2011

httpslidepdfcomreaderfullmetso-minerals-aggregates-3-2011 2736983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088

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

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

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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

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

Page 28: Metso Minerals Aggregates 3 2011

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

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

Page 29: Metso Minerals Aggregates 3 2011

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

Page 30: Metso Minerals Aggregates 3 2011

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

Page 31: Metso Minerals Aggregates 3 2011

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

Page 32: Metso Minerals Aggregates 3 2011

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

Page 33: Metso Minerals Aggregates 3 2011

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

Page 34: Metso Minerals Aggregates 3 2011

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

Page 35: Metso Minerals Aggregates 3 2011

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

Page 36: Metso Minerals Aggregates 3 2011

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