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Page 1: Results Minerals Aggregates 3 2012.ENG

8132019 Results Minerals Aggregates 3 2012ENG

httpslidepdfcomreaderfullresults-minerals-aggregates-3-2012eng 142

The gold rush continues 6

Railway ballast of the

highest quality 20

Win an iPad by participating

to our reader survey 3

minerals amp aggregates

METSOrsquoS CUSTOMER MAGAZINE FOR THE MINING AND CONSTRUCTION INDUSTRIES No 983091983090983088983089983090

results

8132019 Results Minerals Aggregates 3 2012ENG

httpslidepdfcomreaderfullresults-minerals-aggregates-3-2012eng 242983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

Pirjo VirtanenVP Health Safety and Environment

Metso Mining and Construction

Why do we careOver the last three years Metso Mining and Construction has invested heavily in Health Safety and Environment(HSE) particularly in developing the safety of our operations globally Positive results can already be seen ndash our

trend in all the key safety indicators is consistent with a double-digit annual improvement in the incident rate

We are proud of our leading-edge technologies and customer-oriented service around the world Our Metso

commitment to excellence however doesnrsquot stop there Our shared endeavor also extends to workplace safetyndash wherever and whenever Metso professionals are on the job We have named this global commitment to safety

excellence the Metso Safety Pledge

We are serious about making the workplace better than ldquosafe enoughrdquo Some examples of our concrete actions

towards achieving a solid safety culture include global minimum safety standards shared tools and visiblyincreased awareness among our employees In a recent employee survey our commitment to safety was among

the items we most strongly agreed on

The mining and construction business can involve high-risk activities such as lifting and working at heights

and operating tools and equipment The good news is that safety can be managed Our management iscommitted to managing safety and as our maintenance operators know they are not expected to work without

lock-out safety features Unsafe work is simply not the Metso way Safety is not an add-on feature at Metso ndash it is

an integral part of our service and equipment deliveries

Caring for people at work is part of our commitment to sustainable development Sustainability is aboutmeeting todayrsquos needs without compromising the ability of future generations to meet their own needs Metsorsquos

mission is to contribute to a more sustainable world by helping our customers to process natural resources and

recycle materials into valuable products

Our responsibility for people begins with the safety of our customers contractors and Metso employees

We also design our solutions products innovations and services to help our customers improve theirenvironmental performance and safety

Come along with us and contribute to a better future by having a safe day

The Metsosafety pledge

8132019 Results Minerals Aggregates 3 2012ENG

httpslidepdfcomreaderfullresults-minerals-aggregates-3-2012eng 342983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090

2 Editorial

4 News in brief

6 Northern Eldorado

8 Endomines Pampalo ndash a green andresponsible gold mine

12 Nordic Mines ndash on track to becomingone of Europersquos most prominent goldproducers

16 New products

18 Service creates value in China

20 Safe quarrying high-quality aggregates

24 Metso Distribution Centers help youminimize downtime

26 Service shines in Cananea Mexico

27 Metso makes an impact atMINExpo 2012

28 Metso and Boliden Striving togetherfor 97 uptime

31 HP200 cone transforms pebbles into

high-quality sand

32 Where therersquos a will we dig a way

34 Smooth transition to new-generation jaw crusher in Germany

36 Quarrying with certified quality

38 Big Lokotrack LT550GPF boostsquarrying productivity by a third

40 Performance monitoring and reportingfor a mobile crushing plant

41 Metso around the world

983152983157983138983148983145983155983144983141983140 983138983161 983149983141983156983155983151 983149983145983150983141983154983137983148983155 983145983150983139

Fabianinkatu 9 A PO Box 1220FI-00101 Helsinki Finlandtel +358 20 484 100 fax +358 20 484 10e-mail mineralsinfocsrmetsocomwwwmetsocomminingandconstruction

Results minerals amp aggregates customer maga-zine is published 3-4 times a year in English andChinese with French Portuguese Russian andSpanish insertions To receive your personal copyplease contact your nearest Metso office or thee-mail mentioned above

983141983140983145983156983151983154-983145983150-983139983144983145983141983142

Elina Lehtinenelinalehtinenmetsocom983141983140983145983156983151983154

Eero Haumlmaumllaumlineneerohamalainenmetsocom

983139983151983150983156983154983145983138983157983156983151983154983155 983145983150 983156983144983155 983145983155983155983157983141

Pasi Airikka Liliane Boutin Ralf GoffinEero Haumlmaumllaumlinen Sheila Ivers Deanna LeeMonisha Majumdar Sofia Williams Xin Yan

983141983150983143983148983145983155983144 983148983137983150983143983157983137983143983141 983141983140983145983156983145983150983143

Traduct Oy and Kathleen Kuosmanen

983148983137983161-983151983157983156 983137983150983140 983137983154983156 983159983151983154983147

Vanto Design Oy

983152983154983145983150983156983145983150983143

Libris Oy November 2012

copy Copyright 2012 Metso Minerals IncAll rights reserved

Printed on MultiArt Silk 130200 gm2Cocoon offset 120 gm2

Reproduction permitted quotingldquoResults minerals amp aggregatesrdquo as the source

All product names used are trademarksof their respective owners

Addresses Metso Minerals Inc customer data

ISSN 1797-6480

wwwmetsocomminingandconstruction

Printed matter

441 014

COVER PHOTO Managing Director Intildeigo Ajuria of Ofitas de San Felices (right) and Mine EngineerCarlos Fernandez proudly show the first-quality railway ballast produced by Ofitas for the high-speedtrain networks of Renfe the state-owned passenger and freight rail transport operator in Spain

Fill and return our reader survey by visitingwwwmetsocomresults2012 and winan iPad or 10 crystal models of Lokotrack

Help us to serve you better

In this issue

8132019 Results Minerals Aggregates 3 2012ENG

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Worldrsquos biggest mobile crushing plant sold to Kazakhstan

The Lokotrack LT200 weighingalmost 400 tons is the key part

of the system The unit processescopper ore with a nominal capacityof 2500 tons per hour

The Ferrexpo delivery includes 10 vertical grinding mills that will cut the

energy used in the grinding process by 30-50

Metso will supply

the worldrsquos largest fully

mobile track-mounted crushingplant to the Altay Polimetally LLP copper mine

in Kazakhstan The contract also includes large mobile

feeding and conveying systems to move the crushed copper

ore for further processing as well as installation supervision andtraining The complete value of the order exceeds EUR 11 million

ldquoWe see Altay Polimetally as a significant contract in an interest-

ing growing market area Today open-pit mines around the world

are assessing the possibility of saving costs and the environment atthe primary crushing and conveying stages by decreasing on-site

ore trucking With Metsorsquos large-scale fully mobile equipment we

can well meet this customer demandrdquo says Jorma Kempas Busi-

ness Manager In-pit Crushing Solutions Metso

The giant mobile jaw plant will be used in the primary crushingstage at Altay Polimetallyrsquos new open-pit mine in the Karagandy

region

Ferrexpo Poltavarsquos iron ore quality to be improvedwith a complete minerals processing system

Aiming to significantly improve the quality of iron ore produced

Metso will deliver a complete minerals processing system to Fer-

rexpo Poltava Mining Company in Ukraine The value of the order is

EUR 67 million including two previously signed orders worth EUR36 million

Metsorsquos delivery includes high-capacity vertical grinding mills

flotation cells magnetic separators pumps and a crushing and

screening system In addition to equipment the contract includesinstallation and commissioning supervision as well as a tailor-

made automation process control system

ldquoMetso and Ferrexpo have cooperated for more than 30 years

The target of Metsorsquos delivery is to help Ferrexpo Poltava to raisethe iron content in pellets to 65 Fe total and thus enhance the

companyrsquos competitiveness in global marketsrdquo notes Alexy Strikha

Country Manager of Metso Mining and Construction in Ukraine

Ferrexpo plcrsquos iron ore resources in Ukraine are among thelargest in the world

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983150983141983159983155 983145983150 983138

Metso has developedmill lining solutionsthat combine rubberand a variety ofsteel elements tooptimize the weightwear life and ease ofinstallation of linersystems

Metso Mining and Construction recently participated in two Euro-

pean exhibitions in Sweden and the UK unveiling its latest crush-

ing and screening equipmentMaskinExpo the biggest construction machinery exhibition

in the Nordic countries was organized on a golf course near

Stockholm Metsorsquos novelties included the diesel-electric Lokotrack

Exhibiting live at MaskinExpo and Hillhead

Metso is expanding its rubber mill lining production capacity glob-ally by investing in new presses to meet the growing demand in

the global mining market After completing the investment in 2015

Metsorsquos global rubber mill lining production capacity at the existing

wear parts manufacturing plants will increase 30 percent High-quality wear parts ensure mining process reliability at all times

Metso is purchasing straight grate iron ore pelletizing technologyand know-how from Jacobs Engineering Group Inc In addition

key Jacobs Minerals technical staff related to the technology will

become Metso employees as part of the deal

Iron ore pelletizing is used to produce pellets from concen-

trated iron ore for feed to blast furnaces and direct reduced iron

LT120E jaw plant the brand new LT106 jaw plant and the HP3

cone crusher

Hillhead the largest European quarrying and recycling ldquolivequarry showrdquo brought together a record number 17000+ visitors

At the event Metso presented its LT120 and LT106 jaw plants the

HP3 cone and the new C120 jaw crusher

The diesel-electric Lokotrack LT120 jaw plant exhibited at MaskinExpowas sold to the Swedish crushing contractor Johanssons Entreprenad

Metsorsquos crusher newcomers the HP3 cone and C120 jaw raised a lot ofinterest during the Hillhead quarry show in Buxton UK

Mill lining manufacturing capacity to be expanded

Iron ore pelletizing technology and know-how acquired from Jacobs Minerals

The investment totaling approximately EUR 10 million will becompleted in two phases The first set of presses is scheduled to

be in operation by the end of 2013 I t includes the installation of

presses in Chile Sweden Canada Mexico and Peru

plants Metso anticipates continued growth in this market as more

beneficiation and pelletizing plants are needed to maximize theoutput from lower grade ore bodies

Metso currently offers the grate kiln iron ore pelletizing system

With the purchase of straight grate technology from Jacobs Metso

will become the worldrsquos only supplier of both systems

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156983145983139983148983141

Metsorsquos mobile crushing and screening units are in the frontline in the demandingreconstruction efforts in Japan after the nation was ravaged by the biggest earthquakeand tsunami in its recorded history Tracked mobile Lokotracks are the quickest wayto boost the production of aggregates an estimated 200 million tons of which willbe required over the next decadeTEXT amp PHOTOS Eero Haumlmaumllaumlinen

The biggest gold producer in Europe

Agnico Eagle in Kittilauml Northern Finlandcurrently produces some 5000 kg of goldannually The mine plans to expand its daily

ore extracting capacity to 4000 metric

tons which will increase the gold produc-

tion by an additional 1000 kgOther major gold producers in Fin-

land include Nordic Minesrsquo Laiva mine

Endominesrsquo Pampalo mine Lappland

Goldminersrsquo Pahtavaara mine and DragonMiningrsquos Orivesi and Jokisivu mines

Metso with its crushing screening and

minerals processing equipment is a sup-

plier to most Finnish gold mines In addi-tion to the equipment Metso also offers

these gold-mining operations its process

planning expertise and services

New gold deposit discoveries likely

Senior Geoscientist Pasi Eilu from the Geo-

logical Survey of Finland believes that the

possibilities of finding new gold deposits

comparable to the current ones are good

Helping Japan to rebuild

after the tsunami

ldquoIn Finland gold has been found

wherever serious exploration has beencarried out The latest interesting depositshave been located by Mawson Resources

between Tervola and Ylitornio in Northern

Finlandrdquo

According to Eilu the latest findings onlyinclude gold ore exposed at the surface

ldquoIt is very likely that in the near future

gold will be found in the deposits hidden

completely undergroundrdquo he explains ldquoNextyear the Geological Survey of Finland will

publish an estimate on possible gold depos-

its reaching a depth of one kilometer from

the surface This will provide more accurateinformation on potential discoveriesrdquo

The average gold grade in Finnish gold

mines is similar to any gold mine abroad

ldquoThe most common type in Finlandis orogenic gold ore which is similar to

nearly all ores originating in West Austral-

ian and Ontario Canada We also have

volcanic-related gold deposits for example

in the Orivesi mine and small amounts of

gold deposits similar to those found in the

worldrsquos biggest deposits in WitatersrandSouth Africardquo Eilu adds

Focus on green mining

The Finnish Green Mining concept is the

mineral sectorrsquos answer to future chal-

lenges It aims to optimize material and

energy efficiency in the whole productionchain The program aims at efficient pros-

pecting for new deposits and at develop-

ing new solutions for utilizing them It

also aims to minimize local environmentalimpacts and problems to improve work

safety and the workplace atmosphere andto restore mining areas after mining opera-

tions are completed The Green Mining program started in

2011 The main objective is to make Finland

a global leader in the sustainable mineral

industry by 2020 The program encom-

passes two central themes intelligentminimum-impact mines and new mineral

resources

NorthernEldorado Today Finland together with the Nordic countriesfalls within one of the global areas that are experi-encing a gold exploration and mining boomIn recent years major global mining companieshave entered the country and opened gold mines

and they are now set to expand their on-goingoperations A number of promising explorationprojects are simultaneously under way on behalfof some 40 mining companiesTEXT Eero Haumlmaumllaumlinen PHOTO iStockphoto

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156

1

78

9

1011

12

13

15

16

18

19

2021

22

14

2

3

5

6

17

Active Mines and Current Projects February 2012

Kittilauml gold ndash Agnico-Eagle Ltd Pahtavaara gold ndash Lappland Goldminers Ab

Laiva gold ndash Nordic Mines Ab

Pampalo gold ndash Endomines AB

Orivesi gold ndash Dragon Mining Ltd Jokisivu gold ndash Dragon Mining Ltd

Iso-Kuotko gold ndash Agnico-Eagle Ltd

Hanhimaa gold ndash Dragon Mining Ltd

Kettukuusikko gold ndash Taranis Resources IncNaakenavaara gold ndash Taranis Resources Inc

Kiekeroumlmaa gold ndash Tertiary Minerals Plc

Rompasgold uranium ndash Mawson Resources Ltd

Suhanko-Konttijaumlrvi PGE ndash Gold Fields Arctic Platinum OyKuusamo gold ndash Dragon Mining Ltd

Hirsikangas gold ndash Belvedere Resources Finland Oy

Aumlngesneva gold ndash Belvedere Resources Finland Oy

Kopsa gold ndash Belvedere Mining Oy

Taivaljaumlrvi silver ndash Sotkamo Silver ABSeinaumljoki gold antimony ndash Nortec Minerals Corp

Osikonmaumlki gold ndash Belvedere Resources Finland Oy

Haveri gold ndash Lappland Goldminers Ab

Kaapelinkulma gold ndash Dragon Mining Ltd

1

3

5

7

15

11

19

9

17

13

21

2

4

6

8

16

12

20

10

18

14

22

Mine

Prospect

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983110983141983137983156983157983154983141983140 983137983154983156983145983139983148983141

The main minerals processing componentsincluding grinding flotation and pumping

equipment are delivered by Metso

983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

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983110983141983137983156983157983154983141983140 983137983154983156

Endomines

Pampalondash a green andresponsiblegold mineAt Pampalo near the easternmost point of Finland a cleanand environmentally friendly gold mining operation isbeing executed by Endomines With Metsorsquos plant designand a state-of-the-art processing plant Pampalo runs a

green and responsible yet at the same time profitablegold mining operation that avoids acid mine drainagesand targets 100 water recirculationTEXT amp PHOTOS Eero Haumlmaumllaumlinen

With a modest investment of EUR 20

million the Pampalo mine was built fully

operational and now produces 800ndash900 kgof pure gold annually An on-going expan-

sion will increase the minersquos production

capacity by 30 to 50 next yearIn addition to the main underground

mine at Pampalo several promising satellite

gold deposits are being investigated along

the long Karelian gold line The maximum

distance of the satellites is 30 km allowingthe mine to transport and process all of the

produced ore at the Pampalo plant

Small scale can be successful

with hard work

ldquoWith our gold mining operation we can

very well show that with hard work even

small-scale gold mining and production

can be done in a sound and profitable wayrdquosays Markus Ekberg CEO of Endomines

originally founded in Sweden

According to Ekberg the strategy when

building the mine was to split up the jobsinto small separate contracts Metsorsquos part

was the main minerals processing system gt

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156

Increasing capacity makes processing

of lower grades economical

The project to significantly increase the

processing capacity at Pampalo is well

under way with the installation of for

example a second grinding mill and more

flotation cells The expansion will be in

operation during early 2013ldquoThe added capacity also makes it pos-

sible to economically process the nearby

open pits with a lower gold grade In addi-tion it helps us to optimize the crushing

and grinding circuitsrdquo Ekberg concludes

Active exploration drillings have

exposed new mineralized zones furtherextending the lifetime of the Pampalo mine

from the present estimate of 6ndash7 years

More info

Peter Vikman

Tel +358 400 869 845petervikmanmetsocom

Endomines Pampalo gold mine

LOCATION near the community of

Ilomantsi in Eastern Finland

GOLD ORE CONTENT

ndash Pampalo 34 gtndash Hosko 99 gt

ndash Raumlmepuro 39 gt

ndash Muurinsuo 30 gt

PRODUCTION TONNAGE PER YEAR 270000 tons (present)~400000 tons (future)

GOLD PRODUCTION PER YEAR 800ndash900 kg

KNOWN ORE RESERVES IN TOTAL

approx 2 million tons

MINE DEPTH 360 m

MINING METHOD bench cut and fill

NUMBER OF EMPLOYEES

100 including contractors

METSO EQUIPMENT

1 Metso TRN 30 x 48 m

wet ball mill

8 Metso RCS series flotation cells 1 Nordberg MF 1800 x 6100

screen

3 Metso samplers

1 Metso CT thickener

1 Metso TF vacuum filter

33 Metso slurry pumps of various

types and sizes

The gold ore is screened using Metsorsquos MS series mining screen

Markus Ekberg is pleased with the outcome the mine reached the minerals processing utilizationdegree of over 90 just two months after start-up

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156983145983139983148983141

Nordic Mines ndash on track tobecoming one of Europersquosmost prominent goldproducersNordic Mines is the newest member in a long chain of Nordic gold mining operations

Inaugurated in mid-August 2012 this company of Swedish origin aims to become one

of Europersquos most prominent gold producers Metso is one of Nordic Minesrsquo main partners

supplying the Laiva gold mine with crushing screening conveying and minerals

processing equipment at an estimated value of EUR 30 million

TEXT amp PHOTOS Eero Haumlmaumllaumlinen

2983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

The Laiva gold mine was built in record time infrastructure

construction began in spring 2010 ore excavation started in

June 2011 and the first gold bar was casted in December 2011

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983110983141983137983156983157983154983141983140 983137983154983156

Just one year after starting the gold recov-

ery process Nordic Mines is on track toreaching a capacity of 5 kg of gold per day

At present the operations are averaging 3

to 4 kg of gold daily

The ore in the Laiva Gold Mine consists

of packages of gold-bearing quartz-filled

shear structures The deposit is more thana kilometer long and 700 meters wide The

total depth is still unknown but dr illings

carried out thus far have shown gold-bear-ing shear structures 300 meters below the

surface

A typical ore zone includes a large num-

ber of thin shear structures from 5 to 30per meter The ore zones are commonly 50

to 100 meters long several are 10 meters

deep and they range from a few meters to

20 meters cross strike The minimum min-ing width is 25 meters which means that

even a minor ore zone consists of at least10 to 50 shear structures

Conventional pattern blasting

with selective loading

Prior to mining Nordic Mines conducts

grade control drilling which provides

dense gold grade information and makes

it possible to outline the boundaries

between ore and waste The mining

technique applied is conventional pattern

blasting with selective loading This is oneof the most commonly used techniques in

large-scale open-pit mining

A typical blast in the Laiva mine is 50

meters long 100 meters wide and 5 metersdeep After blasting ore and waste aremined by selective loading

After investing some EUR 100 million

the Laiva mine now comprises an open-pit

mine with a modern complete crushinggrinding and processing circuit that ends

with the casting of gold doreacute bars

With a number of mine staff partners

sub-suppliers city and state officials inattendance the Laiva gold mine was offi-

cially inaugurated on August 16 2012

Michael Nilsson Managing Director

of Nordic Mines stressed in his speechthe importance of overcoming challenges

during the building of the mine

ldquoObviously the whole development

took us longer than expected Today weare pleasantly surprised by the size of our

operation We are becoming much bigger

than expectedrdquo gt

Chief Geologist Kimmo Lahtinen presenting narrow gold veins twisting at the Laiva North open-pit mine

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156983145983139983148983141

An international process package

The Metso package for the Laiva gold mine

included the main crushing screening

conveying regrinding leaching and pump-ing elements Metsorsquos office in Sala Swe-

den has served as the main project office

with Metso manufacturing units in FranceGermany Sweden and Finland responsiblefor the equipment supply

At Laiva the gold ore is classified after

selective excavating into two gold con-

tent classes All class A gold ore is takento Metsorsquos sturdy jaw crusher for primary

crushing while the class B ore is stocked for

possible future use After primary grinding

utilizing autogenous technology the ore is

screened and two Metso cones crush the

oversized pebbles For regrinding Metsorsquosball mill is used

During high- and low-grade leaching

processes a number of Metso pumps and

dewatering screens are used The whole

minerals processing system is controlled byMetsoDNA automation

Active exploration drilling going on

According to Mine Manager Tom Soumlder-

man the known gold ore reserves at the

Laiva gold mine amount to 169 million

tons but the potential for additional find-

ings looks good

ldquoWorking at the level of two million tonsper year our expected lifetime is about nine

years We carry out active exploration drill-

ing in Kaukainen Musunneva and Oltava

to locate nearby satellite ore bodies Anupdated detailed mine life plan will be pre-

pared during the autumnrdquo Soumlderman saysNordic Minesrsquo other exploration areas

include Tormua in Finland and Fjaumllltuna

and Vassbo in Sweden

More info

Alf Rydberg

Tel +46 70524 5837

alfrydbergmetsocom

Happy faces during the minersquos inaugural ceremony Mine Manager Tom Soumlderman (left) with Managing Director Michael Nilsson and Deputy Managing Director Krister Soumlderholm

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156

The story behind the discovery of the Laivamine is an interesting one During a hunt-

ing trip in the remote forests of Laivakan-

gas in 1979 Pentti Jaumlmbaumlck found an inter-esting-looking piece of stone Although hecould not see the gold hidden inside the

rock Pentti noticed the striking weight

and somewhat different look of the stone

Upon returning home Pentti sent thesample to Outokumpu which at the time

was the leading state-owned mining com-

pany in Finland After testing a high gold

content of 15 grams per ton was found

Gold deposit founded by a hunter

The founder of the Laiva gold deposit Mr Pentti

Jaumlmbaumlck was the guest of honor during theinauguration

Lennart Schoumlnning Chairman of the Board ofNordic Mines holding a gold doreacute bar worthsome EUR 320000

Outokumpu registered a mining claimon the area and conducted a series of

exploration drilling from 1981 to 1987 Due

to the low price level for gold no mine wasstarted at the time Other mining compa-nies such as Endomines held the mining

rights later

Nordic Mines with its sights set on

locating and exploiting gold in Swedenand Finland was founded in 2005 During

the same year the company purchased its

first mining rights at Laiva

Nordic Minesrsquo Laiva gold mine

LOCATION near the city of Raahe

northwestern Finland

GOLD ORE CONTENT average 16 gt

ORE EXTRACTED PER YEAR

12 million tons (present)

20 million tons (planned)

GOLD RECOVERY 85

TOTAL KNOWN ORE RESERVES

169 million tons

MINING METHOD

Selective open-pit benchingNUMBER OF EMPLOYEES

130 including contractors

METSO MAIN EQUIPMENT

2 Metso VF and 6 EMEG EME

vibrating feeders

8 Screens 1 MF 1 CVB and 6 KS

1 RCS Flash flotation unit

1 Metso SRR ball mill 18 x 4 m

1 Nordberg C160 jaw crusher

1 Nordberg HP100 cone crusher

1 Nordberg HP200 cone crusher

5 Nordberg NB series conveyors

73 Metso Slurry pumps ofvarious types and sizes

8132019 Results Minerals Aggregates 3 2012ENG

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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155

The newest member of the proven GP series cone crushers ndash theNordberg GP220 ndash offers a versatile alternative for any demanding

tertiary or quaternary or even secondary crushing operation fulfill-

ing all crushing needs and maximizing customersrsquo profitability

High-quality components and optimized castings and forgings

contribute to the GP220rsquos enhanced reliability and help to ensurethe highest level of crusher uptime

Thanks to the 200 kW (270 hp) power draw the GP220 performs

at a 20 to 30 percent higher capacity than other cone crusherbrands with an equal head diameter The large feed openingenables the feeding jaw crusher to run at 110 mm css Operational

flexibility is ensured by multiple strokes and six different cavities

Secondary crushing possible

thanks to cavity and stroke options

Thanks to the GP220rsquos cavity and stroke options secondary crush-

ing in addition to tertiary and quaternary stages is also possible

using cavities with a greater intake opening With the GP220 a suit-

able solution for producing excellent end-product gradations

can always be found

With advanced automation using IC50 or IC5000 operation

is safe and trouble-free The low height thanks to the patented

piston design makes replacement installations much easierA dynamic setting adjustment enables a fast response to process

optimization needs

The Nordberg GP220 weighs 10500 kg (23150 lbs) and hasa maximum real feed size of +200 mm (8rdquo) with strokes from

18ndash40 mm (57rdquondash1 47rdquo) The cavity options are EF F MF M C

and EC

A complete modular crusher steel structure is available for allGP series stationary installations including GP220 The platform

includes places for the lubrication unit motor automation or

pressure accumulator and pressurized sealing The only things

left to add are the feed and discharge conveyors

Main new features of the GP220 Large feed opening allows for secondary stage operation

Longer setting range of main shaft for better wear parts utilization

Stronger main components to carry high loads with a powerdraw as high as 200kW

More info

Hannu Vakkuri

Tel +358 50 317 0638

hannuvakkurimetsocom

Thanks to the large feed opening and wide selection of strokes and cavitiesthe new Nordberg GP220 cone crusher is a highly versatile cone novelty

More versatility with the newNordberg GP220 cone crusher

Reinforced head and frame castings combined with a 200kW power

draw make the GP220 cone a reliable crusher with maximum productivity

8132019 Results Minerals Aggregates 3 2012ENG

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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156

Metsorsquos HRCtrade takes high pressure grinding roll technology to the next level

The new Lokotrack mobile conveyors come as tracked and wheeled models

Metsorsquos latest development in comminution equipment the HRCtradeis a major step in the profitable application of high-pressure grind-

ing roll (HPGR) technology Metso has made several key innova-

tions in order to increase throughput and decrease the total cost

of operation

Metsorsquos patented Arch frame creates an even gap setting acrossthe width of the tires limiting skewing that can result in downtime

for mining operations This anti-skewing Arch frame also prevents

damage to the roller bearings (caused by misalignment) that canoccur with the traditional HPGR design

Flanges maximize wear life and increase throughput

Used in place of spring-loaded cheek plates the flanges keep thebed of material within the crushing zone and prevent material

from bypassing the tires This enables greater circuit capacity and

increases the overall crushing efficiency

In addition by preventing material from bypassing the tires

even pressure across the width of the tire is better maintained

Distributing the pressure more evenly maximizes the tire life bypreventing a ldquobath tub effectrdquo in which the center of the tire wears

faster than the edgesVictoria Herman Metsorsquos Product Manager for the HRC notes

that this breakthrough design is a response to the growing needs

in the mining industry ldquoEnergy efficiency has been attracting our

customers to HPGR technology for yearsrdquo she says ldquoBut our design

concept increases capacity and crushing efficiency ndash and thatrsquossomething mining companies are always looking to improve onrdquo

The track-mounted Lokotrack CT32 and wheel-mounted Lokotrack

CW32 mobile conveyors offer an ideal solution for applications

that require high stockpile capacity and excellent material transfer

capabilities They also add flexibility to multi-stage crushing andscreening applications enabling easy and fast closed-circuit opera-

tion of mobile units

The conveyor novelties can be used in both mobile and station-

ary installations providing extra stockpiling capacity in situationswhere for example fewer wheel loaders are available

The HRC is ideal for high-tonnage hard rock applications andcan be used as a tertiary quaternary or pebble crusher Currently

several HRC units are in operation around the world ndash with a total

of 6500 operating hours including over 3800 hours in a mininghard rock application The machine does have range within hardrock applications itrsquos been designed for use in diamond iron ore

copper gold platinum and various industrial minerals

More info

Victoria Herman

Tel +1 717 309 1150

victoriahermanmetsocom

Several optional features such as hydraulic folding of tail sections

and dual hydraulic drive for increased throughput are available

The capacity of the CT32 and CW32 is 400 mtph (440 stph)feed size up to 150 mm (6rdquo) belt width 1050 mm (42rdquo) and dis-charge height 9120 mm (29rsquo 11rdquo) The CT32 is fitted with a Caterpil-

lar C2 diesel engine with 38kw (51 HP) power The CW32 is avail-

able for hydraulic or electric use

More info

Kimmo Anttila

Tel +358 50 433 3745

kimmoanttilametsocom

The new HRCtrade combines high crushing pressure and a low circulatingload resulting in the most efficient comminution

When flexibility in stockpiling capacityis required the answer can be foundin the new Lokotrack CT32 and

CW32 mobile conveyors

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Service creates value in ChinaChinarsquos most important gold producing area Yantai in northeastern China supplies more than 16 of the countryrsquos goldproduction each year With the gold market thriving the scale of gold production in Yantai has been expanding constantly

Zhongjia Mining Industry Co Ltd is one of the beneficiaries of this thriving industryTEXT amp PHOTOS Yan Xin

Inspection and maintenance of the HP500 cone crusher conducted by Metsorsquos service engineers

In 2011 Zhongjia Mining Industry pur-

chased a modular crushing and screen-ing system from Metso for its new gold

production project With the cooperation

between the two companies continuously

intensifying Zhongjia Mining Industry

signed an additional one-year Life CycleService (LCS) contract with Metso incorpo-

rating Metsorsquos global knowledge in equip-

ment processes and services

ldquoMetso customized a series of reason-

able service solutions also referred toas Metso Performance Solutions for us

including preventive maintenance services

process improvement personnel training

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155

and a procurement plan for wear parts

These really suit our needs perfectlyrdquo saysShen Yidong the Manager of ZhongjiaMining Industry

Effective preventive maintenanceFor mining corporations the biggestconcern is the economic losses caused by

the shutdown of equipment As a result

preventative maintenance is of vital impor-

tance During the contract period Metsoservice engineers offered 7-day tracking

service on the production site every month

to eliminate potential problems and thus

ensured the stability of the system

parts caused pressure on our working capi-tal which was not favorable for our long-

term developmentrdquo Shen explains

To solve this problem Metso designed

a rational stock plan of wear parts and built

a field warehouse In accordance with theuse and consumption of the liners the field

service engineers complement the stock tomake production and operations run more

smoothlyldquoNow when we need to replace the

wear parts we can use them before pay-

ment This not only simplifies the procure-

ment process but also liberates a largesum of our operating capital which can

be used for other business development

purposesrdquo says Shen

Best partner

ldquoAlthough the LCS contract incurs some

early purchase costs in the long run Metsorsquosprofessional and quality service will improve

the equipment efficiency reduce ourenergy consumption and ensure stable

operations thus generating more prof-

its This is the greatest value for us so the

investment is really worthwhile overall Inthe future we will choose more Metso prod-

ucts and services Taking all aspects into

consideration we believe Metso is the best

partner for usrdquo Shen Yidong concludes

More info

Thomas Bai Tel +86 13801009114

thomasbaimetsocom

ldquoIn the eight months since the contract

came into effect our corporation has notsuffered any financial losses due to equip-

ment breakdown The regular maintenance

has greatly improved the efficiency of our

entire crushing system In addition the

experienced engineers from Metso also

provided onsite training and guidancefor our staff and the tailored training has

greatly enhanced the operating abilities of

our employees and upgraded their overalllevel of competencerdquo says Shen Yidong

More productivity with

less consumption

Metsorsquos service contract focuses on real-

izing the optimum performance of each

process flow After analyzing Zhongjiarsquos

production system Metsorsquos techniciansproposed an adjustment to the closed side

setting of the HP500 for tertiary crushingin order to improve the efficiency of the

downstream fine crushing and milling pro-

cessing by over 10ldquoThe process flow improvement solu-

tions provided by Metso not only increased

the output of our gold concentrates but

also reduced our energy consumption andcostsrdquo says Shen

In the past wear parts procurement

took up a larger proportion of Zhongjiarsquos

total production costsldquoTo avoid downtime caused by the

shortage of wear parts we had to keepeight sets of various wear parts in place

However the cost of having so many wear

Zhongjia Mining Industryrsquos gold concentrates processing plant in China

8132019 Results Minerals Aggregates 3 2012ENG

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0983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

Safe quarrying high-

quality aggregates

8132019 Results Minerals Aggregates 3 2012ENG

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ldquoWe share a similar zero-accident strategy and target with Metso and have successfullyfollowed it Metso has also helped us to meet the strictest end-product quality andcubicity requirements set in Spainrdquo This is how Managing Director Intildeigo Ajuria ofOfitas de San Felices the leading hard rock quarrying company in Spain describesthe cooperation with MetsoTEXT Eero Haumlmaumllaumlinen PHOTOS Ofitas and Eero Haumlmaumllaumlinen

The San Felices quarry is situated in a picturesque mountainous landscapebetween the companyrsquos Rioja vineyards and the Bilbao-Madrid motorway

8132019 Results Minerals Aggregates 3 2012ENG

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Ofitas has pioneered the implementation

of several Metso novelties in the Spanish

market The company was the first to use

efficient large track-mounted Lokotrack jaw plants the unique mobile conveying

system and also the new-generation HP4

cone crushers

Today the company operates twomodern Metso stationary plants one in

Guadix near Granada and the newest one

in San Felices Haro Rioja community Both

quarries focus on refining hard rock by pro-cessing ophite rock into the highest quality

railway ballast asphalt and concrete mix

grades The company has a satellite quarry

near Vitoria in PentildeacerradaBeing situated next to a highway and

the famous Rioja vineyards Ofitas must pay

special attention to environmental issues

To minimize dust problems all conveyors

have special covers attached

Quality durability and service

The cooperation between Ofitas de San

Felices and Metso started back in 1973when the Ajuria family bought the com-

pany whose quarrying activities began in

1919 Intildeigo Ajuria has a clear vision of why

the cooperation has continued withoutinterruption for almost 40 years

long-standing personal relationshipsrdquoAjuria adds

Serving railways asphalt

and concrete producers

The year-old San Felices stationary instal-lation lies hidden in a mountainous area

south of the city of Vitoria in NorthernSpain The new plant replaces an old one

that complicated the extraction of ophiterock Both plants are delivered by Metso

With its two separate production lines

the new plant is able to produce all the

end products required ndash from railway bal-last to the finer grades needed for asphalt

and concrete

Due to lower demand the quarry cur-

rently produces some 4000 tons per day

At full capacity however the plant canreach 8000 tons of production per day

30ndash35 of which consists of railway ballastfor high-speed trains and 65ndash70 of chips

and sand Thanks to the versatile two-line con-

cept connected by transverse conveyors

up to 12 different end products can be pro-

duced Depending on the demand for endproducts the material can be guided either

to the HP4 cone or HP400 cone followed

by a Barmac vertical shaft impactor

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

The ophite feed is fed to the C125 jaw crusher by a sturdy dump truck

The key people running the new San Felicesquarry Mine Engineer Carlos Fernandez (left)Managing Director Intildeigo Ajuria with ProductionManager Julian Perez

ldquoThrough the years Metso machinery

has proven its production capacity and

durability resulting in high-quality end

products A big plus for us has also beenthe quick response time to our process

challenges or servicerdquo

ldquoIn fact our cooperation extends

beyond day-to-day business matters to

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155

Meeting the strictest cubicity demands

The Spanish regulations concerning end-product cubicity are becoming more

demanding The flakiness percentage of

railway ballast must be below 10 and for

asphalt and concrete aggregates less than

15

ldquoWith Metsorsquos HP4 cone and the Barmacvertical shaft impactor we can meet even

the strictest cubicity demands We believe

that our high quality is helping us to sur-vive in the present recessionrdquo notes Mine

Engineer Carlos Fernandez

ldquoWe hope to increase the total extrac-

tion of the three quarries from the present15 million tons per year because our plant

capacity allows more than double thatrdquo

Fernandez adds

More info

Angel Luis Garcia Tel +34 686 94 35 30

angelluisgarciametsocom

In addition to being the leading Spanish

quarry to process hard rock Ofitas de SanFelices also cultivates 34 hectares of vine-yards next to the quarry which is situated

in the famous Rioja wine area

The company has previously sold a

harvest of over 200000 kg of Tempranillo

grapes to local red-wine makers Recentlythe company built its own wine process-

ing plant to process 10000ndash15000 kg of

grapes themselves

Aggregates and wine production

Andoni Ajuria the founder of Ofitas de san Felices (left) with Intildeigo Ajuria the present ManagingDirector tasting wine from the companyrsquos own vineyards

The first vintage wine of Ofitas har-

vested in autumn 2010 is now maturingin oak barrels After maturing for 12 to 15months the wine is called crianza and after

two years it will be granted the classifica-

tion reserva

ldquoWinemaking is not a business but

a hobby for us We give our wine out aspresents and drink it when we meet

our suppliers and friendsrdquo Intildeigo Ajuria

comments

For environmental protectionall of San Felicesrsquos plantconveyors are covered

Ofitas de San Felices quarry

LOCATION Haro near the city

of Vitoria northern Spain

SIZE 100 hectares

ROCK TYPE Ophite with Los Angeles

index of 9ndash10

PRESENT DAILY EXTRACTION 3000 tons

of ophiteNUMBER OF PERSONNEL 30

RESERVES 10 million tons

MAIN END PRODUCTS 0ndash2 mm

2ndash4 mm 4ndash10 mm 10ndash16 mm

16ndash22 mm 25ndash60 mm (ballast)

METSO MAIN EQUIPMENT

VF feeder

C125 jaw crusher

ndash feed size 0ndash800 mm

ndash css 130ndash140 mm

HP400 cone crusher

ndash feed size 80ndash250 mm

ndash css 40 mm HP4 cone crusher

ndash feed size 40ndash80 mm

ndash css 15 mm

Barmac 6150 VSI crusher

4 CVB2060 screens

2 TS32 screens

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Metso Distribution Centers he

Europe (Tongeren Belgium)

France (Macon)

Czech Republic (Přerov)

Austria (Vienna)

2271 d

Brazil (Sorocaba SP)

1014 d

USA (Columbia SC)

1690 d

USA (Waukesha WI)

434 d

South Africa (Vereeniging)

Ghana (Tarkwa)

Meacutexico (Irapuato)

Peru (Lima)

Chile (Concoacuten)

788 d

Sweden ( Trelleborg)

Finland (Tampere)

UK (Rugby)

865 d

Russia (St Petersburg)

Brazil (Parauapebas PA)

206 d

4983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983122983141983152983151983154983156983145983150983143 983154983141983155

In the case of an equipment failure or

a planned service shutdown resuming

production as quickly as possible is crucialEach hour spent waiting for a spare part to

arrive equals money lost Whether the right

part takes 12 or 48 hours to arrive really

makes a difference

The comprehensive and global Metsospare and wear parts service network pro-

vides you with the right part in the right

place and at the right time Our strategi-

cally located Distribution Centers and

Satellite Warehouses are on call 24 hoursa day 7 days a week ensuring efficient

parts replacement near you

Check out the locations of the MetsoDistribution Centers and how many parts

pass through them each day

More info

Marcelo Farah

Tel +55 15 2102 1315

marcelofarahmetsocom

you minimize downtime

Australia (Perth)

746 d

China (Tianjin)

China (Kunming)

China (Shanghai)

393 d

India (Faridabad)

India (Ahmedabad)

India (Hyderabad)

India (Bhubaneswar)

India (Bangalore)

419 d

Russia (Yekaterinburg)

Australia (Newcastle)

New Zealand (Matamata)

983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088

TEXT Sofia Williams

Singapore (Singapore)

Distribution Center Satellite Warehouse

8132019 Results Minerals Aggregates 3 2012ENG

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Following a large investment

in Metso crushing equipmentand services Buena Vista del

Cobre is now expanding the

mine site to include even more

equipment ndash and with thatexpansion comes the need for

more local service resources

Metso and Buena Vista del

Cobre have entered into a Life

Cycle Service agreement forthe plant and construction of a

brand new Metso service hub

is under way in Cananea

New facility new

level of service

The Cananea service hub

which will be up and running in early 2013will support the recent expansion and resur-

gence of Buena Vista del Cobre Initially it

will be a major repair and assembly center

for pumps crushers and screens and will

provide for rubber covering capabilitiesBut the 8000-square-meter facilityrsquos service

offering will be expansive including a con-

signment stock inventory to help serve theminersquos varying needs Metso currently has

50 service team members on site

Although Buena Vista del Cobre was a

key influencer in building the new servicehub this location will also enable Metso to

expand its capabilities and provide local

support to the entire mining community

in northwest Mexico The Cananea hub

will serve a number of major copper and

gold mines in the region including MineraFriscorsquos San Felipe Fresnillorsquos Milpillas and

Grupo Mexicorsquos Mexicana de Cobre

ldquoBuena Vista del Cobre is the biggestcustomer we have in Mexico today and

with this expansion project itrsquos only going

to grow and be strongerrdquo says Felix Forna-

guera Director of Services Mexico CentralAmerica and Caribbean ldquoWith that said the

idea behind the Cananea service hub is to

provide a central location for local support

for all our major customers in the areardquo

Establishing safety

ldquoIt was key to have our support here in

Cananea because the Buena Vista delCobre started from the ground uprdquo saysFelix ldquoWersquove been able to help the cus-

tomer to establish the best in support

service and operations from the very

beginningrdquo And this ground-up approachincluded a major focus on safety

Metso worked closely with Buena Vista

del Cobre to establish the safety proto-

col by which the mine operates Basedon Metsorsquos expertise the safety measures

put in place have enabled the mine to

become strict and efficient in its operations

and maintenance procedures To achievethis Metso worked closely with local andnational authorities to ensure the safety

plan was comprehensive and in accord-

ance with all established legal bodies

The best in regional support

The service hub in Cananea is a prime

example of Metsorsquos focus on providing local

service and support to its customers all

Service shines in Cananea MexicoAfter three years of inactivity the Buena Vista del Cobre mine in Cananea Sonora Mexico has been operational since 2010A mine that was inactive for such a significant amount of time however requires a great deal of support to successfullyrestart the plant and bring it back to an operational and profitable state

TEXT Deanna Lee PHOTO Metso

over the world ldquoWe are the first

company developing this kindof service in northwest Mexicordquo

adds Felix ldquoOur people have

developed a close relationship

with the team at the mine Itrsquosmore than a supplier relation-

ship our guys are inside the

mine living and working thererdquo

In fact this is the model

that Metso is using in servicehubs all over the globe build-

ing modern facilities bringing

teams on site and workinghand in hand with mine

operators The Cananea Service

hub is only the most recent

example of Metsorsquos commit-ment to service and northwest Mexico is

yet another mining hotbed thatrsquos going to

benefit from the companyrsquos support

More info

Felix Fornaguera Tel +52 4621079227

felixfornaguerametsocom

A mining cone serviced by Metso at the Buena Vista del Cobre mine inSonora Mexico

ldquoThe new Cananea service center will be a majorrepair and assembly center for pumps crushersand screensrdquo says Felix Fornaguera Director ofServices Mexico Central America and Caribbean

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

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During the MINExpo exhibition over 1300 people visited the Metso stand

983122983141983152983151983154983156983145983150983143 983154983141983155

Held every four years MIN-Expo consistently grows so

perennial exhibitors like Metso

are challenged with elevating

their presence and drawingin new (and greater numbers

of ) visitors each year ldquoItrsquos not

necessarily a challenge to lsquotoprsquo

our last showingrdquo says Keith

Ference Vice President ofmarketing and communica-

tions North America ldquoThere

are four years between eachMINExpo so we always have

a lot to say and reveal to our

customersrdquo The real challenge

he says is finding an exciting

and dynamic way to deliverthe message ldquoTherersquos so much

to see here so your booth has

to be compelling from the

outside-in and thatrsquos what

we always try to dordquo

Service sets the stage

The Metso booth created buzzin a number of ways and per-

haps the most striking (partly

due to its size) was the live

theater presentation As visitorspassed through the aisles of the show-

room the sights and sounds from Metsorsquos

theater were hard to miss And once guests

entered they were captivated by a short

high-energy video presentation focused

on Metsorsquos service capabilities The message was simple Metso is ldquoyour

local service partner rdquo for all mining and

construction needs The video showed ourservice teams in action all over the world

and the audience came away with an

understanding about Metsorsquos commitment

to service Customers can count on morethan 70 local service centers run by more

than 1700 expert technicians delivering

Metso makes an impact at MINExpo 2012At this yearrsquos MINExpo International nearly 60000 attendees flocked to Las Vegas Nevada the largest turnout in showhistory The visitors ndash mining professionals from all over the globe ndash explored 850000 square feet of showroom spacefeaturing the industry rsquos latest technology equipment products and services They toured the show for three days

seeking the latest and greatest from more than 1800 exhibitorsTEXT Keith Ference PHOTOS Tracey Ford Perry

detailed descriptions andphotos of all of Metsorsquos mining

and construction products and

services The app also provides

digital access to Results and asearchable database of sales

contacts By day three of the

show MetsoMAP had been

downloaded by more than

500 usersIn addition to the app the

booth was equipped with

several LCD screens each con-trolled by Metso experts who

used their iPads to present new

products like the Megalinertrade

and the HRCtrade A featured

presentation on Metsorsquos lineupof energy-efficient comminu-

tion equipment including the

VERTIMILLreg SMD and MP-1250

cone crusher was also avail-

able letting customers seehow Metso technology delivers

some of the worldrsquos most effi-

cient size reduction

Measuring MINExpo success

After a very busy three days

(on top of months of prepara-tion leading up to the show) everyone

involved with MINExpo ndash from the North

American marketing team responsible for

the booth to the product managers and

sales force that worked the floor ndash is view-

ing the show as a success ldquoTherersquos alwaysa sigh of relief after each (MINExpo)rdquo says

Keith ldquoAnd overall the initial feedback

and response has been very positiverdquoWith more than 1300 visitors to the

booth Metso certainly made an impact

ldquoWe learn a lot from each show and with

some time wersquoll have a better understand-ing of the tangible results of our effortsrdquo

Keith adds

reliable service for mining equipment as

well as customized cost-effective life-cycle

services contracts

Technology ndash MetsoMAP

is an industry firstMINExpo provided the industry with its firstglimpse of Metsorsquos revolutionary iPad app

MetsoMAP The app was demoed to the

boothrsquos visitors via ldquothe worldrsquos largest iPadrdquo

a custom-made 80-inch screen that show-cased all of its capabilities most of which are

groundbreaking in the industry MetsoMAPrsquos

simple interface is highly intuitive making

it easy to view process animations videos

The presentation of the new HP cone crusher attracted a large audience

8132019 Results Minerals Aggregates 3 2012ENG

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When yoursquore allowed less than a dozen days per year for breakdowns repair andmaintenance every single hour during a service shutdown counts There simplyisnrsquot any room for surprises Thatrsquos why Boliden counts on MetsoTEXT amp PHOTOS Sofia Williams

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Kurt Kalla Site Managerof Metso Gaumlllivare ServiceCenter is responsible forthe maintenance of Aitik

Metso and Boliden Strivingtogether for 97 uptime

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983122983141983152983151983154983156983145983150983143 983154983141983155

One of the biggest copper mines in

Europe Bolidenrsquos Aitik is located deep inthe wilderness of Swedish Lapland next to

the small town of Gaumlllivare The mine has

been operating since 1968 and a recent

expansion has increased its annual ore

production to 36 million tons

But the ambitious Swedes are not will-ing to lay back and relax just yet Bolidenrsquos

new aim is to reach a production rate of

45 million tons of ore per year in AitikAfter that Perhaps more than 55 million

tons The ore concentration in Aitik is very

low-grade with a mere 022 copper con-

tent hence the need for high capacityAchieving the ambitious production

goal requires maximum plant availability

This means that everything from the crush-

ers to the filters must be up and runningfor approximately 97 percent of the time

Thatrsquos where Metso comes into play

A cost-per-ton contract in action

The maximum uptime requirement allowsless than a dozen days per year for break-

downs repair and maintenance at Aitik

Every single hour during a service shut-

down counts There simply isnrsquot any roomfor surprises

Executing a successful shutdown under

such conditions requires a reliable service

partner not afraid of challenges and this iswhy Boliden has entrusted Aitikrsquos services

operations to Metso Boliden and Metsohave worked together since the 1960s

and the collaboration took another step

forward in September 2012 when the twocompanies signed a three-year extension

of the services contract for Boliden Aitik

ldquoThe new contract is a cost-per-ton

agreement We get paid based on Aitikrsquos

production Itrsquos a win-win deal for both par-

ties but also a new mindset for usrdquo explainsKurt Kalla Site Manager of Metso Gaumlllivare

Service Center responsible for serving Aitik

From now on the duration of the shut-down is what matters the most According

to Kalla the Metso service organization in

Gaumlllivare is now streamlining its operations

to fit the bill and has already witnessed thestrategy working In August 2012 Metso

carried out a 188-hour service shutdown in

Aitik which turned out to be a success

Zero tolerance for injury

One key factor to the success was theextensive planning of precautionary health

safety and environment procedures under-

taken by Metso prior to the shutdown Thanks to strict measures applied no

injuries or accidents occurred during the

shutdown and the work could easily be

finished on scheduleMats Johansson Health Safety

and Environment Manager for Metso in

Sweden explains how this was achieved

rdquoPlanning of the shutdown included arisk analysis for all new tasks participating

in Bolidenrsquos safety coordination meetingsmeeting with both Metso supervisors and

subcontractor supervisors and finally a

meeting with the entire staff participating

in the shutdown where everyone had to

sign a document stating their commitmentto the information providedrdquo he says

During the actual shutdown plenty of

new barriers signs and awareness cones

were put in place as a result of observa-tions from previous audits and safety plans

and risk analyses were readily available

in the work area Metso and Boliden also

introduced a Mill Inching permit a certifi-cate for completing a mandatory course for

those involved in the process In addition

Metso carried out random safety audits

during the shutdown to make sure thestrict policy was followed

According to Boliden Metsorsquos way of

working is a good example of how health

and safety precautions should be handled

ldquoMetso is a good example of how towork with safety and health plans risk

analysis permits and welding permits

Their table with all binders in the second-

ary mill area was exemplaryrdquo says Kjell-Arne

Johansson a technician from Boliden

The use of the new Metso Megalinertrade

system in the lining of Aitikrsquos Metso AG

mills has also improved the safety of main-tenance staff The Metso Megalinertrade con-

sists of larger-than-average liners bolted

in position from outside the mill Mainte-

nance technicians no longer need to go

inside the mill and stand in the dangerousdrop-zone of the liners gt

Boliden aims to reach a production rate of 45 million tons of ore per yearin the Aitik mine site

ldquoA complete risk analysis was conducted during the planningof the shutdownrdquo comments Mats Johansson Health Safetyand Environment Manager for Metso in Sweden

8132019 Results Minerals Aggregates 3 2012ENG

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Service the Metso way

24 hours a day 365 days a year

In addition to paying close attention to

health and safety issues executing an effi-

cient shutdown requires careful planning

and timing of every step in the mainte-

nance process Wear and spare parts have

to be available on time and a repair shoplarge enough to accommodate equipment

located close by

ldquoTo keep maintenance breaks as short

as possible we aim to replace the pump on

site and bring the old one for repair to our

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

nearby facilities This method gives us the

peace to do a good job and keep the cus-

tomerrsquos operations runningrdquo Kalla describes

the Metso way of handling Aitikrsquos pump

maintenance

Metso is currently expanding its Gaumllli-

vare service center to include a distribu-

tion center for wear and spare parts andalso concentrating its previously scattered

operations under one roof in its Vuoskon-

jaumlrvivaumlgen facility The expansion is due to

be completed by 2014

Metso equipment

delivered to Aitik36

bull 2 AG mills diameter 116 x

137 m gearless 22-MW motor

bull 2 Pebble mills diameter 91 x

113m dual 5-MW pinion drive

bull 3 VPA pressure filters VPA 1540-54

bull 12 sample pumps and pipes

VF50

bull 60 Various slurry pumps up to

MR500 modelbull Appr 5000 m rubber-lined slurry

pipes up to 600 mm diameter

bull Appr 5000 m rubber-lined by

gravity pipes up to 600 mm

diameter

bull Appr 5000 m rubber hoses

up to 600 mm diameter

Not only does the expansion make ser-

vice shutdowns at Aitik run more smoothly

it guarantees a more comprehensive

on-call emergency service response in the

region ndash thanks to the spare and wear parts

inventory available 24 hours a day 365

days a year

More info

Lars Rosenling

Tel +46 70 107 45 90

larsrosenlingmetsocom

Metso grinding equipment dominates the view in the concentrator

Safety on site is made up of small things like

making sure that everyone remembers to secure

the hoses in place

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983122983141983152983151983154983156983145983150983143 983154983141983155

Pebbles have always been a

challenge for producers of sandsince they cannot be returned

to rivers after extraction For

decades the processing of this

material resulted in a huge

environmental liability with alarge amount of pebbles hav-

ing to be stored away and left

unused

Transforming problems into

business opportunities

Areia amp Cia (areia = sand) has

operated in this market forover 20 years and decided to

enlist the help of Metso to find

a profitable solution for the

processing of pebbles

In July 2011 analyses werebegun to assess the abrasive-

ness and crushability of the

material Four alternatives wereidentified for processing and

transforming pebbles into sand

Initially Areia amp Cia was

interested in acquiring an

impactor for its reason-able price level However the

customer wanted to process

all the pebbles that were col-

lected daily in addition to some of the

material that it had stored In weighing theresults expected by the customer and the

excessive abrasiveness of the material the

HP200 cone crusher was decided on as thebest alternative

Areia amp Cia made the required invest-

ment and after using the HP200 for just

six months the company has already beenreporting outstanding results The HP200

not only transforms pebbles into sand but

also produces sand of excellent quality

with high yield and low maintenanceWith minor adjustments the HP200

also enables the production of sand withspecific particle size distribution for special

applications such as filtering sand blasting

and foundry sand adding value to the prod-

uct and increasing the types of sand offeredldquoMetso is pleased that the HP200 not

only enabled the processing of a product

that had been set aside as unusable but

HP200 cone transforms pebblesinto high-quality sandOver the last few decades Brazilian economic growth has been driving demand for construction aggregates The market

for sand in turn has been experiencing major difficulties in maintaining a consistent supply Presently one of the mainchallenges the industry faces is the large amount of pebbles that are obtained in the process of extracting sand at timesconstituting nearly 50 of the volume of material dredged from riverbeds

TEXT Sheila Ivers PHOTO Areia amp Cia

also that it opened up new

market opportunities for Areiaamp Cia Thatrsquos the standard we

seek to deliver to our custom-

ersrdquo states Luiz Oliveira Techni-

cal Salesperson of Metso Brazil

HP cones entering the

Brazilian sand-making

market

Todayrsquos cones such as theHP200 have high resistance

to impacts and abrasiveness

more efficient crushing cham-

bers low maintenance costsand excellent productivity

Following the acquisition of

the HP200 Areia amp Cia is now

also producing special sands

that command a price that is100 higher than common

sand The entire stockpile of

pebbles accumulated through-out the companyrsquos 20 years of

operations has already been

transformed into sand and the

stock of pebbles held by com-

petitors is also being purchasedfor processing

Cristiane Brizolari the

owner of Areia amp Cia confirms

the transformation that has taken place in

the production and commercial processldquoThe HP200 opened up new niches in

the market enabling the production of dif-

ferent types of sand with added valuerdquo

More info

Luiz Oliveira

Tel +55 011 9971 3603

luizoliveirametsocom

After the pebbles are crushed into sand with the HP200 cone crusherdifferent grades are screened for various end uses

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Where therersquos a will we dig a wayAFCONS-Strabag and Metso embark on tunnel project together

When the joint venture AFCONS-Strabag initiated work on the Rohtang bypass tunnel project at an altitude of 3980 metersabove sea level in Himachal Pradesh India they deliberated each aspect with clockwork precision The project involved anumber of surprises and challenges and required technology and project management skills that were second to none

TEXT amp PHOTOS Monisha Majumdar

Cutting a 10-meter-wide and nearly 9-kilo-

meter-long tunnel through the Himalayas

in one of the toughest terrains and cli-mates in India makes for quite a challengeResults set out to find out how AFCONS-

Strabag and Metso are making their way in

one of their most critical projects to date

The only road connection to the north-Indian border region of the province

Himachal-Pradesh and beyond the Manali-

Leh highway leads across the Rohtang

pass Due to the heavy snowfall and high-

velocity winds in this region the towns

located north of the pass are cut off from

the rest of the country during winter for atleast four often even six months each year

A tunnel with strategic importance

With the construction of the tunnel at

3100 m above sea level the Manali-Lehhighway will become an all-weather road

thereby enabling a significant improve-

ment in the economic development of

northern Himachal-Pradesh and an alter-

nate route to the strategically important

Ladakh region

Manali south of the pass is an alreadywell-developed tourist location that is

becoming more and more popular Upon

completion of the tunnel it is likely that

tourist activities will extend to the areanorth of the pass Moreover the tunnel

shortens the distance between the towns

of Manali and Leh by approximately 45 km

thus saving several hours on the small dan-gerous pass road

The Rohtang pass in the Western Himalaya

region of Northern India with its altitude ofalmost four kilometers ranks among thehighest trafficable passes in the world

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983122983141983152983151983154983156983145983150983143 983154983141983155

The 88-km long horse-shoe-shaped

tunnel provides space for a two-lane8-m-wide carriageway as well as a one-

meter-wide footpath on both sides A

22-m-high and 36-m-wide emergency

tunnel will be integrated in the tun-

nel cross-section Altogether more than

800000 msup3 of rock will be moved Tunneling works started around spring

2010 with excavation driven from both por-

tals As the north portal is inaccessible dur-ing winter closure the excavation focused

on the south After a planned construction

period of 55 years the tunnel is scheduled

to be completed by the end of 2015

Best man for the job

The BRO (Border Road Organization)

wanted to roll out a global tender for theproject due to the challenges that such a

project involves and also considering thatitrsquos the first time in India that a project of

this scale was to be carried out This imme-

diately triggered the need to roll out aglobal tender All major Indian construction

companies bid for it some individually and

some in partnerships

Strabag an Austrian tunnel specialistwas one of the companies who bid for the

project along with AFCONS a Mumbai-

based infrastructure company In Septem-

ber 2009 AFCONS-Strabag was awardedthe contract

Mr Sunil Tyagi Deputy Project Man-ager at AFCONS had this to say about the

unique projectldquoThis project is located in the Himalayas

and as far as we understand the terrain

there is among the toughest We came out

with a new technology and to be honestit is a fairly simple one We would generally

start with the traditional technology of drill-

ing and blasting and then obtain our muck

feed from the inwardbottom of the tunnelrdquo

ldquoThe technology is supplied by Rowa Tunneling Logistics and this is the first

time it is being used in Asia A jaw crusheris placed at a distance of about 40-45

meters behind the face The blasted muckextracted from the face is fed to the crusher

to reduce the lump size and then through

an overhead conveyor transport system

it is then transported out of the tunnelrdquoldquoThis enables free movement of man

and machinery in the lower area or spe-

cifically on the ground area If we were to

conforms to the Indian standard for fines amp

coarse aggregates as prescribed in IS383-1970

The plant was up and running in good

condition and performing to AFCONSrsquos

satisfactionldquoWe have worked with Metso in earlier

projects and are quite impressed by thekind of technology amp services they provide

We have a history together so the trust fac-tor also comes inrdquo explains Dhiman on their

choice of Metso as a partner

Service makes the difference

ldquoMetsorsquos services have made a big dif-ference in the project Without them we

would still be struggling with the machin-

ery and production The service is really

good and the service engineers are knowl-edgeable prompt and quick to act Any

problem can be solved by Metso We donrsquothave to wait until a service engineer turns

up ndash they have the capacity to solve prob-lems over the phone as wellrdquo says Dhiman

ldquoThe Metso plant didnrsquot create any prob-

lems for us We had problems in logistics

the feed was sticky and the weather condi-tions were bad but thankfully we did not

face any problems with production and

efficiency as the Metso plant is performing

very wellrdquo Dhiman concludes

More info

Amol Sinha Tel +91 9811 671 924

amolsinhametsocom

use the old conventional technology this

wouldnrsquot have worked for us in the stipu-lated timerdquo Mr Tyagi adds

When the going gets tough

partner with the toughest

Sensitive projects require the best technol-

ogy After AFCONS-Strabag landed theproject Metso was an obvious choice as a

technology provider not only because of

the long-standing business relationshipbut also for the sheer consistency in prod-

uct quality and service deliverance Metso

strives for

ldquoAfter signing the project we faced alot of road blocks including extreme cold

avalanches roadblocks less oxygen ndash you

name it we faced itrdquo explains Ankit Dhi-

man Plant Manager at AFCONS-Strabag The Rohtang valley is known for its

notorious avalanches and landslides SoAFCONS had to take extra steps and safety

precautions against hazards on the site

ldquoIn this freezing cold not just us humansbut also the machines are at increased risk

of damage I remember when we used

to run the plant during winter the diesel

engines would freeze We had to constantlyheat up the fuel container to get the plant

running And even the sand in the sand

trap would freeze so we had to clean it on

a daily basis to stop the pipes from mal-functioningrdquo Dhiman adds

Plant designed for difficult terrain

Difficult terrain coupled with space con-straints led Metso engineers to put their

minds together to come up with a suitable

plant configuration After studying the

requirements of the project Metso sug-

gested a 150-tons-per-hour three-stagemodular plant using a C106 jaw crusher

a GP11F secondary cone crusher and a

B7150 tertiary vertical shaft impact crusher

In addition considering the unpredict-ability of the feed the plant was about

to reach a point where the amount offines to be handled could be increased

dramatically Metso strongly suggested the TK11-27-3V grizzly scalper and this became

the first-ever TK scalper to be supplied by

Metso to an Indian customer Also in order

to get better products a sand trap SF2360was added to the configuration

The sand trap is important equipment

for this project as it washes the sand thatMr Sunil Tyagi Deputy Project ManagerAFCONS-Strabag

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Smooth transition to new-generation jaw crusher in Germany

Roumlhrig is a German company with a rich heritage The company has been quarrying granite at its plant in Bergstrasse inthe Sonderbach district of Heppenheim for three generations

TEXT amp PHOTOS Ralf Goffin

Roumlhrigrsquos superior product variety is onereason why the companyrsquos proximity to its

customers can be understood in more than

just physical terms The companyrsquos high

level of innovation has allowed it to estab-lish itself as a reliable supplier of materials

both regionally and internationally This

operational and technical expertise always

manages to keep in step with growing

market requirements

In terms of technical processing equip-

ment Roumlhrig has used a Nordberg C160stationary jaw crusher from Metso since

1992 At the start of 2012 it was finally

exchanged for a more up-to-date version

from the same model range

Metsorsquos C Series is specifically designed

to pre-crush hard rock and can cope effort-

lessly with even the hardest of materials

The dimensions of the new stationary jawcrusher are identical to those of the old

one which means that it could simply be

slotted into the housing vacated by the

previous version

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983122983141983152983151983154983156983145983150983143 983154983141983155

Third-generation Managing DirectorMarco Roumlhrig expects the new machinersquos

service life to be just as long as the previ-

ous model due to the product upgrades

that have been implemented The integral motor base is another plus

point in models made by other manu-

facturers it is located outside the crusher

This element of good fortune ensured that

Roumlhrig could reuse the housing withoutany additional rebuilding

Another advantage lies in the revision

of the guards for the C160rsquos drivetrain andflywheel The sturdier construction method

used for the crusher requires fewer parts

which facilitates easier installation andmaintenance and it makes it simpler to

access the motor

Under the watchful eye of Metsorsquos

Assembly Manager Maik Engelstaumltterthe entire project including removal and

installation was successfully completed

within two weeks

Installation making the most

of the available space

Roumlhrig will likely remember the day the

new crusher was installed for a long time

the pitman and main frame were deliveredseparately prior to installation and assem-

bled on site It took just one hour to replace

the old stationary crusher with the new

model A lorry-mounted crane was used toposition the 85-ton crusher with millimeter

precision in the crushing plant Once the

new crusher had been positioned in theexisting steel structure the next task wasto fix it into place as securely as possible

despite the limited space Special vibration

dampers were installed at a height of two

meters to prevent the crusher from sliding

Norbert Ried (fourth from left) installed thenew C160rsquos predecessor 20 years ago and isdelighted at the durability of the powerfulcrusher that is now making way for a newermodel Also pictured from left to right ManagerVolker Angermann Assembly Manager Maik

Engelstaumltter Technical Manager Stefan

Koob Project Manager Dominic SchoumlnhardtManaging Director Marco Roumlhrig Service

Technician Stefan Kolze and employees ofthe installation company Stafemo

On the hook after theold C160 was liftedout by crane the newcrusher was installedin almost no timeOnly the roof of thehousing had to beremoved

sideways off its mount An initial test run

with materials was carried out around oneweek later after all the electrical cables had

been installed

Simultaneously with the installation

of the C160 which is the first of the latest

generation of crushers to be installed in

Germany a new Nordberg GP100 conecrusher was also being installed in Roumlhrigrsquos

chipping plant Roumlhrig is convinced that

the technical improvements made tothe new Metso crusher can only be an

advantage worldwide

Roumlhrig places great value on consistent

product quality maximum added valueand optimum refinement of its product

range Bearing in mind that Roumlhrig has

enough reserves of raw material to last

for the next 150 years the company canconfidently continue to develop with an

emphasis on quality rather than quantity

More info

Dominic Schoenhardt

Tel +49 (0)621 727 00 610

dominicschoenhardtmetsocom

8132019 Results Minerals Aggregates 3 2012ENG

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Groupe Charier Carriegravere de la Mariais France

Quarrying with certi1047297ed quality The Charier Group with its 1600-strong workforce is a family business thatthis year celebrates 115 years of quarrying The company pursues a long-termdevelopment policy that since 2007 has seen processing installations upgradedat 4 of its 9 extraction sites

TEXT Liliane Boutin (with extracts from Mines amp Carriegraveres and Terrassements amp Carriegraveres magazines)PHOTO Baloon photo

The processing installation is of the horizontal type with a primary station located 56 meters below the site access road to keep it hidden from view

The crushing and screening installation at

Charierrsquos CM La Mariais quarry (at Donges

on the Loire estuary) has been in opera-tion since September 2011 Based on theoperatorrsquos ideas it was designed by Metso

to replace a worn-out installation installed

right on top of the seam being extracted

Since its commissioning it has becomethe second quarry in the company to

receive ISO 14 001 certification

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983122983141983152983151983154983156983145983150983143 983154983141983155

tertiary material of sand and gravel for the

local market to use in concrete surfacingprefabrication etcrdquo

Incorporation of a screening station

The stone extracted from La Mariais is

according to the quarry granitic gneiss

sound and homogeneous with a LosAngeles index of 15 good wear resist-

ance with an MDE of 10 a true density of

265 and a certain abrasiveness (2000 gt)ldquoCharacteristically it has a tendency to form

blocksrdquo Leblin points out

The main criteria in designing the instal-

lation was to provide an output of 600000metric tons from one station (38 hours

week) to produce materials aimed at the

concrete and surfacing markets ldquowhich

involved providing a tertiary station withscreening plantrdquo he adds

With this new unit the operating com-pany expands its product range through

the addition of fine materials obtained

from the tertiary screening station This unitis capable of producing 170 tonshour of

020

Preserving the environment

and optimizing safety

The screens have motorized bogies and

retractable walkways to facilitate access

when the screens are opened for main-tenance Other walkways provide access

to the tunnel input feeders The feederscan be isolated with hydraulic rod gate

bars this hydraulic assistance eliminatesthe need to use a heavy hammer to lodge

these metal bars

All conveyors transporting fines (02

and 04) are covered with a tarpaulin to

avoid flying dust and all the screens arehooded (metal cover with Trellex seal-

ing) The Brunone company has installed

dust-tight containment at the outlet of the

tertiary station crushers (HP300 and HP4)on the belt located under the screens

and under the hoppers located belowthe tertiary screens The crushers are put

under negative pressure and the finesare extracted through sleeve filters (7000

m3 h) with declogging which deposits the

dust back onto the conveyor belt

A high-pressure 100 bar water mist sys-tem has been installed at the primary sta-

tion discharge at the secondary crusherrsquos

discharge chutes (Omnicone) and at the

transfer points on the belt

Designed to last

ldquoThis type of new installation can easily last

thirty yearsrdquo affirms Project Leader Bruno

Peix of Metso ldquoIt quite simply depends on

how well it is maintained Thatrsquos why weprovide maintenance contracts that call for

our technicians to make regular inspection

visits and carry out preventive mainte-nance and any necessary repairsrdquo

In 2011 Metso commissioned about

10 new processing units in France like

the one at La Mariais quarry

More info

Frederic Bazire

Tel +33 (0)681442804

fredericbaziremetsocom

Key figures

DURATION OF WORKS 15 months

DRAWING OFFICE TIME 7800 hours

HEIGHT OF SILOS AND GRINDER BUILDINGS

15 m

TOTAL LENGTH OF CONVEYORS 14 km

WEIGHT OF THE INSTALLATION

1200 metric tons

CONCRETE POURED 1800 cubic meters

PROJECT SITE WORKFORCE 30

INSTALLED POWER 2200 kW(not including pumps 200 kW)

METSO EQUIPMENT

Primary

Vibrating feeder PF561-2V

Primary grizzly VG540-3V

Grizzly feeder TK13-20-3V

Jaw crusher C145 with

hydraulic setting

Secondary

Vibrating screen CVB 2050

refurbished

Cone crusher Omnicocircne 1352 SX

with Metso IC7000 controller Ellivar 16 (16 msup2 3 decks) screen

refurbished by Metso

Tertiary

Cone crusher HP300

Cone crusher HP4

2 Ellivar 20 screens (20 m23 decks) for final products

Expanding the production range

ldquoSince the mid-1990s when we became

owners of La Mariais we had used mobilemachinery with an assembly of beltconveyorsrdquo recalls Daniel Leblin Charierrsquos

Technical Manager for site construction

and maintenance

ldquoIt became clear that we needed ahigher performance tool to achieve the

dual goals of reaching one million metric

tonsrsquo maximum production and producing

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Big Lokotrack LT550GPF boostsquarrying productivity by a thirdMaximizing the productivity of operations is a key issue when striving for cost-effective quarrying Big Lokotracks are oneway to achieve improved operational efficiency The Lokotrack LT550GPF equipped with the high-volume GP550 conecrusher and a large screen is popular in the Nordic countries and in Germany and Australia ndash countries all known for theirhigh quarrying volumes

TEXT amp PHOTOS Eero Haumlmaumllaumlinen

Kone-Kostamorsquos new mobile coneplant has reached an averagecapacity of 300 tons per hour

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983122983141983152983151983154983156983145983150983143 983154983141983155

ldquoWith the same number of employees we

can achieve 30 more productivity with

our new LT550GPF unit The high-capacityFS screen has also eliminated the bottle-neck often seen at fine screeningrdquo says

Aarno Kostamo Managing Director of

Kone-Kostamo Oy one of Finlandrsquos biggest

crushing contractorsAccording to Kostamo the high capacity

of the GP550 gyratory cone crusher easily

handles feed from the C120 and C125 jaw

crushers For the contract with the Talvivaara

nickel mine the LT550GPF is being fed bythe brand new Lokotrack LT120 jaw plant

Average capacity 300 tons per hour

Talvivaara Europersquos largest nickel mine uti-

lizes large quantities of aggregates Kone-Kostamo has contracted several million

tons of different end products for the mineIn August 75000 tons of 0ndash63 mm

road gravel was crushed Smaller amountsof finer 0ndash6 mm 0ndash16 mm and 0ndash32 mm

aggregates are also being produced

The rainy summer increased the need

for road gravel along the muddy roadswhich must endure dump trucks weighing

as much as 260 tons

ldquoThe mobile process consisting of the

LT120 jaw plant and LT550GPF cone plant

is cost-effective while aggregates of vari-ous sizes can be produced in a two-stage

operation and with high capacity The con-trolled stroke and elliptical movement of

the FS screen secure big passing throughcapacitiesrdquo Kostamo explains

Operated in two shifts for a total of 16

hours per day the LT550GPF has logged

more than 600 working hours over a two-month period

Managing Director Aarno Kostamo (left) and foreman Karri Maumlenpaumlauml studying the cavity optionsavailable for the new Lokotrack LT550GPF

Longer perspective than

a single quarter needed

Kone-Kostamo Oy was founded as an

earth-moving company in Kemijaumlrvi

Northern Finland in 1956 The company

expanded its operations to include crush-

ing contracting in 1964 and later on

switched to concentrating fully on crush-ing activities

Kone-Kostamo consistently crushes

and screens around 28 million tons ofaggregates annually and has net sales of

between EUR 8ndash9 million

ldquoWe believe that issues within the crush-

ing industry including the purchasing ofmachinery must be studied with a longer

perspective than a single quarter The

secret to our success has always been our

solid work ethic and professional employ-eesrdquo Kostamo sums up

More info

Esa Berg

Tel + 358 40 837 8692

esabergmetsocom

8132019 Results Minerals Aggregates 3 2012ENG

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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155

Monitoring-based reporting is vital for

assessing the performance of a mobile

crushing plant Metso provides suchreporting tools through its plant-wideautomation system Metso DNA (Dynamic

Network of Applications) with its infor-

mation platform that links all the mobile

crushing and screen units together as oneentity Basically there is a lot of measured

real-time information available in every

crushing plant On-line information is

obtained either from each Metso crusherrsquosmachine automation system IC (Intelligent

Controller) or from separately installed

additional sensors and belt scales

All the collected data is sent to a motorhome using wireless communication

based on WLAN technology The motor

home is a purpose-built environment

inside an on-site container In this environ-ment selected variables can be monitored

for assessing the plantrsquos performance And

to make all this even more flexible the

data can be transmitted to a crushing plant

company office using GPRS3G mobile

data communication technologies Thismakes all the last-minute reports acces-sible to the crushing plant managerial staff

at anytime and basically anywhere within

reach of the cell phone network

Production and fuel economics reports

Essentially monitoring and reporting can

be customized to fit the customerrsquos needs

However there are certain off-the-shelf

reports that provide a lot of useful informa-tion for plant supervision The production

report is one of these Requiring at least one

belt scale for measuring the total produc-tion the production report shows the pro-duction rate (tons per hour) for a selected

reporting period eg a day or a week The

production report constantly keeps track of

the plantrsquos production storing all the datathroughout the plantrsquos life cycle

Performance monitoring and reportingfor a mobile crushing plantTEXT Pasi Airikka PHOTOS Metso

unit during which the unit is running By

storing the availability times between start-ups and shutdowns the crushing plant

operation time (hours per dayshift) can be

recorded analyzed and reported In addi-

tion the availability report can be tailored

to evaluate efficient crushing hours during

which the plant is really working and pro-ducing aggregates Consequently the ratio

(0-100) between efficient crushing time

and total running time can be reported forany selected period of time This boosts

the efficiency of the plantrsquos operations

and results in better productivity

Reports on non-choke

or inadequate feeding

Non-choke feeding to crushers is avoid-

able through smart plant-wide crushingplant controls But estimating its severity in

a systematic manner is not straight-forwardwithout constant monitoring and reporting

The crusher choke feeding report makes

use of the crusher cavity level sensors byanalyzing their level measurements By

calculating average and min-max values

and deviations from the average it can be

shown how often the single crusher suffersfrom non-choke feeding to it

In some cases the bottleneck in the

crushing plantrsquos productivity is the material

feeding to the process In mobile plants thefeeding is human operated and therefore

subject to variations Occasionally the sizeof the human-operated machine simply

does not allow for adequate feeding to thecrushing plant There are specific reports

indicating time periods when the crushing

plant suffers from inadequate feeding

Condition monitoring for

crushers and screens

Machine-specific condition monitoring

focuses on vibrating components in

crushers and screens such as drive shaftbearings safety plate wearings and gears

The low middle and high frequencies ofmonitored components are measured and

supervised in real-time to detect abnor-malities due to slow or fast wear looseness

or imbalance

More info

Pasi Airikka

Tel +358 40 587 2730

pasiairikkametsocom

Condition monitoring provides a view tovibrating crusher and screen components forpredictive equipment maintenance

The daily production report shows the hour-by-hour production trend and distribution chartfor a selected day with min-max average andvariation statistics for comparison

Fuel consumption is always an interest-ing concern The fuel consumption reportgives the fuel consumption of each crush-

ing unit (liters per hour) and their total

consumption (liters per hour) for a selected

reporting period and can track fuel con-

sumption changes over timeCrushing plant availability can be

assessed as well The availability report

calculates time periods for each crushing

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983149983141983156983155983151 983150

for tissue machines The record of 2210

mmin was set on June 1 2012 during a

24-hour production run by the TM 2 tissue

machine at the companyrsquos mill in Yenikoumlynear the city of Izmit in Turkey

ldquoThe cooperation with Metso has been

beyond excellent and both parties did

their utmost to make the project success-ful The results clearly show that the efforts

were worthwhile on both sides This coop-

eration will extend to cover new projects

in the futurerdquo says Luumlt1047297 Aydin Paper GroupDirector Hayat Kimya

ldquoWe are not surprised that Hayat K imya

managed to break the world speed record

We have had great confidence in the capa-bility of the Hayat team since our project

started in 2009 We certainly know our

machine very well its stability production

efficiency and speed capabilityrdquo says Jan

Erikson Vice President Sales Metso

PowerThe worldrsquos first eco-gas fueled

power plant is up and running

Lahti Energy Ltdrsquos new Kymijaumlrvi II gasifica-

tion plant was officially inaugurated on

May 8 2012 It is the first of its kind in the

RecyclingRecycling with Lokotrack LT106

jaw plant in New York

A brand-new Lokotrack LT106 jaw plant is

used in the city area of New York USA to

recycle demolition materials The crushing

site faces the skyscrapers of ManhattanIsland

Paper amp FiberHayat Kimyarsquos Metso-supplied tissue

machine sets world speed record

Thanks to a skilled crew and dedicated

efforts Hayat Kimya AS in Turkey has suc-

ceeded in breaking the world speed record

world This CHP plant runs on clean eco-

gas that is gasified cleaned and cooled

from recycled waste with Metsorsquos innova-tive technology

ldquoItrsquos actually eco-gas that we combust

in the boilerrdquo comments Lahti EnergyrsquosProduction Director Jukka Manskinen

ldquoWe convert unwanted waste material into

energy in an efficient and environmentally

friendly wayrdquoNever before has any plant gasified

waste on such a large scale In the gasifier

recycled waste is turned into combustible

product gas which is cleaned cooled and

combusted in a high-efficiency gas boiler

to produce steam for the steam turbine The plant produces 50 MW of electricity

and 90 MW of district heat for the city of

Lahti and its neighboring areasMetso delivered the circulating fluidized

bed (CFB) gasification process gas cleaning

and cooling steam boiler environmental

protection system and automation systemto the entire plant The production of elec-

tricity and heat is kept even with the Metso

DNA automation system that covers the

whole plant starting from fuel reception

AutomationMetso develops and supplies plant-

wide crushing control solutions for

crushing plants

Metso has recently signed contracts on

delivering plant-wide automation systems

for mobile and portable rock crushing

plants The key objective of these deliveries

is to stabilize and to increase productivityand efficiency of the plants using one sin-

gle automation and information platform

for integrating crusher-specific IC machinecontrols

Furthermore the plant-wide system

with its information management tools not

only increases plant availability and opera-

tional safety it also makes troubleshoot-ing quicker and performance monitoring

easier The control room for plant-wide

operability is located either in an excavator

cabin or a purpose-built container

Metso around the world

The new LT106 jaw plant is suitable for crushing both hard rock and all rock-based demolition materials

The new world speed record for tissue setby Hayat Kimyarsquos Metso-supplied TM 2 is2210 mmin

8132019 Results Minerals Aggregates 3 2012ENG

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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 2: Results Minerals Aggregates 3 2012.ENG

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Pirjo VirtanenVP Health Safety and Environment

Metso Mining and Construction

Why do we careOver the last three years Metso Mining and Construction has invested heavily in Health Safety and Environment(HSE) particularly in developing the safety of our operations globally Positive results can already be seen ndash our

trend in all the key safety indicators is consistent with a double-digit annual improvement in the incident rate

We are proud of our leading-edge technologies and customer-oriented service around the world Our Metso

commitment to excellence however doesnrsquot stop there Our shared endeavor also extends to workplace safetyndash wherever and whenever Metso professionals are on the job We have named this global commitment to safety

excellence the Metso Safety Pledge

We are serious about making the workplace better than ldquosafe enoughrdquo Some examples of our concrete actions

towards achieving a solid safety culture include global minimum safety standards shared tools and visiblyincreased awareness among our employees In a recent employee survey our commitment to safety was among

the items we most strongly agreed on

The mining and construction business can involve high-risk activities such as lifting and working at heights

and operating tools and equipment The good news is that safety can be managed Our management iscommitted to managing safety and as our maintenance operators know they are not expected to work without

lock-out safety features Unsafe work is simply not the Metso way Safety is not an add-on feature at Metso ndash it is

an integral part of our service and equipment deliveries

Caring for people at work is part of our commitment to sustainable development Sustainability is aboutmeeting todayrsquos needs without compromising the ability of future generations to meet their own needs Metsorsquos

mission is to contribute to a more sustainable world by helping our customers to process natural resources and

recycle materials into valuable products

Our responsibility for people begins with the safety of our customers contractors and Metso employees

We also design our solutions products innovations and services to help our customers improve theirenvironmental performance and safety

Come along with us and contribute to a better future by having a safe day

The Metsosafety pledge

8132019 Results Minerals Aggregates 3 2012ENG

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2 Editorial

4 News in brief

6 Northern Eldorado

8 Endomines Pampalo ndash a green andresponsible gold mine

12 Nordic Mines ndash on track to becomingone of Europersquos most prominent goldproducers

16 New products

18 Service creates value in China

20 Safe quarrying high-quality aggregates

24 Metso Distribution Centers help youminimize downtime

26 Service shines in Cananea Mexico

27 Metso makes an impact atMINExpo 2012

28 Metso and Boliden Striving togetherfor 97 uptime

31 HP200 cone transforms pebbles into

high-quality sand

32 Where therersquos a will we dig a way

34 Smooth transition to new-generation jaw crusher in Germany

36 Quarrying with certified quality

38 Big Lokotrack LT550GPF boostsquarrying productivity by a third

40 Performance monitoring and reportingfor a mobile crushing plant

41 Metso around the world

983152983157983138983148983145983155983144983141983140 983138983161 983149983141983156983155983151 983149983145983150983141983154983137983148983155 983145983150983139

Fabianinkatu 9 A PO Box 1220FI-00101 Helsinki Finlandtel +358 20 484 100 fax +358 20 484 10e-mail mineralsinfocsrmetsocomwwwmetsocomminingandconstruction

Results minerals amp aggregates customer maga-zine is published 3-4 times a year in English andChinese with French Portuguese Russian andSpanish insertions To receive your personal copyplease contact your nearest Metso office or thee-mail mentioned above

983141983140983145983156983151983154-983145983150-983139983144983145983141983142

Elina Lehtinenelinalehtinenmetsocom983141983140983145983156983151983154

Eero Haumlmaumllaumlineneerohamalainenmetsocom

983139983151983150983156983154983145983138983157983156983151983154983155 983145983150 983156983144983155 983145983155983155983157983141

Pasi Airikka Liliane Boutin Ralf GoffinEero Haumlmaumllaumlinen Sheila Ivers Deanna LeeMonisha Majumdar Sofia Williams Xin Yan

983141983150983143983148983145983155983144 983148983137983150983143983157983137983143983141 983141983140983145983156983145983150983143

Traduct Oy and Kathleen Kuosmanen

983148983137983161-983151983157983156 983137983150983140 983137983154983156 983159983151983154983147

Vanto Design Oy

983152983154983145983150983156983145983150983143

Libris Oy November 2012

copy Copyright 2012 Metso Minerals IncAll rights reserved

Printed on MultiArt Silk 130200 gm2Cocoon offset 120 gm2

Reproduction permitted quotingldquoResults minerals amp aggregatesrdquo as the source

All product names used are trademarksof their respective owners

Addresses Metso Minerals Inc customer data

ISSN 1797-6480

wwwmetsocomminingandconstruction

Printed matter

441 014

COVER PHOTO Managing Director Intildeigo Ajuria of Ofitas de San Felices (right) and Mine EngineerCarlos Fernandez proudly show the first-quality railway ballast produced by Ofitas for the high-speedtrain networks of Renfe the state-owned passenger and freight rail transport operator in Spain

Fill and return our reader survey by visitingwwwmetsocomresults2012 and winan iPad or 10 crystal models of Lokotrack

Help us to serve you better

In this issue

8132019 Results Minerals Aggregates 3 2012ENG

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983150983141983159983155 983145983150 983138983154983145983141983142

Worldrsquos biggest mobile crushing plant sold to Kazakhstan

The Lokotrack LT200 weighingalmost 400 tons is the key part

of the system The unit processescopper ore with a nominal capacityof 2500 tons per hour

The Ferrexpo delivery includes 10 vertical grinding mills that will cut the

energy used in the grinding process by 30-50

Metso will supply

the worldrsquos largest fully

mobile track-mounted crushingplant to the Altay Polimetally LLP copper mine

in Kazakhstan The contract also includes large mobile

feeding and conveying systems to move the crushed copper

ore for further processing as well as installation supervision andtraining The complete value of the order exceeds EUR 11 million

ldquoWe see Altay Polimetally as a significant contract in an interest-

ing growing market area Today open-pit mines around the world

are assessing the possibility of saving costs and the environment atthe primary crushing and conveying stages by decreasing on-site

ore trucking With Metsorsquos large-scale fully mobile equipment we

can well meet this customer demandrdquo says Jorma Kempas Busi-

ness Manager In-pit Crushing Solutions Metso

The giant mobile jaw plant will be used in the primary crushingstage at Altay Polimetallyrsquos new open-pit mine in the Karagandy

region

Ferrexpo Poltavarsquos iron ore quality to be improvedwith a complete minerals processing system

Aiming to significantly improve the quality of iron ore produced

Metso will deliver a complete minerals processing system to Fer-

rexpo Poltava Mining Company in Ukraine The value of the order is

EUR 67 million including two previously signed orders worth EUR36 million

Metsorsquos delivery includes high-capacity vertical grinding mills

flotation cells magnetic separators pumps and a crushing and

screening system In addition to equipment the contract includesinstallation and commissioning supervision as well as a tailor-

made automation process control system

ldquoMetso and Ferrexpo have cooperated for more than 30 years

The target of Metsorsquos delivery is to help Ferrexpo Poltava to raisethe iron content in pellets to 65 Fe total and thus enhance the

companyrsquos competitiveness in global marketsrdquo notes Alexy Strikha

Country Manager of Metso Mining and Construction in Ukraine

Ferrexpo plcrsquos iron ore resources in Ukraine are among thelargest in the world

8132019 Results Minerals Aggregates 3 2012ENG

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983150983141983159983155 983145983150 983138

Metso has developedmill lining solutionsthat combine rubberand a variety ofsteel elements tooptimize the weightwear life and ease ofinstallation of linersystems

Metso Mining and Construction recently participated in two Euro-

pean exhibitions in Sweden and the UK unveiling its latest crush-

ing and screening equipmentMaskinExpo the biggest construction machinery exhibition

in the Nordic countries was organized on a golf course near

Stockholm Metsorsquos novelties included the diesel-electric Lokotrack

Exhibiting live at MaskinExpo and Hillhead

Metso is expanding its rubber mill lining production capacity glob-ally by investing in new presses to meet the growing demand in

the global mining market After completing the investment in 2015

Metsorsquos global rubber mill lining production capacity at the existing

wear parts manufacturing plants will increase 30 percent High-quality wear parts ensure mining process reliability at all times

Metso is purchasing straight grate iron ore pelletizing technologyand know-how from Jacobs Engineering Group Inc In addition

key Jacobs Minerals technical staff related to the technology will

become Metso employees as part of the deal

Iron ore pelletizing is used to produce pellets from concen-

trated iron ore for feed to blast furnaces and direct reduced iron

LT120E jaw plant the brand new LT106 jaw plant and the HP3

cone crusher

Hillhead the largest European quarrying and recycling ldquolivequarry showrdquo brought together a record number 17000+ visitors

At the event Metso presented its LT120 and LT106 jaw plants the

HP3 cone and the new C120 jaw crusher

The diesel-electric Lokotrack LT120 jaw plant exhibited at MaskinExpowas sold to the Swedish crushing contractor Johanssons Entreprenad

Metsorsquos crusher newcomers the HP3 cone and C120 jaw raised a lot ofinterest during the Hillhead quarry show in Buxton UK

Mill lining manufacturing capacity to be expanded

Iron ore pelletizing technology and know-how acquired from Jacobs Minerals

The investment totaling approximately EUR 10 million will becompleted in two phases The first set of presses is scheduled to

be in operation by the end of 2013 I t includes the installation of

presses in Chile Sweden Canada Mexico and Peru

plants Metso anticipates continued growth in this market as more

beneficiation and pelletizing plants are needed to maximize theoutput from lower grade ore bodies

Metso currently offers the grate kiln iron ore pelletizing system

With the purchase of straight grate technology from Jacobs Metso

will become the worldrsquos only supplier of both systems

8132019 Results Minerals Aggregates 3 2012ENG

httpslidepdfcomreaderfullresults-minerals-aggregates-3-2012eng 642983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

983110983141983137983156983157983154983141983140 983137983154983156983145983139983148983141

Metsorsquos mobile crushing and screening units are in the frontline in the demandingreconstruction efforts in Japan after the nation was ravaged by the biggest earthquakeand tsunami in its recorded history Tracked mobile Lokotracks are the quickest wayto boost the production of aggregates an estimated 200 million tons of which willbe required over the next decadeTEXT amp PHOTOS Eero Haumlmaumllaumlinen

The biggest gold producer in Europe

Agnico Eagle in Kittilauml Northern Finlandcurrently produces some 5000 kg of goldannually The mine plans to expand its daily

ore extracting capacity to 4000 metric

tons which will increase the gold produc-

tion by an additional 1000 kgOther major gold producers in Fin-

land include Nordic Minesrsquo Laiva mine

Endominesrsquo Pampalo mine Lappland

Goldminersrsquo Pahtavaara mine and DragonMiningrsquos Orivesi and Jokisivu mines

Metso with its crushing screening and

minerals processing equipment is a sup-

plier to most Finnish gold mines In addi-tion to the equipment Metso also offers

these gold-mining operations its process

planning expertise and services

New gold deposit discoveries likely

Senior Geoscientist Pasi Eilu from the Geo-

logical Survey of Finland believes that the

possibilities of finding new gold deposits

comparable to the current ones are good

Helping Japan to rebuild

after the tsunami

ldquoIn Finland gold has been found

wherever serious exploration has beencarried out The latest interesting depositshave been located by Mawson Resources

between Tervola and Ylitornio in Northern

Finlandrdquo

According to Eilu the latest findings onlyinclude gold ore exposed at the surface

ldquoIt is very likely that in the near future

gold will be found in the deposits hidden

completely undergroundrdquo he explains ldquoNextyear the Geological Survey of Finland will

publish an estimate on possible gold depos-

its reaching a depth of one kilometer from

the surface This will provide more accurateinformation on potential discoveriesrdquo

The average gold grade in Finnish gold

mines is similar to any gold mine abroad

ldquoThe most common type in Finlandis orogenic gold ore which is similar to

nearly all ores originating in West Austral-

ian and Ontario Canada We also have

volcanic-related gold deposits for example

in the Orivesi mine and small amounts of

gold deposits similar to those found in the

worldrsquos biggest deposits in WitatersrandSouth Africardquo Eilu adds

Focus on green mining

The Finnish Green Mining concept is the

mineral sectorrsquos answer to future chal-

lenges It aims to optimize material and

energy efficiency in the whole productionchain The program aims at efficient pros-

pecting for new deposits and at develop-

ing new solutions for utilizing them It

also aims to minimize local environmentalimpacts and problems to improve work

safety and the workplace atmosphere andto restore mining areas after mining opera-

tions are completed The Green Mining program started in

2011 The main objective is to make Finland

a global leader in the sustainable mineral

industry by 2020 The program encom-

passes two central themes intelligentminimum-impact mines and new mineral

resources

NorthernEldorado Today Finland together with the Nordic countriesfalls within one of the global areas that are experi-encing a gold exploration and mining boomIn recent years major global mining companieshave entered the country and opened gold mines

and they are now set to expand their on-goingoperations A number of promising explorationprojects are simultaneously under way on behalfof some 40 mining companiesTEXT Eero Haumlmaumllaumlinen PHOTO iStockphoto

8132019 Results Minerals Aggregates 3 2012ENG

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1

78

9

1011

12

13

15

16

18

19

2021

22

14

2

3

5

6

17

Active Mines and Current Projects February 2012

Kittilauml gold ndash Agnico-Eagle Ltd Pahtavaara gold ndash Lappland Goldminers Ab

Laiva gold ndash Nordic Mines Ab

Pampalo gold ndash Endomines AB

Orivesi gold ndash Dragon Mining Ltd Jokisivu gold ndash Dragon Mining Ltd

Iso-Kuotko gold ndash Agnico-Eagle Ltd

Hanhimaa gold ndash Dragon Mining Ltd

Kettukuusikko gold ndash Taranis Resources IncNaakenavaara gold ndash Taranis Resources Inc

Kiekeroumlmaa gold ndash Tertiary Minerals Plc

Rompasgold uranium ndash Mawson Resources Ltd

Suhanko-Konttijaumlrvi PGE ndash Gold Fields Arctic Platinum OyKuusamo gold ndash Dragon Mining Ltd

Hirsikangas gold ndash Belvedere Resources Finland Oy

Aumlngesneva gold ndash Belvedere Resources Finland Oy

Kopsa gold ndash Belvedere Mining Oy

Taivaljaumlrvi silver ndash Sotkamo Silver ABSeinaumljoki gold antimony ndash Nortec Minerals Corp

Osikonmaumlki gold ndash Belvedere Resources Finland Oy

Haveri gold ndash Lappland Goldminers Ab

Kaapelinkulma gold ndash Dragon Mining Ltd

1

3

5

7

15

11

19

9

17

13

21

2

4

6

8

16

12

20

10

18

14

22

Mine

Prospect

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156983145983139983148983141

The main minerals processing componentsincluding grinding flotation and pumping

equipment are delivered by Metso

983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

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983110983141983137983156983157983154983141983140 983137983154983156

Endomines

Pampalondash a green andresponsiblegold mineAt Pampalo near the easternmost point of Finland a cleanand environmentally friendly gold mining operation isbeing executed by Endomines With Metsorsquos plant designand a state-of-the-art processing plant Pampalo runs a

green and responsible yet at the same time profitablegold mining operation that avoids acid mine drainagesand targets 100 water recirculationTEXT amp PHOTOS Eero Haumlmaumllaumlinen

With a modest investment of EUR 20

million the Pampalo mine was built fully

operational and now produces 800ndash900 kgof pure gold annually An on-going expan-

sion will increase the minersquos production

capacity by 30 to 50 next yearIn addition to the main underground

mine at Pampalo several promising satellite

gold deposits are being investigated along

the long Karelian gold line The maximum

distance of the satellites is 30 km allowingthe mine to transport and process all of the

produced ore at the Pampalo plant

Small scale can be successful

with hard work

ldquoWith our gold mining operation we can

very well show that with hard work even

small-scale gold mining and production

can be done in a sound and profitable wayrdquosays Markus Ekberg CEO of Endomines

originally founded in Sweden

According to Ekberg the strategy when

building the mine was to split up the jobsinto small separate contracts Metsorsquos part

was the main minerals processing system gt

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156

Increasing capacity makes processing

of lower grades economical

The project to significantly increase the

processing capacity at Pampalo is well

under way with the installation of for

example a second grinding mill and more

flotation cells The expansion will be in

operation during early 2013ldquoThe added capacity also makes it pos-

sible to economically process the nearby

open pits with a lower gold grade In addi-tion it helps us to optimize the crushing

and grinding circuitsrdquo Ekberg concludes

Active exploration drillings have

exposed new mineralized zones furtherextending the lifetime of the Pampalo mine

from the present estimate of 6ndash7 years

More info

Peter Vikman

Tel +358 400 869 845petervikmanmetsocom

Endomines Pampalo gold mine

LOCATION near the community of

Ilomantsi in Eastern Finland

GOLD ORE CONTENT

ndash Pampalo 34 gtndash Hosko 99 gt

ndash Raumlmepuro 39 gt

ndash Muurinsuo 30 gt

PRODUCTION TONNAGE PER YEAR 270000 tons (present)~400000 tons (future)

GOLD PRODUCTION PER YEAR 800ndash900 kg

KNOWN ORE RESERVES IN TOTAL

approx 2 million tons

MINE DEPTH 360 m

MINING METHOD bench cut and fill

NUMBER OF EMPLOYEES

100 including contractors

METSO EQUIPMENT

1 Metso TRN 30 x 48 m

wet ball mill

8 Metso RCS series flotation cells 1 Nordberg MF 1800 x 6100

screen

3 Metso samplers

1 Metso CT thickener

1 Metso TF vacuum filter

33 Metso slurry pumps of various

types and sizes

The gold ore is screened using Metsorsquos MS series mining screen

Markus Ekberg is pleased with the outcome the mine reached the minerals processing utilizationdegree of over 90 just two months after start-up

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156983145983139983148983141

Nordic Mines ndash on track tobecoming one of Europersquosmost prominent goldproducersNordic Mines is the newest member in a long chain of Nordic gold mining operations

Inaugurated in mid-August 2012 this company of Swedish origin aims to become one

of Europersquos most prominent gold producers Metso is one of Nordic Minesrsquo main partners

supplying the Laiva gold mine with crushing screening conveying and minerals

processing equipment at an estimated value of EUR 30 million

TEXT amp PHOTOS Eero Haumlmaumllaumlinen

2983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

The Laiva gold mine was built in record time infrastructure

construction began in spring 2010 ore excavation started in

June 2011 and the first gold bar was casted in December 2011

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156

Just one year after starting the gold recov-

ery process Nordic Mines is on track toreaching a capacity of 5 kg of gold per day

At present the operations are averaging 3

to 4 kg of gold daily

The ore in the Laiva Gold Mine consists

of packages of gold-bearing quartz-filled

shear structures The deposit is more thana kilometer long and 700 meters wide The

total depth is still unknown but dr illings

carried out thus far have shown gold-bear-ing shear structures 300 meters below the

surface

A typical ore zone includes a large num-

ber of thin shear structures from 5 to 30per meter The ore zones are commonly 50

to 100 meters long several are 10 meters

deep and they range from a few meters to

20 meters cross strike The minimum min-ing width is 25 meters which means that

even a minor ore zone consists of at least10 to 50 shear structures

Conventional pattern blasting

with selective loading

Prior to mining Nordic Mines conducts

grade control drilling which provides

dense gold grade information and makes

it possible to outline the boundaries

between ore and waste The mining

technique applied is conventional pattern

blasting with selective loading This is oneof the most commonly used techniques in

large-scale open-pit mining

A typical blast in the Laiva mine is 50

meters long 100 meters wide and 5 metersdeep After blasting ore and waste aremined by selective loading

After investing some EUR 100 million

the Laiva mine now comprises an open-pit

mine with a modern complete crushinggrinding and processing circuit that ends

with the casting of gold doreacute bars

With a number of mine staff partners

sub-suppliers city and state officials inattendance the Laiva gold mine was offi-

cially inaugurated on August 16 2012

Michael Nilsson Managing Director

of Nordic Mines stressed in his speechthe importance of overcoming challenges

during the building of the mine

ldquoObviously the whole development

took us longer than expected Today weare pleasantly surprised by the size of our

operation We are becoming much bigger

than expectedrdquo gt

Chief Geologist Kimmo Lahtinen presenting narrow gold veins twisting at the Laiva North open-pit mine

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156983145983139983148983141

An international process package

The Metso package for the Laiva gold mine

included the main crushing screening

conveying regrinding leaching and pump-ing elements Metsorsquos office in Sala Swe-

den has served as the main project office

with Metso manufacturing units in FranceGermany Sweden and Finland responsiblefor the equipment supply

At Laiva the gold ore is classified after

selective excavating into two gold con-

tent classes All class A gold ore is takento Metsorsquos sturdy jaw crusher for primary

crushing while the class B ore is stocked for

possible future use After primary grinding

utilizing autogenous technology the ore is

screened and two Metso cones crush the

oversized pebbles For regrinding Metsorsquosball mill is used

During high- and low-grade leaching

processes a number of Metso pumps and

dewatering screens are used The whole

minerals processing system is controlled byMetsoDNA automation

Active exploration drilling going on

According to Mine Manager Tom Soumlder-

man the known gold ore reserves at the

Laiva gold mine amount to 169 million

tons but the potential for additional find-

ings looks good

ldquoWorking at the level of two million tonsper year our expected lifetime is about nine

years We carry out active exploration drill-

ing in Kaukainen Musunneva and Oltava

to locate nearby satellite ore bodies Anupdated detailed mine life plan will be pre-

pared during the autumnrdquo Soumlderman saysNordic Minesrsquo other exploration areas

include Tormua in Finland and Fjaumllltuna

and Vassbo in Sweden

More info

Alf Rydberg

Tel +46 70524 5837

alfrydbergmetsocom

Happy faces during the minersquos inaugural ceremony Mine Manager Tom Soumlderman (left) with Managing Director Michael Nilsson and Deputy Managing Director Krister Soumlderholm

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156

The story behind the discovery of the Laivamine is an interesting one During a hunt-

ing trip in the remote forests of Laivakan-

gas in 1979 Pentti Jaumlmbaumlck found an inter-esting-looking piece of stone Although hecould not see the gold hidden inside the

rock Pentti noticed the striking weight

and somewhat different look of the stone

Upon returning home Pentti sent thesample to Outokumpu which at the time

was the leading state-owned mining com-

pany in Finland After testing a high gold

content of 15 grams per ton was found

Gold deposit founded by a hunter

The founder of the Laiva gold deposit Mr Pentti

Jaumlmbaumlck was the guest of honor during theinauguration

Lennart Schoumlnning Chairman of the Board ofNordic Mines holding a gold doreacute bar worthsome EUR 320000

Outokumpu registered a mining claimon the area and conducted a series of

exploration drilling from 1981 to 1987 Due

to the low price level for gold no mine wasstarted at the time Other mining compa-nies such as Endomines held the mining

rights later

Nordic Mines with its sights set on

locating and exploiting gold in Swedenand Finland was founded in 2005 During

the same year the company purchased its

first mining rights at Laiva

Nordic Minesrsquo Laiva gold mine

LOCATION near the city of Raahe

northwestern Finland

GOLD ORE CONTENT average 16 gt

ORE EXTRACTED PER YEAR

12 million tons (present)

20 million tons (planned)

GOLD RECOVERY 85

TOTAL KNOWN ORE RESERVES

169 million tons

MINING METHOD

Selective open-pit benchingNUMBER OF EMPLOYEES

130 including contractors

METSO MAIN EQUIPMENT

2 Metso VF and 6 EMEG EME

vibrating feeders

8 Screens 1 MF 1 CVB and 6 KS

1 RCS Flash flotation unit

1 Metso SRR ball mill 18 x 4 m

1 Nordberg C160 jaw crusher

1 Nordberg HP100 cone crusher

1 Nordberg HP200 cone crusher

5 Nordberg NB series conveyors

73 Metso Slurry pumps ofvarious types and sizes

8132019 Results Minerals Aggregates 3 2012ENG

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The newest member of the proven GP series cone crushers ndash theNordberg GP220 ndash offers a versatile alternative for any demanding

tertiary or quaternary or even secondary crushing operation fulfill-

ing all crushing needs and maximizing customersrsquo profitability

High-quality components and optimized castings and forgings

contribute to the GP220rsquos enhanced reliability and help to ensurethe highest level of crusher uptime

Thanks to the 200 kW (270 hp) power draw the GP220 performs

at a 20 to 30 percent higher capacity than other cone crusherbrands with an equal head diameter The large feed openingenables the feeding jaw crusher to run at 110 mm css Operational

flexibility is ensured by multiple strokes and six different cavities

Secondary crushing possible

thanks to cavity and stroke options

Thanks to the GP220rsquos cavity and stroke options secondary crush-

ing in addition to tertiary and quaternary stages is also possible

using cavities with a greater intake opening With the GP220 a suit-

able solution for producing excellent end-product gradations

can always be found

With advanced automation using IC50 or IC5000 operation

is safe and trouble-free The low height thanks to the patented

piston design makes replacement installations much easierA dynamic setting adjustment enables a fast response to process

optimization needs

The Nordberg GP220 weighs 10500 kg (23150 lbs) and hasa maximum real feed size of +200 mm (8rdquo) with strokes from

18ndash40 mm (57rdquondash1 47rdquo) The cavity options are EF F MF M C

and EC

A complete modular crusher steel structure is available for allGP series stationary installations including GP220 The platform

includes places for the lubrication unit motor automation or

pressure accumulator and pressurized sealing The only things

left to add are the feed and discharge conveyors

Main new features of the GP220 Large feed opening allows for secondary stage operation

Longer setting range of main shaft for better wear parts utilization

Stronger main components to carry high loads with a powerdraw as high as 200kW

More info

Hannu Vakkuri

Tel +358 50 317 0638

hannuvakkurimetsocom

Thanks to the large feed opening and wide selection of strokes and cavitiesthe new Nordberg GP220 cone crusher is a highly versatile cone novelty

More versatility with the newNordberg GP220 cone crusher

Reinforced head and frame castings combined with a 200kW power

draw make the GP220 cone a reliable crusher with maximum productivity

8132019 Results Minerals Aggregates 3 2012ENG

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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156

Metsorsquos HRCtrade takes high pressure grinding roll technology to the next level

The new Lokotrack mobile conveyors come as tracked and wheeled models

Metsorsquos latest development in comminution equipment the HRCtradeis a major step in the profitable application of high-pressure grind-

ing roll (HPGR) technology Metso has made several key innova-

tions in order to increase throughput and decrease the total cost

of operation

Metsorsquos patented Arch frame creates an even gap setting acrossthe width of the tires limiting skewing that can result in downtime

for mining operations This anti-skewing Arch frame also prevents

damage to the roller bearings (caused by misalignment) that canoccur with the traditional HPGR design

Flanges maximize wear life and increase throughput

Used in place of spring-loaded cheek plates the flanges keep thebed of material within the crushing zone and prevent material

from bypassing the tires This enables greater circuit capacity and

increases the overall crushing efficiency

In addition by preventing material from bypassing the tires

even pressure across the width of the tire is better maintained

Distributing the pressure more evenly maximizes the tire life bypreventing a ldquobath tub effectrdquo in which the center of the tire wears

faster than the edgesVictoria Herman Metsorsquos Product Manager for the HRC notes

that this breakthrough design is a response to the growing needs

in the mining industry ldquoEnergy efficiency has been attracting our

customers to HPGR technology for yearsrdquo she says ldquoBut our design

concept increases capacity and crushing efficiency ndash and thatrsquossomething mining companies are always looking to improve onrdquo

The track-mounted Lokotrack CT32 and wheel-mounted Lokotrack

CW32 mobile conveyors offer an ideal solution for applications

that require high stockpile capacity and excellent material transfer

capabilities They also add flexibility to multi-stage crushing andscreening applications enabling easy and fast closed-circuit opera-

tion of mobile units

The conveyor novelties can be used in both mobile and station-

ary installations providing extra stockpiling capacity in situationswhere for example fewer wheel loaders are available

The HRC is ideal for high-tonnage hard rock applications andcan be used as a tertiary quaternary or pebble crusher Currently

several HRC units are in operation around the world ndash with a total

of 6500 operating hours including over 3800 hours in a mininghard rock application The machine does have range within hardrock applications itrsquos been designed for use in diamond iron ore

copper gold platinum and various industrial minerals

More info

Victoria Herman

Tel +1 717 309 1150

victoriahermanmetsocom

Several optional features such as hydraulic folding of tail sections

and dual hydraulic drive for increased throughput are available

The capacity of the CT32 and CW32 is 400 mtph (440 stph)feed size up to 150 mm (6rdquo) belt width 1050 mm (42rdquo) and dis-charge height 9120 mm (29rsquo 11rdquo) The CT32 is fitted with a Caterpil-

lar C2 diesel engine with 38kw (51 HP) power The CW32 is avail-

able for hydraulic or electric use

More info

Kimmo Anttila

Tel +358 50 433 3745

kimmoanttilametsocom

The new HRCtrade combines high crushing pressure and a low circulatingload resulting in the most efficient comminution

When flexibility in stockpiling capacityis required the answer can be foundin the new Lokotrack CT32 and

CW32 mobile conveyors

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Service creates value in ChinaChinarsquos most important gold producing area Yantai in northeastern China supplies more than 16 of the countryrsquos goldproduction each year With the gold market thriving the scale of gold production in Yantai has been expanding constantly

Zhongjia Mining Industry Co Ltd is one of the beneficiaries of this thriving industryTEXT amp PHOTOS Yan Xin

Inspection and maintenance of the HP500 cone crusher conducted by Metsorsquos service engineers

In 2011 Zhongjia Mining Industry pur-

chased a modular crushing and screen-ing system from Metso for its new gold

production project With the cooperation

between the two companies continuously

intensifying Zhongjia Mining Industry

signed an additional one-year Life CycleService (LCS) contract with Metso incorpo-

rating Metsorsquos global knowledge in equip-

ment processes and services

ldquoMetso customized a series of reason-

able service solutions also referred toas Metso Performance Solutions for us

including preventive maintenance services

process improvement personnel training

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155

and a procurement plan for wear parts

These really suit our needs perfectlyrdquo saysShen Yidong the Manager of ZhongjiaMining Industry

Effective preventive maintenanceFor mining corporations the biggestconcern is the economic losses caused by

the shutdown of equipment As a result

preventative maintenance is of vital impor-

tance During the contract period Metsoservice engineers offered 7-day tracking

service on the production site every month

to eliminate potential problems and thus

ensured the stability of the system

parts caused pressure on our working capi-tal which was not favorable for our long-

term developmentrdquo Shen explains

To solve this problem Metso designed

a rational stock plan of wear parts and built

a field warehouse In accordance with theuse and consumption of the liners the field

service engineers complement the stock tomake production and operations run more

smoothlyldquoNow when we need to replace the

wear parts we can use them before pay-

ment This not only simplifies the procure-

ment process but also liberates a largesum of our operating capital which can

be used for other business development

purposesrdquo says Shen

Best partner

ldquoAlthough the LCS contract incurs some

early purchase costs in the long run Metsorsquosprofessional and quality service will improve

the equipment efficiency reduce ourenergy consumption and ensure stable

operations thus generating more prof-

its This is the greatest value for us so the

investment is really worthwhile overall Inthe future we will choose more Metso prod-

ucts and services Taking all aspects into

consideration we believe Metso is the best

partner for usrdquo Shen Yidong concludes

More info

Thomas Bai Tel +86 13801009114

thomasbaimetsocom

ldquoIn the eight months since the contract

came into effect our corporation has notsuffered any financial losses due to equip-

ment breakdown The regular maintenance

has greatly improved the efficiency of our

entire crushing system In addition the

experienced engineers from Metso also

provided onsite training and guidancefor our staff and the tailored training has

greatly enhanced the operating abilities of

our employees and upgraded their overalllevel of competencerdquo says Shen Yidong

More productivity with

less consumption

Metsorsquos service contract focuses on real-

izing the optimum performance of each

process flow After analyzing Zhongjiarsquos

production system Metsorsquos techniciansproposed an adjustment to the closed side

setting of the HP500 for tertiary crushingin order to improve the efficiency of the

downstream fine crushing and milling pro-

cessing by over 10ldquoThe process flow improvement solu-

tions provided by Metso not only increased

the output of our gold concentrates but

also reduced our energy consumption andcostsrdquo says Shen

In the past wear parts procurement

took up a larger proportion of Zhongjiarsquos

total production costsldquoTo avoid downtime caused by the

shortage of wear parts we had to keepeight sets of various wear parts in place

However the cost of having so many wear

Zhongjia Mining Industryrsquos gold concentrates processing plant in China

8132019 Results Minerals Aggregates 3 2012ENG

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0983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

Safe quarrying high-

quality aggregates

8132019 Results Minerals Aggregates 3 2012ENG

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ldquoWe share a similar zero-accident strategy and target with Metso and have successfullyfollowed it Metso has also helped us to meet the strictest end-product quality andcubicity requirements set in Spainrdquo This is how Managing Director Intildeigo Ajuria ofOfitas de San Felices the leading hard rock quarrying company in Spain describesthe cooperation with MetsoTEXT Eero Haumlmaumllaumlinen PHOTOS Ofitas and Eero Haumlmaumllaumlinen

The San Felices quarry is situated in a picturesque mountainous landscapebetween the companyrsquos Rioja vineyards and the Bilbao-Madrid motorway

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Ofitas has pioneered the implementation

of several Metso novelties in the Spanish

market The company was the first to use

efficient large track-mounted Lokotrack jaw plants the unique mobile conveying

system and also the new-generation HP4

cone crushers

Today the company operates twomodern Metso stationary plants one in

Guadix near Granada and the newest one

in San Felices Haro Rioja community Both

quarries focus on refining hard rock by pro-cessing ophite rock into the highest quality

railway ballast asphalt and concrete mix

grades The company has a satellite quarry

near Vitoria in PentildeacerradaBeing situated next to a highway and

the famous Rioja vineyards Ofitas must pay

special attention to environmental issues

To minimize dust problems all conveyors

have special covers attached

Quality durability and service

The cooperation between Ofitas de San

Felices and Metso started back in 1973when the Ajuria family bought the com-

pany whose quarrying activities began in

1919 Intildeigo Ajuria has a clear vision of why

the cooperation has continued withoutinterruption for almost 40 years

long-standing personal relationshipsrdquoAjuria adds

Serving railways asphalt

and concrete producers

The year-old San Felices stationary instal-lation lies hidden in a mountainous area

south of the city of Vitoria in NorthernSpain The new plant replaces an old one

that complicated the extraction of ophiterock Both plants are delivered by Metso

With its two separate production lines

the new plant is able to produce all the

end products required ndash from railway bal-last to the finer grades needed for asphalt

and concrete

Due to lower demand the quarry cur-

rently produces some 4000 tons per day

At full capacity however the plant canreach 8000 tons of production per day

30ndash35 of which consists of railway ballastfor high-speed trains and 65ndash70 of chips

and sand Thanks to the versatile two-line con-

cept connected by transverse conveyors

up to 12 different end products can be pro-

duced Depending on the demand for endproducts the material can be guided either

to the HP4 cone or HP400 cone followed

by a Barmac vertical shaft impactor

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

The ophite feed is fed to the C125 jaw crusher by a sturdy dump truck

The key people running the new San Felicesquarry Mine Engineer Carlos Fernandez (left)Managing Director Intildeigo Ajuria with ProductionManager Julian Perez

ldquoThrough the years Metso machinery

has proven its production capacity and

durability resulting in high-quality end

products A big plus for us has also beenthe quick response time to our process

challenges or servicerdquo

ldquoIn fact our cooperation extends

beyond day-to-day business matters to

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155

Meeting the strictest cubicity demands

The Spanish regulations concerning end-product cubicity are becoming more

demanding The flakiness percentage of

railway ballast must be below 10 and for

asphalt and concrete aggregates less than

15

ldquoWith Metsorsquos HP4 cone and the Barmacvertical shaft impactor we can meet even

the strictest cubicity demands We believe

that our high quality is helping us to sur-vive in the present recessionrdquo notes Mine

Engineer Carlos Fernandez

ldquoWe hope to increase the total extrac-

tion of the three quarries from the present15 million tons per year because our plant

capacity allows more than double thatrdquo

Fernandez adds

More info

Angel Luis Garcia Tel +34 686 94 35 30

angelluisgarciametsocom

In addition to being the leading Spanish

quarry to process hard rock Ofitas de SanFelices also cultivates 34 hectares of vine-yards next to the quarry which is situated

in the famous Rioja wine area

The company has previously sold a

harvest of over 200000 kg of Tempranillo

grapes to local red-wine makers Recentlythe company built its own wine process-

ing plant to process 10000ndash15000 kg of

grapes themselves

Aggregates and wine production

Andoni Ajuria the founder of Ofitas de san Felices (left) with Intildeigo Ajuria the present ManagingDirector tasting wine from the companyrsquos own vineyards

The first vintage wine of Ofitas har-

vested in autumn 2010 is now maturingin oak barrels After maturing for 12 to 15months the wine is called crianza and after

two years it will be granted the classifica-

tion reserva

ldquoWinemaking is not a business but

a hobby for us We give our wine out aspresents and drink it when we meet

our suppliers and friendsrdquo Intildeigo Ajuria

comments

For environmental protectionall of San Felicesrsquos plantconveyors are covered

Ofitas de San Felices quarry

LOCATION Haro near the city

of Vitoria northern Spain

SIZE 100 hectares

ROCK TYPE Ophite with Los Angeles

index of 9ndash10

PRESENT DAILY EXTRACTION 3000 tons

of ophiteNUMBER OF PERSONNEL 30

RESERVES 10 million tons

MAIN END PRODUCTS 0ndash2 mm

2ndash4 mm 4ndash10 mm 10ndash16 mm

16ndash22 mm 25ndash60 mm (ballast)

METSO MAIN EQUIPMENT

VF feeder

C125 jaw crusher

ndash feed size 0ndash800 mm

ndash css 130ndash140 mm

HP400 cone crusher

ndash feed size 80ndash250 mm

ndash css 40 mm HP4 cone crusher

ndash feed size 40ndash80 mm

ndash css 15 mm

Barmac 6150 VSI crusher

4 CVB2060 screens

2 TS32 screens

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Metso Distribution Centers he

Europe (Tongeren Belgium)

France (Macon)

Czech Republic (Přerov)

Austria (Vienna)

2271 d

Brazil (Sorocaba SP)

1014 d

USA (Columbia SC)

1690 d

USA (Waukesha WI)

434 d

South Africa (Vereeniging)

Ghana (Tarkwa)

Meacutexico (Irapuato)

Peru (Lima)

Chile (Concoacuten)

788 d

Sweden ( Trelleborg)

Finland (Tampere)

UK (Rugby)

865 d

Russia (St Petersburg)

Brazil (Parauapebas PA)

206 d

4983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

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In the case of an equipment failure or

a planned service shutdown resuming

production as quickly as possible is crucialEach hour spent waiting for a spare part to

arrive equals money lost Whether the right

part takes 12 or 48 hours to arrive really

makes a difference

The comprehensive and global Metsospare and wear parts service network pro-

vides you with the right part in the right

place and at the right time Our strategi-

cally located Distribution Centers and

Satellite Warehouses are on call 24 hoursa day 7 days a week ensuring efficient

parts replacement near you

Check out the locations of the MetsoDistribution Centers and how many parts

pass through them each day

More info

Marcelo Farah

Tel +55 15 2102 1315

marcelofarahmetsocom

you minimize downtime

Australia (Perth)

746 d

China (Tianjin)

China (Kunming)

China (Shanghai)

393 d

India (Faridabad)

India (Ahmedabad)

India (Hyderabad)

India (Bhubaneswar)

India (Bangalore)

419 d

Russia (Yekaterinburg)

Australia (Newcastle)

New Zealand (Matamata)

983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088

TEXT Sofia Williams

Singapore (Singapore)

Distribution Center Satellite Warehouse

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Following a large investment

in Metso crushing equipmentand services Buena Vista del

Cobre is now expanding the

mine site to include even more

equipment ndash and with thatexpansion comes the need for

more local service resources

Metso and Buena Vista del

Cobre have entered into a Life

Cycle Service agreement forthe plant and construction of a

brand new Metso service hub

is under way in Cananea

New facility new

level of service

The Cananea service hub

which will be up and running in early 2013will support the recent expansion and resur-

gence of Buena Vista del Cobre Initially it

will be a major repair and assembly center

for pumps crushers and screens and will

provide for rubber covering capabilitiesBut the 8000-square-meter facilityrsquos service

offering will be expansive including a con-

signment stock inventory to help serve theminersquos varying needs Metso currently has

50 service team members on site

Although Buena Vista del Cobre was a

key influencer in building the new servicehub this location will also enable Metso to

expand its capabilities and provide local

support to the entire mining community

in northwest Mexico The Cananea hub

will serve a number of major copper and

gold mines in the region including MineraFriscorsquos San Felipe Fresnillorsquos Milpillas and

Grupo Mexicorsquos Mexicana de Cobre

ldquoBuena Vista del Cobre is the biggestcustomer we have in Mexico today and

with this expansion project itrsquos only going

to grow and be strongerrdquo says Felix Forna-

guera Director of Services Mexico CentralAmerica and Caribbean ldquoWith that said the

idea behind the Cananea service hub is to

provide a central location for local support

for all our major customers in the areardquo

Establishing safety

ldquoIt was key to have our support here in

Cananea because the Buena Vista delCobre started from the ground uprdquo saysFelix ldquoWersquove been able to help the cus-

tomer to establish the best in support

service and operations from the very

beginningrdquo And this ground-up approachincluded a major focus on safety

Metso worked closely with Buena Vista

del Cobre to establish the safety proto-

col by which the mine operates Basedon Metsorsquos expertise the safety measures

put in place have enabled the mine to

become strict and efficient in its operations

and maintenance procedures To achievethis Metso worked closely with local andnational authorities to ensure the safety

plan was comprehensive and in accord-

ance with all established legal bodies

The best in regional support

The service hub in Cananea is a prime

example of Metsorsquos focus on providing local

service and support to its customers all

Service shines in Cananea MexicoAfter three years of inactivity the Buena Vista del Cobre mine in Cananea Sonora Mexico has been operational since 2010A mine that was inactive for such a significant amount of time however requires a great deal of support to successfullyrestart the plant and bring it back to an operational and profitable state

TEXT Deanna Lee PHOTO Metso

over the world ldquoWe are the first

company developing this kindof service in northwest Mexicordquo

adds Felix ldquoOur people have

developed a close relationship

with the team at the mine Itrsquosmore than a supplier relation-

ship our guys are inside the

mine living and working thererdquo

In fact this is the model

that Metso is using in servicehubs all over the globe build-

ing modern facilities bringing

teams on site and workinghand in hand with mine

operators The Cananea Service

hub is only the most recent

example of Metsorsquos commit-ment to service and northwest Mexico is

yet another mining hotbed thatrsquos going to

benefit from the companyrsquos support

More info

Felix Fornaguera Tel +52 4621079227

felixfornaguerametsocom

A mining cone serviced by Metso at the Buena Vista del Cobre mine inSonora Mexico

ldquoThe new Cananea service center will be a majorrepair and assembly center for pumps crushersand screensrdquo says Felix Fornaguera Director ofServices Mexico Central America and Caribbean

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

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During the MINExpo exhibition over 1300 people visited the Metso stand

983122983141983152983151983154983156983145983150983143 983154983141983155

Held every four years MIN-Expo consistently grows so

perennial exhibitors like Metso

are challenged with elevating

their presence and drawingin new (and greater numbers

of ) visitors each year ldquoItrsquos not

necessarily a challenge to lsquotoprsquo

our last showingrdquo says Keith

Ference Vice President ofmarketing and communica-

tions North America ldquoThere

are four years between eachMINExpo so we always have

a lot to say and reveal to our

customersrdquo The real challenge

he says is finding an exciting

and dynamic way to deliverthe message ldquoTherersquos so much

to see here so your booth has

to be compelling from the

outside-in and thatrsquos what

we always try to dordquo

Service sets the stage

The Metso booth created buzzin a number of ways and per-

haps the most striking (partly

due to its size) was the live

theater presentation As visitorspassed through the aisles of the show-

room the sights and sounds from Metsorsquos

theater were hard to miss And once guests

entered they were captivated by a short

high-energy video presentation focused

on Metsorsquos service capabilities The message was simple Metso is ldquoyour

local service partner rdquo for all mining and

construction needs The video showed ourservice teams in action all over the world

and the audience came away with an

understanding about Metsorsquos commitment

to service Customers can count on morethan 70 local service centers run by more

than 1700 expert technicians delivering

Metso makes an impact at MINExpo 2012At this yearrsquos MINExpo International nearly 60000 attendees flocked to Las Vegas Nevada the largest turnout in showhistory The visitors ndash mining professionals from all over the globe ndash explored 850000 square feet of showroom spacefeaturing the industry rsquos latest technology equipment products and services They toured the show for three days

seeking the latest and greatest from more than 1800 exhibitorsTEXT Keith Ference PHOTOS Tracey Ford Perry

detailed descriptions andphotos of all of Metsorsquos mining

and construction products and

services The app also provides

digital access to Results and asearchable database of sales

contacts By day three of the

show MetsoMAP had been

downloaded by more than

500 usersIn addition to the app the

booth was equipped with

several LCD screens each con-trolled by Metso experts who

used their iPads to present new

products like the Megalinertrade

and the HRCtrade A featured

presentation on Metsorsquos lineupof energy-efficient comminu-

tion equipment including the

VERTIMILLreg SMD and MP-1250

cone crusher was also avail-

able letting customers seehow Metso technology delivers

some of the worldrsquos most effi-

cient size reduction

Measuring MINExpo success

After a very busy three days

(on top of months of prepara-tion leading up to the show) everyone

involved with MINExpo ndash from the North

American marketing team responsible for

the booth to the product managers and

sales force that worked the floor ndash is view-

ing the show as a success ldquoTherersquos alwaysa sigh of relief after each (MINExpo)rdquo says

Keith ldquoAnd overall the initial feedback

and response has been very positiverdquoWith more than 1300 visitors to the

booth Metso certainly made an impact

ldquoWe learn a lot from each show and with

some time wersquoll have a better understand-ing of the tangible results of our effortsrdquo

Keith adds

reliable service for mining equipment as

well as customized cost-effective life-cycle

services contracts

Technology ndash MetsoMAP

is an industry firstMINExpo provided the industry with its firstglimpse of Metsorsquos revolutionary iPad app

MetsoMAP The app was demoed to the

boothrsquos visitors via ldquothe worldrsquos largest iPadrdquo

a custom-made 80-inch screen that show-cased all of its capabilities most of which are

groundbreaking in the industry MetsoMAPrsquos

simple interface is highly intuitive making

it easy to view process animations videos

The presentation of the new HP cone crusher attracted a large audience

8132019 Results Minerals Aggregates 3 2012ENG

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When yoursquore allowed less than a dozen days per year for breakdowns repair andmaintenance every single hour during a service shutdown counts There simplyisnrsquot any room for surprises Thatrsquos why Boliden counts on MetsoTEXT amp PHOTOS Sofia Williams

8983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

Kurt Kalla Site Managerof Metso Gaumlllivare ServiceCenter is responsible forthe maintenance of Aitik

Metso and Boliden Strivingtogether for 97 uptime

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983122983141983152983151983154983156983145983150983143 983154983141983155

One of the biggest copper mines in

Europe Bolidenrsquos Aitik is located deep inthe wilderness of Swedish Lapland next to

the small town of Gaumlllivare The mine has

been operating since 1968 and a recent

expansion has increased its annual ore

production to 36 million tons

But the ambitious Swedes are not will-ing to lay back and relax just yet Bolidenrsquos

new aim is to reach a production rate of

45 million tons of ore per year in AitikAfter that Perhaps more than 55 million

tons The ore concentration in Aitik is very

low-grade with a mere 022 copper con-

tent hence the need for high capacityAchieving the ambitious production

goal requires maximum plant availability

This means that everything from the crush-

ers to the filters must be up and runningfor approximately 97 percent of the time

Thatrsquos where Metso comes into play

A cost-per-ton contract in action

The maximum uptime requirement allowsless than a dozen days per year for break-

downs repair and maintenance at Aitik

Every single hour during a service shut-

down counts There simply isnrsquot any roomfor surprises

Executing a successful shutdown under

such conditions requires a reliable service

partner not afraid of challenges and this iswhy Boliden has entrusted Aitikrsquos services

operations to Metso Boliden and Metsohave worked together since the 1960s

and the collaboration took another step

forward in September 2012 when the twocompanies signed a three-year extension

of the services contract for Boliden Aitik

ldquoThe new contract is a cost-per-ton

agreement We get paid based on Aitikrsquos

production Itrsquos a win-win deal for both par-

ties but also a new mindset for usrdquo explainsKurt Kalla Site Manager of Metso Gaumlllivare

Service Center responsible for serving Aitik

From now on the duration of the shut-down is what matters the most According

to Kalla the Metso service organization in

Gaumlllivare is now streamlining its operations

to fit the bill and has already witnessed thestrategy working In August 2012 Metso

carried out a 188-hour service shutdown in

Aitik which turned out to be a success

Zero tolerance for injury

One key factor to the success was theextensive planning of precautionary health

safety and environment procedures under-

taken by Metso prior to the shutdown Thanks to strict measures applied no

injuries or accidents occurred during the

shutdown and the work could easily be

finished on scheduleMats Johansson Health Safety

and Environment Manager for Metso in

Sweden explains how this was achieved

rdquoPlanning of the shutdown included arisk analysis for all new tasks participating

in Bolidenrsquos safety coordination meetingsmeeting with both Metso supervisors and

subcontractor supervisors and finally a

meeting with the entire staff participating

in the shutdown where everyone had to

sign a document stating their commitmentto the information providedrdquo he says

During the actual shutdown plenty of

new barriers signs and awareness cones

were put in place as a result of observa-tions from previous audits and safety plans

and risk analyses were readily available

in the work area Metso and Boliden also

introduced a Mill Inching permit a certifi-cate for completing a mandatory course for

those involved in the process In addition

Metso carried out random safety audits

during the shutdown to make sure thestrict policy was followed

According to Boliden Metsorsquos way of

working is a good example of how health

and safety precautions should be handled

ldquoMetso is a good example of how towork with safety and health plans risk

analysis permits and welding permits

Their table with all binders in the second-

ary mill area was exemplaryrdquo says Kjell-Arne

Johansson a technician from Boliden

The use of the new Metso Megalinertrade

system in the lining of Aitikrsquos Metso AG

mills has also improved the safety of main-tenance staff The Metso Megalinertrade con-

sists of larger-than-average liners bolted

in position from outside the mill Mainte-

nance technicians no longer need to go

inside the mill and stand in the dangerousdrop-zone of the liners gt

Boliden aims to reach a production rate of 45 million tons of ore per yearin the Aitik mine site

ldquoA complete risk analysis was conducted during the planningof the shutdownrdquo comments Mats Johansson Health Safetyand Environment Manager for Metso in Sweden

8132019 Results Minerals Aggregates 3 2012ENG

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Service the Metso way

24 hours a day 365 days a year

In addition to paying close attention to

health and safety issues executing an effi-

cient shutdown requires careful planning

and timing of every step in the mainte-

nance process Wear and spare parts have

to be available on time and a repair shoplarge enough to accommodate equipment

located close by

ldquoTo keep maintenance breaks as short

as possible we aim to replace the pump on

site and bring the old one for repair to our

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

nearby facilities This method gives us the

peace to do a good job and keep the cus-

tomerrsquos operations runningrdquo Kalla describes

the Metso way of handling Aitikrsquos pump

maintenance

Metso is currently expanding its Gaumllli-

vare service center to include a distribu-

tion center for wear and spare parts andalso concentrating its previously scattered

operations under one roof in its Vuoskon-

jaumlrvivaumlgen facility The expansion is due to

be completed by 2014

Metso equipment

delivered to Aitik36

bull 2 AG mills diameter 116 x

137 m gearless 22-MW motor

bull 2 Pebble mills diameter 91 x

113m dual 5-MW pinion drive

bull 3 VPA pressure filters VPA 1540-54

bull 12 sample pumps and pipes

VF50

bull 60 Various slurry pumps up to

MR500 modelbull Appr 5000 m rubber-lined slurry

pipes up to 600 mm diameter

bull Appr 5000 m rubber-lined by

gravity pipes up to 600 mm

diameter

bull Appr 5000 m rubber hoses

up to 600 mm diameter

Not only does the expansion make ser-

vice shutdowns at Aitik run more smoothly

it guarantees a more comprehensive

on-call emergency service response in the

region ndash thanks to the spare and wear parts

inventory available 24 hours a day 365

days a year

More info

Lars Rosenling

Tel +46 70 107 45 90

larsrosenlingmetsocom

Metso grinding equipment dominates the view in the concentrator

Safety on site is made up of small things like

making sure that everyone remembers to secure

the hoses in place

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Pebbles have always been a

challenge for producers of sandsince they cannot be returned

to rivers after extraction For

decades the processing of this

material resulted in a huge

environmental liability with alarge amount of pebbles hav-

ing to be stored away and left

unused

Transforming problems into

business opportunities

Areia amp Cia (areia = sand) has

operated in this market forover 20 years and decided to

enlist the help of Metso to find

a profitable solution for the

processing of pebbles

In July 2011 analyses werebegun to assess the abrasive-

ness and crushability of the

material Four alternatives wereidentified for processing and

transforming pebbles into sand

Initially Areia amp Cia was

interested in acquiring an

impactor for its reason-able price level However the

customer wanted to process

all the pebbles that were col-

lected daily in addition to some of the

material that it had stored In weighing theresults expected by the customer and the

excessive abrasiveness of the material the

HP200 cone crusher was decided on as thebest alternative

Areia amp Cia made the required invest-

ment and after using the HP200 for just

six months the company has already beenreporting outstanding results The HP200

not only transforms pebbles into sand but

also produces sand of excellent quality

with high yield and low maintenanceWith minor adjustments the HP200

also enables the production of sand withspecific particle size distribution for special

applications such as filtering sand blasting

and foundry sand adding value to the prod-

uct and increasing the types of sand offeredldquoMetso is pleased that the HP200 not

only enabled the processing of a product

that had been set aside as unusable but

HP200 cone transforms pebblesinto high-quality sandOver the last few decades Brazilian economic growth has been driving demand for construction aggregates The market

for sand in turn has been experiencing major difficulties in maintaining a consistent supply Presently one of the mainchallenges the industry faces is the large amount of pebbles that are obtained in the process of extracting sand at timesconstituting nearly 50 of the volume of material dredged from riverbeds

TEXT Sheila Ivers PHOTO Areia amp Cia

also that it opened up new

market opportunities for Areiaamp Cia Thatrsquos the standard we

seek to deliver to our custom-

ersrdquo states Luiz Oliveira Techni-

cal Salesperson of Metso Brazil

HP cones entering the

Brazilian sand-making

market

Todayrsquos cones such as theHP200 have high resistance

to impacts and abrasiveness

more efficient crushing cham-

bers low maintenance costsand excellent productivity

Following the acquisition of

the HP200 Areia amp Cia is now

also producing special sands

that command a price that is100 higher than common

sand The entire stockpile of

pebbles accumulated through-out the companyrsquos 20 years of

operations has already been

transformed into sand and the

stock of pebbles held by com-

petitors is also being purchasedfor processing

Cristiane Brizolari the

owner of Areia amp Cia confirms

the transformation that has taken place in

the production and commercial processldquoThe HP200 opened up new niches in

the market enabling the production of dif-

ferent types of sand with added valuerdquo

More info

Luiz Oliveira

Tel +55 011 9971 3603

luizoliveirametsocom

After the pebbles are crushed into sand with the HP200 cone crusherdifferent grades are screened for various end uses

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Where therersquos a will we dig a wayAFCONS-Strabag and Metso embark on tunnel project together

When the joint venture AFCONS-Strabag initiated work on the Rohtang bypass tunnel project at an altitude of 3980 metersabove sea level in Himachal Pradesh India they deliberated each aspect with clockwork precision The project involved anumber of surprises and challenges and required technology and project management skills that were second to none

TEXT amp PHOTOS Monisha Majumdar

Cutting a 10-meter-wide and nearly 9-kilo-

meter-long tunnel through the Himalayas

in one of the toughest terrains and cli-mates in India makes for quite a challengeResults set out to find out how AFCONS-

Strabag and Metso are making their way in

one of their most critical projects to date

The only road connection to the north-Indian border region of the province

Himachal-Pradesh and beyond the Manali-

Leh highway leads across the Rohtang

pass Due to the heavy snowfall and high-

velocity winds in this region the towns

located north of the pass are cut off from

the rest of the country during winter for atleast four often even six months each year

A tunnel with strategic importance

With the construction of the tunnel at

3100 m above sea level the Manali-Lehhighway will become an all-weather road

thereby enabling a significant improve-

ment in the economic development of

northern Himachal-Pradesh and an alter-

nate route to the strategically important

Ladakh region

Manali south of the pass is an alreadywell-developed tourist location that is

becoming more and more popular Upon

completion of the tunnel it is likely that

tourist activities will extend to the areanorth of the pass Moreover the tunnel

shortens the distance between the towns

of Manali and Leh by approximately 45 km

thus saving several hours on the small dan-gerous pass road

The Rohtang pass in the Western Himalaya

region of Northern India with its altitude ofalmost four kilometers ranks among thehighest trafficable passes in the world

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The 88-km long horse-shoe-shaped

tunnel provides space for a two-lane8-m-wide carriageway as well as a one-

meter-wide footpath on both sides A

22-m-high and 36-m-wide emergency

tunnel will be integrated in the tun-

nel cross-section Altogether more than

800000 msup3 of rock will be moved Tunneling works started around spring

2010 with excavation driven from both por-

tals As the north portal is inaccessible dur-ing winter closure the excavation focused

on the south After a planned construction

period of 55 years the tunnel is scheduled

to be completed by the end of 2015

Best man for the job

The BRO (Border Road Organization)

wanted to roll out a global tender for theproject due to the challenges that such a

project involves and also considering thatitrsquos the first time in India that a project of

this scale was to be carried out This imme-

diately triggered the need to roll out aglobal tender All major Indian construction

companies bid for it some individually and

some in partnerships

Strabag an Austrian tunnel specialistwas one of the companies who bid for the

project along with AFCONS a Mumbai-

based infrastructure company In Septem-

ber 2009 AFCONS-Strabag was awardedthe contract

Mr Sunil Tyagi Deputy Project Man-ager at AFCONS had this to say about the

unique projectldquoThis project is located in the Himalayas

and as far as we understand the terrain

there is among the toughest We came out

with a new technology and to be honestit is a fairly simple one We would generally

start with the traditional technology of drill-

ing and blasting and then obtain our muck

feed from the inwardbottom of the tunnelrdquo

ldquoThe technology is supplied by Rowa Tunneling Logistics and this is the first

time it is being used in Asia A jaw crusheris placed at a distance of about 40-45

meters behind the face The blasted muckextracted from the face is fed to the crusher

to reduce the lump size and then through

an overhead conveyor transport system

it is then transported out of the tunnelrdquoldquoThis enables free movement of man

and machinery in the lower area or spe-

cifically on the ground area If we were to

conforms to the Indian standard for fines amp

coarse aggregates as prescribed in IS383-1970

The plant was up and running in good

condition and performing to AFCONSrsquos

satisfactionldquoWe have worked with Metso in earlier

projects and are quite impressed by thekind of technology amp services they provide

We have a history together so the trust fac-tor also comes inrdquo explains Dhiman on their

choice of Metso as a partner

Service makes the difference

ldquoMetsorsquos services have made a big dif-ference in the project Without them we

would still be struggling with the machin-

ery and production The service is really

good and the service engineers are knowl-edgeable prompt and quick to act Any

problem can be solved by Metso We donrsquothave to wait until a service engineer turns

up ndash they have the capacity to solve prob-lems over the phone as wellrdquo says Dhiman

ldquoThe Metso plant didnrsquot create any prob-

lems for us We had problems in logistics

the feed was sticky and the weather condi-tions were bad but thankfully we did not

face any problems with production and

efficiency as the Metso plant is performing

very wellrdquo Dhiman concludes

More info

Amol Sinha Tel +91 9811 671 924

amolsinhametsocom

use the old conventional technology this

wouldnrsquot have worked for us in the stipu-lated timerdquo Mr Tyagi adds

When the going gets tough

partner with the toughest

Sensitive projects require the best technol-

ogy After AFCONS-Strabag landed theproject Metso was an obvious choice as a

technology provider not only because of

the long-standing business relationshipbut also for the sheer consistency in prod-

uct quality and service deliverance Metso

strives for

ldquoAfter signing the project we faced alot of road blocks including extreme cold

avalanches roadblocks less oxygen ndash you

name it we faced itrdquo explains Ankit Dhi-

man Plant Manager at AFCONS-Strabag The Rohtang valley is known for its

notorious avalanches and landslides SoAFCONS had to take extra steps and safety

precautions against hazards on the site

ldquoIn this freezing cold not just us humansbut also the machines are at increased risk

of damage I remember when we used

to run the plant during winter the diesel

engines would freeze We had to constantlyheat up the fuel container to get the plant

running And even the sand in the sand

trap would freeze so we had to clean it on

a daily basis to stop the pipes from mal-functioningrdquo Dhiman adds

Plant designed for difficult terrain

Difficult terrain coupled with space con-straints led Metso engineers to put their

minds together to come up with a suitable

plant configuration After studying the

requirements of the project Metso sug-

gested a 150-tons-per-hour three-stagemodular plant using a C106 jaw crusher

a GP11F secondary cone crusher and a

B7150 tertiary vertical shaft impact crusher

In addition considering the unpredict-ability of the feed the plant was about

to reach a point where the amount offines to be handled could be increased

dramatically Metso strongly suggested the TK11-27-3V grizzly scalper and this became

the first-ever TK scalper to be supplied by

Metso to an Indian customer Also in order

to get better products a sand trap SF2360was added to the configuration

The sand trap is important equipment

for this project as it washes the sand thatMr Sunil Tyagi Deputy Project ManagerAFCONS-Strabag

8132019 Results Minerals Aggregates 3 2012ENG

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Smooth transition to new-generation jaw crusher in Germany

Roumlhrig is a German company with a rich heritage The company has been quarrying granite at its plant in Bergstrasse inthe Sonderbach district of Heppenheim for three generations

TEXT amp PHOTOS Ralf Goffin

Roumlhrigrsquos superior product variety is onereason why the companyrsquos proximity to its

customers can be understood in more than

just physical terms The companyrsquos high

level of innovation has allowed it to estab-lish itself as a reliable supplier of materials

both regionally and internationally This

operational and technical expertise always

manages to keep in step with growing

market requirements

In terms of technical processing equip-

ment Roumlhrig has used a Nordberg C160stationary jaw crusher from Metso since

1992 At the start of 2012 it was finally

exchanged for a more up-to-date version

from the same model range

Metsorsquos C Series is specifically designed

to pre-crush hard rock and can cope effort-

lessly with even the hardest of materials

The dimensions of the new stationary jawcrusher are identical to those of the old

one which means that it could simply be

slotted into the housing vacated by the

previous version

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983122983141983152983151983154983156983145983150983143 983154983141983155

Third-generation Managing DirectorMarco Roumlhrig expects the new machinersquos

service life to be just as long as the previ-

ous model due to the product upgrades

that have been implemented The integral motor base is another plus

point in models made by other manu-

facturers it is located outside the crusher

This element of good fortune ensured that

Roumlhrig could reuse the housing withoutany additional rebuilding

Another advantage lies in the revision

of the guards for the C160rsquos drivetrain andflywheel The sturdier construction method

used for the crusher requires fewer parts

which facilitates easier installation andmaintenance and it makes it simpler to

access the motor

Under the watchful eye of Metsorsquos

Assembly Manager Maik Engelstaumltterthe entire project including removal and

installation was successfully completed

within two weeks

Installation making the most

of the available space

Roumlhrig will likely remember the day the

new crusher was installed for a long time

the pitman and main frame were deliveredseparately prior to installation and assem-

bled on site It took just one hour to replace

the old stationary crusher with the new

model A lorry-mounted crane was used toposition the 85-ton crusher with millimeter

precision in the crushing plant Once the

new crusher had been positioned in theexisting steel structure the next task wasto fix it into place as securely as possible

despite the limited space Special vibration

dampers were installed at a height of two

meters to prevent the crusher from sliding

Norbert Ried (fourth from left) installed thenew C160rsquos predecessor 20 years ago and isdelighted at the durability of the powerfulcrusher that is now making way for a newermodel Also pictured from left to right ManagerVolker Angermann Assembly Manager Maik

Engelstaumltter Technical Manager Stefan

Koob Project Manager Dominic SchoumlnhardtManaging Director Marco Roumlhrig Service

Technician Stefan Kolze and employees ofthe installation company Stafemo

On the hook after theold C160 was liftedout by crane the newcrusher was installedin almost no timeOnly the roof of thehousing had to beremoved

sideways off its mount An initial test run

with materials was carried out around oneweek later after all the electrical cables had

been installed

Simultaneously with the installation

of the C160 which is the first of the latest

generation of crushers to be installed in

Germany a new Nordberg GP100 conecrusher was also being installed in Roumlhrigrsquos

chipping plant Roumlhrig is convinced that

the technical improvements made tothe new Metso crusher can only be an

advantage worldwide

Roumlhrig places great value on consistent

product quality maximum added valueand optimum refinement of its product

range Bearing in mind that Roumlhrig has

enough reserves of raw material to last

for the next 150 years the company canconfidently continue to develop with an

emphasis on quality rather than quantity

More info

Dominic Schoenhardt

Tel +49 (0)621 727 00 610

dominicschoenhardtmetsocom

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Groupe Charier Carriegravere de la Mariais France

Quarrying with certi1047297ed quality The Charier Group with its 1600-strong workforce is a family business thatthis year celebrates 115 years of quarrying The company pursues a long-termdevelopment policy that since 2007 has seen processing installations upgradedat 4 of its 9 extraction sites

TEXT Liliane Boutin (with extracts from Mines amp Carriegraveres and Terrassements amp Carriegraveres magazines)PHOTO Baloon photo

The processing installation is of the horizontal type with a primary station located 56 meters below the site access road to keep it hidden from view

The crushing and screening installation at

Charierrsquos CM La Mariais quarry (at Donges

on the Loire estuary) has been in opera-tion since September 2011 Based on theoperatorrsquos ideas it was designed by Metso

to replace a worn-out installation installed

right on top of the seam being extracted

Since its commissioning it has becomethe second quarry in the company to

receive ISO 14 001 certification

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983122983141983152983151983154983156983145983150983143 983154983141983155

tertiary material of sand and gravel for the

local market to use in concrete surfacingprefabrication etcrdquo

Incorporation of a screening station

The stone extracted from La Mariais is

according to the quarry granitic gneiss

sound and homogeneous with a LosAngeles index of 15 good wear resist-

ance with an MDE of 10 a true density of

265 and a certain abrasiveness (2000 gt)ldquoCharacteristically it has a tendency to form

blocksrdquo Leblin points out

The main criteria in designing the instal-

lation was to provide an output of 600000metric tons from one station (38 hours

week) to produce materials aimed at the

concrete and surfacing markets ldquowhich

involved providing a tertiary station withscreening plantrdquo he adds

With this new unit the operating com-pany expands its product range through

the addition of fine materials obtained

from the tertiary screening station This unitis capable of producing 170 tonshour of

020

Preserving the environment

and optimizing safety

The screens have motorized bogies and

retractable walkways to facilitate access

when the screens are opened for main-tenance Other walkways provide access

to the tunnel input feeders The feederscan be isolated with hydraulic rod gate

bars this hydraulic assistance eliminatesthe need to use a heavy hammer to lodge

these metal bars

All conveyors transporting fines (02

and 04) are covered with a tarpaulin to

avoid flying dust and all the screens arehooded (metal cover with Trellex seal-

ing) The Brunone company has installed

dust-tight containment at the outlet of the

tertiary station crushers (HP300 and HP4)on the belt located under the screens

and under the hoppers located belowthe tertiary screens The crushers are put

under negative pressure and the finesare extracted through sleeve filters (7000

m3 h) with declogging which deposits the

dust back onto the conveyor belt

A high-pressure 100 bar water mist sys-tem has been installed at the primary sta-

tion discharge at the secondary crusherrsquos

discharge chutes (Omnicone) and at the

transfer points on the belt

Designed to last

ldquoThis type of new installation can easily last

thirty yearsrdquo affirms Project Leader Bruno

Peix of Metso ldquoIt quite simply depends on

how well it is maintained Thatrsquos why weprovide maintenance contracts that call for

our technicians to make regular inspection

visits and carry out preventive mainte-nance and any necessary repairsrdquo

In 2011 Metso commissioned about

10 new processing units in France like

the one at La Mariais quarry

More info

Frederic Bazire

Tel +33 (0)681442804

fredericbaziremetsocom

Key figures

DURATION OF WORKS 15 months

DRAWING OFFICE TIME 7800 hours

HEIGHT OF SILOS AND GRINDER BUILDINGS

15 m

TOTAL LENGTH OF CONVEYORS 14 km

WEIGHT OF THE INSTALLATION

1200 metric tons

CONCRETE POURED 1800 cubic meters

PROJECT SITE WORKFORCE 30

INSTALLED POWER 2200 kW(not including pumps 200 kW)

METSO EQUIPMENT

Primary

Vibrating feeder PF561-2V

Primary grizzly VG540-3V

Grizzly feeder TK13-20-3V

Jaw crusher C145 with

hydraulic setting

Secondary

Vibrating screen CVB 2050

refurbished

Cone crusher Omnicocircne 1352 SX

with Metso IC7000 controller Ellivar 16 (16 msup2 3 decks) screen

refurbished by Metso

Tertiary

Cone crusher HP300

Cone crusher HP4

2 Ellivar 20 screens (20 m23 decks) for final products

Expanding the production range

ldquoSince the mid-1990s when we became

owners of La Mariais we had used mobilemachinery with an assembly of beltconveyorsrdquo recalls Daniel Leblin Charierrsquos

Technical Manager for site construction

and maintenance

ldquoIt became clear that we needed ahigher performance tool to achieve the

dual goals of reaching one million metric

tonsrsquo maximum production and producing

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Big Lokotrack LT550GPF boostsquarrying productivity by a thirdMaximizing the productivity of operations is a key issue when striving for cost-effective quarrying Big Lokotracks are oneway to achieve improved operational efficiency The Lokotrack LT550GPF equipped with the high-volume GP550 conecrusher and a large screen is popular in the Nordic countries and in Germany and Australia ndash countries all known for theirhigh quarrying volumes

TEXT amp PHOTOS Eero Haumlmaumllaumlinen

Kone-Kostamorsquos new mobile coneplant has reached an averagecapacity of 300 tons per hour

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983122983141983152983151983154983156983145983150983143 983154983141983155

ldquoWith the same number of employees we

can achieve 30 more productivity with

our new LT550GPF unit The high-capacityFS screen has also eliminated the bottle-neck often seen at fine screeningrdquo says

Aarno Kostamo Managing Director of

Kone-Kostamo Oy one of Finlandrsquos biggest

crushing contractorsAccording to Kostamo the high capacity

of the GP550 gyratory cone crusher easily

handles feed from the C120 and C125 jaw

crushers For the contract with the Talvivaara

nickel mine the LT550GPF is being fed bythe brand new Lokotrack LT120 jaw plant

Average capacity 300 tons per hour

Talvivaara Europersquos largest nickel mine uti-

lizes large quantities of aggregates Kone-Kostamo has contracted several million

tons of different end products for the mineIn August 75000 tons of 0ndash63 mm

road gravel was crushed Smaller amountsof finer 0ndash6 mm 0ndash16 mm and 0ndash32 mm

aggregates are also being produced

The rainy summer increased the need

for road gravel along the muddy roadswhich must endure dump trucks weighing

as much as 260 tons

ldquoThe mobile process consisting of the

LT120 jaw plant and LT550GPF cone plant

is cost-effective while aggregates of vari-ous sizes can be produced in a two-stage

operation and with high capacity The con-trolled stroke and elliptical movement of

the FS screen secure big passing throughcapacitiesrdquo Kostamo explains

Operated in two shifts for a total of 16

hours per day the LT550GPF has logged

more than 600 working hours over a two-month period

Managing Director Aarno Kostamo (left) and foreman Karri Maumlenpaumlauml studying the cavity optionsavailable for the new Lokotrack LT550GPF

Longer perspective than

a single quarter needed

Kone-Kostamo Oy was founded as an

earth-moving company in Kemijaumlrvi

Northern Finland in 1956 The company

expanded its operations to include crush-

ing contracting in 1964 and later on

switched to concentrating fully on crush-ing activities

Kone-Kostamo consistently crushes

and screens around 28 million tons ofaggregates annually and has net sales of

between EUR 8ndash9 million

ldquoWe believe that issues within the crush-

ing industry including the purchasing ofmachinery must be studied with a longer

perspective than a single quarter The

secret to our success has always been our

solid work ethic and professional employ-eesrdquo Kostamo sums up

More info

Esa Berg

Tel + 358 40 837 8692

esabergmetsocom

8132019 Results Minerals Aggregates 3 2012ENG

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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155

Monitoring-based reporting is vital for

assessing the performance of a mobile

crushing plant Metso provides suchreporting tools through its plant-wideautomation system Metso DNA (Dynamic

Network of Applications) with its infor-

mation platform that links all the mobile

crushing and screen units together as oneentity Basically there is a lot of measured

real-time information available in every

crushing plant On-line information is

obtained either from each Metso crusherrsquosmachine automation system IC (Intelligent

Controller) or from separately installed

additional sensors and belt scales

All the collected data is sent to a motorhome using wireless communication

based on WLAN technology The motor

home is a purpose-built environment

inside an on-site container In this environ-ment selected variables can be monitored

for assessing the plantrsquos performance And

to make all this even more flexible the

data can be transmitted to a crushing plant

company office using GPRS3G mobile

data communication technologies Thismakes all the last-minute reports acces-sible to the crushing plant managerial staff

at anytime and basically anywhere within

reach of the cell phone network

Production and fuel economics reports

Essentially monitoring and reporting can

be customized to fit the customerrsquos needs

However there are certain off-the-shelf

reports that provide a lot of useful informa-tion for plant supervision The production

report is one of these Requiring at least one

belt scale for measuring the total produc-tion the production report shows the pro-duction rate (tons per hour) for a selected

reporting period eg a day or a week The

production report constantly keeps track of

the plantrsquos production storing all the datathroughout the plantrsquos life cycle

Performance monitoring and reportingfor a mobile crushing plantTEXT Pasi Airikka PHOTOS Metso

unit during which the unit is running By

storing the availability times between start-ups and shutdowns the crushing plant

operation time (hours per dayshift) can be

recorded analyzed and reported In addi-

tion the availability report can be tailored

to evaluate efficient crushing hours during

which the plant is really working and pro-ducing aggregates Consequently the ratio

(0-100) between efficient crushing time

and total running time can be reported forany selected period of time This boosts

the efficiency of the plantrsquos operations

and results in better productivity

Reports on non-choke

or inadequate feeding

Non-choke feeding to crushers is avoid-

able through smart plant-wide crushingplant controls But estimating its severity in

a systematic manner is not straight-forwardwithout constant monitoring and reporting

The crusher choke feeding report makes

use of the crusher cavity level sensors byanalyzing their level measurements By

calculating average and min-max values

and deviations from the average it can be

shown how often the single crusher suffersfrom non-choke feeding to it

In some cases the bottleneck in the

crushing plantrsquos productivity is the material

feeding to the process In mobile plants thefeeding is human operated and therefore

subject to variations Occasionally the sizeof the human-operated machine simply

does not allow for adequate feeding to thecrushing plant There are specific reports

indicating time periods when the crushing

plant suffers from inadequate feeding

Condition monitoring for

crushers and screens

Machine-specific condition monitoring

focuses on vibrating components in

crushers and screens such as drive shaftbearings safety plate wearings and gears

The low middle and high frequencies ofmonitored components are measured and

supervised in real-time to detect abnor-malities due to slow or fast wear looseness

or imbalance

More info

Pasi Airikka

Tel +358 40 587 2730

pasiairikkametsocom

Condition monitoring provides a view tovibrating crusher and screen components forpredictive equipment maintenance

The daily production report shows the hour-by-hour production trend and distribution chartfor a selected day with min-max average andvariation statistics for comparison

Fuel consumption is always an interest-ing concern The fuel consumption reportgives the fuel consumption of each crush-

ing unit (liters per hour) and their total

consumption (liters per hour) for a selected

reporting period and can track fuel con-

sumption changes over timeCrushing plant availability can be

assessed as well The availability report

calculates time periods for each crushing

8132019 Results Minerals Aggregates 3 2012ENG

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983149983141983156983155983151 983150

for tissue machines The record of 2210

mmin was set on June 1 2012 during a

24-hour production run by the TM 2 tissue

machine at the companyrsquos mill in Yenikoumlynear the city of Izmit in Turkey

ldquoThe cooperation with Metso has been

beyond excellent and both parties did

their utmost to make the project success-ful The results clearly show that the efforts

were worthwhile on both sides This coop-

eration will extend to cover new projects

in the futurerdquo says Luumlt1047297 Aydin Paper GroupDirector Hayat Kimya

ldquoWe are not surprised that Hayat K imya

managed to break the world speed record

We have had great confidence in the capa-bility of the Hayat team since our project

started in 2009 We certainly know our

machine very well its stability production

efficiency and speed capabilityrdquo says Jan

Erikson Vice President Sales Metso

PowerThe worldrsquos first eco-gas fueled

power plant is up and running

Lahti Energy Ltdrsquos new Kymijaumlrvi II gasifica-

tion plant was officially inaugurated on

May 8 2012 It is the first of its kind in the

RecyclingRecycling with Lokotrack LT106

jaw plant in New York

A brand-new Lokotrack LT106 jaw plant is

used in the city area of New York USA to

recycle demolition materials The crushing

site faces the skyscrapers of ManhattanIsland

Paper amp FiberHayat Kimyarsquos Metso-supplied tissue

machine sets world speed record

Thanks to a skilled crew and dedicated

efforts Hayat Kimya AS in Turkey has suc-

ceeded in breaking the world speed record

world This CHP plant runs on clean eco-

gas that is gasified cleaned and cooled

from recycled waste with Metsorsquos innova-tive technology

ldquoItrsquos actually eco-gas that we combust

in the boilerrdquo comments Lahti EnergyrsquosProduction Director Jukka Manskinen

ldquoWe convert unwanted waste material into

energy in an efficient and environmentally

friendly wayrdquoNever before has any plant gasified

waste on such a large scale In the gasifier

recycled waste is turned into combustible

product gas which is cleaned cooled and

combusted in a high-efficiency gas boiler

to produce steam for the steam turbine The plant produces 50 MW of electricity

and 90 MW of district heat for the city of

Lahti and its neighboring areasMetso delivered the circulating fluidized

bed (CFB) gasification process gas cleaning

and cooling steam boiler environmental

protection system and automation systemto the entire plant The production of elec-

tricity and heat is kept even with the Metso

DNA automation system that covers the

whole plant starting from fuel reception

AutomationMetso develops and supplies plant-

wide crushing control solutions for

crushing plants

Metso has recently signed contracts on

delivering plant-wide automation systems

for mobile and portable rock crushing

plants The key objective of these deliveries

is to stabilize and to increase productivityand efficiency of the plants using one sin-

gle automation and information platform

for integrating crusher-specific IC machinecontrols

Furthermore the plant-wide system

with its information management tools not

only increases plant availability and opera-

tional safety it also makes troubleshoot-ing quicker and performance monitoring

easier The control room for plant-wide

operability is located either in an excavator

cabin or a purpose-built container

Metso around the world

The new LT106 jaw plant is suitable for crushing both hard rock and all rock-based demolition materials

The new world speed record for tissue setby Hayat Kimyarsquos Metso-supplied TM 2 is2210 mmin

8132019 Results Minerals Aggregates 3 2012ENG

httpslidepdfcomreaderfullresults-minerals-aggregates-3-2012eng 4242

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: Results Minerals Aggregates 3 2012.ENG

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2 Editorial

4 News in brief

6 Northern Eldorado

8 Endomines Pampalo ndash a green andresponsible gold mine

12 Nordic Mines ndash on track to becomingone of Europersquos most prominent goldproducers

16 New products

18 Service creates value in China

20 Safe quarrying high-quality aggregates

24 Metso Distribution Centers help youminimize downtime

26 Service shines in Cananea Mexico

27 Metso makes an impact atMINExpo 2012

28 Metso and Boliden Striving togetherfor 97 uptime

31 HP200 cone transforms pebbles into

high-quality sand

32 Where therersquos a will we dig a way

34 Smooth transition to new-generation jaw crusher in Germany

36 Quarrying with certified quality

38 Big Lokotrack LT550GPF boostsquarrying productivity by a third

40 Performance monitoring and reportingfor a mobile crushing plant

41 Metso around the world

983152983157983138983148983145983155983144983141983140 983138983161 983149983141983156983155983151 983149983145983150983141983154983137983148983155 983145983150983139

Fabianinkatu 9 A PO Box 1220FI-00101 Helsinki Finlandtel +358 20 484 100 fax +358 20 484 10e-mail mineralsinfocsrmetsocomwwwmetsocomminingandconstruction

Results minerals amp aggregates customer maga-zine is published 3-4 times a year in English andChinese with French Portuguese Russian andSpanish insertions To receive your personal copyplease contact your nearest Metso office or thee-mail mentioned above

983141983140983145983156983151983154-983145983150-983139983144983145983141983142

Elina Lehtinenelinalehtinenmetsocom983141983140983145983156983151983154

Eero Haumlmaumllaumlineneerohamalainenmetsocom

983139983151983150983156983154983145983138983157983156983151983154983155 983145983150 983156983144983155 983145983155983155983157983141

Pasi Airikka Liliane Boutin Ralf GoffinEero Haumlmaumllaumlinen Sheila Ivers Deanna LeeMonisha Majumdar Sofia Williams Xin Yan

983141983150983143983148983145983155983144 983148983137983150983143983157983137983143983141 983141983140983145983156983145983150983143

Traduct Oy and Kathleen Kuosmanen

983148983137983161-983151983157983156 983137983150983140 983137983154983156 983159983151983154983147

Vanto Design Oy

983152983154983145983150983156983145983150983143

Libris Oy November 2012

copy Copyright 2012 Metso Minerals IncAll rights reserved

Printed on MultiArt Silk 130200 gm2Cocoon offset 120 gm2

Reproduction permitted quotingldquoResults minerals amp aggregatesrdquo as the source

All product names used are trademarksof their respective owners

Addresses Metso Minerals Inc customer data

ISSN 1797-6480

wwwmetsocomminingandconstruction

Printed matter

441 014

COVER PHOTO Managing Director Intildeigo Ajuria of Ofitas de San Felices (right) and Mine EngineerCarlos Fernandez proudly show the first-quality railway ballast produced by Ofitas for the high-speedtrain networks of Renfe the state-owned passenger and freight rail transport operator in Spain

Fill and return our reader survey by visitingwwwmetsocomresults2012 and winan iPad or 10 crystal models of Lokotrack

Help us to serve you better

In this issue

8132019 Results Minerals Aggregates 3 2012ENG

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983150983141983159983155 983145983150 983138983154983145983141983142

Worldrsquos biggest mobile crushing plant sold to Kazakhstan

The Lokotrack LT200 weighingalmost 400 tons is the key part

of the system The unit processescopper ore with a nominal capacityof 2500 tons per hour

The Ferrexpo delivery includes 10 vertical grinding mills that will cut the

energy used in the grinding process by 30-50

Metso will supply

the worldrsquos largest fully

mobile track-mounted crushingplant to the Altay Polimetally LLP copper mine

in Kazakhstan The contract also includes large mobile

feeding and conveying systems to move the crushed copper

ore for further processing as well as installation supervision andtraining The complete value of the order exceeds EUR 11 million

ldquoWe see Altay Polimetally as a significant contract in an interest-

ing growing market area Today open-pit mines around the world

are assessing the possibility of saving costs and the environment atthe primary crushing and conveying stages by decreasing on-site

ore trucking With Metsorsquos large-scale fully mobile equipment we

can well meet this customer demandrdquo says Jorma Kempas Busi-

ness Manager In-pit Crushing Solutions Metso

The giant mobile jaw plant will be used in the primary crushingstage at Altay Polimetallyrsquos new open-pit mine in the Karagandy

region

Ferrexpo Poltavarsquos iron ore quality to be improvedwith a complete minerals processing system

Aiming to significantly improve the quality of iron ore produced

Metso will deliver a complete minerals processing system to Fer-

rexpo Poltava Mining Company in Ukraine The value of the order is

EUR 67 million including two previously signed orders worth EUR36 million

Metsorsquos delivery includes high-capacity vertical grinding mills

flotation cells magnetic separators pumps and a crushing and

screening system In addition to equipment the contract includesinstallation and commissioning supervision as well as a tailor-

made automation process control system

ldquoMetso and Ferrexpo have cooperated for more than 30 years

The target of Metsorsquos delivery is to help Ferrexpo Poltava to raisethe iron content in pellets to 65 Fe total and thus enhance the

companyrsquos competitiveness in global marketsrdquo notes Alexy Strikha

Country Manager of Metso Mining and Construction in Ukraine

Ferrexpo plcrsquos iron ore resources in Ukraine are among thelargest in the world

8132019 Results Minerals Aggregates 3 2012ENG

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983150983141983159983155 983145983150 983138

Metso has developedmill lining solutionsthat combine rubberand a variety ofsteel elements tooptimize the weightwear life and ease ofinstallation of linersystems

Metso Mining and Construction recently participated in two Euro-

pean exhibitions in Sweden and the UK unveiling its latest crush-

ing and screening equipmentMaskinExpo the biggest construction machinery exhibition

in the Nordic countries was organized on a golf course near

Stockholm Metsorsquos novelties included the diesel-electric Lokotrack

Exhibiting live at MaskinExpo and Hillhead

Metso is expanding its rubber mill lining production capacity glob-ally by investing in new presses to meet the growing demand in

the global mining market After completing the investment in 2015

Metsorsquos global rubber mill lining production capacity at the existing

wear parts manufacturing plants will increase 30 percent High-quality wear parts ensure mining process reliability at all times

Metso is purchasing straight grate iron ore pelletizing technologyand know-how from Jacobs Engineering Group Inc In addition

key Jacobs Minerals technical staff related to the technology will

become Metso employees as part of the deal

Iron ore pelletizing is used to produce pellets from concen-

trated iron ore for feed to blast furnaces and direct reduced iron

LT120E jaw plant the brand new LT106 jaw plant and the HP3

cone crusher

Hillhead the largest European quarrying and recycling ldquolivequarry showrdquo brought together a record number 17000+ visitors

At the event Metso presented its LT120 and LT106 jaw plants the

HP3 cone and the new C120 jaw crusher

The diesel-electric Lokotrack LT120 jaw plant exhibited at MaskinExpowas sold to the Swedish crushing contractor Johanssons Entreprenad

Metsorsquos crusher newcomers the HP3 cone and C120 jaw raised a lot ofinterest during the Hillhead quarry show in Buxton UK

Mill lining manufacturing capacity to be expanded

Iron ore pelletizing technology and know-how acquired from Jacobs Minerals

The investment totaling approximately EUR 10 million will becompleted in two phases The first set of presses is scheduled to

be in operation by the end of 2013 I t includes the installation of

presses in Chile Sweden Canada Mexico and Peru

plants Metso anticipates continued growth in this market as more

beneficiation and pelletizing plants are needed to maximize theoutput from lower grade ore bodies

Metso currently offers the grate kiln iron ore pelletizing system

With the purchase of straight grate technology from Jacobs Metso

will become the worldrsquos only supplier of both systems

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156983145983139983148983141

Metsorsquos mobile crushing and screening units are in the frontline in the demandingreconstruction efforts in Japan after the nation was ravaged by the biggest earthquakeand tsunami in its recorded history Tracked mobile Lokotracks are the quickest wayto boost the production of aggregates an estimated 200 million tons of which willbe required over the next decadeTEXT amp PHOTOS Eero Haumlmaumllaumlinen

The biggest gold producer in Europe

Agnico Eagle in Kittilauml Northern Finlandcurrently produces some 5000 kg of goldannually The mine plans to expand its daily

ore extracting capacity to 4000 metric

tons which will increase the gold produc-

tion by an additional 1000 kgOther major gold producers in Fin-

land include Nordic Minesrsquo Laiva mine

Endominesrsquo Pampalo mine Lappland

Goldminersrsquo Pahtavaara mine and DragonMiningrsquos Orivesi and Jokisivu mines

Metso with its crushing screening and

minerals processing equipment is a sup-

plier to most Finnish gold mines In addi-tion to the equipment Metso also offers

these gold-mining operations its process

planning expertise and services

New gold deposit discoveries likely

Senior Geoscientist Pasi Eilu from the Geo-

logical Survey of Finland believes that the

possibilities of finding new gold deposits

comparable to the current ones are good

Helping Japan to rebuild

after the tsunami

ldquoIn Finland gold has been found

wherever serious exploration has beencarried out The latest interesting depositshave been located by Mawson Resources

between Tervola and Ylitornio in Northern

Finlandrdquo

According to Eilu the latest findings onlyinclude gold ore exposed at the surface

ldquoIt is very likely that in the near future

gold will be found in the deposits hidden

completely undergroundrdquo he explains ldquoNextyear the Geological Survey of Finland will

publish an estimate on possible gold depos-

its reaching a depth of one kilometer from

the surface This will provide more accurateinformation on potential discoveriesrdquo

The average gold grade in Finnish gold

mines is similar to any gold mine abroad

ldquoThe most common type in Finlandis orogenic gold ore which is similar to

nearly all ores originating in West Austral-

ian and Ontario Canada We also have

volcanic-related gold deposits for example

in the Orivesi mine and small amounts of

gold deposits similar to those found in the

worldrsquos biggest deposits in WitatersrandSouth Africardquo Eilu adds

Focus on green mining

The Finnish Green Mining concept is the

mineral sectorrsquos answer to future chal-

lenges It aims to optimize material and

energy efficiency in the whole productionchain The program aims at efficient pros-

pecting for new deposits and at develop-

ing new solutions for utilizing them It

also aims to minimize local environmentalimpacts and problems to improve work

safety and the workplace atmosphere andto restore mining areas after mining opera-

tions are completed The Green Mining program started in

2011 The main objective is to make Finland

a global leader in the sustainable mineral

industry by 2020 The program encom-

passes two central themes intelligentminimum-impact mines and new mineral

resources

NorthernEldorado Today Finland together with the Nordic countriesfalls within one of the global areas that are experi-encing a gold exploration and mining boomIn recent years major global mining companieshave entered the country and opened gold mines

and they are now set to expand their on-goingoperations A number of promising explorationprojects are simultaneously under way on behalfof some 40 mining companiesTEXT Eero Haumlmaumllaumlinen PHOTO iStockphoto

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156

1

78

9

1011

12

13

15

16

18

19

2021

22

14

2

3

5

6

17

Active Mines and Current Projects February 2012

Kittilauml gold ndash Agnico-Eagle Ltd Pahtavaara gold ndash Lappland Goldminers Ab

Laiva gold ndash Nordic Mines Ab

Pampalo gold ndash Endomines AB

Orivesi gold ndash Dragon Mining Ltd Jokisivu gold ndash Dragon Mining Ltd

Iso-Kuotko gold ndash Agnico-Eagle Ltd

Hanhimaa gold ndash Dragon Mining Ltd

Kettukuusikko gold ndash Taranis Resources IncNaakenavaara gold ndash Taranis Resources Inc

Kiekeroumlmaa gold ndash Tertiary Minerals Plc

Rompasgold uranium ndash Mawson Resources Ltd

Suhanko-Konttijaumlrvi PGE ndash Gold Fields Arctic Platinum OyKuusamo gold ndash Dragon Mining Ltd

Hirsikangas gold ndash Belvedere Resources Finland Oy

Aumlngesneva gold ndash Belvedere Resources Finland Oy

Kopsa gold ndash Belvedere Mining Oy

Taivaljaumlrvi silver ndash Sotkamo Silver ABSeinaumljoki gold antimony ndash Nortec Minerals Corp

Osikonmaumlki gold ndash Belvedere Resources Finland Oy

Haveri gold ndash Lappland Goldminers Ab

Kaapelinkulma gold ndash Dragon Mining Ltd

1

3

5

7

15

11

19

9

17

13

21

2

4

6

8

16

12

20

10

18

14

22

Mine

Prospect

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983110983141983137983156983157983154983141983140 983137983154983156983145983139983148983141

The main minerals processing componentsincluding grinding flotation and pumping

equipment are delivered by Metso

983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

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983110983141983137983156983157983154983141983140 983137983154983156

Endomines

Pampalondash a green andresponsiblegold mineAt Pampalo near the easternmost point of Finland a cleanand environmentally friendly gold mining operation isbeing executed by Endomines With Metsorsquos plant designand a state-of-the-art processing plant Pampalo runs a

green and responsible yet at the same time profitablegold mining operation that avoids acid mine drainagesand targets 100 water recirculationTEXT amp PHOTOS Eero Haumlmaumllaumlinen

With a modest investment of EUR 20

million the Pampalo mine was built fully

operational and now produces 800ndash900 kgof pure gold annually An on-going expan-

sion will increase the minersquos production

capacity by 30 to 50 next yearIn addition to the main underground

mine at Pampalo several promising satellite

gold deposits are being investigated along

the long Karelian gold line The maximum

distance of the satellites is 30 km allowingthe mine to transport and process all of the

produced ore at the Pampalo plant

Small scale can be successful

with hard work

ldquoWith our gold mining operation we can

very well show that with hard work even

small-scale gold mining and production

can be done in a sound and profitable wayrdquosays Markus Ekberg CEO of Endomines

originally founded in Sweden

According to Ekberg the strategy when

building the mine was to split up the jobsinto small separate contracts Metsorsquos part

was the main minerals processing system gt

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156

Increasing capacity makes processing

of lower grades economical

The project to significantly increase the

processing capacity at Pampalo is well

under way with the installation of for

example a second grinding mill and more

flotation cells The expansion will be in

operation during early 2013ldquoThe added capacity also makes it pos-

sible to economically process the nearby

open pits with a lower gold grade In addi-tion it helps us to optimize the crushing

and grinding circuitsrdquo Ekberg concludes

Active exploration drillings have

exposed new mineralized zones furtherextending the lifetime of the Pampalo mine

from the present estimate of 6ndash7 years

More info

Peter Vikman

Tel +358 400 869 845petervikmanmetsocom

Endomines Pampalo gold mine

LOCATION near the community of

Ilomantsi in Eastern Finland

GOLD ORE CONTENT

ndash Pampalo 34 gtndash Hosko 99 gt

ndash Raumlmepuro 39 gt

ndash Muurinsuo 30 gt

PRODUCTION TONNAGE PER YEAR 270000 tons (present)~400000 tons (future)

GOLD PRODUCTION PER YEAR 800ndash900 kg

KNOWN ORE RESERVES IN TOTAL

approx 2 million tons

MINE DEPTH 360 m

MINING METHOD bench cut and fill

NUMBER OF EMPLOYEES

100 including contractors

METSO EQUIPMENT

1 Metso TRN 30 x 48 m

wet ball mill

8 Metso RCS series flotation cells 1 Nordberg MF 1800 x 6100

screen

3 Metso samplers

1 Metso CT thickener

1 Metso TF vacuum filter

33 Metso slurry pumps of various

types and sizes

The gold ore is screened using Metsorsquos MS series mining screen

Markus Ekberg is pleased with the outcome the mine reached the minerals processing utilizationdegree of over 90 just two months after start-up

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156983145983139983148983141

Nordic Mines ndash on track tobecoming one of Europersquosmost prominent goldproducersNordic Mines is the newest member in a long chain of Nordic gold mining operations

Inaugurated in mid-August 2012 this company of Swedish origin aims to become one

of Europersquos most prominent gold producers Metso is one of Nordic Minesrsquo main partners

supplying the Laiva gold mine with crushing screening conveying and minerals

processing equipment at an estimated value of EUR 30 million

TEXT amp PHOTOS Eero Haumlmaumllaumlinen

2983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

The Laiva gold mine was built in record time infrastructure

construction began in spring 2010 ore excavation started in

June 2011 and the first gold bar was casted in December 2011

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156

Just one year after starting the gold recov-

ery process Nordic Mines is on track toreaching a capacity of 5 kg of gold per day

At present the operations are averaging 3

to 4 kg of gold daily

The ore in the Laiva Gold Mine consists

of packages of gold-bearing quartz-filled

shear structures The deposit is more thana kilometer long and 700 meters wide The

total depth is still unknown but dr illings

carried out thus far have shown gold-bear-ing shear structures 300 meters below the

surface

A typical ore zone includes a large num-

ber of thin shear structures from 5 to 30per meter The ore zones are commonly 50

to 100 meters long several are 10 meters

deep and they range from a few meters to

20 meters cross strike The minimum min-ing width is 25 meters which means that

even a minor ore zone consists of at least10 to 50 shear structures

Conventional pattern blasting

with selective loading

Prior to mining Nordic Mines conducts

grade control drilling which provides

dense gold grade information and makes

it possible to outline the boundaries

between ore and waste The mining

technique applied is conventional pattern

blasting with selective loading This is oneof the most commonly used techniques in

large-scale open-pit mining

A typical blast in the Laiva mine is 50

meters long 100 meters wide and 5 metersdeep After blasting ore and waste aremined by selective loading

After investing some EUR 100 million

the Laiva mine now comprises an open-pit

mine with a modern complete crushinggrinding and processing circuit that ends

with the casting of gold doreacute bars

With a number of mine staff partners

sub-suppliers city and state officials inattendance the Laiva gold mine was offi-

cially inaugurated on August 16 2012

Michael Nilsson Managing Director

of Nordic Mines stressed in his speechthe importance of overcoming challenges

during the building of the mine

ldquoObviously the whole development

took us longer than expected Today weare pleasantly surprised by the size of our

operation We are becoming much bigger

than expectedrdquo gt

Chief Geologist Kimmo Lahtinen presenting narrow gold veins twisting at the Laiva North open-pit mine

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156983145983139983148983141

An international process package

The Metso package for the Laiva gold mine

included the main crushing screening

conveying regrinding leaching and pump-ing elements Metsorsquos office in Sala Swe-

den has served as the main project office

with Metso manufacturing units in FranceGermany Sweden and Finland responsiblefor the equipment supply

At Laiva the gold ore is classified after

selective excavating into two gold con-

tent classes All class A gold ore is takento Metsorsquos sturdy jaw crusher for primary

crushing while the class B ore is stocked for

possible future use After primary grinding

utilizing autogenous technology the ore is

screened and two Metso cones crush the

oversized pebbles For regrinding Metsorsquosball mill is used

During high- and low-grade leaching

processes a number of Metso pumps and

dewatering screens are used The whole

minerals processing system is controlled byMetsoDNA automation

Active exploration drilling going on

According to Mine Manager Tom Soumlder-

man the known gold ore reserves at the

Laiva gold mine amount to 169 million

tons but the potential for additional find-

ings looks good

ldquoWorking at the level of two million tonsper year our expected lifetime is about nine

years We carry out active exploration drill-

ing in Kaukainen Musunneva and Oltava

to locate nearby satellite ore bodies Anupdated detailed mine life plan will be pre-

pared during the autumnrdquo Soumlderman saysNordic Minesrsquo other exploration areas

include Tormua in Finland and Fjaumllltuna

and Vassbo in Sweden

More info

Alf Rydberg

Tel +46 70524 5837

alfrydbergmetsocom

Happy faces during the minersquos inaugural ceremony Mine Manager Tom Soumlderman (left) with Managing Director Michael Nilsson and Deputy Managing Director Krister Soumlderholm

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156

The story behind the discovery of the Laivamine is an interesting one During a hunt-

ing trip in the remote forests of Laivakan-

gas in 1979 Pentti Jaumlmbaumlck found an inter-esting-looking piece of stone Although hecould not see the gold hidden inside the

rock Pentti noticed the striking weight

and somewhat different look of the stone

Upon returning home Pentti sent thesample to Outokumpu which at the time

was the leading state-owned mining com-

pany in Finland After testing a high gold

content of 15 grams per ton was found

Gold deposit founded by a hunter

The founder of the Laiva gold deposit Mr Pentti

Jaumlmbaumlck was the guest of honor during theinauguration

Lennart Schoumlnning Chairman of the Board ofNordic Mines holding a gold doreacute bar worthsome EUR 320000

Outokumpu registered a mining claimon the area and conducted a series of

exploration drilling from 1981 to 1987 Due

to the low price level for gold no mine wasstarted at the time Other mining compa-nies such as Endomines held the mining

rights later

Nordic Mines with its sights set on

locating and exploiting gold in Swedenand Finland was founded in 2005 During

the same year the company purchased its

first mining rights at Laiva

Nordic Minesrsquo Laiva gold mine

LOCATION near the city of Raahe

northwestern Finland

GOLD ORE CONTENT average 16 gt

ORE EXTRACTED PER YEAR

12 million tons (present)

20 million tons (planned)

GOLD RECOVERY 85

TOTAL KNOWN ORE RESERVES

169 million tons

MINING METHOD

Selective open-pit benchingNUMBER OF EMPLOYEES

130 including contractors

METSO MAIN EQUIPMENT

2 Metso VF and 6 EMEG EME

vibrating feeders

8 Screens 1 MF 1 CVB and 6 KS

1 RCS Flash flotation unit

1 Metso SRR ball mill 18 x 4 m

1 Nordberg C160 jaw crusher

1 Nordberg HP100 cone crusher

1 Nordberg HP200 cone crusher

5 Nordberg NB series conveyors

73 Metso Slurry pumps ofvarious types and sizes

8132019 Results Minerals Aggregates 3 2012ENG

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The newest member of the proven GP series cone crushers ndash theNordberg GP220 ndash offers a versatile alternative for any demanding

tertiary or quaternary or even secondary crushing operation fulfill-

ing all crushing needs and maximizing customersrsquo profitability

High-quality components and optimized castings and forgings

contribute to the GP220rsquos enhanced reliability and help to ensurethe highest level of crusher uptime

Thanks to the 200 kW (270 hp) power draw the GP220 performs

at a 20 to 30 percent higher capacity than other cone crusherbrands with an equal head diameter The large feed openingenables the feeding jaw crusher to run at 110 mm css Operational

flexibility is ensured by multiple strokes and six different cavities

Secondary crushing possible

thanks to cavity and stroke options

Thanks to the GP220rsquos cavity and stroke options secondary crush-

ing in addition to tertiary and quaternary stages is also possible

using cavities with a greater intake opening With the GP220 a suit-

able solution for producing excellent end-product gradations

can always be found

With advanced automation using IC50 or IC5000 operation

is safe and trouble-free The low height thanks to the patented

piston design makes replacement installations much easierA dynamic setting adjustment enables a fast response to process

optimization needs

The Nordberg GP220 weighs 10500 kg (23150 lbs) and hasa maximum real feed size of +200 mm (8rdquo) with strokes from

18ndash40 mm (57rdquondash1 47rdquo) The cavity options are EF F MF M C

and EC

A complete modular crusher steel structure is available for allGP series stationary installations including GP220 The platform

includes places for the lubrication unit motor automation or

pressure accumulator and pressurized sealing The only things

left to add are the feed and discharge conveyors

Main new features of the GP220 Large feed opening allows for secondary stage operation

Longer setting range of main shaft for better wear parts utilization

Stronger main components to carry high loads with a powerdraw as high as 200kW

More info

Hannu Vakkuri

Tel +358 50 317 0638

hannuvakkurimetsocom

Thanks to the large feed opening and wide selection of strokes and cavitiesthe new Nordberg GP220 cone crusher is a highly versatile cone novelty

More versatility with the newNordberg GP220 cone crusher

Reinforced head and frame castings combined with a 200kW power

draw make the GP220 cone a reliable crusher with maximum productivity

8132019 Results Minerals Aggregates 3 2012ENG

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Metsorsquos HRCtrade takes high pressure grinding roll technology to the next level

The new Lokotrack mobile conveyors come as tracked and wheeled models

Metsorsquos latest development in comminution equipment the HRCtradeis a major step in the profitable application of high-pressure grind-

ing roll (HPGR) technology Metso has made several key innova-

tions in order to increase throughput and decrease the total cost

of operation

Metsorsquos patented Arch frame creates an even gap setting acrossthe width of the tires limiting skewing that can result in downtime

for mining operations This anti-skewing Arch frame also prevents

damage to the roller bearings (caused by misalignment) that canoccur with the traditional HPGR design

Flanges maximize wear life and increase throughput

Used in place of spring-loaded cheek plates the flanges keep thebed of material within the crushing zone and prevent material

from bypassing the tires This enables greater circuit capacity and

increases the overall crushing efficiency

In addition by preventing material from bypassing the tires

even pressure across the width of the tire is better maintained

Distributing the pressure more evenly maximizes the tire life bypreventing a ldquobath tub effectrdquo in which the center of the tire wears

faster than the edgesVictoria Herman Metsorsquos Product Manager for the HRC notes

that this breakthrough design is a response to the growing needs

in the mining industry ldquoEnergy efficiency has been attracting our

customers to HPGR technology for yearsrdquo she says ldquoBut our design

concept increases capacity and crushing efficiency ndash and thatrsquossomething mining companies are always looking to improve onrdquo

The track-mounted Lokotrack CT32 and wheel-mounted Lokotrack

CW32 mobile conveyors offer an ideal solution for applications

that require high stockpile capacity and excellent material transfer

capabilities They also add flexibility to multi-stage crushing andscreening applications enabling easy and fast closed-circuit opera-

tion of mobile units

The conveyor novelties can be used in both mobile and station-

ary installations providing extra stockpiling capacity in situationswhere for example fewer wheel loaders are available

The HRC is ideal for high-tonnage hard rock applications andcan be used as a tertiary quaternary or pebble crusher Currently

several HRC units are in operation around the world ndash with a total

of 6500 operating hours including over 3800 hours in a mininghard rock application The machine does have range within hardrock applications itrsquos been designed for use in diamond iron ore

copper gold platinum and various industrial minerals

More info

Victoria Herman

Tel +1 717 309 1150

victoriahermanmetsocom

Several optional features such as hydraulic folding of tail sections

and dual hydraulic drive for increased throughput are available

The capacity of the CT32 and CW32 is 400 mtph (440 stph)feed size up to 150 mm (6rdquo) belt width 1050 mm (42rdquo) and dis-charge height 9120 mm (29rsquo 11rdquo) The CT32 is fitted with a Caterpil-

lar C2 diesel engine with 38kw (51 HP) power The CW32 is avail-

able for hydraulic or electric use

More info

Kimmo Anttila

Tel +358 50 433 3745

kimmoanttilametsocom

The new HRCtrade combines high crushing pressure and a low circulatingload resulting in the most efficient comminution

When flexibility in stockpiling capacityis required the answer can be foundin the new Lokotrack CT32 and

CW32 mobile conveyors

8132019 Results Minerals Aggregates 3 2012ENG

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Service creates value in ChinaChinarsquos most important gold producing area Yantai in northeastern China supplies more than 16 of the countryrsquos goldproduction each year With the gold market thriving the scale of gold production in Yantai has been expanding constantly

Zhongjia Mining Industry Co Ltd is one of the beneficiaries of this thriving industryTEXT amp PHOTOS Yan Xin

Inspection and maintenance of the HP500 cone crusher conducted by Metsorsquos service engineers

In 2011 Zhongjia Mining Industry pur-

chased a modular crushing and screen-ing system from Metso for its new gold

production project With the cooperation

between the two companies continuously

intensifying Zhongjia Mining Industry

signed an additional one-year Life CycleService (LCS) contract with Metso incorpo-

rating Metsorsquos global knowledge in equip-

ment processes and services

ldquoMetso customized a series of reason-

able service solutions also referred toas Metso Performance Solutions for us

including preventive maintenance services

process improvement personnel training

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155

and a procurement plan for wear parts

These really suit our needs perfectlyrdquo saysShen Yidong the Manager of ZhongjiaMining Industry

Effective preventive maintenanceFor mining corporations the biggestconcern is the economic losses caused by

the shutdown of equipment As a result

preventative maintenance is of vital impor-

tance During the contract period Metsoservice engineers offered 7-day tracking

service on the production site every month

to eliminate potential problems and thus

ensured the stability of the system

parts caused pressure on our working capi-tal which was not favorable for our long-

term developmentrdquo Shen explains

To solve this problem Metso designed

a rational stock plan of wear parts and built

a field warehouse In accordance with theuse and consumption of the liners the field

service engineers complement the stock tomake production and operations run more

smoothlyldquoNow when we need to replace the

wear parts we can use them before pay-

ment This not only simplifies the procure-

ment process but also liberates a largesum of our operating capital which can

be used for other business development

purposesrdquo says Shen

Best partner

ldquoAlthough the LCS contract incurs some

early purchase costs in the long run Metsorsquosprofessional and quality service will improve

the equipment efficiency reduce ourenergy consumption and ensure stable

operations thus generating more prof-

its This is the greatest value for us so the

investment is really worthwhile overall Inthe future we will choose more Metso prod-

ucts and services Taking all aspects into

consideration we believe Metso is the best

partner for usrdquo Shen Yidong concludes

More info

Thomas Bai Tel +86 13801009114

thomasbaimetsocom

ldquoIn the eight months since the contract

came into effect our corporation has notsuffered any financial losses due to equip-

ment breakdown The regular maintenance

has greatly improved the efficiency of our

entire crushing system In addition the

experienced engineers from Metso also

provided onsite training and guidancefor our staff and the tailored training has

greatly enhanced the operating abilities of

our employees and upgraded their overalllevel of competencerdquo says Shen Yidong

More productivity with

less consumption

Metsorsquos service contract focuses on real-

izing the optimum performance of each

process flow After analyzing Zhongjiarsquos

production system Metsorsquos techniciansproposed an adjustment to the closed side

setting of the HP500 for tertiary crushingin order to improve the efficiency of the

downstream fine crushing and milling pro-

cessing by over 10ldquoThe process flow improvement solu-

tions provided by Metso not only increased

the output of our gold concentrates but

also reduced our energy consumption andcostsrdquo says Shen

In the past wear parts procurement

took up a larger proportion of Zhongjiarsquos

total production costsldquoTo avoid downtime caused by the

shortage of wear parts we had to keepeight sets of various wear parts in place

However the cost of having so many wear

Zhongjia Mining Industryrsquos gold concentrates processing plant in China

8132019 Results Minerals Aggregates 3 2012ENG

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0983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

Safe quarrying high-

quality aggregates

8132019 Results Minerals Aggregates 3 2012ENG

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ldquoWe share a similar zero-accident strategy and target with Metso and have successfullyfollowed it Metso has also helped us to meet the strictest end-product quality andcubicity requirements set in Spainrdquo This is how Managing Director Intildeigo Ajuria ofOfitas de San Felices the leading hard rock quarrying company in Spain describesthe cooperation with MetsoTEXT Eero Haumlmaumllaumlinen PHOTOS Ofitas and Eero Haumlmaumllaumlinen

The San Felices quarry is situated in a picturesque mountainous landscapebetween the companyrsquos Rioja vineyards and the Bilbao-Madrid motorway

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Ofitas has pioneered the implementation

of several Metso novelties in the Spanish

market The company was the first to use

efficient large track-mounted Lokotrack jaw plants the unique mobile conveying

system and also the new-generation HP4

cone crushers

Today the company operates twomodern Metso stationary plants one in

Guadix near Granada and the newest one

in San Felices Haro Rioja community Both

quarries focus on refining hard rock by pro-cessing ophite rock into the highest quality

railway ballast asphalt and concrete mix

grades The company has a satellite quarry

near Vitoria in PentildeacerradaBeing situated next to a highway and

the famous Rioja vineyards Ofitas must pay

special attention to environmental issues

To minimize dust problems all conveyors

have special covers attached

Quality durability and service

The cooperation between Ofitas de San

Felices and Metso started back in 1973when the Ajuria family bought the com-

pany whose quarrying activities began in

1919 Intildeigo Ajuria has a clear vision of why

the cooperation has continued withoutinterruption for almost 40 years

long-standing personal relationshipsrdquoAjuria adds

Serving railways asphalt

and concrete producers

The year-old San Felices stationary instal-lation lies hidden in a mountainous area

south of the city of Vitoria in NorthernSpain The new plant replaces an old one

that complicated the extraction of ophiterock Both plants are delivered by Metso

With its two separate production lines

the new plant is able to produce all the

end products required ndash from railway bal-last to the finer grades needed for asphalt

and concrete

Due to lower demand the quarry cur-

rently produces some 4000 tons per day

At full capacity however the plant canreach 8000 tons of production per day

30ndash35 of which consists of railway ballastfor high-speed trains and 65ndash70 of chips

and sand Thanks to the versatile two-line con-

cept connected by transverse conveyors

up to 12 different end products can be pro-

duced Depending on the demand for endproducts the material can be guided either

to the HP4 cone or HP400 cone followed

by a Barmac vertical shaft impactor

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

The ophite feed is fed to the C125 jaw crusher by a sturdy dump truck

The key people running the new San Felicesquarry Mine Engineer Carlos Fernandez (left)Managing Director Intildeigo Ajuria with ProductionManager Julian Perez

ldquoThrough the years Metso machinery

has proven its production capacity and

durability resulting in high-quality end

products A big plus for us has also beenthe quick response time to our process

challenges or servicerdquo

ldquoIn fact our cooperation extends

beyond day-to-day business matters to

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983122983141983152983151983154983156983145983150983143 983154983141983155

Meeting the strictest cubicity demands

The Spanish regulations concerning end-product cubicity are becoming more

demanding The flakiness percentage of

railway ballast must be below 10 and for

asphalt and concrete aggregates less than

15

ldquoWith Metsorsquos HP4 cone and the Barmacvertical shaft impactor we can meet even

the strictest cubicity demands We believe

that our high quality is helping us to sur-vive in the present recessionrdquo notes Mine

Engineer Carlos Fernandez

ldquoWe hope to increase the total extrac-

tion of the three quarries from the present15 million tons per year because our plant

capacity allows more than double thatrdquo

Fernandez adds

More info

Angel Luis Garcia Tel +34 686 94 35 30

angelluisgarciametsocom

In addition to being the leading Spanish

quarry to process hard rock Ofitas de SanFelices also cultivates 34 hectares of vine-yards next to the quarry which is situated

in the famous Rioja wine area

The company has previously sold a

harvest of over 200000 kg of Tempranillo

grapes to local red-wine makers Recentlythe company built its own wine process-

ing plant to process 10000ndash15000 kg of

grapes themselves

Aggregates and wine production

Andoni Ajuria the founder of Ofitas de san Felices (left) with Intildeigo Ajuria the present ManagingDirector tasting wine from the companyrsquos own vineyards

The first vintage wine of Ofitas har-

vested in autumn 2010 is now maturingin oak barrels After maturing for 12 to 15months the wine is called crianza and after

two years it will be granted the classifica-

tion reserva

ldquoWinemaking is not a business but

a hobby for us We give our wine out aspresents and drink it when we meet

our suppliers and friendsrdquo Intildeigo Ajuria

comments

For environmental protectionall of San Felicesrsquos plantconveyors are covered

Ofitas de San Felices quarry

LOCATION Haro near the city

of Vitoria northern Spain

SIZE 100 hectares

ROCK TYPE Ophite with Los Angeles

index of 9ndash10

PRESENT DAILY EXTRACTION 3000 tons

of ophiteNUMBER OF PERSONNEL 30

RESERVES 10 million tons

MAIN END PRODUCTS 0ndash2 mm

2ndash4 mm 4ndash10 mm 10ndash16 mm

16ndash22 mm 25ndash60 mm (ballast)

METSO MAIN EQUIPMENT

VF feeder

C125 jaw crusher

ndash feed size 0ndash800 mm

ndash css 130ndash140 mm

HP400 cone crusher

ndash feed size 80ndash250 mm

ndash css 40 mm HP4 cone crusher

ndash feed size 40ndash80 mm

ndash css 15 mm

Barmac 6150 VSI crusher

4 CVB2060 screens

2 TS32 screens

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Metso Distribution Centers he

Europe (Tongeren Belgium)

France (Macon)

Czech Republic (Přerov)

Austria (Vienna)

2271 d

Brazil (Sorocaba SP)

1014 d

USA (Columbia SC)

1690 d

USA (Waukesha WI)

434 d

South Africa (Vereeniging)

Ghana (Tarkwa)

Meacutexico (Irapuato)

Peru (Lima)

Chile (Concoacuten)

788 d

Sweden ( Trelleborg)

Finland (Tampere)

UK (Rugby)

865 d

Russia (St Petersburg)

Brazil (Parauapebas PA)

206 d

4983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

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983122983141983152983151983154983156983145983150983143 983154983141983155983122983141983152983151983154983156983145983150983143 983154983141983155

In the case of an equipment failure or

a planned service shutdown resuming

production as quickly as possible is crucialEach hour spent waiting for a spare part to

arrive equals money lost Whether the right

part takes 12 or 48 hours to arrive really

makes a difference

The comprehensive and global Metsospare and wear parts service network pro-

vides you with the right part in the right

place and at the right time Our strategi-

cally located Distribution Centers and

Satellite Warehouses are on call 24 hoursa day 7 days a week ensuring efficient

parts replacement near you

Check out the locations of the MetsoDistribution Centers and how many parts

pass through them each day

More info

Marcelo Farah

Tel +55 15 2102 1315

marcelofarahmetsocom

you minimize downtime

Australia (Perth)

746 d

China (Tianjin)

China (Kunming)

China (Shanghai)

393 d

India (Faridabad)

India (Ahmedabad)

India (Hyderabad)

India (Bhubaneswar)

India (Bangalore)

419 d

Russia (Yekaterinburg)

Australia (Newcastle)

New Zealand (Matamata)

983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088

TEXT Sofia Williams

Singapore (Singapore)

Distribution Center Satellite Warehouse

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Following a large investment

in Metso crushing equipmentand services Buena Vista del

Cobre is now expanding the

mine site to include even more

equipment ndash and with thatexpansion comes the need for

more local service resources

Metso and Buena Vista del

Cobre have entered into a Life

Cycle Service agreement forthe plant and construction of a

brand new Metso service hub

is under way in Cananea

New facility new

level of service

The Cananea service hub

which will be up and running in early 2013will support the recent expansion and resur-

gence of Buena Vista del Cobre Initially it

will be a major repair and assembly center

for pumps crushers and screens and will

provide for rubber covering capabilitiesBut the 8000-square-meter facilityrsquos service

offering will be expansive including a con-

signment stock inventory to help serve theminersquos varying needs Metso currently has

50 service team members on site

Although Buena Vista del Cobre was a

key influencer in building the new servicehub this location will also enable Metso to

expand its capabilities and provide local

support to the entire mining community

in northwest Mexico The Cananea hub

will serve a number of major copper and

gold mines in the region including MineraFriscorsquos San Felipe Fresnillorsquos Milpillas and

Grupo Mexicorsquos Mexicana de Cobre

ldquoBuena Vista del Cobre is the biggestcustomer we have in Mexico today and

with this expansion project itrsquos only going

to grow and be strongerrdquo says Felix Forna-

guera Director of Services Mexico CentralAmerica and Caribbean ldquoWith that said the

idea behind the Cananea service hub is to

provide a central location for local support

for all our major customers in the areardquo

Establishing safety

ldquoIt was key to have our support here in

Cananea because the Buena Vista delCobre started from the ground uprdquo saysFelix ldquoWersquove been able to help the cus-

tomer to establish the best in support

service and operations from the very

beginningrdquo And this ground-up approachincluded a major focus on safety

Metso worked closely with Buena Vista

del Cobre to establish the safety proto-

col by which the mine operates Basedon Metsorsquos expertise the safety measures

put in place have enabled the mine to

become strict and efficient in its operations

and maintenance procedures To achievethis Metso worked closely with local andnational authorities to ensure the safety

plan was comprehensive and in accord-

ance with all established legal bodies

The best in regional support

The service hub in Cananea is a prime

example of Metsorsquos focus on providing local

service and support to its customers all

Service shines in Cananea MexicoAfter three years of inactivity the Buena Vista del Cobre mine in Cananea Sonora Mexico has been operational since 2010A mine that was inactive for such a significant amount of time however requires a great deal of support to successfullyrestart the plant and bring it back to an operational and profitable state

TEXT Deanna Lee PHOTO Metso

over the world ldquoWe are the first

company developing this kindof service in northwest Mexicordquo

adds Felix ldquoOur people have

developed a close relationship

with the team at the mine Itrsquosmore than a supplier relation-

ship our guys are inside the

mine living and working thererdquo

In fact this is the model

that Metso is using in servicehubs all over the globe build-

ing modern facilities bringing

teams on site and workinghand in hand with mine

operators The Cananea Service

hub is only the most recent

example of Metsorsquos commit-ment to service and northwest Mexico is

yet another mining hotbed thatrsquos going to

benefit from the companyrsquos support

More info

Felix Fornaguera Tel +52 4621079227

felixfornaguerametsocom

A mining cone serviced by Metso at the Buena Vista del Cobre mine inSonora Mexico

ldquoThe new Cananea service center will be a majorrepair and assembly center for pumps crushersand screensrdquo says Felix Fornaguera Director ofServices Mexico Central America and Caribbean

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

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During the MINExpo exhibition over 1300 people visited the Metso stand

983122983141983152983151983154983156983145983150983143 983154983141983155

Held every four years MIN-Expo consistently grows so

perennial exhibitors like Metso

are challenged with elevating

their presence and drawingin new (and greater numbers

of ) visitors each year ldquoItrsquos not

necessarily a challenge to lsquotoprsquo

our last showingrdquo says Keith

Ference Vice President ofmarketing and communica-

tions North America ldquoThere

are four years between eachMINExpo so we always have

a lot to say and reveal to our

customersrdquo The real challenge

he says is finding an exciting

and dynamic way to deliverthe message ldquoTherersquos so much

to see here so your booth has

to be compelling from the

outside-in and thatrsquos what

we always try to dordquo

Service sets the stage

The Metso booth created buzzin a number of ways and per-

haps the most striking (partly

due to its size) was the live

theater presentation As visitorspassed through the aisles of the show-

room the sights and sounds from Metsorsquos

theater were hard to miss And once guests

entered they were captivated by a short

high-energy video presentation focused

on Metsorsquos service capabilities The message was simple Metso is ldquoyour

local service partner rdquo for all mining and

construction needs The video showed ourservice teams in action all over the world

and the audience came away with an

understanding about Metsorsquos commitment

to service Customers can count on morethan 70 local service centers run by more

than 1700 expert technicians delivering

Metso makes an impact at MINExpo 2012At this yearrsquos MINExpo International nearly 60000 attendees flocked to Las Vegas Nevada the largest turnout in showhistory The visitors ndash mining professionals from all over the globe ndash explored 850000 square feet of showroom spacefeaturing the industry rsquos latest technology equipment products and services They toured the show for three days

seeking the latest and greatest from more than 1800 exhibitorsTEXT Keith Ference PHOTOS Tracey Ford Perry

detailed descriptions andphotos of all of Metsorsquos mining

and construction products and

services The app also provides

digital access to Results and asearchable database of sales

contacts By day three of the

show MetsoMAP had been

downloaded by more than

500 usersIn addition to the app the

booth was equipped with

several LCD screens each con-trolled by Metso experts who

used their iPads to present new

products like the Megalinertrade

and the HRCtrade A featured

presentation on Metsorsquos lineupof energy-efficient comminu-

tion equipment including the

VERTIMILLreg SMD and MP-1250

cone crusher was also avail-

able letting customers seehow Metso technology delivers

some of the worldrsquos most effi-

cient size reduction

Measuring MINExpo success

After a very busy three days

(on top of months of prepara-tion leading up to the show) everyone

involved with MINExpo ndash from the North

American marketing team responsible for

the booth to the product managers and

sales force that worked the floor ndash is view-

ing the show as a success ldquoTherersquos alwaysa sigh of relief after each (MINExpo)rdquo says

Keith ldquoAnd overall the initial feedback

and response has been very positiverdquoWith more than 1300 visitors to the

booth Metso certainly made an impact

ldquoWe learn a lot from each show and with

some time wersquoll have a better understand-ing of the tangible results of our effortsrdquo

Keith adds

reliable service for mining equipment as

well as customized cost-effective life-cycle

services contracts

Technology ndash MetsoMAP

is an industry firstMINExpo provided the industry with its firstglimpse of Metsorsquos revolutionary iPad app

MetsoMAP The app was demoed to the

boothrsquos visitors via ldquothe worldrsquos largest iPadrdquo

a custom-made 80-inch screen that show-cased all of its capabilities most of which are

groundbreaking in the industry MetsoMAPrsquos

simple interface is highly intuitive making

it easy to view process animations videos

The presentation of the new HP cone crusher attracted a large audience

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When yoursquore allowed less than a dozen days per year for breakdowns repair andmaintenance every single hour during a service shutdown counts There simplyisnrsquot any room for surprises Thatrsquos why Boliden counts on MetsoTEXT amp PHOTOS Sofia Williams

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Kurt Kalla Site Managerof Metso Gaumlllivare ServiceCenter is responsible forthe maintenance of Aitik

Metso and Boliden Strivingtogether for 97 uptime

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983122983141983152983151983154983156983145983150983143 983154983141983155

One of the biggest copper mines in

Europe Bolidenrsquos Aitik is located deep inthe wilderness of Swedish Lapland next to

the small town of Gaumlllivare The mine has

been operating since 1968 and a recent

expansion has increased its annual ore

production to 36 million tons

But the ambitious Swedes are not will-ing to lay back and relax just yet Bolidenrsquos

new aim is to reach a production rate of

45 million tons of ore per year in AitikAfter that Perhaps more than 55 million

tons The ore concentration in Aitik is very

low-grade with a mere 022 copper con-

tent hence the need for high capacityAchieving the ambitious production

goal requires maximum plant availability

This means that everything from the crush-

ers to the filters must be up and runningfor approximately 97 percent of the time

Thatrsquos where Metso comes into play

A cost-per-ton contract in action

The maximum uptime requirement allowsless than a dozen days per year for break-

downs repair and maintenance at Aitik

Every single hour during a service shut-

down counts There simply isnrsquot any roomfor surprises

Executing a successful shutdown under

such conditions requires a reliable service

partner not afraid of challenges and this iswhy Boliden has entrusted Aitikrsquos services

operations to Metso Boliden and Metsohave worked together since the 1960s

and the collaboration took another step

forward in September 2012 when the twocompanies signed a three-year extension

of the services contract for Boliden Aitik

ldquoThe new contract is a cost-per-ton

agreement We get paid based on Aitikrsquos

production Itrsquos a win-win deal for both par-

ties but also a new mindset for usrdquo explainsKurt Kalla Site Manager of Metso Gaumlllivare

Service Center responsible for serving Aitik

From now on the duration of the shut-down is what matters the most According

to Kalla the Metso service organization in

Gaumlllivare is now streamlining its operations

to fit the bill and has already witnessed thestrategy working In August 2012 Metso

carried out a 188-hour service shutdown in

Aitik which turned out to be a success

Zero tolerance for injury

One key factor to the success was theextensive planning of precautionary health

safety and environment procedures under-

taken by Metso prior to the shutdown Thanks to strict measures applied no

injuries or accidents occurred during the

shutdown and the work could easily be

finished on scheduleMats Johansson Health Safety

and Environment Manager for Metso in

Sweden explains how this was achieved

rdquoPlanning of the shutdown included arisk analysis for all new tasks participating

in Bolidenrsquos safety coordination meetingsmeeting with both Metso supervisors and

subcontractor supervisors and finally a

meeting with the entire staff participating

in the shutdown where everyone had to

sign a document stating their commitmentto the information providedrdquo he says

During the actual shutdown plenty of

new barriers signs and awareness cones

were put in place as a result of observa-tions from previous audits and safety plans

and risk analyses were readily available

in the work area Metso and Boliden also

introduced a Mill Inching permit a certifi-cate for completing a mandatory course for

those involved in the process In addition

Metso carried out random safety audits

during the shutdown to make sure thestrict policy was followed

According to Boliden Metsorsquos way of

working is a good example of how health

and safety precautions should be handled

ldquoMetso is a good example of how towork with safety and health plans risk

analysis permits and welding permits

Their table with all binders in the second-

ary mill area was exemplaryrdquo says Kjell-Arne

Johansson a technician from Boliden

The use of the new Metso Megalinertrade

system in the lining of Aitikrsquos Metso AG

mills has also improved the safety of main-tenance staff The Metso Megalinertrade con-

sists of larger-than-average liners bolted

in position from outside the mill Mainte-

nance technicians no longer need to go

inside the mill and stand in the dangerousdrop-zone of the liners gt

Boliden aims to reach a production rate of 45 million tons of ore per yearin the Aitik mine site

ldquoA complete risk analysis was conducted during the planningof the shutdownrdquo comments Mats Johansson Health Safetyand Environment Manager for Metso in Sweden

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Service the Metso way

24 hours a day 365 days a year

In addition to paying close attention to

health and safety issues executing an effi-

cient shutdown requires careful planning

and timing of every step in the mainte-

nance process Wear and spare parts have

to be available on time and a repair shoplarge enough to accommodate equipment

located close by

ldquoTo keep maintenance breaks as short

as possible we aim to replace the pump on

site and bring the old one for repair to our

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

nearby facilities This method gives us the

peace to do a good job and keep the cus-

tomerrsquos operations runningrdquo Kalla describes

the Metso way of handling Aitikrsquos pump

maintenance

Metso is currently expanding its Gaumllli-

vare service center to include a distribu-

tion center for wear and spare parts andalso concentrating its previously scattered

operations under one roof in its Vuoskon-

jaumlrvivaumlgen facility The expansion is due to

be completed by 2014

Metso equipment

delivered to Aitik36

bull 2 AG mills diameter 116 x

137 m gearless 22-MW motor

bull 2 Pebble mills diameter 91 x

113m dual 5-MW pinion drive

bull 3 VPA pressure filters VPA 1540-54

bull 12 sample pumps and pipes

VF50

bull 60 Various slurry pumps up to

MR500 modelbull Appr 5000 m rubber-lined slurry

pipes up to 600 mm diameter

bull Appr 5000 m rubber-lined by

gravity pipes up to 600 mm

diameter

bull Appr 5000 m rubber hoses

up to 600 mm diameter

Not only does the expansion make ser-

vice shutdowns at Aitik run more smoothly

it guarantees a more comprehensive

on-call emergency service response in the

region ndash thanks to the spare and wear parts

inventory available 24 hours a day 365

days a year

More info

Lars Rosenling

Tel +46 70 107 45 90

larsrosenlingmetsocom

Metso grinding equipment dominates the view in the concentrator

Safety on site is made up of small things like

making sure that everyone remembers to secure

the hoses in place

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983122983141983152983151983154983156983145983150983143 983154983141983155

Pebbles have always been a

challenge for producers of sandsince they cannot be returned

to rivers after extraction For

decades the processing of this

material resulted in a huge

environmental liability with alarge amount of pebbles hav-

ing to be stored away and left

unused

Transforming problems into

business opportunities

Areia amp Cia (areia = sand) has

operated in this market forover 20 years and decided to

enlist the help of Metso to find

a profitable solution for the

processing of pebbles

In July 2011 analyses werebegun to assess the abrasive-

ness and crushability of the

material Four alternatives wereidentified for processing and

transforming pebbles into sand

Initially Areia amp Cia was

interested in acquiring an

impactor for its reason-able price level However the

customer wanted to process

all the pebbles that were col-

lected daily in addition to some of the

material that it had stored In weighing theresults expected by the customer and the

excessive abrasiveness of the material the

HP200 cone crusher was decided on as thebest alternative

Areia amp Cia made the required invest-

ment and after using the HP200 for just

six months the company has already beenreporting outstanding results The HP200

not only transforms pebbles into sand but

also produces sand of excellent quality

with high yield and low maintenanceWith minor adjustments the HP200

also enables the production of sand withspecific particle size distribution for special

applications such as filtering sand blasting

and foundry sand adding value to the prod-

uct and increasing the types of sand offeredldquoMetso is pleased that the HP200 not

only enabled the processing of a product

that had been set aside as unusable but

HP200 cone transforms pebblesinto high-quality sandOver the last few decades Brazilian economic growth has been driving demand for construction aggregates The market

for sand in turn has been experiencing major difficulties in maintaining a consistent supply Presently one of the mainchallenges the industry faces is the large amount of pebbles that are obtained in the process of extracting sand at timesconstituting nearly 50 of the volume of material dredged from riverbeds

TEXT Sheila Ivers PHOTO Areia amp Cia

also that it opened up new

market opportunities for Areiaamp Cia Thatrsquos the standard we

seek to deliver to our custom-

ersrdquo states Luiz Oliveira Techni-

cal Salesperson of Metso Brazil

HP cones entering the

Brazilian sand-making

market

Todayrsquos cones such as theHP200 have high resistance

to impacts and abrasiveness

more efficient crushing cham-

bers low maintenance costsand excellent productivity

Following the acquisition of

the HP200 Areia amp Cia is now

also producing special sands

that command a price that is100 higher than common

sand The entire stockpile of

pebbles accumulated through-out the companyrsquos 20 years of

operations has already been

transformed into sand and the

stock of pebbles held by com-

petitors is also being purchasedfor processing

Cristiane Brizolari the

owner of Areia amp Cia confirms

the transformation that has taken place in

the production and commercial processldquoThe HP200 opened up new niches in

the market enabling the production of dif-

ferent types of sand with added valuerdquo

More info

Luiz Oliveira

Tel +55 011 9971 3603

luizoliveirametsocom

After the pebbles are crushed into sand with the HP200 cone crusherdifferent grades are screened for various end uses

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Where therersquos a will we dig a wayAFCONS-Strabag and Metso embark on tunnel project together

When the joint venture AFCONS-Strabag initiated work on the Rohtang bypass tunnel project at an altitude of 3980 metersabove sea level in Himachal Pradesh India they deliberated each aspect with clockwork precision The project involved anumber of surprises and challenges and required technology and project management skills that were second to none

TEXT amp PHOTOS Monisha Majumdar

Cutting a 10-meter-wide and nearly 9-kilo-

meter-long tunnel through the Himalayas

in one of the toughest terrains and cli-mates in India makes for quite a challengeResults set out to find out how AFCONS-

Strabag and Metso are making their way in

one of their most critical projects to date

The only road connection to the north-Indian border region of the province

Himachal-Pradesh and beyond the Manali-

Leh highway leads across the Rohtang

pass Due to the heavy snowfall and high-

velocity winds in this region the towns

located north of the pass are cut off from

the rest of the country during winter for atleast four often even six months each year

A tunnel with strategic importance

With the construction of the tunnel at

3100 m above sea level the Manali-Lehhighway will become an all-weather road

thereby enabling a significant improve-

ment in the economic development of

northern Himachal-Pradesh and an alter-

nate route to the strategically important

Ladakh region

Manali south of the pass is an alreadywell-developed tourist location that is

becoming more and more popular Upon

completion of the tunnel it is likely that

tourist activities will extend to the areanorth of the pass Moreover the tunnel

shortens the distance between the towns

of Manali and Leh by approximately 45 km

thus saving several hours on the small dan-gerous pass road

The Rohtang pass in the Western Himalaya

region of Northern India with its altitude ofalmost four kilometers ranks among thehighest trafficable passes in the world

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983122983141983152983151983154983156983145983150983143 983154983141983155

The 88-km long horse-shoe-shaped

tunnel provides space for a two-lane8-m-wide carriageway as well as a one-

meter-wide footpath on both sides A

22-m-high and 36-m-wide emergency

tunnel will be integrated in the tun-

nel cross-section Altogether more than

800000 msup3 of rock will be moved Tunneling works started around spring

2010 with excavation driven from both por-

tals As the north portal is inaccessible dur-ing winter closure the excavation focused

on the south After a planned construction

period of 55 years the tunnel is scheduled

to be completed by the end of 2015

Best man for the job

The BRO (Border Road Organization)

wanted to roll out a global tender for theproject due to the challenges that such a

project involves and also considering thatitrsquos the first time in India that a project of

this scale was to be carried out This imme-

diately triggered the need to roll out aglobal tender All major Indian construction

companies bid for it some individually and

some in partnerships

Strabag an Austrian tunnel specialistwas one of the companies who bid for the

project along with AFCONS a Mumbai-

based infrastructure company In Septem-

ber 2009 AFCONS-Strabag was awardedthe contract

Mr Sunil Tyagi Deputy Project Man-ager at AFCONS had this to say about the

unique projectldquoThis project is located in the Himalayas

and as far as we understand the terrain

there is among the toughest We came out

with a new technology and to be honestit is a fairly simple one We would generally

start with the traditional technology of drill-

ing and blasting and then obtain our muck

feed from the inwardbottom of the tunnelrdquo

ldquoThe technology is supplied by Rowa Tunneling Logistics and this is the first

time it is being used in Asia A jaw crusheris placed at a distance of about 40-45

meters behind the face The blasted muckextracted from the face is fed to the crusher

to reduce the lump size and then through

an overhead conveyor transport system

it is then transported out of the tunnelrdquoldquoThis enables free movement of man

and machinery in the lower area or spe-

cifically on the ground area If we were to

conforms to the Indian standard for fines amp

coarse aggregates as prescribed in IS383-1970

The plant was up and running in good

condition and performing to AFCONSrsquos

satisfactionldquoWe have worked with Metso in earlier

projects and are quite impressed by thekind of technology amp services they provide

We have a history together so the trust fac-tor also comes inrdquo explains Dhiman on their

choice of Metso as a partner

Service makes the difference

ldquoMetsorsquos services have made a big dif-ference in the project Without them we

would still be struggling with the machin-

ery and production The service is really

good and the service engineers are knowl-edgeable prompt and quick to act Any

problem can be solved by Metso We donrsquothave to wait until a service engineer turns

up ndash they have the capacity to solve prob-lems over the phone as wellrdquo says Dhiman

ldquoThe Metso plant didnrsquot create any prob-

lems for us We had problems in logistics

the feed was sticky and the weather condi-tions were bad but thankfully we did not

face any problems with production and

efficiency as the Metso plant is performing

very wellrdquo Dhiman concludes

More info

Amol Sinha Tel +91 9811 671 924

amolsinhametsocom

use the old conventional technology this

wouldnrsquot have worked for us in the stipu-lated timerdquo Mr Tyagi adds

When the going gets tough

partner with the toughest

Sensitive projects require the best technol-

ogy After AFCONS-Strabag landed theproject Metso was an obvious choice as a

technology provider not only because of

the long-standing business relationshipbut also for the sheer consistency in prod-

uct quality and service deliverance Metso

strives for

ldquoAfter signing the project we faced alot of road blocks including extreme cold

avalanches roadblocks less oxygen ndash you

name it we faced itrdquo explains Ankit Dhi-

man Plant Manager at AFCONS-Strabag The Rohtang valley is known for its

notorious avalanches and landslides SoAFCONS had to take extra steps and safety

precautions against hazards on the site

ldquoIn this freezing cold not just us humansbut also the machines are at increased risk

of damage I remember when we used

to run the plant during winter the diesel

engines would freeze We had to constantlyheat up the fuel container to get the plant

running And even the sand in the sand

trap would freeze so we had to clean it on

a daily basis to stop the pipes from mal-functioningrdquo Dhiman adds

Plant designed for difficult terrain

Difficult terrain coupled with space con-straints led Metso engineers to put their

minds together to come up with a suitable

plant configuration After studying the

requirements of the project Metso sug-

gested a 150-tons-per-hour three-stagemodular plant using a C106 jaw crusher

a GP11F secondary cone crusher and a

B7150 tertiary vertical shaft impact crusher

In addition considering the unpredict-ability of the feed the plant was about

to reach a point where the amount offines to be handled could be increased

dramatically Metso strongly suggested the TK11-27-3V grizzly scalper and this became

the first-ever TK scalper to be supplied by

Metso to an Indian customer Also in order

to get better products a sand trap SF2360was added to the configuration

The sand trap is important equipment

for this project as it washes the sand thatMr Sunil Tyagi Deputy Project ManagerAFCONS-Strabag

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Smooth transition to new-generation jaw crusher in Germany

Roumlhrig is a German company with a rich heritage The company has been quarrying granite at its plant in Bergstrasse inthe Sonderbach district of Heppenheim for three generations

TEXT amp PHOTOS Ralf Goffin

Roumlhrigrsquos superior product variety is onereason why the companyrsquos proximity to its

customers can be understood in more than

just physical terms The companyrsquos high

level of innovation has allowed it to estab-lish itself as a reliable supplier of materials

both regionally and internationally This

operational and technical expertise always

manages to keep in step with growing

market requirements

In terms of technical processing equip-

ment Roumlhrig has used a Nordberg C160stationary jaw crusher from Metso since

1992 At the start of 2012 it was finally

exchanged for a more up-to-date version

from the same model range

Metsorsquos C Series is specifically designed

to pre-crush hard rock and can cope effort-

lessly with even the hardest of materials

The dimensions of the new stationary jawcrusher are identical to those of the old

one which means that it could simply be

slotted into the housing vacated by the

previous version

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Third-generation Managing DirectorMarco Roumlhrig expects the new machinersquos

service life to be just as long as the previ-

ous model due to the product upgrades

that have been implemented The integral motor base is another plus

point in models made by other manu-

facturers it is located outside the crusher

This element of good fortune ensured that

Roumlhrig could reuse the housing withoutany additional rebuilding

Another advantage lies in the revision

of the guards for the C160rsquos drivetrain andflywheel The sturdier construction method

used for the crusher requires fewer parts

which facilitates easier installation andmaintenance and it makes it simpler to

access the motor

Under the watchful eye of Metsorsquos

Assembly Manager Maik Engelstaumltterthe entire project including removal and

installation was successfully completed

within two weeks

Installation making the most

of the available space

Roumlhrig will likely remember the day the

new crusher was installed for a long time

the pitman and main frame were deliveredseparately prior to installation and assem-

bled on site It took just one hour to replace

the old stationary crusher with the new

model A lorry-mounted crane was used toposition the 85-ton crusher with millimeter

precision in the crushing plant Once the

new crusher had been positioned in theexisting steel structure the next task wasto fix it into place as securely as possible

despite the limited space Special vibration

dampers were installed at a height of two

meters to prevent the crusher from sliding

Norbert Ried (fourth from left) installed thenew C160rsquos predecessor 20 years ago and isdelighted at the durability of the powerfulcrusher that is now making way for a newermodel Also pictured from left to right ManagerVolker Angermann Assembly Manager Maik

Engelstaumltter Technical Manager Stefan

Koob Project Manager Dominic SchoumlnhardtManaging Director Marco Roumlhrig Service

Technician Stefan Kolze and employees ofthe installation company Stafemo

On the hook after theold C160 was liftedout by crane the newcrusher was installedin almost no timeOnly the roof of thehousing had to beremoved

sideways off its mount An initial test run

with materials was carried out around oneweek later after all the electrical cables had

been installed

Simultaneously with the installation

of the C160 which is the first of the latest

generation of crushers to be installed in

Germany a new Nordberg GP100 conecrusher was also being installed in Roumlhrigrsquos

chipping plant Roumlhrig is convinced that

the technical improvements made tothe new Metso crusher can only be an

advantage worldwide

Roumlhrig places great value on consistent

product quality maximum added valueand optimum refinement of its product

range Bearing in mind that Roumlhrig has

enough reserves of raw material to last

for the next 150 years the company canconfidently continue to develop with an

emphasis on quality rather than quantity

More info

Dominic Schoenhardt

Tel +49 (0)621 727 00 610

dominicschoenhardtmetsocom

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Groupe Charier Carriegravere de la Mariais France

Quarrying with certi1047297ed quality The Charier Group with its 1600-strong workforce is a family business thatthis year celebrates 115 years of quarrying The company pursues a long-termdevelopment policy that since 2007 has seen processing installations upgradedat 4 of its 9 extraction sites

TEXT Liliane Boutin (with extracts from Mines amp Carriegraveres and Terrassements amp Carriegraveres magazines)PHOTO Baloon photo

The processing installation is of the horizontal type with a primary station located 56 meters below the site access road to keep it hidden from view

The crushing and screening installation at

Charierrsquos CM La Mariais quarry (at Donges

on the Loire estuary) has been in opera-tion since September 2011 Based on theoperatorrsquos ideas it was designed by Metso

to replace a worn-out installation installed

right on top of the seam being extracted

Since its commissioning it has becomethe second quarry in the company to

receive ISO 14 001 certification

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983122983141983152983151983154983156983145983150983143 983154983141983155

tertiary material of sand and gravel for the

local market to use in concrete surfacingprefabrication etcrdquo

Incorporation of a screening station

The stone extracted from La Mariais is

according to the quarry granitic gneiss

sound and homogeneous with a LosAngeles index of 15 good wear resist-

ance with an MDE of 10 a true density of

265 and a certain abrasiveness (2000 gt)ldquoCharacteristically it has a tendency to form

blocksrdquo Leblin points out

The main criteria in designing the instal-

lation was to provide an output of 600000metric tons from one station (38 hours

week) to produce materials aimed at the

concrete and surfacing markets ldquowhich

involved providing a tertiary station withscreening plantrdquo he adds

With this new unit the operating com-pany expands its product range through

the addition of fine materials obtained

from the tertiary screening station This unitis capable of producing 170 tonshour of

020

Preserving the environment

and optimizing safety

The screens have motorized bogies and

retractable walkways to facilitate access

when the screens are opened for main-tenance Other walkways provide access

to the tunnel input feeders The feederscan be isolated with hydraulic rod gate

bars this hydraulic assistance eliminatesthe need to use a heavy hammer to lodge

these metal bars

All conveyors transporting fines (02

and 04) are covered with a tarpaulin to

avoid flying dust and all the screens arehooded (metal cover with Trellex seal-

ing) The Brunone company has installed

dust-tight containment at the outlet of the

tertiary station crushers (HP300 and HP4)on the belt located under the screens

and under the hoppers located belowthe tertiary screens The crushers are put

under negative pressure and the finesare extracted through sleeve filters (7000

m3 h) with declogging which deposits the

dust back onto the conveyor belt

A high-pressure 100 bar water mist sys-tem has been installed at the primary sta-

tion discharge at the secondary crusherrsquos

discharge chutes (Omnicone) and at the

transfer points on the belt

Designed to last

ldquoThis type of new installation can easily last

thirty yearsrdquo affirms Project Leader Bruno

Peix of Metso ldquoIt quite simply depends on

how well it is maintained Thatrsquos why weprovide maintenance contracts that call for

our technicians to make regular inspection

visits and carry out preventive mainte-nance and any necessary repairsrdquo

In 2011 Metso commissioned about

10 new processing units in France like

the one at La Mariais quarry

More info

Frederic Bazire

Tel +33 (0)681442804

fredericbaziremetsocom

Key figures

DURATION OF WORKS 15 months

DRAWING OFFICE TIME 7800 hours

HEIGHT OF SILOS AND GRINDER BUILDINGS

15 m

TOTAL LENGTH OF CONVEYORS 14 km

WEIGHT OF THE INSTALLATION

1200 metric tons

CONCRETE POURED 1800 cubic meters

PROJECT SITE WORKFORCE 30

INSTALLED POWER 2200 kW(not including pumps 200 kW)

METSO EQUIPMENT

Primary

Vibrating feeder PF561-2V

Primary grizzly VG540-3V

Grizzly feeder TK13-20-3V

Jaw crusher C145 with

hydraulic setting

Secondary

Vibrating screen CVB 2050

refurbished

Cone crusher Omnicocircne 1352 SX

with Metso IC7000 controller Ellivar 16 (16 msup2 3 decks) screen

refurbished by Metso

Tertiary

Cone crusher HP300

Cone crusher HP4

2 Ellivar 20 screens (20 m23 decks) for final products

Expanding the production range

ldquoSince the mid-1990s when we became

owners of La Mariais we had used mobilemachinery with an assembly of beltconveyorsrdquo recalls Daniel Leblin Charierrsquos

Technical Manager for site construction

and maintenance

ldquoIt became clear that we needed ahigher performance tool to achieve the

dual goals of reaching one million metric

tonsrsquo maximum production and producing

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Big Lokotrack LT550GPF boostsquarrying productivity by a thirdMaximizing the productivity of operations is a key issue when striving for cost-effective quarrying Big Lokotracks are oneway to achieve improved operational efficiency The Lokotrack LT550GPF equipped with the high-volume GP550 conecrusher and a large screen is popular in the Nordic countries and in Germany and Australia ndash countries all known for theirhigh quarrying volumes

TEXT amp PHOTOS Eero Haumlmaumllaumlinen

Kone-Kostamorsquos new mobile coneplant has reached an averagecapacity of 300 tons per hour

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ldquoWith the same number of employees we

can achieve 30 more productivity with

our new LT550GPF unit The high-capacityFS screen has also eliminated the bottle-neck often seen at fine screeningrdquo says

Aarno Kostamo Managing Director of

Kone-Kostamo Oy one of Finlandrsquos biggest

crushing contractorsAccording to Kostamo the high capacity

of the GP550 gyratory cone crusher easily

handles feed from the C120 and C125 jaw

crushers For the contract with the Talvivaara

nickel mine the LT550GPF is being fed bythe brand new Lokotrack LT120 jaw plant

Average capacity 300 tons per hour

Talvivaara Europersquos largest nickel mine uti-

lizes large quantities of aggregates Kone-Kostamo has contracted several million

tons of different end products for the mineIn August 75000 tons of 0ndash63 mm

road gravel was crushed Smaller amountsof finer 0ndash6 mm 0ndash16 mm and 0ndash32 mm

aggregates are also being produced

The rainy summer increased the need

for road gravel along the muddy roadswhich must endure dump trucks weighing

as much as 260 tons

ldquoThe mobile process consisting of the

LT120 jaw plant and LT550GPF cone plant

is cost-effective while aggregates of vari-ous sizes can be produced in a two-stage

operation and with high capacity The con-trolled stroke and elliptical movement of

the FS screen secure big passing throughcapacitiesrdquo Kostamo explains

Operated in two shifts for a total of 16

hours per day the LT550GPF has logged

more than 600 working hours over a two-month period

Managing Director Aarno Kostamo (left) and foreman Karri Maumlenpaumlauml studying the cavity optionsavailable for the new Lokotrack LT550GPF

Longer perspective than

a single quarter needed

Kone-Kostamo Oy was founded as an

earth-moving company in Kemijaumlrvi

Northern Finland in 1956 The company

expanded its operations to include crush-

ing contracting in 1964 and later on

switched to concentrating fully on crush-ing activities

Kone-Kostamo consistently crushes

and screens around 28 million tons ofaggregates annually and has net sales of

between EUR 8ndash9 million

ldquoWe believe that issues within the crush-

ing industry including the purchasing ofmachinery must be studied with a longer

perspective than a single quarter The

secret to our success has always been our

solid work ethic and professional employ-eesrdquo Kostamo sums up

More info

Esa Berg

Tel + 358 40 837 8692

esabergmetsocom

8132019 Results Minerals Aggregates 3 2012ENG

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Monitoring-based reporting is vital for

assessing the performance of a mobile

crushing plant Metso provides suchreporting tools through its plant-wideautomation system Metso DNA (Dynamic

Network of Applications) with its infor-

mation platform that links all the mobile

crushing and screen units together as oneentity Basically there is a lot of measured

real-time information available in every

crushing plant On-line information is

obtained either from each Metso crusherrsquosmachine automation system IC (Intelligent

Controller) or from separately installed

additional sensors and belt scales

All the collected data is sent to a motorhome using wireless communication

based on WLAN technology The motor

home is a purpose-built environment

inside an on-site container In this environ-ment selected variables can be monitored

for assessing the plantrsquos performance And

to make all this even more flexible the

data can be transmitted to a crushing plant

company office using GPRS3G mobile

data communication technologies Thismakes all the last-minute reports acces-sible to the crushing plant managerial staff

at anytime and basically anywhere within

reach of the cell phone network

Production and fuel economics reports

Essentially monitoring and reporting can

be customized to fit the customerrsquos needs

However there are certain off-the-shelf

reports that provide a lot of useful informa-tion for plant supervision The production

report is one of these Requiring at least one

belt scale for measuring the total produc-tion the production report shows the pro-duction rate (tons per hour) for a selected

reporting period eg a day or a week The

production report constantly keeps track of

the plantrsquos production storing all the datathroughout the plantrsquos life cycle

Performance monitoring and reportingfor a mobile crushing plantTEXT Pasi Airikka PHOTOS Metso

unit during which the unit is running By

storing the availability times between start-ups and shutdowns the crushing plant

operation time (hours per dayshift) can be

recorded analyzed and reported In addi-

tion the availability report can be tailored

to evaluate efficient crushing hours during

which the plant is really working and pro-ducing aggregates Consequently the ratio

(0-100) between efficient crushing time

and total running time can be reported forany selected period of time This boosts

the efficiency of the plantrsquos operations

and results in better productivity

Reports on non-choke

or inadequate feeding

Non-choke feeding to crushers is avoid-

able through smart plant-wide crushingplant controls But estimating its severity in

a systematic manner is not straight-forwardwithout constant monitoring and reporting

The crusher choke feeding report makes

use of the crusher cavity level sensors byanalyzing their level measurements By

calculating average and min-max values

and deviations from the average it can be

shown how often the single crusher suffersfrom non-choke feeding to it

In some cases the bottleneck in the

crushing plantrsquos productivity is the material

feeding to the process In mobile plants thefeeding is human operated and therefore

subject to variations Occasionally the sizeof the human-operated machine simply

does not allow for adequate feeding to thecrushing plant There are specific reports

indicating time periods when the crushing

plant suffers from inadequate feeding

Condition monitoring for

crushers and screens

Machine-specific condition monitoring

focuses on vibrating components in

crushers and screens such as drive shaftbearings safety plate wearings and gears

The low middle and high frequencies ofmonitored components are measured and

supervised in real-time to detect abnor-malities due to slow or fast wear looseness

or imbalance

More info

Pasi Airikka

Tel +358 40 587 2730

pasiairikkametsocom

Condition monitoring provides a view tovibrating crusher and screen components forpredictive equipment maintenance

The daily production report shows the hour-by-hour production trend and distribution chartfor a selected day with min-max average andvariation statistics for comparison

Fuel consumption is always an interest-ing concern The fuel consumption reportgives the fuel consumption of each crush-

ing unit (liters per hour) and their total

consumption (liters per hour) for a selected

reporting period and can track fuel con-

sumption changes over timeCrushing plant availability can be

assessed as well The availability report

calculates time periods for each crushing

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983149983141983156983155983151 983150

for tissue machines The record of 2210

mmin was set on June 1 2012 during a

24-hour production run by the TM 2 tissue

machine at the companyrsquos mill in Yenikoumlynear the city of Izmit in Turkey

ldquoThe cooperation with Metso has been

beyond excellent and both parties did

their utmost to make the project success-ful The results clearly show that the efforts

were worthwhile on both sides This coop-

eration will extend to cover new projects

in the futurerdquo says Luumlt1047297 Aydin Paper GroupDirector Hayat Kimya

ldquoWe are not surprised that Hayat K imya

managed to break the world speed record

We have had great confidence in the capa-bility of the Hayat team since our project

started in 2009 We certainly know our

machine very well its stability production

efficiency and speed capabilityrdquo says Jan

Erikson Vice President Sales Metso

PowerThe worldrsquos first eco-gas fueled

power plant is up and running

Lahti Energy Ltdrsquos new Kymijaumlrvi II gasifica-

tion plant was officially inaugurated on

May 8 2012 It is the first of its kind in the

RecyclingRecycling with Lokotrack LT106

jaw plant in New York

A brand-new Lokotrack LT106 jaw plant is

used in the city area of New York USA to

recycle demolition materials The crushing

site faces the skyscrapers of ManhattanIsland

Paper amp FiberHayat Kimyarsquos Metso-supplied tissue

machine sets world speed record

Thanks to a skilled crew and dedicated

efforts Hayat Kimya AS in Turkey has suc-

ceeded in breaking the world speed record

world This CHP plant runs on clean eco-

gas that is gasified cleaned and cooled

from recycled waste with Metsorsquos innova-tive technology

ldquoItrsquos actually eco-gas that we combust

in the boilerrdquo comments Lahti EnergyrsquosProduction Director Jukka Manskinen

ldquoWe convert unwanted waste material into

energy in an efficient and environmentally

friendly wayrdquoNever before has any plant gasified

waste on such a large scale In the gasifier

recycled waste is turned into combustible

product gas which is cleaned cooled and

combusted in a high-efficiency gas boiler

to produce steam for the steam turbine The plant produces 50 MW of electricity

and 90 MW of district heat for the city of

Lahti and its neighboring areasMetso delivered the circulating fluidized

bed (CFB) gasification process gas cleaning

and cooling steam boiler environmental

protection system and automation systemto the entire plant The production of elec-

tricity and heat is kept even with the Metso

DNA automation system that covers the

whole plant starting from fuel reception

AutomationMetso develops and supplies plant-

wide crushing control solutions for

crushing plants

Metso has recently signed contracts on

delivering plant-wide automation systems

for mobile and portable rock crushing

plants The key objective of these deliveries

is to stabilize and to increase productivityand efficiency of the plants using one sin-

gle automation and information platform

for integrating crusher-specific IC machinecontrols

Furthermore the plant-wide system

with its information management tools not

only increases plant availability and opera-

tional safety it also makes troubleshoot-ing quicker and performance monitoring

easier The control room for plant-wide

operability is located either in an excavator

cabin or a purpose-built container

Metso around the world

The new LT106 jaw plant is suitable for crushing both hard rock and all rock-based demolition materials

The new world speed record for tissue setby Hayat Kimyarsquos Metso-supplied TM 2 is2210 mmin

8132019 Results Minerals Aggregates 3 2012ENG

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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: Results Minerals Aggregates 3 2012.ENG

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983150983141983159983155 983145983150 983138983154983145983141983142

Worldrsquos biggest mobile crushing plant sold to Kazakhstan

The Lokotrack LT200 weighingalmost 400 tons is the key part

of the system The unit processescopper ore with a nominal capacityof 2500 tons per hour

The Ferrexpo delivery includes 10 vertical grinding mills that will cut the

energy used in the grinding process by 30-50

Metso will supply

the worldrsquos largest fully

mobile track-mounted crushingplant to the Altay Polimetally LLP copper mine

in Kazakhstan The contract also includes large mobile

feeding and conveying systems to move the crushed copper

ore for further processing as well as installation supervision andtraining The complete value of the order exceeds EUR 11 million

ldquoWe see Altay Polimetally as a significant contract in an interest-

ing growing market area Today open-pit mines around the world

are assessing the possibility of saving costs and the environment atthe primary crushing and conveying stages by decreasing on-site

ore trucking With Metsorsquos large-scale fully mobile equipment we

can well meet this customer demandrdquo says Jorma Kempas Busi-

ness Manager In-pit Crushing Solutions Metso

The giant mobile jaw plant will be used in the primary crushingstage at Altay Polimetallyrsquos new open-pit mine in the Karagandy

region

Ferrexpo Poltavarsquos iron ore quality to be improvedwith a complete minerals processing system

Aiming to significantly improve the quality of iron ore produced

Metso will deliver a complete minerals processing system to Fer-

rexpo Poltava Mining Company in Ukraine The value of the order is

EUR 67 million including two previously signed orders worth EUR36 million

Metsorsquos delivery includes high-capacity vertical grinding mills

flotation cells magnetic separators pumps and a crushing and

screening system In addition to equipment the contract includesinstallation and commissioning supervision as well as a tailor-

made automation process control system

ldquoMetso and Ferrexpo have cooperated for more than 30 years

The target of Metsorsquos delivery is to help Ferrexpo Poltava to raisethe iron content in pellets to 65 Fe total and thus enhance the

companyrsquos competitiveness in global marketsrdquo notes Alexy Strikha

Country Manager of Metso Mining and Construction in Ukraine

Ferrexpo plcrsquos iron ore resources in Ukraine are among thelargest in the world

8132019 Results Minerals Aggregates 3 2012ENG

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983150983141983159983155 983145983150 983138

Metso has developedmill lining solutionsthat combine rubberand a variety ofsteel elements tooptimize the weightwear life and ease ofinstallation of linersystems

Metso Mining and Construction recently participated in two Euro-

pean exhibitions in Sweden and the UK unveiling its latest crush-

ing and screening equipmentMaskinExpo the biggest construction machinery exhibition

in the Nordic countries was organized on a golf course near

Stockholm Metsorsquos novelties included the diesel-electric Lokotrack

Exhibiting live at MaskinExpo and Hillhead

Metso is expanding its rubber mill lining production capacity glob-ally by investing in new presses to meet the growing demand in

the global mining market After completing the investment in 2015

Metsorsquos global rubber mill lining production capacity at the existing

wear parts manufacturing plants will increase 30 percent High-quality wear parts ensure mining process reliability at all times

Metso is purchasing straight grate iron ore pelletizing technologyand know-how from Jacobs Engineering Group Inc In addition

key Jacobs Minerals technical staff related to the technology will

become Metso employees as part of the deal

Iron ore pelletizing is used to produce pellets from concen-

trated iron ore for feed to blast furnaces and direct reduced iron

LT120E jaw plant the brand new LT106 jaw plant and the HP3

cone crusher

Hillhead the largest European quarrying and recycling ldquolivequarry showrdquo brought together a record number 17000+ visitors

At the event Metso presented its LT120 and LT106 jaw plants the

HP3 cone and the new C120 jaw crusher

The diesel-electric Lokotrack LT120 jaw plant exhibited at MaskinExpowas sold to the Swedish crushing contractor Johanssons Entreprenad

Metsorsquos crusher newcomers the HP3 cone and C120 jaw raised a lot ofinterest during the Hillhead quarry show in Buxton UK

Mill lining manufacturing capacity to be expanded

Iron ore pelletizing technology and know-how acquired from Jacobs Minerals

The investment totaling approximately EUR 10 million will becompleted in two phases The first set of presses is scheduled to

be in operation by the end of 2013 I t includes the installation of

presses in Chile Sweden Canada Mexico and Peru

plants Metso anticipates continued growth in this market as more

beneficiation and pelletizing plants are needed to maximize theoutput from lower grade ore bodies

Metso currently offers the grate kiln iron ore pelletizing system

With the purchase of straight grate technology from Jacobs Metso

will become the worldrsquos only supplier of both systems

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156983145983139983148983141

Metsorsquos mobile crushing and screening units are in the frontline in the demandingreconstruction efforts in Japan after the nation was ravaged by the biggest earthquakeand tsunami in its recorded history Tracked mobile Lokotracks are the quickest wayto boost the production of aggregates an estimated 200 million tons of which willbe required over the next decadeTEXT amp PHOTOS Eero Haumlmaumllaumlinen

The biggest gold producer in Europe

Agnico Eagle in Kittilauml Northern Finlandcurrently produces some 5000 kg of goldannually The mine plans to expand its daily

ore extracting capacity to 4000 metric

tons which will increase the gold produc-

tion by an additional 1000 kgOther major gold producers in Fin-

land include Nordic Minesrsquo Laiva mine

Endominesrsquo Pampalo mine Lappland

Goldminersrsquo Pahtavaara mine and DragonMiningrsquos Orivesi and Jokisivu mines

Metso with its crushing screening and

minerals processing equipment is a sup-

plier to most Finnish gold mines In addi-tion to the equipment Metso also offers

these gold-mining operations its process

planning expertise and services

New gold deposit discoveries likely

Senior Geoscientist Pasi Eilu from the Geo-

logical Survey of Finland believes that the

possibilities of finding new gold deposits

comparable to the current ones are good

Helping Japan to rebuild

after the tsunami

ldquoIn Finland gold has been found

wherever serious exploration has beencarried out The latest interesting depositshave been located by Mawson Resources

between Tervola and Ylitornio in Northern

Finlandrdquo

According to Eilu the latest findings onlyinclude gold ore exposed at the surface

ldquoIt is very likely that in the near future

gold will be found in the deposits hidden

completely undergroundrdquo he explains ldquoNextyear the Geological Survey of Finland will

publish an estimate on possible gold depos-

its reaching a depth of one kilometer from

the surface This will provide more accurateinformation on potential discoveriesrdquo

The average gold grade in Finnish gold

mines is similar to any gold mine abroad

ldquoThe most common type in Finlandis orogenic gold ore which is similar to

nearly all ores originating in West Austral-

ian and Ontario Canada We also have

volcanic-related gold deposits for example

in the Orivesi mine and small amounts of

gold deposits similar to those found in the

worldrsquos biggest deposits in WitatersrandSouth Africardquo Eilu adds

Focus on green mining

The Finnish Green Mining concept is the

mineral sectorrsquos answer to future chal-

lenges It aims to optimize material and

energy efficiency in the whole productionchain The program aims at efficient pros-

pecting for new deposits and at develop-

ing new solutions for utilizing them It

also aims to minimize local environmentalimpacts and problems to improve work

safety and the workplace atmosphere andto restore mining areas after mining opera-

tions are completed The Green Mining program started in

2011 The main objective is to make Finland

a global leader in the sustainable mineral

industry by 2020 The program encom-

passes two central themes intelligentminimum-impact mines and new mineral

resources

NorthernEldorado Today Finland together with the Nordic countriesfalls within one of the global areas that are experi-encing a gold exploration and mining boomIn recent years major global mining companieshave entered the country and opened gold mines

and they are now set to expand their on-goingoperations A number of promising explorationprojects are simultaneously under way on behalfof some 40 mining companiesTEXT Eero Haumlmaumllaumlinen PHOTO iStockphoto

8132019 Results Minerals Aggregates 3 2012ENG

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1

78

9

1011

12

13

15

16

18

19

2021

22

14

2

3

5

6

17

Active Mines and Current Projects February 2012

Kittilauml gold ndash Agnico-Eagle Ltd Pahtavaara gold ndash Lappland Goldminers Ab

Laiva gold ndash Nordic Mines Ab

Pampalo gold ndash Endomines AB

Orivesi gold ndash Dragon Mining Ltd Jokisivu gold ndash Dragon Mining Ltd

Iso-Kuotko gold ndash Agnico-Eagle Ltd

Hanhimaa gold ndash Dragon Mining Ltd

Kettukuusikko gold ndash Taranis Resources IncNaakenavaara gold ndash Taranis Resources Inc

Kiekeroumlmaa gold ndash Tertiary Minerals Plc

Rompasgold uranium ndash Mawson Resources Ltd

Suhanko-Konttijaumlrvi PGE ndash Gold Fields Arctic Platinum OyKuusamo gold ndash Dragon Mining Ltd

Hirsikangas gold ndash Belvedere Resources Finland Oy

Aumlngesneva gold ndash Belvedere Resources Finland Oy

Kopsa gold ndash Belvedere Mining Oy

Taivaljaumlrvi silver ndash Sotkamo Silver ABSeinaumljoki gold antimony ndash Nortec Minerals Corp

Osikonmaumlki gold ndash Belvedere Resources Finland Oy

Haveri gold ndash Lappland Goldminers Ab

Kaapelinkulma gold ndash Dragon Mining Ltd

1

3

5

7

15

11

19

9

17

13

21

2

4

6

8

16

12

20

10

18

14

22

Mine

Prospect

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156983145983139983148983141

The main minerals processing componentsincluding grinding flotation and pumping

equipment are delivered by Metso

983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

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983110983141983137983156983157983154983141983140 983137983154983156

Endomines

Pampalondash a green andresponsiblegold mineAt Pampalo near the easternmost point of Finland a cleanand environmentally friendly gold mining operation isbeing executed by Endomines With Metsorsquos plant designand a state-of-the-art processing plant Pampalo runs a

green and responsible yet at the same time profitablegold mining operation that avoids acid mine drainagesand targets 100 water recirculationTEXT amp PHOTOS Eero Haumlmaumllaumlinen

With a modest investment of EUR 20

million the Pampalo mine was built fully

operational and now produces 800ndash900 kgof pure gold annually An on-going expan-

sion will increase the minersquos production

capacity by 30 to 50 next yearIn addition to the main underground

mine at Pampalo several promising satellite

gold deposits are being investigated along

the long Karelian gold line The maximum

distance of the satellites is 30 km allowingthe mine to transport and process all of the

produced ore at the Pampalo plant

Small scale can be successful

with hard work

ldquoWith our gold mining operation we can

very well show that with hard work even

small-scale gold mining and production

can be done in a sound and profitable wayrdquosays Markus Ekberg CEO of Endomines

originally founded in Sweden

According to Ekberg the strategy when

building the mine was to split up the jobsinto small separate contracts Metsorsquos part

was the main minerals processing system gt

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156

Increasing capacity makes processing

of lower grades economical

The project to significantly increase the

processing capacity at Pampalo is well

under way with the installation of for

example a second grinding mill and more

flotation cells The expansion will be in

operation during early 2013ldquoThe added capacity also makes it pos-

sible to economically process the nearby

open pits with a lower gold grade In addi-tion it helps us to optimize the crushing

and grinding circuitsrdquo Ekberg concludes

Active exploration drillings have

exposed new mineralized zones furtherextending the lifetime of the Pampalo mine

from the present estimate of 6ndash7 years

More info

Peter Vikman

Tel +358 400 869 845petervikmanmetsocom

Endomines Pampalo gold mine

LOCATION near the community of

Ilomantsi in Eastern Finland

GOLD ORE CONTENT

ndash Pampalo 34 gtndash Hosko 99 gt

ndash Raumlmepuro 39 gt

ndash Muurinsuo 30 gt

PRODUCTION TONNAGE PER YEAR 270000 tons (present)~400000 tons (future)

GOLD PRODUCTION PER YEAR 800ndash900 kg

KNOWN ORE RESERVES IN TOTAL

approx 2 million tons

MINE DEPTH 360 m

MINING METHOD bench cut and fill

NUMBER OF EMPLOYEES

100 including contractors

METSO EQUIPMENT

1 Metso TRN 30 x 48 m

wet ball mill

8 Metso RCS series flotation cells 1 Nordberg MF 1800 x 6100

screen

3 Metso samplers

1 Metso CT thickener

1 Metso TF vacuum filter

33 Metso slurry pumps of various

types and sizes

The gold ore is screened using Metsorsquos MS series mining screen

Markus Ekberg is pleased with the outcome the mine reached the minerals processing utilizationdegree of over 90 just two months after start-up

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156983145983139983148983141

Nordic Mines ndash on track tobecoming one of Europersquosmost prominent goldproducersNordic Mines is the newest member in a long chain of Nordic gold mining operations

Inaugurated in mid-August 2012 this company of Swedish origin aims to become one

of Europersquos most prominent gold producers Metso is one of Nordic Minesrsquo main partners

supplying the Laiva gold mine with crushing screening conveying and minerals

processing equipment at an estimated value of EUR 30 million

TEXT amp PHOTOS Eero Haumlmaumllaumlinen

2983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

The Laiva gold mine was built in record time infrastructure

construction began in spring 2010 ore excavation started in

June 2011 and the first gold bar was casted in December 2011

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156

Just one year after starting the gold recov-

ery process Nordic Mines is on track toreaching a capacity of 5 kg of gold per day

At present the operations are averaging 3

to 4 kg of gold daily

The ore in the Laiva Gold Mine consists

of packages of gold-bearing quartz-filled

shear structures The deposit is more thana kilometer long and 700 meters wide The

total depth is still unknown but dr illings

carried out thus far have shown gold-bear-ing shear structures 300 meters below the

surface

A typical ore zone includes a large num-

ber of thin shear structures from 5 to 30per meter The ore zones are commonly 50

to 100 meters long several are 10 meters

deep and they range from a few meters to

20 meters cross strike The minimum min-ing width is 25 meters which means that

even a minor ore zone consists of at least10 to 50 shear structures

Conventional pattern blasting

with selective loading

Prior to mining Nordic Mines conducts

grade control drilling which provides

dense gold grade information and makes

it possible to outline the boundaries

between ore and waste The mining

technique applied is conventional pattern

blasting with selective loading This is oneof the most commonly used techniques in

large-scale open-pit mining

A typical blast in the Laiva mine is 50

meters long 100 meters wide and 5 metersdeep After blasting ore and waste aremined by selective loading

After investing some EUR 100 million

the Laiva mine now comprises an open-pit

mine with a modern complete crushinggrinding and processing circuit that ends

with the casting of gold doreacute bars

With a number of mine staff partners

sub-suppliers city and state officials inattendance the Laiva gold mine was offi-

cially inaugurated on August 16 2012

Michael Nilsson Managing Director

of Nordic Mines stressed in his speechthe importance of overcoming challenges

during the building of the mine

ldquoObviously the whole development

took us longer than expected Today weare pleasantly surprised by the size of our

operation We are becoming much bigger

than expectedrdquo gt

Chief Geologist Kimmo Lahtinen presenting narrow gold veins twisting at the Laiva North open-pit mine

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156983145983139983148983141

An international process package

The Metso package for the Laiva gold mine

included the main crushing screening

conveying regrinding leaching and pump-ing elements Metsorsquos office in Sala Swe-

den has served as the main project office

with Metso manufacturing units in FranceGermany Sweden and Finland responsiblefor the equipment supply

At Laiva the gold ore is classified after

selective excavating into two gold con-

tent classes All class A gold ore is takento Metsorsquos sturdy jaw crusher for primary

crushing while the class B ore is stocked for

possible future use After primary grinding

utilizing autogenous technology the ore is

screened and two Metso cones crush the

oversized pebbles For regrinding Metsorsquosball mill is used

During high- and low-grade leaching

processes a number of Metso pumps and

dewatering screens are used The whole

minerals processing system is controlled byMetsoDNA automation

Active exploration drilling going on

According to Mine Manager Tom Soumlder-

man the known gold ore reserves at the

Laiva gold mine amount to 169 million

tons but the potential for additional find-

ings looks good

ldquoWorking at the level of two million tonsper year our expected lifetime is about nine

years We carry out active exploration drill-

ing in Kaukainen Musunneva and Oltava

to locate nearby satellite ore bodies Anupdated detailed mine life plan will be pre-

pared during the autumnrdquo Soumlderman saysNordic Minesrsquo other exploration areas

include Tormua in Finland and Fjaumllltuna

and Vassbo in Sweden

More info

Alf Rydberg

Tel +46 70524 5837

alfrydbergmetsocom

Happy faces during the minersquos inaugural ceremony Mine Manager Tom Soumlderman (left) with Managing Director Michael Nilsson and Deputy Managing Director Krister Soumlderholm

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156

The story behind the discovery of the Laivamine is an interesting one During a hunt-

ing trip in the remote forests of Laivakan-

gas in 1979 Pentti Jaumlmbaumlck found an inter-esting-looking piece of stone Although hecould not see the gold hidden inside the

rock Pentti noticed the striking weight

and somewhat different look of the stone

Upon returning home Pentti sent thesample to Outokumpu which at the time

was the leading state-owned mining com-

pany in Finland After testing a high gold

content of 15 grams per ton was found

Gold deposit founded by a hunter

The founder of the Laiva gold deposit Mr Pentti

Jaumlmbaumlck was the guest of honor during theinauguration

Lennart Schoumlnning Chairman of the Board ofNordic Mines holding a gold doreacute bar worthsome EUR 320000

Outokumpu registered a mining claimon the area and conducted a series of

exploration drilling from 1981 to 1987 Due

to the low price level for gold no mine wasstarted at the time Other mining compa-nies such as Endomines held the mining

rights later

Nordic Mines with its sights set on

locating and exploiting gold in Swedenand Finland was founded in 2005 During

the same year the company purchased its

first mining rights at Laiva

Nordic Minesrsquo Laiva gold mine

LOCATION near the city of Raahe

northwestern Finland

GOLD ORE CONTENT average 16 gt

ORE EXTRACTED PER YEAR

12 million tons (present)

20 million tons (planned)

GOLD RECOVERY 85

TOTAL KNOWN ORE RESERVES

169 million tons

MINING METHOD

Selective open-pit benchingNUMBER OF EMPLOYEES

130 including contractors

METSO MAIN EQUIPMENT

2 Metso VF and 6 EMEG EME

vibrating feeders

8 Screens 1 MF 1 CVB and 6 KS

1 RCS Flash flotation unit

1 Metso SRR ball mill 18 x 4 m

1 Nordberg C160 jaw crusher

1 Nordberg HP100 cone crusher

1 Nordberg HP200 cone crusher

5 Nordberg NB series conveyors

73 Metso Slurry pumps ofvarious types and sizes

8132019 Results Minerals Aggregates 3 2012ENG

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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155

The newest member of the proven GP series cone crushers ndash theNordberg GP220 ndash offers a versatile alternative for any demanding

tertiary or quaternary or even secondary crushing operation fulfill-

ing all crushing needs and maximizing customersrsquo profitability

High-quality components and optimized castings and forgings

contribute to the GP220rsquos enhanced reliability and help to ensurethe highest level of crusher uptime

Thanks to the 200 kW (270 hp) power draw the GP220 performs

at a 20 to 30 percent higher capacity than other cone crusherbrands with an equal head diameter The large feed openingenables the feeding jaw crusher to run at 110 mm css Operational

flexibility is ensured by multiple strokes and six different cavities

Secondary crushing possible

thanks to cavity and stroke options

Thanks to the GP220rsquos cavity and stroke options secondary crush-

ing in addition to tertiary and quaternary stages is also possible

using cavities with a greater intake opening With the GP220 a suit-

able solution for producing excellent end-product gradations

can always be found

With advanced automation using IC50 or IC5000 operation

is safe and trouble-free The low height thanks to the patented

piston design makes replacement installations much easierA dynamic setting adjustment enables a fast response to process

optimization needs

The Nordberg GP220 weighs 10500 kg (23150 lbs) and hasa maximum real feed size of +200 mm (8rdquo) with strokes from

18ndash40 mm (57rdquondash1 47rdquo) The cavity options are EF F MF M C

and EC

A complete modular crusher steel structure is available for allGP series stationary installations including GP220 The platform

includes places for the lubrication unit motor automation or

pressure accumulator and pressurized sealing The only things

left to add are the feed and discharge conveyors

Main new features of the GP220 Large feed opening allows for secondary stage operation

Longer setting range of main shaft for better wear parts utilization

Stronger main components to carry high loads with a powerdraw as high as 200kW

More info

Hannu Vakkuri

Tel +358 50 317 0638

hannuvakkurimetsocom

Thanks to the large feed opening and wide selection of strokes and cavitiesthe new Nordberg GP220 cone crusher is a highly versatile cone novelty

More versatility with the newNordberg GP220 cone crusher

Reinforced head and frame castings combined with a 200kW power

draw make the GP220 cone a reliable crusher with maximum productivity

8132019 Results Minerals Aggregates 3 2012ENG

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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156

Metsorsquos HRCtrade takes high pressure grinding roll technology to the next level

The new Lokotrack mobile conveyors come as tracked and wheeled models

Metsorsquos latest development in comminution equipment the HRCtradeis a major step in the profitable application of high-pressure grind-

ing roll (HPGR) technology Metso has made several key innova-

tions in order to increase throughput and decrease the total cost

of operation

Metsorsquos patented Arch frame creates an even gap setting acrossthe width of the tires limiting skewing that can result in downtime

for mining operations This anti-skewing Arch frame also prevents

damage to the roller bearings (caused by misalignment) that canoccur with the traditional HPGR design

Flanges maximize wear life and increase throughput

Used in place of spring-loaded cheek plates the flanges keep thebed of material within the crushing zone and prevent material

from bypassing the tires This enables greater circuit capacity and

increases the overall crushing efficiency

In addition by preventing material from bypassing the tires

even pressure across the width of the tire is better maintained

Distributing the pressure more evenly maximizes the tire life bypreventing a ldquobath tub effectrdquo in which the center of the tire wears

faster than the edgesVictoria Herman Metsorsquos Product Manager for the HRC notes

that this breakthrough design is a response to the growing needs

in the mining industry ldquoEnergy efficiency has been attracting our

customers to HPGR technology for yearsrdquo she says ldquoBut our design

concept increases capacity and crushing efficiency ndash and thatrsquossomething mining companies are always looking to improve onrdquo

The track-mounted Lokotrack CT32 and wheel-mounted Lokotrack

CW32 mobile conveyors offer an ideal solution for applications

that require high stockpile capacity and excellent material transfer

capabilities They also add flexibility to multi-stage crushing andscreening applications enabling easy and fast closed-circuit opera-

tion of mobile units

The conveyor novelties can be used in both mobile and station-

ary installations providing extra stockpiling capacity in situationswhere for example fewer wheel loaders are available

The HRC is ideal for high-tonnage hard rock applications andcan be used as a tertiary quaternary or pebble crusher Currently

several HRC units are in operation around the world ndash with a total

of 6500 operating hours including over 3800 hours in a mininghard rock application The machine does have range within hardrock applications itrsquos been designed for use in diamond iron ore

copper gold platinum and various industrial minerals

More info

Victoria Herman

Tel +1 717 309 1150

victoriahermanmetsocom

Several optional features such as hydraulic folding of tail sections

and dual hydraulic drive for increased throughput are available

The capacity of the CT32 and CW32 is 400 mtph (440 stph)feed size up to 150 mm (6rdquo) belt width 1050 mm (42rdquo) and dis-charge height 9120 mm (29rsquo 11rdquo) The CT32 is fitted with a Caterpil-

lar C2 diesel engine with 38kw (51 HP) power The CW32 is avail-

able for hydraulic or electric use

More info

Kimmo Anttila

Tel +358 50 433 3745

kimmoanttilametsocom

The new HRCtrade combines high crushing pressure and a low circulatingload resulting in the most efficient comminution

When flexibility in stockpiling capacityis required the answer can be foundin the new Lokotrack CT32 and

CW32 mobile conveyors

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Service creates value in ChinaChinarsquos most important gold producing area Yantai in northeastern China supplies more than 16 of the countryrsquos goldproduction each year With the gold market thriving the scale of gold production in Yantai has been expanding constantly

Zhongjia Mining Industry Co Ltd is one of the beneficiaries of this thriving industryTEXT amp PHOTOS Yan Xin

Inspection and maintenance of the HP500 cone crusher conducted by Metsorsquos service engineers

In 2011 Zhongjia Mining Industry pur-

chased a modular crushing and screen-ing system from Metso for its new gold

production project With the cooperation

between the two companies continuously

intensifying Zhongjia Mining Industry

signed an additional one-year Life CycleService (LCS) contract with Metso incorpo-

rating Metsorsquos global knowledge in equip-

ment processes and services

ldquoMetso customized a series of reason-

able service solutions also referred toas Metso Performance Solutions for us

including preventive maintenance services

process improvement personnel training

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155

and a procurement plan for wear parts

These really suit our needs perfectlyrdquo saysShen Yidong the Manager of ZhongjiaMining Industry

Effective preventive maintenanceFor mining corporations the biggestconcern is the economic losses caused by

the shutdown of equipment As a result

preventative maintenance is of vital impor-

tance During the contract period Metsoservice engineers offered 7-day tracking

service on the production site every month

to eliminate potential problems and thus

ensured the stability of the system

parts caused pressure on our working capi-tal which was not favorable for our long-

term developmentrdquo Shen explains

To solve this problem Metso designed

a rational stock plan of wear parts and built

a field warehouse In accordance with theuse and consumption of the liners the field

service engineers complement the stock tomake production and operations run more

smoothlyldquoNow when we need to replace the

wear parts we can use them before pay-

ment This not only simplifies the procure-

ment process but also liberates a largesum of our operating capital which can

be used for other business development

purposesrdquo says Shen

Best partner

ldquoAlthough the LCS contract incurs some

early purchase costs in the long run Metsorsquosprofessional and quality service will improve

the equipment efficiency reduce ourenergy consumption and ensure stable

operations thus generating more prof-

its This is the greatest value for us so the

investment is really worthwhile overall Inthe future we will choose more Metso prod-

ucts and services Taking all aspects into

consideration we believe Metso is the best

partner for usrdquo Shen Yidong concludes

More info

Thomas Bai Tel +86 13801009114

thomasbaimetsocom

ldquoIn the eight months since the contract

came into effect our corporation has notsuffered any financial losses due to equip-

ment breakdown The regular maintenance

has greatly improved the efficiency of our

entire crushing system In addition the

experienced engineers from Metso also

provided onsite training and guidancefor our staff and the tailored training has

greatly enhanced the operating abilities of

our employees and upgraded their overalllevel of competencerdquo says Shen Yidong

More productivity with

less consumption

Metsorsquos service contract focuses on real-

izing the optimum performance of each

process flow After analyzing Zhongjiarsquos

production system Metsorsquos techniciansproposed an adjustment to the closed side

setting of the HP500 for tertiary crushingin order to improve the efficiency of the

downstream fine crushing and milling pro-

cessing by over 10ldquoThe process flow improvement solu-

tions provided by Metso not only increased

the output of our gold concentrates but

also reduced our energy consumption andcostsrdquo says Shen

In the past wear parts procurement

took up a larger proportion of Zhongjiarsquos

total production costsldquoTo avoid downtime caused by the

shortage of wear parts we had to keepeight sets of various wear parts in place

However the cost of having so many wear

Zhongjia Mining Industryrsquos gold concentrates processing plant in China

8132019 Results Minerals Aggregates 3 2012ENG

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0983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

Safe quarrying high-

quality aggregates

8132019 Results Minerals Aggregates 3 2012ENG

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ldquoWe share a similar zero-accident strategy and target with Metso and have successfullyfollowed it Metso has also helped us to meet the strictest end-product quality andcubicity requirements set in Spainrdquo This is how Managing Director Intildeigo Ajuria ofOfitas de San Felices the leading hard rock quarrying company in Spain describesthe cooperation with MetsoTEXT Eero Haumlmaumllaumlinen PHOTOS Ofitas and Eero Haumlmaumllaumlinen

The San Felices quarry is situated in a picturesque mountainous landscapebetween the companyrsquos Rioja vineyards and the Bilbao-Madrid motorway

8132019 Results Minerals Aggregates 3 2012ENG

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Ofitas has pioneered the implementation

of several Metso novelties in the Spanish

market The company was the first to use

efficient large track-mounted Lokotrack jaw plants the unique mobile conveying

system and also the new-generation HP4

cone crushers

Today the company operates twomodern Metso stationary plants one in

Guadix near Granada and the newest one

in San Felices Haro Rioja community Both

quarries focus on refining hard rock by pro-cessing ophite rock into the highest quality

railway ballast asphalt and concrete mix

grades The company has a satellite quarry

near Vitoria in PentildeacerradaBeing situated next to a highway and

the famous Rioja vineyards Ofitas must pay

special attention to environmental issues

To minimize dust problems all conveyors

have special covers attached

Quality durability and service

The cooperation between Ofitas de San

Felices and Metso started back in 1973when the Ajuria family bought the com-

pany whose quarrying activities began in

1919 Intildeigo Ajuria has a clear vision of why

the cooperation has continued withoutinterruption for almost 40 years

long-standing personal relationshipsrdquoAjuria adds

Serving railways asphalt

and concrete producers

The year-old San Felices stationary instal-lation lies hidden in a mountainous area

south of the city of Vitoria in NorthernSpain The new plant replaces an old one

that complicated the extraction of ophiterock Both plants are delivered by Metso

With its two separate production lines

the new plant is able to produce all the

end products required ndash from railway bal-last to the finer grades needed for asphalt

and concrete

Due to lower demand the quarry cur-

rently produces some 4000 tons per day

At full capacity however the plant canreach 8000 tons of production per day

30ndash35 of which consists of railway ballastfor high-speed trains and 65ndash70 of chips

and sand Thanks to the versatile two-line con-

cept connected by transverse conveyors

up to 12 different end products can be pro-

duced Depending on the demand for endproducts the material can be guided either

to the HP4 cone or HP400 cone followed

by a Barmac vertical shaft impactor

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

The ophite feed is fed to the C125 jaw crusher by a sturdy dump truck

The key people running the new San Felicesquarry Mine Engineer Carlos Fernandez (left)Managing Director Intildeigo Ajuria with ProductionManager Julian Perez

ldquoThrough the years Metso machinery

has proven its production capacity and

durability resulting in high-quality end

products A big plus for us has also beenthe quick response time to our process

challenges or servicerdquo

ldquoIn fact our cooperation extends

beyond day-to-day business matters to

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155

Meeting the strictest cubicity demands

The Spanish regulations concerning end-product cubicity are becoming more

demanding The flakiness percentage of

railway ballast must be below 10 and for

asphalt and concrete aggregates less than

15

ldquoWith Metsorsquos HP4 cone and the Barmacvertical shaft impactor we can meet even

the strictest cubicity demands We believe

that our high quality is helping us to sur-vive in the present recessionrdquo notes Mine

Engineer Carlos Fernandez

ldquoWe hope to increase the total extrac-

tion of the three quarries from the present15 million tons per year because our plant

capacity allows more than double thatrdquo

Fernandez adds

More info

Angel Luis Garcia Tel +34 686 94 35 30

angelluisgarciametsocom

In addition to being the leading Spanish

quarry to process hard rock Ofitas de SanFelices also cultivates 34 hectares of vine-yards next to the quarry which is situated

in the famous Rioja wine area

The company has previously sold a

harvest of over 200000 kg of Tempranillo

grapes to local red-wine makers Recentlythe company built its own wine process-

ing plant to process 10000ndash15000 kg of

grapes themselves

Aggregates and wine production

Andoni Ajuria the founder of Ofitas de san Felices (left) with Intildeigo Ajuria the present ManagingDirector tasting wine from the companyrsquos own vineyards

The first vintage wine of Ofitas har-

vested in autumn 2010 is now maturingin oak barrels After maturing for 12 to 15months the wine is called crianza and after

two years it will be granted the classifica-

tion reserva

ldquoWinemaking is not a business but

a hobby for us We give our wine out aspresents and drink it when we meet

our suppliers and friendsrdquo Intildeigo Ajuria

comments

For environmental protectionall of San Felicesrsquos plantconveyors are covered

Ofitas de San Felices quarry

LOCATION Haro near the city

of Vitoria northern Spain

SIZE 100 hectares

ROCK TYPE Ophite with Los Angeles

index of 9ndash10

PRESENT DAILY EXTRACTION 3000 tons

of ophiteNUMBER OF PERSONNEL 30

RESERVES 10 million tons

MAIN END PRODUCTS 0ndash2 mm

2ndash4 mm 4ndash10 mm 10ndash16 mm

16ndash22 mm 25ndash60 mm (ballast)

METSO MAIN EQUIPMENT

VF feeder

C125 jaw crusher

ndash feed size 0ndash800 mm

ndash css 130ndash140 mm

HP400 cone crusher

ndash feed size 80ndash250 mm

ndash css 40 mm HP4 cone crusher

ndash feed size 40ndash80 mm

ndash css 15 mm

Barmac 6150 VSI crusher

4 CVB2060 screens

2 TS32 screens

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Metso Distribution Centers he

Europe (Tongeren Belgium)

France (Macon)

Czech Republic (Přerov)

Austria (Vienna)

2271 d

Brazil (Sorocaba SP)

1014 d

USA (Columbia SC)

1690 d

USA (Waukesha WI)

434 d

South Africa (Vereeniging)

Ghana (Tarkwa)

Meacutexico (Irapuato)

Peru (Lima)

Chile (Concoacuten)

788 d

Sweden ( Trelleborg)

Finland (Tampere)

UK (Rugby)

865 d

Russia (St Petersburg)

Brazil (Parauapebas PA)

206 d

4983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983122983141983152983151983154983156983145983150983143 983154983141983155

In the case of an equipment failure or

a planned service shutdown resuming

production as quickly as possible is crucialEach hour spent waiting for a spare part to

arrive equals money lost Whether the right

part takes 12 or 48 hours to arrive really

makes a difference

The comprehensive and global Metsospare and wear parts service network pro-

vides you with the right part in the right

place and at the right time Our strategi-

cally located Distribution Centers and

Satellite Warehouses are on call 24 hoursa day 7 days a week ensuring efficient

parts replacement near you

Check out the locations of the MetsoDistribution Centers and how many parts

pass through them each day

More info

Marcelo Farah

Tel +55 15 2102 1315

marcelofarahmetsocom

you minimize downtime

Australia (Perth)

746 d

China (Tianjin)

China (Kunming)

China (Shanghai)

393 d

India (Faridabad)

India (Ahmedabad)

India (Hyderabad)

India (Bhubaneswar)

India (Bangalore)

419 d

Russia (Yekaterinburg)

Australia (Newcastle)

New Zealand (Matamata)

983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088

TEXT Sofia Williams

Singapore (Singapore)

Distribution Center Satellite Warehouse

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Following a large investment

in Metso crushing equipmentand services Buena Vista del

Cobre is now expanding the

mine site to include even more

equipment ndash and with thatexpansion comes the need for

more local service resources

Metso and Buena Vista del

Cobre have entered into a Life

Cycle Service agreement forthe plant and construction of a

brand new Metso service hub

is under way in Cananea

New facility new

level of service

The Cananea service hub

which will be up and running in early 2013will support the recent expansion and resur-

gence of Buena Vista del Cobre Initially it

will be a major repair and assembly center

for pumps crushers and screens and will

provide for rubber covering capabilitiesBut the 8000-square-meter facilityrsquos service

offering will be expansive including a con-

signment stock inventory to help serve theminersquos varying needs Metso currently has

50 service team members on site

Although Buena Vista del Cobre was a

key influencer in building the new servicehub this location will also enable Metso to

expand its capabilities and provide local

support to the entire mining community

in northwest Mexico The Cananea hub

will serve a number of major copper and

gold mines in the region including MineraFriscorsquos San Felipe Fresnillorsquos Milpillas and

Grupo Mexicorsquos Mexicana de Cobre

ldquoBuena Vista del Cobre is the biggestcustomer we have in Mexico today and

with this expansion project itrsquos only going

to grow and be strongerrdquo says Felix Forna-

guera Director of Services Mexico CentralAmerica and Caribbean ldquoWith that said the

idea behind the Cananea service hub is to

provide a central location for local support

for all our major customers in the areardquo

Establishing safety

ldquoIt was key to have our support here in

Cananea because the Buena Vista delCobre started from the ground uprdquo saysFelix ldquoWersquove been able to help the cus-

tomer to establish the best in support

service and operations from the very

beginningrdquo And this ground-up approachincluded a major focus on safety

Metso worked closely with Buena Vista

del Cobre to establish the safety proto-

col by which the mine operates Basedon Metsorsquos expertise the safety measures

put in place have enabled the mine to

become strict and efficient in its operations

and maintenance procedures To achievethis Metso worked closely with local andnational authorities to ensure the safety

plan was comprehensive and in accord-

ance with all established legal bodies

The best in regional support

The service hub in Cananea is a prime

example of Metsorsquos focus on providing local

service and support to its customers all

Service shines in Cananea MexicoAfter three years of inactivity the Buena Vista del Cobre mine in Cananea Sonora Mexico has been operational since 2010A mine that was inactive for such a significant amount of time however requires a great deal of support to successfullyrestart the plant and bring it back to an operational and profitable state

TEXT Deanna Lee PHOTO Metso

over the world ldquoWe are the first

company developing this kindof service in northwest Mexicordquo

adds Felix ldquoOur people have

developed a close relationship

with the team at the mine Itrsquosmore than a supplier relation-

ship our guys are inside the

mine living and working thererdquo

In fact this is the model

that Metso is using in servicehubs all over the globe build-

ing modern facilities bringing

teams on site and workinghand in hand with mine

operators The Cananea Service

hub is only the most recent

example of Metsorsquos commit-ment to service and northwest Mexico is

yet another mining hotbed thatrsquos going to

benefit from the companyrsquos support

More info

Felix Fornaguera Tel +52 4621079227

felixfornaguerametsocom

A mining cone serviced by Metso at the Buena Vista del Cobre mine inSonora Mexico

ldquoThe new Cananea service center will be a majorrepair and assembly center for pumps crushersand screensrdquo says Felix Fornaguera Director ofServices Mexico Central America and Caribbean

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

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During the MINExpo exhibition over 1300 people visited the Metso stand

983122983141983152983151983154983156983145983150983143 983154983141983155

Held every four years MIN-Expo consistently grows so

perennial exhibitors like Metso

are challenged with elevating

their presence and drawingin new (and greater numbers

of ) visitors each year ldquoItrsquos not

necessarily a challenge to lsquotoprsquo

our last showingrdquo says Keith

Ference Vice President ofmarketing and communica-

tions North America ldquoThere

are four years between eachMINExpo so we always have

a lot to say and reveal to our

customersrdquo The real challenge

he says is finding an exciting

and dynamic way to deliverthe message ldquoTherersquos so much

to see here so your booth has

to be compelling from the

outside-in and thatrsquos what

we always try to dordquo

Service sets the stage

The Metso booth created buzzin a number of ways and per-

haps the most striking (partly

due to its size) was the live

theater presentation As visitorspassed through the aisles of the show-

room the sights and sounds from Metsorsquos

theater were hard to miss And once guests

entered they were captivated by a short

high-energy video presentation focused

on Metsorsquos service capabilities The message was simple Metso is ldquoyour

local service partner rdquo for all mining and

construction needs The video showed ourservice teams in action all over the world

and the audience came away with an

understanding about Metsorsquos commitment

to service Customers can count on morethan 70 local service centers run by more

than 1700 expert technicians delivering

Metso makes an impact at MINExpo 2012At this yearrsquos MINExpo International nearly 60000 attendees flocked to Las Vegas Nevada the largest turnout in showhistory The visitors ndash mining professionals from all over the globe ndash explored 850000 square feet of showroom spacefeaturing the industry rsquos latest technology equipment products and services They toured the show for three days

seeking the latest and greatest from more than 1800 exhibitorsTEXT Keith Ference PHOTOS Tracey Ford Perry

detailed descriptions andphotos of all of Metsorsquos mining

and construction products and

services The app also provides

digital access to Results and asearchable database of sales

contacts By day three of the

show MetsoMAP had been

downloaded by more than

500 usersIn addition to the app the

booth was equipped with

several LCD screens each con-trolled by Metso experts who

used their iPads to present new

products like the Megalinertrade

and the HRCtrade A featured

presentation on Metsorsquos lineupof energy-efficient comminu-

tion equipment including the

VERTIMILLreg SMD and MP-1250

cone crusher was also avail-

able letting customers seehow Metso technology delivers

some of the worldrsquos most effi-

cient size reduction

Measuring MINExpo success

After a very busy three days

(on top of months of prepara-tion leading up to the show) everyone

involved with MINExpo ndash from the North

American marketing team responsible for

the booth to the product managers and

sales force that worked the floor ndash is view-

ing the show as a success ldquoTherersquos alwaysa sigh of relief after each (MINExpo)rdquo says

Keith ldquoAnd overall the initial feedback

and response has been very positiverdquoWith more than 1300 visitors to the

booth Metso certainly made an impact

ldquoWe learn a lot from each show and with

some time wersquoll have a better understand-ing of the tangible results of our effortsrdquo

Keith adds

reliable service for mining equipment as

well as customized cost-effective life-cycle

services contracts

Technology ndash MetsoMAP

is an industry firstMINExpo provided the industry with its firstglimpse of Metsorsquos revolutionary iPad app

MetsoMAP The app was demoed to the

boothrsquos visitors via ldquothe worldrsquos largest iPadrdquo

a custom-made 80-inch screen that show-cased all of its capabilities most of which are

groundbreaking in the industry MetsoMAPrsquos

simple interface is highly intuitive making

it easy to view process animations videos

The presentation of the new HP cone crusher attracted a large audience

8132019 Results Minerals Aggregates 3 2012ENG

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When yoursquore allowed less than a dozen days per year for breakdowns repair andmaintenance every single hour during a service shutdown counts There simplyisnrsquot any room for surprises Thatrsquos why Boliden counts on MetsoTEXT amp PHOTOS Sofia Williams

8983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

Kurt Kalla Site Managerof Metso Gaumlllivare ServiceCenter is responsible forthe maintenance of Aitik

Metso and Boliden Strivingtogether for 97 uptime

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155

One of the biggest copper mines in

Europe Bolidenrsquos Aitik is located deep inthe wilderness of Swedish Lapland next to

the small town of Gaumlllivare The mine has

been operating since 1968 and a recent

expansion has increased its annual ore

production to 36 million tons

But the ambitious Swedes are not will-ing to lay back and relax just yet Bolidenrsquos

new aim is to reach a production rate of

45 million tons of ore per year in AitikAfter that Perhaps more than 55 million

tons The ore concentration in Aitik is very

low-grade with a mere 022 copper con-

tent hence the need for high capacityAchieving the ambitious production

goal requires maximum plant availability

This means that everything from the crush-

ers to the filters must be up and runningfor approximately 97 percent of the time

Thatrsquos where Metso comes into play

A cost-per-ton contract in action

The maximum uptime requirement allowsless than a dozen days per year for break-

downs repair and maintenance at Aitik

Every single hour during a service shut-

down counts There simply isnrsquot any roomfor surprises

Executing a successful shutdown under

such conditions requires a reliable service

partner not afraid of challenges and this iswhy Boliden has entrusted Aitikrsquos services

operations to Metso Boliden and Metsohave worked together since the 1960s

and the collaboration took another step

forward in September 2012 when the twocompanies signed a three-year extension

of the services contract for Boliden Aitik

ldquoThe new contract is a cost-per-ton

agreement We get paid based on Aitikrsquos

production Itrsquos a win-win deal for both par-

ties but also a new mindset for usrdquo explainsKurt Kalla Site Manager of Metso Gaumlllivare

Service Center responsible for serving Aitik

From now on the duration of the shut-down is what matters the most According

to Kalla the Metso service organization in

Gaumlllivare is now streamlining its operations

to fit the bill and has already witnessed thestrategy working In August 2012 Metso

carried out a 188-hour service shutdown in

Aitik which turned out to be a success

Zero tolerance for injury

One key factor to the success was theextensive planning of precautionary health

safety and environment procedures under-

taken by Metso prior to the shutdown Thanks to strict measures applied no

injuries or accidents occurred during the

shutdown and the work could easily be

finished on scheduleMats Johansson Health Safety

and Environment Manager for Metso in

Sweden explains how this was achieved

rdquoPlanning of the shutdown included arisk analysis for all new tasks participating

in Bolidenrsquos safety coordination meetingsmeeting with both Metso supervisors and

subcontractor supervisors and finally a

meeting with the entire staff participating

in the shutdown where everyone had to

sign a document stating their commitmentto the information providedrdquo he says

During the actual shutdown plenty of

new barriers signs and awareness cones

were put in place as a result of observa-tions from previous audits and safety plans

and risk analyses were readily available

in the work area Metso and Boliden also

introduced a Mill Inching permit a certifi-cate for completing a mandatory course for

those involved in the process In addition

Metso carried out random safety audits

during the shutdown to make sure thestrict policy was followed

According to Boliden Metsorsquos way of

working is a good example of how health

and safety precautions should be handled

ldquoMetso is a good example of how towork with safety and health plans risk

analysis permits and welding permits

Their table with all binders in the second-

ary mill area was exemplaryrdquo says Kjell-Arne

Johansson a technician from Boliden

The use of the new Metso Megalinertrade

system in the lining of Aitikrsquos Metso AG

mills has also improved the safety of main-tenance staff The Metso Megalinertrade con-

sists of larger-than-average liners bolted

in position from outside the mill Mainte-

nance technicians no longer need to go

inside the mill and stand in the dangerousdrop-zone of the liners gt

Boliden aims to reach a production rate of 45 million tons of ore per yearin the Aitik mine site

ldquoA complete risk analysis was conducted during the planningof the shutdownrdquo comments Mats Johansson Health Safetyand Environment Manager for Metso in Sweden

8132019 Results Minerals Aggregates 3 2012ENG

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Service the Metso way

24 hours a day 365 days a year

In addition to paying close attention to

health and safety issues executing an effi-

cient shutdown requires careful planning

and timing of every step in the mainte-

nance process Wear and spare parts have

to be available on time and a repair shoplarge enough to accommodate equipment

located close by

ldquoTo keep maintenance breaks as short

as possible we aim to replace the pump on

site and bring the old one for repair to our

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

nearby facilities This method gives us the

peace to do a good job and keep the cus-

tomerrsquos operations runningrdquo Kalla describes

the Metso way of handling Aitikrsquos pump

maintenance

Metso is currently expanding its Gaumllli-

vare service center to include a distribu-

tion center for wear and spare parts andalso concentrating its previously scattered

operations under one roof in its Vuoskon-

jaumlrvivaumlgen facility The expansion is due to

be completed by 2014

Metso equipment

delivered to Aitik36

bull 2 AG mills diameter 116 x

137 m gearless 22-MW motor

bull 2 Pebble mills diameter 91 x

113m dual 5-MW pinion drive

bull 3 VPA pressure filters VPA 1540-54

bull 12 sample pumps and pipes

VF50

bull 60 Various slurry pumps up to

MR500 modelbull Appr 5000 m rubber-lined slurry

pipes up to 600 mm diameter

bull Appr 5000 m rubber-lined by

gravity pipes up to 600 mm

diameter

bull Appr 5000 m rubber hoses

up to 600 mm diameter

Not only does the expansion make ser-

vice shutdowns at Aitik run more smoothly

it guarantees a more comprehensive

on-call emergency service response in the

region ndash thanks to the spare and wear parts

inventory available 24 hours a day 365

days a year

More info

Lars Rosenling

Tel +46 70 107 45 90

larsrosenlingmetsocom

Metso grinding equipment dominates the view in the concentrator

Safety on site is made up of small things like

making sure that everyone remembers to secure

the hoses in place

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Pebbles have always been a

challenge for producers of sandsince they cannot be returned

to rivers after extraction For

decades the processing of this

material resulted in a huge

environmental liability with alarge amount of pebbles hav-

ing to be stored away and left

unused

Transforming problems into

business opportunities

Areia amp Cia (areia = sand) has

operated in this market forover 20 years and decided to

enlist the help of Metso to find

a profitable solution for the

processing of pebbles

In July 2011 analyses werebegun to assess the abrasive-

ness and crushability of the

material Four alternatives wereidentified for processing and

transforming pebbles into sand

Initially Areia amp Cia was

interested in acquiring an

impactor for its reason-able price level However the

customer wanted to process

all the pebbles that were col-

lected daily in addition to some of the

material that it had stored In weighing theresults expected by the customer and the

excessive abrasiveness of the material the

HP200 cone crusher was decided on as thebest alternative

Areia amp Cia made the required invest-

ment and after using the HP200 for just

six months the company has already beenreporting outstanding results The HP200

not only transforms pebbles into sand but

also produces sand of excellent quality

with high yield and low maintenanceWith minor adjustments the HP200

also enables the production of sand withspecific particle size distribution for special

applications such as filtering sand blasting

and foundry sand adding value to the prod-

uct and increasing the types of sand offeredldquoMetso is pleased that the HP200 not

only enabled the processing of a product

that had been set aside as unusable but

HP200 cone transforms pebblesinto high-quality sandOver the last few decades Brazilian economic growth has been driving demand for construction aggregates The market

for sand in turn has been experiencing major difficulties in maintaining a consistent supply Presently one of the mainchallenges the industry faces is the large amount of pebbles that are obtained in the process of extracting sand at timesconstituting nearly 50 of the volume of material dredged from riverbeds

TEXT Sheila Ivers PHOTO Areia amp Cia

also that it opened up new

market opportunities for Areiaamp Cia Thatrsquos the standard we

seek to deliver to our custom-

ersrdquo states Luiz Oliveira Techni-

cal Salesperson of Metso Brazil

HP cones entering the

Brazilian sand-making

market

Todayrsquos cones such as theHP200 have high resistance

to impacts and abrasiveness

more efficient crushing cham-

bers low maintenance costsand excellent productivity

Following the acquisition of

the HP200 Areia amp Cia is now

also producing special sands

that command a price that is100 higher than common

sand The entire stockpile of

pebbles accumulated through-out the companyrsquos 20 years of

operations has already been

transformed into sand and the

stock of pebbles held by com-

petitors is also being purchasedfor processing

Cristiane Brizolari the

owner of Areia amp Cia confirms

the transformation that has taken place in

the production and commercial processldquoThe HP200 opened up new niches in

the market enabling the production of dif-

ferent types of sand with added valuerdquo

More info

Luiz Oliveira

Tel +55 011 9971 3603

luizoliveirametsocom

After the pebbles are crushed into sand with the HP200 cone crusherdifferent grades are screened for various end uses

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Where therersquos a will we dig a wayAFCONS-Strabag and Metso embark on tunnel project together

When the joint venture AFCONS-Strabag initiated work on the Rohtang bypass tunnel project at an altitude of 3980 metersabove sea level in Himachal Pradesh India they deliberated each aspect with clockwork precision The project involved anumber of surprises and challenges and required technology and project management skills that were second to none

TEXT amp PHOTOS Monisha Majumdar

Cutting a 10-meter-wide and nearly 9-kilo-

meter-long tunnel through the Himalayas

in one of the toughest terrains and cli-mates in India makes for quite a challengeResults set out to find out how AFCONS-

Strabag and Metso are making their way in

one of their most critical projects to date

The only road connection to the north-Indian border region of the province

Himachal-Pradesh and beyond the Manali-

Leh highway leads across the Rohtang

pass Due to the heavy snowfall and high-

velocity winds in this region the towns

located north of the pass are cut off from

the rest of the country during winter for atleast four often even six months each year

A tunnel with strategic importance

With the construction of the tunnel at

3100 m above sea level the Manali-Lehhighway will become an all-weather road

thereby enabling a significant improve-

ment in the economic development of

northern Himachal-Pradesh and an alter-

nate route to the strategically important

Ladakh region

Manali south of the pass is an alreadywell-developed tourist location that is

becoming more and more popular Upon

completion of the tunnel it is likely that

tourist activities will extend to the areanorth of the pass Moreover the tunnel

shortens the distance between the towns

of Manali and Leh by approximately 45 km

thus saving several hours on the small dan-gerous pass road

The Rohtang pass in the Western Himalaya

region of Northern India with its altitude ofalmost four kilometers ranks among thehighest trafficable passes in the world

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The 88-km long horse-shoe-shaped

tunnel provides space for a two-lane8-m-wide carriageway as well as a one-

meter-wide footpath on both sides A

22-m-high and 36-m-wide emergency

tunnel will be integrated in the tun-

nel cross-section Altogether more than

800000 msup3 of rock will be moved Tunneling works started around spring

2010 with excavation driven from both por-

tals As the north portal is inaccessible dur-ing winter closure the excavation focused

on the south After a planned construction

period of 55 years the tunnel is scheduled

to be completed by the end of 2015

Best man for the job

The BRO (Border Road Organization)

wanted to roll out a global tender for theproject due to the challenges that such a

project involves and also considering thatitrsquos the first time in India that a project of

this scale was to be carried out This imme-

diately triggered the need to roll out aglobal tender All major Indian construction

companies bid for it some individually and

some in partnerships

Strabag an Austrian tunnel specialistwas one of the companies who bid for the

project along with AFCONS a Mumbai-

based infrastructure company In Septem-

ber 2009 AFCONS-Strabag was awardedthe contract

Mr Sunil Tyagi Deputy Project Man-ager at AFCONS had this to say about the

unique projectldquoThis project is located in the Himalayas

and as far as we understand the terrain

there is among the toughest We came out

with a new technology and to be honestit is a fairly simple one We would generally

start with the traditional technology of drill-

ing and blasting and then obtain our muck

feed from the inwardbottom of the tunnelrdquo

ldquoThe technology is supplied by Rowa Tunneling Logistics and this is the first

time it is being used in Asia A jaw crusheris placed at a distance of about 40-45

meters behind the face The blasted muckextracted from the face is fed to the crusher

to reduce the lump size and then through

an overhead conveyor transport system

it is then transported out of the tunnelrdquoldquoThis enables free movement of man

and machinery in the lower area or spe-

cifically on the ground area If we were to

conforms to the Indian standard for fines amp

coarse aggregates as prescribed in IS383-1970

The plant was up and running in good

condition and performing to AFCONSrsquos

satisfactionldquoWe have worked with Metso in earlier

projects and are quite impressed by thekind of technology amp services they provide

We have a history together so the trust fac-tor also comes inrdquo explains Dhiman on their

choice of Metso as a partner

Service makes the difference

ldquoMetsorsquos services have made a big dif-ference in the project Without them we

would still be struggling with the machin-

ery and production The service is really

good and the service engineers are knowl-edgeable prompt and quick to act Any

problem can be solved by Metso We donrsquothave to wait until a service engineer turns

up ndash they have the capacity to solve prob-lems over the phone as wellrdquo says Dhiman

ldquoThe Metso plant didnrsquot create any prob-

lems for us We had problems in logistics

the feed was sticky and the weather condi-tions were bad but thankfully we did not

face any problems with production and

efficiency as the Metso plant is performing

very wellrdquo Dhiman concludes

More info

Amol Sinha Tel +91 9811 671 924

amolsinhametsocom

use the old conventional technology this

wouldnrsquot have worked for us in the stipu-lated timerdquo Mr Tyagi adds

When the going gets tough

partner with the toughest

Sensitive projects require the best technol-

ogy After AFCONS-Strabag landed theproject Metso was an obvious choice as a

technology provider not only because of

the long-standing business relationshipbut also for the sheer consistency in prod-

uct quality and service deliverance Metso

strives for

ldquoAfter signing the project we faced alot of road blocks including extreme cold

avalanches roadblocks less oxygen ndash you

name it we faced itrdquo explains Ankit Dhi-

man Plant Manager at AFCONS-Strabag The Rohtang valley is known for its

notorious avalanches and landslides SoAFCONS had to take extra steps and safety

precautions against hazards on the site

ldquoIn this freezing cold not just us humansbut also the machines are at increased risk

of damage I remember when we used

to run the plant during winter the diesel

engines would freeze We had to constantlyheat up the fuel container to get the plant

running And even the sand in the sand

trap would freeze so we had to clean it on

a daily basis to stop the pipes from mal-functioningrdquo Dhiman adds

Plant designed for difficult terrain

Difficult terrain coupled with space con-straints led Metso engineers to put their

minds together to come up with a suitable

plant configuration After studying the

requirements of the project Metso sug-

gested a 150-tons-per-hour three-stagemodular plant using a C106 jaw crusher

a GP11F secondary cone crusher and a

B7150 tertiary vertical shaft impact crusher

In addition considering the unpredict-ability of the feed the plant was about

to reach a point where the amount offines to be handled could be increased

dramatically Metso strongly suggested the TK11-27-3V grizzly scalper and this became

the first-ever TK scalper to be supplied by

Metso to an Indian customer Also in order

to get better products a sand trap SF2360was added to the configuration

The sand trap is important equipment

for this project as it washes the sand thatMr Sunil Tyagi Deputy Project ManagerAFCONS-Strabag

8132019 Results Minerals Aggregates 3 2012ENG

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Smooth transition to new-generation jaw crusher in Germany

Roumlhrig is a German company with a rich heritage The company has been quarrying granite at its plant in Bergstrasse inthe Sonderbach district of Heppenheim for three generations

TEXT amp PHOTOS Ralf Goffin

Roumlhrigrsquos superior product variety is onereason why the companyrsquos proximity to its

customers can be understood in more than

just physical terms The companyrsquos high

level of innovation has allowed it to estab-lish itself as a reliable supplier of materials

both regionally and internationally This

operational and technical expertise always

manages to keep in step with growing

market requirements

In terms of technical processing equip-

ment Roumlhrig has used a Nordberg C160stationary jaw crusher from Metso since

1992 At the start of 2012 it was finally

exchanged for a more up-to-date version

from the same model range

Metsorsquos C Series is specifically designed

to pre-crush hard rock and can cope effort-

lessly with even the hardest of materials

The dimensions of the new stationary jawcrusher are identical to those of the old

one which means that it could simply be

slotted into the housing vacated by the

previous version

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983122983141983152983151983154983156983145983150983143 983154983141983155

Third-generation Managing DirectorMarco Roumlhrig expects the new machinersquos

service life to be just as long as the previ-

ous model due to the product upgrades

that have been implemented The integral motor base is another plus

point in models made by other manu-

facturers it is located outside the crusher

This element of good fortune ensured that

Roumlhrig could reuse the housing withoutany additional rebuilding

Another advantage lies in the revision

of the guards for the C160rsquos drivetrain andflywheel The sturdier construction method

used for the crusher requires fewer parts

which facilitates easier installation andmaintenance and it makes it simpler to

access the motor

Under the watchful eye of Metsorsquos

Assembly Manager Maik Engelstaumltterthe entire project including removal and

installation was successfully completed

within two weeks

Installation making the most

of the available space

Roumlhrig will likely remember the day the

new crusher was installed for a long time

the pitman and main frame were deliveredseparately prior to installation and assem-

bled on site It took just one hour to replace

the old stationary crusher with the new

model A lorry-mounted crane was used toposition the 85-ton crusher with millimeter

precision in the crushing plant Once the

new crusher had been positioned in theexisting steel structure the next task wasto fix it into place as securely as possible

despite the limited space Special vibration

dampers were installed at a height of two

meters to prevent the crusher from sliding

Norbert Ried (fourth from left) installed thenew C160rsquos predecessor 20 years ago and isdelighted at the durability of the powerfulcrusher that is now making way for a newermodel Also pictured from left to right ManagerVolker Angermann Assembly Manager Maik

Engelstaumltter Technical Manager Stefan

Koob Project Manager Dominic SchoumlnhardtManaging Director Marco Roumlhrig Service

Technician Stefan Kolze and employees ofthe installation company Stafemo

On the hook after theold C160 was liftedout by crane the newcrusher was installedin almost no timeOnly the roof of thehousing had to beremoved

sideways off its mount An initial test run

with materials was carried out around oneweek later after all the electrical cables had

been installed

Simultaneously with the installation

of the C160 which is the first of the latest

generation of crushers to be installed in

Germany a new Nordberg GP100 conecrusher was also being installed in Roumlhrigrsquos

chipping plant Roumlhrig is convinced that

the technical improvements made tothe new Metso crusher can only be an

advantage worldwide

Roumlhrig places great value on consistent

product quality maximum added valueand optimum refinement of its product

range Bearing in mind that Roumlhrig has

enough reserves of raw material to last

for the next 150 years the company canconfidently continue to develop with an

emphasis on quality rather than quantity

More info

Dominic Schoenhardt

Tel +49 (0)621 727 00 610

dominicschoenhardtmetsocom

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Groupe Charier Carriegravere de la Mariais France

Quarrying with certi1047297ed quality The Charier Group with its 1600-strong workforce is a family business thatthis year celebrates 115 years of quarrying The company pursues a long-termdevelopment policy that since 2007 has seen processing installations upgradedat 4 of its 9 extraction sites

TEXT Liliane Boutin (with extracts from Mines amp Carriegraveres and Terrassements amp Carriegraveres magazines)PHOTO Baloon photo

The processing installation is of the horizontal type with a primary station located 56 meters below the site access road to keep it hidden from view

The crushing and screening installation at

Charierrsquos CM La Mariais quarry (at Donges

on the Loire estuary) has been in opera-tion since September 2011 Based on theoperatorrsquos ideas it was designed by Metso

to replace a worn-out installation installed

right on top of the seam being extracted

Since its commissioning it has becomethe second quarry in the company to

receive ISO 14 001 certification

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983122983141983152983151983154983156983145983150983143 983154983141983155

tertiary material of sand and gravel for the

local market to use in concrete surfacingprefabrication etcrdquo

Incorporation of a screening station

The stone extracted from La Mariais is

according to the quarry granitic gneiss

sound and homogeneous with a LosAngeles index of 15 good wear resist-

ance with an MDE of 10 a true density of

265 and a certain abrasiveness (2000 gt)ldquoCharacteristically it has a tendency to form

blocksrdquo Leblin points out

The main criteria in designing the instal-

lation was to provide an output of 600000metric tons from one station (38 hours

week) to produce materials aimed at the

concrete and surfacing markets ldquowhich

involved providing a tertiary station withscreening plantrdquo he adds

With this new unit the operating com-pany expands its product range through

the addition of fine materials obtained

from the tertiary screening station This unitis capable of producing 170 tonshour of

020

Preserving the environment

and optimizing safety

The screens have motorized bogies and

retractable walkways to facilitate access

when the screens are opened for main-tenance Other walkways provide access

to the tunnel input feeders The feederscan be isolated with hydraulic rod gate

bars this hydraulic assistance eliminatesthe need to use a heavy hammer to lodge

these metal bars

All conveyors transporting fines (02

and 04) are covered with a tarpaulin to

avoid flying dust and all the screens arehooded (metal cover with Trellex seal-

ing) The Brunone company has installed

dust-tight containment at the outlet of the

tertiary station crushers (HP300 and HP4)on the belt located under the screens

and under the hoppers located belowthe tertiary screens The crushers are put

under negative pressure and the finesare extracted through sleeve filters (7000

m3 h) with declogging which deposits the

dust back onto the conveyor belt

A high-pressure 100 bar water mist sys-tem has been installed at the primary sta-

tion discharge at the secondary crusherrsquos

discharge chutes (Omnicone) and at the

transfer points on the belt

Designed to last

ldquoThis type of new installation can easily last

thirty yearsrdquo affirms Project Leader Bruno

Peix of Metso ldquoIt quite simply depends on

how well it is maintained Thatrsquos why weprovide maintenance contracts that call for

our technicians to make regular inspection

visits and carry out preventive mainte-nance and any necessary repairsrdquo

In 2011 Metso commissioned about

10 new processing units in France like

the one at La Mariais quarry

More info

Frederic Bazire

Tel +33 (0)681442804

fredericbaziremetsocom

Key figures

DURATION OF WORKS 15 months

DRAWING OFFICE TIME 7800 hours

HEIGHT OF SILOS AND GRINDER BUILDINGS

15 m

TOTAL LENGTH OF CONVEYORS 14 km

WEIGHT OF THE INSTALLATION

1200 metric tons

CONCRETE POURED 1800 cubic meters

PROJECT SITE WORKFORCE 30

INSTALLED POWER 2200 kW(not including pumps 200 kW)

METSO EQUIPMENT

Primary

Vibrating feeder PF561-2V

Primary grizzly VG540-3V

Grizzly feeder TK13-20-3V

Jaw crusher C145 with

hydraulic setting

Secondary

Vibrating screen CVB 2050

refurbished

Cone crusher Omnicocircne 1352 SX

with Metso IC7000 controller Ellivar 16 (16 msup2 3 decks) screen

refurbished by Metso

Tertiary

Cone crusher HP300

Cone crusher HP4

2 Ellivar 20 screens (20 m23 decks) for final products

Expanding the production range

ldquoSince the mid-1990s when we became

owners of La Mariais we had used mobilemachinery with an assembly of beltconveyorsrdquo recalls Daniel Leblin Charierrsquos

Technical Manager for site construction

and maintenance

ldquoIt became clear that we needed ahigher performance tool to achieve the

dual goals of reaching one million metric

tonsrsquo maximum production and producing

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Big Lokotrack LT550GPF boostsquarrying productivity by a thirdMaximizing the productivity of operations is a key issue when striving for cost-effective quarrying Big Lokotracks are oneway to achieve improved operational efficiency The Lokotrack LT550GPF equipped with the high-volume GP550 conecrusher and a large screen is popular in the Nordic countries and in Germany and Australia ndash countries all known for theirhigh quarrying volumes

TEXT amp PHOTOS Eero Haumlmaumllaumlinen

Kone-Kostamorsquos new mobile coneplant has reached an averagecapacity of 300 tons per hour

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983122983141983152983151983154983156983145983150983143 983154983141983155

ldquoWith the same number of employees we

can achieve 30 more productivity with

our new LT550GPF unit The high-capacityFS screen has also eliminated the bottle-neck often seen at fine screeningrdquo says

Aarno Kostamo Managing Director of

Kone-Kostamo Oy one of Finlandrsquos biggest

crushing contractorsAccording to Kostamo the high capacity

of the GP550 gyratory cone crusher easily

handles feed from the C120 and C125 jaw

crushers For the contract with the Talvivaara

nickel mine the LT550GPF is being fed bythe brand new Lokotrack LT120 jaw plant

Average capacity 300 tons per hour

Talvivaara Europersquos largest nickel mine uti-

lizes large quantities of aggregates Kone-Kostamo has contracted several million

tons of different end products for the mineIn August 75000 tons of 0ndash63 mm

road gravel was crushed Smaller amountsof finer 0ndash6 mm 0ndash16 mm and 0ndash32 mm

aggregates are also being produced

The rainy summer increased the need

for road gravel along the muddy roadswhich must endure dump trucks weighing

as much as 260 tons

ldquoThe mobile process consisting of the

LT120 jaw plant and LT550GPF cone plant

is cost-effective while aggregates of vari-ous sizes can be produced in a two-stage

operation and with high capacity The con-trolled stroke and elliptical movement of

the FS screen secure big passing throughcapacitiesrdquo Kostamo explains

Operated in two shifts for a total of 16

hours per day the LT550GPF has logged

more than 600 working hours over a two-month period

Managing Director Aarno Kostamo (left) and foreman Karri Maumlenpaumlauml studying the cavity optionsavailable for the new Lokotrack LT550GPF

Longer perspective than

a single quarter needed

Kone-Kostamo Oy was founded as an

earth-moving company in Kemijaumlrvi

Northern Finland in 1956 The company

expanded its operations to include crush-

ing contracting in 1964 and later on

switched to concentrating fully on crush-ing activities

Kone-Kostamo consistently crushes

and screens around 28 million tons ofaggregates annually and has net sales of

between EUR 8ndash9 million

ldquoWe believe that issues within the crush-

ing industry including the purchasing ofmachinery must be studied with a longer

perspective than a single quarter The

secret to our success has always been our

solid work ethic and professional employ-eesrdquo Kostamo sums up

More info

Esa Berg

Tel + 358 40 837 8692

esabergmetsocom

8132019 Results Minerals Aggregates 3 2012ENG

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Monitoring-based reporting is vital for

assessing the performance of a mobile

crushing plant Metso provides suchreporting tools through its plant-wideautomation system Metso DNA (Dynamic

Network of Applications) with its infor-

mation platform that links all the mobile

crushing and screen units together as oneentity Basically there is a lot of measured

real-time information available in every

crushing plant On-line information is

obtained either from each Metso crusherrsquosmachine automation system IC (Intelligent

Controller) or from separately installed

additional sensors and belt scales

All the collected data is sent to a motorhome using wireless communication

based on WLAN technology The motor

home is a purpose-built environment

inside an on-site container In this environ-ment selected variables can be monitored

for assessing the plantrsquos performance And

to make all this even more flexible the

data can be transmitted to a crushing plant

company office using GPRS3G mobile

data communication technologies Thismakes all the last-minute reports acces-sible to the crushing plant managerial staff

at anytime and basically anywhere within

reach of the cell phone network

Production and fuel economics reports

Essentially monitoring and reporting can

be customized to fit the customerrsquos needs

However there are certain off-the-shelf

reports that provide a lot of useful informa-tion for plant supervision The production

report is one of these Requiring at least one

belt scale for measuring the total produc-tion the production report shows the pro-duction rate (tons per hour) for a selected

reporting period eg a day or a week The

production report constantly keeps track of

the plantrsquos production storing all the datathroughout the plantrsquos life cycle

Performance monitoring and reportingfor a mobile crushing plantTEXT Pasi Airikka PHOTOS Metso

unit during which the unit is running By

storing the availability times between start-ups and shutdowns the crushing plant

operation time (hours per dayshift) can be

recorded analyzed and reported In addi-

tion the availability report can be tailored

to evaluate efficient crushing hours during

which the plant is really working and pro-ducing aggregates Consequently the ratio

(0-100) between efficient crushing time

and total running time can be reported forany selected period of time This boosts

the efficiency of the plantrsquos operations

and results in better productivity

Reports on non-choke

or inadequate feeding

Non-choke feeding to crushers is avoid-

able through smart plant-wide crushingplant controls But estimating its severity in

a systematic manner is not straight-forwardwithout constant monitoring and reporting

The crusher choke feeding report makes

use of the crusher cavity level sensors byanalyzing their level measurements By

calculating average and min-max values

and deviations from the average it can be

shown how often the single crusher suffersfrom non-choke feeding to it

In some cases the bottleneck in the

crushing plantrsquos productivity is the material

feeding to the process In mobile plants thefeeding is human operated and therefore

subject to variations Occasionally the sizeof the human-operated machine simply

does not allow for adequate feeding to thecrushing plant There are specific reports

indicating time periods when the crushing

plant suffers from inadequate feeding

Condition monitoring for

crushers and screens

Machine-specific condition monitoring

focuses on vibrating components in

crushers and screens such as drive shaftbearings safety plate wearings and gears

The low middle and high frequencies ofmonitored components are measured and

supervised in real-time to detect abnor-malities due to slow or fast wear looseness

or imbalance

More info

Pasi Airikka

Tel +358 40 587 2730

pasiairikkametsocom

Condition monitoring provides a view tovibrating crusher and screen components forpredictive equipment maintenance

The daily production report shows the hour-by-hour production trend and distribution chartfor a selected day with min-max average andvariation statistics for comparison

Fuel consumption is always an interest-ing concern The fuel consumption reportgives the fuel consumption of each crush-

ing unit (liters per hour) and their total

consumption (liters per hour) for a selected

reporting period and can track fuel con-

sumption changes over timeCrushing plant availability can be

assessed as well The availability report

calculates time periods for each crushing

8132019 Results Minerals Aggregates 3 2012ENG

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983149983141983156983155983151 983150

for tissue machines The record of 2210

mmin was set on June 1 2012 during a

24-hour production run by the TM 2 tissue

machine at the companyrsquos mill in Yenikoumlynear the city of Izmit in Turkey

ldquoThe cooperation with Metso has been

beyond excellent and both parties did

their utmost to make the project success-ful The results clearly show that the efforts

were worthwhile on both sides This coop-

eration will extend to cover new projects

in the futurerdquo says Luumlt1047297 Aydin Paper GroupDirector Hayat Kimya

ldquoWe are not surprised that Hayat K imya

managed to break the world speed record

We have had great confidence in the capa-bility of the Hayat team since our project

started in 2009 We certainly know our

machine very well its stability production

efficiency and speed capabilityrdquo says Jan

Erikson Vice President Sales Metso

PowerThe worldrsquos first eco-gas fueled

power plant is up and running

Lahti Energy Ltdrsquos new Kymijaumlrvi II gasifica-

tion plant was officially inaugurated on

May 8 2012 It is the first of its kind in the

RecyclingRecycling with Lokotrack LT106

jaw plant in New York

A brand-new Lokotrack LT106 jaw plant is

used in the city area of New York USA to

recycle demolition materials The crushing

site faces the skyscrapers of ManhattanIsland

Paper amp FiberHayat Kimyarsquos Metso-supplied tissue

machine sets world speed record

Thanks to a skilled crew and dedicated

efforts Hayat Kimya AS in Turkey has suc-

ceeded in breaking the world speed record

world This CHP plant runs on clean eco-

gas that is gasified cleaned and cooled

from recycled waste with Metsorsquos innova-tive technology

ldquoItrsquos actually eco-gas that we combust

in the boilerrdquo comments Lahti EnergyrsquosProduction Director Jukka Manskinen

ldquoWe convert unwanted waste material into

energy in an efficient and environmentally

friendly wayrdquoNever before has any plant gasified

waste on such a large scale In the gasifier

recycled waste is turned into combustible

product gas which is cleaned cooled and

combusted in a high-efficiency gas boiler

to produce steam for the steam turbine The plant produces 50 MW of electricity

and 90 MW of district heat for the city of

Lahti and its neighboring areasMetso delivered the circulating fluidized

bed (CFB) gasification process gas cleaning

and cooling steam boiler environmental

protection system and automation systemto the entire plant The production of elec-

tricity and heat is kept even with the Metso

DNA automation system that covers the

whole plant starting from fuel reception

AutomationMetso develops and supplies plant-

wide crushing control solutions for

crushing plants

Metso has recently signed contracts on

delivering plant-wide automation systems

for mobile and portable rock crushing

plants The key objective of these deliveries

is to stabilize and to increase productivityand efficiency of the plants using one sin-

gle automation and information platform

for integrating crusher-specific IC machinecontrols

Furthermore the plant-wide system

with its information management tools not

only increases plant availability and opera-

tional safety it also makes troubleshoot-ing quicker and performance monitoring

easier The control room for plant-wide

operability is located either in an excavator

cabin or a purpose-built container

Metso around the world

The new LT106 jaw plant is suitable for crushing both hard rock and all rock-based demolition materials

The new world speed record for tissue setby Hayat Kimyarsquos Metso-supplied TM 2 is2210 mmin

8132019 Results Minerals Aggregates 3 2012ENG

httpslidepdfcomreaderfullresults-minerals-aggregates-3-2012eng 4242

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: Results Minerals Aggregates 3 2012.ENG

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983150983141983159983155 983145983150 983138

Metso has developedmill lining solutionsthat combine rubberand a variety ofsteel elements tooptimize the weightwear life and ease ofinstallation of linersystems

Metso Mining and Construction recently participated in two Euro-

pean exhibitions in Sweden and the UK unveiling its latest crush-

ing and screening equipmentMaskinExpo the biggest construction machinery exhibition

in the Nordic countries was organized on a golf course near

Stockholm Metsorsquos novelties included the diesel-electric Lokotrack

Exhibiting live at MaskinExpo and Hillhead

Metso is expanding its rubber mill lining production capacity glob-ally by investing in new presses to meet the growing demand in

the global mining market After completing the investment in 2015

Metsorsquos global rubber mill lining production capacity at the existing

wear parts manufacturing plants will increase 30 percent High-quality wear parts ensure mining process reliability at all times

Metso is purchasing straight grate iron ore pelletizing technologyand know-how from Jacobs Engineering Group Inc In addition

key Jacobs Minerals technical staff related to the technology will

become Metso employees as part of the deal

Iron ore pelletizing is used to produce pellets from concen-

trated iron ore for feed to blast furnaces and direct reduced iron

LT120E jaw plant the brand new LT106 jaw plant and the HP3

cone crusher

Hillhead the largest European quarrying and recycling ldquolivequarry showrdquo brought together a record number 17000+ visitors

At the event Metso presented its LT120 and LT106 jaw plants the

HP3 cone and the new C120 jaw crusher

The diesel-electric Lokotrack LT120 jaw plant exhibited at MaskinExpowas sold to the Swedish crushing contractor Johanssons Entreprenad

Metsorsquos crusher newcomers the HP3 cone and C120 jaw raised a lot ofinterest during the Hillhead quarry show in Buxton UK

Mill lining manufacturing capacity to be expanded

Iron ore pelletizing technology and know-how acquired from Jacobs Minerals

The investment totaling approximately EUR 10 million will becompleted in two phases The first set of presses is scheduled to

be in operation by the end of 2013 I t includes the installation of

presses in Chile Sweden Canada Mexico and Peru

plants Metso anticipates continued growth in this market as more

beneficiation and pelletizing plants are needed to maximize theoutput from lower grade ore bodies

Metso currently offers the grate kiln iron ore pelletizing system

With the purchase of straight grate technology from Jacobs Metso

will become the worldrsquos only supplier of both systems

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156983145983139983148983141

Metsorsquos mobile crushing and screening units are in the frontline in the demandingreconstruction efforts in Japan after the nation was ravaged by the biggest earthquakeand tsunami in its recorded history Tracked mobile Lokotracks are the quickest wayto boost the production of aggregates an estimated 200 million tons of which willbe required over the next decadeTEXT amp PHOTOS Eero Haumlmaumllaumlinen

The biggest gold producer in Europe

Agnico Eagle in Kittilauml Northern Finlandcurrently produces some 5000 kg of goldannually The mine plans to expand its daily

ore extracting capacity to 4000 metric

tons which will increase the gold produc-

tion by an additional 1000 kgOther major gold producers in Fin-

land include Nordic Minesrsquo Laiva mine

Endominesrsquo Pampalo mine Lappland

Goldminersrsquo Pahtavaara mine and DragonMiningrsquos Orivesi and Jokisivu mines

Metso with its crushing screening and

minerals processing equipment is a sup-

plier to most Finnish gold mines In addi-tion to the equipment Metso also offers

these gold-mining operations its process

planning expertise and services

New gold deposit discoveries likely

Senior Geoscientist Pasi Eilu from the Geo-

logical Survey of Finland believes that the

possibilities of finding new gold deposits

comparable to the current ones are good

Helping Japan to rebuild

after the tsunami

ldquoIn Finland gold has been found

wherever serious exploration has beencarried out The latest interesting depositshave been located by Mawson Resources

between Tervola and Ylitornio in Northern

Finlandrdquo

According to Eilu the latest findings onlyinclude gold ore exposed at the surface

ldquoIt is very likely that in the near future

gold will be found in the deposits hidden

completely undergroundrdquo he explains ldquoNextyear the Geological Survey of Finland will

publish an estimate on possible gold depos-

its reaching a depth of one kilometer from

the surface This will provide more accurateinformation on potential discoveriesrdquo

The average gold grade in Finnish gold

mines is similar to any gold mine abroad

ldquoThe most common type in Finlandis orogenic gold ore which is similar to

nearly all ores originating in West Austral-

ian and Ontario Canada We also have

volcanic-related gold deposits for example

in the Orivesi mine and small amounts of

gold deposits similar to those found in the

worldrsquos biggest deposits in WitatersrandSouth Africardquo Eilu adds

Focus on green mining

The Finnish Green Mining concept is the

mineral sectorrsquos answer to future chal-

lenges It aims to optimize material and

energy efficiency in the whole productionchain The program aims at efficient pros-

pecting for new deposits and at develop-

ing new solutions for utilizing them It

also aims to minimize local environmentalimpacts and problems to improve work

safety and the workplace atmosphere andto restore mining areas after mining opera-

tions are completed The Green Mining program started in

2011 The main objective is to make Finland

a global leader in the sustainable mineral

industry by 2020 The program encom-

passes two central themes intelligentminimum-impact mines and new mineral

resources

NorthernEldorado Today Finland together with the Nordic countriesfalls within one of the global areas that are experi-encing a gold exploration and mining boomIn recent years major global mining companieshave entered the country and opened gold mines

and they are now set to expand their on-goingoperations A number of promising explorationprojects are simultaneously under way on behalfof some 40 mining companiesTEXT Eero Haumlmaumllaumlinen PHOTO iStockphoto

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156

1

78

9

1011

12

13

15

16

18

19

2021

22

14

2

3

5

6

17

Active Mines and Current Projects February 2012

Kittilauml gold ndash Agnico-Eagle Ltd Pahtavaara gold ndash Lappland Goldminers Ab

Laiva gold ndash Nordic Mines Ab

Pampalo gold ndash Endomines AB

Orivesi gold ndash Dragon Mining Ltd Jokisivu gold ndash Dragon Mining Ltd

Iso-Kuotko gold ndash Agnico-Eagle Ltd

Hanhimaa gold ndash Dragon Mining Ltd

Kettukuusikko gold ndash Taranis Resources IncNaakenavaara gold ndash Taranis Resources Inc

Kiekeroumlmaa gold ndash Tertiary Minerals Plc

Rompasgold uranium ndash Mawson Resources Ltd

Suhanko-Konttijaumlrvi PGE ndash Gold Fields Arctic Platinum OyKuusamo gold ndash Dragon Mining Ltd

Hirsikangas gold ndash Belvedere Resources Finland Oy

Aumlngesneva gold ndash Belvedere Resources Finland Oy

Kopsa gold ndash Belvedere Mining Oy

Taivaljaumlrvi silver ndash Sotkamo Silver ABSeinaumljoki gold antimony ndash Nortec Minerals Corp

Osikonmaumlki gold ndash Belvedere Resources Finland Oy

Haveri gold ndash Lappland Goldminers Ab

Kaapelinkulma gold ndash Dragon Mining Ltd

1

3

5

7

15

11

19

9

17

13

21

2

4

6

8

16

12

20

10

18

14

22

Mine

Prospect

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156983145983139983148983141

The main minerals processing componentsincluding grinding flotation and pumping

equipment are delivered by Metso

983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

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983110983141983137983156983157983154983141983140 983137983154983156

Endomines

Pampalondash a green andresponsiblegold mineAt Pampalo near the easternmost point of Finland a cleanand environmentally friendly gold mining operation isbeing executed by Endomines With Metsorsquos plant designand a state-of-the-art processing plant Pampalo runs a

green and responsible yet at the same time profitablegold mining operation that avoids acid mine drainagesand targets 100 water recirculationTEXT amp PHOTOS Eero Haumlmaumllaumlinen

With a modest investment of EUR 20

million the Pampalo mine was built fully

operational and now produces 800ndash900 kgof pure gold annually An on-going expan-

sion will increase the minersquos production

capacity by 30 to 50 next yearIn addition to the main underground

mine at Pampalo several promising satellite

gold deposits are being investigated along

the long Karelian gold line The maximum

distance of the satellites is 30 km allowingthe mine to transport and process all of the

produced ore at the Pampalo plant

Small scale can be successful

with hard work

ldquoWith our gold mining operation we can

very well show that with hard work even

small-scale gold mining and production

can be done in a sound and profitable wayrdquosays Markus Ekberg CEO of Endomines

originally founded in Sweden

According to Ekberg the strategy when

building the mine was to split up the jobsinto small separate contracts Metsorsquos part

was the main minerals processing system gt

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156

Increasing capacity makes processing

of lower grades economical

The project to significantly increase the

processing capacity at Pampalo is well

under way with the installation of for

example a second grinding mill and more

flotation cells The expansion will be in

operation during early 2013ldquoThe added capacity also makes it pos-

sible to economically process the nearby

open pits with a lower gold grade In addi-tion it helps us to optimize the crushing

and grinding circuitsrdquo Ekberg concludes

Active exploration drillings have

exposed new mineralized zones furtherextending the lifetime of the Pampalo mine

from the present estimate of 6ndash7 years

More info

Peter Vikman

Tel +358 400 869 845petervikmanmetsocom

Endomines Pampalo gold mine

LOCATION near the community of

Ilomantsi in Eastern Finland

GOLD ORE CONTENT

ndash Pampalo 34 gtndash Hosko 99 gt

ndash Raumlmepuro 39 gt

ndash Muurinsuo 30 gt

PRODUCTION TONNAGE PER YEAR 270000 tons (present)~400000 tons (future)

GOLD PRODUCTION PER YEAR 800ndash900 kg

KNOWN ORE RESERVES IN TOTAL

approx 2 million tons

MINE DEPTH 360 m

MINING METHOD bench cut and fill

NUMBER OF EMPLOYEES

100 including contractors

METSO EQUIPMENT

1 Metso TRN 30 x 48 m

wet ball mill

8 Metso RCS series flotation cells 1 Nordberg MF 1800 x 6100

screen

3 Metso samplers

1 Metso CT thickener

1 Metso TF vacuum filter

33 Metso slurry pumps of various

types and sizes

The gold ore is screened using Metsorsquos MS series mining screen

Markus Ekberg is pleased with the outcome the mine reached the minerals processing utilizationdegree of over 90 just two months after start-up

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156983145983139983148983141

Nordic Mines ndash on track tobecoming one of Europersquosmost prominent goldproducersNordic Mines is the newest member in a long chain of Nordic gold mining operations

Inaugurated in mid-August 2012 this company of Swedish origin aims to become one

of Europersquos most prominent gold producers Metso is one of Nordic Minesrsquo main partners

supplying the Laiva gold mine with crushing screening conveying and minerals

processing equipment at an estimated value of EUR 30 million

TEXT amp PHOTOS Eero Haumlmaumllaumlinen

2983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

The Laiva gold mine was built in record time infrastructure

construction began in spring 2010 ore excavation started in

June 2011 and the first gold bar was casted in December 2011

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156

Just one year after starting the gold recov-

ery process Nordic Mines is on track toreaching a capacity of 5 kg of gold per day

At present the operations are averaging 3

to 4 kg of gold daily

The ore in the Laiva Gold Mine consists

of packages of gold-bearing quartz-filled

shear structures The deposit is more thana kilometer long and 700 meters wide The

total depth is still unknown but dr illings

carried out thus far have shown gold-bear-ing shear structures 300 meters below the

surface

A typical ore zone includes a large num-

ber of thin shear structures from 5 to 30per meter The ore zones are commonly 50

to 100 meters long several are 10 meters

deep and they range from a few meters to

20 meters cross strike The minimum min-ing width is 25 meters which means that

even a minor ore zone consists of at least10 to 50 shear structures

Conventional pattern blasting

with selective loading

Prior to mining Nordic Mines conducts

grade control drilling which provides

dense gold grade information and makes

it possible to outline the boundaries

between ore and waste The mining

technique applied is conventional pattern

blasting with selective loading This is oneof the most commonly used techniques in

large-scale open-pit mining

A typical blast in the Laiva mine is 50

meters long 100 meters wide and 5 metersdeep After blasting ore and waste aremined by selective loading

After investing some EUR 100 million

the Laiva mine now comprises an open-pit

mine with a modern complete crushinggrinding and processing circuit that ends

with the casting of gold doreacute bars

With a number of mine staff partners

sub-suppliers city and state officials inattendance the Laiva gold mine was offi-

cially inaugurated on August 16 2012

Michael Nilsson Managing Director

of Nordic Mines stressed in his speechthe importance of overcoming challenges

during the building of the mine

ldquoObviously the whole development

took us longer than expected Today weare pleasantly surprised by the size of our

operation We are becoming much bigger

than expectedrdquo gt

Chief Geologist Kimmo Lahtinen presenting narrow gold veins twisting at the Laiva North open-pit mine

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156983145983139983148983141

An international process package

The Metso package for the Laiva gold mine

included the main crushing screening

conveying regrinding leaching and pump-ing elements Metsorsquos office in Sala Swe-

den has served as the main project office

with Metso manufacturing units in FranceGermany Sweden and Finland responsiblefor the equipment supply

At Laiva the gold ore is classified after

selective excavating into two gold con-

tent classes All class A gold ore is takento Metsorsquos sturdy jaw crusher for primary

crushing while the class B ore is stocked for

possible future use After primary grinding

utilizing autogenous technology the ore is

screened and two Metso cones crush the

oversized pebbles For regrinding Metsorsquosball mill is used

During high- and low-grade leaching

processes a number of Metso pumps and

dewatering screens are used The whole

minerals processing system is controlled byMetsoDNA automation

Active exploration drilling going on

According to Mine Manager Tom Soumlder-

man the known gold ore reserves at the

Laiva gold mine amount to 169 million

tons but the potential for additional find-

ings looks good

ldquoWorking at the level of two million tonsper year our expected lifetime is about nine

years We carry out active exploration drill-

ing in Kaukainen Musunneva and Oltava

to locate nearby satellite ore bodies Anupdated detailed mine life plan will be pre-

pared during the autumnrdquo Soumlderman saysNordic Minesrsquo other exploration areas

include Tormua in Finland and Fjaumllltuna

and Vassbo in Sweden

More info

Alf Rydberg

Tel +46 70524 5837

alfrydbergmetsocom

Happy faces during the minersquos inaugural ceremony Mine Manager Tom Soumlderman (left) with Managing Director Michael Nilsson and Deputy Managing Director Krister Soumlderholm

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156

The story behind the discovery of the Laivamine is an interesting one During a hunt-

ing trip in the remote forests of Laivakan-

gas in 1979 Pentti Jaumlmbaumlck found an inter-esting-looking piece of stone Although hecould not see the gold hidden inside the

rock Pentti noticed the striking weight

and somewhat different look of the stone

Upon returning home Pentti sent thesample to Outokumpu which at the time

was the leading state-owned mining com-

pany in Finland After testing a high gold

content of 15 grams per ton was found

Gold deposit founded by a hunter

The founder of the Laiva gold deposit Mr Pentti

Jaumlmbaumlck was the guest of honor during theinauguration

Lennart Schoumlnning Chairman of the Board ofNordic Mines holding a gold doreacute bar worthsome EUR 320000

Outokumpu registered a mining claimon the area and conducted a series of

exploration drilling from 1981 to 1987 Due

to the low price level for gold no mine wasstarted at the time Other mining compa-nies such as Endomines held the mining

rights later

Nordic Mines with its sights set on

locating and exploiting gold in Swedenand Finland was founded in 2005 During

the same year the company purchased its

first mining rights at Laiva

Nordic Minesrsquo Laiva gold mine

LOCATION near the city of Raahe

northwestern Finland

GOLD ORE CONTENT average 16 gt

ORE EXTRACTED PER YEAR

12 million tons (present)

20 million tons (planned)

GOLD RECOVERY 85

TOTAL KNOWN ORE RESERVES

169 million tons

MINING METHOD

Selective open-pit benchingNUMBER OF EMPLOYEES

130 including contractors

METSO MAIN EQUIPMENT

2 Metso VF and 6 EMEG EME

vibrating feeders

8 Screens 1 MF 1 CVB and 6 KS

1 RCS Flash flotation unit

1 Metso SRR ball mill 18 x 4 m

1 Nordberg C160 jaw crusher

1 Nordberg HP100 cone crusher

1 Nordberg HP200 cone crusher

5 Nordberg NB series conveyors

73 Metso Slurry pumps ofvarious types and sizes

8132019 Results Minerals Aggregates 3 2012ENG

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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155

The newest member of the proven GP series cone crushers ndash theNordberg GP220 ndash offers a versatile alternative for any demanding

tertiary or quaternary or even secondary crushing operation fulfill-

ing all crushing needs and maximizing customersrsquo profitability

High-quality components and optimized castings and forgings

contribute to the GP220rsquos enhanced reliability and help to ensurethe highest level of crusher uptime

Thanks to the 200 kW (270 hp) power draw the GP220 performs

at a 20 to 30 percent higher capacity than other cone crusherbrands with an equal head diameter The large feed openingenables the feeding jaw crusher to run at 110 mm css Operational

flexibility is ensured by multiple strokes and six different cavities

Secondary crushing possible

thanks to cavity and stroke options

Thanks to the GP220rsquos cavity and stroke options secondary crush-

ing in addition to tertiary and quaternary stages is also possible

using cavities with a greater intake opening With the GP220 a suit-

able solution for producing excellent end-product gradations

can always be found

With advanced automation using IC50 or IC5000 operation

is safe and trouble-free The low height thanks to the patented

piston design makes replacement installations much easierA dynamic setting adjustment enables a fast response to process

optimization needs

The Nordberg GP220 weighs 10500 kg (23150 lbs) and hasa maximum real feed size of +200 mm (8rdquo) with strokes from

18ndash40 mm (57rdquondash1 47rdquo) The cavity options are EF F MF M C

and EC

A complete modular crusher steel structure is available for allGP series stationary installations including GP220 The platform

includes places for the lubrication unit motor automation or

pressure accumulator and pressurized sealing The only things

left to add are the feed and discharge conveyors

Main new features of the GP220 Large feed opening allows for secondary stage operation

Longer setting range of main shaft for better wear parts utilization

Stronger main components to carry high loads with a powerdraw as high as 200kW

More info

Hannu Vakkuri

Tel +358 50 317 0638

hannuvakkurimetsocom

Thanks to the large feed opening and wide selection of strokes and cavitiesthe new Nordberg GP220 cone crusher is a highly versatile cone novelty

More versatility with the newNordberg GP220 cone crusher

Reinforced head and frame castings combined with a 200kW power

draw make the GP220 cone a reliable crusher with maximum productivity

8132019 Results Minerals Aggregates 3 2012ENG

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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156

Metsorsquos HRCtrade takes high pressure grinding roll technology to the next level

The new Lokotrack mobile conveyors come as tracked and wheeled models

Metsorsquos latest development in comminution equipment the HRCtradeis a major step in the profitable application of high-pressure grind-

ing roll (HPGR) technology Metso has made several key innova-

tions in order to increase throughput and decrease the total cost

of operation

Metsorsquos patented Arch frame creates an even gap setting acrossthe width of the tires limiting skewing that can result in downtime

for mining operations This anti-skewing Arch frame also prevents

damage to the roller bearings (caused by misalignment) that canoccur with the traditional HPGR design

Flanges maximize wear life and increase throughput

Used in place of spring-loaded cheek plates the flanges keep thebed of material within the crushing zone and prevent material

from bypassing the tires This enables greater circuit capacity and

increases the overall crushing efficiency

In addition by preventing material from bypassing the tires

even pressure across the width of the tire is better maintained

Distributing the pressure more evenly maximizes the tire life bypreventing a ldquobath tub effectrdquo in which the center of the tire wears

faster than the edgesVictoria Herman Metsorsquos Product Manager for the HRC notes

that this breakthrough design is a response to the growing needs

in the mining industry ldquoEnergy efficiency has been attracting our

customers to HPGR technology for yearsrdquo she says ldquoBut our design

concept increases capacity and crushing efficiency ndash and thatrsquossomething mining companies are always looking to improve onrdquo

The track-mounted Lokotrack CT32 and wheel-mounted Lokotrack

CW32 mobile conveyors offer an ideal solution for applications

that require high stockpile capacity and excellent material transfer

capabilities They also add flexibility to multi-stage crushing andscreening applications enabling easy and fast closed-circuit opera-

tion of mobile units

The conveyor novelties can be used in both mobile and station-

ary installations providing extra stockpiling capacity in situationswhere for example fewer wheel loaders are available

The HRC is ideal for high-tonnage hard rock applications andcan be used as a tertiary quaternary or pebble crusher Currently

several HRC units are in operation around the world ndash with a total

of 6500 operating hours including over 3800 hours in a mininghard rock application The machine does have range within hardrock applications itrsquos been designed for use in diamond iron ore

copper gold platinum and various industrial minerals

More info

Victoria Herman

Tel +1 717 309 1150

victoriahermanmetsocom

Several optional features such as hydraulic folding of tail sections

and dual hydraulic drive for increased throughput are available

The capacity of the CT32 and CW32 is 400 mtph (440 stph)feed size up to 150 mm (6rdquo) belt width 1050 mm (42rdquo) and dis-charge height 9120 mm (29rsquo 11rdquo) The CT32 is fitted with a Caterpil-

lar C2 diesel engine with 38kw (51 HP) power The CW32 is avail-

able for hydraulic or electric use

More info

Kimmo Anttila

Tel +358 50 433 3745

kimmoanttilametsocom

The new HRCtrade combines high crushing pressure and a low circulatingload resulting in the most efficient comminution

When flexibility in stockpiling capacityis required the answer can be foundin the new Lokotrack CT32 and

CW32 mobile conveyors

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Service creates value in ChinaChinarsquos most important gold producing area Yantai in northeastern China supplies more than 16 of the countryrsquos goldproduction each year With the gold market thriving the scale of gold production in Yantai has been expanding constantly

Zhongjia Mining Industry Co Ltd is one of the beneficiaries of this thriving industryTEXT amp PHOTOS Yan Xin

Inspection and maintenance of the HP500 cone crusher conducted by Metsorsquos service engineers

In 2011 Zhongjia Mining Industry pur-

chased a modular crushing and screen-ing system from Metso for its new gold

production project With the cooperation

between the two companies continuously

intensifying Zhongjia Mining Industry

signed an additional one-year Life CycleService (LCS) contract with Metso incorpo-

rating Metsorsquos global knowledge in equip-

ment processes and services

ldquoMetso customized a series of reason-

able service solutions also referred toas Metso Performance Solutions for us

including preventive maintenance services

process improvement personnel training

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155

and a procurement plan for wear parts

These really suit our needs perfectlyrdquo saysShen Yidong the Manager of ZhongjiaMining Industry

Effective preventive maintenanceFor mining corporations the biggestconcern is the economic losses caused by

the shutdown of equipment As a result

preventative maintenance is of vital impor-

tance During the contract period Metsoservice engineers offered 7-day tracking

service on the production site every month

to eliminate potential problems and thus

ensured the stability of the system

parts caused pressure on our working capi-tal which was not favorable for our long-

term developmentrdquo Shen explains

To solve this problem Metso designed

a rational stock plan of wear parts and built

a field warehouse In accordance with theuse and consumption of the liners the field

service engineers complement the stock tomake production and operations run more

smoothlyldquoNow when we need to replace the

wear parts we can use them before pay-

ment This not only simplifies the procure-

ment process but also liberates a largesum of our operating capital which can

be used for other business development

purposesrdquo says Shen

Best partner

ldquoAlthough the LCS contract incurs some

early purchase costs in the long run Metsorsquosprofessional and quality service will improve

the equipment efficiency reduce ourenergy consumption and ensure stable

operations thus generating more prof-

its This is the greatest value for us so the

investment is really worthwhile overall Inthe future we will choose more Metso prod-

ucts and services Taking all aspects into

consideration we believe Metso is the best

partner for usrdquo Shen Yidong concludes

More info

Thomas Bai Tel +86 13801009114

thomasbaimetsocom

ldquoIn the eight months since the contract

came into effect our corporation has notsuffered any financial losses due to equip-

ment breakdown The regular maintenance

has greatly improved the efficiency of our

entire crushing system In addition the

experienced engineers from Metso also

provided onsite training and guidancefor our staff and the tailored training has

greatly enhanced the operating abilities of

our employees and upgraded their overalllevel of competencerdquo says Shen Yidong

More productivity with

less consumption

Metsorsquos service contract focuses on real-

izing the optimum performance of each

process flow After analyzing Zhongjiarsquos

production system Metsorsquos techniciansproposed an adjustment to the closed side

setting of the HP500 for tertiary crushingin order to improve the efficiency of the

downstream fine crushing and milling pro-

cessing by over 10ldquoThe process flow improvement solu-

tions provided by Metso not only increased

the output of our gold concentrates but

also reduced our energy consumption andcostsrdquo says Shen

In the past wear parts procurement

took up a larger proportion of Zhongjiarsquos

total production costsldquoTo avoid downtime caused by the

shortage of wear parts we had to keepeight sets of various wear parts in place

However the cost of having so many wear

Zhongjia Mining Industryrsquos gold concentrates processing plant in China

8132019 Results Minerals Aggregates 3 2012ENG

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0983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

Safe quarrying high-

quality aggregates

8132019 Results Minerals Aggregates 3 2012ENG

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ldquoWe share a similar zero-accident strategy and target with Metso and have successfullyfollowed it Metso has also helped us to meet the strictest end-product quality andcubicity requirements set in Spainrdquo This is how Managing Director Intildeigo Ajuria ofOfitas de San Felices the leading hard rock quarrying company in Spain describesthe cooperation with MetsoTEXT Eero Haumlmaumllaumlinen PHOTOS Ofitas and Eero Haumlmaumllaumlinen

The San Felices quarry is situated in a picturesque mountainous landscapebetween the companyrsquos Rioja vineyards and the Bilbao-Madrid motorway

8132019 Results Minerals Aggregates 3 2012ENG

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Ofitas has pioneered the implementation

of several Metso novelties in the Spanish

market The company was the first to use

efficient large track-mounted Lokotrack jaw plants the unique mobile conveying

system and also the new-generation HP4

cone crushers

Today the company operates twomodern Metso stationary plants one in

Guadix near Granada and the newest one

in San Felices Haro Rioja community Both

quarries focus on refining hard rock by pro-cessing ophite rock into the highest quality

railway ballast asphalt and concrete mix

grades The company has a satellite quarry

near Vitoria in PentildeacerradaBeing situated next to a highway and

the famous Rioja vineyards Ofitas must pay

special attention to environmental issues

To minimize dust problems all conveyors

have special covers attached

Quality durability and service

The cooperation between Ofitas de San

Felices and Metso started back in 1973when the Ajuria family bought the com-

pany whose quarrying activities began in

1919 Intildeigo Ajuria has a clear vision of why

the cooperation has continued withoutinterruption for almost 40 years

long-standing personal relationshipsrdquoAjuria adds

Serving railways asphalt

and concrete producers

The year-old San Felices stationary instal-lation lies hidden in a mountainous area

south of the city of Vitoria in NorthernSpain The new plant replaces an old one

that complicated the extraction of ophiterock Both plants are delivered by Metso

With its two separate production lines

the new plant is able to produce all the

end products required ndash from railway bal-last to the finer grades needed for asphalt

and concrete

Due to lower demand the quarry cur-

rently produces some 4000 tons per day

At full capacity however the plant canreach 8000 tons of production per day

30ndash35 of which consists of railway ballastfor high-speed trains and 65ndash70 of chips

and sand Thanks to the versatile two-line con-

cept connected by transverse conveyors

up to 12 different end products can be pro-

duced Depending on the demand for endproducts the material can be guided either

to the HP4 cone or HP400 cone followed

by a Barmac vertical shaft impactor

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

The ophite feed is fed to the C125 jaw crusher by a sturdy dump truck

The key people running the new San Felicesquarry Mine Engineer Carlos Fernandez (left)Managing Director Intildeigo Ajuria with ProductionManager Julian Perez

ldquoThrough the years Metso machinery

has proven its production capacity and

durability resulting in high-quality end

products A big plus for us has also beenthe quick response time to our process

challenges or servicerdquo

ldquoIn fact our cooperation extends

beyond day-to-day business matters to

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155

Meeting the strictest cubicity demands

The Spanish regulations concerning end-product cubicity are becoming more

demanding The flakiness percentage of

railway ballast must be below 10 and for

asphalt and concrete aggregates less than

15

ldquoWith Metsorsquos HP4 cone and the Barmacvertical shaft impactor we can meet even

the strictest cubicity demands We believe

that our high quality is helping us to sur-vive in the present recessionrdquo notes Mine

Engineer Carlos Fernandez

ldquoWe hope to increase the total extrac-

tion of the three quarries from the present15 million tons per year because our plant

capacity allows more than double thatrdquo

Fernandez adds

More info

Angel Luis Garcia Tel +34 686 94 35 30

angelluisgarciametsocom

In addition to being the leading Spanish

quarry to process hard rock Ofitas de SanFelices also cultivates 34 hectares of vine-yards next to the quarry which is situated

in the famous Rioja wine area

The company has previously sold a

harvest of over 200000 kg of Tempranillo

grapes to local red-wine makers Recentlythe company built its own wine process-

ing plant to process 10000ndash15000 kg of

grapes themselves

Aggregates and wine production

Andoni Ajuria the founder of Ofitas de san Felices (left) with Intildeigo Ajuria the present ManagingDirector tasting wine from the companyrsquos own vineyards

The first vintage wine of Ofitas har-

vested in autumn 2010 is now maturingin oak barrels After maturing for 12 to 15months the wine is called crianza and after

two years it will be granted the classifica-

tion reserva

ldquoWinemaking is not a business but

a hobby for us We give our wine out aspresents and drink it when we meet

our suppliers and friendsrdquo Intildeigo Ajuria

comments

For environmental protectionall of San Felicesrsquos plantconveyors are covered

Ofitas de San Felices quarry

LOCATION Haro near the city

of Vitoria northern Spain

SIZE 100 hectares

ROCK TYPE Ophite with Los Angeles

index of 9ndash10

PRESENT DAILY EXTRACTION 3000 tons

of ophiteNUMBER OF PERSONNEL 30

RESERVES 10 million tons

MAIN END PRODUCTS 0ndash2 mm

2ndash4 mm 4ndash10 mm 10ndash16 mm

16ndash22 mm 25ndash60 mm (ballast)

METSO MAIN EQUIPMENT

VF feeder

C125 jaw crusher

ndash feed size 0ndash800 mm

ndash css 130ndash140 mm

HP400 cone crusher

ndash feed size 80ndash250 mm

ndash css 40 mm HP4 cone crusher

ndash feed size 40ndash80 mm

ndash css 15 mm

Barmac 6150 VSI crusher

4 CVB2060 screens

2 TS32 screens

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Metso Distribution Centers he

Europe (Tongeren Belgium)

France (Macon)

Czech Republic (Přerov)

Austria (Vienna)

2271 d

Brazil (Sorocaba SP)

1014 d

USA (Columbia SC)

1690 d

USA (Waukesha WI)

434 d

South Africa (Vereeniging)

Ghana (Tarkwa)

Meacutexico (Irapuato)

Peru (Lima)

Chile (Concoacuten)

788 d

Sweden ( Trelleborg)

Finland (Tampere)

UK (Rugby)

865 d

Russia (St Petersburg)

Brazil (Parauapebas PA)

206 d

4983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983122983141983152983151983154983156983145983150983143 983154983141983155

In the case of an equipment failure or

a planned service shutdown resuming

production as quickly as possible is crucialEach hour spent waiting for a spare part to

arrive equals money lost Whether the right

part takes 12 or 48 hours to arrive really

makes a difference

The comprehensive and global Metsospare and wear parts service network pro-

vides you with the right part in the right

place and at the right time Our strategi-

cally located Distribution Centers and

Satellite Warehouses are on call 24 hoursa day 7 days a week ensuring efficient

parts replacement near you

Check out the locations of the MetsoDistribution Centers and how many parts

pass through them each day

More info

Marcelo Farah

Tel +55 15 2102 1315

marcelofarahmetsocom

you minimize downtime

Australia (Perth)

746 d

China (Tianjin)

China (Kunming)

China (Shanghai)

393 d

India (Faridabad)

India (Ahmedabad)

India (Hyderabad)

India (Bhubaneswar)

India (Bangalore)

419 d

Russia (Yekaterinburg)

Australia (Newcastle)

New Zealand (Matamata)

983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088

TEXT Sofia Williams

Singapore (Singapore)

Distribution Center Satellite Warehouse

8132019 Results Minerals Aggregates 3 2012ENG

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Following a large investment

in Metso crushing equipmentand services Buena Vista del

Cobre is now expanding the

mine site to include even more

equipment ndash and with thatexpansion comes the need for

more local service resources

Metso and Buena Vista del

Cobre have entered into a Life

Cycle Service agreement forthe plant and construction of a

brand new Metso service hub

is under way in Cananea

New facility new

level of service

The Cananea service hub

which will be up and running in early 2013will support the recent expansion and resur-

gence of Buena Vista del Cobre Initially it

will be a major repair and assembly center

for pumps crushers and screens and will

provide for rubber covering capabilitiesBut the 8000-square-meter facilityrsquos service

offering will be expansive including a con-

signment stock inventory to help serve theminersquos varying needs Metso currently has

50 service team members on site

Although Buena Vista del Cobre was a

key influencer in building the new servicehub this location will also enable Metso to

expand its capabilities and provide local

support to the entire mining community

in northwest Mexico The Cananea hub

will serve a number of major copper and

gold mines in the region including MineraFriscorsquos San Felipe Fresnillorsquos Milpillas and

Grupo Mexicorsquos Mexicana de Cobre

ldquoBuena Vista del Cobre is the biggestcustomer we have in Mexico today and

with this expansion project itrsquos only going

to grow and be strongerrdquo says Felix Forna-

guera Director of Services Mexico CentralAmerica and Caribbean ldquoWith that said the

idea behind the Cananea service hub is to

provide a central location for local support

for all our major customers in the areardquo

Establishing safety

ldquoIt was key to have our support here in

Cananea because the Buena Vista delCobre started from the ground uprdquo saysFelix ldquoWersquove been able to help the cus-

tomer to establish the best in support

service and operations from the very

beginningrdquo And this ground-up approachincluded a major focus on safety

Metso worked closely with Buena Vista

del Cobre to establish the safety proto-

col by which the mine operates Basedon Metsorsquos expertise the safety measures

put in place have enabled the mine to

become strict and efficient in its operations

and maintenance procedures To achievethis Metso worked closely with local andnational authorities to ensure the safety

plan was comprehensive and in accord-

ance with all established legal bodies

The best in regional support

The service hub in Cananea is a prime

example of Metsorsquos focus on providing local

service and support to its customers all

Service shines in Cananea MexicoAfter three years of inactivity the Buena Vista del Cobre mine in Cananea Sonora Mexico has been operational since 2010A mine that was inactive for such a significant amount of time however requires a great deal of support to successfullyrestart the plant and bring it back to an operational and profitable state

TEXT Deanna Lee PHOTO Metso

over the world ldquoWe are the first

company developing this kindof service in northwest Mexicordquo

adds Felix ldquoOur people have

developed a close relationship

with the team at the mine Itrsquosmore than a supplier relation-

ship our guys are inside the

mine living and working thererdquo

In fact this is the model

that Metso is using in servicehubs all over the globe build-

ing modern facilities bringing

teams on site and workinghand in hand with mine

operators The Cananea Service

hub is only the most recent

example of Metsorsquos commit-ment to service and northwest Mexico is

yet another mining hotbed thatrsquos going to

benefit from the companyrsquos support

More info

Felix Fornaguera Tel +52 4621079227

felixfornaguerametsocom

A mining cone serviced by Metso at the Buena Vista del Cobre mine inSonora Mexico

ldquoThe new Cananea service center will be a majorrepair and assembly center for pumps crushersand screensrdquo says Felix Fornaguera Director ofServices Mexico Central America and Caribbean

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

8132019 Results Minerals Aggregates 3 2012ENG

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During the MINExpo exhibition over 1300 people visited the Metso stand

983122983141983152983151983154983156983145983150983143 983154983141983155

Held every four years MIN-Expo consistently grows so

perennial exhibitors like Metso

are challenged with elevating

their presence and drawingin new (and greater numbers

of ) visitors each year ldquoItrsquos not

necessarily a challenge to lsquotoprsquo

our last showingrdquo says Keith

Ference Vice President ofmarketing and communica-

tions North America ldquoThere

are four years between eachMINExpo so we always have

a lot to say and reveal to our

customersrdquo The real challenge

he says is finding an exciting

and dynamic way to deliverthe message ldquoTherersquos so much

to see here so your booth has

to be compelling from the

outside-in and thatrsquos what

we always try to dordquo

Service sets the stage

The Metso booth created buzzin a number of ways and per-

haps the most striking (partly

due to its size) was the live

theater presentation As visitorspassed through the aisles of the show-

room the sights and sounds from Metsorsquos

theater were hard to miss And once guests

entered they were captivated by a short

high-energy video presentation focused

on Metsorsquos service capabilities The message was simple Metso is ldquoyour

local service partner rdquo for all mining and

construction needs The video showed ourservice teams in action all over the world

and the audience came away with an

understanding about Metsorsquos commitment

to service Customers can count on morethan 70 local service centers run by more

than 1700 expert technicians delivering

Metso makes an impact at MINExpo 2012At this yearrsquos MINExpo International nearly 60000 attendees flocked to Las Vegas Nevada the largest turnout in showhistory The visitors ndash mining professionals from all over the globe ndash explored 850000 square feet of showroom spacefeaturing the industry rsquos latest technology equipment products and services They toured the show for three days

seeking the latest and greatest from more than 1800 exhibitorsTEXT Keith Ference PHOTOS Tracey Ford Perry

detailed descriptions andphotos of all of Metsorsquos mining

and construction products and

services The app also provides

digital access to Results and asearchable database of sales

contacts By day three of the

show MetsoMAP had been

downloaded by more than

500 usersIn addition to the app the

booth was equipped with

several LCD screens each con-trolled by Metso experts who

used their iPads to present new

products like the Megalinertrade

and the HRCtrade A featured

presentation on Metsorsquos lineupof energy-efficient comminu-

tion equipment including the

VERTIMILLreg SMD and MP-1250

cone crusher was also avail-

able letting customers seehow Metso technology delivers

some of the worldrsquos most effi-

cient size reduction

Measuring MINExpo success

After a very busy three days

(on top of months of prepara-tion leading up to the show) everyone

involved with MINExpo ndash from the North

American marketing team responsible for

the booth to the product managers and

sales force that worked the floor ndash is view-

ing the show as a success ldquoTherersquos alwaysa sigh of relief after each (MINExpo)rdquo says

Keith ldquoAnd overall the initial feedback

and response has been very positiverdquoWith more than 1300 visitors to the

booth Metso certainly made an impact

ldquoWe learn a lot from each show and with

some time wersquoll have a better understand-ing of the tangible results of our effortsrdquo

Keith adds

reliable service for mining equipment as

well as customized cost-effective life-cycle

services contracts

Technology ndash MetsoMAP

is an industry firstMINExpo provided the industry with its firstglimpse of Metsorsquos revolutionary iPad app

MetsoMAP The app was demoed to the

boothrsquos visitors via ldquothe worldrsquos largest iPadrdquo

a custom-made 80-inch screen that show-cased all of its capabilities most of which are

groundbreaking in the industry MetsoMAPrsquos

simple interface is highly intuitive making

it easy to view process animations videos

The presentation of the new HP cone crusher attracted a large audience

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When yoursquore allowed less than a dozen days per year for breakdowns repair andmaintenance every single hour during a service shutdown counts There simplyisnrsquot any room for surprises Thatrsquos why Boliden counts on MetsoTEXT amp PHOTOS Sofia Williams

8983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

Kurt Kalla Site Managerof Metso Gaumlllivare ServiceCenter is responsible forthe maintenance of Aitik

Metso and Boliden Strivingtogether for 97 uptime

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983122983141983152983151983154983156983145983150983143 983154983141983155

One of the biggest copper mines in

Europe Bolidenrsquos Aitik is located deep inthe wilderness of Swedish Lapland next to

the small town of Gaumlllivare The mine has

been operating since 1968 and a recent

expansion has increased its annual ore

production to 36 million tons

But the ambitious Swedes are not will-ing to lay back and relax just yet Bolidenrsquos

new aim is to reach a production rate of

45 million tons of ore per year in AitikAfter that Perhaps more than 55 million

tons The ore concentration in Aitik is very

low-grade with a mere 022 copper con-

tent hence the need for high capacityAchieving the ambitious production

goal requires maximum plant availability

This means that everything from the crush-

ers to the filters must be up and runningfor approximately 97 percent of the time

Thatrsquos where Metso comes into play

A cost-per-ton contract in action

The maximum uptime requirement allowsless than a dozen days per year for break-

downs repair and maintenance at Aitik

Every single hour during a service shut-

down counts There simply isnrsquot any roomfor surprises

Executing a successful shutdown under

such conditions requires a reliable service

partner not afraid of challenges and this iswhy Boliden has entrusted Aitikrsquos services

operations to Metso Boliden and Metsohave worked together since the 1960s

and the collaboration took another step

forward in September 2012 when the twocompanies signed a three-year extension

of the services contract for Boliden Aitik

ldquoThe new contract is a cost-per-ton

agreement We get paid based on Aitikrsquos

production Itrsquos a win-win deal for both par-

ties but also a new mindset for usrdquo explainsKurt Kalla Site Manager of Metso Gaumlllivare

Service Center responsible for serving Aitik

From now on the duration of the shut-down is what matters the most According

to Kalla the Metso service organization in

Gaumlllivare is now streamlining its operations

to fit the bill and has already witnessed thestrategy working In August 2012 Metso

carried out a 188-hour service shutdown in

Aitik which turned out to be a success

Zero tolerance for injury

One key factor to the success was theextensive planning of precautionary health

safety and environment procedures under-

taken by Metso prior to the shutdown Thanks to strict measures applied no

injuries or accidents occurred during the

shutdown and the work could easily be

finished on scheduleMats Johansson Health Safety

and Environment Manager for Metso in

Sweden explains how this was achieved

rdquoPlanning of the shutdown included arisk analysis for all new tasks participating

in Bolidenrsquos safety coordination meetingsmeeting with both Metso supervisors and

subcontractor supervisors and finally a

meeting with the entire staff participating

in the shutdown where everyone had to

sign a document stating their commitmentto the information providedrdquo he says

During the actual shutdown plenty of

new barriers signs and awareness cones

were put in place as a result of observa-tions from previous audits and safety plans

and risk analyses were readily available

in the work area Metso and Boliden also

introduced a Mill Inching permit a certifi-cate for completing a mandatory course for

those involved in the process In addition

Metso carried out random safety audits

during the shutdown to make sure thestrict policy was followed

According to Boliden Metsorsquos way of

working is a good example of how health

and safety precautions should be handled

ldquoMetso is a good example of how towork with safety and health plans risk

analysis permits and welding permits

Their table with all binders in the second-

ary mill area was exemplaryrdquo says Kjell-Arne

Johansson a technician from Boliden

The use of the new Metso Megalinertrade

system in the lining of Aitikrsquos Metso AG

mills has also improved the safety of main-tenance staff The Metso Megalinertrade con-

sists of larger-than-average liners bolted

in position from outside the mill Mainte-

nance technicians no longer need to go

inside the mill and stand in the dangerousdrop-zone of the liners gt

Boliden aims to reach a production rate of 45 million tons of ore per yearin the Aitik mine site

ldquoA complete risk analysis was conducted during the planningof the shutdownrdquo comments Mats Johansson Health Safetyand Environment Manager for Metso in Sweden

8132019 Results Minerals Aggregates 3 2012ENG

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Service the Metso way

24 hours a day 365 days a year

In addition to paying close attention to

health and safety issues executing an effi-

cient shutdown requires careful planning

and timing of every step in the mainte-

nance process Wear and spare parts have

to be available on time and a repair shoplarge enough to accommodate equipment

located close by

ldquoTo keep maintenance breaks as short

as possible we aim to replace the pump on

site and bring the old one for repair to our

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

nearby facilities This method gives us the

peace to do a good job and keep the cus-

tomerrsquos operations runningrdquo Kalla describes

the Metso way of handling Aitikrsquos pump

maintenance

Metso is currently expanding its Gaumllli-

vare service center to include a distribu-

tion center for wear and spare parts andalso concentrating its previously scattered

operations under one roof in its Vuoskon-

jaumlrvivaumlgen facility The expansion is due to

be completed by 2014

Metso equipment

delivered to Aitik36

bull 2 AG mills diameter 116 x

137 m gearless 22-MW motor

bull 2 Pebble mills diameter 91 x

113m dual 5-MW pinion drive

bull 3 VPA pressure filters VPA 1540-54

bull 12 sample pumps and pipes

VF50

bull 60 Various slurry pumps up to

MR500 modelbull Appr 5000 m rubber-lined slurry

pipes up to 600 mm diameter

bull Appr 5000 m rubber-lined by

gravity pipes up to 600 mm

diameter

bull Appr 5000 m rubber hoses

up to 600 mm diameter

Not only does the expansion make ser-

vice shutdowns at Aitik run more smoothly

it guarantees a more comprehensive

on-call emergency service response in the

region ndash thanks to the spare and wear parts

inventory available 24 hours a day 365

days a year

More info

Lars Rosenling

Tel +46 70 107 45 90

larsrosenlingmetsocom

Metso grinding equipment dominates the view in the concentrator

Safety on site is made up of small things like

making sure that everyone remembers to secure

the hoses in place

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Pebbles have always been a

challenge for producers of sandsince they cannot be returned

to rivers after extraction For

decades the processing of this

material resulted in a huge

environmental liability with alarge amount of pebbles hav-

ing to be stored away and left

unused

Transforming problems into

business opportunities

Areia amp Cia (areia = sand) has

operated in this market forover 20 years and decided to

enlist the help of Metso to find

a profitable solution for the

processing of pebbles

In July 2011 analyses werebegun to assess the abrasive-

ness and crushability of the

material Four alternatives wereidentified for processing and

transforming pebbles into sand

Initially Areia amp Cia was

interested in acquiring an

impactor for its reason-able price level However the

customer wanted to process

all the pebbles that were col-

lected daily in addition to some of the

material that it had stored In weighing theresults expected by the customer and the

excessive abrasiveness of the material the

HP200 cone crusher was decided on as thebest alternative

Areia amp Cia made the required invest-

ment and after using the HP200 for just

six months the company has already beenreporting outstanding results The HP200

not only transforms pebbles into sand but

also produces sand of excellent quality

with high yield and low maintenanceWith minor adjustments the HP200

also enables the production of sand withspecific particle size distribution for special

applications such as filtering sand blasting

and foundry sand adding value to the prod-

uct and increasing the types of sand offeredldquoMetso is pleased that the HP200 not

only enabled the processing of a product

that had been set aside as unusable but

HP200 cone transforms pebblesinto high-quality sandOver the last few decades Brazilian economic growth has been driving demand for construction aggregates The market

for sand in turn has been experiencing major difficulties in maintaining a consistent supply Presently one of the mainchallenges the industry faces is the large amount of pebbles that are obtained in the process of extracting sand at timesconstituting nearly 50 of the volume of material dredged from riverbeds

TEXT Sheila Ivers PHOTO Areia amp Cia

also that it opened up new

market opportunities for Areiaamp Cia Thatrsquos the standard we

seek to deliver to our custom-

ersrdquo states Luiz Oliveira Techni-

cal Salesperson of Metso Brazil

HP cones entering the

Brazilian sand-making

market

Todayrsquos cones such as theHP200 have high resistance

to impacts and abrasiveness

more efficient crushing cham-

bers low maintenance costsand excellent productivity

Following the acquisition of

the HP200 Areia amp Cia is now

also producing special sands

that command a price that is100 higher than common

sand The entire stockpile of

pebbles accumulated through-out the companyrsquos 20 years of

operations has already been

transformed into sand and the

stock of pebbles held by com-

petitors is also being purchasedfor processing

Cristiane Brizolari the

owner of Areia amp Cia confirms

the transformation that has taken place in

the production and commercial processldquoThe HP200 opened up new niches in

the market enabling the production of dif-

ferent types of sand with added valuerdquo

More info

Luiz Oliveira

Tel +55 011 9971 3603

luizoliveirametsocom

After the pebbles are crushed into sand with the HP200 cone crusherdifferent grades are screened for various end uses

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Where therersquos a will we dig a wayAFCONS-Strabag and Metso embark on tunnel project together

When the joint venture AFCONS-Strabag initiated work on the Rohtang bypass tunnel project at an altitude of 3980 metersabove sea level in Himachal Pradesh India they deliberated each aspect with clockwork precision The project involved anumber of surprises and challenges and required technology and project management skills that were second to none

TEXT amp PHOTOS Monisha Majumdar

Cutting a 10-meter-wide and nearly 9-kilo-

meter-long tunnel through the Himalayas

in one of the toughest terrains and cli-mates in India makes for quite a challengeResults set out to find out how AFCONS-

Strabag and Metso are making their way in

one of their most critical projects to date

The only road connection to the north-Indian border region of the province

Himachal-Pradesh and beyond the Manali-

Leh highway leads across the Rohtang

pass Due to the heavy snowfall and high-

velocity winds in this region the towns

located north of the pass are cut off from

the rest of the country during winter for atleast four often even six months each year

A tunnel with strategic importance

With the construction of the tunnel at

3100 m above sea level the Manali-Lehhighway will become an all-weather road

thereby enabling a significant improve-

ment in the economic development of

northern Himachal-Pradesh and an alter-

nate route to the strategically important

Ladakh region

Manali south of the pass is an alreadywell-developed tourist location that is

becoming more and more popular Upon

completion of the tunnel it is likely that

tourist activities will extend to the areanorth of the pass Moreover the tunnel

shortens the distance between the towns

of Manali and Leh by approximately 45 km

thus saving several hours on the small dan-gerous pass road

The Rohtang pass in the Western Himalaya

region of Northern India with its altitude ofalmost four kilometers ranks among thehighest trafficable passes in the world

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983122983141983152983151983154983156983145983150983143 983154983141983155

The 88-km long horse-shoe-shaped

tunnel provides space for a two-lane8-m-wide carriageway as well as a one-

meter-wide footpath on both sides A

22-m-high and 36-m-wide emergency

tunnel will be integrated in the tun-

nel cross-section Altogether more than

800000 msup3 of rock will be moved Tunneling works started around spring

2010 with excavation driven from both por-

tals As the north portal is inaccessible dur-ing winter closure the excavation focused

on the south After a planned construction

period of 55 years the tunnel is scheduled

to be completed by the end of 2015

Best man for the job

The BRO (Border Road Organization)

wanted to roll out a global tender for theproject due to the challenges that such a

project involves and also considering thatitrsquos the first time in India that a project of

this scale was to be carried out This imme-

diately triggered the need to roll out aglobal tender All major Indian construction

companies bid for it some individually and

some in partnerships

Strabag an Austrian tunnel specialistwas one of the companies who bid for the

project along with AFCONS a Mumbai-

based infrastructure company In Septem-

ber 2009 AFCONS-Strabag was awardedthe contract

Mr Sunil Tyagi Deputy Project Man-ager at AFCONS had this to say about the

unique projectldquoThis project is located in the Himalayas

and as far as we understand the terrain

there is among the toughest We came out

with a new technology and to be honestit is a fairly simple one We would generally

start with the traditional technology of drill-

ing and blasting and then obtain our muck

feed from the inwardbottom of the tunnelrdquo

ldquoThe technology is supplied by Rowa Tunneling Logistics and this is the first

time it is being used in Asia A jaw crusheris placed at a distance of about 40-45

meters behind the face The blasted muckextracted from the face is fed to the crusher

to reduce the lump size and then through

an overhead conveyor transport system

it is then transported out of the tunnelrdquoldquoThis enables free movement of man

and machinery in the lower area or spe-

cifically on the ground area If we were to

conforms to the Indian standard for fines amp

coarse aggregates as prescribed in IS383-1970

The plant was up and running in good

condition and performing to AFCONSrsquos

satisfactionldquoWe have worked with Metso in earlier

projects and are quite impressed by thekind of technology amp services they provide

We have a history together so the trust fac-tor also comes inrdquo explains Dhiman on their

choice of Metso as a partner

Service makes the difference

ldquoMetsorsquos services have made a big dif-ference in the project Without them we

would still be struggling with the machin-

ery and production The service is really

good and the service engineers are knowl-edgeable prompt and quick to act Any

problem can be solved by Metso We donrsquothave to wait until a service engineer turns

up ndash they have the capacity to solve prob-lems over the phone as wellrdquo says Dhiman

ldquoThe Metso plant didnrsquot create any prob-

lems for us We had problems in logistics

the feed was sticky and the weather condi-tions were bad but thankfully we did not

face any problems with production and

efficiency as the Metso plant is performing

very wellrdquo Dhiman concludes

More info

Amol Sinha Tel +91 9811 671 924

amolsinhametsocom

use the old conventional technology this

wouldnrsquot have worked for us in the stipu-lated timerdquo Mr Tyagi adds

When the going gets tough

partner with the toughest

Sensitive projects require the best technol-

ogy After AFCONS-Strabag landed theproject Metso was an obvious choice as a

technology provider not only because of

the long-standing business relationshipbut also for the sheer consistency in prod-

uct quality and service deliverance Metso

strives for

ldquoAfter signing the project we faced alot of road blocks including extreme cold

avalanches roadblocks less oxygen ndash you

name it we faced itrdquo explains Ankit Dhi-

man Plant Manager at AFCONS-Strabag The Rohtang valley is known for its

notorious avalanches and landslides SoAFCONS had to take extra steps and safety

precautions against hazards on the site

ldquoIn this freezing cold not just us humansbut also the machines are at increased risk

of damage I remember when we used

to run the plant during winter the diesel

engines would freeze We had to constantlyheat up the fuel container to get the plant

running And even the sand in the sand

trap would freeze so we had to clean it on

a daily basis to stop the pipes from mal-functioningrdquo Dhiman adds

Plant designed for difficult terrain

Difficult terrain coupled with space con-straints led Metso engineers to put their

minds together to come up with a suitable

plant configuration After studying the

requirements of the project Metso sug-

gested a 150-tons-per-hour three-stagemodular plant using a C106 jaw crusher

a GP11F secondary cone crusher and a

B7150 tertiary vertical shaft impact crusher

In addition considering the unpredict-ability of the feed the plant was about

to reach a point where the amount offines to be handled could be increased

dramatically Metso strongly suggested the TK11-27-3V grizzly scalper and this became

the first-ever TK scalper to be supplied by

Metso to an Indian customer Also in order

to get better products a sand trap SF2360was added to the configuration

The sand trap is important equipment

for this project as it washes the sand thatMr Sunil Tyagi Deputy Project ManagerAFCONS-Strabag

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Smooth transition to new-generation jaw crusher in Germany

Roumlhrig is a German company with a rich heritage The company has been quarrying granite at its plant in Bergstrasse inthe Sonderbach district of Heppenheim for three generations

TEXT amp PHOTOS Ralf Goffin

Roumlhrigrsquos superior product variety is onereason why the companyrsquos proximity to its

customers can be understood in more than

just physical terms The companyrsquos high

level of innovation has allowed it to estab-lish itself as a reliable supplier of materials

both regionally and internationally This

operational and technical expertise always

manages to keep in step with growing

market requirements

In terms of technical processing equip-

ment Roumlhrig has used a Nordberg C160stationary jaw crusher from Metso since

1992 At the start of 2012 it was finally

exchanged for a more up-to-date version

from the same model range

Metsorsquos C Series is specifically designed

to pre-crush hard rock and can cope effort-

lessly with even the hardest of materials

The dimensions of the new stationary jawcrusher are identical to those of the old

one which means that it could simply be

slotted into the housing vacated by the

previous version

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983122983141983152983151983154983156983145983150983143 983154983141983155

Third-generation Managing DirectorMarco Roumlhrig expects the new machinersquos

service life to be just as long as the previ-

ous model due to the product upgrades

that have been implemented The integral motor base is another plus

point in models made by other manu-

facturers it is located outside the crusher

This element of good fortune ensured that

Roumlhrig could reuse the housing withoutany additional rebuilding

Another advantage lies in the revision

of the guards for the C160rsquos drivetrain andflywheel The sturdier construction method

used for the crusher requires fewer parts

which facilitates easier installation andmaintenance and it makes it simpler to

access the motor

Under the watchful eye of Metsorsquos

Assembly Manager Maik Engelstaumltterthe entire project including removal and

installation was successfully completed

within two weeks

Installation making the most

of the available space

Roumlhrig will likely remember the day the

new crusher was installed for a long time

the pitman and main frame were deliveredseparately prior to installation and assem-

bled on site It took just one hour to replace

the old stationary crusher with the new

model A lorry-mounted crane was used toposition the 85-ton crusher with millimeter

precision in the crushing plant Once the

new crusher had been positioned in theexisting steel structure the next task wasto fix it into place as securely as possible

despite the limited space Special vibration

dampers were installed at a height of two

meters to prevent the crusher from sliding

Norbert Ried (fourth from left) installed thenew C160rsquos predecessor 20 years ago and isdelighted at the durability of the powerfulcrusher that is now making way for a newermodel Also pictured from left to right ManagerVolker Angermann Assembly Manager Maik

Engelstaumltter Technical Manager Stefan

Koob Project Manager Dominic SchoumlnhardtManaging Director Marco Roumlhrig Service

Technician Stefan Kolze and employees ofthe installation company Stafemo

On the hook after theold C160 was liftedout by crane the newcrusher was installedin almost no timeOnly the roof of thehousing had to beremoved

sideways off its mount An initial test run

with materials was carried out around oneweek later after all the electrical cables had

been installed

Simultaneously with the installation

of the C160 which is the first of the latest

generation of crushers to be installed in

Germany a new Nordberg GP100 conecrusher was also being installed in Roumlhrigrsquos

chipping plant Roumlhrig is convinced that

the technical improvements made tothe new Metso crusher can only be an

advantage worldwide

Roumlhrig places great value on consistent

product quality maximum added valueand optimum refinement of its product

range Bearing in mind that Roumlhrig has

enough reserves of raw material to last

for the next 150 years the company canconfidently continue to develop with an

emphasis on quality rather than quantity

More info

Dominic Schoenhardt

Tel +49 (0)621 727 00 610

dominicschoenhardtmetsocom

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Groupe Charier Carriegravere de la Mariais France

Quarrying with certi1047297ed quality The Charier Group with its 1600-strong workforce is a family business thatthis year celebrates 115 years of quarrying The company pursues a long-termdevelopment policy that since 2007 has seen processing installations upgradedat 4 of its 9 extraction sites

TEXT Liliane Boutin (with extracts from Mines amp Carriegraveres and Terrassements amp Carriegraveres magazines)PHOTO Baloon photo

The processing installation is of the horizontal type with a primary station located 56 meters below the site access road to keep it hidden from view

The crushing and screening installation at

Charierrsquos CM La Mariais quarry (at Donges

on the Loire estuary) has been in opera-tion since September 2011 Based on theoperatorrsquos ideas it was designed by Metso

to replace a worn-out installation installed

right on top of the seam being extracted

Since its commissioning it has becomethe second quarry in the company to

receive ISO 14 001 certification

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983122983141983152983151983154983156983145983150983143 983154983141983155

tertiary material of sand and gravel for the

local market to use in concrete surfacingprefabrication etcrdquo

Incorporation of a screening station

The stone extracted from La Mariais is

according to the quarry granitic gneiss

sound and homogeneous with a LosAngeles index of 15 good wear resist-

ance with an MDE of 10 a true density of

265 and a certain abrasiveness (2000 gt)ldquoCharacteristically it has a tendency to form

blocksrdquo Leblin points out

The main criteria in designing the instal-

lation was to provide an output of 600000metric tons from one station (38 hours

week) to produce materials aimed at the

concrete and surfacing markets ldquowhich

involved providing a tertiary station withscreening plantrdquo he adds

With this new unit the operating com-pany expands its product range through

the addition of fine materials obtained

from the tertiary screening station This unitis capable of producing 170 tonshour of

020

Preserving the environment

and optimizing safety

The screens have motorized bogies and

retractable walkways to facilitate access

when the screens are opened for main-tenance Other walkways provide access

to the tunnel input feeders The feederscan be isolated with hydraulic rod gate

bars this hydraulic assistance eliminatesthe need to use a heavy hammer to lodge

these metal bars

All conveyors transporting fines (02

and 04) are covered with a tarpaulin to

avoid flying dust and all the screens arehooded (metal cover with Trellex seal-

ing) The Brunone company has installed

dust-tight containment at the outlet of the

tertiary station crushers (HP300 and HP4)on the belt located under the screens

and under the hoppers located belowthe tertiary screens The crushers are put

under negative pressure and the finesare extracted through sleeve filters (7000

m3 h) with declogging which deposits the

dust back onto the conveyor belt

A high-pressure 100 bar water mist sys-tem has been installed at the primary sta-

tion discharge at the secondary crusherrsquos

discharge chutes (Omnicone) and at the

transfer points on the belt

Designed to last

ldquoThis type of new installation can easily last

thirty yearsrdquo affirms Project Leader Bruno

Peix of Metso ldquoIt quite simply depends on

how well it is maintained Thatrsquos why weprovide maintenance contracts that call for

our technicians to make regular inspection

visits and carry out preventive mainte-nance and any necessary repairsrdquo

In 2011 Metso commissioned about

10 new processing units in France like

the one at La Mariais quarry

More info

Frederic Bazire

Tel +33 (0)681442804

fredericbaziremetsocom

Key figures

DURATION OF WORKS 15 months

DRAWING OFFICE TIME 7800 hours

HEIGHT OF SILOS AND GRINDER BUILDINGS

15 m

TOTAL LENGTH OF CONVEYORS 14 km

WEIGHT OF THE INSTALLATION

1200 metric tons

CONCRETE POURED 1800 cubic meters

PROJECT SITE WORKFORCE 30

INSTALLED POWER 2200 kW(not including pumps 200 kW)

METSO EQUIPMENT

Primary

Vibrating feeder PF561-2V

Primary grizzly VG540-3V

Grizzly feeder TK13-20-3V

Jaw crusher C145 with

hydraulic setting

Secondary

Vibrating screen CVB 2050

refurbished

Cone crusher Omnicocircne 1352 SX

with Metso IC7000 controller Ellivar 16 (16 msup2 3 decks) screen

refurbished by Metso

Tertiary

Cone crusher HP300

Cone crusher HP4

2 Ellivar 20 screens (20 m23 decks) for final products

Expanding the production range

ldquoSince the mid-1990s when we became

owners of La Mariais we had used mobilemachinery with an assembly of beltconveyorsrdquo recalls Daniel Leblin Charierrsquos

Technical Manager for site construction

and maintenance

ldquoIt became clear that we needed ahigher performance tool to achieve the

dual goals of reaching one million metric

tonsrsquo maximum production and producing

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Big Lokotrack LT550GPF boostsquarrying productivity by a thirdMaximizing the productivity of operations is a key issue when striving for cost-effective quarrying Big Lokotracks are oneway to achieve improved operational efficiency The Lokotrack LT550GPF equipped with the high-volume GP550 conecrusher and a large screen is popular in the Nordic countries and in Germany and Australia ndash countries all known for theirhigh quarrying volumes

TEXT amp PHOTOS Eero Haumlmaumllaumlinen

Kone-Kostamorsquos new mobile coneplant has reached an averagecapacity of 300 tons per hour

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155

ldquoWith the same number of employees we

can achieve 30 more productivity with

our new LT550GPF unit The high-capacityFS screen has also eliminated the bottle-neck often seen at fine screeningrdquo says

Aarno Kostamo Managing Director of

Kone-Kostamo Oy one of Finlandrsquos biggest

crushing contractorsAccording to Kostamo the high capacity

of the GP550 gyratory cone crusher easily

handles feed from the C120 and C125 jaw

crushers For the contract with the Talvivaara

nickel mine the LT550GPF is being fed bythe brand new Lokotrack LT120 jaw plant

Average capacity 300 tons per hour

Talvivaara Europersquos largest nickel mine uti-

lizes large quantities of aggregates Kone-Kostamo has contracted several million

tons of different end products for the mineIn August 75000 tons of 0ndash63 mm

road gravel was crushed Smaller amountsof finer 0ndash6 mm 0ndash16 mm and 0ndash32 mm

aggregates are also being produced

The rainy summer increased the need

for road gravel along the muddy roadswhich must endure dump trucks weighing

as much as 260 tons

ldquoThe mobile process consisting of the

LT120 jaw plant and LT550GPF cone plant

is cost-effective while aggregates of vari-ous sizes can be produced in a two-stage

operation and with high capacity The con-trolled stroke and elliptical movement of

the FS screen secure big passing throughcapacitiesrdquo Kostamo explains

Operated in two shifts for a total of 16

hours per day the LT550GPF has logged

more than 600 working hours over a two-month period

Managing Director Aarno Kostamo (left) and foreman Karri Maumlenpaumlauml studying the cavity optionsavailable for the new Lokotrack LT550GPF

Longer perspective than

a single quarter needed

Kone-Kostamo Oy was founded as an

earth-moving company in Kemijaumlrvi

Northern Finland in 1956 The company

expanded its operations to include crush-

ing contracting in 1964 and later on

switched to concentrating fully on crush-ing activities

Kone-Kostamo consistently crushes

and screens around 28 million tons ofaggregates annually and has net sales of

between EUR 8ndash9 million

ldquoWe believe that issues within the crush-

ing industry including the purchasing ofmachinery must be studied with a longer

perspective than a single quarter The

secret to our success has always been our

solid work ethic and professional employ-eesrdquo Kostamo sums up

More info

Esa Berg

Tel + 358 40 837 8692

esabergmetsocom

8132019 Results Minerals Aggregates 3 2012ENG

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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155

Monitoring-based reporting is vital for

assessing the performance of a mobile

crushing plant Metso provides suchreporting tools through its plant-wideautomation system Metso DNA (Dynamic

Network of Applications) with its infor-

mation platform that links all the mobile

crushing and screen units together as oneentity Basically there is a lot of measured

real-time information available in every

crushing plant On-line information is

obtained either from each Metso crusherrsquosmachine automation system IC (Intelligent

Controller) or from separately installed

additional sensors and belt scales

All the collected data is sent to a motorhome using wireless communication

based on WLAN technology The motor

home is a purpose-built environment

inside an on-site container In this environ-ment selected variables can be monitored

for assessing the plantrsquos performance And

to make all this even more flexible the

data can be transmitted to a crushing plant

company office using GPRS3G mobile

data communication technologies Thismakes all the last-minute reports acces-sible to the crushing plant managerial staff

at anytime and basically anywhere within

reach of the cell phone network

Production and fuel economics reports

Essentially monitoring and reporting can

be customized to fit the customerrsquos needs

However there are certain off-the-shelf

reports that provide a lot of useful informa-tion for plant supervision The production

report is one of these Requiring at least one

belt scale for measuring the total produc-tion the production report shows the pro-duction rate (tons per hour) for a selected

reporting period eg a day or a week The

production report constantly keeps track of

the plantrsquos production storing all the datathroughout the plantrsquos life cycle

Performance monitoring and reportingfor a mobile crushing plantTEXT Pasi Airikka PHOTOS Metso

unit during which the unit is running By

storing the availability times between start-ups and shutdowns the crushing plant

operation time (hours per dayshift) can be

recorded analyzed and reported In addi-

tion the availability report can be tailored

to evaluate efficient crushing hours during

which the plant is really working and pro-ducing aggregates Consequently the ratio

(0-100) between efficient crushing time

and total running time can be reported forany selected period of time This boosts

the efficiency of the plantrsquos operations

and results in better productivity

Reports on non-choke

or inadequate feeding

Non-choke feeding to crushers is avoid-

able through smart plant-wide crushingplant controls But estimating its severity in

a systematic manner is not straight-forwardwithout constant monitoring and reporting

The crusher choke feeding report makes

use of the crusher cavity level sensors byanalyzing their level measurements By

calculating average and min-max values

and deviations from the average it can be

shown how often the single crusher suffersfrom non-choke feeding to it

In some cases the bottleneck in the

crushing plantrsquos productivity is the material

feeding to the process In mobile plants thefeeding is human operated and therefore

subject to variations Occasionally the sizeof the human-operated machine simply

does not allow for adequate feeding to thecrushing plant There are specific reports

indicating time periods when the crushing

plant suffers from inadequate feeding

Condition monitoring for

crushers and screens

Machine-specific condition monitoring

focuses on vibrating components in

crushers and screens such as drive shaftbearings safety plate wearings and gears

The low middle and high frequencies ofmonitored components are measured and

supervised in real-time to detect abnor-malities due to slow or fast wear looseness

or imbalance

More info

Pasi Airikka

Tel +358 40 587 2730

pasiairikkametsocom

Condition monitoring provides a view tovibrating crusher and screen components forpredictive equipment maintenance

The daily production report shows the hour-by-hour production trend and distribution chartfor a selected day with min-max average andvariation statistics for comparison

Fuel consumption is always an interest-ing concern The fuel consumption reportgives the fuel consumption of each crush-

ing unit (liters per hour) and their total

consumption (liters per hour) for a selected

reporting period and can track fuel con-

sumption changes over timeCrushing plant availability can be

assessed as well The availability report

calculates time periods for each crushing

8132019 Results Minerals Aggregates 3 2012ENG

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983149983141983156983155983151 983150

for tissue machines The record of 2210

mmin was set on June 1 2012 during a

24-hour production run by the TM 2 tissue

machine at the companyrsquos mill in Yenikoumlynear the city of Izmit in Turkey

ldquoThe cooperation with Metso has been

beyond excellent and both parties did

their utmost to make the project success-ful The results clearly show that the efforts

were worthwhile on both sides This coop-

eration will extend to cover new projects

in the futurerdquo says Luumlt1047297 Aydin Paper GroupDirector Hayat Kimya

ldquoWe are not surprised that Hayat K imya

managed to break the world speed record

We have had great confidence in the capa-bility of the Hayat team since our project

started in 2009 We certainly know our

machine very well its stability production

efficiency and speed capabilityrdquo says Jan

Erikson Vice President Sales Metso

PowerThe worldrsquos first eco-gas fueled

power plant is up and running

Lahti Energy Ltdrsquos new Kymijaumlrvi II gasifica-

tion plant was officially inaugurated on

May 8 2012 It is the first of its kind in the

RecyclingRecycling with Lokotrack LT106

jaw plant in New York

A brand-new Lokotrack LT106 jaw plant is

used in the city area of New York USA to

recycle demolition materials The crushing

site faces the skyscrapers of ManhattanIsland

Paper amp FiberHayat Kimyarsquos Metso-supplied tissue

machine sets world speed record

Thanks to a skilled crew and dedicated

efforts Hayat Kimya AS in Turkey has suc-

ceeded in breaking the world speed record

world This CHP plant runs on clean eco-

gas that is gasified cleaned and cooled

from recycled waste with Metsorsquos innova-tive technology

ldquoItrsquos actually eco-gas that we combust

in the boilerrdquo comments Lahti EnergyrsquosProduction Director Jukka Manskinen

ldquoWe convert unwanted waste material into

energy in an efficient and environmentally

friendly wayrdquoNever before has any plant gasified

waste on such a large scale In the gasifier

recycled waste is turned into combustible

product gas which is cleaned cooled and

combusted in a high-efficiency gas boiler

to produce steam for the steam turbine The plant produces 50 MW of electricity

and 90 MW of district heat for the city of

Lahti and its neighboring areasMetso delivered the circulating fluidized

bed (CFB) gasification process gas cleaning

and cooling steam boiler environmental

protection system and automation systemto the entire plant The production of elec-

tricity and heat is kept even with the Metso

DNA automation system that covers the

whole plant starting from fuel reception

AutomationMetso develops and supplies plant-

wide crushing control solutions for

crushing plants

Metso has recently signed contracts on

delivering plant-wide automation systems

for mobile and portable rock crushing

plants The key objective of these deliveries

is to stabilize and to increase productivityand efficiency of the plants using one sin-

gle automation and information platform

for integrating crusher-specific IC machinecontrols

Furthermore the plant-wide system

with its information management tools not

only increases plant availability and opera-

tional safety it also makes troubleshoot-ing quicker and performance monitoring

easier The control room for plant-wide

operability is located either in an excavator

cabin or a purpose-built container

Metso around the world

The new LT106 jaw plant is suitable for crushing both hard rock and all rock-based demolition materials

The new world speed record for tissue setby Hayat Kimyarsquos Metso-supplied TM 2 is2210 mmin

8132019 Results Minerals Aggregates 3 2012ENG

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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 6: Results Minerals Aggregates 3 2012.ENG

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983110983141983137983156983157983154983141983140 983137983154983156983145983139983148983141

Metsorsquos mobile crushing and screening units are in the frontline in the demandingreconstruction efforts in Japan after the nation was ravaged by the biggest earthquakeand tsunami in its recorded history Tracked mobile Lokotracks are the quickest wayto boost the production of aggregates an estimated 200 million tons of which willbe required over the next decadeTEXT amp PHOTOS Eero Haumlmaumllaumlinen

The biggest gold producer in Europe

Agnico Eagle in Kittilauml Northern Finlandcurrently produces some 5000 kg of goldannually The mine plans to expand its daily

ore extracting capacity to 4000 metric

tons which will increase the gold produc-

tion by an additional 1000 kgOther major gold producers in Fin-

land include Nordic Minesrsquo Laiva mine

Endominesrsquo Pampalo mine Lappland

Goldminersrsquo Pahtavaara mine and DragonMiningrsquos Orivesi and Jokisivu mines

Metso with its crushing screening and

minerals processing equipment is a sup-

plier to most Finnish gold mines In addi-tion to the equipment Metso also offers

these gold-mining operations its process

planning expertise and services

New gold deposit discoveries likely

Senior Geoscientist Pasi Eilu from the Geo-

logical Survey of Finland believes that the

possibilities of finding new gold deposits

comparable to the current ones are good

Helping Japan to rebuild

after the tsunami

ldquoIn Finland gold has been found

wherever serious exploration has beencarried out The latest interesting depositshave been located by Mawson Resources

between Tervola and Ylitornio in Northern

Finlandrdquo

According to Eilu the latest findings onlyinclude gold ore exposed at the surface

ldquoIt is very likely that in the near future

gold will be found in the deposits hidden

completely undergroundrdquo he explains ldquoNextyear the Geological Survey of Finland will

publish an estimate on possible gold depos-

its reaching a depth of one kilometer from

the surface This will provide more accurateinformation on potential discoveriesrdquo

The average gold grade in Finnish gold

mines is similar to any gold mine abroad

ldquoThe most common type in Finlandis orogenic gold ore which is similar to

nearly all ores originating in West Austral-

ian and Ontario Canada We also have

volcanic-related gold deposits for example

in the Orivesi mine and small amounts of

gold deposits similar to those found in the

worldrsquos biggest deposits in WitatersrandSouth Africardquo Eilu adds

Focus on green mining

The Finnish Green Mining concept is the

mineral sectorrsquos answer to future chal-

lenges It aims to optimize material and

energy efficiency in the whole productionchain The program aims at efficient pros-

pecting for new deposits and at develop-

ing new solutions for utilizing them It

also aims to minimize local environmentalimpacts and problems to improve work

safety and the workplace atmosphere andto restore mining areas after mining opera-

tions are completed The Green Mining program started in

2011 The main objective is to make Finland

a global leader in the sustainable mineral

industry by 2020 The program encom-

passes two central themes intelligentminimum-impact mines and new mineral

resources

NorthernEldorado Today Finland together with the Nordic countriesfalls within one of the global areas that are experi-encing a gold exploration and mining boomIn recent years major global mining companieshave entered the country and opened gold mines

and they are now set to expand their on-goingoperations A number of promising explorationprojects are simultaneously under way on behalfof some 40 mining companiesTEXT Eero Haumlmaumllaumlinen PHOTO iStockphoto

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156

1

78

9

1011

12

13

15

16

18

19

2021

22

14

2

3

5

6

17

Active Mines and Current Projects February 2012

Kittilauml gold ndash Agnico-Eagle Ltd Pahtavaara gold ndash Lappland Goldminers Ab

Laiva gold ndash Nordic Mines Ab

Pampalo gold ndash Endomines AB

Orivesi gold ndash Dragon Mining Ltd Jokisivu gold ndash Dragon Mining Ltd

Iso-Kuotko gold ndash Agnico-Eagle Ltd

Hanhimaa gold ndash Dragon Mining Ltd

Kettukuusikko gold ndash Taranis Resources IncNaakenavaara gold ndash Taranis Resources Inc

Kiekeroumlmaa gold ndash Tertiary Minerals Plc

Rompasgold uranium ndash Mawson Resources Ltd

Suhanko-Konttijaumlrvi PGE ndash Gold Fields Arctic Platinum OyKuusamo gold ndash Dragon Mining Ltd

Hirsikangas gold ndash Belvedere Resources Finland Oy

Aumlngesneva gold ndash Belvedere Resources Finland Oy

Kopsa gold ndash Belvedere Mining Oy

Taivaljaumlrvi silver ndash Sotkamo Silver ABSeinaumljoki gold antimony ndash Nortec Minerals Corp

Osikonmaumlki gold ndash Belvedere Resources Finland Oy

Haveri gold ndash Lappland Goldminers Ab

Kaapelinkulma gold ndash Dragon Mining Ltd

1

3

5

7

15

11

19

9

17

13

21

2

4

6

8

16

12

20

10

18

14

22

Mine

Prospect

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983110983141983137983156983157983154983141983140 983137983154983156983145983139983148983141

The main minerals processing componentsincluding grinding flotation and pumping

equipment are delivered by Metso

983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

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983110983141983137983156983157983154983141983140 983137983154983156

Endomines

Pampalondash a green andresponsiblegold mineAt Pampalo near the easternmost point of Finland a cleanand environmentally friendly gold mining operation isbeing executed by Endomines With Metsorsquos plant designand a state-of-the-art processing plant Pampalo runs a

green and responsible yet at the same time profitablegold mining operation that avoids acid mine drainagesand targets 100 water recirculationTEXT amp PHOTOS Eero Haumlmaumllaumlinen

With a modest investment of EUR 20

million the Pampalo mine was built fully

operational and now produces 800ndash900 kgof pure gold annually An on-going expan-

sion will increase the minersquos production

capacity by 30 to 50 next yearIn addition to the main underground

mine at Pampalo several promising satellite

gold deposits are being investigated along

the long Karelian gold line The maximum

distance of the satellites is 30 km allowingthe mine to transport and process all of the

produced ore at the Pampalo plant

Small scale can be successful

with hard work

ldquoWith our gold mining operation we can

very well show that with hard work even

small-scale gold mining and production

can be done in a sound and profitable wayrdquosays Markus Ekberg CEO of Endomines

originally founded in Sweden

According to Ekberg the strategy when

building the mine was to split up the jobsinto small separate contracts Metsorsquos part

was the main minerals processing system gt

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983110983141983137983156983157983154983141983140 983137983154983156

Increasing capacity makes processing

of lower grades economical

The project to significantly increase the

processing capacity at Pampalo is well

under way with the installation of for

example a second grinding mill and more

flotation cells The expansion will be in

operation during early 2013ldquoThe added capacity also makes it pos-

sible to economically process the nearby

open pits with a lower gold grade In addi-tion it helps us to optimize the crushing

and grinding circuitsrdquo Ekberg concludes

Active exploration drillings have

exposed new mineralized zones furtherextending the lifetime of the Pampalo mine

from the present estimate of 6ndash7 years

More info

Peter Vikman

Tel +358 400 869 845petervikmanmetsocom

Endomines Pampalo gold mine

LOCATION near the community of

Ilomantsi in Eastern Finland

GOLD ORE CONTENT

ndash Pampalo 34 gtndash Hosko 99 gt

ndash Raumlmepuro 39 gt

ndash Muurinsuo 30 gt

PRODUCTION TONNAGE PER YEAR 270000 tons (present)~400000 tons (future)

GOLD PRODUCTION PER YEAR 800ndash900 kg

KNOWN ORE RESERVES IN TOTAL

approx 2 million tons

MINE DEPTH 360 m

MINING METHOD bench cut and fill

NUMBER OF EMPLOYEES

100 including contractors

METSO EQUIPMENT

1 Metso TRN 30 x 48 m

wet ball mill

8 Metso RCS series flotation cells 1 Nordberg MF 1800 x 6100

screen

3 Metso samplers

1 Metso CT thickener

1 Metso TF vacuum filter

33 Metso slurry pumps of various

types and sizes

The gold ore is screened using Metsorsquos MS series mining screen

Markus Ekberg is pleased with the outcome the mine reached the minerals processing utilizationdegree of over 90 just two months after start-up

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156983145983139983148983141

Nordic Mines ndash on track tobecoming one of Europersquosmost prominent goldproducersNordic Mines is the newest member in a long chain of Nordic gold mining operations

Inaugurated in mid-August 2012 this company of Swedish origin aims to become one

of Europersquos most prominent gold producers Metso is one of Nordic Minesrsquo main partners

supplying the Laiva gold mine with crushing screening conveying and minerals

processing equipment at an estimated value of EUR 30 million

TEXT amp PHOTOS Eero Haumlmaumllaumlinen

2983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

The Laiva gold mine was built in record time infrastructure

construction began in spring 2010 ore excavation started in

June 2011 and the first gold bar was casted in December 2011

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156

Just one year after starting the gold recov-

ery process Nordic Mines is on track toreaching a capacity of 5 kg of gold per day

At present the operations are averaging 3

to 4 kg of gold daily

The ore in the Laiva Gold Mine consists

of packages of gold-bearing quartz-filled

shear structures The deposit is more thana kilometer long and 700 meters wide The

total depth is still unknown but dr illings

carried out thus far have shown gold-bear-ing shear structures 300 meters below the

surface

A typical ore zone includes a large num-

ber of thin shear structures from 5 to 30per meter The ore zones are commonly 50

to 100 meters long several are 10 meters

deep and they range from a few meters to

20 meters cross strike The minimum min-ing width is 25 meters which means that

even a minor ore zone consists of at least10 to 50 shear structures

Conventional pattern blasting

with selective loading

Prior to mining Nordic Mines conducts

grade control drilling which provides

dense gold grade information and makes

it possible to outline the boundaries

between ore and waste The mining

technique applied is conventional pattern

blasting with selective loading This is oneof the most commonly used techniques in

large-scale open-pit mining

A typical blast in the Laiva mine is 50

meters long 100 meters wide and 5 metersdeep After blasting ore and waste aremined by selective loading

After investing some EUR 100 million

the Laiva mine now comprises an open-pit

mine with a modern complete crushinggrinding and processing circuit that ends

with the casting of gold doreacute bars

With a number of mine staff partners

sub-suppliers city and state officials inattendance the Laiva gold mine was offi-

cially inaugurated on August 16 2012

Michael Nilsson Managing Director

of Nordic Mines stressed in his speechthe importance of overcoming challenges

during the building of the mine

ldquoObviously the whole development

took us longer than expected Today weare pleasantly surprised by the size of our

operation We are becoming much bigger

than expectedrdquo gt

Chief Geologist Kimmo Lahtinen presenting narrow gold veins twisting at the Laiva North open-pit mine

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156983145983139983148983141

An international process package

The Metso package for the Laiva gold mine

included the main crushing screening

conveying regrinding leaching and pump-ing elements Metsorsquos office in Sala Swe-

den has served as the main project office

with Metso manufacturing units in FranceGermany Sweden and Finland responsiblefor the equipment supply

At Laiva the gold ore is classified after

selective excavating into two gold con-

tent classes All class A gold ore is takento Metsorsquos sturdy jaw crusher for primary

crushing while the class B ore is stocked for

possible future use After primary grinding

utilizing autogenous technology the ore is

screened and two Metso cones crush the

oversized pebbles For regrinding Metsorsquosball mill is used

During high- and low-grade leaching

processes a number of Metso pumps and

dewatering screens are used The whole

minerals processing system is controlled byMetsoDNA automation

Active exploration drilling going on

According to Mine Manager Tom Soumlder-

man the known gold ore reserves at the

Laiva gold mine amount to 169 million

tons but the potential for additional find-

ings looks good

ldquoWorking at the level of two million tonsper year our expected lifetime is about nine

years We carry out active exploration drill-

ing in Kaukainen Musunneva and Oltava

to locate nearby satellite ore bodies Anupdated detailed mine life plan will be pre-

pared during the autumnrdquo Soumlderman saysNordic Minesrsquo other exploration areas

include Tormua in Finland and Fjaumllltuna

and Vassbo in Sweden

More info

Alf Rydberg

Tel +46 70524 5837

alfrydbergmetsocom

Happy faces during the minersquos inaugural ceremony Mine Manager Tom Soumlderman (left) with Managing Director Michael Nilsson and Deputy Managing Director Krister Soumlderholm

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156

The story behind the discovery of the Laivamine is an interesting one During a hunt-

ing trip in the remote forests of Laivakan-

gas in 1979 Pentti Jaumlmbaumlck found an inter-esting-looking piece of stone Although hecould not see the gold hidden inside the

rock Pentti noticed the striking weight

and somewhat different look of the stone

Upon returning home Pentti sent thesample to Outokumpu which at the time

was the leading state-owned mining com-

pany in Finland After testing a high gold

content of 15 grams per ton was found

Gold deposit founded by a hunter

The founder of the Laiva gold deposit Mr Pentti

Jaumlmbaumlck was the guest of honor during theinauguration

Lennart Schoumlnning Chairman of the Board ofNordic Mines holding a gold doreacute bar worthsome EUR 320000

Outokumpu registered a mining claimon the area and conducted a series of

exploration drilling from 1981 to 1987 Due

to the low price level for gold no mine wasstarted at the time Other mining compa-nies such as Endomines held the mining

rights later

Nordic Mines with its sights set on

locating and exploiting gold in Swedenand Finland was founded in 2005 During

the same year the company purchased its

first mining rights at Laiva

Nordic Minesrsquo Laiva gold mine

LOCATION near the city of Raahe

northwestern Finland

GOLD ORE CONTENT average 16 gt

ORE EXTRACTED PER YEAR

12 million tons (present)

20 million tons (planned)

GOLD RECOVERY 85

TOTAL KNOWN ORE RESERVES

169 million tons

MINING METHOD

Selective open-pit benchingNUMBER OF EMPLOYEES

130 including contractors

METSO MAIN EQUIPMENT

2 Metso VF and 6 EMEG EME

vibrating feeders

8 Screens 1 MF 1 CVB and 6 KS

1 RCS Flash flotation unit

1 Metso SRR ball mill 18 x 4 m

1 Nordberg C160 jaw crusher

1 Nordberg HP100 cone crusher

1 Nordberg HP200 cone crusher

5 Nordberg NB series conveyors

73 Metso Slurry pumps ofvarious types and sizes

8132019 Results Minerals Aggregates 3 2012ENG

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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155

The newest member of the proven GP series cone crushers ndash theNordberg GP220 ndash offers a versatile alternative for any demanding

tertiary or quaternary or even secondary crushing operation fulfill-

ing all crushing needs and maximizing customersrsquo profitability

High-quality components and optimized castings and forgings

contribute to the GP220rsquos enhanced reliability and help to ensurethe highest level of crusher uptime

Thanks to the 200 kW (270 hp) power draw the GP220 performs

at a 20 to 30 percent higher capacity than other cone crusherbrands with an equal head diameter The large feed openingenables the feeding jaw crusher to run at 110 mm css Operational

flexibility is ensured by multiple strokes and six different cavities

Secondary crushing possible

thanks to cavity and stroke options

Thanks to the GP220rsquos cavity and stroke options secondary crush-

ing in addition to tertiary and quaternary stages is also possible

using cavities with a greater intake opening With the GP220 a suit-

able solution for producing excellent end-product gradations

can always be found

With advanced automation using IC50 or IC5000 operation

is safe and trouble-free The low height thanks to the patented

piston design makes replacement installations much easierA dynamic setting adjustment enables a fast response to process

optimization needs

The Nordberg GP220 weighs 10500 kg (23150 lbs) and hasa maximum real feed size of +200 mm (8rdquo) with strokes from

18ndash40 mm (57rdquondash1 47rdquo) The cavity options are EF F MF M C

and EC

A complete modular crusher steel structure is available for allGP series stationary installations including GP220 The platform

includes places for the lubrication unit motor automation or

pressure accumulator and pressurized sealing The only things

left to add are the feed and discharge conveyors

Main new features of the GP220 Large feed opening allows for secondary stage operation

Longer setting range of main shaft for better wear parts utilization

Stronger main components to carry high loads with a powerdraw as high as 200kW

More info

Hannu Vakkuri

Tel +358 50 317 0638

hannuvakkurimetsocom

Thanks to the large feed opening and wide selection of strokes and cavitiesthe new Nordberg GP220 cone crusher is a highly versatile cone novelty

More versatility with the newNordberg GP220 cone crusher

Reinforced head and frame castings combined with a 200kW power

draw make the GP220 cone a reliable crusher with maximum productivity

8132019 Results Minerals Aggregates 3 2012ENG

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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156

Metsorsquos HRCtrade takes high pressure grinding roll technology to the next level

The new Lokotrack mobile conveyors come as tracked and wheeled models

Metsorsquos latest development in comminution equipment the HRCtradeis a major step in the profitable application of high-pressure grind-

ing roll (HPGR) technology Metso has made several key innova-

tions in order to increase throughput and decrease the total cost

of operation

Metsorsquos patented Arch frame creates an even gap setting acrossthe width of the tires limiting skewing that can result in downtime

for mining operations This anti-skewing Arch frame also prevents

damage to the roller bearings (caused by misalignment) that canoccur with the traditional HPGR design

Flanges maximize wear life and increase throughput

Used in place of spring-loaded cheek plates the flanges keep thebed of material within the crushing zone and prevent material

from bypassing the tires This enables greater circuit capacity and

increases the overall crushing efficiency

In addition by preventing material from bypassing the tires

even pressure across the width of the tire is better maintained

Distributing the pressure more evenly maximizes the tire life bypreventing a ldquobath tub effectrdquo in which the center of the tire wears

faster than the edgesVictoria Herman Metsorsquos Product Manager for the HRC notes

that this breakthrough design is a response to the growing needs

in the mining industry ldquoEnergy efficiency has been attracting our

customers to HPGR technology for yearsrdquo she says ldquoBut our design

concept increases capacity and crushing efficiency ndash and thatrsquossomething mining companies are always looking to improve onrdquo

The track-mounted Lokotrack CT32 and wheel-mounted Lokotrack

CW32 mobile conveyors offer an ideal solution for applications

that require high stockpile capacity and excellent material transfer

capabilities They also add flexibility to multi-stage crushing andscreening applications enabling easy and fast closed-circuit opera-

tion of mobile units

The conveyor novelties can be used in both mobile and station-

ary installations providing extra stockpiling capacity in situationswhere for example fewer wheel loaders are available

The HRC is ideal for high-tonnage hard rock applications andcan be used as a tertiary quaternary or pebble crusher Currently

several HRC units are in operation around the world ndash with a total

of 6500 operating hours including over 3800 hours in a mininghard rock application The machine does have range within hardrock applications itrsquos been designed for use in diamond iron ore

copper gold platinum and various industrial minerals

More info

Victoria Herman

Tel +1 717 309 1150

victoriahermanmetsocom

Several optional features such as hydraulic folding of tail sections

and dual hydraulic drive for increased throughput are available

The capacity of the CT32 and CW32 is 400 mtph (440 stph)feed size up to 150 mm (6rdquo) belt width 1050 mm (42rdquo) and dis-charge height 9120 mm (29rsquo 11rdquo) The CT32 is fitted with a Caterpil-

lar C2 diesel engine with 38kw (51 HP) power The CW32 is avail-

able for hydraulic or electric use

More info

Kimmo Anttila

Tel +358 50 433 3745

kimmoanttilametsocom

The new HRCtrade combines high crushing pressure and a low circulatingload resulting in the most efficient comminution

When flexibility in stockpiling capacityis required the answer can be foundin the new Lokotrack CT32 and

CW32 mobile conveyors

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Service creates value in ChinaChinarsquos most important gold producing area Yantai in northeastern China supplies more than 16 of the countryrsquos goldproduction each year With the gold market thriving the scale of gold production in Yantai has been expanding constantly

Zhongjia Mining Industry Co Ltd is one of the beneficiaries of this thriving industryTEXT amp PHOTOS Yan Xin

Inspection and maintenance of the HP500 cone crusher conducted by Metsorsquos service engineers

In 2011 Zhongjia Mining Industry pur-

chased a modular crushing and screen-ing system from Metso for its new gold

production project With the cooperation

between the two companies continuously

intensifying Zhongjia Mining Industry

signed an additional one-year Life CycleService (LCS) contract with Metso incorpo-

rating Metsorsquos global knowledge in equip-

ment processes and services

ldquoMetso customized a series of reason-

able service solutions also referred toas Metso Performance Solutions for us

including preventive maintenance services

process improvement personnel training

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155

and a procurement plan for wear parts

These really suit our needs perfectlyrdquo saysShen Yidong the Manager of ZhongjiaMining Industry

Effective preventive maintenanceFor mining corporations the biggestconcern is the economic losses caused by

the shutdown of equipment As a result

preventative maintenance is of vital impor-

tance During the contract period Metsoservice engineers offered 7-day tracking

service on the production site every month

to eliminate potential problems and thus

ensured the stability of the system

parts caused pressure on our working capi-tal which was not favorable for our long-

term developmentrdquo Shen explains

To solve this problem Metso designed

a rational stock plan of wear parts and built

a field warehouse In accordance with theuse and consumption of the liners the field

service engineers complement the stock tomake production and operations run more

smoothlyldquoNow when we need to replace the

wear parts we can use them before pay-

ment This not only simplifies the procure-

ment process but also liberates a largesum of our operating capital which can

be used for other business development

purposesrdquo says Shen

Best partner

ldquoAlthough the LCS contract incurs some

early purchase costs in the long run Metsorsquosprofessional and quality service will improve

the equipment efficiency reduce ourenergy consumption and ensure stable

operations thus generating more prof-

its This is the greatest value for us so the

investment is really worthwhile overall Inthe future we will choose more Metso prod-

ucts and services Taking all aspects into

consideration we believe Metso is the best

partner for usrdquo Shen Yidong concludes

More info

Thomas Bai Tel +86 13801009114

thomasbaimetsocom

ldquoIn the eight months since the contract

came into effect our corporation has notsuffered any financial losses due to equip-

ment breakdown The regular maintenance

has greatly improved the efficiency of our

entire crushing system In addition the

experienced engineers from Metso also

provided onsite training and guidancefor our staff and the tailored training has

greatly enhanced the operating abilities of

our employees and upgraded their overalllevel of competencerdquo says Shen Yidong

More productivity with

less consumption

Metsorsquos service contract focuses on real-

izing the optimum performance of each

process flow After analyzing Zhongjiarsquos

production system Metsorsquos techniciansproposed an adjustment to the closed side

setting of the HP500 for tertiary crushingin order to improve the efficiency of the

downstream fine crushing and milling pro-

cessing by over 10ldquoThe process flow improvement solu-

tions provided by Metso not only increased

the output of our gold concentrates but

also reduced our energy consumption andcostsrdquo says Shen

In the past wear parts procurement

took up a larger proportion of Zhongjiarsquos

total production costsldquoTo avoid downtime caused by the

shortage of wear parts we had to keepeight sets of various wear parts in place

However the cost of having so many wear

Zhongjia Mining Industryrsquos gold concentrates processing plant in China

8132019 Results Minerals Aggregates 3 2012ENG

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0983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

Safe quarrying high-

quality aggregates

8132019 Results Minerals Aggregates 3 2012ENG

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ldquoWe share a similar zero-accident strategy and target with Metso and have successfullyfollowed it Metso has also helped us to meet the strictest end-product quality andcubicity requirements set in Spainrdquo This is how Managing Director Intildeigo Ajuria ofOfitas de San Felices the leading hard rock quarrying company in Spain describesthe cooperation with MetsoTEXT Eero Haumlmaumllaumlinen PHOTOS Ofitas and Eero Haumlmaumllaumlinen

The San Felices quarry is situated in a picturesque mountainous landscapebetween the companyrsquos Rioja vineyards and the Bilbao-Madrid motorway

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Ofitas has pioneered the implementation

of several Metso novelties in the Spanish

market The company was the first to use

efficient large track-mounted Lokotrack jaw plants the unique mobile conveying

system and also the new-generation HP4

cone crushers

Today the company operates twomodern Metso stationary plants one in

Guadix near Granada and the newest one

in San Felices Haro Rioja community Both

quarries focus on refining hard rock by pro-cessing ophite rock into the highest quality

railway ballast asphalt and concrete mix

grades The company has a satellite quarry

near Vitoria in PentildeacerradaBeing situated next to a highway and

the famous Rioja vineyards Ofitas must pay

special attention to environmental issues

To minimize dust problems all conveyors

have special covers attached

Quality durability and service

The cooperation between Ofitas de San

Felices and Metso started back in 1973when the Ajuria family bought the com-

pany whose quarrying activities began in

1919 Intildeigo Ajuria has a clear vision of why

the cooperation has continued withoutinterruption for almost 40 years

long-standing personal relationshipsrdquoAjuria adds

Serving railways asphalt

and concrete producers

The year-old San Felices stationary instal-lation lies hidden in a mountainous area

south of the city of Vitoria in NorthernSpain The new plant replaces an old one

that complicated the extraction of ophiterock Both plants are delivered by Metso

With its two separate production lines

the new plant is able to produce all the

end products required ndash from railway bal-last to the finer grades needed for asphalt

and concrete

Due to lower demand the quarry cur-

rently produces some 4000 tons per day

At full capacity however the plant canreach 8000 tons of production per day

30ndash35 of which consists of railway ballastfor high-speed trains and 65ndash70 of chips

and sand Thanks to the versatile two-line con-

cept connected by transverse conveyors

up to 12 different end products can be pro-

duced Depending on the demand for endproducts the material can be guided either

to the HP4 cone or HP400 cone followed

by a Barmac vertical shaft impactor

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

The ophite feed is fed to the C125 jaw crusher by a sturdy dump truck

The key people running the new San Felicesquarry Mine Engineer Carlos Fernandez (left)Managing Director Intildeigo Ajuria with ProductionManager Julian Perez

ldquoThrough the years Metso machinery

has proven its production capacity and

durability resulting in high-quality end

products A big plus for us has also beenthe quick response time to our process

challenges or servicerdquo

ldquoIn fact our cooperation extends

beyond day-to-day business matters to

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155

Meeting the strictest cubicity demands

The Spanish regulations concerning end-product cubicity are becoming more

demanding The flakiness percentage of

railway ballast must be below 10 and for

asphalt and concrete aggregates less than

15

ldquoWith Metsorsquos HP4 cone and the Barmacvertical shaft impactor we can meet even

the strictest cubicity demands We believe

that our high quality is helping us to sur-vive in the present recessionrdquo notes Mine

Engineer Carlos Fernandez

ldquoWe hope to increase the total extrac-

tion of the three quarries from the present15 million tons per year because our plant

capacity allows more than double thatrdquo

Fernandez adds

More info

Angel Luis Garcia Tel +34 686 94 35 30

angelluisgarciametsocom

In addition to being the leading Spanish

quarry to process hard rock Ofitas de SanFelices also cultivates 34 hectares of vine-yards next to the quarry which is situated

in the famous Rioja wine area

The company has previously sold a

harvest of over 200000 kg of Tempranillo

grapes to local red-wine makers Recentlythe company built its own wine process-

ing plant to process 10000ndash15000 kg of

grapes themselves

Aggregates and wine production

Andoni Ajuria the founder of Ofitas de san Felices (left) with Intildeigo Ajuria the present ManagingDirector tasting wine from the companyrsquos own vineyards

The first vintage wine of Ofitas har-

vested in autumn 2010 is now maturingin oak barrels After maturing for 12 to 15months the wine is called crianza and after

two years it will be granted the classifica-

tion reserva

ldquoWinemaking is not a business but

a hobby for us We give our wine out aspresents and drink it when we meet

our suppliers and friendsrdquo Intildeigo Ajuria

comments

For environmental protectionall of San Felicesrsquos plantconveyors are covered

Ofitas de San Felices quarry

LOCATION Haro near the city

of Vitoria northern Spain

SIZE 100 hectares

ROCK TYPE Ophite with Los Angeles

index of 9ndash10

PRESENT DAILY EXTRACTION 3000 tons

of ophiteNUMBER OF PERSONNEL 30

RESERVES 10 million tons

MAIN END PRODUCTS 0ndash2 mm

2ndash4 mm 4ndash10 mm 10ndash16 mm

16ndash22 mm 25ndash60 mm (ballast)

METSO MAIN EQUIPMENT

VF feeder

C125 jaw crusher

ndash feed size 0ndash800 mm

ndash css 130ndash140 mm

HP400 cone crusher

ndash feed size 80ndash250 mm

ndash css 40 mm HP4 cone crusher

ndash feed size 40ndash80 mm

ndash css 15 mm

Barmac 6150 VSI crusher

4 CVB2060 screens

2 TS32 screens

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Metso Distribution Centers he

Europe (Tongeren Belgium)

France (Macon)

Czech Republic (Přerov)

Austria (Vienna)

2271 d

Brazil (Sorocaba SP)

1014 d

USA (Columbia SC)

1690 d

USA (Waukesha WI)

434 d

South Africa (Vereeniging)

Ghana (Tarkwa)

Meacutexico (Irapuato)

Peru (Lima)

Chile (Concoacuten)

788 d

Sweden ( Trelleborg)

Finland (Tampere)

UK (Rugby)

865 d

Russia (St Petersburg)

Brazil (Parauapebas PA)

206 d

4983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983122983141983152983151983154983156983145983150983143 983154983141983155

In the case of an equipment failure or

a planned service shutdown resuming

production as quickly as possible is crucialEach hour spent waiting for a spare part to

arrive equals money lost Whether the right

part takes 12 or 48 hours to arrive really

makes a difference

The comprehensive and global Metsospare and wear parts service network pro-

vides you with the right part in the right

place and at the right time Our strategi-

cally located Distribution Centers and

Satellite Warehouses are on call 24 hoursa day 7 days a week ensuring efficient

parts replacement near you

Check out the locations of the MetsoDistribution Centers and how many parts

pass through them each day

More info

Marcelo Farah

Tel +55 15 2102 1315

marcelofarahmetsocom

you minimize downtime

Australia (Perth)

746 d

China (Tianjin)

China (Kunming)

China (Shanghai)

393 d

India (Faridabad)

India (Ahmedabad)

India (Hyderabad)

India (Bhubaneswar)

India (Bangalore)

419 d

Russia (Yekaterinburg)

Australia (Newcastle)

New Zealand (Matamata)

983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088

TEXT Sofia Williams

Singapore (Singapore)

Distribution Center Satellite Warehouse

8132019 Results Minerals Aggregates 3 2012ENG

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Following a large investment

in Metso crushing equipmentand services Buena Vista del

Cobre is now expanding the

mine site to include even more

equipment ndash and with thatexpansion comes the need for

more local service resources

Metso and Buena Vista del

Cobre have entered into a Life

Cycle Service agreement forthe plant and construction of a

brand new Metso service hub

is under way in Cananea

New facility new

level of service

The Cananea service hub

which will be up and running in early 2013will support the recent expansion and resur-

gence of Buena Vista del Cobre Initially it

will be a major repair and assembly center

for pumps crushers and screens and will

provide for rubber covering capabilitiesBut the 8000-square-meter facilityrsquos service

offering will be expansive including a con-

signment stock inventory to help serve theminersquos varying needs Metso currently has

50 service team members on site

Although Buena Vista del Cobre was a

key influencer in building the new servicehub this location will also enable Metso to

expand its capabilities and provide local

support to the entire mining community

in northwest Mexico The Cananea hub

will serve a number of major copper and

gold mines in the region including MineraFriscorsquos San Felipe Fresnillorsquos Milpillas and

Grupo Mexicorsquos Mexicana de Cobre

ldquoBuena Vista del Cobre is the biggestcustomer we have in Mexico today and

with this expansion project itrsquos only going

to grow and be strongerrdquo says Felix Forna-

guera Director of Services Mexico CentralAmerica and Caribbean ldquoWith that said the

idea behind the Cananea service hub is to

provide a central location for local support

for all our major customers in the areardquo

Establishing safety

ldquoIt was key to have our support here in

Cananea because the Buena Vista delCobre started from the ground uprdquo saysFelix ldquoWersquove been able to help the cus-

tomer to establish the best in support

service and operations from the very

beginningrdquo And this ground-up approachincluded a major focus on safety

Metso worked closely with Buena Vista

del Cobre to establish the safety proto-

col by which the mine operates Basedon Metsorsquos expertise the safety measures

put in place have enabled the mine to

become strict and efficient in its operations

and maintenance procedures To achievethis Metso worked closely with local andnational authorities to ensure the safety

plan was comprehensive and in accord-

ance with all established legal bodies

The best in regional support

The service hub in Cananea is a prime

example of Metsorsquos focus on providing local

service and support to its customers all

Service shines in Cananea MexicoAfter three years of inactivity the Buena Vista del Cobre mine in Cananea Sonora Mexico has been operational since 2010A mine that was inactive for such a significant amount of time however requires a great deal of support to successfullyrestart the plant and bring it back to an operational and profitable state

TEXT Deanna Lee PHOTO Metso

over the world ldquoWe are the first

company developing this kindof service in northwest Mexicordquo

adds Felix ldquoOur people have

developed a close relationship

with the team at the mine Itrsquosmore than a supplier relation-

ship our guys are inside the

mine living and working thererdquo

In fact this is the model

that Metso is using in servicehubs all over the globe build-

ing modern facilities bringing

teams on site and workinghand in hand with mine

operators The Cananea Service

hub is only the most recent

example of Metsorsquos commit-ment to service and northwest Mexico is

yet another mining hotbed thatrsquos going to

benefit from the companyrsquos support

More info

Felix Fornaguera Tel +52 4621079227

felixfornaguerametsocom

A mining cone serviced by Metso at the Buena Vista del Cobre mine inSonora Mexico

ldquoThe new Cananea service center will be a majorrepair and assembly center for pumps crushersand screensrdquo says Felix Fornaguera Director ofServices Mexico Central America and Caribbean

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

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During the MINExpo exhibition over 1300 people visited the Metso stand

983122983141983152983151983154983156983145983150983143 983154983141983155

Held every four years MIN-Expo consistently grows so

perennial exhibitors like Metso

are challenged with elevating

their presence and drawingin new (and greater numbers

of ) visitors each year ldquoItrsquos not

necessarily a challenge to lsquotoprsquo

our last showingrdquo says Keith

Ference Vice President ofmarketing and communica-

tions North America ldquoThere

are four years between eachMINExpo so we always have

a lot to say and reveal to our

customersrdquo The real challenge

he says is finding an exciting

and dynamic way to deliverthe message ldquoTherersquos so much

to see here so your booth has

to be compelling from the

outside-in and thatrsquos what

we always try to dordquo

Service sets the stage

The Metso booth created buzzin a number of ways and per-

haps the most striking (partly

due to its size) was the live

theater presentation As visitorspassed through the aisles of the show-

room the sights and sounds from Metsorsquos

theater were hard to miss And once guests

entered they were captivated by a short

high-energy video presentation focused

on Metsorsquos service capabilities The message was simple Metso is ldquoyour

local service partner rdquo for all mining and

construction needs The video showed ourservice teams in action all over the world

and the audience came away with an

understanding about Metsorsquos commitment

to service Customers can count on morethan 70 local service centers run by more

than 1700 expert technicians delivering

Metso makes an impact at MINExpo 2012At this yearrsquos MINExpo International nearly 60000 attendees flocked to Las Vegas Nevada the largest turnout in showhistory The visitors ndash mining professionals from all over the globe ndash explored 850000 square feet of showroom spacefeaturing the industry rsquos latest technology equipment products and services They toured the show for three days

seeking the latest and greatest from more than 1800 exhibitorsTEXT Keith Ference PHOTOS Tracey Ford Perry

detailed descriptions andphotos of all of Metsorsquos mining

and construction products and

services The app also provides

digital access to Results and asearchable database of sales

contacts By day three of the

show MetsoMAP had been

downloaded by more than

500 usersIn addition to the app the

booth was equipped with

several LCD screens each con-trolled by Metso experts who

used their iPads to present new

products like the Megalinertrade

and the HRCtrade A featured

presentation on Metsorsquos lineupof energy-efficient comminu-

tion equipment including the

VERTIMILLreg SMD and MP-1250

cone crusher was also avail-

able letting customers seehow Metso technology delivers

some of the worldrsquos most effi-

cient size reduction

Measuring MINExpo success

After a very busy three days

(on top of months of prepara-tion leading up to the show) everyone

involved with MINExpo ndash from the North

American marketing team responsible for

the booth to the product managers and

sales force that worked the floor ndash is view-

ing the show as a success ldquoTherersquos alwaysa sigh of relief after each (MINExpo)rdquo says

Keith ldquoAnd overall the initial feedback

and response has been very positiverdquoWith more than 1300 visitors to the

booth Metso certainly made an impact

ldquoWe learn a lot from each show and with

some time wersquoll have a better understand-ing of the tangible results of our effortsrdquo

Keith adds

reliable service for mining equipment as

well as customized cost-effective life-cycle

services contracts

Technology ndash MetsoMAP

is an industry firstMINExpo provided the industry with its firstglimpse of Metsorsquos revolutionary iPad app

MetsoMAP The app was demoed to the

boothrsquos visitors via ldquothe worldrsquos largest iPadrdquo

a custom-made 80-inch screen that show-cased all of its capabilities most of which are

groundbreaking in the industry MetsoMAPrsquos

simple interface is highly intuitive making

it easy to view process animations videos

The presentation of the new HP cone crusher attracted a large audience

8132019 Results Minerals Aggregates 3 2012ENG

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When yoursquore allowed less than a dozen days per year for breakdowns repair andmaintenance every single hour during a service shutdown counts There simplyisnrsquot any room for surprises Thatrsquos why Boliden counts on MetsoTEXT amp PHOTOS Sofia Williams

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Kurt Kalla Site Managerof Metso Gaumlllivare ServiceCenter is responsible forthe maintenance of Aitik

Metso and Boliden Strivingtogether for 97 uptime

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983122983141983152983151983154983156983145983150983143 983154983141983155

One of the biggest copper mines in

Europe Bolidenrsquos Aitik is located deep inthe wilderness of Swedish Lapland next to

the small town of Gaumlllivare The mine has

been operating since 1968 and a recent

expansion has increased its annual ore

production to 36 million tons

But the ambitious Swedes are not will-ing to lay back and relax just yet Bolidenrsquos

new aim is to reach a production rate of

45 million tons of ore per year in AitikAfter that Perhaps more than 55 million

tons The ore concentration in Aitik is very

low-grade with a mere 022 copper con-

tent hence the need for high capacityAchieving the ambitious production

goal requires maximum plant availability

This means that everything from the crush-

ers to the filters must be up and runningfor approximately 97 percent of the time

Thatrsquos where Metso comes into play

A cost-per-ton contract in action

The maximum uptime requirement allowsless than a dozen days per year for break-

downs repair and maintenance at Aitik

Every single hour during a service shut-

down counts There simply isnrsquot any roomfor surprises

Executing a successful shutdown under

such conditions requires a reliable service

partner not afraid of challenges and this iswhy Boliden has entrusted Aitikrsquos services

operations to Metso Boliden and Metsohave worked together since the 1960s

and the collaboration took another step

forward in September 2012 when the twocompanies signed a three-year extension

of the services contract for Boliden Aitik

ldquoThe new contract is a cost-per-ton

agreement We get paid based on Aitikrsquos

production Itrsquos a win-win deal for both par-

ties but also a new mindset for usrdquo explainsKurt Kalla Site Manager of Metso Gaumlllivare

Service Center responsible for serving Aitik

From now on the duration of the shut-down is what matters the most According

to Kalla the Metso service organization in

Gaumlllivare is now streamlining its operations

to fit the bill and has already witnessed thestrategy working In August 2012 Metso

carried out a 188-hour service shutdown in

Aitik which turned out to be a success

Zero tolerance for injury

One key factor to the success was theextensive planning of precautionary health

safety and environment procedures under-

taken by Metso prior to the shutdown Thanks to strict measures applied no

injuries or accidents occurred during the

shutdown and the work could easily be

finished on scheduleMats Johansson Health Safety

and Environment Manager for Metso in

Sweden explains how this was achieved

rdquoPlanning of the shutdown included arisk analysis for all new tasks participating

in Bolidenrsquos safety coordination meetingsmeeting with both Metso supervisors and

subcontractor supervisors and finally a

meeting with the entire staff participating

in the shutdown where everyone had to

sign a document stating their commitmentto the information providedrdquo he says

During the actual shutdown plenty of

new barriers signs and awareness cones

were put in place as a result of observa-tions from previous audits and safety plans

and risk analyses were readily available

in the work area Metso and Boliden also

introduced a Mill Inching permit a certifi-cate for completing a mandatory course for

those involved in the process In addition

Metso carried out random safety audits

during the shutdown to make sure thestrict policy was followed

According to Boliden Metsorsquos way of

working is a good example of how health

and safety precautions should be handled

ldquoMetso is a good example of how towork with safety and health plans risk

analysis permits and welding permits

Their table with all binders in the second-

ary mill area was exemplaryrdquo says Kjell-Arne

Johansson a technician from Boliden

The use of the new Metso Megalinertrade

system in the lining of Aitikrsquos Metso AG

mills has also improved the safety of main-tenance staff The Metso Megalinertrade con-

sists of larger-than-average liners bolted

in position from outside the mill Mainte-

nance technicians no longer need to go

inside the mill and stand in the dangerousdrop-zone of the liners gt

Boliden aims to reach a production rate of 45 million tons of ore per yearin the Aitik mine site

ldquoA complete risk analysis was conducted during the planningof the shutdownrdquo comments Mats Johansson Health Safetyand Environment Manager for Metso in Sweden

8132019 Results Minerals Aggregates 3 2012ENG

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Service the Metso way

24 hours a day 365 days a year

In addition to paying close attention to

health and safety issues executing an effi-

cient shutdown requires careful planning

and timing of every step in the mainte-

nance process Wear and spare parts have

to be available on time and a repair shoplarge enough to accommodate equipment

located close by

ldquoTo keep maintenance breaks as short

as possible we aim to replace the pump on

site and bring the old one for repair to our

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

nearby facilities This method gives us the

peace to do a good job and keep the cus-

tomerrsquos operations runningrdquo Kalla describes

the Metso way of handling Aitikrsquos pump

maintenance

Metso is currently expanding its Gaumllli-

vare service center to include a distribu-

tion center for wear and spare parts andalso concentrating its previously scattered

operations under one roof in its Vuoskon-

jaumlrvivaumlgen facility The expansion is due to

be completed by 2014

Metso equipment

delivered to Aitik36

bull 2 AG mills diameter 116 x

137 m gearless 22-MW motor

bull 2 Pebble mills diameter 91 x

113m dual 5-MW pinion drive

bull 3 VPA pressure filters VPA 1540-54

bull 12 sample pumps and pipes

VF50

bull 60 Various slurry pumps up to

MR500 modelbull Appr 5000 m rubber-lined slurry

pipes up to 600 mm diameter

bull Appr 5000 m rubber-lined by

gravity pipes up to 600 mm

diameter

bull Appr 5000 m rubber hoses

up to 600 mm diameter

Not only does the expansion make ser-

vice shutdowns at Aitik run more smoothly

it guarantees a more comprehensive

on-call emergency service response in the

region ndash thanks to the spare and wear parts

inventory available 24 hours a day 365

days a year

More info

Lars Rosenling

Tel +46 70 107 45 90

larsrosenlingmetsocom

Metso grinding equipment dominates the view in the concentrator

Safety on site is made up of small things like

making sure that everyone remembers to secure

the hoses in place

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983122983141983152983151983154983156983145983150983143 983154983141983155

Pebbles have always been a

challenge for producers of sandsince they cannot be returned

to rivers after extraction For

decades the processing of this

material resulted in a huge

environmental liability with alarge amount of pebbles hav-

ing to be stored away and left

unused

Transforming problems into

business opportunities

Areia amp Cia (areia = sand) has

operated in this market forover 20 years and decided to

enlist the help of Metso to find

a profitable solution for the

processing of pebbles

In July 2011 analyses werebegun to assess the abrasive-

ness and crushability of the

material Four alternatives wereidentified for processing and

transforming pebbles into sand

Initially Areia amp Cia was

interested in acquiring an

impactor for its reason-able price level However the

customer wanted to process

all the pebbles that were col-

lected daily in addition to some of the

material that it had stored In weighing theresults expected by the customer and the

excessive abrasiveness of the material the

HP200 cone crusher was decided on as thebest alternative

Areia amp Cia made the required invest-

ment and after using the HP200 for just

six months the company has already beenreporting outstanding results The HP200

not only transforms pebbles into sand but

also produces sand of excellent quality

with high yield and low maintenanceWith minor adjustments the HP200

also enables the production of sand withspecific particle size distribution for special

applications such as filtering sand blasting

and foundry sand adding value to the prod-

uct and increasing the types of sand offeredldquoMetso is pleased that the HP200 not

only enabled the processing of a product

that had been set aside as unusable but

HP200 cone transforms pebblesinto high-quality sandOver the last few decades Brazilian economic growth has been driving demand for construction aggregates The market

for sand in turn has been experiencing major difficulties in maintaining a consistent supply Presently one of the mainchallenges the industry faces is the large amount of pebbles that are obtained in the process of extracting sand at timesconstituting nearly 50 of the volume of material dredged from riverbeds

TEXT Sheila Ivers PHOTO Areia amp Cia

also that it opened up new

market opportunities for Areiaamp Cia Thatrsquos the standard we

seek to deliver to our custom-

ersrdquo states Luiz Oliveira Techni-

cal Salesperson of Metso Brazil

HP cones entering the

Brazilian sand-making

market

Todayrsquos cones such as theHP200 have high resistance

to impacts and abrasiveness

more efficient crushing cham-

bers low maintenance costsand excellent productivity

Following the acquisition of

the HP200 Areia amp Cia is now

also producing special sands

that command a price that is100 higher than common

sand The entire stockpile of

pebbles accumulated through-out the companyrsquos 20 years of

operations has already been

transformed into sand and the

stock of pebbles held by com-

petitors is also being purchasedfor processing

Cristiane Brizolari the

owner of Areia amp Cia confirms

the transformation that has taken place in

the production and commercial processldquoThe HP200 opened up new niches in

the market enabling the production of dif-

ferent types of sand with added valuerdquo

More info

Luiz Oliveira

Tel +55 011 9971 3603

luizoliveirametsocom

After the pebbles are crushed into sand with the HP200 cone crusherdifferent grades are screened for various end uses

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Where therersquos a will we dig a wayAFCONS-Strabag and Metso embark on tunnel project together

When the joint venture AFCONS-Strabag initiated work on the Rohtang bypass tunnel project at an altitude of 3980 metersabove sea level in Himachal Pradesh India they deliberated each aspect with clockwork precision The project involved anumber of surprises and challenges and required technology and project management skills that were second to none

TEXT amp PHOTOS Monisha Majumdar

Cutting a 10-meter-wide and nearly 9-kilo-

meter-long tunnel through the Himalayas

in one of the toughest terrains and cli-mates in India makes for quite a challengeResults set out to find out how AFCONS-

Strabag and Metso are making their way in

one of their most critical projects to date

The only road connection to the north-Indian border region of the province

Himachal-Pradesh and beyond the Manali-

Leh highway leads across the Rohtang

pass Due to the heavy snowfall and high-

velocity winds in this region the towns

located north of the pass are cut off from

the rest of the country during winter for atleast four often even six months each year

A tunnel with strategic importance

With the construction of the tunnel at

3100 m above sea level the Manali-Lehhighway will become an all-weather road

thereby enabling a significant improve-

ment in the economic development of

northern Himachal-Pradesh and an alter-

nate route to the strategically important

Ladakh region

Manali south of the pass is an alreadywell-developed tourist location that is

becoming more and more popular Upon

completion of the tunnel it is likely that

tourist activities will extend to the areanorth of the pass Moreover the tunnel

shortens the distance between the towns

of Manali and Leh by approximately 45 km

thus saving several hours on the small dan-gerous pass road

The Rohtang pass in the Western Himalaya

region of Northern India with its altitude ofalmost four kilometers ranks among thehighest trafficable passes in the world

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983122983141983152983151983154983156983145983150983143 983154983141983155

The 88-km long horse-shoe-shaped

tunnel provides space for a two-lane8-m-wide carriageway as well as a one-

meter-wide footpath on both sides A

22-m-high and 36-m-wide emergency

tunnel will be integrated in the tun-

nel cross-section Altogether more than

800000 msup3 of rock will be moved Tunneling works started around spring

2010 with excavation driven from both por-

tals As the north portal is inaccessible dur-ing winter closure the excavation focused

on the south After a planned construction

period of 55 years the tunnel is scheduled

to be completed by the end of 2015

Best man for the job

The BRO (Border Road Organization)

wanted to roll out a global tender for theproject due to the challenges that such a

project involves and also considering thatitrsquos the first time in India that a project of

this scale was to be carried out This imme-

diately triggered the need to roll out aglobal tender All major Indian construction

companies bid for it some individually and

some in partnerships

Strabag an Austrian tunnel specialistwas one of the companies who bid for the

project along with AFCONS a Mumbai-

based infrastructure company In Septem-

ber 2009 AFCONS-Strabag was awardedthe contract

Mr Sunil Tyagi Deputy Project Man-ager at AFCONS had this to say about the

unique projectldquoThis project is located in the Himalayas

and as far as we understand the terrain

there is among the toughest We came out

with a new technology and to be honestit is a fairly simple one We would generally

start with the traditional technology of drill-

ing and blasting and then obtain our muck

feed from the inwardbottom of the tunnelrdquo

ldquoThe technology is supplied by Rowa Tunneling Logistics and this is the first

time it is being used in Asia A jaw crusheris placed at a distance of about 40-45

meters behind the face The blasted muckextracted from the face is fed to the crusher

to reduce the lump size and then through

an overhead conveyor transport system

it is then transported out of the tunnelrdquoldquoThis enables free movement of man

and machinery in the lower area or spe-

cifically on the ground area If we were to

conforms to the Indian standard for fines amp

coarse aggregates as prescribed in IS383-1970

The plant was up and running in good

condition and performing to AFCONSrsquos

satisfactionldquoWe have worked with Metso in earlier

projects and are quite impressed by thekind of technology amp services they provide

We have a history together so the trust fac-tor also comes inrdquo explains Dhiman on their

choice of Metso as a partner

Service makes the difference

ldquoMetsorsquos services have made a big dif-ference in the project Without them we

would still be struggling with the machin-

ery and production The service is really

good and the service engineers are knowl-edgeable prompt and quick to act Any

problem can be solved by Metso We donrsquothave to wait until a service engineer turns

up ndash they have the capacity to solve prob-lems over the phone as wellrdquo says Dhiman

ldquoThe Metso plant didnrsquot create any prob-

lems for us We had problems in logistics

the feed was sticky and the weather condi-tions were bad but thankfully we did not

face any problems with production and

efficiency as the Metso plant is performing

very wellrdquo Dhiman concludes

More info

Amol Sinha Tel +91 9811 671 924

amolsinhametsocom

use the old conventional technology this

wouldnrsquot have worked for us in the stipu-lated timerdquo Mr Tyagi adds

When the going gets tough

partner with the toughest

Sensitive projects require the best technol-

ogy After AFCONS-Strabag landed theproject Metso was an obvious choice as a

technology provider not only because of

the long-standing business relationshipbut also for the sheer consistency in prod-

uct quality and service deliverance Metso

strives for

ldquoAfter signing the project we faced alot of road blocks including extreme cold

avalanches roadblocks less oxygen ndash you

name it we faced itrdquo explains Ankit Dhi-

man Plant Manager at AFCONS-Strabag The Rohtang valley is known for its

notorious avalanches and landslides SoAFCONS had to take extra steps and safety

precautions against hazards on the site

ldquoIn this freezing cold not just us humansbut also the machines are at increased risk

of damage I remember when we used

to run the plant during winter the diesel

engines would freeze We had to constantlyheat up the fuel container to get the plant

running And even the sand in the sand

trap would freeze so we had to clean it on

a daily basis to stop the pipes from mal-functioningrdquo Dhiman adds

Plant designed for difficult terrain

Difficult terrain coupled with space con-straints led Metso engineers to put their

minds together to come up with a suitable

plant configuration After studying the

requirements of the project Metso sug-

gested a 150-tons-per-hour three-stagemodular plant using a C106 jaw crusher

a GP11F secondary cone crusher and a

B7150 tertiary vertical shaft impact crusher

In addition considering the unpredict-ability of the feed the plant was about

to reach a point where the amount offines to be handled could be increased

dramatically Metso strongly suggested the TK11-27-3V grizzly scalper and this became

the first-ever TK scalper to be supplied by

Metso to an Indian customer Also in order

to get better products a sand trap SF2360was added to the configuration

The sand trap is important equipment

for this project as it washes the sand thatMr Sunil Tyagi Deputy Project ManagerAFCONS-Strabag

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Smooth transition to new-generation jaw crusher in Germany

Roumlhrig is a German company with a rich heritage The company has been quarrying granite at its plant in Bergstrasse inthe Sonderbach district of Heppenheim for three generations

TEXT amp PHOTOS Ralf Goffin

Roumlhrigrsquos superior product variety is onereason why the companyrsquos proximity to its

customers can be understood in more than

just physical terms The companyrsquos high

level of innovation has allowed it to estab-lish itself as a reliable supplier of materials

both regionally and internationally This

operational and technical expertise always

manages to keep in step with growing

market requirements

In terms of technical processing equip-

ment Roumlhrig has used a Nordberg C160stationary jaw crusher from Metso since

1992 At the start of 2012 it was finally

exchanged for a more up-to-date version

from the same model range

Metsorsquos C Series is specifically designed

to pre-crush hard rock and can cope effort-

lessly with even the hardest of materials

The dimensions of the new stationary jawcrusher are identical to those of the old

one which means that it could simply be

slotted into the housing vacated by the

previous version

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155

Third-generation Managing DirectorMarco Roumlhrig expects the new machinersquos

service life to be just as long as the previ-

ous model due to the product upgrades

that have been implemented The integral motor base is another plus

point in models made by other manu-

facturers it is located outside the crusher

This element of good fortune ensured that

Roumlhrig could reuse the housing withoutany additional rebuilding

Another advantage lies in the revision

of the guards for the C160rsquos drivetrain andflywheel The sturdier construction method

used for the crusher requires fewer parts

which facilitates easier installation andmaintenance and it makes it simpler to

access the motor

Under the watchful eye of Metsorsquos

Assembly Manager Maik Engelstaumltterthe entire project including removal and

installation was successfully completed

within two weeks

Installation making the most

of the available space

Roumlhrig will likely remember the day the

new crusher was installed for a long time

the pitman and main frame were deliveredseparately prior to installation and assem-

bled on site It took just one hour to replace

the old stationary crusher with the new

model A lorry-mounted crane was used toposition the 85-ton crusher with millimeter

precision in the crushing plant Once the

new crusher had been positioned in theexisting steel structure the next task wasto fix it into place as securely as possible

despite the limited space Special vibration

dampers were installed at a height of two

meters to prevent the crusher from sliding

Norbert Ried (fourth from left) installed thenew C160rsquos predecessor 20 years ago and isdelighted at the durability of the powerfulcrusher that is now making way for a newermodel Also pictured from left to right ManagerVolker Angermann Assembly Manager Maik

Engelstaumltter Technical Manager Stefan

Koob Project Manager Dominic SchoumlnhardtManaging Director Marco Roumlhrig Service

Technician Stefan Kolze and employees ofthe installation company Stafemo

On the hook after theold C160 was liftedout by crane the newcrusher was installedin almost no timeOnly the roof of thehousing had to beremoved

sideways off its mount An initial test run

with materials was carried out around oneweek later after all the electrical cables had

been installed

Simultaneously with the installation

of the C160 which is the first of the latest

generation of crushers to be installed in

Germany a new Nordberg GP100 conecrusher was also being installed in Roumlhrigrsquos

chipping plant Roumlhrig is convinced that

the technical improvements made tothe new Metso crusher can only be an

advantage worldwide

Roumlhrig places great value on consistent

product quality maximum added valueand optimum refinement of its product

range Bearing in mind that Roumlhrig has

enough reserves of raw material to last

for the next 150 years the company canconfidently continue to develop with an

emphasis on quality rather than quantity

More info

Dominic Schoenhardt

Tel +49 (0)621 727 00 610

dominicschoenhardtmetsocom

8132019 Results Minerals Aggregates 3 2012ENG

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Groupe Charier Carriegravere de la Mariais France

Quarrying with certi1047297ed quality The Charier Group with its 1600-strong workforce is a family business thatthis year celebrates 115 years of quarrying The company pursues a long-termdevelopment policy that since 2007 has seen processing installations upgradedat 4 of its 9 extraction sites

TEXT Liliane Boutin (with extracts from Mines amp Carriegraveres and Terrassements amp Carriegraveres magazines)PHOTO Baloon photo

The processing installation is of the horizontal type with a primary station located 56 meters below the site access road to keep it hidden from view

The crushing and screening installation at

Charierrsquos CM La Mariais quarry (at Donges

on the Loire estuary) has been in opera-tion since September 2011 Based on theoperatorrsquos ideas it was designed by Metso

to replace a worn-out installation installed

right on top of the seam being extracted

Since its commissioning it has becomethe second quarry in the company to

receive ISO 14 001 certification

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983122983141983152983151983154983156983145983150983143 983154983141983155

tertiary material of sand and gravel for the

local market to use in concrete surfacingprefabrication etcrdquo

Incorporation of a screening station

The stone extracted from La Mariais is

according to the quarry granitic gneiss

sound and homogeneous with a LosAngeles index of 15 good wear resist-

ance with an MDE of 10 a true density of

265 and a certain abrasiveness (2000 gt)ldquoCharacteristically it has a tendency to form

blocksrdquo Leblin points out

The main criteria in designing the instal-

lation was to provide an output of 600000metric tons from one station (38 hours

week) to produce materials aimed at the

concrete and surfacing markets ldquowhich

involved providing a tertiary station withscreening plantrdquo he adds

With this new unit the operating com-pany expands its product range through

the addition of fine materials obtained

from the tertiary screening station This unitis capable of producing 170 tonshour of

020

Preserving the environment

and optimizing safety

The screens have motorized bogies and

retractable walkways to facilitate access

when the screens are opened for main-tenance Other walkways provide access

to the tunnel input feeders The feederscan be isolated with hydraulic rod gate

bars this hydraulic assistance eliminatesthe need to use a heavy hammer to lodge

these metal bars

All conveyors transporting fines (02

and 04) are covered with a tarpaulin to

avoid flying dust and all the screens arehooded (metal cover with Trellex seal-

ing) The Brunone company has installed

dust-tight containment at the outlet of the

tertiary station crushers (HP300 and HP4)on the belt located under the screens

and under the hoppers located belowthe tertiary screens The crushers are put

under negative pressure and the finesare extracted through sleeve filters (7000

m3 h) with declogging which deposits the

dust back onto the conveyor belt

A high-pressure 100 bar water mist sys-tem has been installed at the primary sta-

tion discharge at the secondary crusherrsquos

discharge chutes (Omnicone) and at the

transfer points on the belt

Designed to last

ldquoThis type of new installation can easily last

thirty yearsrdquo affirms Project Leader Bruno

Peix of Metso ldquoIt quite simply depends on

how well it is maintained Thatrsquos why weprovide maintenance contracts that call for

our technicians to make regular inspection

visits and carry out preventive mainte-nance and any necessary repairsrdquo

In 2011 Metso commissioned about

10 new processing units in France like

the one at La Mariais quarry

More info

Frederic Bazire

Tel +33 (0)681442804

fredericbaziremetsocom

Key figures

DURATION OF WORKS 15 months

DRAWING OFFICE TIME 7800 hours

HEIGHT OF SILOS AND GRINDER BUILDINGS

15 m

TOTAL LENGTH OF CONVEYORS 14 km

WEIGHT OF THE INSTALLATION

1200 metric tons

CONCRETE POURED 1800 cubic meters

PROJECT SITE WORKFORCE 30

INSTALLED POWER 2200 kW(not including pumps 200 kW)

METSO EQUIPMENT

Primary

Vibrating feeder PF561-2V

Primary grizzly VG540-3V

Grizzly feeder TK13-20-3V

Jaw crusher C145 with

hydraulic setting

Secondary

Vibrating screen CVB 2050

refurbished

Cone crusher Omnicocircne 1352 SX

with Metso IC7000 controller Ellivar 16 (16 msup2 3 decks) screen

refurbished by Metso

Tertiary

Cone crusher HP300

Cone crusher HP4

2 Ellivar 20 screens (20 m23 decks) for final products

Expanding the production range

ldquoSince the mid-1990s when we became

owners of La Mariais we had used mobilemachinery with an assembly of beltconveyorsrdquo recalls Daniel Leblin Charierrsquos

Technical Manager for site construction

and maintenance

ldquoIt became clear that we needed ahigher performance tool to achieve the

dual goals of reaching one million metric

tonsrsquo maximum production and producing

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Big Lokotrack LT550GPF boostsquarrying productivity by a thirdMaximizing the productivity of operations is a key issue when striving for cost-effective quarrying Big Lokotracks are oneway to achieve improved operational efficiency The Lokotrack LT550GPF equipped with the high-volume GP550 conecrusher and a large screen is popular in the Nordic countries and in Germany and Australia ndash countries all known for theirhigh quarrying volumes

TEXT amp PHOTOS Eero Haumlmaumllaumlinen

Kone-Kostamorsquos new mobile coneplant has reached an averagecapacity of 300 tons per hour

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983122983141983152983151983154983156983145983150983143 983154983141983155

ldquoWith the same number of employees we

can achieve 30 more productivity with

our new LT550GPF unit The high-capacityFS screen has also eliminated the bottle-neck often seen at fine screeningrdquo says

Aarno Kostamo Managing Director of

Kone-Kostamo Oy one of Finlandrsquos biggest

crushing contractorsAccording to Kostamo the high capacity

of the GP550 gyratory cone crusher easily

handles feed from the C120 and C125 jaw

crushers For the contract with the Talvivaara

nickel mine the LT550GPF is being fed bythe brand new Lokotrack LT120 jaw plant

Average capacity 300 tons per hour

Talvivaara Europersquos largest nickel mine uti-

lizes large quantities of aggregates Kone-Kostamo has contracted several million

tons of different end products for the mineIn August 75000 tons of 0ndash63 mm

road gravel was crushed Smaller amountsof finer 0ndash6 mm 0ndash16 mm and 0ndash32 mm

aggregates are also being produced

The rainy summer increased the need

for road gravel along the muddy roadswhich must endure dump trucks weighing

as much as 260 tons

ldquoThe mobile process consisting of the

LT120 jaw plant and LT550GPF cone plant

is cost-effective while aggregates of vari-ous sizes can be produced in a two-stage

operation and with high capacity The con-trolled stroke and elliptical movement of

the FS screen secure big passing throughcapacitiesrdquo Kostamo explains

Operated in two shifts for a total of 16

hours per day the LT550GPF has logged

more than 600 working hours over a two-month period

Managing Director Aarno Kostamo (left) and foreman Karri Maumlenpaumlauml studying the cavity optionsavailable for the new Lokotrack LT550GPF

Longer perspective than

a single quarter needed

Kone-Kostamo Oy was founded as an

earth-moving company in Kemijaumlrvi

Northern Finland in 1956 The company

expanded its operations to include crush-

ing contracting in 1964 and later on

switched to concentrating fully on crush-ing activities

Kone-Kostamo consistently crushes

and screens around 28 million tons ofaggregates annually and has net sales of

between EUR 8ndash9 million

ldquoWe believe that issues within the crush-

ing industry including the purchasing ofmachinery must be studied with a longer

perspective than a single quarter The

secret to our success has always been our

solid work ethic and professional employ-eesrdquo Kostamo sums up

More info

Esa Berg

Tel + 358 40 837 8692

esabergmetsocom

8132019 Results Minerals Aggregates 3 2012ENG

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Monitoring-based reporting is vital for

assessing the performance of a mobile

crushing plant Metso provides suchreporting tools through its plant-wideautomation system Metso DNA (Dynamic

Network of Applications) with its infor-

mation platform that links all the mobile

crushing and screen units together as oneentity Basically there is a lot of measured

real-time information available in every

crushing plant On-line information is

obtained either from each Metso crusherrsquosmachine automation system IC (Intelligent

Controller) or from separately installed

additional sensors and belt scales

All the collected data is sent to a motorhome using wireless communication

based on WLAN technology The motor

home is a purpose-built environment

inside an on-site container In this environ-ment selected variables can be monitored

for assessing the plantrsquos performance And

to make all this even more flexible the

data can be transmitted to a crushing plant

company office using GPRS3G mobile

data communication technologies Thismakes all the last-minute reports acces-sible to the crushing plant managerial staff

at anytime and basically anywhere within

reach of the cell phone network

Production and fuel economics reports

Essentially monitoring and reporting can

be customized to fit the customerrsquos needs

However there are certain off-the-shelf

reports that provide a lot of useful informa-tion for plant supervision The production

report is one of these Requiring at least one

belt scale for measuring the total produc-tion the production report shows the pro-duction rate (tons per hour) for a selected

reporting period eg a day or a week The

production report constantly keeps track of

the plantrsquos production storing all the datathroughout the plantrsquos life cycle

Performance monitoring and reportingfor a mobile crushing plantTEXT Pasi Airikka PHOTOS Metso

unit during which the unit is running By

storing the availability times between start-ups and shutdowns the crushing plant

operation time (hours per dayshift) can be

recorded analyzed and reported In addi-

tion the availability report can be tailored

to evaluate efficient crushing hours during

which the plant is really working and pro-ducing aggregates Consequently the ratio

(0-100) between efficient crushing time

and total running time can be reported forany selected period of time This boosts

the efficiency of the plantrsquos operations

and results in better productivity

Reports on non-choke

or inadequate feeding

Non-choke feeding to crushers is avoid-

able through smart plant-wide crushingplant controls But estimating its severity in

a systematic manner is not straight-forwardwithout constant monitoring and reporting

The crusher choke feeding report makes

use of the crusher cavity level sensors byanalyzing their level measurements By

calculating average and min-max values

and deviations from the average it can be

shown how often the single crusher suffersfrom non-choke feeding to it

In some cases the bottleneck in the

crushing plantrsquos productivity is the material

feeding to the process In mobile plants thefeeding is human operated and therefore

subject to variations Occasionally the sizeof the human-operated machine simply

does not allow for adequate feeding to thecrushing plant There are specific reports

indicating time periods when the crushing

plant suffers from inadequate feeding

Condition monitoring for

crushers and screens

Machine-specific condition monitoring

focuses on vibrating components in

crushers and screens such as drive shaftbearings safety plate wearings and gears

The low middle and high frequencies ofmonitored components are measured and

supervised in real-time to detect abnor-malities due to slow or fast wear looseness

or imbalance

More info

Pasi Airikka

Tel +358 40 587 2730

pasiairikkametsocom

Condition monitoring provides a view tovibrating crusher and screen components forpredictive equipment maintenance

The daily production report shows the hour-by-hour production trend and distribution chartfor a selected day with min-max average andvariation statistics for comparison

Fuel consumption is always an interest-ing concern The fuel consumption reportgives the fuel consumption of each crush-

ing unit (liters per hour) and their total

consumption (liters per hour) for a selected

reporting period and can track fuel con-

sumption changes over timeCrushing plant availability can be

assessed as well The availability report

calculates time periods for each crushing

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983149983141983156983155983151 983150

for tissue machines The record of 2210

mmin was set on June 1 2012 during a

24-hour production run by the TM 2 tissue

machine at the companyrsquos mill in Yenikoumlynear the city of Izmit in Turkey

ldquoThe cooperation with Metso has been

beyond excellent and both parties did

their utmost to make the project success-ful The results clearly show that the efforts

were worthwhile on both sides This coop-

eration will extend to cover new projects

in the futurerdquo says Luumlt1047297 Aydin Paper GroupDirector Hayat Kimya

ldquoWe are not surprised that Hayat K imya

managed to break the world speed record

We have had great confidence in the capa-bility of the Hayat team since our project

started in 2009 We certainly know our

machine very well its stability production

efficiency and speed capabilityrdquo says Jan

Erikson Vice President Sales Metso

PowerThe worldrsquos first eco-gas fueled

power plant is up and running

Lahti Energy Ltdrsquos new Kymijaumlrvi II gasifica-

tion plant was officially inaugurated on

May 8 2012 It is the first of its kind in the

RecyclingRecycling with Lokotrack LT106

jaw plant in New York

A brand-new Lokotrack LT106 jaw plant is

used in the city area of New York USA to

recycle demolition materials The crushing

site faces the skyscrapers of ManhattanIsland

Paper amp FiberHayat Kimyarsquos Metso-supplied tissue

machine sets world speed record

Thanks to a skilled crew and dedicated

efforts Hayat Kimya AS in Turkey has suc-

ceeded in breaking the world speed record

world This CHP plant runs on clean eco-

gas that is gasified cleaned and cooled

from recycled waste with Metsorsquos innova-tive technology

ldquoItrsquos actually eco-gas that we combust

in the boilerrdquo comments Lahti EnergyrsquosProduction Director Jukka Manskinen

ldquoWe convert unwanted waste material into

energy in an efficient and environmentally

friendly wayrdquoNever before has any plant gasified

waste on such a large scale In the gasifier

recycled waste is turned into combustible

product gas which is cleaned cooled and

combusted in a high-efficiency gas boiler

to produce steam for the steam turbine The plant produces 50 MW of electricity

and 90 MW of district heat for the city of

Lahti and its neighboring areasMetso delivered the circulating fluidized

bed (CFB) gasification process gas cleaning

and cooling steam boiler environmental

protection system and automation systemto the entire plant The production of elec-

tricity and heat is kept even with the Metso

DNA automation system that covers the

whole plant starting from fuel reception

AutomationMetso develops and supplies plant-

wide crushing control solutions for

crushing plants

Metso has recently signed contracts on

delivering plant-wide automation systems

for mobile and portable rock crushing

plants The key objective of these deliveries

is to stabilize and to increase productivityand efficiency of the plants using one sin-

gle automation and information platform

for integrating crusher-specific IC machinecontrols

Furthermore the plant-wide system

with its information management tools not

only increases plant availability and opera-

tional safety it also makes troubleshoot-ing quicker and performance monitoring

easier The control room for plant-wide

operability is located either in an excavator

cabin or a purpose-built container

Metso around the world

The new LT106 jaw plant is suitable for crushing both hard rock and all rock-based demolition materials

The new world speed record for tissue setby Hayat Kimyarsquos Metso-supplied TM 2 is2210 mmin

8132019 Results Minerals Aggregates 3 2012ENG

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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 7: Results Minerals Aggregates 3 2012.ENG

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983110983141983137983156983157983154983141983140 983137983154983156

1

78

9

1011

12

13

15

16

18

19

2021

22

14

2

3

5

6

17

Active Mines and Current Projects February 2012

Kittilauml gold ndash Agnico-Eagle Ltd Pahtavaara gold ndash Lappland Goldminers Ab

Laiva gold ndash Nordic Mines Ab

Pampalo gold ndash Endomines AB

Orivesi gold ndash Dragon Mining Ltd Jokisivu gold ndash Dragon Mining Ltd

Iso-Kuotko gold ndash Agnico-Eagle Ltd

Hanhimaa gold ndash Dragon Mining Ltd

Kettukuusikko gold ndash Taranis Resources IncNaakenavaara gold ndash Taranis Resources Inc

Kiekeroumlmaa gold ndash Tertiary Minerals Plc

Rompasgold uranium ndash Mawson Resources Ltd

Suhanko-Konttijaumlrvi PGE ndash Gold Fields Arctic Platinum OyKuusamo gold ndash Dragon Mining Ltd

Hirsikangas gold ndash Belvedere Resources Finland Oy

Aumlngesneva gold ndash Belvedere Resources Finland Oy

Kopsa gold ndash Belvedere Mining Oy

Taivaljaumlrvi silver ndash Sotkamo Silver ABSeinaumljoki gold antimony ndash Nortec Minerals Corp

Osikonmaumlki gold ndash Belvedere Resources Finland Oy

Haveri gold ndash Lappland Goldminers Ab

Kaapelinkulma gold ndash Dragon Mining Ltd

1

3

5

7

15

11

19

9

17

13

21

2

4

6

8

16

12

20

10

18

14

22

Mine

Prospect

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983110983141983137983156983157983154983141983140 983137983154983156983145983139983148983141

The main minerals processing componentsincluding grinding flotation and pumping

equipment are delivered by Metso

983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

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983110983141983137983156983157983154983141983140 983137983154983156

Endomines

Pampalondash a green andresponsiblegold mineAt Pampalo near the easternmost point of Finland a cleanand environmentally friendly gold mining operation isbeing executed by Endomines With Metsorsquos plant designand a state-of-the-art processing plant Pampalo runs a

green and responsible yet at the same time profitablegold mining operation that avoids acid mine drainagesand targets 100 water recirculationTEXT amp PHOTOS Eero Haumlmaumllaumlinen

With a modest investment of EUR 20

million the Pampalo mine was built fully

operational and now produces 800ndash900 kgof pure gold annually An on-going expan-

sion will increase the minersquos production

capacity by 30 to 50 next yearIn addition to the main underground

mine at Pampalo several promising satellite

gold deposits are being investigated along

the long Karelian gold line The maximum

distance of the satellites is 30 km allowingthe mine to transport and process all of the

produced ore at the Pampalo plant

Small scale can be successful

with hard work

ldquoWith our gold mining operation we can

very well show that with hard work even

small-scale gold mining and production

can be done in a sound and profitable wayrdquosays Markus Ekberg CEO of Endomines

originally founded in Sweden

According to Ekberg the strategy when

building the mine was to split up the jobsinto small separate contracts Metsorsquos part

was the main minerals processing system gt

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983110983141983137983156983157983154983141983140 983137983154983156

Increasing capacity makes processing

of lower grades economical

The project to significantly increase the

processing capacity at Pampalo is well

under way with the installation of for

example a second grinding mill and more

flotation cells The expansion will be in

operation during early 2013ldquoThe added capacity also makes it pos-

sible to economically process the nearby

open pits with a lower gold grade In addi-tion it helps us to optimize the crushing

and grinding circuitsrdquo Ekberg concludes

Active exploration drillings have

exposed new mineralized zones furtherextending the lifetime of the Pampalo mine

from the present estimate of 6ndash7 years

More info

Peter Vikman

Tel +358 400 869 845petervikmanmetsocom

Endomines Pampalo gold mine

LOCATION near the community of

Ilomantsi in Eastern Finland

GOLD ORE CONTENT

ndash Pampalo 34 gtndash Hosko 99 gt

ndash Raumlmepuro 39 gt

ndash Muurinsuo 30 gt

PRODUCTION TONNAGE PER YEAR 270000 tons (present)~400000 tons (future)

GOLD PRODUCTION PER YEAR 800ndash900 kg

KNOWN ORE RESERVES IN TOTAL

approx 2 million tons

MINE DEPTH 360 m

MINING METHOD bench cut and fill

NUMBER OF EMPLOYEES

100 including contractors

METSO EQUIPMENT

1 Metso TRN 30 x 48 m

wet ball mill

8 Metso RCS series flotation cells 1 Nordberg MF 1800 x 6100

screen

3 Metso samplers

1 Metso CT thickener

1 Metso TF vacuum filter

33 Metso slurry pumps of various

types and sizes

The gold ore is screened using Metsorsquos MS series mining screen

Markus Ekberg is pleased with the outcome the mine reached the minerals processing utilizationdegree of over 90 just two months after start-up

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156983145983139983148983141

Nordic Mines ndash on track tobecoming one of Europersquosmost prominent goldproducersNordic Mines is the newest member in a long chain of Nordic gold mining operations

Inaugurated in mid-August 2012 this company of Swedish origin aims to become one

of Europersquos most prominent gold producers Metso is one of Nordic Minesrsquo main partners

supplying the Laiva gold mine with crushing screening conveying and minerals

processing equipment at an estimated value of EUR 30 million

TEXT amp PHOTOS Eero Haumlmaumllaumlinen

2983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

The Laiva gold mine was built in record time infrastructure

construction began in spring 2010 ore excavation started in

June 2011 and the first gold bar was casted in December 2011

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156

Just one year after starting the gold recov-

ery process Nordic Mines is on track toreaching a capacity of 5 kg of gold per day

At present the operations are averaging 3

to 4 kg of gold daily

The ore in the Laiva Gold Mine consists

of packages of gold-bearing quartz-filled

shear structures The deposit is more thana kilometer long and 700 meters wide The

total depth is still unknown but dr illings

carried out thus far have shown gold-bear-ing shear structures 300 meters below the

surface

A typical ore zone includes a large num-

ber of thin shear structures from 5 to 30per meter The ore zones are commonly 50

to 100 meters long several are 10 meters

deep and they range from a few meters to

20 meters cross strike The minimum min-ing width is 25 meters which means that

even a minor ore zone consists of at least10 to 50 shear structures

Conventional pattern blasting

with selective loading

Prior to mining Nordic Mines conducts

grade control drilling which provides

dense gold grade information and makes

it possible to outline the boundaries

between ore and waste The mining

technique applied is conventional pattern

blasting with selective loading This is oneof the most commonly used techniques in

large-scale open-pit mining

A typical blast in the Laiva mine is 50

meters long 100 meters wide and 5 metersdeep After blasting ore and waste aremined by selective loading

After investing some EUR 100 million

the Laiva mine now comprises an open-pit

mine with a modern complete crushinggrinding and processing circuit that ends

with the casting of gold doreacute bars

With a number of mine staff partners

sub-suppliers city and state officials inattendance the Laiva gold mine was offi-

cially inaugurated on August 16 2012

Michael Nilsson Managing Director

of Nordic Mines stressed in his speechthe importance of overcoming challenges

during the building of the mine

ldquoObviously the whole development

took us longer than expected Today weare pleasantly surprised by the size of our

operation We are becoming much bigger

than expectedrdquo gt

Chief Geologist Kimmo Lahtinen presenting narrow gold veins twisting at the Laiva North open-pit mine

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156983145983139983148983141

An international process package

The Metso package for the Laiva gold mine

included the main crushing screening

conveying regrinding leaching and pump-ing elements Metsorsquos office in Sala Swe-

den has served as the main project office

with Metso manufacturing units in FranceGermany Sweden and Finland responsiblefor the equipment supply

At Laiva the gold ore is classified after

selective excavating into two gold con-

tent classes All class A gold ore is takento Metsorsquos sturdy jaw crusher for primary

crushing while the class B ore is stocked for

possible future use After primary grinding

utilizing autogenous technology the ore is

screened and two Metso cones crush the

oversized pebbles For regrinding Metsorsquosball mill is used

During high- and low-grade leaching

processes a number of Metso pumps and

dewatering screens are used The whole

minerals processing system is controlled byMetsoDNA automation

Active exploration drilling going on

According to Mine Manager Tom Soumlder-

man the known gold ore reserves at the

Laiva gold mine amount to 169 million

tons but the potential for additional find-

ings looks good

ldquoWorking at the level of two million tonsper year our expected lifetime is about nine

years We carry out active exploration drill-

ing in Kaukainen Musunneva and Oltava

to locate nearby satellite ore bodies Anupdated detailed mine life plan will be pre-

pared during the autumnrdquo Soumlderman saysNordic Minesrsquo other exploration areas

include Tormua in Finland and Fjaumllltuna

and Vassbo in Sweden

More info

Alf Rydberg

Tel +46 70524 5837

alfrydbergmetsocom

Happy faces during the minersquos inaugural ceremony Mine Manager Tom Soumlderman (left) with Managing Director Michael Nilsson and Deputy Managing Director Krister Soumlderholm

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156

The story behind the discovery of the Laivamine is an interesting one During a hunt-

ing trip in the remote forests of Laivakan-

gas in 1979 Pentti Jaumlmbaumlck found an inter-esting-looking piece of stone Although hecould not see the gold hidden inside the

rock Pentti noticed the striking weight

and somewhat different look of the stone

Upon returning home Pentti sent thesample to Outokumpu which at the time

was the leading state-owned mining com-

pany in Finland After testing a high gold

content of 15 grams per ton was found

Gold deposit founded by a hunter

The founder of the Laiva gold deposit Mr Pentti

Jaumlmbaumlck was the guest of honor during theinauguration

Lennart Schoumlnning Chairman of the Board ofNordic Mines holding a gold doreacute bar worthsome EUR 320000

Outokumpu registered a mining claimon the area and conducted a series of

exploration drilling from 1981 to 1987 Due

to the low price level for gold no mine wasstarted at the time Other mining compa-nies such as Endomines held the mining

rights later

Nordic Mines with its sights set on

locating and exploiting gold in Swedenand Finland was founded in 2005 During

the same year the company purchased its

first mining rights at Laiva

Nordic Minesrsquo Laiva gold mine

LOCATION near the city of Raahe

northwestern Finland

GOLD ORE CONTENT average 16 gt

ORE EXTRACTED PER YEAR

12 million tons (present)

20 million tons (planned)

GOLD RECOVERY 85

TOTAL KNOWN ORE RESERVES

169 million tons

MINING METHOD

Selective open-pit benchingNUMBER OF EMPLOYEES

130 including contractors

METSO MAIN EQUIPMENT

2 Metso VF and 6 EMEG EME

vibrating feeders

8 Screens 1 MF 1 CVB and 6 KS

1 RCS Flash flotation unit

1 Metso SRR ball mill 18 x 4 m

1 Nordberg C160 jaw crusher

1 Nordberg HP100 cone crusher

1 Nordberg HP200 cone crusher

5 Nordberg NB series conveyors

73 Metso Slurry pumps ofvarious types and sizes

8132019 Results Minerals Aggregates 3 2012ENG

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The newest member of the proven GP series cone crushers ndash theNordberg GP220 ndash offers a versatile alternative for any demanding

tertiary or quaternary or even secondary crushing operation fulfill-

ing all crushing needs and maximizing customersrsquo profitability

High-quality components and optimized castings and forgings

contribute to the GP220rsquos enhanced reliability and help to ensurethe highest level of crusher uptime

Thanks to the 200 kW (270 hp) power draw the GP220 performs

at a 20 to 30 percent higher capacity than other cone crusherbrands with an equal head diameter The large feed openingenables the feeding jaw crusher to run at 110 mm css Operational

flexibility is ensured by multiple strokes and six different cavities

Secondary crushing possible

thanks to cavity and stroke options

Thanks to the GP220rsquos cavity and stroke options secondary crush-

ing in addition to tertiary and quaternary stages is also possible

using cavities with a greater intake opening With the GP220 a suit-

able solution for producing excellent end-product gradations

can always be found

With advanced automation using IC50 or IC5000 operation

is safe and trouble-free The low height thanks to the patented

piston design makes replacement installations much easierA dynamic setting adjustment enables a fast response to process

optimization needs

The Nordberg GP220 weighs 10500 kg (23150 lbs) and hasa maximum real feed size of +200 mm (8rdquo) with strokes from

18ndash40 mm (57rdquondash1 47rdquo) The cavity options are EF F MF M C

and EC

A complete modular crusher steel structure is available for allGP series stationary installations including GP220 The platform

includes places for the lubrication unit motor automation or

pressure accumulator and pressurized sealing The only things

left to add are the feed and discharge conveyors

Main new features of the GP220 Large feed opening allows for secondary stage operation

Longer setting range of main shaft for better wear parts utilization

Stronger main components to carry high loads with a powerdraw as high as 200kW

More info

Hannu Vakkuri

Tel +358 50 317 0638

hannuvakkurimetsocom

Thanks to the large feed opening and wide selection of strokes and cavitiesthe new Nordberg GP220 cone crusher is a highly versatile cone novelty

More versatility with the newNordberg GP220 cone crusher

Reinforced head and frame castings combined with a 200kW power

draw make the GP220 cone a reliable crusher with maximum productivity

8132019 Results Minerals Aggregates 3 2012ENG

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Metsorsquos HRCtrade takes high pressure grinding roll technology to the next level

The new Lokotrack mobile conveyors come as tracked and wheeled models

Metsorsquos latest development in comminution equipment the HRCtradeis a major step in the profitable application of high-pressure grind-

ing roll (HPGR) technology Metso has made several key innova-

tions in order to increase throughput and decrease the total cost

of operation

Metsorsquos patented Arch frame creates an even gap setting acrossthe width of the tires limiting skewing that can result in downtime

for mining operations This anti-skewing Arch frame also prevents

damage to the roller bearings (caused by misalignment) that canoccur with the traditional HPGR design

Flanges maximize wear life and increase throughput

Used in place of spring-loaded cheek plates the flanges keep thebed of material within the crushing zone and prevent material

from bypassing the tires This enables greater circuit capacity and

increases the overall crushing efficiency

In addition by preventing material from bypassing the tires

even pressure across the width of the tire is better maintained

Distributing the pressure more evenly maximizes the tire life bypreventing a ldquobath tub effectrdquo in which the center of the tire wears

faster than the edgesVictoria Herman Metsorsquos Product Manager for the HRC notes

that this breakthrough design is a response to the growing needs

in the mining industry ldquoEnergy efficiency has been attracting our

customers to HPGR technology for yearsrdquo she says ldquoBut our design

concept increases capacity and crushing efficiency ndash and thatrsquossomething mining companies are always looking to improve onrdquo

The track-mounted Lokotrack CT32 and wheel-mounted Lokotrack

CW32 mobile conveyors offer an ideal solution for applications

that require high stockpile capacity and excellent material transfer

capabilities They also add flexibility to multi-stage crushing andscreening applications enabling easy and fast closed-circuit opera-

tion of mobile units

The conveyor novelties can be used in both mobile and station-

ary installations providing extra stockpiling capacity in situationswhere for example fewer wheel loaders are available

The HRC is ideal for high-tonnage hard rock applications andcan be used as a tertiary quaternary or pebble crusher Currently

several HRC units are in operation around the world ndash with a total

of 6500 operating hours including over 3800 hours in a mininghard rock application The machine does have range within hardrock applications itrsquos been designed for use in diamond iron ore

copper gold platinum and various industrial minerals

More info

Victoria Herman

Tel +1 717 309 1150

victoriahermanmetsocom

Several optional features such as hydraulic folding of tail sections

and dual hydraulic drive for increased throughput are available

The capacity of the CT32 and CW32 is 400 mtph (440 stph)feed size up to 150 mm (6rdquo) belt width 1050 mm (42rdquo) and dis-charge height 9120 mm (29rsquo 11rdquo) The CT32 is fitted with a Caterpil-

lar C2 diesel engine with 38kw (51 HP) power The CW32 is avail-

able for hydraulic or electric use

More info

Kimmo Anttila

Tel +358 50 433 3745

kimmoanttilametsocom

The new HRCtrade combines high crushing pressure and a low circulatingload resulting in the most efficient comminution

When flexibility in stockpiling capacityis required the answer can be foundin the new Lokotrack CT32 and

CW32 mobile conveyors

8132019 Results Minerals Aggregates 3 2012ENG

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Service creates value in ChinaChinarsquos most important gold producing area Yantai in northeastern China supplies more than 16 of the countryrsquos goldproduction each year With the gold market thriving the scale of gold production in Yantai has been expanding constantly

Zhongjia Mining Industry Co Ltd is one of the beneficiaries of this thriving industryTEXT amp PHOTOS Yan Xin

Inspection and maintenance of the HP500 cone crusher conducted by Metsorsquos service engineers

In 2011 Zhongjia Mining Industry pur-

chased a modular crushing and screen-ing system from Metso for its new gold

production project With the cooperation

between the two companies continuously

intensifying Zhongjia Mining Industry

signed an additional one-year Life CycleService (LCS) contract with Metso incorpo-

rating Metsorsquos global knowledge in equip-

ment processes and services

ldquoMetso customized a series of reason-

able service solutions also referred toas Metso Performance Solutions for us

including preventive maintenance services

process improvement personnel training

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155

and a procurement plan for wear parts

These really suit our needs perfectlyrdquo saysShen Yidong the Manager of ZhongjiaMining Industry

Effective preventive maintenanceFor mining corporations the biggestconcern is the economic losses caused by

the shutdown of equipment As a result

preventative maintenance is of vital impor-

tance During the contract period Metsoservice engineers offered 7-day tracking

service on the production site every month

to eliminate potential problems and thus

ensured the stability of the system

parts caused pressure on our working capi-tal which was not favorable for our long-

term developmentrdquo Shen explains

To solve this problem Metso designed

a rational stock plan of wear parts and built

a field warehouse In accordance with theuse and consumption of the liners the field

service engineers complement the stock tomake production and operations run more

smoothlyldquoNow when we need to replace the

wear parts we can use them before pay-

ment This not only simplifies the procure-

ment process but also liberates a largesum of our operating capital which can

be used for other business development

purposesrdquo says Shen

Best partner

ldquoAlthough the LCS contract incurs some

early purchase costs in the long run Metsorsquosprofessional and quality service will improve

the equipment efficiency reduce ourenergy consumption and ensure stable

operations thus generating more prof-

its This is the greatest value for us so the

investment is really worthwhile overall Inthe future we will choose more Metso prod-

ucts and services Taking all aspects into

consideration we believe Metso is the best

partner for usrdquo Shen Yidong concludes

More info

Thomas Bai Tel +86 13801009114

thomasbaimetsocom

ldquoIn the eight months since the contract

came into effect our corporation has notsuffered any financial losses due to equip-

ment breakdown The regular maintenance

has greatly improved the efficiency of our

entire crushing system In addition the

experienced engineers from Metso also

provided onsite training and guidancefor our staff and the tailored training has

greatly enhanced the operating abilities of

our employees and upgraded their overalllevel of competencerdquo says Shen Yidong

More productivity with

less consumption

Metsorsquos service contract focuses on real-

izing the optimum performance of each

process flow After analyzing Zhongjiarsquos

production system Metsorsquos techniciansproposed an adjustment to the closed side

setting of the HP500 for tertiary crushingin order to improve the efficiency of the

downstream fine crushing and milling pro-

cessing by over 10ldquoThe process flow improvement solu-

tions provided by Metso not only increased

the output of our gold concentrates but

also reduced our energy consumption andcostsrdquo says Shen

In the past wear parts procurement

took up a larger proportion of Zhongjiarsquos

total production costsldquoTo avoid downtime caused by the

shortage of wear parts we had to keepeight sets of various wear parts in place

However the cost of having so many wear

Zhongjia Mining Industryrsquos gold concentrates processing plant in China

8132019 Results Minerals Aggregates 3 2012ENG

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0983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

Safe quarrying high-

quality aggregates

8132019 Results Minerals Aggregates 3 2012ENG

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ldquoWe share a similar zero-accident strategy and target with Metso and have successfullyfollowed it Metso has also helped us to meet the strictest end-product quality andcubicity requirements set in Spainrdquo This is how Managing Director Intildeigo Ajuria ofOfitas de San Felices the leading hard rock quarrying company in Spain describesthe cooperation with MetsoTEXT Eero Haumlmaumllaumlinen PHOTOS Ofitas and Eero Haumlmaumllaumlinen

The San Felices quarry is situated in a picturesque mountainous landscapebetween the companyrsquos Rioja vineyards and the Bilbao-Madrid motorway

8132019 Results Minerals Aggregates 3 2012ENG

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Ofitas has pioneered the implementation

of several Metso novelties in the Spanish

market The company was the first to use

efficient large track-mounted Lokotrack jaw plants the unique mobile conveying

system and also the new-generation HP4

cone crushers

Today the company operates twomodern Metso stationary plants one in

Guadix near Granada and the newest one

in San Felices Haro Rioja community Both

quarries focus on refining hard rock by pro-cessing ophite rock into the highest quality

railway ballast asphalt and concrete mix

grades The company has a satellite quarry

near Vitoria in PentildeacerradaBeing situated next to a highway and

the famous Rioja vineyards Ofitas must pay

special attention to environmental issues

To minimize dust problems all conveyors

have special covers attached

Quality durability and service

The cooperation between Ofitas de San

Felices and Metso started back in 1973when the Ajuria family bought the com-

pany whose quarrying activities began in

1919 Intildeigo Ajuria has a clear vision of why

the cooperation has continued withoutinterruption for almost 40 years

long-standing personal relationshipsrdquoAjuria adds

Serving railways asphalt

and concrete producers

The year-old San Felices stationary instal-lation lies hidden in a mountainous area

south of the city of Vitoria in NorthernSpain The new plant replaces an old one

that complicated the extraction of ophiterock Both plants are delivered by Metso

With its two separate production lines

the new plant is able to produce all the

end products required ndash from railway bal-last to the finer grades needed for asphalt

and concrete

Due to lower demand the quarry cur-

rently produces some 4000 tons per day

At full capacity however the plant canreach 8000 tons of production per day

30ndash35 of which consists of railway ballastfor high-speed trains and 65ndash70 of chips

and sand Thanks to the versatile two-line con-

cept connected by transverse conveyors

up to 12 different end products can be pro-

duced Depending on the demand for endproducts the material can be guided either

to the HP4 cone or HP400 cone followed

by a Barmac vertical shaft impactor

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

The ophite feed is fed to the C125 jaw crusher by a sturdy dump truck

The key people running the new San Felicesquarry Mine Engineer Carlos Fernandez (left)Managing Director Intildeigo Ajuria with ProductionManager Julian Perez

ldquoThrough the years Metso machinery

has proven its production capacity and

durability resulting in high-quality end

products A big plus for us has also beenthe quick response time to our process

challenges or servicerdquo

ldquoIn fact our cooperation extends

beyond day-to-day business matters to

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983122983141983152983151983154983156983145983150983143 983154983141983155

Meeting the strictest cubicity demands

The Spanish regulations concerning end-product cubicity are becoming more

demanding The flakiness percentage of

railway ballast must be below 10 and for

asphalt and concrete aggregates less than

15

ldquoWith Metsorsquos HP4 cone and the Barmacvertical shaft impactor we can meet even

the strictest cubicity demands We believe

that our high quality is helping us to sur-vive in the present recessionrdquo notes Mine

Engineer Carlos Fernandez

ldquoWe hope to increase the total extrac-

tion of the three quarries from the present15 million tons per year because our plant

capacity allows more than double thatrdquo

Fernandez adds

More info

Angel Luis Garcia Tel +34 686 94 35 30

angelluisgarciametsocom

In addition to being the leading Spanish

quarry to process hard rock Ofitas de SanFelices also cultivates 34 hectares of vine-yards next to the quarry which is situated

in the famous Rioja wine area

The company has previously sold a

harvest of over 200000 kg of Tempranillo

grapes to local red-wine makers Recentlythe company built its own wine process-

ing plant to process 10000ndash15000 kg of

grapes themselves

Aggregates and wine production

Andoni Ajuria the founder of Ofitas de san Felices (left) with Intildeigo Ajuria the present ManagingDirector tasting wine from the companyrsquos own vineyards

The first vintage wine of Ofitas har-

vested in autumn 2010 is now maturingin oak barrels After maturing for 12 to 15months the wine is called crianza and after

two years it will be granted the classifica-

tion reserva

ldquoWinemaking is not a business but

a hobby for us We give our wine out aspresents and drink it when we meet

our suppliers and friendsrdquo Intildeigo Ajuria

comments

For environmental protectionall of San Felicesrsquos plantconveyors are covered

Ofitas de San Felices quarry

LOCATION Haro near the city

of Vitoria northern Spain

SIZE 100 hectares

ROCK TYPE Ophite with Los Angeles

index of 9ndash10

PRESENT DAILY EXTRACTION 3000 tons

of ophiteNUMBER OF PERSONNEL 30

RESERVES 10 million tons

MAIN END PRODUCTS 0ndash2 mm

2ndash4 mm 4ndash10 mm 10ndash16 mm

16ndash22 mm 25ndash60 mm (ballast)

METSO MAIN EQUIPMENT

VF feeder

C125 jaw crusher

ndash feed size 0ndash800 mm

ndash css 130ndash140 mm

HP400 cone crusher

ndash feed size 80ndash250 mm

ndash css 40 mm HP4 cone crusher

ndash feed size 40ndash80 mm

ndash css 15 mm

Barmac 6150 VSI crusher

4 CVB2060 screens

2 TS32 screens

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Metso Distribution Centers he

Europe (Tongeren Belgium)

France (Macon)

Czech Republic (Přerov)

Austria (Vienna)

2271 d

Brazil (Sorocaba SP)

1014 d

USA (Columbia SC)

1690 d

USA (Waukesha WI)

434 d

South Africa (Vereeniging)

Ghana (Tarkwa)

Meacutexico (Irapuato)

Peru (Lima)

Chile (Concoacuten)

788 d

Sweden ( Trelleborg)

Finland (Tampere)

UK (Rugby)

865 d

Russia (St Petersburg)

Brazil (Parauapebas PA)

206 d

4983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

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In the case of an equipment failure or

a planned service shutdown resuming

production as quickly as possible is crucialEach hour spent waiting for a spare part to

arrive equals money lost Whether the right

part takes 12 or 48 hours to arrive really

makes a difference

The comprehensive and global Metsospare and wear parts service network pro-

vides you with the right part in the right

place and at the right time Our strategi-

cally located Distribution Centers and

Satellite Warehouses are on call 24 hoursa day 7 days a week ensuring efficient

parts replacement near you

Check out the locations of the MetsoDistribution Centers and how many parts

pass through them each day

More info

Marcelo Farah

Tel +55 15 2102 1315

marcelofarahmetsocom

you minimize downtime

Australia (Perth)

746 d

China (Tianjin)

China (Kunming)

China (Shanghai)

393 d

India (Faridabad)

India (Ahmedabad)

India (Hyderabad)

India (Bhubaneswar)

India (Bangalore)

419 d

Russia (Yekaterinburg)

Australia (Newcastle)

New Zealand (Matamata)

983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088

TEXT Sofia Williams

Singapore (Singapore)

Distribution Center Satellite Warehouse

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Following a large investment

in Metso crushing equipmentand services Buena Vista del

Cobre is now expanding the

mine site to include even more

equipment ndash and with thatexpansion comes the need for

more local service resources

Metso and Buena Vista del

Cobre have entered into a Life

Cycle Service agreement forthe plant and construction of a

brand new Metso service hub

is under way in Cananea

New facility new

level of service

The Cananea service hub

which will be up and running in early 2013will support the recent expansion and resur-

gence of Buena Vista del Cobre Initially it

will be a major repair and assembly center

for pumps crushers and screens and will

provide for rubber covering capabilitiesBut the 8000-square-meter facilityrsquos service

offering will be expansive including a con-

signment stock inventory to help serve theminersquos varying needs Metso currently has

50 service team members on site

Although Buena Vista del Cobre was a

key influencer in building the new servicehub this location will also enable Metso to

expand its capabilities and provide local

support to the entire mining community

in northwest Mexico The Cananea hub

will serve a number of major copper and

gold mines in the region including MineraFriscorsquos San Felipe Fresnillorsquos Milpillas and

Grupo Mexicorsquos Mexicana de Cobre

ldquoBuena Vista del Cobre is the biggestcustomer we have in Mexico today and

with this expansion project itrsquos only going

to grow and be strongerrdquo says Felix Forna-

guera Director of Services Mexico CentralAmerica and Caribbean ldquoWith that said the

idea behind the Cananea service hub is to

provide a central location for local support

for all our major customers in the areardquo

Establishing safety

ldquoIt was key to have our support here in

Cananea because the Buena Vista delCobre started from the ground uprdquo saysFelix ldquoWersquove been able to help the cus-

tomer to establish the best in support

service and operations from the very

beginningrdquo And this ground-up approachincluded a major focus on safety

Metso worked closely with Buena Vista

del Cobre to establish the safety proto-

col by which the mine operates Basedon Metsorsquos expertise the safety measures

put in place have enabled the mine to

become strict and efficient in its operations

and maintenance procedures To achievethis Metso worked closely with local andnational authorities to ensure the safety

plan was comprehensive and in accord-

ance with all established legal bodies

The best in regional support

The service hub in Cananea is a prime

example of Metsorsquos focus on providing local

service and support to its customers all

Service shines in Cananea MexicoAfter three years of inactivity the Buena Vista del Cobre mine in Cananea Sonora Mexico has been operational since 2010A mine that was inactive for such a significant amount of time however requires a great deal of support to successfullyrestart the plant and bring it back to an operational and profitable state

TEXT Deanna Lee PHOTO Metso

over the world ldquoWe are the first

company developing this kindof service in northwest Mexicordquo

adds Felix ldquoOur people have

developed a close relationship

with the team at the mine Itrsquosmore than a supplier relation-

ship our guys are inside the

mine living and working thererdquo

In fact this is the model

that Metso is using in servicehubs all over the globe build-

ing modern facilities bringing

teams on site and workinghand in hand with mine

operators The Cananea Service

hub is only the most recent

example of Metsorsquos commit-ment to service and northwest Mexico is

yet another mining hotbed thatrsquos going to

benefit from the companyrsquos support

More info

Felix Fornaguera Tel +52 4621079227

felixfornaguerametsocom

A mining cone serviced by Metso at the Buena Vista del Cobre mine inSonora Mexico

ldquoThe new Cananea service center will be a majorrepair and assembly center for pumps crushersand screensrdquo says Felix Fornaguera Director ofServices Mexico Central America and Caribbean

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

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During the MINExpo exhibition over 1300 people visited the Metso stand

983122983141983152983151983154983156983145983150983143 983154983141983155

Held every four years MIN-Expo consistently grows so

perennial exhibitors like Metso

are challenged with elevating

their presence and drawingin new (and greater numbers

of ) visitors each year ldquoItrsquos not

necessarily a challenge to lsquotoprsquo

our last showingrdquo says Keith

Ference Vice President ofmarketing and communica-

tions North America ldquoThere

are four years between eachMINExpo so we always have

a lot to say and reveal to our

customersrdquo The real challenge

he says is finding an exciting

and dynamic way to deliverthe message ldquoTherersquos so much

to see here so your booth has

to be compelling from the

outside-in and thatrsquos what

we always try to dordquo

Service sets the stage

The Metso booth created buzzin a number of ways and per-

haps the most striking (partly

due to its size) was the live

theater presentation As visitorspassed through the aisles of the show-

room the sights and sounds from Metsorsquos

theater were hard to miss And once guests

entered they were captivated by a short

high-energy video presentation focused

on Metsorsquos service capabilities The message was simple Metso is ldquoyour

local service partner rdquo for all mining and

construction needs The video showed ourservice teams in action all over the world

and the audience came away with an

understanding about Metsorsquos commitment

to service Customers can count on morethan 70 local service centers run by more

than 1700 expert technicians delivering

Metso makes an impact at MINExpo 2012At this yearrsquos MINExpo International nearly 60000 attendees flocked to Las Vegas Nevada the largest turnout in showhistory The visitors ndash mining professionals from all over the globe ndash explored 850000 square feet of showroom spacefeaturing the industry rsquos latest technology equipment products and services They toured the show for three days

seeking the latest and greatest from more than 1800 exhibitorsTEXT Keith Ference PHOTOS Tracey Ford Perry

detailed descriptions andphotos of all of Metsorsquos mining

and construction products and

services The app also provides

digital access to Results and asearchable database of sales

contacts By day three of the

show MetsoMAP had been

downloaded by more than

500 usersIn addition to the app the

booth was equipped with

several LCD screens each con-trolled by Metso experts who

used their iPads to present new

products like the Megalinertrade

and the HRCtrade A featured

presentation on Metsorsquos lineupof energy-efficient comminu-

tion equipment including the

VERTIMILLreg SMD and MP-1250

cone crusher was also avail-

able letting customers seehow Metso technology delivers

some of the worldrsquos most effi-

cient size reduction

Measuring MINExpo success

After a very busy three days

(on top of months of prepara-tion leading up to the show) everyone

involved with MINExpo ndash from the North

American marketing team responsible for

the booth to the product managers and

sales force that worked the floor ndash is view-

ing the show as a success ldquoTherersquos alwaysa sigh of relief after each (MINExpo)rdquo says

Keith ldquoAnd overall the initial feedback

and response has been very positiverdquoWith more than 1300 visitors to the

booth Metso certainly made an impact

ldquoWe learn a lot from each show and with

some time wersquoll have a better understand-ing of the tangible results of our effortsrdquo

Keith adds

reliable service for mining equipment as

well as customized cost-effective life-cycle

services contracts

Technology ndash MetsoMAP

is an industry firstMINExpo provided the industry with its firstglimpse of Metsorsquos revolutionary iPad app

MetsoMAP The app was demoed to the

boothrsquos visitors via ldquothe worldrsquos largest iPadrdquo

a custom-made 80-inch screen that show-cased all of its capabilities most of which are

groundbreaking in the industry MetsoMAPrsquos

simple interface is highly intuitive making

it easy to view process animations videos

The presentation of the new HP cone crusher attracted a large audience

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When yoursquore allowed less than a dozen days per year for breakdowns repair andmaintenance every single hour during a service shutdown counts There simplyisnrsquot any room for surprises Thatrsquos why Boliden counts on MetsoTEXT amp PHOTOS Sofia Williams

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Kurt Kalla Site Managerof Metso Gaumlllivare ServiceCenter is responsible forthe maintenance of Aitik

Metso and Boliden Strivingtogether for 97 uptime

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983122983141983152983151983154983156983145983150983143 983154983141983155

One of the biggest copper mines in

Europe Bolidenrsquos Aitik is located deep inthe wilderness of Swedish Lapland next to

the small town of Gaumlllivare The mine has

been operating since 1968 and a recent

expansion has increased its annual ore

production to 36 million tons

But the ambitious Swedes are not will-ing to lay back and relax just yet Bolidenrsquos

new aim is to reach a production rate of

45 million tons of ore per year in AitikAfter that Perhaps more than 55 million

tons The ore concentration in Aitik is very

low-grade with a mere 022 copper con-

tent hence the need for high capacityAchieving the ambitious production

goal requires maximum plant availability

This means that everything from the crush-

ers to the filters must be up and runningfor approximately 97 percent of the time

Thatrsquos where Metso comes into play

A cost-per-ton contract in action

The maximum uptime requirement allowsless than a dozen days per year for break-

downs repair and maintenance at Aitik

Every single hour during a service shut-

down counts There simply isnrsquot any roomfor surprises

Executing a successful shutdown under

such conditions requires a reliable service

partner not afraid of challenges and this iswhy Boliden has entrusted Aitikrsquos services

operations to Metso Boliden and Metsohave worked together since the 1960s

and the collaboration took another step

forward in September 2012 when the twocompanies signed a three-year extension

of the services contract for Boliden Aitik

ldquoThe new contract is a cost-per-ton

agreement We get paid based on Aitikrsquos

production Itrsquos a win-win deal for both par-

ties but also a new mindset for usrdquo explainsKurt Kalla Site Manager of Metso Gaumlllivare

Service Center responsible for serving Aitik

From now on the duration of the shut-down is what matters the most According

to Kalla the Metso service organization in

Gaumlllivare is now streamlining its operations

to fit the bill and has already witnessed thestrategy working In August 2012 Metso

carried out a 188-hour service shutdown in

Aitik which turned out to be a success

Zero tolerance for injury

One key factor to the success was theextensive planning of precautionary health

safety and environment procedures under-

taken by Metso prior to the shutdown Thanks to strict measures applied no

injuries or accidents occurred during the

shutdown and the work could easily be

finished on scheduleMats Johansson Health Safety

and Environment Manager for Metso in

Sweden explains how this was achieved

rdquoPlanning of the shutdown included arisk analysis for all new tasks participating

in Bolidenrsquos safety coordination meetingsmeeting with both Metso supervisors and

subcontractor supervisors and finally a

meeting with the entire staff participating

in the shutdown where everyone had to

sign a document stating their commitmentto the information providedrdquo he says

During the actual shutdown plenty of

new barriers signs and awareness cones

were put in place as a result of observa-tions from previous audits and safety plans

and risk analyses were readily available

in the work area Metso and Boliden also

introduced a Mill Inching permit a certifi-cate for completing a mandatory course for

those involved in the process In addition

Metso carried out random safety audits

during the shutdown to make sure thestrict policy was followed

According to Boliden Metsorsquos way of

working is a good example of how health

and safety precautions should be handled

ldquoMetso is a good example of how towork with safety and health plans risk

analysis permits and welding permits

Their table with all binders in the second-

ary mill area was exemplaryrdquo says Kjell-Arne

Johansson a technician from Boliden

The use of the new Metso Megalinertrade

system in the lining of Aitikrsquos Metso AG

mills has also improved the safety of main-tenance staff The Metso Megalinertrade con-

sists of larger-than-average liners bolted

in position from outside the mill Mainte-

nance technicians no longer need to go

inside the mill and stand in the dangerousdrop-zone of the liners gt

Boliden aims to reach a production rate of 45 million tons of ore per yearin the Aitik mine site

ldquoA complete risk analysis was conducted during the planningof the shutdownrdquo comments Mats Johansson Health Safetyand Environment Manager for Metso in Sweden

8132019 Results Minerals Aggregates 3 2012ENG

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Service the Metso way

24 hours a day 365 days a year

In addition to paying close attention to

health and safety issues executing an effi-

cient shutdown requires careful planning

and timing of every step in the mainte-

nance process Wear and spare parts have

to be available on time and a repair shoplarge enough to accommodate equipment

located close by

ldquoTo keep maintenance breaks as short

as possible we aim to replace the pump on

site and bring the old one for repair to our

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

nearby facilities This method gives us the

peace to do a good job and keep the cus-

tomerrsquos operations runningrdquo Kalla describes

the Metso way of handling Aitikrsquos pump

maintenance

Metso is currently expanding its Gaumllli-

vare service center to include a distribu-

tion center for wear and spare parts andalso concentrating its previously scattered

operations under one roof in its Vuoskon-

jaumlrvivaumlgen facility The expansion is due to

be completed by 2014

Metso equipment

delivered to Aitik36

bull 2 AG mills diameter 116 x

137 m gearless 22-MW motor

bull 2 Pebble mills diameter 91 x

113m dual 5-MW pinion drive

bull 3 VPA pressure filters VPA 1540-54

bull 12 sample pumps and pipes

VF50

bull 60 Various slurry pumps up to

MR500 modelbull Appr 5000 m rubber-lined slurry

pipes up to 600 mm diameter

bull Appr 5000 m rubber-lined by

gravity pipes up to 600 mm

diameter

bull Appr 5000 m rubber hoses

up to 600 mm diameter

Not only does the expansion make ser-

vice shutdowns at Aitik run more smoothly

it guarantees a more comprehensive

on-call emergency service response in the

region ndash thanks to the spare and wear parts

inventory available 24 hours a day 365

days a year

More info

Lars Rosenling

Tel +46 70 107 45 90

larsrosenlingmetsocom

Metso grinding equipment dominates the view in the concentrator

Safety on site is made up of small things like

making sure that everyone remembers to secure

the hoses in place

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983122983141983152983151983154983156983145983150983143 983154983141983155

Pebbles have always been a

challenge for producers of sandsince they cannot be returned

to rivers after extraction For

decades the processing of this

material resulted in a huge

environmental liability with alarge amount of pebbles hav-

ing to be stored away and left

unused

Transforming problems into

business opportunities

Areia amp Cia (areia = sand) has

operated in this market forover 20 years and decided to

enlist the help of Metso to find

a profitable solution for the

processing of pebbles

In July 2011 analyses werebegun to assess the abrasive-

ness and crushability of the

material Four alternatives wereidentified for processing and

transforming pebbles into sand

Initially Areia amp Cia was

interested in acquiring an

impactor for its reason-able price level However the

customer wanted to process

all the pebbles that were col-

lected daily in addition to some of the

material that it had stored In weighing theresults expected by the customer and the

excessive abrasiveness of the material the

HP200 cone crusher was decided on as thebest alternative

Areia amp Cia made the required invest-

ment and after using the HP200 for just

six months the company has already beenreporting outstanding results The HP200

not only transforms pebbles into sand but

also produces sand of excellent quality

with high yield and low maintenanceWith minor adjustments the HP200

also enables the production of sand withspecific particle size distribution for special

applications such as filtering sand blasting

and foundry sand adding value to the prod-

uct and increasing the types of sand offeredldquoMetso is pleased that the HP200 not

only enabled the processing of a product

that had been set aside as unusable but

HP200 cone transforms pebblesinto high-quality sandOver the last few decades Brazilian economic growth has been driving demand for construction aggregates The market

for sand in turn has been experiencing major difficulties in maintaining a consistent supply Presently one of the mainchallenges the industry faces is the large amount of pebbles that are obtained in the process of extracting sand at timesconstituting nearly 50 of the volume of material dredged from riverbeds

TEXT Sheila Ivers PHOTO Areia amp Cia

also that it opened up new

market opportunities for Areiaamp Cia Thatrsquos the standard we

seek to deliver to our custom-

ersrdquo states Luiz Oliveira Techni-

cal Salesperson of Metso Brazil

HP cones entering the

Brazilian sand-making

market

Todayrsquos cones such as theHP200 have high resistance

to impacts and abrasiveness

more efficient crushing cham-

bers low maintenance costsand excellent productivity

Following the acquisition of

the HP200 Areia amp Cia is now

also producing special sands

that command a price that is100 higher than common

sand The entire stockpile of

pebbles accumulated through-out the companyrsquos 20 years of

operations has already been

transformed into sand and the

stock of pebbles held by com-

petitors is also being purchasedfor processing

Cristiane Brizolari the

owner of Areia amp Cia confirms

the transformation that has taken place in

the production and commercial processldquoThe HP200 opened up new niches in

the market enabling the production of dif-

ferent types of sand with added valuerdquo

More info

Luiz Oliveira

Tel +55 011 9971 3603

luizoliveirametsocom

After the pebbles are crushed into sand with the HP200 cone crusherdifferent grades are screened for various end uses

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Where therersquos a will we dig a wayAFCONS-Strabag and Metso embark on tunnel project together

When the joint venture AFCONS-Strabag initiated work on the Rohtang bypass tunnel project at an altitude of 3980 metersabove sea level in Himachal Pradesh India they deliberated each aspect with clockwork precision The project involved anumber of surprises and challenges and required technology and project management skills that were second to none

TEXT amp PHOTOS Monisha Majumdar

Cutting a 10-meter-wide and nearly 9-kilo-

meter-long tunnel through the Himalayas

in one of the toughest terrains and cli-mates in India makes for quite a challengeResults set out to find out how AFCONS-

Strabag and Metso are making their way in

one of their most critical projects to date

The only road connection to the north-Indian border region of the province

Himachal-Pradesh and beyond the Manali-

Leh highway leads across the Rohtang

pass Due to the heavy snowfall and high-

velocity winds in this region the towns

located north of the pass are cut off from

the rest of the country during winter for atleast four often even six months each year

A tunnel with strategic importance

With the construction of the tunnel at

3100 m above sea level the Manali-Lehhighway will become an all-weather road

thereby enabling a significant improve-

ment in the economic development of

northern Himachal-Pradesh and an alter-

nate route to the strategically important

Ladakh region

Manali south of the pass is an alreadywell-developed tourist location that is

becoming more and more popular Upon

completion of the tunnel it is likely that

tourist activities will extend to the areanorth of the pass Moreover the tunnel

shortens the distance between the towns

of Manali and Leh by approximately 45 km

thus saving several hours on the small dan-gerous pass road

The Rohtang pass in the Western Himalaya

region of Northern India with its altitude ofalmost four kilometers ranks among thehighest trafficable passes in the world

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983122983141983152983151983154983156983145983150983143 983154983141983155

The 88-km long horse-shoe-shaped

tunnel provides space for a two-lane8-m-wide carriageway as well as a one-

meter-wide footpath on both sides A

22-m-high and 36-m-wide emergency

tunnel will be integrated in the tun-

nel cross-section Altogether more than

800000 msup3 of rock will be moved Tunneling works started around spring

2010 with excavation driven from both por-

tals As the north portal is inaccessible dur-ing winter closure the excavation focused

on the south After a planned construction

period of 55 years the tunnel is scheduled

to be completed by the end of 2015

Best man for the job

The BRO (Border Road Organization)

wanted to roll out a global tender for theproject due to the challenges that such a

project involves and also considering thatitrsquos the first time in India that a project of

this scale was to be carried out This imme-

diately triggered the need to roll out aglobal tender All major Indian construction

companies bid for it some individually and

some in partnerships

Strabag an Austrian tunnel specialistwas one of the companies who bid for the

project along with AFCONS a Mumbai-

based infrastructure company In Septem-

ber 2009 AFCONS-Strabag was awardedthe contract

Mr Sunil Tyagi Deputy Project Man-ager at AFCONS had this to say about the

unique projectldquoThis project is located in the Himalayas

and as far as we understand the terrain

there is among the toughest We came out

with a new technology and to be honestit is a fairly simple one We would generally

start with the traditional technology of drill-

ing and blasting and then obtain our muck

feed from the inwardbottom of the tunnelrdquo

ldquoThe technology is supplied by Rowa Tunneling Logistics and this is the first

time it is being used in Asia A jaw crusheris placed at a distance of about 40-45

meters behind the face The blasted muckextracted from the face is fed to the crusher

to reduce the lump size and then through

an overhead conveyor transport system

it is then transported out of the tunnelrdquoldquoThis enables free movement of man

and machinery in the lower area or spe-

cifically on the ground area If we were to

conforms to the Indian standard for fines amp

coarse aggregates as prescribed in IS383-1970

The plant was up and running in good

condition and performing to AFCONSrsquos

satisfactionldquoWe have worked with Metso in earlier

projects and are quite impressed by thekind of technology amp services they provide

We have a history together so the trust fac-tor also comes inrdquo explains Dhiman on their

choice of Metso as a partner

Service makes the difference

ldquoMetsorsquos services have made a big dif-ference in the project Without them we

would still be struggling with the machin-

ery and production The service is really

good and the service engineers are knowl-edgeable prompt and quick to act Any

problem can be solved by Metso We donrsquothave to wait until a service engineer turns

up ndash they have the capacity to solve prob-lems over the phone as wellrdquo says Dhiman

ldquoThe Metso plant didnrsquot create any prob-

lems for us We had problems in logistics

the feed was sticky and the weather condi-tions were bad but thankfully we did not

face any problems with production and

efficiency as the Metso plant is performing

very wellrdquo Dhiman concludes

More info

Amol Sinha Tel +91 9811 671 924

amolsinhametsocom

use the old conventional technology this

wouldnrsquot have worked for us in the stipu-lated timerdquo Mr Tyagi adds

When the going gets tough

partner with the toughest

Sensitive projects require the best technol-

ogy After AFCONS-Strabag landed theproject Metso was an obvious choice as a

technology provider not only because of

the long-standing business relationshipbut also for the sheer consistency in prod-

uct quality and service deliverance Metso

strives for

ldquoAfter signing the project we faced alot of road blocks including extreme cold

avalanches roadblocks less oxygen ndash you

name it we faced itrdquo explains Ankit Dhi-

man Plant Manager at AFCONS-Strabag The Rohtang valley is known for its

notorious avalanches and landslides SoAFCONS had to take extra steps and safety

precautions against hazards on the site

ldquoIn this freezing cold not just us humansbut also the machines are at increased risk

of damage I remember when we used

to run the plant during winter the diesel

engines would freeze We had to constantlyheat up the fuel container to get the plant

running And even the sand in the sand

trap would freeze so we had to clean it on

a daily basis to stop the pipes from mal-functioningrdquo Dhiman adds

Plant designed for difficult terrain

Difficult terrain coupled with space con-straints led Metso engineers to put their

minds together to come up with a suitable

plant configuration After studying the

requirements of the project Metso sug-

gested a 150-tons-per-hour three-stagemodular plant using a C106 jaw crusher

a GP11F secondary cone crusher and a

B7150 tertiary vertical shaft impact crusher

In addition considering the unpredict-ability of the feed the plant was about

to reach a point where the amount offines to be handled could be increased

dramatically Metso strongly suggested the TK11-27-3V grizzly scalper and this became

the first-ever TK scalper to be supplied by

Metso to an Indian customer Also in order

to get better products a sand trap SF2360was added to the configuration

The sand trap is important equipment

for this project as it washes the sand thatMr Sunil Tyagi Deputy Project ManagerAFCONS-Strabag

8132019 Results Minerals Aggregates 3 2012ENG

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Smooth transition to new-generation jaw crusher in Germany

Roumlhrig is a German company with a rich heritage The company has been quarrying granite at its plant in Bergstrasse inthe Sonderbach district of Heppenheim for three generations

TEXT amp PHOTOS Ralf Goffin

Roumlhrigrsquos superior product variety is onereason why the companyrsquos proximity to its

customers can be understood in more than

just physical terms The companyrsquos high

level of innovation has allowed it to estab-lish itself as a reliable supplier of materials

both regionally and internationally This

operational and technical expertise always

manages to keep in step with growing

market requirements

In terms of technical processing equip-

ment Roumlhrig has used a Nordberg C160stationary jaw crusher from Metso since

1992 At the start of 2012 it was finally

exchanged for a more up-to-date version

from the same model range

Metsorsquos C Series is specifically designed

to pre-crush hard rock and can cope effort-

lessly with even the hardest of materials

The dimensions of the new stationary jawcrusher are identical to those of the old

one which means that it could simply be

slotted into the housing vacated by the

previous version

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983122983141983152983151983154983156983145983150983143 983154983141983155

Third-generation Managing DirectorMarco Roumlhrig expects the new machinersquos

service life to be just as long as the previ-

ous model due to the product upgrades

that have been implemented The integral motor base is another plus

point in models made by other manu-

facturers it is located outside the crusher

This element of good fortune ensured that

Roumlhrig could reuse the housing withoutany additional rebuilding

Another advantage lies in the revision

of the guards for the C160rsquos drivetrain andflywheel The sturdier construction method

used for the crusher requires fewer parts

which facilitates easier installation andmaintenance and it makes it simpler to

access the motor

Under the watchful eye of Metsorsquos

Assembly Manager Maik Engelstaumltterthe entire project including removal and

installation was successfully completed

within two weeks

Installation making the most

of the available space

Roumlhrig will likely remember the day the

new crusher was installed for a long time

the pitman and main frame were deliveredseparately prior to installation and assem-

bled on site It took just one hour to replace

the old stationary crusher with the new

model A lorry-mounted crane was used toposition the 85-ton crusher with millimeter

precision in the crushing plant Once the

new crusher had been positioned in theexisting steel structure the next task wasto fix it into place as securely as possible

despite the limited space Special vibration

dampers were installed at a height of two

meters to prevent the crusher from sliding

Norbert Ried (fourth from left) installed thenew C160rsquos predecessor 20 years ago and isdelighted at the durability of the powerfulcrusher that is now making way for a newermodel Also pictured from left to right ManagerVolker Angermann Assembly Manager Maik

Engelstaumltter Technical Manager Stefan

Koob Project Manager Dominic SchoumlnhardtManaging Director Marco Roumlhrig Service

Technician Stefan Kolze and employees ofthe installation company Stafemo

On the hook after theold C160 was liftedout by crane the newcrusher was installedin almost no timeOnly the roof of thehousing had to beremoved

sideways off its mount An initial test run

with materials was carried out around oneweek later after all the electrical cables had

been installed

Simultaneously with the installation

of the C160 which is the first of the latest

generation of crushers to be installed in

Germany a new Nordberg GP100 conecrusher was also being installed in Roumlhrigrsquos

chipping plant Roumlhrig is convinced that

the technical improvements made tothe new Metso crusher can only be an

advantage worldwide

Roumlhrig places great value on consistent

product quality maximum added valueand optimum refinement of its product

range Bearing in mind that Roumlhrig has

enough reserves of raw material to last

for the next 150 years the company canconfidently continue to develop with an

emphasis on quality rather than quantity

More info

Dominic Schoenhardt

Tel +49 (0)621 727 00 610

dominicschoenhardtmetsocom

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Groupe Charier Carriegravere de la Mariais France

Quarrying with certi1047297ed quality The Charier Group with its 1600-strong workforce is a family business thatthis year celebrates 115 years of quarrying The company pursues a long-termdevelopment policy that since 2007 has seen processing installations upgradedat 4 of its 9 extraction sites

TEXT Liliane Boutin (with extracts from Mines amp Carriegraveres and Terrassements amp Carriegraveres magazines)PHOTO Baloon photo

The processing installation is of the horizontal type with a primary station located 56 meters below the site access road to keep it hidden from view

The crushing and screening installation at

Charierrsquos CM La Mariais quarry (at Donges

on the Loire estuary) has been in opera-tion since September 2011 Based on theoperatorrsquos ideas it was designed by Metso

to replace a worn-out installation installed

right on top of the seam being extracted

Since its commissioning it has becomethe second quarry in the company to

receive ISO 14 001 certification

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983122983141983152983151983154983156983145983150983143 983154983141983155

tertiary material of sand and gravel for the

local market to use in concrete surfacingprefabrication etcrdquo

Incorporation of a screening station

The stone extracted from La Mariais is

according to the quarry granitic gneiss

sound and homogeneous with a LosAngeles index of 15 good wear resist-

ance with an MDE of 10 a true density of

265 and a certain abrasiveness (2000 gt)ldquoCharacteristically it has a tendency to form

blocksrdquo Leblin points out

The main criteria in designing the instal-

lation was to provide an output of 600000metric tons from one station (38 hours

week) to produce materials aimed at the

concrete and surfacing markets ldquowhich

involved providing a tertiary station withscreening plantrdquo he adds

With this new unit the operating com-pany expands its product range through

the addition of fine materials obtained

from the tertiary screening station This unitis capable of producing 170 tonshour of

020

Preserving the environment

and optimizing safety

The screens have motorized bogies and

retractable walkways to facilitate access

when the screens are opened for main-tenance Other walkways provide access

to the tunnel input feeders The feederscan be isolated with hydraulic rod gate

bars this hydraulic assistance eliminatesthe need to use a heavy hammer to lodge

these metal bars

All conveyors transporting fines (02

and 04) are covered with a tarpaulin to

avoid flying dust and all the screens arehooded (metal cover with Trellex seal-

ing) The Brunone company has installed

dust-tight containment at the outlet of the

tertiary station crushers (HP300 and HP4)on the belt located under the screens

and under the hoppers located belowthe tertiary screens The crushers are put

under negative pressure and the finesare extracted through sleeve filters (7000

m3 h) with declogging which deposits the

dust back onto the conveyor belt

A high-pressure 100 bar water mist sys-tem has been installed at the primary sta-

tion discharge at the secondary crusherrsquos

discharge chutes (Omnicone) and at the

transfer points on the belt

Designed to last

ldquoThis type of new installation can easily last

thirty yearsrdquo affirms Project Leader Bruno

Peix of Metso ldquoIt quite simply depends on

how well it is maintained Thatrsquos why weprovide maintenance contracts that call for

our technicians to make regular inspection

visits and carry out preventive mainte-nance and any necessary repairsrdquo

In 2011 Metso commissioned about

10 new processing units in France like

the one at La Mariais quarry

More info

Frederic Bazire

Tel +33 (0)681442804

fredericbaziremetsocom

Key figures

DURATION OF WORKS 15 months

DRAWING OFFICE TIME 7800 hours

HEIGHT OF SILOS AND GRINDER BUILDINGS

15 m

TOTAL LENGTH OF CONVEYORS 14 km

WEIGHT OF THE INSTALLATION

1200 metric tons

CONCRETE POURED 1800 cubic meters

PROJECT SITE WORKFORCE 30

INSTALLED POWER 2200 kW(not including pumps 200 kW)

METSO EQUIPMENT

Primary

Vibrating feeder PF561-2V

Primary grizzly VG540-3V

Grizzly feeder TK13-20-3V

Jaw crusher C145 with

hydraulic setting

Secondary

Vibrating screen CVB 2050

refurbished

Cone crusher Omnicocircne 1352 SX

with Metso IC7000 controller Ellivar 16 (16 msup2 3 decks) screen

refurbished by Metso

Tertiary

Cone crusher HP300

Cone crusher HP4

2 Ellivar 20 screens (20 m23 decks) for final products

Expanding the production range

ldquoSince the mid-1990s when we became

owners of La Mariais we had used mobilemachinery with an assembly of beltconveyorsrdquo recalls Daniel Leblin Charierrsquos

Technical Manager for site construction

and maintenance

ldquoIt became clear that we needed ahigher performance tool to achieve the

dual goals of reaching one million metric

tonsrsquo maximum production and producing

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Big Lokotrack LT550GPF boostsquarrying productivity by a thirdMaximizing the productivity of operations is a key issue when striving for cost-effective quarrying Big Lokotracks are oneway to achieve improved operational efficiency The Lokotrack LT550GPF equipped with the high-volume GP550 conecrusher and a large screen is popular in the Nordic countries and in Germany and Australia ndash countries all known for theirhigh quarrying volumes

TEXT amp PHOTOS Eero Haumlmaumllaumlinen

Kone-Kostamorsquos new mobile coneplant has reached an averagecapacity of 300 tons per hour

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983122983141983152983151983154983156983145983150983143 983154983141983155

ldquoWith the same number of employees we

can achieve 30 more productivity with

our new LT550GPF unit The high-capacityFS screen has also eliminated the bottle-neck often seen at fine screeningrdquo says

Aarno Kostamo Managing Director of

Kone-Kostamo Oy one of Finlandrsquos biggest

crushing contractorsAccording to Kostamo the high capacity

of the GP550 gyratory cone crusher easily

handles feed from the C120 and C125 jaw

crushers For the contract with the Talvivaara

nickel mine the LT550GPF is being fed bythe brand new Lokotrack LT120 jaw plant

Average capacity 300 tons per hour

Talvivaara Europersquos largest nickel mine uti-

lizes large quantities of aggregates Kone-Kostamo has contracted several million

tons of different end products for the mineIn August 75000 tons of 0ndash63 mm

road gravel was crushed Smaller amountsof finer 0ndash6 mm 0ndash16 mm and 0ndash32 mm

aggregates are also being produced

The rainy summer increased the need

for road gravel along the muddy roadswhich must endure dump trucks weighing

as much as 260 tons

ldquoThe mobile process consisting of the

LT120 jaw plant and LT550GPF cone plant

is cost-effective while aggregates of vari-ous sizes can be produced in a two-stage

operation and with high capacity The con-trolled stroke and elliptical movement of

the FS screen secure big passing throughcapacitiesrdquo Kostamo explains

Operated in two shifts for a total of 16

hours per day the LT550GPF has logged

more than 600 working hours over a two-month period

Managing Director Aarno Kostamo (left) and foreman Karri Maumlenpaumlauml studying the cavity optionsavailable for the new Lokotrack LT550GPF

Longer perspective than

a single quarter needed

Kone-Kostamo Oy was founded as an

earth-moving company in Kemijaumlrvi

Northern Finland in 1956 The company

expanded its operations to include crush-

ing contracting in 1964 and later on

switched to concentrating fully on crush-ing activities

Kone-Kostamo consistently crushes

and screens around 28 million tons ofaggregates annually and has net sales of

between EUR 8ndash9 million

ldquoWe believe that issues within the crush-

ing industry including the purchasing ofmachinery must be studied with a longer

perspective than a single quarter The

secret to our success has always been our

solid work ethic and professional employ-eesrdquo Kostamo sums up

More info

Esa Berg

Tel + 358 40 837 8692

esabergmetsocom

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Monitoring-based reporting is vital for

assessing the performance of a mobile

crushing plant Metso provides suchreporting tools through its plant-wideautomation system Metso DNA (Dynamic

Network of Applications) with its infor-

mation platform that links all the mobile

crushing and screen units together as oneentity Basically there is a lot of measured

real-time information available in every

crushing plant On-line information is

obtained either from each Metso crusherrsquosmachine automation system IC (Intelligent

Controller) or from separately installed

additional sensors and belt scales

All the collected data is sent to a motorhome using wireless communication

based on WLAN technology The motor

home is a purpose-built environment

inside an on-site container In this environ-ment selected variables can be monitored

for assessing the plantrsquos performance And

to make all this even more flexible the

data can be transmitted to a crushing plant

company office using GPRS3G mobile

data communication technologies Thismakes all the last-minute reports acces-sible to the crushing plant managerial staff

at anytime and basically anywhere within

reach of the cell phone network

Production and fuel economics reports

Essentially monitoring and reporting can

be customized to fit the customerrsquos needs

However there are certain off-the-shelf

reports that provide a lot of useful informa-tion for plant supervision The production

report is one of these Requiring at least one

belt scale for measuring the total produc-tion the production report shows the pro-duction rate (tons per hour) for a selected

reporting period eg a day or a week The

production report constantly keeps track of

the plantrsquos production storing all the datathroughout the plantrsquos life cycle

Performance monitoring and reportingfor a mobile crushing plantTEXT Pasi Airikka PHOTOS Metso

unit during which the unit is running By

storing the availability times between start-ups and shutdowns the crushing plant

operation time (hours per dayshift) can be

recorded analyzed and reported In addi-

tion the availability report can be tailored

to evaluate efficient crushing hours during

which the plant is really working and pro-ducing aggregates Consequently the ratio

(0-100) between efficient crushing time

and total running time can be reported forany selected period of time This boosts

the efficiency of the plantrsquos operations

and results in better productivity

Reports on non-choke

or inadequate feeding

Non-choke feeding to crushers is avoid-

able through smart plant-wide crushingplant controls But estimating its severity in

a systematic manner is not straight-forwardwithout constant monitoring and reporting

The crusher choke feeding report makes

use of the crusher cavity level sensors byanalyzing their level measurements By

calculating average and min-max values

and deviations from the average it can be

shown how often the single crusher suffersfrom non-choke feeding to it

In some cases the bottleneck in the

crushing plantrsquos productivity is the material

feeding to the process In mobile plants thefeeding is human operated and therefore

subject to variations Occasionally the sizeof the human-operated machine simply

does not allow for adequate feeding to thecrushing plant There are specific reports

indicating time periods when the crushing

plant suffers from inadequate feeding

Condition monitoring for

crushers and screens

Machine-specific condition monitoring

focuses on vibrating components in

crushers and screens such as drive shaftbearings safety plate wearings and gears

The low middle and high frequencies ofmonitored components are measured and

supervised in real-time to detect abnor-malities due to slow or fast wear looseness

or imbalance

More info

Pasi Airikka

Tel +358 40 587 2730

pasiairikkametsocom

Condition monitoring provides a view tovibrating crusher and screen components forpredictive equipment maintenance

The daily production report shows the hour-by-hour production trend and distribution chartfor a selected day with min-max average andvariation statistics for comparison

Fuel consumption is always an interest-ing concern The fuel consumption reportgives the fuel consumption of each crush-

ing unit (liters per hour) and their total

consumption (liters per hour) for a selected

reporting period and can track fuel con-

sumption changes over timeCrushing plant availability can be

assessed as well The availability report

calculates time periods for each crushing

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983149983141983156983155983151 983150

for tissue machines The record of 2210

mmin was set on June 1 2012 during a

24-hour production run by the TM 2 tissue

machine at the companyrsquos mill in Yenikoumlynear the city of Izmit in Turkey

ldquoThe cooperation with Metso has been

beyond excellent and both parties did

their utmost to make the project success-ful The results clearly show that the efforts

were worthwhile on both sides This coop-

eration will extend to cover new projects

in the futurerdquo says Luumlt1047297 Aydin Paper GroupDirector Hayat Kimya

ldquoWe are not surprised that Hayat K imya

managed to break the world speed record

We have had great confidence in the capa-bility of the Hayat team since our project

started in 2009 We certainly know our

machine very well its stability production

efficiency and speed capabilityrdquo says Jan

Erikson Vice President Sales Metso

PowerThe worldrsquos first eco-gas fueled

power plant is up and running

Lahti Energy Ltdrsquos new Kymijaumlrvi II gasifica-

tion plant was officially inaugurated on

May 8 2012 It is the first of its kind in the

RecyclingRecycling with Lokotrack LT106

jaw plant in New York

A brand-new Lokotrack LT106 jaw plant is

used in the city area of New York USA to

recycle demolition materials The crushing

site faces the skyscrapers of ManhattanIsland

Paper amp FiberHayat Kimyarsquos Metso-supplied tissue

machine sets world speed record

Thanks to a skilled crew and dedicated

efforts Hayat Kimya AS in Turkey has suc-

ceeded in breaking the world speed record

world This CHP plant runs on clean eco-

gas that is gasified cleaned and cooled

from recycled waste with Metsorsquos innova-tive technology

ldquoItrsquos actually eco-gas that we combust

in the boilerrdquo comments Lahti EnergyrsquosProduction Director Jukka Manskinen

ldquoWe convert unwanted waste material into

energy in an efficient and environmentally

friendly wayrdquoNever before has any plant gasified

waste on such a large scale In the gasifier

recycled waste is turned into combustible

product gas which is cleaned cooled and

combusted in a high-efficiency gas boiler

to produce steam for the steam turbine The plant produces 50 MW of electricity

and 90 MW of district heat for the city of

Lahti and its neighboring areasMetso delivered the circulating fluidized

bed (CFB) gasification process gas cleaning

and cooling steam boiler environmental

protection system and automation systemto the entire plant The production of elec-

tricity and heat is kept even with the Metso

DNA automation system that covers the

whole plant starting from fuel reception

AutomationMetso develops and supplies plant-

wide crushing control solutions for

crushing plants

Metso has recently signed contracts on

delivering plant-wide automation systems

for mobile and portable rock crushing

plants The key objective of these deliveries

is to stabilize and to increase productivityand efficiency of the plants using one sin-

gle automation and information platform

for integrating crusher-specific IC machinecontrols

Furthermore the plant-wide system

with its information management tools not

only increases plant availability and opera-

tional safety it also makes troubleshoot-ing quicker and performance monitoring

easier The control room for plant-wide

operability is located either in an excavator

cabin or a purpose-built container

Metso around the world

The new LT106 jaw plant is suitable for crushing both hard rock and all rock-based demolition materials

The new world speed record for tissue setby Hayat Kimyarsquos Metso-supplied TM 2 is2210 mmin

8132019 Results Minerals Aggregates 3 2012ENG

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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: Results Minerals Aggregates 3 2012.ENG

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983110983141983137983156983157983154983141983140 983137983154983156983145983139983148983141

The main minerals processing componentsincluding grinding flotation and pumping

equipment are delivered by Metso

983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

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983110983141983137983156983157983154983141983140 983137983154983156

Endomines

Pampalondash a green andresponsiblegold mineAt Pampalo near the easternmost point of Finland a cleanand environmentally friendly gold mining operation isbeing executed by Endomines With Metsorsquos plant designand a state-of-the-art processing plant Pampalo runs a

green and responsible yet at the same time profitablegold mining operation that avoids acid mine drainagesand targets 100 water recirculationTEXT amp PHOTOS Eero Haumlmaumllaumlinen

With a modest investment of EUR 20

million the Pampalo mine was built fully

operational and now produces 800ndash900 kgof pure gold annually An on-going expan-

sion will increase the minersquos production

capacity by 30 to 50 next yearIn addition to the main underground

mine at Pampalo several promising satellite

gold deposits are being investigated along

the long Karelian gold line The maximum

distance of the satellites is 30 km allowingthe mine to transport and process all of the

produced ore at the Pampalo plant

Small scale can be successful

with hard work

ldquoWith our gold mining operation we can

very well show that with hard work even

small-scale gold mining and production

can be done in a sound and profitable wayrdquosays Markus Ekberg CEO of Endomines

originally founded in Sweden

According to Ekberg the strategy when

building the mine was to split up the jobsinto small separate contracts Metsorsquos part

was the main minerals processing system gt

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983110983141983137983156983157983154983141983140 983137983154983156

Increasing capacity makes processing

of lower grades economical

The project to significantly increase the

processing capacity at Pampalo is well

under way with the installation of for

example a second grinding mill and more

flotation cells The expansion will be in

operation during early 2013ldquoThe added capacity also makes it pos-

sible to economically process the nearby

open pits with a lower gold grade In addi-tion it helps us to optimize the crushing

and grinding circuitsrdquo Ekberg concludes

Active exploration drillings have

exposed new mineralized zones furtherextending the lifetime of the Pampalo mine

from the present estimate of 6ndash7 years

More info

Peter Vikman

Tel +358 400 869 845petervikmanmetsocom

Endomines Pampalo gold mine

LOCATION near the community of

Ilomantsi in Eastern Finland

GOLD ORE CONTENT

ndash Pampalo 34 gtndash Hosko 99 gt

ndash Raumlmepuro 39 gt

ndash Muurinsuo 30 gt

PRODUCTION TONNAGE PER YEAR 270000 tons (present)~400000 tons (future)

GOLD PRODUCTION PER YEAR 800ndash900 kg

KNOWN ORE RESERVES IN TOTAL

approx 2 million tons

MINE DEPTH 360 m

MINING METHOD bench cut and fill

NUMBER OF EMPLOYEES

100 including contractors

METSO EQUIPMENT

1 Metso TRN 30 x 48 m

wet ball mill

8 Metso RCS series flotation cells 1 Nordberg MF 1800 x 6100

screen

3 Metso samplers

1 Metso CT thickener

1 Metso TF vacuum filter

33 Metso slurry pumps of various

types and sizes

The gold ore is screened using Metsorsquos MS series mining screen

Markus Ekberg is pleased with the outcome the mine reached the minerals processing utilizationdegree of over 90 just two months after start-up

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156983145983139983148983141

Nordic Mines ndash on track tobecoming one of Europersquosmost prominent goldproducersNordic Mines is the newest member in a long chain of Nordic gold mining operations

Inaugurated in mid-August 2012 this company of Swedish origin aims to become one

of Europersquos most prominent gold producers Metso is one of Nordic Minesrsquo main partners

supplying the Laiva gold mine with crushing screening conveying and minerals

processing equipment at an estimated value of EUR 30 million

TEXT amp PHOTOS Eero Haumlmaumllaumlinen

2983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

The Laiva gold mine was built in record time infrastructure

construction began in spring 2010 ore excavation started in

June 2011 and the first gold bar was casted in December 2011

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156

Just one year after starting the gold recov-

ery process Nordic Mines is on track toreaching a capacity of 5 kg of gold per day

At present the operations are averaging 3

to 4 kg of gold daily

The ore in the Laiva Gold Mine consists

of packages of gold-bearing quartz-filled

shear structures The deposit is more thana kilometer long and 700 meters wide The

total depth is still unknown but dr illings

carried out thus far have shown gold-bear-ing shear structures 300 meters below the

surface

A typical ore zone includes a large num-

ber of thin shear structures from 5 to 30per meter The ore zones are commonly 50

to 100 meters long several are 10 meters

deep and they range from a few meters to

20 meters cross strike The minimum min-ing width is 25 meters which means that

even a minor ore zone consists of at least10 to 50 shear structures

Conventional pattern blasting

with selective loading

Prior to mining Nordic Mines conducts

grade control drilling which provides

dense gold grade information and makes

it possible to outline the boundaries

between ore and waste The mining

technique applied is conventional pattern

blasting with selective loading This is oneof the most commonly used techniques in

large-scale open-pit mining

A typical blast in the Laiva mine is 50

meters long 100 meters wide and 5 metersdeep After blasting ore and waste aremined by selective loading

After investing some EUR 100 million

the Laiva mine now comprises an open-pit

mine with a modern complete crushinggrinding and processing circuit that ends

with the casting of gold doreacute bars

With a number of mine staff partners

sub-suppliers city and state officials inattendance the Laiva gold mine was offi-

cially inaugurated on August 16 2012

Michael Nilsson Managing Director

of Nordic Mines stressed in his speechthe importance of overcoming challenges

during the building of the mine

ldquoObviously the whole development

took us longer than expected Today weare pleasantly surprised by the size of our

operation We are becoming much bigger

than expectedrdquo gt

Chief Geologist Kimmo Lahtinen presenting narrow gold veins twisting at the Laiva North open-pit mine

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156983145983139983148983141

An international process package

The Metso package for the Laiva gold mine

included the main crushing screening

conveying regrinding leaching and pump-ing elements Metsorsquos office in Sala Swe-

den has served as the main project office

with Metso manufacturing units in FranceGermany Sweden and Finland responsiblefor the equipment supply

At Laiva the gold ore is classified after

selective excavating into two gold con-

tent classes All class A gold ore is takento Metsorsquos sturdy jaw crusher for primary

crushing while the class B ore is stocked for

possible future use After primary grinding

utilizing autogenous technology the ore is

screened and two Metso cones crush the

oversized pebbles For regrinding Metsorsquosball mill is used

During high- and low-grade leaching

processes a number of Metso pumps and

dewatering screens are used The whole

minerals processing system is controlled byMetsoDNA automation

Active exploration drilling going on

According to Mine Manager Tom Soumlder-

man the known gold ore reserves at the

Laiva gold mine amount to 169 million

tons but the potential for additional find-

ings looks good

ldquoWorking at the level of two million tonsper year our expected lifetime is about nine

years We carry out active exploration drill-

ing in Kaukainen Musunneva and Oltava

to locate nearby satellite ore bodies Anupdated detailed mine life plan will be pre-

pared during the autumnrdquo Soumlderman saysNordic Minesrsquo other exploration areas

include Tormua in Finland and Fjaumllltuna

and Vassbo in Sweden

More info

Alf Rydberg

Tel +46 70524 5837

alfrydbergmetsocom

Happy faces during the minersquos inaugural ceremony Mine Manager Tom Soumlderman (left) with Managing Director Michael Nilsson and Deputy Managing Director Krister Soumlderholm

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156

The story behind the discovery of the Laivamine is an interesting one During a hunt-

ing trip in the remote forests of Laivakan-

gas in 1979 Pentti Jaumlmbaumlck found an inter-esting-looking piece of stone Although hecould not see the gold hidden inside the

rock Pentti noticed the striking weight

and somewhat different look of the stone

Upon returning home Pentti sent thesample to Outokumpu which at the time

was the leading state-owned mining com-

pany in Finland After testing a high gold

content of 15 grams per ton was found

Gold deposit founded by a hunter

The founder of the Laiva gold deposit Mr Pentti

Jaumlmbaumlck was the guest of honor during theinauguration

Lennart Schoumlnning Chairman of the Board ofNordic Mines holding a gold doreacute bar worthsome EUR 320000

Outokumpu registered a mining claimon the area and conducted a series of

exploration drilling from 1981 to 1987 Due

to the low price level for gold no mine wasstarted at the time Other mining compa-nies such as Endomines held the mining

rights later

Nordic Mines with its sights set on

locating and exploiting gold in Swedenand Finland was founded in 2005 During

the same year the company purchased its

first mining rights at Laiva

Nordic Minesrsquo Laiva gold mine

LOCATION near the city of Raahe

northwestern Finland

GOLD ORE CONTENT average 16 gt

ORE EXTRACTED PER YEAR

12 million tons (present)

20 million tons (planned)

GOLD RECOVERY 85

TOTAL KNOWN ORE RESERVES

169 million tons

MINING METHOD

Selective open-pit benchingNUMBER OF EMPLOYEES

130 including contractors

METSO MAIN EQUIPMENT

2 Metso VF and 6 EMEG EME

vibrating feeders

8 Screens 1 MF 1 CVB and 6 KS

1 RCS Flash flotation unit

1 Metso SRR ball mill 18 x 4 m

1 Nordberg C160 jaw crusher

1 Nordberg HP100 cone crusher

1 Nordberg HP200 cone crusher

5 Nordberg NB series conveyors

73 Metso Slurry pumps ofvarious types and sizes

8132019 Results Minerals Aggregates 3 2012ENG

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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155

The newest member of the proven GP series cone crushers ndash theNordberg GP220 ndash offers a versatile alternative for any demanding

tertiary or quaternary or even secondary crushing operation fulfill-

ing all crushing needs and maximizing customersrsquo profitability

High-quality components and optimized castings and forgings

contribute to the GP220rsquos enhanced reliability and help to ensurethe highest level of crusher uptime

Thanks to the 200 kW (270 hp) power draw the GP220 performs

at a 20 to 30 percent higher capacity than other cone crusherbrands with an equal head diameter The large feed openingenables the feeding jaw crusher to run at 110 mm css Operational

flexibility is ensured by multiple strokes and six different cavities

Secondary crushing possible

thanks to cavity and stroke options

Thanks to the GP220rsquos cavity and stroke options secondary crush-

ing in addition to tertiary and quaternary stages is also possible

using cavities with a greater intake opening With the GP220 a suit-

able solution for producing excellent end-product gradations

can always be found

With advanced automation using IC50 or IC5000 operation

is safe and trouble-free The low height thanks to the patented

piston design makes replacement installations much easierA dynamic setting adjustment enables a fast response to process

optimization needs

The Nordberg GP220 weighs 10500 kg (23150 lbs) and hasa maximum real feed size of +200 mm (8rdquo) with strokes from

18ndash40 mm (57rdquondash1 47rdquo) The cavity options are EF F MF M C

and EC

A complete modular crusher steel structure is available for allGP series stationary installations including GP220 The platform

includes places for the lubrication unit motor automation or

pressure accumulator and pressurized sealing The only things

left to add are the feed and discharge conveyors

Main new features of the GP220 Large feed opening allows for secondary stage operation

Longer setting range of main shaft for better wear parts utilization

Stronger main components to carry high loads with a powerdraw as high as 200kW

More info

Hannu Vakkuri

Tel +358 50 317 0638

hannuvakkurimetsocom

Thanks to the large feed opening and wide selection of strokes and cavitiesthe new Nordberg GP220 cone crusher is a highly versatile cone novelty

More versatility with the newNordberg GP220 cone crusher

Reinforced head and frame castings combined with a 200kW power

draw make the GP220 cone a reliable crusher with maximum productivity

8132019 Results Minerals Aggregates 3 2012ENG

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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156

Metsorsquos HRCtrade takes high pressure grinding roll technology to the next level

The new Lokotrack mobile conveyors come as tracked and wheeled models

Metsorsquos latest development in comminution equipment the HRCtradeis a major step in the profitable application of high-pressure grind-

ing roll (HPGR) technology Metso has made several key innova-

tions in order to increase throughput and decrease the total cost

of operation

Metsorsquos patented Arch frame creates an even gap setting acrossthe width of the tires limiting skewing that can result in downtime

for mining operations This anti-skewing Arch frame also prevents

damage to the roller bearings (caused by misalignment) that canoccur with the traditional HPGR design

Flanges maximize wear life and increase throughput

Used in place of spring-loaded cheek plates the flanges keep thebed of material within the crushing zone and prevent material

from bypassing the tires This enables greater circuit capacity and

increases the overall crushing efficiency

In addition by preventing material from bypassing the tires

even pressure across the width of the tire is better maintained

Distributing the pressure more evenly maximizes the tire life bypreventing a ldquobath tub effectrdquo in which the center of the tire wears

faster than the edgesVictoria Herman Metsorsquos Product Manager for the HRC notes

that this breakthrough design is a response to the growing needs

in the mining industry ldquoEnergy efficiency has been attracting our

customers to HPGR technology for yearsrdquo she says ldquoBut our design

concept increases capacity and crushing efficiency ndash and thatrsquossomething mining companies are always looking to improve onrdquo

The track-mounted Lokotrack CT32 and wheel-mounted Lokotrack

CW32 mobile conveyors offer an ideal solution for applications

that require high stockpile capacity and excellent material transfer

capabilities They also add flexibility to multi-stage crushing andscreening applications enabling easy and fast closed-circuit opera-

tion of mobile units

The conveyor novelties can be used in both mobile and station-

ary installations providing extra stockpiling capacity in situationswhere for example fewer wheel loaders are available

The HRC is ideal for high-tonnage hard rock applications andcan be used as a tertiary quaternary or pebble crusher Currently

several HRC units are in operation around the world ndash with a total

of 6500 operating hours including over 3800 hours in a mininghard rock application The machine does have range within hardrock applications itrsquos been designed for use in diamond iron ore

copper gold platinum and various industrial minerals

More info

Victoria Herman

Tel +1 717 309 1150

victoriahermanmetsocom

Several optional features such as hydraulic folding of tail sections

and dual hydraulic drive for increased throughput are available

The capacity of the CT32 and CW32 is 400 mtph (440 stph)feed size up to 150 mm (6rdquo) belt width 1050 mm (42rdquo) and dis-charge height 9120 mm (29rsquo 11rdquo) The CT32 is fitted with a Caterpil-

lar C2 diesel engine with 38kw (51 HP) power The CW32 is avail-

able for hydraulic or electric use

More info

Kimmo Anttila

Tel +358 50 433 3745

kimmoanttilametsocom

The new HRCtrade combines high crushing pressure and a low circulatingload resulting in the most efficient comminution

When flexibility in stockpiling capacityis required the answer can be foundin the new Lokotrack CT32 and

CW32 mobile conveyors

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Service creates value in ChinaChinarsquos most important gold producing area Yantai in northeastern China supplies more than 16 of the countryrsquos goldproduction each year With the gold market thriving the scale of gold production in Yantai has been expanding constantly

Zhongjia Mining Industry Co Ltd is one of the beneficiaries of this thriving industryTEXT amp PHOTOS Yan Xin

Inspection and maintenance of the HP500 cone crusher conducted by Metsorsquos service engineers

In 2011 Zhongjia Mining Industry pur-

chased a modular crushing and screen-ing system from Metso for its new gold

production project With the cooperation

between the two companies continuously

intensifying Zhongjia Mining Industry

signed an additional one-year Life CycleService (LCS) contract with Metso incorpo-

rating Metsorsquos global knowledge in equip-

ment processes and services

ldquoMetso customized a series of reason-

able service solutions also referred toas Metso Performance Solutions for us

including preventive maintenance services

process improvement personnel training

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155

and a procurement plan for wear parts

These really suit our needs perfectlyrdquo saysShen Yidong the Manager of ZhongjiaMining Industry

Effective preventive maintenanceFor mining corporations the biggestconcern is the economic losses caused by

the shutdown of equipment As a result

preventative maintenance is of vital impor-

tance During the contract period Metsoservice engineers offered 7-day tracking

service on the production site every month

to eliminate potential problems and thus

ensured the stability of the system

parts caused pressure on our working capi-tal which was not favorable for our long-

term developmentrdquo Shen explains

To solve this problem Metso designed

a rational stock plan of wear parts and built

a field warehouse In accordance with theuse and consumption of the liners the field

service engineers complement the stock tomake production and operations run more

smoothlyldquoNow when we need to replace the

wear parts we can use them before pay-

ment This not only simplifies the procure-

ment process but also liberates a largesum of our operating capital which can

be used for other business development

purposesrdquo says Shen

Best partner

ldquoAlthough the LCS contract incurs some

early purchase costs in the long run Metsorsquosprofessional and quality service will improve

the equipment efficiency reduce ourenergy consumption and ensure stable

operations thus generating more prof-

its This is the greatest value for us so the

investment is really worthwhile overall Inthe future we will choose more Metso prod-

ucts and services Taking all aspects into

consideration we believe Metso is the best

partner for usrdquo Shen Yidong concludes

More info

Thomas Bai Tel +86 13801009114

thomasbaimetsocom

ldquoIn the eight months since the contract

came into effect our corporation has notsuffered any financial losses due to equip-

ment breakdown The regular maintenance

has greatly improved the efficiency of our

entire crushing system In addition the

experienced engineers from Metso also

provided onsite training and guidancefor our staff and the tailored training has

greatly enhanced the operating abilities of

our employees and upgraded their overalllevel of competencerdquo says Shen Yidong

More productivity with

less consumption

Metsorsquos service contract focuses on real-

izing the optimum performance of each

process flow After analyzing Zhongjiarsquos

production system Metsorsquos techniciansproposed an adjustment to the closed side

setting of the HP500 for tertiary crushingin order to improve the efficiency of the

downstream fine crushing and milling pro-

cessing by over 10ldquoThe process flow improvement solu-

tions provided by Metso not only increased

the output of our gold concentrates but

also reduced our energy consumption andcostsrdquo says Shen

In the past wear parts procurement

took up a larger proportion of Zhongjiarsquos

total production costsldquoTo avoid downtime caused by the

shortage of wear parts we had to keepeight sets of various wear parts in place

However the cost of having so many wear

Zhongjia Mining Industryrsquos gold concentrates processing plant in China

8132019 Results Minerals Aggregates 3 2012ENG

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0983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

Safe quarrying high-

quality aggregates

8132019 Results Minerals Aggregates 3 2012ENG

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ldquoWe share a similar zero-accident strategy and target with Metso and have successfullyfollowed it Metso has also helped us to meet the strictest end-product quality andcubicity requirements set in Spainrdquo This is how Managing Director Intildeigo Ajuria ofOfitas de San Felices the leading hard rock quarrying company in Spain describesthe cooperation with MetsoTEXT Eero Haumlmaumllaumlinen PHOTOS Ofitas and Eero Haumlmaumllaumlinen

The San Felices quarry is situated in a picturesque mountainous landscapebetween the companyrsquos Rioja vineyards and the Bilbao-Madrid motorway

8132019 Results Minerals Aggregates 3 2012ENG

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Ofitas has pioneered the implementation

of several Metso novelties in the Spanish

market The company was the first to use

efficient large track-mounted Lokotrack jaw plants the unique mobile conveying

system and also the new-generation HP4

cone crushers

Today the company operates twomodern Metso stationary plants one in

Guadix near Granada and the newest one

in San Felices Haro Rioja community Both

quarries focus on refining hard rock by pro-cessing ophite rock into the highest quality

railway ballast asphalt and concrete mix

grades The company has a satellite quarry

near Vitoria in PentildeacerradaBeing situated next to a highway and

the famous Rioja vineyards Ofitas must pay

special attention to environmental issues

To minimize dust problems all conveyors

have special covers attached

Quality durability and service

The cooperation between Ofitas de San

Felices and Metso started back in 1973when the Ajuria family bought the com-

pany whose quarrying activities began in

1919 Intildeigo Ajuria has a clear vision of why

the cooperation has continued withoutinterruption for almost 40 years

long-standing personal relationshipsrdquoAjuria adds

Serving railways asphalt

and concrete producers

The year-old San Felices stationary instal-lation lies hidden in a mountainous area

south of the city of Vitoria in NorthernSpain The new plant replaces an old one

that complicated the extraction of ophiterock Both plants are delivered by Metso

With its two separate production lines

the new plant is able to produce all the

end products required ndash from railway bal-last to the finer grades needed for asphalt

and concrete

Due to lower demand the quarry cur-

rently produces some 4000 tons per day

At full capacity however the plant canreach 8000 tons of production per day

30ndash35 of which consists of railway ballastfor high-speed trains and 65ndash70 of chips

and sand Thanks to the versatile two-line con-

cept connected by transverse conveyors

up to 12 different end products can be pro-

duced Depending on the demand for endproducts the material can be guided either

to the HP4 cone or HP400 cone followed

by a Barmac vertical shaft impactor

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

The ophite feed is fed to the C125 jaw crusher by a sturdy dump truck

The key people running the new San Felicesquarry Mine Engineer Carlos Fernandez (left)Managing Director Intildeigo Ajuria with ProductionManager Julian Perez

ldquoThrough the years Metso machinery

has proven its production capacity and

durability resulting in high-quality end

products A big plus for us has also beenthe quick response time to our process

challenges or servicerdquo

ldquoIn fact our cooperation extends

beyond day-to-day business matters to

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983122983141983152983151983154983156983145983150983143 983154983141983155

Meeting the strictest cubicity demands

The Spanish regulations concerning end-product cubicity are becoming more

demanding The flakiness percentage of

railway ballast must be below 10 and for

asphalt and concrete aggregates less than

15

ldquoWith Metsorsquos HP4 cone and the Barmacvertical shaft impactor we can meet even

the strictest cubicity demands We believe

that our high quality is helping us to sur-vive in the present recessionrdquo notes Mine

Engineer Carlos Fernandez

ldquoWe hope to increase the total extrac-

tion of the three quarries from the present15 million tons per year because our plant

capacity allows more than double thatrdquo

Fernandez adds

More info

Angel Luis Garcia Tel +34 686 94 35 30

angelluisgarciametsocom

In addition to being the leading Spanish

quarry to process hard rock Ofitas de SanFelices also cultivates 34 hectares of vine-yards next to the quarry which is situated

in the famous Rioja wine area

The company has previously sold a

harvest of over 200000 kg of Tempranillo

grapes to local red-wine makers Recentlythe company built its own wine process-

ing plant to process 10000ndash15000 kg of

grapes themselves

Aggregates and wine production

Andoni Ajuria the founder of Ofitas de san Felices (left) with Intildeigo Ajuria the present ManagingDirector tasting wine from the companyrsquos own vineyards

The first vintage wine of Ofitas har-

vested in autumn 2010 is now maturingin oak barrels After maturing for 12 to 15months the wine is called crianza and after

two years it will be granted the classifica-

tion reserva

ldquoWinemaking is not a business but

a hobby for us We give our wine out aspresents and drink it when we meet

our suppliers and friendsrdquo Intildeigo Ajuria

comments

For environmental protectionall of San Felicesrsquos plantconveyors are covered

Ofitas de San Felices quarry

LOCATION Haro near the city

of Vitoria northern Spain

SIZE 100 hectares

ROCK TYPE Ophite with Los Angeles

index of 9ndash10

PRESENT DAILY EXTRACTION 3000 tons

of ophiteNUMBER OF PERSONNEL 30

RESERVES 10 million tons

MAIN END PRODUCTS 0ndash2 mm

2ndash4 mm 4ndash10 mm 10ndash16 mm

16ndash22 mm 25ndash60 mm (ballast)

METSO MAIN EQUIPMENT

VF feeder

C125 jaw crusher

ndash feed size 0ndash800 mm

ndash css 130ndash140 mm

HP400 cone crusher

ndash feed size 80ndash250 mm

ndash css 40 mm HP4 cone crusher

ndash feed size 40ndash80 mm

ndash css 15 mm

Barmac 6150 VSI crusher

4 CVB2060 screens

2 TS32 screens

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Metso Distribution Centers he

Europe (Tongeren Belgium)

France (Macon)

Czech Republic (Přerov)

Austria (Vienna)

2271 d

Brazil (Sorocaba SP)

1014 d

USA (Columbia SC)

1690 d

USA (Waukesha WI)

434 d

South Africa (Vereeniging)

Ghana (Tarkwa)

Meacutexico (Irapuato)

Peru (Lima)

Chile (Concoacuten)

788 d

Sweden ( Trelleborg)

Finland (Tampere)

UK (Rugby)

865 d

Russia (St Petersburg)

Brazil (Parauapebas PA)

206 d

4983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

8132019 Results Minerals Aggregates 3 2012ENG

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In the case of an equipment failure or

a planned service shutdown resuming

production as quickly as possible is crucialEach hour spent waiting for a spare part to

arrive equals money lost Whether the right

part takes 12 or 48 hours to arrive really

makes a difference

The comprehensive and global Metsospare and wear parts service network pro-

vides you with the right part in the right

place and at the right time Our strategi-

cally located Distribution Centers and

Satellite Warehouses are on call 24 hoursa day 7 days a week ensuring efficient

parts replacement near you

Check out the locations of the MetsoDistribution Centers and how many parts

pass through them each day

More info

Marcelo Farah

Tel +55 15 2102 1315

marcelofarahmetsocom

you minimize downtime

Australia (Perth)

746 d

China (Tianjin)

China (Kunming)

China (Shanghai)

393 d

India (Faridabad)

India (Ahmedabad)

India (Hyderabad)

India (Bhubaneswar)

India (Bangalore)

419 d

Russia (Yekaterinburg)

Australia (Newcastle)

New Zealand (Matamata)

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TEXT Sofia Williams

Singapore (Singapore)

Distribution Center Satellite Warehouse

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Following a large investment

in Metso crushing equipmentand services Buena Vista del

Cobre is now expanding the

mine site to include even more

equipment ndash and with thatexpansion comes the need for

more local service resources

Metso and Buena Vista del

Cobre have entered into a Life

Cycle Service agreement forthe plant and construction of a

brand new Metso service hub

is under way in Cananea

New facility new

level of service

The Cananea service hub

which will be up and running in early 2013will support the recent expansion and resur-

gence of Buena Vista del Cobre Initially it

will be a major repair and assembly center

for pumps crushers and screens and will

provide for rubber covering capabilitiesBut the 8000-square-meter facilityrsquos service

offering will be expansive including a con-

signment stock inventory to help serve theminersquos varying needs Metso currently has

50 service team members on site

Although Buena Vista del Cobre was a

key influencer in building the new servicehub this location will also enable Metso to

expand its capabilities and provide local

support to the entire mining community

in northwest Mexico The Cananea hub

will serve a number of major copper and

gold mines in the region including MineraFriscorsquos San Felipe Fresnillorsquos Milpillas and

Grupo Mexicorsquos Mexicana de Cobre

ldquoBuena Vista del Cobre is the biggestcustomer we have in Mexico today and

with this expansion project itrsquos only going

to grow and be strongerrdquo says Felix Forna-

guera Director of Services Mexico CentralAmerica and Caribbean ldquoWith that said the

idea behind the Cananea service hub is to

provide a central location for local support

for all our major customers in the areardquo

Establishing safety

ldquoIt was key to have our support here in

Cananea because the Buena Vista delCobre started from the ground uprdquo saysFelix ldquoWersquove been able to help the cus-

tomer to establish the best in support

service and operations from the very

beginningrdquo And this ground-up approachincluded a major focus on safety

Metso worked closely with Buena Vista

del Cobre to establish the safety proto-

col by which the mine operates Basedon Metsorsquos expertise the safety measures

put in place have enabled the mine to

become strict and efficient in its operations

and maintenance procedures To achievethis Metso worked closely with local andnational authorities to ensure the safety

plan was comprehensive and in accord-

ance with all established legal bodies

The best in regional support

The service hub in Cananea is a prime

example of Metsorsquos focus on providing local

service and support to its customers all

Service shines in Cananea MexicoAfter three years of inactivity the Buena Vista del Cobre mine in Cananea Sonora Mexico has been operational since 2010A mine that was inactive for such a significant amount of time however requires a great deal of support to successfullyrestart the plant and bring it back to an operational and profitable state

TEXT Deanna Lee PHOTO Metso

over the world ldquoWe are the first

company developing this kindof service in northwest Mexicordquo

adds Felix ldquoOur people have

developed a close relationship

with the team at the mine Itrsquosmore than a supplier relation-

ship our guys are inside the

mine living and working thererdquo

In fact this is the model

that Metso is using in servicehubs all over the globe build-

ing modern facilities bringing

teams on site and workinghand in hand with mine

operators The Cananea Service

hub is only the most recent

example of Metsorsquos commit-ment to service and northwest Mexico is

yet another mining hotbed thatrsquos going to

benefit from the companyrsquos support

More info

Felix Fornaguera Tel +52 4621079227

felixfornaguerametsocom

A mining cone serviced by Metso at the Buena Vista del Cobre mine inSonora Mexico

ldquoThe new Cananea service center will be a majorrepair and assembly center for pumps crushersand screensrdquo says Felix Fornaguera Director ofServices Mexico Central America and Caribbean

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

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During the MINExpo exhibition over 1300 people visited the Metso stand

983122983141983152983151983154983156983145983150983143 983154983141983155

Held every four years MIN-Expo consistently grows so

perennial exhibitors like Metso

are challenged with elevating

their presence and drawingin new (and greater numbers

of ) visitors each year ldquoItrsquos not

necessarily a challenge to lsquotoprsquo

our last showingrdquo says Keith

Ference Vice President ofmarketing and communica-

tions North America ldquoThere

are four years between eachMINExpo so we always have

a lot to say and reveal to our

customersrdquo The real challenge

he says is finding an exciting

and dynamic way to deliverthe message ldquoTherersquos so much

to see here so your booth has

to be compelling from the

outside-in and thatrsquos what

we always try to dordquo

Service sets the stage

The Metso booth created buzzin a number of ways and per-

haps the most striking (partly

due to its size) was the live

theater presentation As visitorspassed through the aisles of the show-

room the sights and sounds from Metsorsquos

theater were hard to miss And once guests

entered they were captivated by a short

high-energy video presentation focused

on Metsorsquos service capabilities The message was simple Metso is ldquoyour

local service partner rdquo for all mining and

construction needs The video showed ourservice teams in action all over the world

and the audience came away with an

understanding about Metsorsquos commitment

to service Customers can count on morethan 70 local service centers run by more

than 1700 expert technicians delivering

Metso makes an impact at MINExpo 2012At this yearrsquos MINExpo International nearly 60000 attendees flocked to Las Vegas Nevada the largest turnout in showhistory The visitors ndash mining professionals from all over the globe ndash explored 850000 square feet of showroom spacefeaturing the industry rsquos latest technology equipment products and services They toured the show for three days

seeking the latest and greatest from more than 1800 exhibitorsTEXT Keith Ference PHOTOS Tracey Ford Perry

detailed descriptions andphotos of all of Metsorsquos mining

and construction products and

services The app also provides

digital access to Results and asearchable database of sales

contacts By day three of the

show MetsoMAP had been

downloaded by more than

500 usersIn addition to the app the

booth was equipped with

several LCD screens each con-trolled by Metso experts who

used their iPads to present new

products like the Megalinertrade

and the HRCtrade A featured

presentation on Metsorsquos lineupof energy-efficient comminu-

tion equipment including the

VERTIMILLreg SMD and MP-1250

cone crusher was also avail-

able letting customers seehow Metso technology delivers

some of the worldrsquos most effi-

cient size reduction

Measuring MINExpo success

After a very busy three days

(on top of months of prepara-tion leading up to the show) everyone

involved with MINExpo ndash from the North

American marketing team responsible for

the booth to the product managers and

sales force that worked the floor ndash is view-

ing the show as a success ldquoTherersquos alwaysa sigh of relief after each (MINExpo)rdquo says

Keith ldquoAnd overall the initial feedback

and response has been very positiverdquoWith more than 1300 visitors to the

booth Metso certainly made an impact

ldquoWe learn a lot from each show and with

some time wersquoll have a better understand-ing of the tangible results of our effortsrdquo

Keith adds

reliable service for mining equipment as

well as customized cost-effective life-cycle

services contracts

Technology ndash MetsoMAP

is an industry firstMINExpo provided the industry with its firstglimpse of Metsorsquos revolutionary iPad app

MetsoMAP The app was demoed to the

boothrsquos visitors via ldquothe worldrsquos largest iPadrdquo

a custom-made 80-inch screen that show-cased all of its capabilities most of which are

groundbreaking in the industry MetsoMAPrsquos

simple interface is highly intuitive making

it easy to view process animations videos

The presentation of the new HP cone crusher attracted a large audience

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When yoursquore allowed less than a dozen days per year for breakdowns repair andmaintenance every single hour during a service shutdown counts There simplyisnrsquot any room for surprises Thatrsquos why Boliden counts on MetsoTEXT amp PHOTOS Sofia Williams

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Kurt Kalla Site Managerof Metso Gaumlllivare ServiceCenter is responsible forthe maintenance of Aitik

Metso and Boliden Strivingtogether for 97 uptime

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983122983141983152983151983154983156983145983150983143 983154983141983155

One of the biggest copper mines in

Europe Bolidenrsquos Aitik is located deep inthe wilderness of Swedish Lapland next to

the small town of Gaumlllivare The mine has

been operating since 1968 and a recent

expansion has increased its annual ore

production to 36 million tons

But the ambitious Swedes are not will-ing to lay back and relax just yet Bolidenrsquos

new aim is to reach a production rate of

45 million tons of ore per year in AitikAfter that Perhaps more than 55 million

tons The ore concentration in Aitik is very

low-grade with a mere 022 copper con-

tent hence the need for high capacityAchieving the ambitious production

goal requires maximum plant availability

This means that everything from the crush-

ers to the filters must be up and runningfor approximately 97 percent of the time

Thatrsquos where Metso comes into play

A cost-per-ton contract in action

The maximum uptime requirement allowsless than a dozen days per year for break-

downs repair and maintenance at Aitik

Every single hour during a service shut-

down counts There simply isnrsquot any roomfor surprises

Executing a successful shutdown under

such conditions requires a reliable service

partner not afraid of challenges and this iswhy Boliden has entrusted Aitikrsquos services

operations to Metso Boliden and Metsohave worked together since the 1960s

and the collaboration took another step

forward in September 2012 when the twocompanies signed a three-year extension

of the services contract for Boliden Aitik

ldquoThe new contract is a cost-per-ton

agreement We get paid based on Aitikrsquos

production Itrsquos a win-win deal for both par-

ties but also a new mindset for usrdquo explainsKurt Kalla Site Manager of Metso Gaumlllivare

Service Center responsible for serving Aitik

From now on the duration of the shut-down is what matters the most According

to Kalla the Metso service organization in

Gaumlllivare is now streamlining its operations

to fit the bill and has already witnessed thestrategy working In August 2012 Metso

carried out a 188-hour service shutdown in

Aitik which turned out to be a success

Zero tolerance for injury

One key factor to the success was theextensive planning of precautionary health

safety and environment procedures under-

taken by Metso prior to the shutdown Thanks to strict measures applied no

injuries or accidents occurred during the

shutdown and the work could easily be

finished on scheduleMats Johansson Health Safety

and Environment Manager for Metso in

Sweden explains how this was achieved

rdquoPlanning of the shutdown included arisk analysis for all new tasks participating

in Bolidenrsquos safety coordination meetingsmeeting with both Metso supervisors and

subcontractor supervisors and finally a

meeting with the entire staff participating

in the shutdown where everyone had to

sign a document stating their commitmentto the information providedrdquo he says

During the actual shutdown plenty of

new barriers signs and awareness cones

were put in place as a result of observa-tions from previous audits and safety plans

and risk analyses were readily available

in the work area Metso and Boliden also

introduced a Mill Inching permit a certifi-cate for completing a mandatory course for

those involved in the process In addition

Metso carried out random safety audits

during the shutdown to make sure thestrict policy was followed

According to Boliden Metsorsquos way of

working is a good example of how health

and safety precautions should be handled

ldquoMetso is a good example of how towork with safety and health plans risk

analysis permits and welding permits

Their table with all binders in the second-

ary mill area was exemplaryrdquo says Kjell-Arne

Johansson a technician from Boliden

The use of the new Metso Megalinertrade

system in the lining of Aitikrsquos Metso AG

mills has also improved the safety of main-tenance staff The Metso Megalinertrade con-

sists of larger-than-average liners bolted

in position from outside the mill Mainte-

nance technicians no longer need to go

inside the mill and stand in the dangerousdrop-zone of the liners gt

Boliden aims to reach a production rate of 45 million tons of ore per yearin the Aitik mine site

ldquoA complete risk analysis was conducted during the planningof the shutdownrdquo comments Mats Johansson Health Safetyand Environment Manager for Metso in Sweden

8132019 Results Minerals Aggregates 3 2012ENG

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Service the Metso way

24 hours a day 365 days a year

In addition to paying close attention to

health and safety issues executing an effi-

cient shutdown requires careful planning

and timing of every step in the mainte-

nance process Wear and spare parts have

to be available on time and a repair shoplarge enough to accommodate equipment

located close by

ldquoTo keep maintenance breaks as short

as possible we aim to replace the pump on

site and bring the old one for repair to our

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

nearby facilities This method gives us the

peace to do a good job and keep the cus-

tomerrsquos operations runningrdquo Kalla describes

the Metso way of handling Aitikrsquos pump

maintenance

Metso is currently expanding its Gaumllli-

vare service center to include a distribu-

tion center for wear and spare parts andalso concentrating its previously scattered

operations under one roof in its Vuoskon-

jaumlrvivaumlgen facility The expansion is due to

be completed by 2014

Metso equipment

delivered to Aitik36

bull 2 AG mills diameter 116 x

137 m gearless 22-MW motor

bull 2 Pebble mills diameter 91 x

113m dual 5-MW pinion drive

bull 3 VPA pressure filters VPA 1540-54

bull 12 sample pumps and pipes

VF50

bull 60 Various slurry pumps up to

MR500 modelbull Appr 5000 m rubber-lined slurry

pipes up to 600 mm diameter

bull Appr 5000 m rubber-lined by

gravity pipes up to 600 mm

diameter

bull Appr 5000 m rubber hoses

up to 600 mm diameter

Not only does the expansion make ser-

vice shutdowns at Aitik run more smoothly

it guarantees a more comprehensive

on-call emergency service response in the

region ndash thanks to the spare and wear parts

inventory available 24 hours a day 365

days a year

More info

Lars Rosenling

Tel +46 70 107 45 90

larsrosenlingmetsocom

Metso grinding equipment dominates the view in the concentrator

Safety on site is made up of small things like

making sure that everyone remembers to secure

the hoses in place

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983122983141983152983151983154983156983145983150983143 983154983141983155

Pebbles have always been a

challenge for producers of sandsince they cannot be returned

to rivers after extraction For

decades the processing of this

material resulted in a huge

environmental liability with alarge amount of pebbles hav-

ing to be stored away and left

unused

Transforming problems into

business opportunities

Areia amp Cia (areia = sand) has

operated in this market forover 20 years and decided to

enlist the help of Metso to find

a profitable solution for the

processing of pebbles

In July 2011 analyses werebegun to assess the abrasive-

ness and crushability of the

material Four alternatives wereidentified for processing and

transforming pebbles into sand

Initially Areia amp Cia was

interested in acquiring an

impactor for its reason-able price level However the

customer wanted to process

all the pebbles that were col-

lected daily in addition to some of the

material that it had stored In weighing theresults expected by the customer and the

excessive abrasiveness of the material the

HP200 cone crusher was decided on as thebest alternative

Areia amp Cia made the required invest-

ment and after using the HP200 for just

six months the company has already beenreporting outstanding results The HP200

not only transforms pebbles into sand but

also produces sand of excellent quality

with high yield and low maintenanceWith minor adjustments the HP200

also enables the production of sand withspecific particle size distribution for special

applications such as filtering sand blasting

and foundry sand adding value to the prod-

uct and increasing the types of sand offeredldquoMetso is pleased that the HP200 not

only enabled the processing of a product

that had been set aside as unusable but

HP200 cone transforms pebblesinto high-quality sandOver the last few decades Brazilian economic growth has been driving demand for construction aggregates The market

for sand in turn has been experiencing major difficulties in maintaining a consistent supply Presently one of the mainchallenges the industry faces is the large amount of pebbles that are obtained in the process of extracting sand at timesconstituting nearly 50 of the volume of material dredged from riverbeds

TEXT Sheila Ivers PHOTO Areia amp Cia

also that it opened up new

market opportunities for Areiaamp Cia Thatrsquos the standard we

seek to deliver to our custom-

ersrdquo states Luiz Oliveira Techni-

cal Salesperson of Metso Brazil

HP cones entering the

Brazilian sand-making

market

Todayrsquos cones such as theHP200 have high resistance

to impacts and abrasiveness

more efficient crushing cham-

bers low maintenance costsand excellent productivity

Following the acquisition of

the HP200 Areia amp Cia is now

also producing special sands

that command a price that is100 higher than common

sand The entire stockpile of

pebbles accumulated through-out the companyrsquos 20 years of

operations has already been

transformed into sand and the

stock of pebbles held by com-

petitors is also being purchasedfor processing

Cristiane Brizolari the

owner of Areia amp Cia confirms

the transformation that has taken place in

the production and commercial processldquoThe HP200 opened up new niches in

the market enabling the production of dif-

ferent types of sand with added valuerdquo

More info

Luiz Oliveira

Tel +55 011 9971 3603

luizoliveirametsocom

After the pebbles are crushed into sand with the HP200 cone crusherdifferent grades are screened for various end uses

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Where therersquos a will we dig a wayAFCONS-Strabag and Metso embark on tunnel project together

When the joint venture AFCONS-Strabag initiated work on the Rohtang bypass tunnel project at an altitude of 3980 metersabove sea level in Himachal Pradesh India they deliberated each aspect with clockwork precision The project involved anumber of surprises and challenges and required technology and project management skills that were second to none

TEXT amp PHOTOS Monisha Majumdar

Cutting a 10-meter-wide and nearly 9-kilo-

meter-long tunnel through the Himalayas

in one of the toughest terrains and cli-mates in India makes for quite a challengeResults set out to find out how AFCONS-

Strabag and Metso are making their way in

one of their most critical projects to date

The only road connection to the north-Indian border region of the province

Himachal-Pradesh and beyond the Manali-

Leh highway leads across the Rohtang

pass Due to the heavy snowfall and high-

velocity winds in this region the towns

located north of the pass are cut off from

the rest of the country during winter for atleast four often even six months each year

A tunnel with strategic importance

With the construction of the tunnel at

3100 m above sea level the Manali-Lehhighway will become an all-weather road

thereby enabling a significant improve-

ment in the economic development of

northern Himachal-Pradesh and an alter-

nate route to the strategically important

Ladakh region

Manali south of the pass is an alreadywell-developed tourist location that is

becoming more and more popular Upon

completion of the tunnel it is likely that

tourist activities will extend to the areanorth of the pass Moreover the tunnel

shortens the distance between the towns

of Manali and Leh by approximately 45 km

thus saving several hours on the small dan-gerous pass road

The Rohtang pass in the Western Himalaya

region of Northern India with its altitude ofalmost four kilometers ranks among thehighest trafficable passes in the world

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983122983141983152983151983154983156983145983150983143 983154983141983155

The 88-km long horse-shoe-shaped

tunnel provides space for a two-lane8-m-wide carriageway as well as a one-

meter-wide footpath on both sides A

22-m-high and 36-m-wide emergency

tunnel will be integrated in the tun-

nel cross-section Altogether more than

800000 msup3 of rock will be moved Tunneling works started around spring

2010 with excavation driven from both por-

tals As the north portal is inaccessible dur-ing winter closure the excavation focused

on the south After a planned construction

period of 55 years the tunnel is scheduled

to be completed by the end of 2015

Best man for the job

The BRO (Border Road Organization)

wanted to roll out a global tender for theproject due to the challenges that such a

project involves and also considering thatitrsquos the first time in India that a project of

this scale was to be carried out This imme-

diately triggered the need to roll out aglobal tender All major Indian construction

companies bid for it some individually and

some in partnerships

Strabag an Austrian tunnel specialistwas one of the companies who bid for the

project along with AFCONS a Mumbai-

based infrastructure company In Septem-

ber 2009 AFCONS-Strabag was awardedthe contract

Mr Sunil Tyagi Deputy Project Man-ager at AFCONS had this to say about the

unique projectldquoThis project is located in the Himalayas

and as far as we understand the terrain

there is among the toughest We came out

with a new technology and to be honestit is a fairly simple one We would generally

start with the traditional technology of drill-

ing and blasting and then obtain our muck

feed from the inwardbottom of the tunnelrdquo

ldquoThe technology is supplied by Rowa Tunneling Logistics and this is the first

time it is being used in Asia A jaw crusheris placed at a distance of about 40-45

meters behind the face The blasted muckextracted from the face is fed to the crusher

to reduce the lump size and then through

an overhead conveyor transport system

it is then transported out of the tunnelrdquoldquoThis enables free movement of man

and machinery in the lower area or spe-

cifically on the ground area If we were to

conforms to the Indian standard for fines amp

coarse aggregates as prescribed in IS383-1970

The plant was up and running in good

condition and performing to AFCONSrsquos

satisfactionldquoWe have worked with Metso in earlier

projects and are quite impressed by thekind of technology amp services they provide

We have a history together so the trust fac-tor also comes inrdquo explains Dhiman on their

choice of Metso as a partner

Service makes the difference

ldquoMetsorsquos services have made a big dif-ference in the project Without them we

would still be struggling with the machin-

ery and production The service is really

good and the service engineers are knowl-edgeable prompt and quick to act Any

problem can be solved by Metso We donrsquothave to wait until a service engineer turns

up ndash they have the capacity to solve prob-lems over the phone as wellrdquo says Dhiman

ldquoThe Metso plant didnrsquot create any prob-

lems for us We had problems in logistics

the feed was sticky and the weather condi-tions were bad but thankfully we did not

face any problems with production and

efficiency as the Metso plant is performing

very wellrdquo Dhiman concludes

More info

Amol Sinha Tel +91 9811 671 924

amolsinhametsocom

use the old conventional technology this

wouldnrsquot have worked for us in the stipu-lated timerdquo Mr Tyagi adds

When the going gets tough

partner with the toughest

Sensitive projects require the best technol-

ogy After AFCONS-Strabag landed theproject Metso was an obvious choice as a

technology provider not only because of

the long-standing business relationshipbut also for the sheer consistency in prod-

uct quality and service deliverance Metso

strives for

ldquoAfter signing the project we faced alot of road blocks including extreme cold

avalanches roadblocks less oxygen ndash you

name it we faced itrdquo explains Ankit Dhi-

man Plant Manager at AFCONS-Strabag The Rohtang valley is known for its

notorious avalanches and landslides SoAFCONS had to take extra steps and safety

precautions against hazards on the site

ldquoIn this freezing cold not just us humansbut also the machines are at increased risk

of damage I remember when we used

to run the plant during winter the diesel

engines would freeze We had to constantlyheat up the fuel container to get the plant

running And even the sand in the sand

trap would freeze so we had to clean it on

a daily basis to stop the pipes from mal-functioningrdquo Dhiman adds

Plant designed for difficult terrain

Difficult terrain coupled with space con-straints led Metso engineers to put their

minds together to come up with a suitable

plant configuration After studying the

requirements of the project Metso sug-

gested a 150-tons-per-hour three-stagemodular plant using a C106 jaw crusher

a GP11F secondary cone crusher and a

B7150 tertiary vertical shaft impact crusher

In addition considering the unpredict-ability of the feed the plant was about

to reach a point where the amount offines to be handled could be increased

dramatically Metso strongly suggested the TK11-27-3V grizzly scalper and this became

the first-ever TK scalper to be supplied by

Metso to an Indian customer Also in order

to get better products a sand trap SF2360was added to the configuration

The sand trap is important equipment

for this project as it washes the sand thatMr Sunil Tyagi Deputy Project ManagerAFCONS-Strabag

8132019 Results Minerals Aggregates 3 2012ENG

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Smooth transition to new-generation jaw crusher in Germany

Roumlhrig is a German company with a rich heritage The company has been quarrying granite at its plant in Bergstrasse inthe Sonderbach district of Heppenheim for three generations

TEXT amp PHOTOS Ralf Goffin

Roumlhrigrsquos superior product variety is onereason why the companyrsquos proximity to its

customers can be understood in more than

just physical terms The companyrsquos high

level of innovation has allowed it to estab-lish itself as a reliable supplier of materials

both regionally and internationally This

operational and technical expertise always

manages to keep in step with growing

market requirements

In terms of technical processing equip-

ment Roumlhrig has used a Nordberg C160stationary jaw crusher from Metso since

1992 At the start of 2012 it was finally

exchanged for a more up-to-date version

from the same model range

Metsorsquos C Series is specifically designed

to pre-crush hard rock and can cope effort-

lessly with even the hardest of materials

The dimensions of the new stationary jawcrusher are identical to those of the old

one which means that it could simply be

slotted into the housing vacated by the

previous version

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983122983141983152983151983154983156983145983150983143 983154983141983155

Third-generation Managing DirectorMarco Roumlhrig expects the new machinersquos

service life to be just as long as the previ-

ous model due to the product upgrades

that have been implemented The integral motor base is another plus

point in models made by other manu-

facturers it is located outside the crusher

This element of good fortune ensured that

Roumlhrig could reuse the housing withoutany additional rebuilding

Another advantage lies in the revision

of the guards for the C160rsquos drivetrain andflywheel The sturdier construction method

used for the crusher requires fewer parts

which facilitates easier installation andmaintenance and it makes it simpler to

access the motor

Under the watchful eye of Metsorsquos

Assembly Manager Maik Engelstaumltterthe entire project including removal and

installation was successfully completed

within two weeks

Installation making the most

of the available space

Roumlhrig will likely remember the day the

new crusher was installed for a long time

the pitman and main frame were deliveredseparately prior to installation and assem-

bled on site It took just one hour to replace

the old stationary crusher with the new

model A lorry-mounted crane was used toposition the 85-ton crusher with millimeter

precision in the crushing plant Once the

new crusher had been positioned in theexisting steel structure the next task wasto fix it into place as securely as possible

despite the limited space Special vibration

dampers were installed at a height of two

meters to prevent the crusher from sliding

Norbert Ried (fourth from left) installed thenew C160rsquos predecessor 20 years ago and isdelighted at the durability of the powerfulcrusher that is now making way for a newermodel Also pictured from left to right ManagerVolker Angermann Assembly Manager Maik

Engelstaumltter Technical Manager Stefan

Koob Project Manager Dominic SchoumlnhardtManaging Director Marco Roumlhrig Service

Technician Stefan Kolze and employees ofthe installation company Stafemo

On the hook after theold C160 was liftedout by crane the newcrusher was installedin almost no timeOnly the roof of thehousing had to beremoved

sideways off its mount An initial test run

with materials was carried out around oneweek later after all the electrical cables had

been installed

Simultaneously with the installation

of the C160 which is the first of the latest

generation of crushers to be installed in

Germany a new Nordberg GP100 conecrusher was also being installed in Roumlhrigrsquos

chipping plant Roumlhrig is convinced that

the technical improvements made tothe new Metso crusher can only be an

advantage worldwide

Roumlhrig places great value on consistent

product quality maximum added valueand optimum refinement of its product

range Bearing in mind that Roumlhrig has

enough reserves of raw material to last

for the next 150 years the company canconfidently continue to develop with an

emphasis on quality rather than quantity

More info

Dominic Schoenhardt

Tel +49 (0)621 727 00 610

dominicschoenhardtmetsocom

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Groupe Charier Carriegravere de la Mariais France

Quarrying with certi1047297ed quality The Charier Group with its 1600-strong workforce is a family business thatthis year celebrates 115 years of quarrying The company pursues a long-termdevelopment policy that since 2007 has seen processing installations upgradedat 4 of its 9 extraction sites

TEXT Liliane Boutin (with extracts from Mines amp Carriegraveres and Terrassements amp Carriegraveres magazines)PHOTO Baloon photo

The processing installation is of the horizontal type with a primary station located 56 meters below the site access road to keep it hidden from view

The crushing and screening installation at

Charierrsquos CM La Mariais quarry (at Donges

on the Loire estuary) has been in opera-tion since September 2011 Based on theoperatorrsquos ideas it was designed by Metso

to replace a worn-out installation installed

right on top of the seam being extracted

Since its commissioning it has becomethe second quarry in the company to

receive ISO 14 001 certification

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983122983141983152983151983154983156983145983150983143 983154983141983155

tertiary material of sand and gravel for the

local market to use in concrete surfacingprefabrication etcrdquo

Incorporation of a screening station

The stone extracted from La Mariais is

according to the quarry granitic gneiss

sound and homogeneous with a LosAngeles index of 15 good wear resist-

ance with an MDE of 10 a true density of

265 and a certain abrasiveness (2000 gt)ldquoCharacteristically it has a tendency to form

blocksrdquo Leblin points out

The main criteria in designing the instal-

lation was to provide an output of 600000metric tons from one station (38 hours

week) to produce materials aimed at the

concrete and surfacing markets ldquowhich

involved providing a tertiary station withscreening plantrdquo he adds

With this new unit the operating com-pany expands its product range through

the addition of fine materials obtained

from the tertiary screening station This unitis capable of producing 170 tonshour of

020

Preserving the environment

and optimizing safety

The screens have motorized bogies and

retractable walkways to facilitate access

when the screens are opened for main-tenance Other walkways provide access

to the tunnel input feeders The feederscan be isolated with hydraulic rod gate

bars this hydraulic assistance eliminatesthe need to use a heavy hammer to lodge

these metal bars

All conveyors transporting fines (02

and 04) are covered with a tarpaulin to

avoid flying dust and all the screens arehooded (metal cover with Trellex seal-

ing) The Brunone company has installed

dust-tight containment at the outlet of the

tertiary station crushers (HP300 and HP4)on the belt located under the screens

and under the hoppers located belowthe tertiary screens The crushers are put

under negative pressure and the finesare extracted through sleeve filters (7000

m3 h) with declogging which deposits the

dust back onto the conveyor belt

A high-pressure 100 bar water mist sys-tem has been installed at the primary sta-

tion discharge at the secondary crusherrsquos

discharge chutes (Omnicone) and at the

transfer points on the belt

Designed to last

ldquoThis type of new installation can easily last

thirty yearsrdquo affirms Project Leader Bruno

Peix of Metso ldquoIt quite simply depends on

how well it is maintained Thatrsquos why weprovide maintenance contracts that call for

our technicians to make regular inspection

visits and carry out preventive mainte-nance and any necessary repairsrdquo

In 2011 Metso commissioned about

10 new processing units in France like

the one at La Mariais quarry

More info

Frederic Bazire

Tel +33 (0)681442804

fredericbaziremetsocom

Key figures

DURATION OF WORKS 15 months

DRAWING OFFICE TIME 7800 hours

HEIGHT OF SILOS AND GRINDER BUILDINGS

15 m

TOTAL LENGTH OF CONVEYORS 14 km

WEIGHT OF THE INSTALLATION

1200 metric tons

CONCRETE POURED 1800 cubic meters

PROJECT SITE WORKFORCE 30

INSTALLED POWER 2200 kW(not including pumps 200 kW)

METSO EQUIPMENT

Primary

Vibrating feeder PF561-2V

Primary grizzly VG540-3V

Grizzly feeder TK13-20-3V

Jaw crusher C145 with

hydraulic setting

Secondary

Vibrating screen CVB 2050

refurbished

Cone crusher Omnicocircne 1352 SX

with Metso IC7000 controller Ellivar 16 (16 msup2 3 decks) screen

refurbished by Metso

Tertiary

Cone crusher HP300

Cone crusher HP4

2 Ellivar 20 screens (20 m23 decks) for final products

Expanding the production range

ldquoSince the mid-1990s when we became

owners of La Mariais we had used mobilemachinery with an assembly of beltconveyorsrdquo recalls Daniel Leblin Charierrsquos

Technical Manager for site construction

and maintenance

ldquoIt became clear that we needed ahigher performance tool to achieve the

dual goals of reaching one million metric

tonsrsquo maximum production and producing

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Big Lokotrack LT550GPF boostsquarrying productivity by a thirdMaximizing the productivity of operations is a key issue when striving for cost-effective quarrying Big Lokotracks are oneway to achieve improved operational efficiency The Lokotrack LT550GPF equipped with the high-volume GP550 conecrusher and a large screen is popular in the Nordic countries and in Germany and Australia ndash countries all known for theirhigh quarrying volumes

TEXT amp PHOTOS Eero Haumlmaumllaumlinen

Kone-Kostamorsquos new mobile coneplant has reached an averagecapacity of 300 tons per hour

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983122983141983152983151983154983156983145983150983143 983154983141983155

ldquoWith the same number of employees we

can achieve 30 more productivity with

our new LT550GPF unit The high-capacityFS screen has also eliminated the bottle-neck often seen at fine screeningrdquo says

Aarno Kostamo Managing Director of

Kone-Kostamo Oy one of Finlandrsquos biggest

crushing contractorsAccording to Kostamo the high capacity

of the GP550 gyratory cone crusher easily

handles feed from the C120 and C125 jaw

crushers For the contract with the Talvivaara

nickel mine the LT550GPF is being fed bythe brand new Lokotrack LT120 jaw plant

Average capacity 300 tons per hour

Talvivaara Europersquos largest nickel mine uti-

lizes large quantities of aggregates Kone-Kostamo has contracted several million

tons of different end products for the mineIn August 75000 tons of 0ndash63 mm

road gravel was crushed Smaller amountsof finer 0ndash6 mm 0ndash16 mm and 0ndash32 mm

aggregates are also being produced

The rainy summer increased the need

for road gravel along the muddy roadswhich must endure dump trucks weighing

as much as 260 tons

ldquoThe mobile process consisting of the

LT120 jaw plant and LT550GPF cone plant

is cost-effective while aggregates of vari-ous sizes can be produced in a two-stage

operation and with high capacity The con-trolled stroke and elliptical movement of

the FS screen secure big passing throughcapacitiesrdquo Kostamo explains

Operated in two shifts for a total of 16

hours per day the LT550GPF has logged

more than 600 working hours over a two-month period

Managing Director Aarno Kostamo (left) and foreman Karri Maumlenpaumlauml studying the cavity optionsavailable for the new Lokotrack LT550GPF

Longer perspective than

a single quarter needed

Kone-Kostamo Oy was founded as an

earth-moving company in Kemijaumlrvi

Northern Finland in 1956 The company

expanded its operations to include crush-

ing contracting in 1964 and later on

switched to concentrating fully on crush-ing activities

Kone-Kostamo consistently crushes

and screens around 28 million tons ofaggregates annually and has net sales of

between EUR 8ndash9 million

ldquoWe believe that issues within the crush-

ing industry including the purchasing ofmachinery must be studied with a longer

perspective than a single quarter The

secret to our success has always been our

solid work ethic and professional employ-eesrdquo Kostamo sums up

More info

Esa Berg

Tel + 358 40 837 8692

esabergmetsocom

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Monitoring-based reporting is vital for

assessing the performance of a mobile

crushing plant Metso provides suchreporting tools through its plant-wideautomation system Metso DNA (Dynamic

Network of Applications) with its infor-

mation platform that links all the mobile

crushing and screen units together as oneentity Basically there is a lot of measured

real-time information available in every

crushing plant On-line information is

obtained either from each Metso crusherrsquosmachine automation system IC (Intelligent

Controller) or from separately installed

additional sensors and belt scales

All the collected data is sent to a motorhome using wireless communication

based on WLAN technology The motor

home is a purpose-built environment

inside an on-site container In this environ-ment selected variables can be monitored

for assessing the plantrsquos performance And

to make all this even more flexible the

data can be transmitted to a crushing plant

company office using GPRS3G mobile

data communication technologies Thismakes all the last-minute reports acces-sible to the crushing plant managerial staff

at anytime and basically anywhere within

reach of the cell phone network

Production and fuel economics reports

Essentially monitoring and reporting can

be customized to fit the customerrsquos needs

However there are certain off-the-shelf

reports that provide a lot of useful informa-tion for plant supervision The production

report is one of these Requiring at least one

belt scale for measuring the total produc-tion the production report shows the pro-duction rate (tons per hour) for a selected

reporting period eg a day or a week The

production report constantly keeps track of

the plantrsquos production storing all the datathroughout the plantrsquos life cycle

Performance monitoring and reportingfor a mobile crushing plantTEXT Pasi Airikka PHOTOS Metso

unit during which the unit is running By

storing the availability times between start-ups and shutdowns the crushing plant

operation time (hours per dayshift) can be

recorded analyzed and reported In addi-

tion the availability report can be tailored

to evaluate efficient crushing hours during

which the plant is really working and pro-ducing aggregates Consequently the ratio

(0-100) between efficient crushing time

and total running time can be reported forany selected period of time This boosts

the efficiency of the plantrsquos operations

and results in better productivity

Reports on non-choke

or inadequate feeding

Non-choke feeding to crushers is avoid-

able through smart plant-wide crushingplant controls But estimating its severity in

a systematic manner is not straight-forwardwithout constant monitoring and reporting

The crusher choke feeding report makes

use of the crusher cavity level sensors byanalyzing their level measurements By

calculating average and min-max values

and deviations from the average it can be

shown how often the single crusher suffersfrom non-choke feeding to it

In some cases the bottleneck in the

crushing plantrsquos productivity is the material

feeding to the process In mobile plants thefeeding is human operated and therefore

subject to variations Occasionally the sizeof the human-operated machine simply

does not allow for adequate feeding to thecrushing plant There are specific reports

indicating time periods when the crushing

plant suffers from inadequate feeding

Condition monitoring for

crushers and screens

Machine-specific condition monitoring

focuses on vibrating components in

crushers and screens such as drive shaftbearings safety plate wearings and gears

The low middle and high frequencies ofmonitored components are measured and

supervised in real-time to detect abnor-malities due to slow or fast wear looseness

or imbalance

More info

Pasi Airikka

Tel +358 40 587 2730

pasiairikkametsocom

Condition monitoring provides a view tovibrating crusher and screen components forpredictive equipment maintenance

The daily production report shows the hour-by-hour production trend and distribution chartfor a selected day with min-max average andvariation statistics for comparison

Fuel consumption is always an interest-ing concern The fuel consumption reportgives the fuel consumption of each crush-

ing unit (liters per hour) and their total

consumption (liters per hour) for a selected

reporting period and can track fuel con-

sumption changes over timeCrushing plant availability can be

assessed as well The availability report

calculates time periods for each crushing

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983149983141983156983155983151 983150

for tissue machines The record of 2210

mmin was set on June 1 2012 during a

24-hour production run by the TM 2 tissue

machine at the companyrsquos mill in Yenikoumlynear the city of Izmit in Turkey

ldquoThe cooperation with Metso has been

beyond excellent and both parties did

their utmost to make the project success-ful The results clearly show that the efforts

were worthwhile on both sides This coop-

eration will extend to cover new projects

in the futurerdquo says Luumlt1047297 Aydin Paper GroupDirector Hayat Kimya

ldquoWe are not surprised that Hayat K imya

managed to break the world speed record

We have had great confidence in the capa-bility of the Hayat team since our project

started in 2009 We certainly know our

machine very well its stability production

efficiency and speed capabilityrdquo says Jan

Erikson Vice President Sales Metso

PowerThe worldrsquos first eco-gas fueled

power plant is up and running

Lahti Energy Ltdrsquos new Kymijaumlrvi II gasifica-

tion plant was officially inaugurated on

May 8 2012 It is the first of its kind in the

RecyclingRecycling with Lokotrack LT106

jaw plant in New York

A brand-new Lokotrack LT106 jaw plant is

used in the city area of New York USA to

recycle demolition materials The crushing

site faces the skyscrapers of ManhattanIsland

Paper amp FiberHayat Kimyarsquos Metso-supplied tissue

machine sets world speed record

Thanks to a skilled crew and dedicated

efforts Hayat Kimya AS in Turkey has suc-

ceeded in breaking the world speed record

world This CHP plant runs on clean eco-

gas that is gasified cleaned and cooled

from recycled waste with Metsorsquos innova-tive technology

ldquoItrsquos actually eco-gas that we combust

in the boilerrdquo comments Lahti EnergyrsquosProduction Director Jukka Manskinen

ldquoWe convert unwanted waste material into

energy in an efficient and environmentally

friendly wayrdquoNever before has any plant gasified

waste on such a large scale In the gasifier

recycled waste is turned into combustible

product gas which is cleaned cooled and

combusted in a high-efficiency gas boiler

to produce steam for the steam turbine The plant produces 50 MW of electricity

and 90 MW of district heat for the city of

Lahti and its neighboring areasMetso delivered the circulating fluidized

bed (CFB) gasification process gas cleaning

and cooling steam boiler environmental

protection system and automation systemto the entire plant The production of elec-

tricity and heat is kept even with the Metso

DNA automation system that covers the

whole plant starting from fuel reception

AutomationMetso develops and supplies plant-

wide crushing control solutions for

crushing plants

Metso has recently signed contracts on

delivering plant-wide automation systems

for mobile and portable rock crushing

plants The key objective of these deliveries

is to stabilize and to increase productivityand efficiency of the plants using one sin-

gle automation and information platform

for integrating crusher-specific IC machinecontrols

Furthermore the plant-wide system

with its information management tools not

only increases plant availability and opera-

tional safety it also makes troubleshoot-ing quicker and performance monitoring

easier The control room for plant-wide

operability is located either in an excavator

cabin or a purpose-built container

Metso around the world

The new LT106 jaw plant is suitable for crushing both hard rock and all rock-based demolition materials

The new world speed record for tissue setby Hayat Kimyarsquos Metso-supplied TM 2 is2210 mmin

8132019 Results Minerals Aggregates 3 2012ENG

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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 9: Results Minerals Aggregates 3 2012.ENG

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983110983141983137983156983157983154983141983140 983137983154983156

Endomines

Pampalondash a green andresponsiblegold mineAt Pampalo near the easternmost point of Finland a cleanand environmentally friendly gold mining operation isbeing executed by Endomines With Metsorsquos plant designand a state-of-the-art processing plant Pampalo runs a

green and responsible yet at the same time profitablegold mining operation that avoids acid mine drainagesand targets 100 water recirculationTEXT amp PHOTOS Eero Haumlmaumllaumlinen

With a modest investment of EUR 20

million the Pampalo mine was built fully

operational and now produces 800ndash900 kgof pure gold annually An on-going expan-

sion will increase the minersquos production

capacity by 30 to 50 next yearIn addition to the main underground

mine at Pampalo several promising satellite

gold deposits are being investigated along

the long Karelian gold line The maximum

distance of the satellites is 30 km allowingthe mine to transport and process all of the

produced ore at the Pampalo plant

Small scale can be successful

with hard work

ldquoWith our gold mining operation we can

very well show that with hard work even

small-scale gold mining and production

can be done in a sound and profitable wayrdquosays Markus Ekberg CEO of Endomines

originally founded in Sweden

According to Ekberg the strategy when

building the mine was to split up the jobsinto small separate contracts Metsorsquos part

was the main minerals processing system gt

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983110983141983137983156983157983154983141983140 983137983154983156

Increasing capacity makes processing

of lower grades economical

The project to significantly increase the

processing capacity at Pampalo is well

under way with the installation of for

example a second grinding mill and more

flotation cells The expansion will be in

operation during early 2013ldquoThe added capacity also makes it pos-

sible to economically process the nearby

open pits with a lower gold grade In addi-tion it helps us to optimize the crushing

and grinding circuitsrdquo Ekberg concludes

Active exploration drillings have

exposed new mineralized zones furtherextending the lifetime of the Pampalo mine

from the present estimate of 6ndash7 years

More info

Peter Vikman

Tel +358 400 869 845petervikmanmetsocom

Endomines Pampalo gold mine

LOCATION near the community of

Ilomantsi in Eastern Finland

GOLD ORE CONTENT

ndash Pampalo 34 gtndash Hosko 99 gt

ndash Raumlmepuro 39 gt

ndash Muurinsuo 30 gt

PRODUCTION TONNAGE PER YEAR 270000 tons (present)~400000 tons (future)

GOLD PRODUCTION PER YEAR 800ndash900 kg

KNOWN ORE RESERVES IN TOTAL

approx 2 million tons

MINE DEPTH 360 m

MINING METHOD bench cut and fill

NUMBER OF EMPLOYEES

100 including contractors

METSO EQUIPMENT

1 Metso TRN 30 x 48 m

wet ball mill

8 Metso RCS series flotation cells 1 Nordberg MF 1800 x 6100

screen

3 Metso samplers

1 Metso CT thickener

1 Metso TF vacuum filter

33 Metso slurry pumps of various

types and sizes

The gold ore is screened using Metsorsquos MS series mining screen

Markus Ekberg is pleased with the outcome the mine reached the minerals processing utilizationdegree of over 90 just two months after start-up

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156983145983139983148983141

Nordic Mines ndash on track tobecoming one of Europersquosmost prominent goldproducersNordic Mines is the newest member in a long chain of Nordic gold mining operations

Inaugurated in mid-August 2012 this company of Swedish origin aims to become one

of Europersquos most prominent gold producers Metso is one of Nordic Minesrsquo main partners

supplying the Laiva gold mine with crushing screening conveying and minerals

processing equipment at an estimated value of EUR 30 million

TEXT amp PHOTOS Eero Haumlmaumllaumlinen

2983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

The Laiva gold mine was built in record time infrastructure

construction began in spring 2010 ore excavation started in

June 2011 and the first gold bar was casted in December 2011

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156

Just one year after starting the gold recov-

ery process Nordic Mines is on track toreaching a capacity of 5 kg of gold per day

At present the operations are averaging 3

to 4 kg of gold daily

The ore in the Laiva Gold Mine consists

of packages of gold-bearing quartz-filled

shear structures The deposit is more thana kilometer long and 700 meters wide The

total depth is still unknown but dr illings

carried out thus far have shown gold-bear-ing shear structures 300 meters below the

surface

A typical ore zone includes a large num-

ber of thin shear structures from 5 to 30per meter The ore zones are commonly 50

to 100 meters long several are 10 meters

deep and they range from a few meters to

20 meters cross strike The minimum min-ing width is 25 meters which means that

even a minor ore zone consists of at least10 to 50 shear structures

Conventional pattern blasting

with selective loading

Prior to mining Nordic Mines conducts

grade control drilling which provides

dense gold grade information and makes

it possible to outline the boundaries

between ore and waste The mining

technique applied is conventional pattern

blasting with selective loading This is oneof the most commonly used techniques in

large-scale open-pit mining

A typical blast in the Laiva mine is 50

meters long 100 meters wide and 5 metersdeep After blasting ore and waste aremined by selective loading

After investing some EUR 100 million

the Laiva mine now comprises an open-pit

mine with a modern complete crushinggrinding and processing circuit that ends

with the casting of gold doreacute bars

With a number of mine staff partners

sub-suppliers city and state officials inattendance the Laiva gold mine was offi-

cially inaugurated on August 16 2012

Michael Nilsson Managing Director

of Nordic Mines stressed in his speechthe importance of overcoming challenges

during the building of the mine

ldquoObviously the whole development

took us longer than expected Today weare pleasantly surprised by the size of our

operation We are becoming much bigger

than expectedrdquo gt

Chief Geologist Kimmo Lahtinen presenting narrow gold veins twisting at the Laiva North open-pit mine

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156983145983139983148983141

An international process package

The Metso package for the Laiva gold mine

included the main crushing screening

conveying regrinding leaching and pump-ing elements Metsorsquos office in Sala Swe-

den has served as the main project office

with Metso manufacturing units in FranceGermany Sweden and Finland responsiblefor the equipment supply

At Laiva the gold ore is classified after

selective excavating into two gold con-

tent classes All class A gold ore is takento Metsorsquos sturdy jaw crusher for primary

crushing while the class B ore is stocked for

possible future use After primary grinding

utilizing autogenous technology the ore is

screened and two Metso cones crush the

oversized pebbles For regrinding Metsorsquosball mill is used

During high- and low-grade leaching

processes a number of Metso pumps and

dewatering screens are used The whole

minerals processing system is controlled byMetsoDNA automation

Active exploration drilling going on

According to Mine Manager Tom Soumlder-

man the known gold ore reserves at the

Laiva gold mine amount to 169 million

tons but the potential for additional find-

ings looks good

ldquoWorking at the level of two million tonsper year our expected lifetime is about nine

years We carry out active exploration drill-

ing in Kaukainen Musunneva and Oltava

to locate nearby satellite ore bodies Anupdated detailed mine life plan will be pre-

pared during the autumnrdquo Soumlderman saysNordic Minesrsquo other exploration areas

include Tormua in Finland and Fjaumllltuna

and Vassbo in Sweden

More info

Alf Rydberg

Tel +46 70524 5837

alfrydbergmetsocom

Happy faces during the minersquos inaugural ceremony Mine Manager Tom Soumlderman (left) with Managing Director Michael Nilsson and Deputy Managing Director Krister Soumlderholm

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156

The story behind the discovery of the Laivamine is an interesting one During a hunt-

ing trip in the remote forests of Laivakan-

gas in 1979 Pentti Jaumlmbaumlck found an inter-esting-looking piece of stone Although hecould not see the gold hidden inside the

rock Pentti noticed the striking weight

and somewhat different look of the stone

Upon returning home Pentti sent thesample to Outokumpu which at the time

was the leading state-owned mining com-

pany in Finland After testing a high gold

content of 15 grams per ton was found

Gold deposit founded by a hunter

The founder of the Laiva gold deposit Mr Pentti

Jaumlmbaumlck was the guest of honor during theinauguration

Lennart Schoumlnning Chairman of the Board ofNordic Mines holding a gold doreacute bar worthsome EUR 320000

Outokumpu registered a mining claimon the area and conducted a series of

exploration drilling from 1981 to 1987 Due

to the low price level for gold no mine wasstarted at the time Other mining compa-nies such as Endomines held the mining

rights later

Nordic Mines with its sights set on

locating and exploiting gold in Swedenand Finland was founded in 2005 During

the same year the company purchased its

first mining rights at Laiva

Nordic Minesrsquo Laiva gold mine

LOCATION near the city of Raahe

northwestern Finland

GOLD ORE CONTENT average 16 gt

ORE EXTRACTED PER YEAR

12 million tons (present)

20 million tons (planned)

GOLD RECOVERY 85

TOTAL KNOWN ORE RESERVES

169 million tons

MINING METHOD

Selective open-pit benchingNUMBER OF EMPLOYEES

130 including contractors

METSO MAIN EQUIPMENT

2 Metso VF and 6 EMEG EME

vibrating feeders

8 Screens 1 MF 1 CVB and 6 KS

1 RCS Flash flotation unit

1 Metso SRR ball mill 18 x 4 m

1 Nordberg C160 jaw crusher

1 Nordberg HP100 cone crusher

1 Nordberg HP200 cone crusher

5 Nordberg NB series conveyors

73 Metso Slurry pumps ofvarious types and sizes

8132019 Results Minerals Aggregates 3 2012ENG

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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155

The newest member of the proven GP series cone crushers ndash theNordberg GP220 ndash offers a versatile alternative for any demanding

tertiary or quaternary or even secondary crushing operation fulfill-

ing all crushing needs and maximizing customersrsquo profitability

High-quality components and optimized castings and forgings

contribute to the GP220rsquos enhanced reliability and help to ensurethe highest level of crusher uptime

Thanks to the 200 kW (270 hp) power draw the GP220 performs

at a 20 to 30 percent higher capacity than other cone crusherbrands with an equal head diameter The large feed openingenables the feeding jaw crusher to run at 110 mm css Operational

flexibility is ensured by multiple strokes and six different cavities

Secondary crushing possible

thanks to cavity and stroke options

Thanks to the GP220rsquos cavity and stroke options secondary crush-

ing in addition to tertiary and quaternary stages is also possible

using cavities with a greater intake opening With the GP220 a suit-

able solution for producing excellent end-product gradations

can always be found

With advanced automation using IC50 or IC5000 operation

is safe and trouble-free The low height thanks to the patented

piston design makes replacement installations much easierA dynamic setting adjustment enables a fast response to process

optimization needs

The Nordberg GP220 weighs 10500 kg (23150 lbs) and hasa maximum real feed size of +200 mm (8rdquo) with strokes from

18ndash40 mm (57rdquondash1 47rdquo) The cavity options are EF F MF M C

and EC

A complete modular crusher steel structure is available for allGP series stationary installations including GP220 The platform

includes places for the lubrication unit motor automation or

pressure accumulator and pressurized sealing The only things

left to add are the feed and discharge conveyors

Main new features of the GP220 Large feed opening allows for secondary stage operation

Longer setting range of main shaft for better wear parts utilization

Stronger main components to carry high loads with a powerdraw as high as 200kW

More info

Hannu Vakkuri

Tel +358 50 317 0638

hannuvakkurimetsocom

Thanks to the large feed opening and wide selection of strokes and cavitiesthe new Nordberg GP220 cone crusher is a highly versatile cone novelty

More versatility with the newNordberg GP220 cone crusher

Reinforced head and frame castings combined with a 200kW power

draw make the GP220 cone a reliable crusher with maximum productivity

8132019 Results Minerals Aggregates 3 2012ENG

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Metsorsquos HRCtrade takes high pressure grinding roll technology to the next level

The new Lokotrack mobile conveyors come as tracked and wheeled models

Metsorsquos latest development in comminution equipment the HRCtradeis a major step in the profitable application of high-pressure grind-

ing roll (HPGR) technology Metso has made several key innova-

tions in order to increase throughput and decrease the total cost

of operation

Metsorsquos patented Arch frame creates an even gap setting acrossthe width of the tires limiting skewing that can result in downtime

for mining operations This anti-skewing Arch frame also prevents

damage to the roller bearings (caused by misalignment) that canoccur with the traditional HPGR design

Flanges maximize wear life and increase throughput

Used in place of spring-loaded cheek plates the flanges keep thebed of material within the crushing zone and prevent material

from bypassing the tires This enables greater circuit capacity and

increases the overall crushing efficiency

In addition by preventing material from bypassing the tires

even pressure across the width of the tire is better maintained

Distributing the pressure more evenly maximizes the tire life bypreventing a ldquobath tub effectrdquo in which the center of the tire wears

faster than the edgesVictoria Herman Metsorsquos Product Manager for the HRC notes

that this breakthrough design is a response to the growing needs

in the mining industry ldquoEnergy efficiency has been attracting our

customers to HPGR technology for yearsrdquo she says ldquoBut our design

concept increases capacity and crushing efficiency ndash and thatrsquossomething mining companies are always looking to improve onrdquo

The track-mounted Lokotrack CT32 and wheel-mounted Lokotrack

CW32 mobile conveyors offer an ideal solution for applications

that require high stockpile capacity and excellent material transfer

capabilities They also add flexibility to multi-stage crushing andscreening applications enabling easy and fast closed-circuit opera-

tion of mobile units

The conveyor novelties can be used in both mobile and station-

ary installations providing extra stockpiling capacity in situationswhere for example fewer wheel loaders are available

The HRC is ideal for high-tonnage hard rock applications andcan be used as a tertiary quaternary or pebble crusher Currently

several HRC units are in operation around the world ndash with a total

of 6500 operating hours including over 3800 hours in a mininghard rock application The machine does have range within hardrock applications itrsquos been designed for use in diamond iron ore

copper gold platinum and various industrial minerals

More info

Victoria Herman

Tel +1 717 309 1150

victoriahermanmetsocom

Several optional features such as hydraulic folding of tail sections

and dual hydraulic drive for increased throughput are available

The capacity of the CT32 and CW32 is 400 mtph (440 stph)feed size up to 150 mm (6rdquo) belt width 1050 mm (42rdquo) and dis-charge height 9120 mm (29rsquo 11rdquo) The CT32 is fitted with a Caterpil-

lar C2 diesel engine with 38kw (51 HP) power The CW32 is avail-

able for hydraulic or electric use

More info

Kimmo Anttila

Tel +358 50 433 3745

kimmoanttilametsocom

The new HRCtrade combines high crushing pressure and a low circulatingload resulting in the most efficient comminution

When flexibility in stockpiling capacityis required the answer can be foundin the new Lokotrack CT32 and

CW32 mobile conveyors

8132019 Results Minerals Aggregates 3 2012ENG

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Service creates value in ChinaChinarsquos most important gold producing area Yantai in northeastern China supplies more than 16 of the countryrsquos goldproduction each year With the gold market thriving the scale of gold production in Yantai has been expanding constantly

Zhongjia Mining Industry Co Ltd is one of the beneficiaries of this thriving industryTEXT amp PHOTOS Yan Xin

Inspection and maintenance of the HP500 cone crusher conducted by Metsorsquos service engineers

In 2011 Zhongjia Mining Industry pur-

chased a modular crushing and screen-ing system from Metso for its new gold

production project With the cooperation

between the two companies continuously

intensifying Zhongjia Mining Industry

signed an additional one-year Life CycleService (LCS) contract with Metso incorpo-

rating Metsorsquos global knowledge in equip-

ment processes and services

ldquoMetso customized a series of reason-

able service solutions also referred toas Metso Performance Solutions for us

including preventive maintenance services

process improvement personnel training

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155

and a procurement plan for wear parts

These really suit our needs perfectlyrdquo saysShen Yidong the Manager of ZhongjiaMining Industry

Effective preventive maintenanceFor mining corporations the biggestconcern is the economic losses caused by

the shutdown of equipment As a result

preventative maintenance is of vital impor-

tance During the contract period Metsoservice engineers offered 7-day tracking

service on the production site every month

to eliminate potential problems and thus

ensured the stability of the system

parts caused pressure on our working capi-tal which was not favorable for our long-

term developmentrdquo Shen explains

To solve this problem Metso designed

a rational stock plan of wear parts and built

a field warehouse In accordance with theuse and consumption of the liners the field

service engineers complement the stock tomake production and operations run more

smoothlyldquoNow when we need to replace the

wear parts we can use them before pay-

ment This not only simplifies the procure-

ment process but also liberates a largesum of our operating capital which can

be used for other business development

purposesrdquo says Shen

Best partner

ldquoAlthough the LCS contract incurs some

early purchase costs in the long run Metsorsquosprofessional and quality service will improve

the equipment efficiency reduce ourenergy consumption and ensure stable

operations thus generating more prof-

its This is the greatest value for us so the

investment is really worthwhile overall Inthe future we will choose more Metso prod-

ucts and services Taking all aspects into

consideration we believe Metso is the best

partner for usrdquo Shen Yidong concludes

More info

Thomas Bai Tel +86 13801009114

thomasbaimetsocom

ldquoIn the eight months since the contract

came into effect our corporation has notsuffered any financial losses due to equip-

ment breakdown The regular maintenance

has greatly improved the efficiency of our

entire crushing system In addition the

experienced engineers from Metso also

provided onsite training and guidancefor our staff and the tailored training has

greatly enhanced the operating abilities of

our employees and upgraded their overalllevel of competencerdquo says Shen Yidong

More productivity with

less consumption

Metsorsquos service contract focuses on real-

izing the optimum performance of each

process flow After analyzing Zhongjiarsquos

production system Metsorsquos techniciansproposed an adjustment to the closed side

setting of the HP500 for tertiary crushingin order to improve the efficiency of the

downstream fine crushing and milling pro-

cessing by over 10ldquoThe process flow improvement solu-

tions provided by Metso not only increased

the output of our gold concentrates but

also reduced our energy consumption andcostsrdquo says Shen

In the past wear parts procurement

took up a larger proportion of Zhongjiarsquos

total production costsldquoTo avoid downtime caused by the

shortage of wear parts we had to keepeight sets of various wear parts in place

However the cost of having so many wear

Zhongjia Mining Industryrsquos gold concentrates processing plant in China

8132019 Results Minerals Aggregates 3 2012ENG

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0983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

Safe quarrying high-

quality aggregates

8132019 Results Minerals Aggregates 3 2012ENG

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ldquoWe share a similar zero-accident strategy and target with Metso and have successfullyfollowed it Metso has also helped us to meet the strictest end-product quality andcubicity requirements set in Spainrdquo This is how Managing Director Intildeigo Ajuria ofOfitas de San Felices the leading hard rock quarrying company in Spain describesthe cooperation with MetsoTEXT Eero Haumlmaumllaumlinen PHOTOS Ofitas and Eero Haumlmaumllaumlinen

The San Felices quarry is situated in a picturesque mountainous landscapebetween the companyrsquos Rioja vineyards and the Bilbao-Madrid motorway

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Ofitas has pioneered the implementation

of several Metso novelties in the Spanish

market The company was the first to use

efficient large track-mounted Lokotrack jaw plants the unique mobile conveying

system and also the new-generation HP4

cone crushers

Today the company operates twomodern Metso stationary plants one in

Guadix near Granada and the newest one

in San Felices Haro Rioja community Both

quarries focus on refining hard rock by pro-cessing ophite rock into the highest quality

railway ballast asphalt and concrete mix

grades The company has a satellite quarry

near Vitoria in PentildeacerradaBeing situated next to a highway and

the famous Rioja vineyards Ofitas must pay

special attention to environmental issues

To minimize dust problems all conveyors

have special covers attached

Quality durability and service

The cooperation between Ofitas de San

Felices and Metso started back in 1973when the Ajuria family bought the com-

pany whose quarrying activities began in

1919 Intildeigo Ajuria has a clear vision of why

the cooperation has continued withoutinterruption for almost 40 years

long-standing personal relationshipsrdquoAjuria adds

Serving railways asphalt

and concrete producers

The year-old San Felices stationary instal-lation lies hidden in a mountainous area

south of the city of Vitoria in NorthernSpain The new plant replaces an old one

that complicated the extraction of ophiterock Both plants are delivered by Metso

With its two separate production lines

the new plant is able to produce all the

end products required ndash from railway bal-last to the finer grades needed for asphalt

and concrete

Due to lower demand the quarry cur-

rently produces some 4000 tons per day

At full capacity however the plant canreach 8000 tons of production per day

30ndash35 of which consists of railway ballastfor high-speed trains and 65ndash70 of chips

and sand Thanks to the versatile two-line con-

cept connected by transverse conveyors

up to 12 different end products can be pro-

duced Depending on the demand for endproducts the material can be guided either

to the HP4 cone or HP400 cone followed

by a Barmac vertical shaft impactor

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

The ophite feed is fed to the C125 jaw crusher by a sturdy dump truck

The key people running the new San Felicesquarry Mine Engineer Carlos Fernandez (left)Managing Director Intildeigo Ajuria with ProductionManager Julian Perez

ldquoThrough the years Metso machinery

has proven its production capacity and

durability resulting in high-quality end

products A big plus for us has also beenthe quick response time to our process

challenges or servicerdquo

ldquoIn fact our cooperation extends

beyond day-to-day business matters to

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983122983141983152983151983154983156983145983150983143 983154983141983155

Meeting the strictest cubicity demands

The Spanish regulations concerning end-product cubicity are becoming more

demanding The flakiness percentage of

railway ballast must be below 10 and for

asphalt and concrete aggregates less than

15

ldquoWith Metsorsquos HP4 cone and the Barmacvertical shaft impactor we can meet even

the strictest cubicity demands We believe

that our high quality is helping us to sur-vive in the present recessionrdquo notes Mine

Engineer Carlos Fernandez

ldquoWe hope to increase the total extrac-

tion of the three quarries from the present15 million tons per year because our plant

capacity allows more than double thatrdquo

Fernandez adds

More info

Angel Luis Garcia Tel +34 686 94 35 30

angelluisgarciametsocom

In addition to being the leading Spanish

quarry to process hard rock Ofitas de SanFelices also cultivates 34 hectares of vine-yards next to the quarry which is situated

in the famous Rioja wine area

The company has previously sold a

harvest of over 200000 kg of Tempranillo

grapes to local red-wine makers Recentlythe company built its own wine process-

ing plant to process 10000ndash15000 kg of

grapes themselves

Aggregates and wine production

Andoni Ajuria the founder of Ofitas de san Felices (left) with Intildeigo Ajuria the present ManagingDirector tasting wine from the companyrsquos own vineyards

The first vintage wine of Ofitas har-

vested in autumn 2010 is now maturingin oak barrels After maturing for 12 to 15months the wine is called crianza and after

two years it will be granted the classifica-

tion reserva

ldquoWinemaking is not a business but

a hobby for us We give our wine out aspresents and drink it when we meet

our suppliers and friendsrdquo Intildeigo Ajuria

comments

For environmental protectionall of San Felicesrsquos plantconveyors are covered

Ofitas de San Felices quarry

LOCATION Haro near the city

of Vitoria northern Spain

SIZE 100 hectares

ROCK TYPE Ophite with Los Angeles

index of 9ndash10

PRESENT DAILY EXTRACTION 3000 tons

of ophiteNUMBER OF PERSONNEL 30

RESERVES 10 million tons

MAIN END PRODUCTS 0ndash2 mm

2ndash4 mm 4ndash10 mm 10ndash16 mm

16ndash22 mm 25ndash60 mm (ballast)

METSO MAIN EQUIPMENT

VF feeder

C125 jaw crusher

ndash feed size 0ndash800 mm

ndash css 130ndash140 mm

HP400 cone crusher

ndash feed size 80ndash250 mm

ndash css 40 mm HP4 cone crusher

ndash feed size 40ndash80 mm

ndash css 15 mm

Barmac 6150 VSI crusher

4 CVB2060 screens

2 TS32 screens

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Metso Distribution Centers he

Europe (Tongeren Belgium)

France (Macon)

Czech Republic (Přerov)

Austria (Vienna)

2271 d

Brazil (Sorocaba SP)

1014 d

USA (Columbia SC)

1690 d

USA (Waukesha WI)

434 d

South Africa (Vereeniging)

Ghana (Tarkwa)

Meacutexico (Irapuato)

Peru (Lima)

Chile (Concoacuten)

788 d

Sweden ( Trelleborg)

Finland (Tampere)

UK (Rugby)

865 d

Russia (St Petersburg)

Brazil (Parauapebas PA)

206 d

4983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

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In the case of an equipment failure or

a planned service shutdown resuming

production as quickly as possible is crucialEach hour spent waiting for a spare part to

arrive equals money lost Whether the right

part takes 12 or 48 hours to arrive really

makes a difference

The comprehensive and global Metsospare and wear parts service network pro-

vides you with the right part in the right

place and at the right time Our strategi-

cally located Distribution Centers and

Satellite Warehouses are on call 24 hoursa day 7 days a week ensuring efficient

parts replacement near you

Check out the locations of the MetsoDistribution Centers and how many parts

pass through them each day

More info

Marcelo Farah

Tel +55 15 2102 1315

marcelofarahmetsocom

you minimize downtime

Australia (Perth)

746 d

China (Tianjin)

China (Kunming)

China (Shanghai)

393 d

India (Faridabad)

India (Ahmedabad)

India (Hyderabad)

India (Bhubaneswar)

India (Bangalore)

419 d

Russia (Yekaterinburg)

Australia (Newcastle)

New Zealand (Matamata)

983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088

TEXT Sofia Williams

Singapore (Singapore)

Distribution Center Satellite Warehouse

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Following a large investment

in Metso crushing equipmentand services Buena Vista del

Cobre is now expanding the

mine site to include even more

equipment ndash and with thatexpansion comes the need for

more local service resources

Metso and Buena Vista del

Cobre have entered into a Life

Cycle Service agreement forthe plant and construction of a

brand new Metso service hub

is under way in Cananea

New facility new

level of service

The Cananea service hub

which will be up and running in early 2013will support the recent expansion and resur-

gence of Buena Vista del Cobre Initially it

will be a major repair and assembly center

for pumps crushers and screens and will

provide for rubber covering capabilitiesBut the 8000-square-meter facilityrsquos service

offering will be expansive including a con-

signment stock inventory to help serve theminersquos varying needs Metso currently has

50 service team members on site

Although Buena Vista del Cobre was a

key influencer in building the new servicehub this location will also enable Metso to

expand its capabilities and provide local

support to the entire mining community

in northwest Mexico The Cananea hub

will serve a number of major copper and

gold mines in the region including MineraFriscorsquos San Felipe Fresnillorsquos Milpillas and

Grupo Mexicorsquos Mexicana de Cobre

ldquoBuena Vista del Cobre is the biggestcustomer we have in Mexico today and

with this expansion project itrsquos only going

to grow and be strongerrdquo says Felix Forna-

guera Director of Services Mexico CentralAmerica and Caribbean ldquoWith that said the

idea behind the Cananea service hub is to

provide a central location for local support

for all our major customers in the areardquo

Establishing safety

ldquoIt was key to have our support here in

Cananea because the Buena Vista delCobre started from the ground uprdquo saysFelix ldquoWersquove been able to help the cus-

tomer to establish the best in support

service and operations from the very

beginningrdquo And this ground-up approachincluded a major focus on safety

Metso worked closely with Buena Vista

del Cobre to establish the safety proto-

col by which the mine operates Basedon Metsorsquos expertise the safety measures

put in place have enabled the mine to

become strict and efficient in its operations

and maintenance procedures To achievethis Metso worked closely with local andnational authorities to ensure the safety

plan was comprehensive and in accord-

ance with all established legal bodies

The best in regional support

The service hub in Cananea is a prime

example of Metsorsquos focus on providing local

service and support to its customers all

Service shines in Cananea MexicoAfter three years of inactivity the Buena Vista del Cobre mine in Cananea Sonora Mexico has been operational since 2010A mine that was inactive for such a significant amount of time however requires a great deal of support to successfullyrestart the plant and bring it back to an operational and profitable state

TEXT Deanna Lee PHOTO Metso

over the world ldquoWe are the first

company developing this kindof service in northwest Mexicordquo

adds Felix ldquoOur people have

developed a close relationship

with the team at the mine Itrsquosmore than a supplier relation-

ship our guys are inside the

mine living and working thererdquo

In fact this is the model

that Metso is using in servicehubs all over the globe build-

ing modern facilities bringing

teams on site and workinghand in hand with mine

operators The Cananea Service

hub is only the most recent

example of Metsorsquos commit-ment to service and northwest Mexico is

yet another mining hotbed thatrsquos going to

benefit from the companyrsquos support

More info

Felix Fornaguera Tel +52 4621079227

felixfornaguerametsocom

A mining cone serviced by Metso at the Buena Vista del Cobre mine inSonora Mexico

ldquoThe new Cananea service center will be a majorrepair and assembly center for pumps crushersand screensrdquo says Felix Fornaguera Director ofServices Mexico Central America and Caribbean

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

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During the MINExpo exhibition over 1300 people visited the Metso stand

983122983141983152983151983154983156983145983150983143 983154983141983155

Held every four years MIN-Expo consistently grows so

perennial exhibitors like Metso

are challenged with elevating

their presence and drawingin new (and greater numbers

of ) visitors each year ldquoItrsquos not

necessarily a challenge to lsquotoprsquo

our last showingrdquo says Keith

Ference Vice President ofmarketing and communica-

tions North America ldquoThere

are four years between eachMINExpo so we always have

a lot to say and reveal to our

customersrdquo The real challenge

he says is finding an exciting

and dynamic way to deliverthe message ldquoTherersquos so much

to see here so your booth has

to be compelling from the

outside-in and thatrsquos what

we always try to dordquo

Service sets the stage

The Metso booth created buzzin a number of ways and per-

haps the most striking (partly

due to its size) was the live

theater presentation As visitorspassed through the aisles of the show-

room the sights and sounds from Metsorsquos

theater were hard to miss And once guests

entered they were captivated by a short

high-energy video presentation focused

on Metsorsquos service capabilities The message was simple Metso is ldquoyour

local service partner rdquo for all mining and

construction needs The video showed ourservice teams in action all over the world

and the audience came away with an

understanding about Metsorsquos commitment

to service Customers can count on morethan 70 local service centers run by more

than 1700 expert technicians delivering

Metso makes an impact at MINExpo 2012At this yearrsquos MINExpo International nearly 60000 attendees flocked to Las Vegas Nevada the largest turnout in showhistory The visitors ndash mining professionals from all over the globe ndash explored 850000 square feet of showroom spacefeaturing the industry rsquos latest technology equipment products and services They toured the show for three days

seeking the latest and greatest from more than 1800 exhibitorsTEXT Keith Ference PHOTOS Tracey Ford Perry

detailed descriptions andphotos of all of Metsorsquos mining

and construction products and

services The app also provides

digital access to Results and asearchable database of sales

contacts By day three of the

show MetsoMAP had been

downloaded by more than

500 usersIn addition to the app the

booth was equipped with

several LCD screens each con-trolled by Metso experts who

used their iPads to present new

products like the Megalinertrade

and the HRCtrade A featured

presentation on Metsorsquos lineupof energy-efficient comminu-

tion equipment including the

VERTIMILLreg SMD and MP-1250

cone crusher was also avail-

able letting customers seehow Metso technology delivers

some of the worldrsquos most effi-

cient size reduction

Measuring MINExpo success

After a very busy three days

(on top of months of prepara-tion leading up to the show) everyone

involved with MINExpo ndash from the North

American marketing team responsible for

the booth to the product managers and

sales force that worked the floor ndash is view-

ing the show as a success ldquoTherersquos alwaysa sigh of relief after each (MINExpo)rdquo says

Keith ldquoAnd overall the initial feedback

and response has been very positiverdquoWith more than 1300 visitors to the

booth Metso certainly made an impact

ldquoWe learn a lot from each show and with

some time wersquoll have a better understand-ing of the tangible results of our effortsrdquo

Keith adds

reliable service for mining equipment as

well as customized cost-effective life-cycle

services contracts

Technology ndash MetsoMAP

is an industry firstMINExpo provided the industry with its firstglimpse of Metsorsquos revolutionary iPad app

MetsoMAP The app was demoed to the

boothrsquos visitors via ldquothe worldrsquos largest iPadrdquo

a custom-made 80-inch screen that show-cased all of its capabilities most of which are

groundbreaking in the industry MetsoMAPrsquos

simple interface is highly intuitive making

it easy to view process animations videos

The presentation of the new HP cone crusher attracted a large audience

8132019 Results Minerals Aggregates 3 2012ENG

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When yoursquore allowed less than a dozen days per year for breakdowns repair andmaintenance every single hour during a service shutdown counts There simplyisnrsquot any room for surprises Thatrsquos why Boliden counts on MetsoTEXT amp PHOTOS Sofia Williams

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Kurt Kalla Site Managerof Metso Gaumlllivare ServiceCenter is responsible forthe maintenance of Aitik

Metso and Boliden Strivingtogether for 97 uptime

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983122983141983152983151983154983156983145983150983143 983154983141983155

One of the biggest copper mines in

Europe Bolidenrsquos Aitik is located deep inthe wilderness of Swedish Lapland next to

the small town of Gaumlllivare The mine has

been operating since 1968 and a recent

expansion has increased its annual ore

production to 36 million tons

But the ambitious Swedes are not will-ing to lay back and relax just yet Bolidenrsquos

new aim is to reach a production rate of

45 million tons of ore per year in AitikAfter that Perhaps more than 55 million

tons The ore concentration in Aitik is very

low-grade with a mere 022 copper con-

tent hence the need for high capacityAchieving the ambitious production

goal requires maximum plant availability

This means that everything from the crush-

ers to the filters must be up and runningfor approximately 97 percent of the time

Thatrsquos where Metso comes into play

A cost-per-ton contract in action

The maximum uptime requirement allowsless than a dozen days per year for break-

downs repair and maintenance at Aitik

Every single hour during a service shut-

down counts There simply isnrsquot any roomfor surprises

Executing a successful shutdown under

such conditions requires a reliable service

partner not afraid of challenges and this iswhy Boliden has entrusted Aitikrsquos services

operations to Metso Boliden and Metsohave worked together since the 1960s

and the collaboration took another step

forward in September 2012 when the twocompanies signed a three-year extension

of the services contract for Boliden Aitik

ldquoThe new contract is a cost-per-ton

agreement We get paid based on Aitikrsquos

production Itrsquos a win-win deal for both par-

ties but also a new mindset for usrdquo explainsKurt Kalla Site Manager of Metso Gaumlllivare

Service Center responsible for serving Aitik

From now on the duration of the shut-down is what matters the most According

to Kalla the Metso service organization in

Gaumlllivare is now streamlining its operations

to fit the bill and has already witnessed thestrategy working In August 2012 Metso

carried out a 188-hour service shutdown in

Aitik which turned out to be a success

Zero tolerance for injury

One key factor to the success was theextensive planning of precautionary health

safety and environment procedures under-

taken by Metso prior to the shutdown Thanks to strict measures applied no

injuries or accidents occurred during the

shutdown and the work could easily be

finished on scheduleMats Johansson Health Safety

and Environment Manager for Metso in

Sweden explains how this was achieved

rdquoPlanning of the shutdown included arisk analysis for all new tasks participating

in Bolidenrsquos safety coordination meetingsmeeting with both Metso supervisors and

subcontractor supervisors and finally a

meeting with the entire staff participating

in the shutdown where everyone had to

sign a document stating their commitmentto the information providedrdquo he says

During the actual shutdown plenty of

new barriers signs and awareness cones

were put in place as a result of observa-tions from previous audits and safety plans

and risk analyses were readily available

in the work area Metso and Boliden also

introduced a Mill Inching permit a certifi-cate for completing a mandatory course for

those involved in the process In addition

Metso carried out random safety audits

during the shutdown to make sure thestrict policy was followed

According to Boliden Metsorsquos way of

working is a good example of how health

and safety precautions should be handled

ldquoMetso is a good example of how towork with safety and health plans risk

analysis permits and welding permits

Their table with all binders in the second-

ary mill area was exemplaryrdquo says Kjell-Arne

Johansson a technician from Boliden

The use of the new Metso Megalinertrade

system in the lining of Aitikrsquos Metso AG

mills has also improved the safety of main-tenance staff The Metso Megalinertrade con-

sists of larger-than-average liners bolted

in position from outside the mill Mainte-

nance technicians no longer need to go

inside the mill and stand in the dangerousdrop-zone of the liners gt

Boliden aims to reach a production rate of 45 million tons of ore per yearin the Aitik mine site

ldquoA complete risk analysis was conducted during the planningof the shutdownrdquo comments Mats Johansson Health Safetyand Environment Manager for Metso in Sweden

8132019 Results Minerals Aggregates 3 2012ENG

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Service the Metso way

24 hours a day 365 days a year

In addition to paying close attention to

health and safety issues executing an effi-

cient shutdown requires careful planning

and timing of every step in the mainte-

nance process Wear and spare parts have

to be available on time and a repair shoplarge enough to accommodate equipment

located close by

ldquoTo keep maintenance breaks as short

as possible we aim to replace the pump on

site and bring the old one for repair to our

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

nearby facilities This method gives us the

peace to do a good job and keep the cus-

tomerrsquos operations runningrdquo Kalla describes

the Metso way of handling Aitikrsquos pump

maintenance

Metso is currently expanding its Gaumllli-

vare service center to include a distribu-

tion center for wear and spare parts andalso concentrating its previously scattered

operations under one roof in its Vuoskon-

jaumlrvivaumlgen facility The expansion is due to

be completed by 2014

Metso equipment

delivered to Aitik36

bull 2 AG mills diameter 116 x

137 m gearless 22-MW motor

bull 2 Pebble mills diameter 91 x

113m dual 5-MW pinion drive

bull 3 VPA pressure filters VPA 1540-54

bull 12 sample pumps and pipes

VF50

bull 60 Various slurry pumps up to

MR500 modelbull Appr 5000 m rubber-lined slurry

pipes up to 600 mm diameter

bull Appr 5000 m rubber-lined by

gravity pipes up to 600 mm

diameter

bull Appr 5000 m rubber hoses

up to 600 mm diameter

Not only does the expansion make ser-

vice shutdowns at Aitik run more smoothly

it guarantees a more comprehensive

on-call emergency service response in the

region ndash thanks to the spare and wear parts

inventory available 24 hours a day 365

days a year

More info

Lars Rosenling

Tel +46 70 107 45 90

larsrosenlingmetsocom

Metso grinding equipment dominates the view in the concentrator

Safety on site is made up of small things like

making sure that everyone remembers to secure

the hoses in place

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983122983141983152983151983154983156983145983150983143 983154983141983155

Pebbles have always been a

challenge for producers of sandsince they cannot be returned

to rivers after extraction For

decades the processing of this

material resulted in a huge

environmental liability with alarge amount of pebbles hav-

ing to be stored away and left

unused

Transforming problems into

business opportunities

Areia amp Cia (areia = sand) has

operated in this market forover 20 years and decided to

enlist the help of Metso to find

a profitable solution for the

processing of pebbles

In July 2011 analyses werebegun to assess the abrasive-

ness and crushability of the

material Four alternatives wereidentified for processing and

transforming pebbles into sand

Initially Areia amp Cia was

interested in acquiring an

impactor for its reason-able price level However the

customer wanted to process

all the pebbles that were col-

lected daily in addition to some of the

material that it had stored In weighing theresults expected by the customer and the

excessive abrasiveness of the material the

HP200 cone crusher was decided on as thebest alternative

Areia amp Cia made the required invest-

ment and after using the HP200 for just

six months the company has already beenreporting outstanding results The HP200

not only transforms pebbles into sand but

also produces sand of excellent quality

with high yield and low maintenanceWith minor adjustments the HP200

also enables the production of sand withspecific particle size distribution for special

applications such as filtering sand blasting

and foundry sand adding value to the prod-

uct and increasing the types of sand offeredldquoMetso is pleased that the HP200 not

only enabled the processing of a product

that had been set aside as unusable but

HP200 cone transforms pebblesinto high-quality sandOver the last few decades Brazilian economic growth has been driving demand for construction aggregates The market

for sand in turn has been experiencing major difficulties in maintaining a consistent supply Presently one of the mainchallenges the industry faces is the large amount of pebbles that are obtained in the process of extracting sand at timesconstituting nearly 50 of the volume of material dredged from riverbeds

TEXT Sheila Ivers PHOTO Areia amp Cia

also that it opened up new

market opportunities for Areiaamp Cia Thatrsquos the standard we

seek to deliver to our custom-

ersrdquo states Luiz Oliveira Techni-

cal Salesperson of Metso Brazil

HP cones entering the

Brazilian sand-making

market

Todayrsquos cones such as theHP200 have high resistance

to impacts and abrasiveness

more efficient crushing cham-

bers low maintenance costsand excellent productivity

Following the acquisition of

the HP200 Areia amp Cia is now

also producing special sands

that command a price that is100 higher than common

sand The entire stockpile of

pebbles accumulated through-out the companyrsquos 20 years of

operations has already been

transformed into sand and the

stock of pebbles held by com-

petitors is also being purchasedfor processing

Cristiane Brizolari the

owner of Areia amp Cia confirms

the transformation that has taken place in

the production and commercial processldquoThe HP200 opened up new niches in

the market enabling the production of dif-

ferent types of sand with added valuerdquo

More info

Luiz Oliveira

Tel +55 011 9971 3603

luizoliveirametsocom

After the pebbles are crushed into sand with the HP200 cone crusherdifferent grades are screened for various end uses

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Where therersquos a will we dig a wayAFCONS-Strabag and Metso embark on tunnel project together

When the joint venture AFCONS-Strabag initiated work on the Rohtang bypass tunnel project at an altitude of 3980 metersabove sea level in Himachal Pradesh India they deliberated each aspect with clockwork precision The project involved anumber of surprises and challenges and required technology and project management skills that were second to none

TEXT amp PHOTOS Monisha Majumdar

Cutting a 10-meter-wide and nearly 9-kilo-

meter-long tunnel through the Himalayas

in one of the toughest terrains and cli-mates in India makes for quite a challengeResults set out to find out how AFCONS-

Strabag and Metso are making their way in

one of their most critical projects to date

The only road connection to the north-Indian border region of the province

Himachal-Pradesh and beyond the Manali-

Leh highway leads across the Rohtang

pass Due to the heavy snowfall and high-

velocity winds in this region the towns

located north of the pass are cut off from

the rest of the country during winter for atleast four often even six months each year

A tunnel with strategic importance

With the construction of the tunnel at

3100 m above sea level the Manali-Lehhighway will become an all-weather road

thereby enabling a significant improve-

ment in the economic development of

northern Himachal-Pradesh and an alter-

nate route to the strategically important

Ladakh region

Manali south of the pass is an alreadywell-developed tourist location that is

becoming more and more popular Upon

completion of the tunnel it is likely that

tourist activities will extend to the areanorth of the pass Moreover the tunnel

shortens the distance between the towns

of Manali and Leh by approximately 45 km

thus saving several hours on the small dan-gerous pass road

The Rohtang pass in the Western Himalaya

region of Northern India with its altitude ofalmost four kilometers ranks among thehighest trafficable passes in the world

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983122983141983152983151983154983156983145983150983143 983154983141983155

The 88-km long horse-shoe-shaped

tunnel provides space for a two-lane8-m-wide carriageway as well as a one-

meter-wide footpath on both sides A

22-m-high and 36-m-wide emergency

tunnel will be integrated in the tun-

nel cross-section Altogether more than

800000 msup3 of rock will be moved Tunneling works started around spring

2010 with excavation driven from both por-

tals As the north portal is inaccessible dur-ing winter closure the excavation focused

on the south After a planned construction

period of 55 years the tunnel is scheduled

to be completed by the end of 2015

Best man for the job

The BRO (Border Road Organization)

wanted to roll out a global tender for theproject due to the challenges that such a

project involves and also considering thatitrsquos the first time in India that a project of

this scale was to be carried out This imme-

diately triggered the need to roll out aglobal tender All major Indian construction

companies bid for it some individually and

some in partnerships

Strabag an Austrian tunnel specialistwas one of the companies who bid for the

project along with AFCONS a Mumbai-

based infrastructure company In Septem-

ber 2009 AFCONS-Strabag was awardedthe contract

Mr Sunil Tyagi Deputy Project Man-ager at AFCONS had this to say about the

unique projectldquoThis project is located in the Himalayas

and as far as we understand the terrain

there is among the toughest We came out

with a new technology and to be honestit is a fairly simple one We would generally

start with the traditional technology of drill-

ing and blasting and then obtain our muck

feed from the inwardbottom of the tunnelrdquo

ldquoThe technology is supplied by Rowa Tunneling Logistics and this is the first

time it is being used in Asia A jaw crusheris placed at a distance of about 40-45

meters behind the face The blasted muckextracted from the face is fed to the crusher

to reduce the lump size and then through

an overhead conveyor transport system

it is then transported out of the tunnelrdquoldquoThis enables free movement of man

and machinery in the lower area or spe-

cifically on the ground area If we were to

conforms to the Indian standard for fines amp

coarse aggregates as prescribed in IS383-1970

The plant was up and running in good

condition and performing to AFCONSrsquos

satisfactionldquoWe have worked with Metso in earlier

projects and are quite impressed by thekind of technology amp services they provide

We have a history together so the trust fac-tor also comes inrdquo explains Dhiman on their

choice of Metso as a partner

Service makes the difference

ldquoMetsorsquos services have made a big dif-ference in the project Without them we

would still be struggling with the machin-

ery and production The service is really

good and the service engineers are knowl-edgeable prompt and quick to act Any

problem can be solved by Metso We donrsquothave to wait until a service engineer turns

up ndash they have the capacity to solve prob-lems over the phone as wellrdquo says Dhiman

ldquoThe Metso plant didnrsquot create any prob-

lems for us We had problems in logistics

the feed was sticky and the weather condi-tions were bad but thankfully we did not

face any problems with production and

efficiency as the Metso plant is performing

very wellrdquo Dhiman concludes

More info

Amol Sinha Tel +91 9811 671 924

amolsinhametsocom

use the old conventional technology this

wouldnrsquot have worked for us in the stipu-lated timerdquo Mr Tyagi adds

When the going gets tough

partner with the toughest

Sensitive projects require the best technol-

ogy After AFCONS-Strabag landed theproject Metso was an obvious choice as a

technology provider not only because of

the long-standing business relationshipbut also for the sheer consistency in prod-

uct quality and service deliverance Metso

strives for

ldquoAfter signing the project we faced alot of road blocks including extreme cold

avalanches roadblocks less oxygen ndash you

name it we faced itrdquo explains Ankit Dhi-

man Plant Manager at AFCONS-Strabag The Rohtang valley is known for its

notorious avalanches and landslides SoAFCONS had to take extra steps and safety

precautions against hazards on the site

ldquoIn this freezing cold not just us humansbut also the machines are at increased risk

of damage I remember when we used

to run the plant during winter the diesel

engines would freeze We had to constantlyheat up the fuel container to get the plant

running And even the sand in the sand

trap would freeze so we had to clean it on

a daily basis to stop the pipes from mal-functioningrdquo Dhiman adds

Plant designed for difficult terrain

Difficult terrain coupled with space con-straints led Metso engineers to put their

minds together to come up with a suitable

plant configuration After studying the

requirements of the project Metso sug-

gested a 150-tons-per-hour three-stagemodular plant using a C106 jaw crusher

a GP11F secondary cone crusher and a

B7150 tertiary vertical shaft impact crusher

In addition considering the unpredict-ability of the feed the plant was about

to reach a point where the amount offines to be handled could be increased

dramatically Metso strongly suggested the TK11-27-3V grizzly scalper and this became

the first-ever TK scalper to be supplied by

Metso to an Indian customer Also in order

to get better products a sand trap SF2360was added to the configuration

The sand trap is important equipment

for this project as it washes the sand thatMr Sunil Tyagi Deputy Project ManagerAFCONS-Strabag

8132019 Results Minerals Aggregates 3 2012ENG

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Smooth transition to new-generation jaw crusher in Germany

Roumlhrig is a German company with a rich heritage The company has been quarrying granite at its plant in Bergstrasse inthe Sonderbach district of Heppenheim for three generations

TEXT amp PHOTOS Ralf Goffin

Roumlhrigrsquos superior product variety is onereason why the companyrsquos proximity to its

customers can be understood in more than

just physical terms The companyrsquos high

level of innovation has allowed it to estab-lish itself as a reliable supplier of materials

both regionally and internationally This

operational and technical expertise always

manages to keep in step with growing

market requirements

In terms of technical processing equip-

ment Roumlhrig has used a Nordberg C160stationary jaw crusher from Metso since

1992 At the start of 2012 it was finally

exchanged for a more up-to-date version

from the same model range

Metsorsquos C Series is specifically designed

to pre-crush hard rock and can cope effort-

lessly with even the hardest of materials

The dimensions of the new stationary jawcrusher are identical to those of the old

one which means that it could simply be

slotted into the housing vacated by the

previous version

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983122983141983152983151983154983156983145983150983143 983154983141983155

Third-generation Managing DirectorMarco Roumlhrig expects the new machinersquos

service life to be just as long as the previ-

ous model due to the product upgrades

that have been implemented The integral motor base is another plus

point in models made by other manu-

facturers it is located outside the crusher

This element of good fortune ensured that

Roumlhrig could reuse the housing withoutany additional rebuilding

Another advantage lies in the revision

of the guards for the C160rsquos drivetrain andflywheel The sturdier construction method

used for the crusher requires fewer parts

which facilitates easier installation andmaintenance and it makes it simpler to

access the motor

Under the watchful eye of Metsorsquos

Assembly Manager Maik Engelstaumltterthe entire project including removal and

installation was successfully completed

within two weeks

Installation making the most

of the available space

Roumlhrig will likely remember the day the

new crusher was installed for a long time

the pitman and main frame were deliveredseparately prior to installation and assem-

bled on site It took just one hour to replace

the old stationary crusher with the new

model A lorry-mounted crane was used toposition the 85-ton crusher with millimeter

precision in the crushing plant Once the

new crusher had been positioned in theexisting steel structure the next task wasto fix it into place as securely as possible

despite the limited space Special vibration

dampers were installed at a height of two

meters to prevent the crusher from sliding

Norbert Ried (fourth from left) installed thenew C160rsquos predecessor 20 years ago and isdelighted at the durability of the powerfulcrusher that is now making way for a newermodel Also pictured from left to right ManagerVolker Angermann Assembly Manager Maik

Engelstaumltter Technical Manager Stefan

Koob Project Manager Dominic SchoumlnhardtManaging Director Marco Roumlhrig Service

Technician Stefan Kolze and employees ofthe installation company Stafemo

On the hook after theold C160 was liftedout by crane the newcrusher was installedin almost no timeOnly the roof of thehousing had to beremoved

sideways off its mount An initial test run

with materials was carried out around oneweek later after all the electrical cables had

been installed

Simultaneously with the installation

of the C160 which is the first of the latest

generation of crushers to be installed in

Germany a new Nordberg GP100 conecrusher was also being installed in Roumlhrigrsquos

chipping plant Roumlhrig is convinced that

the technical improvements made tothe new Metso crusher can only be an

advantage worldwide

Roumlhrig places great value on consistent

product quality maximum added valueand optimum refinement of its product

range Bearing in mind that Roumlhrig has

enough reserves of raw material to last

for the next 150 years the company canconfidently continue to develop with an

emphasis on quality rather than quantity

More info

Dominic Schoenhardt

Tel +49 (0)621 727 00 610

dominicschoenhardtmetsocom

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Groupe Charier Carriegravere de la Mariais France

Quarrying with certi1047297ed quality The Charier Group with its 1600-strong workforce is a family business thatthis year celebrates 115 years of quarrying The company pursues a long-termdevelopment policy that since 2007 has seen processing installations upgradedat 4 of its 9 extraction sites

TEXT Liliane Boutin (with extracts from Mines amp Carriegraveres and Terrassements amp Carriegraveres magazines)PHOTO Baloon photo

The processing installation is of the horizontal type with a primary station located 56 meters below the site access road to keep it hidden from view

The crushing and screening installation at

Charierrsquos CM La Mariais quarry (at Donges

on the Loire estuary) has been in opera-tion since September 2011 Based on theoperatorrsquos ideas it was designed by Metso

to replace a worn-out installation installed

right on top of the seam being extracted

Since its commissioning it has becomethe second quarry in the company to

receive ISO 14 001 certification

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983122983141983152983151983154983156983145983150983143 983154983141983155

tertiary material of sand and gravel for the

local market to use in concrete surfacingprefabrication etcrdquo

Incorporation of a screening station

The stone extracted from La Mariais is

according to the quarry granitic gneiss

sound and homogeneous with a LosAngeles index of 15 good wear resist-

ance with an MDE of 10 a true density of

265 and a certain abrasiveness (2000 gt)ldquoCharacteristically it has a tendency to form

blocksrdquo Leblin points out

The main criteria in designing the instal-

lation was to provide an output of 600000metric tons from one station (38 hours

week) to produce materials aimed at the

concrete and surfacing markets ldquowhich

involved providing a tertiary station withscreening plantrdquo he adds

With this new unit the operating com-pany expands its product range through

the addition of fine materials obtained

from the tertiary screening station This unitis capable of producing 170 tonshour of

020

Preserving the environment

and optimizing safety

The screens have motorized bogies and

retractable walkways to facilitate access

when the screens are opened for main-tenance Other walkways provide access

to the tunnel input feeders The feederscan be isolated with hydraulic rod gate

bars this hydraulic assistance eliminatesthe need to use a heavy hammer to lodge

these metal bars

All conveyors transporting fines (02

and 04) are covered with a tarpaulin to

avoid flying dust and all the screens arehooded (metal cover with Trellex seal-

ing) The Brunone company has installed

dust-tight containment at the outlet of the

tertiary station crushers (HP300 and HP4)on the belt located under the screens

and under the hoppers located belowthe tertiary screens The crushers are put

under negative pressure and the finesare extracted through sleeve filters (7000

m3 h) with declogging which deposits the

dust back onto the conveyor belt

A high-pressure 100 bar water mist sys-tem has been installed at the primary sta-

tion discharge at the secondary crusherrsquos

discharge chutes (Omnicone) and at the

transfer points on the belt

Designed to last

ldquoThis type of new installation can easily last

thirty yearsrdquo affirms Project Leader Bruno

Peix of Metso ldquoIt quite simply depends on

how well it is maintained Thatrsquos why weprovide maintenance contracts that call for

our technicians to make regular inspection

visits and carry out preventive mainte-nance and any necessary repairsrdquo

In 2011 Metso commissioned about

10 new processing units in France like

the one at La Mariais quarry

More info

Frederic Bazire

Tel +33 (0)681442804

fredericbaziremetsocom

Key figures

DURATION OF WORKS 15 months

DRAWING OFFICE TIME 7800 hours

HEIGHT OF SILOS AND GRINDER BUILDINGS

15 m

TOTAL LENGTH OF CONVEYORS 14 km

WEIGHT OF THE INSTALLATION

1200 metric tons

CONCRETE POURED 1800 cubic meters

PROJECT SITE WORKFORCE 30

INSTALLED POWER 2200 kW(not including pumps 200 kW)

METSO EQUIPMENT

Primary

Vibrating feeder PF561-2V

Primary grizzly VG540-3V

Grizzly feeder TK13-20-3V

Jaw crusher C145 with

hydraulic setting

Secondary

Vibrating screen CVB 2050

refurbished

Cone crusher Omnicocircne 1352 SX

with Metso IC7000 controller Ellivar 16 (16 msup2 3 decks) screen

refurbished by Metso

Tertiary

Cone crusher HP300

Cone crusher HP4

2 Ellivar 20 screens (20 m23 decks) for final products

Expanding the production range

ldquoSince the mid-1990s when we became

owners of La Mariais we had used mobilemachinery with an assembly of beltconveyorsrdquo recalls Daniel Leblin Charierrsquos

Technical Manager for site construction

and maintenance

ldquoIt became clear that we needed ahigher performance tool to achieve the

dual goals of reaching one million metric

tonsrsquo maximum production and producing

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Big Lokotrack LT550GPF boostsquarrying productivity by a thirdMaximizing the productivity of operations is a key issue when striving for cost-effective quarrying Big Lokotracks are oneway to achieve improved operational efficiency The Lokotrack LT550GPF equipped with the high-volume GP550 conecrusher and a large screen is popular in the Nordic countries and in Germany and Australia ndash countries all known for theirhigh quarrying volumes

TEXT amp PHOTOS Eero Haumlmaumllaumlinen

Kone-Kostamorsquos new mobile coneplant has reached an averagecapacity of 300 tons per hour

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983122983141983152983151983154983156983145983150983143 983154983141983155

ldquoWith the same number of employees we

can achieve 30 more productivity with

our new LT550GPF unit The high-capacityFS screen has also eliminated the bottle-neck often seen at fine screeningrdquo says

Aarno Kostamo Managing Director of

Kone-Kostamo Oy one of Finlandrsquos biggest

crushing contractorsAccording to Kostamo the high capacity

of the GP550 gyratory cone crusher easily

handles feed from the C120 and C125 jaw

crushers For the contract with the Talvivaara

nickel mine the LT550GPF is being fed bythe brand new Lokotrack LT120 jaw plant

Average capacity 300 tons per hour

Talvivaara Europersquos largest nickel mine uti-

lizes large quantities of aggregates Kone-Kostamo has contracted several million

tons of different end products for the mineIn August 75000 tons of 0ndash63 mm

road gravel was crushed Smaller amountsof finer 0ndash6 mm 0ndash16 mm and 0ndash32 mm

aggregates are also being produced

The rainy summer increased the need

for road gravel along the muddy roadswhich must endure dump trucks weighing

as much as 260 tons

ldquoThe mobile process consisting of the

LT120 jaw plant and LT550GPF cone plant

is cost-effective while aggregates of vari-ous sizes can be produced in a two-stage

operation and with high capacity The con-trolled stroke and elliptical movement of

the FS screen secure big passing throughcapacitiesrdquo Kostamo explains

Operated in two shifts for a total of 16

hours per day the LT550GPF has logged

more than 600 working hours over a two-month period

Managing Director Aarno Kostamo (left) and foreman Karri Maumlenpaumlauml studying the cavity optionsavailable for the new Lokotrack LT550GPF

Longer perspective than

a single quarter needed

Kone-Kostamo Oy was founded as an

earth-moving company in Kemijaumlrvi

Northern Finland in 1956 The company

expanded its operations to include crush-

ing contracting in 1964 and later on

switched to concentrating fully on crush-ing activities

Kone-Kostamo consistently crushes

and screens around 28 million tons ofaggregates annually and has net sales of

between EUR 8ndash9 million

ldquoWe believe that issues within the crush-

ing industry including the purchasing ofmachinery must be studied with a longer

perspective than a single quarter The

secret to our success has always been our

solid work ethic and professional employ-eesrdquo Kostamo sums up

More info

Esa Berg

Tel + 358 40 837 8692

esabergmetsocom

8132019 Results Minerals Aggregates 3 2012ENG

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Monitoring-based reporting is vital for

assessing the performance of a mobile

crushing plant Metso provides suchreporting tools through its plant-wideautomation system Metso DNA (Dynamic

Network of Applications) with its infor-

mation platform that links all the mobile

crushing and screen units together as oneentity Basically there is a lot of measured

real-time information available in every

crushing plant On-line information is

obtained either from each Metso crusherrsquosmachine automation system IC (Intelligent

Controller) or from separately installed

additional sensors and belt scales

All the collected data is sent to a motorhome using wireless communication

based on WLAN technology The motor

home is a purpose-built environment

inside an on-site container In this environ-ment selected variables can be monitored

for assessing the plantrsquos performance And

to make all this even more flexible the

data can be transmitted to a crushing plant

company office using GPRS3G mobile

data communication technologies Thismakes all the last-minute reports acces-sible to the crushing plant managerial staff

at anytime and basically anywhere within

reach of the cell phone network

Production and fuel economics reports

Essentially monitoring and reporting can

be customized to fit the customerrsquos needs

However there are certain off-the-shelf

reports that provide a lot of useful informa-tion for plant supervision The production

report is one of these Requiring at least one

belt scale for measuring the total produc-tion the production report shows the pro-duction rate (tons per hour) for a selected

reporting period eg a day or a week The

production report constantly keeps track of

the plantrsquos production storing all the datathroughout the plantrsquos life cycle

Performance monitoring and reportingfor a mobile crushing plantTEXT Pasi Airikka PHOTOS Metso

unit during which the unit is running By

storing the availability times between start-ups and shutdowns the crushing plant

operation time (hours per dayshift) can be

recorded analyzed and reported In addi-

tion the availability report can be tailored

to evaluate efficient crushing hours during

which the plant is really working and pro-ducing aggregates Consequently the ratio

(0-100) between efficient crushing time

and total running time can be reported forany selected period of time This boosts

the efficiency of the plantrsquos operations

and results in better productivity

Reports on non-choke

or inadequate feeding

Non-choke feeding to crushers is avoid-

able through smart plant-wide crushingplant controls But estimating its severity in

a systematic manner is not straight-forwardwithout constant monitoring and reporting

The crusher choke feeding report makes

use of the crusher cavity level sensors byanalyzing their level measurements By

calculating average and min-max values

and deviations from the average it can be

shown how often the single crusher suffersfrom non-choke feeding to it

In some cases the bottleneck in the

crushing plantrsquos productivity is the material

feeding to the process In mobile plants thefeeding is human operated and therefore

subject to variations Occasionally the sizeof the human-operated machine simply

does not allow for adequate feeding to thecrushing plant There are specific reports

indicating time periods when the crushing

plant suffers from inadequate feeding

Condition monitoring for

crushers and screens

Machine-specific condition monitoring

focuses on vibrating components in

crushers and screens such as drive shaftbearings safety plate wearings and gears

The low middle and high frequencies ofmonitored components are measured and

supervised in real-time to detect abnor-malities due to slow or fast wear looseness

or imbalance

More info

Pasi Airikka

Tel +358 40 587 2730

pasiairikkametsocom

Condition monitoring provides a view tovibrating crusher and screen components forpredictive equipment maintenance

The daily production report shows the hour-by-hour production trend and distribution chartfor a selected day with min-max average andvariation statistics for comparison

Fuel consumption is always an interest-ing concern The fuel consumption reportgives the fuel consumption of each crush-

ing unit (liters per hour) and their total

consumption (liters per hour) for a selected

reporting period and can track fuel con-

sumption changes over timeCrushing plant availability can be

assessed as well The availability report

calculates time periods for each crushing

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983149983141983156983155983151 983150

for tissue machines The record of 2210

mmin was set on June 1 2012 during a

24-hour production run by the TM 2 tissue

machine at the companyrsquos mill in Yenikoumlynear the city of Izmit in Turkey

ldquoThe cooperation with Metso has been

beyond excellent and both parties did

their utmost to make the project success-ful The results clearly show that the efforts

were worthwhile on both sides This coop-

eration will extend to cover new projects

in the futurerdquo says Luumlt1047297 Aydin Paper GroupDirector Hayat Kimya

ldquoWe are not surprised that Hayat K imya

managed to break the world speed record

We have had great confidence in the capa-bility of the Hayat team since our project

started in 2009 We certainly know our

machine very well its stability production

efficiency and speed capabilityrdquo says Jan

Erikson Vice President Sales Metso

PowerThe worldrsquos first eco-gas fueled

power plant is up and running

Lahti Energy Ltdrsquos new Kymijaumlrvi II gasifica-

tion plant was officially inaugurated on

May 8 2012 It is the first of its kind in the

RecyclingRecycling with Lokotrack LT106

jaw plant in New York

A brand-new Lokotrack LT106 jaw plant is

used in the city area of New York USA to

recycle demolition materials The crushing

site faces the skyscrapers of ManhattanIsland

Paper amp FiberHayat Kimyarsquos Metso-supplied tissue

machine sets world speed record

Thanks to a skilled crew and dedicated

efforts Hayat Kimya AS in Turkey has suc-

ceeded in breaking the world speed record

world This CHP plant runs on clean eco-

gas that is gasified cleaned and cooled

from recycled waste with Metsorsquos innova-tive technology

ldquoItrsquos actually eco-gas that we combust

in the boilerrdquo comments Lahti EnergyrsquosProduction Director Jukka Manskinen

ldquoWe convert unwanted waste material into

energy in an efficient and environmentally

friendly wayrdquoNever before has any plant gasified

waste on such a large scale In the gasifier

recycled waste is turned into combustible

product gas which is cleaned cooled and

combusted in a high-efficiency gas boiler

to produce steam for the steam turbine The plant produces 50 MW of electricity

and 90 MW of district heat for the city of

Lahti and its neighboring areasMetso delivered the circulating fluidized

bed (CFB) gasification process gas cleaning

and cooling steam boiler environmental

protection system and automation systemto the entire plant The production of elec-

tricity and heat is kept even with the Metso

DNA automation system that covers the

whole plant starting from fuel reception

AutomationMetso develops and supplies plant-

wide crushing control solutions for

crushing plants

Metso has recently signed contracts on

delivering plant-wide automation systems

for mobile and portable rock crushing

plants The key objective of these deliveries

is to stabilize and to increase productivityand efficiency of the plants using one sin-

gle automation and information platform

for integrating crusher-specific IC machinecontrols

Furthermore the plant-wide system

with its information management tools not

only increases plant availability and opera-

tional safety it also makes troubleshoot-ing quicker and performance monitoring

easier The control room for plant-wide

operability is located either in an excavator

cabin or a purpose-built container

Metso around the world

The new LT106 jaw plant is suitable for crushing both hard rock and all rock-based demolition materials

The new world speed record for tissue setby Hayat Kimyarsquos Metso-supplied TM 2 is2210 mmin

8132019 Results Minerals Aggregates 3 2012ENG

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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 10: Results Minerals Aggregates 3 2012.ENG

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983110983141983137983156983157983154983141983140 983137983154983156

Increasing capacity makes processing

of lower grades economical

The project to significantly increase the

processing capacity at Pampalo is well

under way with the installation of for

example a second grinding mill and more

flotation cells The expansion will be in

operation during early 2013ldquoThe added capacity also makes it pos-

sible to economically process the nearby

open pits with a lower gold grade In addi-tion it helps us to optimize the crushing

and grinding circuitsrdquo Ekberg concludes

Active exploration drillings have

exposed new mineralized zones furtherextending the lifetime of the Pampalo mine

from the present estimate of 6ndash7 years

More info

Peter Vikman

Tel +358 400 869 845petervikmanmetsocom

Endomines Pampalo gold mine

LOCATION near the community of

Ilomantsi in Eastern Finland

GOLD ORE CONTENT

ndash Pampalo 34 gtndash Hosko 99 gt

ndash Raumlmepuro 39 gt

ndash Muurinsuo 30 gt

PRODUCTION TONNAGE PER YEAR 270000 tons (present)~400000 tons (future)

GOLD PRODUCTION PER YEAR 800ndash900 kg

KNOWN ORE RESERVES IN TOTAL

approx 2 million tons

MINE DEPTH 360 m

MINING METHOD bench cut and fill

NUMBER OF EMPLOYEES

100 including contractors

METSO EQUIPMENT

1 Metso TRN 30 x 48 m

wet ball mill

8 Metso RCS series flotation cells 1 Nordberg MF 1800 x 6100

screen

3 Metso samplers

1 Metso CT thickener

1 Metso TF vacuum filter

33 Metso slurry pumps of various

types and sizes

The gold ore is screened using Metsorsquos MS series mining screen

Markus Ekberg is pleased with the outcome the mine reached the minerals processing utilizationdegree of over 90 just two months after start-up

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156983145983139983148983141

Nordic Mines ndash on track tobecoming one of Europersquosmost prominent goldproducersNordic Mines is the newest member in a long chain of Nordic gold mining operations

Inaugurated in mid-August 2012 this company of Swedish origin aims to become one

of Europersquos most prominent gold producers Metso is one of Nordic Minesrsquo main partners

supplying the Laiva gold mine with crushing screening conveying and minerals

processing equipment at an estimated value of EUR 30 million

TEXT amp PHOTOS Eero Haumlmaumllaumlinen

2983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

The Laiva gold mine was built in record time infrastructure

construction began in spring 2010 ore excavation started in

June 2011 and the first gold bar was casted in December 2011

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156

Just one year after starting the gold recov-

ery process Nordic Mines is on track toreaching a capacity of 5 kg of gold per day

At present the operations are averaging 3

to 4 kg of gold daily

The ore in the Laiva Gold Mine consists

of packages of gold-bearing quartz-filled

shear structures The deposit is more thana kilometer long and 700 meters wide The

total depth is still unknown but dr illings

carried out thus far have shown gold-bear-ing shear structures 300 meters below the

surface

A typical ore zone includes a large num-

ber of thin shear structures from 5 to 30per meter The ore zones are commonly 50

to 100 meters long several are 10 meters

deep and they range from a few meters to

20 meters cross strike The minimum min-ing width is 25 meters which means that

even a minor ore zone consists of at least10 to 50 shear structures

Conventional pattern blasting

with selective loading

Prior to mining Nordic Mines conducts

grade control drilling which provides

dense gold grade information and makes

it possible to outline the boundaries

between ore and waste The mining

technique applied is conventional pattern

blasting with selective loading This is oneof the most commonly used techniques in

large-scale open-pit mining

A typical blast in the Laiva mine is 50

meters long 100 meters wide and 5 metersdeep After blasting ore and waste aremined by selective loading

After investing some EUR 100 million

the Laiva mine now comprises an open-pit

mine with a modern complete crushinggrinding and processing circuit that ends

with the casting of gold doreacute bars

With a number of mine staff partners

sub-suppliers city and state officials inattendance the Laiva gold mine was offi-

cially inaugurated on August 16 2012

Michael Nilsson Managing Director

of Nordic Mines stressed in his speechthe importance of overcoming challenges

during the building of the mine

ldquoObviously the whole development

took us longer than expected Today weare pleasantly surprised by the size of our

operation We are becoming much bigger

than expectedrdquo gt

Chief Geologist Kimmo Lahtinen presenting narrow gold veins twisting at the Laiva North open-pit mine

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156983145983139983148983141

An international process package

The Metso package for the Laiva gold mine

included the main crushing screening

conveying regrinding leaching and pump-ing elements Metsorsquos office in Sala Swe-

den has served as the main project office

with Metso manufacturing units in FranceGermany Sweden and Finland responsiblefor the equipment supply

At Laiva the gold ore is classified after

selective excavating into two gold con-

tent classes All class A gold ore is takento Metsorsquos sturdy jaw crusher for primary

crushing while the class B ore is stocked for

possible future use After primary grinding

utilizing autogenous technology the ore is

screened and two Metso cones crush the

oversized pebbles For regrinding Metsorsquosball mill is used

During high- and low-grade leaching

processes a number of Metso pumps and

dewatering screens are used The whole

minerals processing system is controlled byMetsoDNA automation

Active exploration drilling going on

According to Mine Manager Tom Soumlder-

man the known gold ore reserves at the

Laiva gold mine amount to 169 million

tons but the potential for additional find-

ings looks good

ldquoWorking at the level of two million tonsper year our expected lifetime is about nine

years We carry out active exploration drill-

ing in Kaukainen Musunneva and Oltava

to locate nearby satellite ore bodies Anupdated detailed mine life plan will be pre-

pared during the autumnrdquo Soumlderman saysNordic Minesrsquo other exploration areas

include Tormua in Finland and Fjaumllltuna

and Vassbo in Sweden

More info

Alf Rydberg

Tel +46 70524 5837

alfrydbergmetsocom

Happy faces during the minersquos inaugural ceremony Mine Manager Tom Soumlderman (left) with Managing Director Michael Nilsson and Deputy Managing Director Krister Soumlderholm

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156

The story behind the discovery of the Laivamine is an interesting one During a hunt-

ing trip in the remote forests of Laivakan-

gas in 1979 Pentti Jaumlmbaumlck found an inter-esting-looking piece of stone Although hecould not see the gold hidden inside the

rock Pentti noticed the striking weight

and somewhat different look of the stone

Upon returning home Pentti sent thesample to Outokumpu which at the time

was the leading state-owned mining com-

pany in Finland After testing a high gold

content of 15 grams per ton was found

Gold deposit founded by a hunter

The founder of the Laiva gold deposit Mr Pentti

Jaumlmbaumlck was the guest of honor during theinauguration

Lennart Schoumlnning Chairman of the Board ofNordic Mines holding a gold doreacute bar worthsome EUR 320000

Outokumpu registered a mining claimon the area and conducted a series of

exploration drilling from 1981 to 1987 Due

to the low price level for gold no mine wasstarted at the time Other mining compa-nies such as Endomines held the mining

rights later

Nordic Mines with its sights set on

locating and exploiting gold in Swedenand Finland was founded in 2005 During

the same year the company purchased its

first mining rights at Laiva

Nordic Minesrsquo Laiva gold mine

LOCATION near the city of Raahe

northwestern Finland

GOLD ORE CONTENT average 16 gt

ORE EXTRACTED PER YEAR

12 million tons (present)

20 million tons (planned)

GOLD RECOVERY 85

TOTAL KNOWN ORE RESERVES

169 million tons

MINING METHOD

Selective open-pit benchingNUMBER OF EMPLOYEES

130 including contractors

METSO MAIN EQUIPMENT

2 Metso VF and 6 EMEG EME

vibrating feeders

8 Screens 1 MF 1 CVB and 6 KS

1 RCS Flash flotation unit

1 Metso SRR ball mill 18 x 4 m

1 Nordberg C160 jaw crusher

1 Nordberg HP100 cone crusher

1 Nordberg HP200 cone crusher

5 Nordberg NB series conveyors

73 Metso Slurry pumps ofvarious types and sizes

8132019 Results Minerals Aggregates 3 2012ENG

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The newest member of the proven GP series cone crushers ndash theNordberg GP220 ndash offers a versatile alternative for any demanding

tertiary or quaternary or even secondary crushing operation fulfill-

ing all crushing needs and maximizing customersrsquo profitability

High-quality components and optimized castings and forgings

contribute to the GP220rsquos enhanced reliability and help to ensurethe highest level of crusher uptime

Thanks to the 200 kW (270 hp) power draw the GP220 performs

at a 20 to 30 percent higher capacity than other cone crusherbrands with an equal head diameter The large feed openingenables the feeding jaw crusher to run at 110 mm css Operational

flexibility is ensured by multiple strokes and six different cavities

Secondary crushing possible

thanks to cavity and stroke options

Thanks to the GP220rsquos cavity and stroke options secondary crush-

ing in addition to tertiary and quaternary stages is also possible

using cavities with a greater intake opening With the GP220 a suit-

able solution for producing excellent end-product gradations

can always be found

With advanced automation using IC50 or IC5000 operation

is safe and trouble-free The low height thanks to the patented

piston design makes replacement installations much easierA dynamic setting adjustment enables a fast response to process

optimization needs

The Nordberg GP220 weighs 10500 kg (23150 lbs) and hasa maximum real feed size of +200 mm (8rdquo) with strokes from

18ndash40 mm (57rdquondash1 47rdquo) The cavity options are EF F MF M C

and EC

A complete modular crusher steel structure is available for allGP series stationary installations including GP220 The platform

includes places for the lubrication unit motor automation or

pressure accumulator and pressurized sealing The only things

left to add are the feed and discharge conveyors

Main new features of the GP220 Large feed opening allows for secondary stage operation

Longer setting range of main shaft for better wear parts utilization

Stronger main components to carry high loads with a powerdraw as high as 200kW

More info

Hannu Vakkuri

Tel +358 50 317 0638

hannuvakkurimetsocom

Thanks to the large feed opening and wide selection of strokes and cavitiesthe new Nordberg GP220 cone crusher is a highly versatile cone novelty

More versatility with the newNordberg GP220 cone crusher

Reinforced head and frame castings combined with a 200kW power

draw make the GP220 cone a reliable crusher with maximum productivity

8132019 Results Minerals Aggregates 3 2012ENG

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Metsorsquos HRCtrade takes high pressure grinding roll technology to the next level

The new Lokotrack mobile conveyors come as tracked and wheeled models

Metsorsquos latest development in comminution equipment the HRCtradeis a major step in the profitable application of high-pressure grind-

ing roll (HPGR) technology Metso has made several key innova-

tions in order to increase throughput and decrease the total cost

of operation

Metsorsquos patented Arch frame creates an even gap setting acrossthe width of the tires limiting skewing that can result in downtime

for mining operations This anti-skewing Arch frame also prevents

damage to the roller bearings (caused by misalignment) that canoccur with the traditional HPGR design

Flanges maximize wear life and increase throughput

Used in place of spring-loaded cheek plates the flanges keep thebed of material within the crushing zone and prevent material

from bypassing the tires This enables greater circuit capacity and

increases the overall crushing efficiency

In addition by preventing material from bypassing the tires

even pressure across the width of the tire is better maintained

Distributing the pressure more evenly maximizes the tire life bypreventing a ldquobath tub effectrdquo in which the center of the tire wears

faster than the edgesVictoria Herman Metsorsquos Product Manager for the HRC notes

that this breakthrough design is a response to the growing needs

in the mining industry ldquoEnergy efficiency has been attracting our

customers to HPGR technology for yearsrdquo she says ldquoBut our design

concept increases capacity and crushing efficiency ndash and thatrsquossomething mining companies are always looking to improve onrdquo

The track-mounted Lokotrack CT32 and wheel-mounted Lokotrack

CW32 mobile conveyors offer an ideal solution for applications

that require high stockpile capacity and excellent material transfer

capabilities They also add flexibility to multi-stage crushing andscreening applications enabling easy and fast closed-circuit opera-

tion of mobile units

The conveyor novelties can be used in both mobile and station-

ary installations providing extra stockpiling capacity in situationswhere for example fewer wheel loaders are available

The HRC is ideal for high-tonnage hard rock applications andcan be used as a tertiary quaternary or pebble crusher Currently

several HRC units are in operation around the world ndash with a total

of 6500 operating hours including over 3800 hours in a mininghard rock application The machine does have range within hardrock applications itrsquos been designed for use in diamond iron ore

copper gold platinum and various industrial minerals

More info

Victoria Herman

Tel +1 717 309 1150

victoriahermanmetsocom

Several optional features such as hydraulic folding of tail sections

and dual hydraulic drive for increased throughput are available

The capacity of the CT32 and CW32 is 400 mtph (440 stph)feed size up to 150 mm (6rdquo) belt width 1050 mm (42rdquo) and dis-charge height 9120 mm (29rsquo 11rdquo) The CT32 is fitted with a Caterpil-

lar C2 diesel engine with 38kw (51 HP) power The CW32 is avail-

able for hydraulic or electric use

More info

Kimmo Anttila

Tel +358 50 433 3745

kimmoanttilametsocom

The new HRCtrade combines high crushing pressure and a low circulatingload resulting in the most efficient comminution

When flexibility in stockpiling capacityis required the answer can be foundin the new Lokotrack CT32 and

CW32 mobile conveyors

8132019 Results Minerals Aggregates 3 2012ENG

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Service creates value in ChinaChinarsquos most important gold producing area Yantai in northeastern China supplies more than 16 of the countryrsquos goldproduction each year With the gold market thriving the scale of gold production in Yantai has been expanding constantly

Zhongjia Mining Industry Co Ltd is one of the beneficiaries of this thriving industryTEXT amp PHOTOS Yan Xin

Inspection and maintenance of the HP500 cone crusher conducted by Metsorsquos service engineers

In 2011 Zhongjia Mining Industry pur-

chased a modular crushing and screen-ing system from Metso for its new gold

production project With the cooperation

between the two companies continuously

intensifying Zhongjia Mining Industry

signed an additional one-year Life CycleService (LCS) contract with Metso incorpo-

rating Metsorsquos global knowledge in equip-

ment processes and services

ldquoMetso customized a series of reason-

able service solutions also referred toas Metso Performance Solutions for us

including preventive maintenance services

process improvement personnel training

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155

and a procurement plan for wear parts

These really suit our needs perfectlyrdquo saysShen Yidong the Manager of ZhongjiaMining Industry

Effective preventive maintenanceFor mining corporations the biggestconcern is the economic losses caused by

the shutdown of equipment As a result

preventative maintenance is of vital impor-

tance During the contract period Metsoservice engineers offered 7-day tracking

service on the production site every month

to eliminate potential problems and thus

ensured the stability of the system

parts caused pressure on our working capi-tal which was not favorable for our long-

term developmentrdquo Shen explains

To solve this problem Metso designed

a rational stock plan of wear parts and built

a field warehouse In accordance with theuse and consumption of the liners the field

service engineers complement the stock tomake production and operations run more

smoothlyldquoNow when we need to replace the

wear parts we can use them before pay-

ment This not only simplifies the procure-

ment process but also liberates a largesum of our operating capital which can

be used for other business development

purposesrdquo says Shen

Best partner

ldquoAlthough the LCS contract incurs some

early purchase costs in the long run Metsorsquosprofessional and quality service will improve

the equipment efficiency reduce ourenergy consumption and ensure stable

operations thus generating more prof-

its This is the greatest value for us so the

investment is really worthwhile overall Inthe future we will choose more Metso prod-

ucts and services Taking all aspects into

consideration we believe Metso is the best

partner for usrdquo Shen Yidong concludes

More info

Thomas Bai Tel +86 13801009114

thomasbaimetsocom

ldquoIn the eight months since the contract

came into effect our corporation has notsuffered any financial losses due to equip-

ment breakdown The regular maintenance

has greatly improved the efficiency of our

entire crushing system In addition the

experienced engineers from Metso also

provided onsite training and guidancefor our staff and the tailored training has

greatly enhanced the operating abilities of

our employees and upgraded their overalllevel of competencerdquo says Shen Yidong

More productivity with

less consumption

Metsorsquos service contract focuses on real-

izing the optimum performance of each

process flow After analyzing Zhongjiarsquos

production system Metsorsquos techniciansproposed an adjustment to the closed side

setting of the HP500 for tertiary crushingin order to improve the efficiency of the

downstream fine crushing and milling pro-

cessing by over 10ldquoThe process flow improvement solu-

tions provided by Metso not only increased

the output of our gold concentrates but

also reduced our energy consumption andcostsrdquo says Shen

In the past wear parts procurement

took up a larger proportion of Zhongjiarsquos

total production costsldquoTo avoid downtime caused by the

shortage of wear parts we had to keepeight sets of various wear parts in place

However the cost of having so many wear

Zhongjia Mining Industryrsquos gold concentrates processing plant in China

8132019 Results Minerals Aggregates 3 2012ENG

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0983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

Safe quarrying high-

quality aggregates

8132019 Results Minerals Aggregates 3 2012ENG

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ldquoWe share a similar zero-accident strategy and target with Metso and have successfullyfollowed it Metso has also helped us to meet the strictest end-product quality andcubicity requirements set in Spainrdquo This is how Managing Director Intildeigo Ajuria ofOfitas de San Felices the leading hard rock quarrying company in Spain describesthe cooperation with MetsoTEXT Eero Haumlmaumllaumlinen PHOTOS Ofitas and Eero Haumlmaumllaumlinen

The San Felices quarry is situated in a picturesque mountainous landscapebetween the companyrsquos Rioja vineyards and the Bilbao-Madrid motorway

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Ofitas has pioneered the implementation

of several Metso novelties in the Spanish

market The company was the first to use

efficient large track-mounted Lokotrack jaw plants the unique mobile conveying

system and also the new-generation HP4

cone crushers

Today the company operates twomodern Metso stationary plants one in

Guadix near Granada and the newest one

in San Felices Haro Rioja community Both

quarries focus on refining hard rock by pro-cessing ophite rock into the highest quality

railway ballast asphalt and concrete mix

grades The company has a satellite quarry

near Vitoria in PentildeacerradaBeing situated next to a highway and

the famous Rioja vineyards Ofitas must pay

special attention to environmental issues

To minimize dust problems all conveyors

have special covers attached

Quality durability and service

The cooperation between Ofitas de San

Felices and Metso started back in 1973when the Ajuria family bought the com-

pany whose quarrying activities began in

1919 Intildeigo Ajuria has a clear vision of why

the cooperation has continued withoutinterruption for almost 40 years

long-standing personal relationshipsrdquoAjuria adds

Serving railways asphalt

and concrete producers

The year-old San Felices stationary instal-lation lies hidden in a mountainous area

south of the city of Vitoria in NorthernSpain The new plant replaces an old one

that complicated the extraction of ophiterock Both plants are delivered by Metso

With its two separate production lines

the new plant is able to produce all the

end products required ndash from railway bal-last to the finer grades needed for asphalt

and concrete

Due to lower demand the quarry cur-

rently produces some 4000 tons per day

At full capacity however the plant canreach 8000 tons of production per day

30ndash35 of which consists of railway ballastfor high-speed trains and 65ndash70 of chips

and sand Thanks to the versatile two-line con-

cept connected by transverse conveyors

up to 12 different end products can be pro-

duced Depending on the demand for endproducts the material can be guided either

to the HP4 cone or HP400 cone followed

by a Barmac vertical shaft impactor

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

The ophite feed is fed to the C125 jaw crusher by a sturdy dump truck

The key people running the new San Felicesquarry Mine Engineer Carlos Fernandez (left)Managing Director Intildeigo Ajuria with ProductionManager Julian Perez

ldquoThrough the years Metso machinery

has proven its production capacity and

durability resulting in high-quality end

products A big plus for us has also beenthe quick response time to our process

challenges or servicerdquo

ldquoIn fact our cooperation extends

beyond day-to-day business matters to

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983122983141983152983151983154983156983145983150983143 983154983141983155

Meeting the strictest cubicity demands

The Spanish regulations concerning end-product cubicity are becoming more

demanding The flakiness percentage of

railway ballast must be below 10 and for

asphalt and concrete aggregates less than

15

ldquoWith Metsorsquos HP4 cone and the Barmacvertical shaft impactor we can meet even

the strictest cubicity demands We believe

that our high quality is helping us to sur-vive in the present recessionrdquo notes Mine

Engineer Carlos Fernandez

ldquoWe hope to increase the total extrac-

tion of the three quarries from the present15 million tons per year because our plant

capacity allows more than double thatrdquo

Fernandez adds

More info

Angel Luis Garcia Tel +34 686 94 35 30

angelluisgarciametsocom

In addition to being the leading Spanish

quarry to process hard rock Ofitas de SanFelices also cultivates 34 hectares of vine-yards next to the quarry which is situated

in the famous Rioja wine area

The company has previously sold a

harvest of over 200000 kg of Tempranillo

grapes to local red-wine makers Recentlythe company built its own wine process-

ing plant to process 10000ndash15000 kg of

grapes themselves

Aggregates and wine production

Andoni Ajuria the founder of Ofitas de san Felices (left) with Intildeigo Ajuria the present ManagingDirector tasting wine from the companyrsquos own vineyards

The first vintage wine of Ofitas har-

vested in autumn 2010 is now maturingin oak barrels After maturing for 12 to 15months the wine is called crianza and after

two years it will be granted the classifica-

tion reserva

ldquoWinemaking is not a business but

a hobby for us We give our wine out aspresents and drink it when we meet

our suppliers and friendsrdquo Intildeigo Ajuria

comments

For environmental protectionall of San Felicesrsquos plantconveyors are covered

Ofitas de San Felices quarry

LOCATION Haro near the city

of Vitoria northern Spain

SIZE 100 hectares

ROCK TYPE Ophite with Los Angeles

index of 9ndash10

PRESENT DAILY EXTRACTION 3000 tons

of ophiteNUMBER OF PERSONNEL 30

RESERVES 10 million tons

MAIN END PRODUCTS 0ndash2 mm

2ndash4 mm 4ndash10 mm 10ndash16 mm

16ndash22 mm 25ndash60 mm (ballast)

METSO MAIN EQUIPMENT

VF feeder

C125 jaw crusher

ndash feed size 0ndash800 mm

ndash css 130ndash140 mm

HP400 cone crusher

ndash feed size 80ndash250 mm

ndash css 40 mm HP4 cone crusher

ndash feed size 40ndash80 mm

ndash css 15 mm

Barmac 6150 VSI crusher

4 CVB2060 screens

2 TS32 screens

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Metso Distribution Centers he

Europe (Tongeren Belgium)

France (Macon)

Czech Republic (Přerov)

Austria (Vienna)

2271 d

Brazil (Sorocaba SP)

1014 d

USA (Columbia SC)

1690 d

USA (Waukesha WI)

434 d

South Africa (Vereeniging)

Ghana (Tarkwa)

Meacutexico (Irapuato)

Peru (Lima)

Chile (Concoacuten)

788 d

Sweden ( Trelleborg)

Finland (Tampere)

UK (Rugby)

865 d

Russia (St Petersburg)

Brazil (Parauapebas PA)

206 d

4983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

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983122983141983152983151983154983156983145983150983143 983154983141983155983122983141983152983151983154983156983145983150983143 983154983141983155

In the case of an equipment failure or

a planned service shutdown resuming

production as quickly as possible is crucialEach hour spent waiting for a spare part to

arrive equals money lost Whether the right

part takes 12 or 48 hours to arrive really

makes a difference

The comprehensive and global Metsospare and wear parts service network pro-

vides you with the right part in the right

place and at the right time Our strategi-

cally located Distribution Centers and

Satellite Warehouses are on call 24 hoursa day 7 days a week ensuring efficient

parts replacement near you

Check out the locations of the MetsoDistribution Centers and how many parts

pass through them each day

More info

Marcelo Farah

Tel +55 15 2102 1315

marcelofarahmetsocom

you minimize downtime

Australia (Perth)

746 d

China (Tianjin)

China (Kunming)

China (Shanghai)

393 d

India (Faridabad)

India (Ahmedabad)

India (Hyderabad)

India (Bhubaneswar)

India (Bangalore)

419 d

Russia (Yekaterinburg)

Australia (Newcastle)

New Zealand (Matamata)

983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088

TEXT Sofia Williams

Singapore (Singapore)

Distribution Center Satellite Warehouse

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Following a large investment

in Metso crushing equipmentand services Buena Vista del

Cobre is now expanding the

mine site to include even more

equipment ndash and with thatexpansion comes the need for

more local service resources

Metso and Buena Vista del

Cobre have entered into a Life

Cycle Service agreement forthe plant and construction of a

brand new Metso service hub

is under way in Cananea

New facility new

level of service

The Cananea service hub

which will be up and running in early 2013will support the recent expansion and resur-

gence of Buena Vista del Cobre Initially it

will be a major repair and assembly center

for pumps crushers and screens and will

provide for rubber covering capabilitiesBut the 8000-square-meter facilityrsquos service

offering will be expansive including a con-

signment stock inventory to help serve theminersquos varying needs Metso currently has

50 service team members on site

Although Buena Vista del Cobre was a

key influencer in building the new servicehub this location will also enable Metso to

expand its capabilities and provide local

support to the entire mining community

in northwest Mexico The Cananea hub

will serve a number of major copper and

gold mines in the region including MineraFriscorsquos San Felipe Fresnillorsquos Milpillas and

Grupo Mexicorsquos Mexicana de Cobre

ldquoBuena Vista del Cobre is the biggestcustomer we have in Mexico today and

with this expansion project itrsquos only going

to grow and be strongerrdquo says Felix Forna-

guera Director of Services Mexico CentralAmerica and Caribbean ldquoWith that said the

idea behind the Cananea service hub is to

provide a central location for local support

for all our major customers in the areardquo

Establishing safety

ldquoIt was key to have our support here in

Cananea because the Buena Vista delCobre started from the ground uprdquo saysFelix ldquoWersquove been able to help the cus-

tomer to establish the best in support

service and operations from the very

beginningrdquo And this ground-up approachincluded a major focus on safety

Metso worked closely with Buena Vista

del Cobre to establish the safety proto-

col by which the mine operates Basedon Metsorsquos expertise the safety measures

put in place have enabled the mine to

become strict and efficient in its operations

and maintenance procedures To achievethis Metso worked closely with local andnational authorities to ensure the safety

plan was comprehensive and in accord-

ance with all established legal bodies

The best in regional support

The service hub in Cananea is a prime

example of Metsorsquos focus on providing local

service and support to its customers all

Service shines in Cananea MexicoAfter three years of inactivity the Buena Vista del Cobre mine in Cananea Sonora Mexico has been operational since 2010A mine that was inactive for such a significant amount of time however requires a great deal of support to successfullyrestart the plant and bring it back to an operational and profitable state

TEXT Deanna Lee PHOTO Metso

over the world ldquoWe are the first

company developing this kindof service in northwest Mexicordquo

adds Felix ldquoOur people have

developed a close relationship

with the team at the mine Itrsquosmore than a supplier relation-

ship our guys are inside the

mine living and working thererdquo

In fact this is the model

that Metso is using in servicehubs all over the globe build-

ing modern facilities bringing

teams on site and workinghand in hand with mine

operators The Cananea Service

hub is only the most recent

example of Metsorsquos commit-ment to service and northwest Mexico is

yet another mining hotbed thatrsquos going to

benefit from the companyrsquos support

More info

Felix Fornaguera Tel +52 4621079227

felixfornaguerametsocom

A mining cone serviced by Metso at the Buena Vista del Cobre mine inSonora Mexico

ldquoThe new Cananea service center will be a majorrepair and assembly center for pumps crushersand screensrdquo says Felix Fornaguera Director ofServices Mexico Central America and Caribbean

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

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During the MINExpo exhibition over 1300 people visited the Metso stand

983122983141983152983151983154983156983145983150983143 983154983141983155

Held every four years MIN-Expo consistently grows so

perennial exhibitors like Metso

are challenged with elevating

their presence and drawingin new (and greater numbers

of ) visitors each year ldquoItrsquos not

necessarily a challenge to lsquotoprsquo

our last showingrdquo says Keith

Ference Vice President ofmarketing and communica-

tions North America ldquoThere

are four years between eachMINExpo so we always have

a lot to say and reveal to our

customersrdquo The real challenge

he says is finding an exciting

and dynamic way to deliverthe message ldquoTherersquos so much

to see here so your booth has

to be compelling from the

outside-in and thatrsquos what

we always try to dordquo

Service sets the stage

The Metso booth created buzzin a number of ways and per-

haps the most striking (partly

due to its size) was the live

theater presentation As visitorspassed through the aisles of the show-

room the sights and sounds from Metsorsquos

theater were hard to miss And once guests

entered they were captivated by a short

high-energy video presentation focused

on Metsorsquos service capabilities The message was simple Metso is ldquoyour

local service partner rdquo for all mining and

construction needs The video showed ourservice teams in action all over the world

and the audience came away with an

understanding about Metsorsquos commitment

to service Customers can count on morethan 70 local service centers run by more

than 1700 expert technicians delivering

Metso makes an impact at MINExpo 2012At this yearrsquos MINExpo International nearly 60000 attendees flocked to Las Vegas Nevada the largest turnout in showhistory The visitors ndash mining professionals from all over the globe ndash explored 850000 square feet of showroom spacefeaturing the industry rsquos latest technology equipment products and services They toured the show for three days

seeking the latest and greatest from more than 1800 exhibitorsTEXT Keith Ference PHOTOS Tracey Ford Perry

detailed descriptions andphotos of all of Metsorsquos mining

and construction products and

services The app also provides

digital access to Results and asearchable database of sales

contacts By day three of the

show MetsoMAP had been

downloaded by more than

500 usersIn addition to the app the

booth was equipped with

several LCD screens each con-trolled by Metso experts who

used their iPads to present new

products like the Megalinertrade

and the HRCtrade A featured

presentation on Metsorsquos lineupof energy-efficient comminu-

tion equipment including the

VERTIMILLreg SMD and MP-1250

cone crusher was also avail-

able letting customers seehow Metso technology delivers

some of the worldrsquos most effi-

cient size reduction

Measuring MINExpo success

After a very busy three days

(on top of months of prepara-tion leading up to the show) everyone

involved with MINExpo ndash from the North

American marketing team responsible for

the booth to the product managers and

sales force that worked the floor ndash is view-

ing the show as a success ldquoTherersquos alwaysa sigh of relief after each (MINExpo)rdquo says

Keith ldquoAnd overall the initial feedback

and response has been very positiverdquoWith more than 1300 visitors to the

booth Metso certainly made an impact

ldquoWe learn a lot from each show and with

some time wersquoll have a better understand-ing of the tangible results of our effortsrdquo

Keith adds

reliable service for mining equipment as

well as customized cost-effective life-cycle

services contracts

Technology ndash MetsoMAP

is an industry firstMINExpo provided the industry with its firstglimpse of Metsorsquos revolutionary iPad app

MetsoMAP The app was demoed to the

boothrsquos visitors via ldquothe worldrsquos largest iPadrdquo

a custom-made 80-inch screen that show-cased all of its capabilities most of which are

groundbreaking in the industry MetsoMAPrsquos

simple interface is highly intuitive making

it easy to view process animations videos

The presentation of the new HP cone crusher attracted a large audience

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When yoursquore allowed less than a dozen days per year for breakdowns repair andmaintenance every single hour during a service shutdown counts There simplyisnrsquot any room for surprises Thatrsquos why Boliden counts on MetsoTEXT amp PHOTOS Sofia Williams

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Kurt Kalla Site Managerof Metso Gaumlllivare ServiceCenter is responsible forthe maintenance of Aitik

Metso and Boliden Strivingtogether for 97 uptime

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983122983141983152983151983154983156983145983150983143 983154983141983155

One of the biggest copper mines in

Europe Bolidenrsquos Aitik is located deep inthe wilderness of Swedish Lapland next to

the small town of Gaumlllivare The mine has

been operating since 1968 and a recent

expansion has increased its annual ore

production to 36 million tons

But the ambitious Swedes are not will-ing to lay back and relax just yet Bolidenrsquos

new aim is to reach a production rate of

45 million tons of ore per year in AitikAfter that Perhaps more than 55 million

tons The ore concentration in Aitik is very

low-grade with a mere 022 copper con-

tent hence the need for high capacityAchieving the ambitious production

goal requires maximum plant availability

This means that everything from the crush-

ers to the filters must be up and runningfor approximately 97 percent of the time

Thatrsquos where Metso comes into play

A cost-per-ton contract in action

The maximum uptime requirement allowsless than a dozen days per year for break-

downs repair and maintenance at Aitik

Every single hour during a service shut-

down counts There simply isnrsquot any roomfor surprises

Executing a successful shutdown under

such conditions requires a reliable service

partner not afraid of challenges and this iswhy Boliden has entrusted Aitikrsquos services

operations to Metso Boliden and Metsohave worked together since the 1960s

and the collaboration took another step

forward in September 2012 when the twocompanies signed a three-year extension

of the services contract for Boliden Aitik

ldquoThe new contract is a cost-per-ton

agreement We get paid based on Aitikrsquos

production Itrsquos a win-win deal for both par-

ties but also a new mindset for usrdquo explainsKurt Kalla Site Manager of Metso Gaumlllivare

Service Center responsible for serving Aitik

From now on the duration of the shut-down is what matters the most According

to Kalla the Metso service organization in

Gaumlllivare is now streamlining its operations

to fit the bill and has already witnessed thestrategy working In August 2012 Metso

carried out a 188-hour service shutdown in

Aitik which turned out to be a success

Zero tolerance for injury

One key factor to the success was theextensive planning of precautionary health

safety and environment procedures under-

taken by Metso prior to the shutdown Thanks to strict measures applied no

injuries or accidents occurred during the

shutdown and the work could easily be

finished on scheduleMats Johansson Health Safety

and Environment Manager for Metso in

Sweden explains how this was achieved

rdquoPlanning of the shutdown included arisk analysis for all new tasks participating

in Bolidenrsquos safety coordination meetingsmeeting with both Metso supervisors and

subcontractor supervisors and finally a

meeting with the entire staff participating

in the shutdown where everyone had to

sign a document stating their commitmentto the information providedrdquo he says

During the actual shutdown plenty of

new barriers signs and awareness cones

were put in place as a result of observa-tions from previous audits and safety plans

and risk analyses were readily available

in the work area Metso and Boliden also

introduced a Mill Inching permit a certifi-cate for completing a mandatory course for

those involved in the process In addition

Metso carried out random safety audits

during the shutdown to make sure thestrict policy was followed

According to Boliden Metsorsquos way of

working is a good example of how health

and safety precautions should be handled

ldquoMetso is a good example of how towork with safety and health plans risk

analysis permits and welding permits

Their table with all binders in the second-

ary mill area was exemplaryrdquo says Kjell-Arne

Johansson a technician from Boliden

The use of the new Metso Megalinertrade

system in the lining of Aitikrsquos Metso AG

mills has also improved the safety of main-tenance staff The Metso Megalinertrade con-

sists of larger-than-average liners bolted

in position from outside the mill Mainte-

nance technicians no longer need to go

inside the mill and stand in the dangerousdrop-zone of the liners gt

Boliden aims to reach a production rate of 45 million tons of ore per yearin the Aitik mine site

ldquoA complete risk analysis was conducted during the planningof the shutdownrdquo comments Mats Johansson Health Safetyand Environment Manager for Metso in Sweden

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Service the Metso way

24 hours a day 365 days a year

In addition to paying close attention to

health and safety issues executing an effi-

cient shutdown requires careful planning

and timing of every step in the mainte-

nance process Wear and spare parts have

to be available on time and a repair shoplarge enough to accommodate equipment

located close by

ldquoTo keep maintenance breaks as short

as possible we aim to replace the pump on

site and bring the old one for repair to our

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

nearby facilities This method gives us the

peace to do a good job and keep the cus-

tomerrsquos operations runningrdquo Kalla describes

the Metso way of handling Aitikrsquos pump

maintenance

Metso is currently expanding its Gaumllli-

vare service center to include a distribu-

tion center for wear and spare parts andalso concentrating its previously scattered

operations under one roof in its Vuoskon-

jaumlrvivaumlgen facility The expansion is due to

be completed by 2014

Metso equipment

delivered to Aitik36

bull 2 AG mills diameter 116 x

137 m gearless 22-MW motor

bull 2 Pebble mills diameter 91 x

113m dual 5-MW pinion drive

bull 3 VPA pressure filters VPA 1540-54

bull 12 sample pumps and pipes

VF50

bull 60 Various slurry pumps up to

MR500 modelbull Appr 5000 m rubber-lined slurry

pipes up to 600 mm diameter

bull Appr 5000 m rubber-lined by

gravity pipes up to 600 mm

diameter

bull Appr 5000 m rubber hoses

up to 600 mm diameter

Not only does the expansion make ser-

vice shutdowns at Aitik run more smoothly

it guarantees a more comprehensive

on-call emergency service response in the

region ndash thanks to the spare and wear parts

inventory available 24 hours a day 365

days a year

More info

Lars Rosenling

Tel +46 70 107 45 90

larsrosenlingmetsocom

Metso grinding equipment dominates the view in the concentrator

Safety on site is made up of small things like

making sure that everyone remembers to secure

the hoses in place

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983122983141983152983151983154983156983145983150983143 983154983141983155

Pebbles have always been a

challenge for producers of sandsince they cannot be returned

to rivers after extraction For

decades the processing of this

material resulted in a huge

environmental liability with alarge amount of pebbles hav-

ing to be stored away and left

unused

Transforming problems into

business opportunities

Areia amp Cia (areia = sand) has

operated in this market forover 20 years and decided to

enlist the help of Metso to find

a profitable solution for the

processing of pebbles

In July 2011 analyses werebegun to assess the abrasive-

ness and crushability of the

material Four alternatives wereidentified for processing and

transforming pebbles into sand

Initially Areia amp Cia was

interested in acquiring an

impactor for its reason-able price level However the

customer wanted to process

all the pebbles that were col-

lected daily in addition to some of the

material that it had stored In weighing theresults expected by the customer and the

excessive abrasiveness of the material the

HP200 cone crusher was decided on as thebest alternative

Areia amp Cia made the required invest-

ment and after using the HP200 for just

six months the company has already beenreporting outstanding results The HP200

not only transforms pebbles into sand but

also produces sand of excellent quality

with high yield and low maintenanceWith minor adjustments the HP200

also enables the production of sand withspecific particle size distribution for special

applications such as filtering sand blasting

and foundry sand adding value to the prod-

uct and increasing the types of sand offeredldquoMetso is pleased that the HP200 not

only enabled the processing of a product

that had been set aside as unusable but

HP200 cone transforms pebblesinto high-quality sandOver the last few decades Brazilian economic growth has been driving demand for construction aggregates The market

for sand in turn has been experiencing major difficulties in maintaining a consistent supply Presently one of the mainchallenges the industry faces is the large amount of pebbles that are obtained in the process of extracting sand at timesconstituting nearly 50 of the volume of material dredged from riverbeds

TEXT Sheila Ivers PHOTO Areia amp Cia

also that it opened up new

market opportunities for Areiaamp Cia Thatrsquos the standard we

seek to deliver to our custom-

ersrdquo states Luiz Oliveira Techni-

cal Salesperson of Metso Brazil

HP cones entering the

Brazilian sand-making

market

Todayrsquos cones such as theHP200 have high resistance

to impacts and abrasiveness

more efficient crushing cham-

bers low maintenance costsand excellent productivity

Following the acquisition of

the HP200 Areia amp Cia is now

also producing special sands

that command a price that is100 higher than common

sand The entire stockpile of

pebbles accumulated through-out the companyrsquos 20 years of

operations has already been

transformed into sand and the

stock of pebbles held by com-

petitors is also being purchasedfor processing

Cristiane Brizolari the

owner of Areia amp Cia confirms

the transformation that has taken place in

the production and commercial processldquoThe HP200 opened up new niches in

the market enabling the production of dif-

ferent types of sand with added valuerdquo

More info

Luiz Oliveira

Tel +55 011 9971 3603

luizoliveirametsocom

After the pebbles are crushed into sand with the HP200 cone crusherdifferent grades are screened for various end uses

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Where therersquos a will we dig a wayAFCONS-Strabag and Metso embark on tunnel project together

When the joint venture AFCONS-Strabag initiated work on the Rohtang bypass tunnel project at an altitude of 3980 metersabove sea level in Himachal Pradesh India they deliberated each aspect with clockwork precision The project involved anumber of surprises and challenges and required technology and project management skills that were second to none

TEXT amp PHOTOS Monisha Majumdar

Cutting a 10-meter-wide and nearly 9-kilo-

meter-long tunnel through the Himalayas

in one of the toughest terrains and cli-mates in India makes for quite a challengeResults set out to find out how AFCONS-

Strabag and Metso are making their way in

one of their most critical projects to date

The only road connection to the north-Indian border region of the province

Himachal-Pradesh and beyond the Manali-

Leh highway leads across the Rohtang

pass Due to the heavy snowfall and high-

velocity winds in this region the towns

located north of the pass are cut off from

the rest of the country during winter for atleast four often even six months each year

A tunnel with strategic importance

With the construction of the tunnel at

3100 m above sea level the Manali-Lehhighway will become an all-weather road

thereby enabling a significant improve-

ment in the economic development of

northern Himachal-Pradesh and an alter-

nate route to the strategically important

Ladakh region

Manali south of the pass is an alreadywell-developed tourist location that is

becoming more and more popular Upon

completion of the tunnel it is likely that

tourist activities will extend to the areanorth of the pass Moreover the tunnel

shortens the distance between the towns

of Manali and Leh by approximately 45 km

thus saving several hours on the small dan-gerous pass road

The Rohtang pass in the Western Himalaya

region of Northern India with its altitude ofalmost four kilometers ranks among thehighest trafficable passes in the world

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983122983141983152983151983154983156983145983150983143 983154983141983155

The 88-km long horse-shoe-shaped

tunnel provides space for a two-lane8-m-wide carriageway as well as a one-

meter-wide footpath on both sides A

22-m-high and 36-m-wide emergency

tunnel will be integrated in the tun-

nel cross-section Altogether more than

800000 msup3 of rock will be moved Tunneling works started around spring

2010 with excavation driven from both por-

tals As the north portal is inaccessible dur-ing winter closure the excavation focused

on the south After a planned construction

period of 55 years the tunnel is scheduled

to be completed by the end of 2015

Best man for the job

The BRO (Border Road Organization)

wanted to roll out a global tender for theproject due to the challenges that such a

project involves and also considering thatitrsquos the first time in India that a project of

this scale was to be carried out This imme-

diately triggered the need to roll out aglobal tender All major Indian construction

companies bid for it some individually and

some in partnerships

Strabag an Austrian tunnel specialistwas one of the companies who bid for the

project along with AFCONS a Mumbai-

based infrastructure company In Septem-

ber 2009 AFCONS-Strabag was awardedthe contract

Mr Sunil Tyagi Deputy Project Man-ager at AFCONS had this to say about the

unique projectldquoThis project is located in the Himalayas

and as far as we understand the terrain

there is among the toughest We came out

with a new technology and to be honestit is a fairly simple one We would generally

start with the traditional technology of drill-

ing and blasting and then obtain our muck

feed from the inwardbottom of the tunnelrdquo

ldquoThe technology is supplied by Rowa Tunneling Logistics and this is the first

time it is being used in Asia A jaw crusheris placed at a distance of about 40-45

meters behind the face The blasted muckextracted from the face is fed to the crusher

to reduce the lump size and then through

an overhead conveyor transport system

it is then transported out of the tunnelrdquoldquoThis enables free movement of man

and machinery in the lower area or spe-

cifically on the ground area If we were to

conforms to the Indian standard for fines amp

coarse aggregates as prescribed in IS383-1970

The plant was up and running in good

condition and performing to AFCONSrsquos

satisfactionldquoWe have worked with Metso in earlier

projects and are quite impressed by thekind of technology amp services they provide

We have a history together so the trust fac-tor also comes inrdquo explains Dhiman on their

choice of Metso as a partner

Service makes the difference

ldquoMetsorsquos services have made a big dif-ference in the project Without them we

would still be struggling with the machin-

ery and production The service is really

good and the service engineers are knowl-edgeable prompt and quick to act Any

problem can be solved by Metso We donrsquothave to wait until a service engineer turns

up ndash they have the capacity to solve prob-lems over the phone as wellrdquo says Dhiman

ldquoThe Metso plant didnrsquot create any prob-

lems for us We had problems in logistics

the feed was sticky and the weather condi-tions were bad but thankfully we did not

face any problems with production and

efficiency as the Metso plant is performing

very wellrdquo Dhiman concludes

More info

Amol Sinha Tel +91 9811 671 924

amolsinhametsocom

use the old conventional technology this

wouldnrsquot have worked for us in the stipu-lated timerdquo Mr Tyagi adds

When the going gets tough

partner with the toughest

Sensitive projects require the best technol-

ogy After AFCONS-Strabag landed theproject Metso was an obvious choice as a

technology provider not only because of

the long-standing business relationshipbut also for the sheer consistency in prod-

uct quality and service deliverance Metso

strives for

ldquoAfter signing the project we faced alot of road blocks including extreme cold

avalanches roadblocks less oxygen ndash you

name it we faced itrdquo explains Ankit Dhi-

man Plant Manager at AFCONS-Strabag The Rohtang valley is known for its

notorious avalanches and landslides SoAFCONS had to take extra steps and safety

precautions against hazards on the site

ldquoIn this freezing cold not just us humansbut also the machines are at increased risk

of damage I remember when we used

to run the plant during winter the diesel

engines would freeze We had to constantlyheat up the fuel container to get the plant

running And even the sand in the sand

trap would freeze so we had to clean it on

a daily basis to stop the pipes from mal-functioningrdquo Dhiman adds

Plant designed for difficult terrain

Difficult terrain coupled with space con-straints led Metso engineers to put their

minds together to come up with a suitable

plant configuration After studying the

requirements of the project Metso sug-

gested a 150-tons-per-hour three-stagemodular plant using a C106 jaw crusher

a GP11F secondary cone crusher and a

B7150 tertiary vertical shaft impact crusher

In addition considering the unpredict-ability of the feed the plant was about

to reach a point where the amount offines to be handled could be increased

dramatically Metso strongly suggested the TK11-27-3V grizzly scalper and this became

the first-ever TK scalper to be supplied by

Metso to an Indian customer Also in order

to get better products a sand trap SF2360was added to the configuration

The sand trap is important equipment

for this project as it washes the sand thatMr Sunil Tyagi Deputy Project ManagerAFCONS-Strabag

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Smooth transition to new-generation jaw crusher in Germany

Roumlhrig is a German company with a rich heritage The company has been quarrying granite at its plant in Bergstrasse inthe Sonderbach district of Heppenheim for three generations

TEXT amp PHOTOS Ralf Goffin

Roumlhrigrsquos superior product variety is onereason why the companyrsquos proximity to its

customers can be understood in more than

just physical terms The companyrsquos high

level of innovation has allowed it to estab-lish itself as a reliable supplier of materials

both regionally and internationally This

operational and technical expertise always

manages to keep in step with growing

market requirements

In terms of technical processing equip-

ment Roumlhrig has used a Nordberg C160stationary jaw crusher from Metso since

1992 At the start of 2012 it was finally

exchanged for a more up-to-date version

from the same model range

Metsorsquos C Series is specifically designed

to pre-crush hard rock and can cope effort-

lessly with even the hardest of materials

The dimensions of the new stationary jawcrusher are identical to those of the old

one which means that it could simply be

slotted into the housing vacated by the

previous version

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983122983141983152983151983154983156983145983150983143 983154983141983155

Third-generation Managing DirectorMarco Roumlhrig expects the new machinersquos

service life to be just as long as the previ-

ous model due to the product upgrades

that have been implemented The integral motor base is another plus

point in models made by other manu-

facturers it is located outside the crusher

This element of good fortune ensured that

Roumlhrig could reuse the housing withoutany additional rebuilding

Another advantage lies in the revision

of the guards for the C160rsquos drivetrain andflywheel The sturdier construction method

used for the crusher requires fewer parts

which facilitates easier installation andmaintenance and it makes it simpler to

access the motor

Under the watchful eye of Metsorsquos

Assembly Manager Maik Engelstaumltterthe entire project including removal and

installation was successfully completed

within two weeks

Installation making the most

of the available space

Roumlhrig will likely remember the day the

new crusher was installed for a long time

the pitman and main frame were deliveredseparately prior to installation and assem-

bled on site It took just one hour to replace

the old stationary crusher with the new

model A lorry-mounted crane was used toposition the 85-ton crusher with millimeter

precision in the crushing plant Once the

new crusher had been positioned in theexisting steel structure the next task wasto fix it into place as securely as possible

despite the limited space Special vibration

dampers were installed at a height of two

meters to prevent the crusher from sliding

Norbert Ried (fourth from left) installed thenew C160rsquos predecessor 20 years ago and isdelighted at the durability of the powerfulcrusher that is now making way for a newermodel Also pictured from left to right ManagerVolker Angermann Assembly Manager Maik

Engelstaumltter Technical Manager Stefan

Koob Project Manager Dominic SchoumlnhardtManaging Director Marco Roumlhrig Service

Technician Stefan Kolze and employees ofthe installation company Stafemo

On the hook after theold C160 was liftedout by crane the newcrusher was installedin almost no timeOnly the roof of thehousing had to beremoved

sideways off its mount An initial test run

with materials was carried out around oneweek later after all the electrical cables had

been installed

Simultaneously with the installation

of the C160 which is the first of the latest

generation of crushers to be installed in

Germany a new Nordberg GP100 conecrusher was also being installed in Roumlhrigrsquos

chipping plant Roumlhrig is convinced that

the technical improvements made tothe new Metso crusher can only be an

advantage worldwide

Roumlhrig places great value on consistent

product quality maximum added valueand optimum refinement of its product

range Bearing in mind that Roumlhrig has

enough reserves of raw material to last

for the next 150 years the company canconfidently continue to develop with an

emphasis on quality rather than quantity

More info

Dominic Schoenhardt

Tel +49 (0)621 727 00 610

dominicschoenhardtmetsocom

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Groupe Charier Carriegravere de la Mariais France

Quarrying with certi1047297ed quality The Charier Group with its 1600-strong workforce is a family business thatthis year celebrates 115 years of quarrying The company pursues a long-termdevelopment policy that since 2007 has seen processing installations upgradedat 4 of its 9 extraction sites

TEXT Liliane Boutin (with extracts from Mines amp Carriegraveres and Terrassements amp Carriegraveres magazines)PHOTO Baloon photo

The processing installation is of the horizontal type with a primary station located 56 meters below the site access road to keep it hidden from view

The crushing and screening installation at

Charierrsquos CM La Mariais quarry (at Donges

on the Loire estuary) has been in opera-tion since September 2011 Based on theoperatorrsquos ideas it was designed by Metso

to replace a worn-out installation installed

right on top of the seam being extracted

Since its commissioning it has becomethe second quarry in the company to

receive ISO 14 001 certification

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983122983141983152983151983154983156983145983150983143 983154983141983155

tertiary material of sand and gravel for the

local market to use in concrete surfacingprefabrication etcrdquo

Incorporation of a screening station

The stone extracted from La Mariais is

according to the quarry granitic gneiss

sound and homogeneous with a LosAngeles index of 15 good wear resist-

ance with an MDE of 10 a true density of

265 and a certain abrasiveness (2000 gt)ldquoCharacteristically it has a tendency to form

blocksrdquo Leblin points out

The main criteria in designing the instal-

lation was to provide an output of 600000metric tons from one station (38 hours

week) to produce materials aimed at the

concrete and surfacing markets ldquowhich

involved providing a tertiary station withscreening plantrdquo he adds

With this new unit the operating com-pany expands its product range through

the addition of fine materials obtained

from the tertiary screening station This unitis capable of producing 170 tonshour of

020

Preserving the environment

and optimizing safety

The screens have motorized bogies and

retractable walkways to facilitate access

when the screens are opened for main-tenance Other walkways provide access

to the tunnel input feeders The feederscan be isolated with hydraulic rod gate

bars this hydraulic assistance eliminatesthe need to use a heavy hammer to lodge

these metal bars

All conveyors transporting fines (02

and 04) are covered with a tarpaulin to

avoid flying dust and all the screens arehooded (metal cover with Trellex seal-

ing) The Brunone company has installed

dust-tight containment at the outlet of the

tertiary station crushers (HP300 and HP4)on the belt located under the screens

and under the hoppers located belowthe tertiary screens The crushers are put

under negative pressure and the finesare extracted through sleeve filters (7000

m3 h) with declogging which deposits the

dust back onto the conveyor belt

A high-pressure 100 bar water mist sys-tem has been installed at the primary sta-

tion discharge at the secondary crusherrsquos

discharge chutes (Omnicone) and at the

transfer points on the belt

Designed to last

ldquoThis type of new installation can easily last

thirty yearsrdquo affirms Project Leader Bruno

Peix of Metso ldquoIt quite simply depends on

how well it is maintained Thatrsquos why weprovide maintenance contracts that call for

our technicians to make regular inspection

visits and carry out preventive mainte-nance and any necessary repairsrdquo

In 2011 Metso commissioned about

10 new processing units in France like

the one at La Mariais quarry

More info

Frederic Bazire

Tel +33 (0)681442804

fredericbaziremetsocom

Key figures

DURATION OF WORKS 15 months

DRAWING OFFICE TIME 7800 hours

HEIGHT OF SILOS AND GRINDER BUILDINGS

15 m

TOTAL LENGTH OF CONVEYORS 14 km

WEIGHT OF THE INSTALLATION

1200 metric tons

CONCRETE POURED 1800 cubic meters

PROJECT SITE WORKFORCE 30

INSTALLED POWER 2200 kW(not including pumps 200 kW)

METSO EQUIPMENT

Primary

Vibrating feeder PF561-2V

Primary grizzly VG540-3V

Grizzly feeder TK13-20-3V

Jaw crusher C145 with

hydraulic setting

Secondary

Vibrating screen CVB 2050

refurbished

Cone crusher Omnicocircne 1352 SX

with Metso IC7000 controller Ellivar 16 (16 msup2 3 decks) screen

refurbished by Metso

Tertiary

Cone crusher HP300

Cone crusher HP4

2 Ellivar 20 screens (20 m23 decks) for final products

Expanding the production range

ldquoSince the mid-1990s when we became

owners of La Mariais we had used mobilemachinery with an assembly of beltconveyorsrdquo recalls Daniel Leblin Charierrsquos

Technical Manager for site construction

and maintenance

ldquoIt became clear that we needed ahigher performance tool to achieve the

dual goals of reaching one million metric

tonsrsquo maximum production and producing

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Big Lokotrack LT550GPF boostsquarrying productivity by a thirdMaximizing the productivity of operations is a key issue when striving for cost-effective quarrying Big Lokotracks are oneway to achieve improved operational efficiency The Lokotrack LT550GPF equipped with the high-volume GP550 conecrusher and a large screen is popular in the Nordic countries and in Germany and Australia ndash countries all known for theirhigh quarrying volumes

TEXT amp PHOTOS Eero Haumlmaumllaumlinen

Kone-Kostamorsquos new mobile coneplant has reached an averagecapacity of 300 tons per hour

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ldquoWith the same number of employees we

can achieve 30 more productivity with

our new LT550GPF unit The high-capacityFS screen has also eliminated the bottle-neck often seen at fine screeningrdquo says

Aarno Kostamo Managing Director of

Kone-Kostamo Oy one of Finlandrsquos biggest

crushing contractorsAccording to Kostamo the high capacity

of the GP550 gyratory cone crusher easily

handles feed from the C120 and C125 jaw

crushers For the contract with the Talvivaara

nickel mine the LT550GPF is being fed bythe brand new Lokotrack LT120 jaw plant

Average capacity 300 tons per hour

Talvivaara Europersquos largest nickel mine uti-

lizes large quantities of aggregates Kone-Kostamo has contracted several million

tons of different end products for the mineIn August 75000 tons of 0ndash63 mm

road gravel was crushed Smaller amountsof finer 0ndash6 mm 0ndash16 mm and 0ndash32 mm

aggregates are also being produced

The rainy summer increased the need

for road gravel along the muddy roadswhich must endure dump trucks weighing

as much as 260 tons

ldquoThe mobile process consisting of the

LT120 jaw plant and LT550GPF cone plant

is cost-effective while aggregates of vari-ous sizes can be produced in a two-stage

operation and with high capacity The con-trolled stroke and elliptical movement of

the FS screen secure big passing throughcapacitiesrdquo Kostamo explains

Operated in two shifts for a total of 16

hours per day the LT550GPF has logged

more than 600 working hours over a two-month period

Managing Director Aarno Kostamo (left) and foreman Karri Maumlenpaumlauml studying the cavity optionsavailable for the new Lokotrack LT550GPF

Longer perspective than

a single quarter needed

Kone-Kostamo Oy was founded as an

earth-moving company in Kemijaumlrvi

Northern Finland in 1956 The company

expanded its operations to include crush-

ing contracting in 1964 and later on

switched to concentrating fully on crush-ing activities

Kone-Kostamo consistently crushes

and screens around 28 million tons ofaggregates annually and has net sales of

between EUR 8ndash9 million

ldquoWe believe that issues within the crush-

ing industry including the purchasing ofmachinery must be studied with a longer

perspective than a single quarter The

secret to our success has always been our

solid work ethic and professional employ-eesrdquo Kostamo sums up

More info

Esa Berg

Tel + 358 40 837 8692

esabergmetsocom

8132019 Results Minerals Aggregates 3 2012ENG

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Monitoring-based reporting is vital for

assessing the performance of a mobile

crushing plant Metso provides suchreporting tools through its plant-wideautomation system Metso DNA (Dynamic

Network of Applications) with its infor-

mation platform that links all the mobile

crushing and screen units together as oneentity Basically there is a lot of measured

real-time information available in every

crushing plant On-line information is

obtained either from each Metso crusherrsquosmachine automation system IC (Intelligent

Controller) or from separately installed

additional sensors and belt scales

All the collected data is sent to a motorhome using wireless communication

based on WLAN technology The motor

home is a purpose-built environment

inside an on-site container In this environ-ment selected variables can be monitored

for assessing the plantrsquos performance And

to make all this even more flexible the

data can be transmitted to a crushing plant

company office using GPRS3G mobile

data communication technologies Thismakes all the last-minute reports acces-sible to the crushing plant managerial staff

at anytime and basically anywhere within

reach of the cell phone network

Production and fuel economics reports

Essentially monitoring and reporting can

be customized to fit the customerrsquos needs

However there are certain off-the-shelf

reports that provide a lot of useful informa-tion for plant supervision The production

report is one of these Requiring at least one

belt scale for measuring the total produc-tion the production report shows the pro-duction rate (tons per hour) for a selected

reporting period eg a day or a week The

production report constantly keeps track of

the plantrsquos production storing all the datathroughout the plantrsquos life cycle

Performance monitoring and reportingfor a mobile crushing plantTEXT Pasi Airikka PHOTOS Metso

unit during which the unit is running By

storing the availability times between start-ups and shutdowns the crushing plant

operation time (hours per dayshift) can be

recorded analyzed and reported In addi-

tion the availability report can be tailored

to evaluate efficient crushing hours during

which the plant is really working and pro-ducing aggregates Consequently the ratio

(0-100) between efficient crushing time

and total running time can be reported forany selected period of time This boosts

the efficiency of the plantrsquos operations

and results in better productivity

Reports on non-choke

or inadequate feeding

Non-choke feeding to crushers is avoid-

able through smart plant-wide crushingplant controls But estimating its severity in

a systematic manner is not straight-forwardwithout constant monitoring and reporting

The crusher choke feeding report makes

use of the crusher cavity level sensors byanalyzing their level measurements By

calculating average and min-max values

and deviations from the average it can be

shown how often the single crusher suffersfrom non-choke feeding to it

In some cases the bottleneck in the

crushing plantrsquos productivity is the material

feeding to the process In mobile plants thefeeding is human operated and therefore

subject to variations Occasionally the sizeof the human-operated machine simply

does not allow for adequate feeding to thecrushing plant There are specific reports

indicating time periods when the crushing

plant suffers from inadequate feeding

Condition monitoring for

crushers and screens

Machine-specific condition monitoring

focuses on vibrating components in

crushers and screens such as drive shaftbearings safety plate wearings and gears

The low middle and high frequencies ofmonitored components are measured and

supervised in real-time to detect abnor-malities due to slow or fast wear looseness

or imbalance

More info

Pasi Airikka

Tel +358 40 587 2730

pasiairikkametsocom

Condition monitoring provides a view tovibrating crusher and screen components forpredictive equipment maintenance

The daily production report shows the hour-by-hour production trend and distribution chartfor a selected day with min-max average andvariation statistics for comparison

Fuel consumption is always an interest-ing concern The fuel consumption reportgives the fuel consumption of each crush-

ing unit (liters per hour) and their total

consumption (liters per hour) for a selected

reporting period and can track fuel con-

sumption changes over timeCrushing plant availability can be

assessed as well The availability report

calculates time periods for each crushing

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983149983141983156983155983151 983150

for tissue machines The record of 2210

mmin was set on June 1 2012 during a

24-hour production run by the TM 2 tissue

machine at the companyrsquos mill in Yenikoumlynear the city of Izmit in Turkey

ldquoThe cooperation with Metso has been

beyond excellent and both parties did

their utmost to make the project success-ful The results clearly show that the efforts

were worthwhile on both sides This coop-

eration will extend to cover new projects

in the futurerdquo says Luumlt1047297 Aydin Paper GroupDirector Hayat Kimya

ldquoWe are not surprised that Hayat K imya

managed to break the world speed record

We have had great confidence in the capa-bility of the Hayat team since our project

started in 2009 We certainly know our

machine very well its stability production

efficiency and speed capabilityrdquo says Jan

Erikson Vice President Sales Metso

PowerThe worldrsquos first eco-gas fueled

power plant is up and running

Lahti Energy Ltdrsquos new Kymijaumlrvi II gasifica-

tion plant was officially inaugurated on

May 8 2012 It is the first of its kind in the

RecyclingRecycling with Lokotrack LT106

jaw plant in New York

A brand-new Lokotrack LT106 jaw plant is

used in the city area of New York USA to

recycle demolition materials The crushing

site faces the skyscrapers of ManhattanIsland

Paper amp FiberHayat Kimyarsquos Metso-supplied tissue

machine sets world speed record

Thanks to a skilled crew and dedicated

efforts Hayat Kimya AS in Turkey has suc-

ceeded in breaking the world speed record

world This CHP plant runs on clean eco-

gas that is gasified cleaned and cooled

from recycled waste with Metsorsquos innova-tive technology

ldquoItrsquos actually eco-gas that we combust

in the boilerrdquo comments Lahti EnergyrsquosProduction Director Jukka Manskinen

ldquoWe convert unwanted waste material into

energy in an efficient and environmentally

friendly wayrdquoNever before has any plant gasified

waste on such a large scale In the gasifier

recycled waste is turned into combustible

product gas which is cleaned cooled and

combusted in a high-efficiency gas boiler

to produce steam for the steam turbine The plant produces 50 MW of electricity

and 90 MW of district heat for the city of

Lahti and its neighboring areasMetso delivered the circulating fluidized

bed (CFB) gasification process gas cleaning

and cooling steam boiler environmental

protection system and automation systemto the entire plant The production of elec-

tricity and heat is kept even with the Metso

DNA automation system that covers the

whole plant starting from fuel reception

AutomationMetso develops and supplies plant-

wide crushing control solutions for

crushing plants

Metso has recently signed contracts on

delivering plant-wide automation systems

for mobile and portable rock crushing

plants The key objective of these deliveries

is to stabilize and to increase productivityand efficiency of the plants using one sin-

gle automation and information platform

for integrating crusher-specific IC machinecontrols

Furthermore the plant-wide system

with its information management tools not

only increases plant availability and opera-

tional safety it also makes troubleshoot-ing quicker and performance monitoring

easier The control room for plant-wide

operability is located either in an excavator

cabin or a purpose-built container

Metso around the world

The new LT106 jaw plant is suitable for crushing both hard rock and all rock-based demolition materials

The new world speed record for tissue setby Hayat Kimyarsquos Metso-supplied TM 2 is2210 mmin

8132019 Results Minerals Aggregates 3 2012ENG

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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: Results Minerals Aggregates 3 2012.ENG

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983110983141983137983156983157983154983141983140 983137983154983156

Increasing capacity makes processing

of lower grades economical

The project to significantly increase the

processing capacity at Pampalo is well

under way with the installation of for

example a second grinding mill and more

flotation cells The expansion will be in

operation during early 2013ldquoThe added capacity also makes it pos-

sible to economically process the nearby

open pits with a lower gold grade In addi-tion it helps us to optimize the crushing

and grinding circuitsrdquo Ekberg concludes

Active exploration drillings have

exposed new mineralized zones furtherextending the lifetime of the Pampalo mine

from the present estimate of 6ndash7 years

More info

Peter Vikman

Tel +358 400 869 845petervikmanmetsocom

Endomines Pampalo gold mine

LOCATION near the community of

Ilomantsi in Eastern Finland

GOLD ORE CONTENT

ndash Pampalo 34 gtndash Hosko 99 gt

ndash Raumlmepuro 39 gt

ndash Muurinsuo 30 gt

PRODUCTION TONNAGE PER YEAR 270000 tons (present)~400000 tons (future)

GOLD PRODUCTION PER YEAR 800ndash900 kg

KNOWN ORE RESERVES IN TOTAL

approx 2 million tons

MINE DEPTH 360 m

MINING METHOD bench cut and fill

NUMBER OF EMPLOYEES

100 including contractors

METSO EQUIPMENT

1 Metso TRN 30 x 48 m

wet ball mill

8 Metso RCS series flotation cells 1 Nordberg MF 1800 x 6100

screen

3 Metso samplers

1 Metso CT thickener

1 Metso TF vacuum filter

33 Metso slurry pumps of various

types and sizes

The gold ore is screened using Metsorsquos MS series mining screen

Markus Ekberg is pleased with the outcome the mine reached the minerals processing utilizationdegree of over 90 just two months after start-up

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983110983141983137983156983157983154983141983140 983137983154983156983145983139983148983141

Nordic Mines ndash on track tobecoming one of Europersquosmost prominent goldproducersNordic Mines is the newest member in a long chain of Nordic gold mining operations

Inaugurated in mid-August 2012 this company of Swedish origin aims to become one

of Europersquos most prominent gold producers Metso is one of Nordic Minesrsquo main partners

supplying the Laiva gold mine with crushing screening conveying and minerals

processing equipment at an estimated value of EUR 30 million

TEXT amp PHOTOS Eero Haumlmaumllaumlinen

2983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

The Laiva gold mine was built in record time infrastructure

construction began in spring 2010 ore excavation started in

June 2011 and the first gold bar was casted in December 2011

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983110983141983137983156983157983154983141983140 983137983154983156

Just one year after starting the gold recov-

ery process Nordic Mines is on track toreaching a capacity of 5 kg of gold per day

At present the operations are averaging 3

to 4 kg of gold daily

The ore in the Laiva Gold Mine consists

of packages of gold-bearing quartz-filled

shear structures The deposit is more thana kilometer long and 700 meters wide The

total depth is still unknown but dr illings

carried out thus far have shown gold-bear-ing shear structures 300 meters below the

surface

A typical ore zone includes a large num-

ber of thin shear structures from 5 to 30per meter The ore zones are commonly 50

to 100 meters long several are 10 meters

deep and they range from a few meters to

20 meters cross strike The minimum min-ing width is 25 meters which means that

even a minor ore zone consists of at least10 to 50 shear structures

Conventional pattern blasting

with selective loading

Prior to mining Nordic Mines conducts

grade control drilling which provides

dense gold grade information and makes

it possible to outline the boundaries

between ore and waste The mining

technique applied is conventional pattern

blasting with selective loading This is oneof the most commonly used techniques in

large-scale open-pit mining

A typical blast in the Laiva mine is 50

meters long 100 meters wide and 5 metersdeep After blasting ore and waste aremined by selective loading

After investing some EUR 100 million

the Laiva mine now comprises an open-pit

mine with a modern complete crushinggrinding and processing circuit that ends

with the casting of gold doreacute bars

With a number of mine staff partners

sub-suppliers city and state officials inattendance the Laiva gold mine was offi-

cially inaugurated on August 16 2012

Michael Nilsson Managing Director

of Nordic Mines stressed in his speechthe importance of overcoming challenges

during the building of the mine

ldquoObviously the whole development

took us longer than expected Today weare pleasantly surprised by the size of our

operation We are becoming much bigger

than expectedrdquo gt

Chief Geologist Kimmo Lahtinen presenting narrow gold veins twisting at the Laiva North open-pit mine

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156983145983139983148983141

An international process package

The Metso package for the Laiva gold mine

included the main crushing screening

conveying regrinding leaching and pump-ing elements Metsorsquos office in Sala Swe-

den has served as the main project office

with Metso manufacturing units in FranceGermany Sweden and Finland responsiblefor the equipment supply

At Laiva the gold ore is classified after

selective excavating into two gold con-

tent classes All class A gold ore is takento Metsorsquos sturdy jaw crusher for primary

crushing while the class B ore is stocked for

possible future use After primary grinding

utilizing autogenous technology the ore is

screened and two Metso cones crush the

oversized pebbles For regrinding Metsorsquosball mill is used

During high- and low-grade leaching

processes a number of Metso pumps and

dewatering screens are used The whole

minerals processing system is controlled byMetsoDNA automation

Active exploration drilling going on

According to Mine Manager Tom Soumlder-

man the known gold ore reserves at the

Laiva gold mine amount to 169 million

tons but the potential for additional find-

ings looks good

ldquoWorking at the level of two million tonsper year our expected lifetime is about nine

years We carry out active exploration drill-

ing in Kaukainen Musunneva and Oltava

to locate nearby satellite ore bodies Anupdated detailed mine life plan will be pre-

pared during the autumnrdquo Soumlderman saysNordic Minesrsquo other exploration areas

include Tormua in Finland and Fjaumllltuna

and Vassbo in Sweden

More info

Alf Rydberg

Tel +46 70524 5837

alfrydbergmetsocom

Happy faces during the minersquos inaugural ceremony Mine Manager Tom Soumlderman (left) with Managing Director Michael Nilsson and Deputy Managing Director Krister Soumlderholm

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156

The story behind the discovery of the Laivamine is an interesting one During a hunt-

ing trip in the remote forests of Laivakan-

gas in 1979 Pentti Jaumlmbaumlck found an inter-esting-looking piece of stone Although hecould not see the gold hidden inside the

rock Pentti noticed the striking weight

and somewhat different look of the stone

Upon returning home Pentti sent thesample to Outokumpu which at the time

was the leading state-owned mining com-

pany in Finland After testing a high gold

content of 15 grams per ton was found

Gold deposit founded by a hunter

The founder of the Laiva gold deposit Mr Pentti

Jaumlmbaumlck was the guest of honor during theinauguration

Lennart Schoumlnning Chairman of the Board ofNordic Mines holding a gold doreacute bar worthsome EUR 320000

Outokumpu registered a mining claimon the area and conducted a series of

exploration drilling from 1981 to 1987 Due

to the low price level for gold no mine wasstarted at the time Other mining compa-nies such as Endomines held the mining

rights later

Nordic Mines with its sights set on

locating and exploiting gold in Swedenand Finland was founded in 2005 During

the same year the company purchased its

first mining rights at Laiva

Nordic Minesrsquo Laiva gold mine

LOCATION near the city of Raahe

northwestern Finland

GOLD ORE CONTENT average 16 gt

ORE EXTRACTED PER YEAR

12 million tons (present)

20 million tons (planned)

GOLD RECOVERY 85

TOTAL KNOWN ORE RESERVES

169 million tons

MINING METHOD

Selective open-pit benchingNUMBER OF EMPLOYEES

130 including contractors

METSO MAIN EQUIPMENT

2 Metso VF and 6 EMEG EME

vibrating feeders

8 Screens 1 MF 1 CVB and 6 KS

1 RCS Flash flotation unit

1 Metso SRR ball mill 18 x 4 m

1 Nordberg C160 jaw crusher

1 Nordberg HP100 cone crusher

1 Nordberg HP200 cone crusher

5 Nordberg NB series conveyors

73 Metso Slurry pumps ofvarious types and sizes

8132019 Results Minerals Aggregates 3 2012ENG

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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155

The newest member of the proven GP series cone crushers ndash theNordberg GP220 ndash offers a versatile alternative for any demanding

tertiary or quaternary or even secondary crushing operation fulfill-

ing all crushing needs and maximizing customersrsquo profitability

High-quality components and optimized castings and forgings

contribute to the GP220rsquos enhanced reliability and help to ensurethe highest level of crusher uptime

Thanks to the 200 kW (270 hp) power draw the GP220 performs

at a 20 to 30 percent higher capacity than other cone crusherbrands with an equal head diameter The large feed openingenables the feeding jaw crusher to run at 110 mm css Operational

flexibility is ensured by multiple strokes and six different cavities

Secondary crushing possible

thanks to cavity and stroke options

Thanks to the GP220rsquos cavity and stroke options secondary crush-

ing in addition to tertiary and quaternary stages is also possible

using cavities with a greater intake opening With the GP220 a suit-

able solution for producing excellent end-product gradations

can always be found

With advanced automation using IC50 or IC5000 operation

is safe and trouble-free The low height thanks to the patented

piston design makes replacement installations much easierA dynamic setting adjustment enables a fast response to process

optimization needs

The Nordberg GP220 weighs 10500 kg (23150 lbs) and hasa maximum real feed size of +200 mm (8rdquo) with strokes from

18ndash40 mm (57rdquondash1 47rdquo) The cavity options are EF F MF M C

and EC

A complete modular crusher steel structure is available for allGP series stationary installations including GP220 The platform

includes places for the lubrication unit motor automation or

pressure accumulator and pressurized sealing The only things

left to add are the feed and discharge conveyors

Main new features of the GP220 Large feed opening allows for secondary stage operation

Longer setting range of main shaft for better wear parts utilization

Stronger main components to carry high loads with a powerdraw as high as 200kW

More info

Hannu Vakkuri

Tel +358 50 317 0638

hannuvakkurimetsocom

Thanks to the large feed opening and wide selection of strokes and cavitiesthe new Nordberg GP220 cone crusher is a highly versatile cone novelty

More versatility with the newNordberg GP220 cone crusher

Reinforced head and frame castings combined with a 200kW power

draw make the GP220 cone a reliable crusher with maximum productivity

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Metsorsquos HRCtrade takes high pressure grinding roll technology to the next level

The new Lokotrack mobile conveyors come as tracked and wheeled models

Metsorsquos latest development in comminution equipment the HRCtradeis a major step in the profitable application of high-pressure grind-

ing roll (HPGR) technology Metso has made several key innova-

tions in order to increase throughput and decrease the total cost

of operation

Metsorsquos patented Arch frame creates an even gap setting acrossthe width of the tires limiting skewing that can result in downtime

for mining operations This anti-skewing Arch frame also prevents

damage to the roller bearings (caused by misalignment) that canoccur with the traditional HPGR design

Flanges maximize wear life and increase throughput

Used in place of spring-loaded cheek plates the flanges keep thebed of material within the crushing zone and prevent material

from bypassing the tires This enables greater circuit capacity and

increases the overall crushing efficiency

In addition by preventing material from bypassing the tires

even pressure across the width of the tire is better maintained

Distributing the pressure more evenly maximizes the tire life bypreventing a ldquobath tub effectrdquo in which the center of the tire wears

faster than the edgesVictoria Herman Metsorsquos Product Manager for the HRC notes

that this breakthrough design is a response to the growing needs

in the mining industry ldquoEnergy efficiency has been attracting our

customers to HPGR technology for yearsrdquo she says ldquoBut our design

concept increases capacity and crushing efficiency ndash and thatrsquossomething mining companies are always looking to improve onrdquo

The track-mounted Lokotrack CT32 and wheel-mounted Lokotrack

CW32 mobile conveyors offer an ideal solution for applications

that require high stockpile capacity and excellent material transfer

capabilities They also add flexibility to multi-stage crushing andscreening applications enabling easy and fast closed-circuit opera-

tion of mobile units

The conveyor novelties can be used in both mobile and station-

ary installations providing extra stockpiling capacity in situationswhere for example fewer wheel loaders are available

The HRC is ideal for high-tonnage hard rock applications andcan be used as a tertiary quaternary or pebble crusher Currently

several HRC units are in operation around the world ndash with a total

of 6500 operating hours including over 3800 hours in a mininghard rock application The machine does have range within hardrock applications itrsquos been designed for use in diamond iron ore

copper gold platinum and various industrial minerals

More info

Victoria Herman

Tel +1 717 309 1150

victoriahermanmetsocom

Several optional features such as hydraulic folding of tail sections

and dual hydraulic drive for increased throughput are available

The capacity of the CT32 and CW32 is 400 mtph (440 stph)feed size up to 150 mm (6rdquo) belt width 1050 mm (42rdquo) and dis-charge height 9120 mm (29rsquo 11rdquo) The CT32 is fitted with a Caterpil-

lar C2 diesel engine with 38kw (51 HP) power The CW32 is avail-

able for hydraulic or electric use

More info

Kimmo Anttila

Tel +358 50 433 3745

kimmoanttilametsocom

The new HRCtrade combines high crushing pressure and a low circulatingload resulting in the most efficient comminution

When flexibility in stockpiling capacityis required the answer can be foundin the new Lokotrack CT32 and

CW32 mobile conveyors

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Service creates value in ChinaChinarsquos most important gold producing area Yantai in northeastern China supplies more than 16 of the countryrsquos goldproduction each year With the gold market thriving the scale of gold production in Yantai has been expanding constantly

Zhongjia Mining Industry Co Ltd is one of the beneficiaries of this thriving industryTEXT amp PHOTOS Yan Xin

Inspection and maintenance of the HP500 cone crusher conducted by Metsorsquos service engineers

In 2011 Zhongjia Mining Industry pur-

chased a modular crushing and screen-ing system from Metso for its new gold

production project With the cooperation

between the two companies continuously

intensifying Zhongjia Mining Industry

signed an additional one-year Life CycleService (LCS) contract with Metso incorpo-

rating Metsorsquos global knowledge in equip-

ment processes and services

ldquoMetso customized a series of reason-

able service solutions also referred toas Metso Performance Solutions for us

including preventive maintenance services

process improvement personnel training

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155

and a procurement plan for wear parts

These really suit our needs perfectlyrdquo saysShen Yidong the Manager of ZhongjiaMining Industry

Effective preventive maintenanceFor mining corporations the biggestconcern is the economic losses caused by

the shutdown of equipment As a result

preventative maintenance is of vital impor-

tance During the contract period Metsoservice engineers offered 7-day tracking

service on the production site every month

to eliminate potential problems and thus

ensured the stability of the system

parts caused pressure on our working capi-tal which was not favorable for our long-

term developmentrdquo Shen explains

To solve this problem Metso designed

a rational stock plan of wear parts and built

a field warehouse In accordance with theuse and consumption of the liners the field

service engineers complement the stock tomake production and operations run more

smoothlyldquoNow when we need to replace the

wear parts we can use them before pay-

ment This not only simplifies the procure-

ment process but also liberates a largesum of our operating capital which can

be used for other business development

purposesrdquo says Shen

Best partner

ldquoAlthough the LCS contract incurs some

early purchase costs in the long run Metsorsquosprofessional and quality service will improve

the equipment efficiency reduce ourenergy consumption and ensure stable

operations thus generating more prof-

its This is the greatest value for us so the

investment is really worthwhile overall Inthe future we will choose more Metso prod-

ucts and services Taking all aspects into

consideration we believe Metso is the best

partner for usrdquo Shen Yidong concludes

More info

Thomas Bai Tel +86 13801009114

thomasbaimetsocom

ldquoIn the eight months since the contract

came into effect our corporation has notsuffered any financial losses due to equip-

ment breakdown The regular maintenance

has greatly improved the efficiency of our

entire crushing system In addition the

experienced engineers from Metso also

provided onsite training and guidancefor our staff and the tailored training has

greatly enhanced the operating abilities of

our employees and upgraded their overalllevel of competencerdquo says Shen Yidong

More productivity with

less consumption

Metsorsquos service contract focuses on real-

izing the optimum performance of each

process flow After analyzing Zhongjiarsquos

production system Metsorsquos techniciansproposed an adjustment to the closed side

setting of the HP500 for tertiary crushingin order to improve the efficiency of the

downstream fine crushing and milling pro-

cessing by over 10ldquoThe process flow improvement solu-

tions provided by Metso not only increased

the output of our gold concentrates but

also reduced our energy consumption andcostsrdquo says Shen

In the past wear parts procurement

took up a larger proportion of Zhongjiarsquos

total production costsldquoTo avoid downtime caused by the

shortage of wear parts we had to keepeight sets of various wear parts in place

However the cost of having so many wear

Zhongjia Mining Industryrsquos gold concentrates processing plant in China

8132019 Results Minerals Aggregates 3 2012ENG

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0983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

Safe quarrying high-

quality aggregates

8132019 Results Minerals Aggregates 3 2012ENG

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ldquoWe share a similar zero-accident strategy and target with Metso and have successfullyfollowed it Metso has also helped us to meet the strictest end-product quality andcubicity requirements set in Spainrdquo This is how Managing Director Intildeigo Ajuria ofOfitas de San Felices the leading hard rock quarrying company in Spain describesthe cooperation with MetsoTEXT Eero Haumlmaumllaumlinen PHOTOS Ofitas and Eero Haumlmaumllaumlinen

The San Felices quarry is situated in a picturesque mountainous landscapebetween the companyrsquos Rioja vineyards and the Bilbao-Madrid motorway

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Ofitas has pioneered the implementation

of several Metso novelties in the Spanish

market The company was the first to use

efficient large track-mounted Lokotrack jaw plants the unique mobile conveying

system and also the new-generation HP4

cone crushers

Today the company operates twomodern Metso stationary plants one in

Guadix near Granada and the newest one

in San Felices Haro Rioja community Both

quarries focus on refining hard rock by pro-cessing ophite rock into the highest quality

railway ballast asphalt and concrete mix

grades The company has a satellite quarry

near Vitoria in PentildeacerradaBeing situated next to a highway and

the famous Rioja vineyards Ofitas must pay

special attention to environmental issues

To minimize dust problems all conveyors

have special covers attached

Quality durability and service

The cooperation between Ofitas de San

Felices and Metso started back in 1973when the Ajuria family bought the com-

pany whose quarrying activities began in

1919 Intildeigo Ajuria has a clear vision of why

the cooperation has continued withoutinterruption for almost 40 years

long-standing personal relationshipsrdquoAjuria adds

Serving railways asphalt

and concrete producers

The year-old San Felices stationary instal-lation lies hidden in a mountainous area

south of the city of Vitoria in NorthernSpain The new plant replaces an old one

that complicated the extraction of ophiterock Both plants are delivered by Metso

With its two separate production lines

the new plant is able to produce all the

end products required ndash from railway bal-last to the finer grades needed for asphalt

and concrete

Due to lower demand the quarry cur-

rently produces some 4000 tons per day

At full capacity however the plant canreach 8000 tons of production per day

30ndash35 of which consists of railway ballastfor high-speed trains and 65ndash70 of chips

and sand Thanks to the versatile two-line con-

cept connected by transverse conveyors

up to 12 different end products can be pro-

duced Depending on the demand for endproducts the material can be guided either

to the HP4 cone or HP400 cone followed

by a Barmac vertical shaft impactor

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

The ophite feed is fed to the C125 jaw crusher by a sturdy dump truck

The key people running the new San Felicesquarry Mine Engineer Carlos Fernandez (left)Managing Director Intildeigo Ajuria with ProductionManager Julian Perez

ldquoThrough the years Metso machinery

has proven its production capacity and

durability resulting in high-quality end

products A big plus for us has also beenthe quick response time to our process

challenges or servicerdquo

ldquoIn fact our cooperation extends

beyond day-to-day business matters to

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155

Meeting the strictest cubicity demands

The Spanish regulations concerning end-product cubicity are becoming more

demanding The flakiness percentage of

railway ballast must be below 10 and for

asphalt and concrete aggregates less than

15

ldquoWith Metsorsquos HP4 cone and the Barmacvertical shaft impactor we can meet even

the strictest cubicity demands We believe

that our high quality is helping us to sur-vive in the present recessionrdquo notes Mine

Engineer Carlos Fernandez

ldquoWe hope to increase the total extrac-

tion of the three quarries from the present15 million tons per year because our plant

capacity allows more than double thatrdquo

Fernandez adds

More info

Angel Luis Garcia Tel +34 686 94 35 30

angelluisgarciametsocom

In addition to being the leading Spanish

quarry to process hard rock Ofitas de SanFelices also cultivates 34 hectares of vine-yards next to the quarry which is situated

in the famous Rioja wine area

The company has previously sold a

harvest of over 200000 kg of Tempranillo

grapes to local red-wine makers Recentlythe company built its own wine process-

ing plant to process 10000ndash15000 kg of

grapes themselves

Aggregates and wine production

Andoni Ajuria the founder of Ofitas de san Felices (left) with Intildeigo Ajuria the present ManagingDirector tasting wine from the companyrsquos own vineyards

The first vintage wine of Ofitas har-

vested in autumn 2010 is now maturingin oak barrels After maturing for 12 to 15months the wine is called crianza and after

two years it will be granted the classifica-

tion reserva

ldquoWinemaking is not a business but

a hobby for us We give our wine out aspresents and drink it when we meet

our suppliers and friendsrdquo Intildeigo Ajuria

comments

For environmental protectionall of San Felicesrsquos plantconveyors are covered

Ofitas de San Felices quarry

LOCATION Haro near the city

of Vitoria northern Spain

SIZE 100 hectares

ROCK TYPE Ophite with Los Angeles

index of 9ndash10

PRESENT DAILY EXTRACTION 3000 tons

of ophiteNUMBER OF PERSONNEL 30

RESERVES 10 million tons

MAIN END PRODUCTS 0ndash2 mm

2ndash4 mm 4ndash10 mm 10ndash16 mm

16ndash22 mm 25ndash60 mm (ballast)

METSO MAIN EQUIPMENT

VF feeder

C125 jaw crusher

ndash feed size 0ndash800 mm

ndash css 130ndash140 mm

HP400 cone crusher

ndash feed size 80ndash250 mm

ndash css 40 mm HP4 cone crusher

ndash feed size 40ndash80 mm

ndash css 15 mm

Barmac 6150 VSI crusher

4 CVB2060 screens

2 TS32 screens

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Metso Distribution Centers he

Europe (Tongeren Belgium)

France (Macon)

Czech Republic (Přerov)

Austria (Vienna)

2271 d

Brazil (Sorocaba SP)

1014 d

USA (Columbia SC)

1690 d

USA (Waukesha WI)

434 d

South Africa (Vereeniging)

Ghana (Tarkwa)

Meacutexico (Irapuato)

Peru (Lima)

Chile (Concoacuten)

788 d

Sweden ( Trelleborg)

Finland (Tampere)

UK (Rugby)

865 d

Russia (St Petersburg)

Brazil (Parauapebas PA)

206 d

4983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983122983141983152983151983154983156983145983150983143 983154983141983155

In the case of an equipment failure or

a planned service shutdown resuming

production as quickly as possible is crucialEach hour spent waiting for a spare part to

arrive equals money lost Whether the right

part takes 12 or 48 hours to arrive really

makes a difference

The comprehensive and global Metsospare and wear parts service network pro-

vides you with the right part in the right

place and at the right time Our strategi-

cally located Distribution Centers and

Satellite Warehouses are on call 24 hoursa day 7 days a week ensuring efficient

parts replacement near you

Check out the locations of the MetsoDistribution Centers and how many parts

pass through them each day

More info

Marcelo Farah

Tel +55 15 2102 1315

marcelofarahmetsocom

you minimize downtime

Australia (Perth)

746 d

China (Tianjin)

China (Kunming)

China (Shanghai)

393 d

India (Faridabad)

India (Ahmedabad)

India (Hyderabad)

India (Bhubaneswar)

India (Bangalore)

419 d

Russia (Yekaterinburg)

Australia (Newcastle)

New Zealand (Matamata)

983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088

TEXT Sofia Williams

Singapore (Singapore)

Distribution Center Satellite Warehouse

8132019 Results Minerals Aggregates 3 2012ENG

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Following a large investment

in Metso crushing equipmentand services Buena Vista del

Cobre is now expanding the

mine site to include even more

equipment ndash and with thatexpansion comes the need for

more local service resources

Metso and Buena Vista del

Cobre have entered into a Life

Cycle Service agreement forthe plant and construction of a

brand new Metso service hub

is under way in Cananea

New facility new

level of service

The Cananea service hub

which will be up and running in early 2013will support the recent expansion and resur-

gence of Buena Vista del Cobre Initially it

will be a major repair and assembly center

for pumps crushers and screens and will

provide for rubber covering capabilitiesBut the 8000-square-meter facilityrsquos service

offering will be expansive including a con-

signment stock inventory to help serve theminersquos varying needs Metso currently has

50 service team members on site

Although Buena Vista del Cobre was a

key influencer in building the new servicehub this location will also enable Metso to

expand its capabilities and provide local

support to the entire mining community

in northwest Mexico The Cananea hub

will serve a number of major copper and

gold mines in the region including MineraFriscorsquos San Felipe Fresnillorsquos Milpillas and

Grupo Mexicorsquos Mexicana de Cobre

ldquoBuena Vista del Cobre is the biggestcustomer we have in Mexico today and

with this expansion project itrsquos only going

to grow and be strongerrdquo says Felix Forna-

guera Director of Services Mexico CentralAmerica and Caribbean ldquoWith that said the

idea behind the Cananea service hub is to

provide a central location for local support

for all our major customers in the areardquo

Establishing safety

ldquoIt was key to have our support here in

Cananea because the Buena Vista delCobre started from the ground uprdquo saysFelix ldquoWersquove been able to help the cus-

tomer to establish the best in support

service and operations from the very

beginningrdquo And this ground-up approachincluded a major focus on safety

Metso worked closely with Buena Vista

del Cobre to establish the safety proto-

col by which the mine operates Basedon Metsorsquos expertise the safety measures

put in place have enabled the mine to

become strict and efficient in its operations

and maintenance procedures To achievethis Metso worked closely with local andnational authorities to ensure the safety

plan was comprehensive and in accord-

ance with all established legal bodies

The best in regional support

The service hub in Cananea is a prime

example of Metsorsquos focus on providing local

service and support to its customers all

Service shines in Cananea MexicoAfter three years of inactivity the Buena Vista del Cobre mine in Cananea Sonora Mexico has been operational since 2010A mine that was inactive for such a significant amount of time however requires a great deal of support to successfullyrestart the plant and bring it back to an operational and profitable state

TEXT Deanna Lee PHOTO Metso

over the world ldquoWe are the first

company developing this kindof service in northwest Mexicordquo

adds Felix ldquoOur people have

developed a close relationship

with the team at the mine Itrsquosmore than a supplier relation-

ship our guys are inside the

mine living and working thererdquo

In fact this is the model

that Metso is using in servicehubs all over the globe build-

ing modern facilities bringing

teams on site and workinghand in hand with mine

operators The Cananea Service

hub is only the most recent

example of Metsorsquos commit-ment to service and northwest Mexico is

yet another mining hotbed thatrsquos going to

benefit from the companyrsquos support

More info

Felix Fornaguera Tel +52 4621079227

felixfornaguerametsocom

A mining cone serviced by Metso at the Buena Vista del Cobre mine inSonora Mexico

ldquoThe new Cananea service center will be a majorrepair and assembly center for pumps crushersand screensrdquo says Felix Fornaguera Director ofServices Mexico Central America and Caribbean

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

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During the MINExpo exhibition over 1300 people visited the Metso stand

983122983141983152983151983154983156983145983150983143 983154983141983155

Held every four years MIN-Expo consistently grows so

perennial exhibitors like Metso

are challenged with elevating

their presence and drawingin new (and greater numbers

of ) visitors each year ldquoItrsquos not

necessarily a challenge to lsquotoprsquo

our last showingrdquo says Keith

Ference Vice President ofmarketing and communica-

tions North America ldquoThere

are four years between eachMINExpo so we always have

a lot to say and reveal to our

customersrdquo The real challenge

he says is finding an exciting

and dynamic way to deliverthe message ldquoTherersquos so much

to see here so your booth has

to be compelling from the

outside-in and thatrsquos what

we always try to dordquo

Service sets the stage

The Metso booth created buzzin a number of ways and per-

haps the most striking (partly

due to its size) was the live

theater presentation As visitorspassed through the aisles of the show-

room the sights and sounds from Metsorsquos

theater were hard to miss And once guests

entered they were captivated by a short

high-energy video presentation focused

on Metsorsquos service capabilities The message was simple Metso is ldquoyour

local service partner rdquo for all mining and

construction needs The video showed ourservice teams in action all over the world

and the audience came away with an

understanding about Metsorsquos commitment

to service Customers can count on morethan 70 local service centers run by more

than 1700 expert technicians delivering

Metso makes an impact at MINExpo 2012At this yearrsquos MINExpo International nearly 60000 attendees flocked to Las Vegas Nevada the largest turnout in showhistory The visitors ndash mining professionals from all over the globe ndash explored 850000 square feet of showroom spacefeaturing the industry rsquos latest technology equipment products and services They toured the show for three days

seeking the latest and greatest from more than 1800 exhibitorsTEXT Keith Ference PHOTOS Tracey Ford Perry

detailed descriptions andphotos of all of Metsorsquos mining

and construction products and

services The app also provides

digital access to Results and asearchable database of sales

contacts By day three of the

show MetsoMAP had been

downloaded by more than

500 usersIn addition to the app the

booth was equipped with

several LCD screens each con-trolled by Metso experts who

used their iPads to present new

products like the Megalinertrade

and the HRCtrade A featured

presentation on Metsorsquos lineupof energy-efficient comminu-

tion equipment including the

VERTIMILLreg SMD and MP-1250

cone crusher was also avail-

able letting customers seehow Metso technology delivers

some of the worldrsquos most effi-

cient size reduction

Measuring MINExpo success

After a very busy three days

(on top of months of prepara-tion leading up to the show) everyone

involved with MINExpo ndash from the North

American marketing team responsible for

the booth to the product managers and

sales force that worked the floor ndash is view-

ing the show as a success ldquoTherersquos alwaysa sigh of relief after each (MINExpo)rdquo says

Keith ldquoAnd overall the initial feedback

and response has been very positiverdquoWith more than 1300 visitors to the

booth Metso certainly made an impact

ldquoWe learn a lot from each show and with

some time wersquoll have a better understand-ing of the tangible results of our effortsrdquo

Keith adds

reliable service for mining equipment as

well as customized cost-effective life-cycle

services contracts

Technology ndash MetsoMAP

is an industry firstMINExpo provided the industry with its firstglimpse of Metsorsquos revolutionary iPad app

MetsoMAP The app was demoed to the

boothrsquos visitors via ldquothe worldrsquos largest iPadrdquo

a custom-made 80-inch screen that show-cased all of its capabilities most of which are

groundbreaking in the industry MetsoMAPrsquos

simple interface is highly intuitive making

it easy to view process animations videos

The presentation of the new HP cone crusher attracted a large audience

8132019 Results Minerals Aggregates 3 2012ENG

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When yoursquore allowed less than a dozen days per year for breakdowns repair andmaintenance every single hour during a service shutdown counts There simplyisnrsquot any room for surprises Thatrsquos why Boliden counts on MetsoTEXT amp PHOTOS Sofia Williams

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Kurt Kalla Site Managerof Metso Gaumlllivare ServiceCenter is responsible forthe maintenance of Aitik

Metso and Boliden Strivingtogether for 97 uptime

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983122983141983152983151983154983156983145983150983143 983154983141983155

One of the biggest copper mines in

Europe Bolidenrsquos Aitik is located deep inthe wilderness of Swedish Lapland next to

the small town of Gaumlllivare The mine has

been operating since 1968 and a recent

expansion has increased its annual ore

production to 36 million tons

But the ambitious Swedes are not will-ing to lay back and relax just yet Bolidenrsquos

new aim is to reach a production rate of

45 million tons of ore per year in AitikAfter that Perhaps more than 55 million

tons The ore concentration in Aitik is very

low-grade with a mere 022 copper con-

tent hence the need for high capacityAchieving the ambitious production

goal requires maximum plant availability

This means that everything from the crush-

ers to the filters must be up and runningfor approximately 97 percent of the time

Thatrsquos where Metso comes into play

A cost-per-ton contract in action

The maximum uptime requirement allowsless than a dozen days per year for break-

downs repair and maintenance at Aitik

Every single hour during a service shut-

down counts There simply isnrsquot any roomfor surprises

Executing a successful shutdown under

such conditions requires a reliable service

partner not afraid of challenges and this iswhy Boliden has entrusted Aitikrsquos services

operations to Metso Boliden and Metsohave worked together since the 1960s

and the collaboration took another step

forward in September 2012 when the twocompanies signed a three-year extension

of the services contract for Boliden Aitik

ldquoThe new contract is a cost-per-ton

agreement We get paid based on Aitikrsquos

production Itrsquos a win-win deal for both par-

ties but also a new mindset for usrdquo explainsKurt Kalla Site Manager of Metso Gaumlllivare

Service Center responsible for serving Aitik

From now on the duration of the shut-down is what matters the most According

to Kalla the Metso service organization in

Gaumlllivare is now streamlining its operations

to fit the bill and has already witnessed thestrategy working In August 2012 Metso

carried out a 188-hour service shutdown in

Aitik which turned out to be a success

Zero tolerance for injury

One key factor to the success was theextensive planning of precautionary health

safety and environment procedures under-

taken by Metso prior to the shutdown Thanks to strict measures applied no

injuries or accidents occurred during the

shutdown and the work could easily be

finished on scheduleMats Johansson Health Safety

and Environment Manager for Metso in

Sweden explains how this was achieved

rdquoPlanning of the shutdown included arisk analysis for all new tasks participating

in Bolidenrsquos safety coordination meetingsmeeting with both Metso supervisors and

subcontractor supervisors and finally a

meeting with the entire staff participating

in the shutdown where everyone had to

sign a document stating their commitmentto the information providedrdquo he says

During the actual shutdown plenty of

new barriers signs and awareness cones

were put in place as a result of observa-tions from previous audits and safety plans

and risk analyses were readily available

in the work area Metso and Boliden also

introduced a Mill Inching permit a certifi-cate for completing a mandatory course for

those involved in the process In addition

Metso carried out random safety audits

during the shutdown to make sure thestrict policy was followed

According to Boliden Metsorsquos way of

working is a good example of how health

and safety precautions should be handled

ldquoMetso is a good example of how towork with safety and health plans risk

analysis permits and welding permits

Their table with all binders in the second-

ary mill area was exemplaryrdquo says Kjell-Arne

Johansson a technician from Boliden

The use of the new Metso Megalinertrade

system in the lining of Aitikrsquos Metso AG

mills has also improved the safety of main-tenance staff The Metso Megalinertrade con-

sists of larger-than-average liners bolted

in position from outside the mill Mainte-

nance technicians no longer need to go

inside the mill and stand in the dangerousdrop-zone of the liners gt

Boliden aims to reach a production rate of 45 million tons of ore per yearin the Aitik mine site

ldquoA complete risk analysis was conducted during the planningof the shutdownrdquo comments Mats Johansson Health Safetyand Environment Manager for Metso in Sweden

8132019 Results Minerals Aggregates 3 2012ENG

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Service the Metso way

24 hours a day 365 days a year

In addition to paying close attention to

health and safety issues executing an effi-

cient shutdown requires careful planning

and timing of every step in the mainte-

nance process Wear and spare parts have

to be available on time and a repair shoplarge enough to accommodate equipment

located close by

ldquoTo keep maintenance breaks as short

as possible we aim to replace the pump on

site and bring the old one for repair to our

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

nearby facilities This method gives us the

peace to do a good job and keep the cus-

tomerrsquos operations runningrdquo Kalla describes

the Metso way of handling Aitikrsquos pump

maintenance

Metso is currently expanding its Gaumllli-

vare service center to include a distribu-

tion center for wear and spare parts andalso concentrating its previously scattered

operations under one roof in its Vuoskon-

jaumlrvivaumlgen facility The expansion is due to

be completed by 2014

Metso equipment

delivered to Aitik36

bull 2 AG mills diameter 116 x

137 m gearless 22-MW motor

bull 2 Pebble mills diameter 91 x

113m dual 5-MW pinion drive

bull 3 VPA pressure filters VPA 1540-54

bull 12 sample pumps and pipes

VF50

bull 60 Various slurry pumps up to

MR500 modelbull Appr 5000 m rubber-lined slurry

pipes up to 600 mm diameter

bull Appr 5000 m rubber-lined by

gravity pipes up to 600 mm

diameter

bull Appr 5000 m rubber hoses

up to 600 mm diameter

Not only does the expansion make ser-

vice shutdowns at Aitik run more smoothly

it guarantees a more comprehensive

on-call emergency service response in the

region ndash thanks to the spare and wear parts

inventory available 24 hours a day 365

days a year

More info

Lars Rosenling

Tel +46 70 107 45 90

larsrosenlingmetsocom

Metso grinding equipment dominates the view in the concentrator

Safety on site is made up of small things like

making sure that everyone remembers to secure

the hoses in place

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983122983141983152983151983154983156983145983150983143 983154983141983155

Pebbles have always been a

challenge for producers of sandsince they cannot be returned

to rivers after extraction For

decades the processing of this

material resulted in a huge

environmental liability with alarge amount of pebbles hav-

ing to be stored away and left

unused

Transforming problems into

business opportunities

Areia amp Cia (areia = sand) has

operated in this market forover 20 years and decided to

enlist the help of Metso to find

a profitable solution for the

processing of pebbles

In July 2011 analyses werebegun to assess the abrasive-

ness and crushability of the

material Four alternatives wereidentified for processing and

transforming pebbles into sand

Initially Areia amp Cia was

interested in acquiring an

impactor for its reason-able price level However the

customer wanted to process

all the pebbles that were col-

lected daily in addition to some of the

material that it had stored In weighing theresults expected by the customer and the

excessive abrasiveness of the material the

HP200 cone crusher was decided on as thebest alternative

Areia amp Cia made the required invest-

ment and after using the HP200 for just

six months the company has already beenreporting outstanding results The HP200

not only transforms pebbles into sand but

also produces sand of excellent quality

with high yield and low maintenanceWith minor adjustments the HP200

also enables the production of sand withspecific particle size distribution for special

applications such as filtering sand blasting

and foundry sand adding value to the prod-

uct and increasing the types of sand offeredldquoMetso is pleased that the HP200 not

only enabled the processing of a product

that had been set aside as unusable but

HP200 cone transforms pebblesinto high-quality sandOver the last few decades Brazilian economic growth has been driving demand for construction aggregates The market

for sand in turn has been experiencing major difficulties in maintaining a consistent supply Presently one of the mainchallenges the industry faces is the large amount of pebbles that are obtained in the process of extracting sand at timesconstituting nearly 50 of the volume of material dredged from riverbeds

TEXT Sheila Ivers PHOTO Areia amp Cia

also that it opened up new

market opportunities for Areiaamp Cia Thatrsquos the standard we

seek to deliver to our custom-

ersrdquo states Luiz Oliveira Techni-

cal Salesperson of Metso Brazil

HP cones entering the

Brazilian sand-making

market

Todayrsquos cones such as theHP200 have high resistance

to impacts and abrasiveness

more efficient crushing cham-

bers low maintenance costsand excellent productivity

Following the acquisition of

the HP200 Areia amp Cia is now

also producing special sands

that command a price that is100 higher than common

sand The entire stockpile of

pebbles accumulated through-out the companyrsquos 20 years of

operations has already been

transformed into sand and the

stock of pebbles held by com-

petitors is also being purchasedfor processing

Cristiane Brizolari the

owner of Areia amp Cia confirms

the transformation that has taken place in

the production and commercial processldquoThe HP200 opened up new niches in

the market enabling the production of dif-

ferent types of sand with added valuerdquo

More info

Luiz Oliveira

Tel +55 011 9971 3603

luizoliveirametsocom

After the pebbles are crushed into sand with the HP200 cone crusherdifferent grades are screened for various end uses

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Where therersquos a will we dig a wayAFCONS-Strabag and Metso embark on tunnel project together

When the joint venture AFCONS-Strabag initiated work on the Rohtang bypass tunnel project at an altitude of 3980 metersabove sea level in Himachal Pradesh India they deliberated each aspect with clockwork precision The project involved anumber of surprises and challenges and required technology and project management skills that were second to none

TEXT amp PHOTOS Monisha Majumdar

Cutting a 10-meter-wide and nearly 9-kilo-

meter-long tunnel through the Himalayas

in one of the toughest terrains and cli-mates in India makes for quite a challengeResults set out to find out how AFCONS-

Strabag and Metso are making their way in

one of their most critical projects to date

The only road connection to the north-Indian border region of the province

Himachal-Pradesh and beyond the Manali-

Leh highway leads across the Rohtang

pass Due to the heavy snowfall and high-

velocity winds in this region the towns

located north of the pass are cut off from

the rest of the country during winter for atleast four often even six months each year

A tunnel with strategic importance

With the construction of the tunnel at

3100 m above sea level the Manali-Lehhighway will become an all-weather road

thereby enabling a significant improve-

ment in the economic development of

northern Himachal-Pradesh and an alter-

nate route to the strategically important

Ladakh region

Manali south of the pass is an alreadywell-developed tourist location that is

becoming more and more popular Upon

completion of the tunnel it is likely that

tourist activities will extend to the areanorth of the pass Moreover the tunnel

shortens the distance between the towns

of Manali and Leh by approximately 45 km

thus saving several hours on the small dan-gerous pass road

The Rohtang pass in the Western Himalaya

region of Northern India with its altitude ofalmost four kilometers ranks among thehighest trafficable passes in the world

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983122983141983152983151983154983156983145983150983143 983154983141983155

The 88-km long horse-shoe-shaped

tunnel provides space for a two-lane8-m-wide carriageway as well as a one-

meter-wide footpath on both sides A

22-m-high and 36-m-wide emergency

tunnel will be integrated in the tun-

nel cross-section Altogether more than

800000 msup3 of rock will be moved Tunneling works started around spring

2010 with excavation driven from both por-

tals As the north portal is inaccessible dur-ing winter closure the excavation focused

on the south After a planned construction

period of 55 years the tunnel is scheduled

to be completed by the end of 2015

Best man for the job

The BRO (Border Road Organization)

wanted to roll out a global tender for theproject due to the challenges that such a

project involves and also considering thatitrsquos the first time in India that a project of

this scale was to be carried out This imme-

diately triggered the need to roll out aglobal tender All major Indian construction

companies bid for it some individually and

some in partnerships

Strabag an Austrian tunnel specialistwas one of the companies who bid for the

project along with AFCONS a Mumbai-

based infrastructure company In Septem-

ber 2009 AFCONS-Strabag was awardedthe contract

Mr Sunil Tyagi Deputy Project Man-ager at AFCONS had this to say about the

unique projectldquoThis project is located in the Himalayas

and as far as we understand the terrain

there is among the toughest We came out

with a new technology and to be honestit is a fairly simple one We would generally

start with the traditional technology of drill-

ing and blasting and then obtain our muck

feed from the inwardbottom of the tunnelrdquo

ldquoThe technology is supplied by Rowa Tunneling Logistics and this is the first

time it is being used in Asia A jaw crusheris placed at a distance of about 40-45

meters behind the face The blasted muckextracted from the face is fed to the crusher

to reduce the lump size and then through

an overhead conveyor transport system

it is then transported out of the tunnelrdquoldquoThis enables free movement of man

and machinery in the lower area or spe-

cifically on the ground area If we were to

conforms to the Indian standard for fines amp

coarse aggregates as prescribed in IS383-1970

The plant was up and running in good

condition and performing to AFCONSrsquos

satisfactionldquoWe have worked with Metso in earlier

projects and are quite impressed by thekind of technology amp services they provide

We have a history together so the trust fac-tor also comes inrdquo explains Dhiman on their

choice of Metso as a partner

Service makes the difference

ldquoMetsorsquos services have made a big dif-ference in the project Without them we

would still be struggling with the machin-

ery and production The service is really

good and the service engineers are knowl-edgeable prompt and quick to act Any

problem can be solved by Metso We donrsquothave to wait until a service engineer turns

up ndash they have the capacity to solve prob-lems over the phone as wellrdquo says Dhiman

ldquoThe Metso plant didnrsquot create any prob-

lems for us We had problems in logistics

the feed was sticky and the weather condi-tions were bad but thankfully we did not

face any problems with production and

efficiency as the Metso plant is performing

very wellrdquo Dhiman concludes

More info

Amol Sinha Tel +91 9811 671 924

amolsinhametsocom

use the old conventional technology this

wouldnrsquot have worked for us in the stipu-lated timerdquo Mr Tyagi adds

When the going gets tough

partner with the toughest

Sensitive projects require the best technol-

ogy After AFCONS-Strabag landed theproject Metso was an obvious choice as a

technology provider not only because of

the long-standing business relationshipbut also for the sheer consistency in prod-

uct quality and service deliverance Metso

strives for

ldquoAfter signing the project we faced alot of road blocks including extreme cold

avalanches roadblocks less oxygen ndash you

name it we faced itrdquo explains Ankit Dhi-

man Plant Manager at AFCONS-Strabag The Rohtang valley is known for its

notorious avalanches and landslides SoAFCONS had to take extra steps and safety

precautions against hazards on the site

ldquoIn this freezing cold not just us humansbut also the machines are at increased risk

of damage I remember when we used

to run the plant during winter the diesel

engines would freeze We had to constantlyheat up the fuel container to get the plant

running And even the sand in the sand

trap would freeze so we had to clean it on

a daily basis to stop the pipes from mal-functioningrdquo Dhiman adds

Plant designed for difficult terrain

Difficult terrain coupled with space con-straints led Metso engineers to put their

minds together to come up with a suitable

plant configuration After studying the

requirements of the project Metso sug-

gested a 150-tons-per-hour three-stagemodular plant using a C106 jaw crusher

a GP11F secondary cone crusher and a

B7150 tertiary vertical shaft impact crusher

In addition considering the unpredict-ability of the feed the plant was about

to reach a point where the amount offines to be handled could be increased

dramatically Metso strongly suggested the TK11-27-3V grizzly scalper and this became

the first-ever TK scalper to be supplied by

Metso to an Indian customer Also in order

to get better products a sand trap SF2360was added to the configuration

The sand trap is important equipment

for this project as it washes the sand thatMr Sunil Tyagi Deputy Project ManagerAFCONS-Strabag

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Smooth transition to new-generation jaw crusher in Germany

Roumlhrig is a German company with a rich heritage The company has been quarrying granite at its plant in Bergstrasse inthe Sonderbach district of Heppenheim for three generations

TEXT amp PHOTOS Ralf Goffin

Roumlhrigrsquos superior product variety is onereason why the companyrsquos proximity to its

customers can be understood in more than

just physical terms The companyrsquos high

level of innovation has allowed it to estab-lish itself as a reliable supplier of materials

both regionally and internationally This

operational and technical expertise always

manages to keep in step with growing

market requirements

In terms of technical processing equip-

ment Roumlhrig has used a Nordberg C160stationary jaw crusher from Metso since

1992 At the start of 2012 it was finally

exchanged for a more up-to-date version

from the same model range

Metsorsquos C Series is specifically designed

to pre-crush hard rock and can cope effort-

lessly with even the hardest of materials

The dimensions of the new stationary jawcrusher are identical to those of the old

one which means that it could simply be

slotted into the housing vacated by the

previous version

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983122983141983152983151983154983156983145983150983143 983154983141983155

Third-generation Managing DirectorMarco Roumlhrig expects the new machinersquos

service life to be just as long as the previ-

ous model due to the product upgrades

that have been implemented The integral motor base is another plus

point in models made by other manu-

facturers it is located outside the crusher

This element of good fortune ensured that

Roumlhrig could reuse the housing withoutany additional rebuilding

Another advantage lies in the revision

of the guards for the C160rsquos drivetrain andflywheel The sturdier construction method

used for the crusher requires fewer parts

which facilitates easier installation andmaintenance and it makes it simpler to

access the motor

Under the watchful eye of Metsorsquos

Assembly Manager Maik Engelstaumltterthe entire project including removal and

installation was successfully completed

within two weeks

Installation making the most

of the available space

Roumlhrig will likely remember the day the

new crusher was installed for a long time

the pitman and main frame were deliveredseparately prior to installation and assem-

bled on site It took just one hour to replace

the old stationary crusher with the new

model A lorry-mounted crane was used toposition the 85-ton crusher with millimeter

precision in the crushing plant Once the

new crusher had been positioned in theexisting steel structure the next task wasto fix it into place as securely as possible

despite the limited space Special vibration

dampers were installed at a height of two

meters to prevent the crusher from sliding

Norbert Ried (fourth from left) installed thenew C160rsquos predecessor 20 years ago and isdelighted at the durability of the powerfulcrusher that is now making way for a newermodel Also pictured from left to right ManagerVolker Angermann Assembly Manager Maik

Engelstaumltter Technical Manager Stefan

Koob Project Manager Dominic SchoumlnhardtManaging Director Marco Roumlhrig Service

Technician Stefan Kolze and employees ofthe installation company Stafemo

On the hook after theold C160 was liftedout by crane the newcrusher was installedin almost no timeOnly the roof of thehousing had to beremoved

sideways off its mount An initial test run

with materials was carried out around oneweek later after all the electrical cables had

been installed

Simultaneously with the installation

of the C160 which is the first of the latest

generation of crushers to be installed in

Germany a new Nordberg GP100 conecrusher was also being installed in Roumlhrigrsquos

chipping plant Roumlhrig is convinced that

the technical improvements made tothe new Metso crusher can only be an

advantage worldwide

Roumlhrig places great value on consistent

product quality maximum added valueand optimum refinement of its product

range Bearing in mind that Roumlhrig has

enough reserves of raw material to last

for the next 150 years the company canconfidently continue to develop with an

emphasis on quality rather than quantity

More info

Dominic Schoenhardt

Tel +49 (0)621 727 00 610

dominicschoenhardtmetsocom

8132019 Results Minerals Aggregates 3 2012ENG

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Groupe Charier Carriegravere de la Mariais France

Quarrying with certi1047297ed quality The Charier Group with its 1600-strong workforce is a family business thatthis year celebrates 115 years of quarrying The company pursues a long-termdevelopment policy that since 2007 has seen processing installations upgradedat 4 of its 9 extraction sites

TEXT Liliane Boutin (with extracts from Mines amp Carriegraveres and Terrassements amp Carriegraveres magazines)PHOTO Baloon photo

The processing installation is of the horizontal type with a primary station located 56 meters below the site access road to keep it hidden from view

The crushing and screening installation at

Charierrsquos CM La Mariais quarry (at Donges

on the Loire estuary) has been in opera-tion since September 2011 Based on theoperatorrsquos ideas it was designed by Metso

to replace a worn-out installation installed

right on top of the seam being extracted

Since its commissioning it has becomethe second quarry in the company to

receive ISO 14 001 certification

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983122983141983152983151983154983156983145983150983143 983154983141983155

tertiary material of sand and gravel for the

local market to use in concrete surfacingprefabrication etcrdquo

Incorporation of a screening station

The stone extracted from La Mariais is

according to the quarry granitic gneiss

sound and homogeneous with a LosAngeles index of 15 good wear resist-

ance with an MDE of 10 a true density of

265 and a certain abrasiveness (2000 gt)ldquoCharacteristically it has a tendency to form

blocksrdquo Leblin points out

The main criteria in designing the instal-

lation was to provide an output of 600000metric tons from one station (38 hours

week) to produce materials aimed at the

concrete and surfacing markets ldquowhich

involved providing a tertiary station withscreening plantrdquo he adds

With this new unit the operating com-pany expands its product range through

the addition of fine materials obtained

from the tertiary screening station This unitis capable of producing 170 tonshour of

020

Preserving the environment

and optimizing safety

The screens have motorized bogies and

retractable walkways to facilitate access

when the screens are opened for main-tenance Other walkways provide access

to the tunnel input feeders The feederscan be isolated with hydraulic rod gate

bars this hydraulic assistance eliminatesthe need to use a heavy hammer to lodge

these metal bars

All conveyors transporting fines (02

and 04) are covered with a tarpaulin to

avoid flying dust and all the screens arehooded (metal cover with Trellex seal-

ing) The Brunone company has installed

dust-tight containment at the outlet of the

tertiary station crushers (HP300 and HP4)on the belt located under the screens

and under the hoppers located belowthe tertiary screens The crushers are put

under negative pressure and the finesare extracted through sleeve filters (7000

m3 h) with declogging which deposits the

dust back onto the conveyor belt

A high-pressure 100 bar water mist sys-tem has been installed at the primary sta-

tion discharge at the secondary crusherrsquos

discharge chutes (Omnicone) and at the

transfer points on the belt

Designed to last

ldquoThis type of new installation can easily last

thirty yearsrdquo affirms Project Leader Bruno

Peix of Metso ldquoIt quite simply depends on

how well it is maintained Thatrsquos why weprovide maintenance contracts that call for

our technicians to make regular inspection

visits and carry out preventive mainte-nance and any necessary repairsrdquo

In 2011 Metso commissioned about

10 new processing units in France like

the one at La Mariais quarry

More info

Frederic Bazire

Tel +33 (0)681442804

fredericbaziremetsocom

Key figures

DURATION OF WORKS 15 months

DRAWING OFFICE TIME 7800 hours

HEIGHT OF SILOS AND GRINDER BUILDINGS

15 m

TOTAL LENGTH OF CONVEYORS 14 km

WEIGHT OF THE INSTALLATION

1200 metric tons

CONCRETE POURED 1800 cubic meters

PROJECT SITE WORKFORCE 30

INSTALLED POWER 2200 kW(not including pumps 200 kW)

METSO EQUIPMENT

Primary

Vibrating feeder PF561-2V

Primary grizzly VG540-3V

Grizzly feeder TK13-20-3V

Jaw crusher C145 with

hydraulic setting

Secondary

Vibrating screen CVB 2050

refurbished

Cone crusher Omnicocircne 1352 SX

with Metso IC7000 controller Ellivar 16 (16 msup2 3 decks) screen

refurbished by Metso

Tertiary

Cone crusher HP300

Cone crusher HP4

2 Ellivar 20 screens (20 m23 decks) for final products

Expanding the production range

ldquoSince the mid-1990s when we became

owners of La Mariais we had used mobilemachinery with an assembly of beltconveyorsrdquo recalls Daniel Leblin Charierrsquos

Technical Manager for site construction

and maintenance

ldquoIt became clear that we needed ahigher performance tool to achieve the

dual goals of reaching one million metric

tonsrsquo maximum production and producing

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Big Lokotrack LT550GPF boostsquarrying productivity by a thirdMaximizing the productivity of operations is a key issue when striving for cost-effective quarrying Big Lokotracks are oneway to achieve improved operational efficiency The Lokotrack LT550GPF equipped with the high-volume GP550 conecrusher and a large screen is popular in the Nordic countries and in Germany and Australia ndash countries all known for theirhigh quarrying volumes

TEXT amp PHOTOS Eero Haumlmaumllaumlinen

Kone-Kostamorsquos new mobile coneplant has reached an averagecapacity of 300 tons per hour

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983122983141983152983151983154983156983145983150983143 983154983141983155

ldquoWith the same number of employees we

can achieve 30 more productivity with

our new LT550GPF unit The high-capacityFS screen has also eliminated the bottle-neck often seen at fine screeningrdquo says

Aarno Kostamo Managing Director of

Kone-Kostamo Oy one of Finlandrsquos biggest

crushing contractorsAccording to Kostamo the high capacity

of the GP550 gyratory cone crusher easily

handles feed from the C120 and C125 jaw

crushers For the contract with the Talvivaara

nickel mine the LT550GPF is being fed bythe brand new Lokotrack LT120 jaw plant

Average capacity 300 tons per hour

Talvivaara Europersquos largest nickel mine uti-

lizes large quantities of aggregates Kone-Kostamo has contracted several million

tons of different end products for the mineIn August 75000 tons of 0ndash63 mm

road gravel was crushed Smaller amountsof finer 0ndash6 mm 0ndash16 mm and 0ndash32 mm

aggregates are also being produced

The rainy summer increased the need

for road gravel along the muddy roadswhich must endure dump trucks weighing

as much as 260 tons

ldquoThe mobile process consisting of the

LT120 jaw plant and LT550GPF cone plant

is cost-effective while aggregates of vari-ous sizes can be produced in a two-stage

operation and with high capacity The con-trolled stroke and elliptical movement of

the FS screen secure big passing throughcapacitiesrdquo Kostamo explains

Operated in two shifts for a total of 16

hours per day the LT550GPF has logged

more than 600 working hours over a two-month period

Managing Director Aarno Kostamo (left) and foreman Karri Maumlenpaumlauml studying the cavity optionsavailable for the new Lokotrack LT550GPF

Longer perspective than

a single quarter needed

Kone-Kostamo Oy was founded as an

earth-moving company in Kemijaumlrvi

Northern Finland in 1956 The company

expanded its operations to include crush-

ing contracting in 1964 and later on

switched to concentrating fully on crush-ing activities

Kone-Kostamo consistently crushes

and screens around 28 million tons ofaggregates annually and has net sales of

between EUR 8ndash9 million

ldquoWe believe that issues within the crush-

ing industry including the purchasing ofmachinery must be studied with a longer

perspective than a single quarter The

secret to our success has always been our

solid work ethic and professional employ-eesrdquo Kostamo sums up

More info

Esa Berg

Tel + 358 40 837 8692

esabergmetsocom

8132019 Results Minerals Aggregates 3 2012ENG

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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155

Monitoring-based reporting is vital for

assessing the performance of a mobile

crushing plant Metso provides suchreporting tools through its plant-wideautomation system Metso DNA (Dynamic

Network of Applications) with its infor-

mation platform that links all the mobile

crushing and screen units together as oneentity Basically there is a lot of measured

real-time information available in every

crushing plant On-line information is

obtained either from each Metso crusherrsquosmachine automation system IC (Intelligent

Controller) or from separately installed

additional sensors and belt scales

All the collected data is sent to a motorhome using wireless communication

based on WLAN technology The motor

home is a purpose-built environment

inside an on-site container In this environ-ment selected variables can be monitored

for assessing the plantrsquos performance And

to make all this even more flexible the

data can be transmitted to a crushing plant

company office using GPRS3G mobile

data communication technologies Thismakes all the last-minute reports acces-sible to the crushing plant managerial staff

at anytime and basically anywhere within

reach of the cell phone network

Production and fuel economics reports

Essentially monitoring and reporting can

be customized to fit the customerrsquos needs

However there are certain off-the-shelf

reports that provide a lot of useful informa-tion for plant supervision The production

report is one of these Requiring at least one

belt scale for measuring the total produc-tion the production report shows the pro-duction rate (tons per hour) for a selected

reporting period eg a day or a week The

production report constantly keeps track of

the plantrsquos production storing all the datathroughout the plantrsquos life cycle

Performance monitoring and reportingfor a mobile crushing plantTEXT Pasi Airikka PHOTOS Metso

unit during which the unit is running By

storing the availability times between start-ups and shutdowns the crushing plant

operation time (hours per dayshift) can be

recorded analyzed and reported In addi-

tion the availability report can be tailored

to evaluate efficient crushing hours during

which the plant is really working and pro-ducing aggregates Consequently the ratio

(0-100) between efficient crushing time

and total running time can be reported forany selected period of time This boosts

the efficiency of the plantrsquos operations

and results in better productivity

Reports on non-choke

or inadequate feeding

Non-choke feeding to crushers is avoid-

able through smart plant-wide crushingplant controls But estimating its severity in

a systematic manner is not straight-forwardwithout constant monitoring and reporting

The crusher choke feeding report makes

use of the crusher cavity level sensors byanalyzing their level measurements By

calculating average and min-max values

and deviations from the average it can be

shown how often the single crusher suffersfrom non-choke feeding to it

In some cases the bottleneck in the

crushing plantrsquos productivity is the material

feeding to the process In mobile plants thefeeding is human operated and therefore

subject to variations Occasionally the sizeof the human-operated machine simply

does not allow for adequate feeding to thecrushing plant There are specific reports

indicating time periods when the crushing

plant suffers from inadequate feeding

Condition monitoring for

crushers and screens

Machine-specific condition monitoring

focuses on vibrating components in

crushers and screens such as drive shaftbearings safety plate wearings and gears

The low middle and high frequencies ofmonitored components are measured and

supervised in real-time to detect abnor-malities due to slow or fast wear looseness

or imbalance

More info

Pasi Airikka

Tel +358 40 587 2730

pasiairikkametsocom

Condition monitoring provides a view tovibrating crusher and screen components forpredictive equipment maintenance

The daily production report shows the hour-by-hour production trend and distribution chartfor a selected day with min-max average andvariation statistics for comparison

Fuel consumption is always an interest-ing concern The fuel consumption reportgives the fuel consumption of each crush-

ing unit (liters per hour) and their total

consumption (liters per hour) for a selected

reporting period and can track fuel con-

sumption changes over timeCrushing plant availability can be

assessed as well The availability report

calculates time periods for each crushing

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983149983141983156983155983151 983150

for tissue machines The record of 2210

mmin was set on June 1 2012 during a

24-hour production run by the TM 2 tissue

machine at the companyrsquos mill in Yenikoumlynear the city of Izmit in Turkey

ldquoThe cooperation with Metso has been

beyond excellent and both parties did

their utmost to make the project success-ful The results clearly show that the efforts

were worthwhile on both sides This coop-

eration will extend to cover new projects

in the futurerdquo says Luumlt1047297 Aydin Paper GroupDirector Hayat Kimya

ldquoWe are not surprised that Hayat K imya

managed to break the world speed record

We have had great confidence in the capa-bility of the Hayat team since our project

started in 2009 We certainly know our

machine very well its stability production

efficiency and speed capabilityrdquo says Jan

Erikson Vice President Sales Metso

PowerThe worldrsquos first eco-gas fueled

power plant is up and running

Lahti Energy Ltdrsquos new Kymijaumlrvi II gasifica-

tion plant was officially inaugurated on

May 8 2012 It is the first of its kind in the

RecyclingRecycling with Lokotrack LT106

jaw plant in New York

A brand-new Lokotrack LT106 jaw plant is

used in the city area of New York USA to

recycle demolition materials The crushing

site faces the skyscrapers of ManhattanIsland

Paper amp FiberHayat Kimyarsquos Metso-supplied tissue

machine sets world speed record

Thanks to a skilled crew and dedicated

efforts Hayat Kimya AS in Turkey has suc-

ceeded in breaking the world speed record

world This CHP plant runs on clean eco-

gas that is gasified cleaned and cooled

from recycled waste with Metsorsquos innova-tive technology

ldquoItrsquos actually eco-gas that we combust

in the boilerrdquo comments Lahti EnergyrsquosProduction Director Jukka Manskinen

ldquoWe convert unwanted waste material into

energy in an efficient and environmentally

friendly wayrdquoNever before has any plant gasified

waste on such a large scale In the gasifier

recycled waste is turned into combustible

product gas which is cleaned cooled and

combusted in a high-efficiency gas boiler

to produce steam for the steam turbine The plant produces 50 MW of electricity

and 90 MW of district heat for the city of

Lahti and its neighboring areasMetso delivered the circulating fluidized

bed (CFB) gasification process gas cleaning

and cooling steam boiler environmental

protection system and automation systemto the entire plant The production of elec-

tricity and heat is kept even with the Metso

DNA automation system that covers the

whole plant starting from fuel reception

AutomationMetso develops and supplies plant-

wide crushing control solutions for

crushing plants

Metso has recently signed contracts on

delivering plant-wide automation systems

for mobile and portable rock crushing

plants The key objective of these deliveries

is to stabilize and to increase productivityand efficiency of the plants using one sin-

gle automation and information platform

for integrating crusher-specific IC machinecontrols

Furthermore the plant-wide system

with its information management tools not

only increases plant availability and opera-

tional safety it also makes troubleshoot-ing quicker and performance monitoring

easier The control room for plant-wide

operability is located either in an excavator

cabin or a purpose-built container

Metso around the world

The new LT106 jaw plant is suitable for crushing both hard rock and all rock-based demolition materials

The new world speed record for tissue setby Hayat Kimyarsquos Metso-supplied TM 2 is2210 mmin

8132019 Results Minerals Aggregates 3 2012ENG

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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 12: Results Minerals Aggregates 3 2012.ENG

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983110983141983137983156983157983154983141983140 983137983154983156983145983139983148983141

Nordic Mines ndash on track tobecoming one of Europersquosmost prominent goldproducersNordic Mines is the newest member in a long chain of Nordic gold mining operations

Inaugurated in mid-August 2012 this company of Swedish origin aims to become one

of Europersquos most prominent gold producers Metso is one of Nordic Minesrsquo main partners

supplying the Laiva gold mine with crushing screening conveying and minerals

processing equipment at an estimated value of EUR 30 million

TEXT amp PHOTOS Eero Haumlmaumllaumlinen

2983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

The Laiva gold mine was built in record time infrastructure

construction began in spring 2010 ore excavation started in

June 2011 and the first gold bar was casted in December 2011

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983110983141983137983156983157983154983141983140 983137983154983156

Just one year after starting the gold recov-

ery process Nordic Mines is on track toreaching a capacity of 5 kg of gold per day

At present the operations are averaging 3

to 4 kg of gold daily

The ore in the Laiva Gold Mine consists

of packages of gold-bearing quartz-filled

shear structures The deposit is more thana kilometer long and 700 meters wide The

total depth is still unknown but dr illings

carried out thus far have shown gold-bear-ing shear structures 300 meters below the

surface

A typical ore zone includes a large num-

ber of thin shear structures from 5 to 30per meter The ore zones are commonly 50

to 100 meters long several are 10 meters

deep and they range from a few meters to

20 meters cross strike The minimum min-ing width is 25 meters which means that

even a minor ore zone consists of at least10 to 50 shear structures

Conventional pattern blasting

with selective loading

Prior to mining Nordic Mines conducts

grade control drilling which provides

dense gold grade information and makes

it possible to outline the boundaries

between ore and waste The mining

technique applied is conventional pattern

blasting with selective loading This is oneof the most commonly used techniques in

large-scale open-pit mining

A typical blast in the Laiva mine is 50

meters long 100 meters wide and 5 metersdeep After blasting ore and waste aremined by selective loading

After investing some EUR 100 million

the Laiva mine now comprises an open-pit

mine with a modern complete crushinggrinding and processing circuit that ends

with the casting of gold doreacute bars

With a number of mine staff partners

sub-suppliers city and state officials inattendance the Laiva gold mine was offi-

cially inaugurated on August 16 2012

Michael Nilsson Managing Director

of Nordic Mines stressed in his speechthe importance of overcoming challenges

during the building of the mine

ldquoObviously the whole development

took us longer than expected Today weare pleasantly surprised by the size of our

operation We are becoming much bigger

than expectedrdquo gt

Chief Geologist Kimmo Lahtinen presenting narrow gold veins twisting at the Laiva North open-pit mine

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983110983141983137983156983157983154983141983140 983137983154983156983145983139983148983141

An international process package

The Metso package for the Laiva gold mine

included the main crushing screening

conveying regrinding leaching and pump-ing elements Metsorsquos office in Sala Swe-

den has served as the main project office

with Metso manufacturing units in FranceGermany Sweden and Finland responsiblefor the equipment supply

At Laiva the gold ore is classified after

selective excavating into two gold con-

tent classes All class A gold ore is takento Metsorsquos sturdy jaw crusher for primary

crushing while the class B ore is stocked for

possible future use After primary grinding

utilizing autogenous technology the ore is

screened and two Metso cones crush the

oversized pebbles For regrinding Metsorsquosball mill is used

During high- and low-grade leaching

processes a number of Metso pumps and

dewatering screens are used The whole

minerals processing system is controlled byMetsoDNA automation

Active exploration drilling going on

According to Mine Manager Tom Soumlder-

man the known gold ore reserves at the

Laiva gold mine amount to 169 million

tons but the potential for additional find-

ings looks good

ldquoWorking at the level of two million tonsper year our expected lifetime is about nine

years We carry out active exploration drill-

ing in Kaukainen Musunneva and Oltava

to locate nearby satellite ore bodies Anupdated detailed mine life plan will be pre-

pared during the autumnrdquo Soumlderman saysNordic Minesrsquo other exploration areas

include Tormua in Finland and Fjaumllltuna

and Vassbo in Sweden

More info

Alf Rydberg

Tel +46 70524 5837

alfrydbergmetsocom

Happy faces during the minersquos inaugural ceremony Mine Manager Tom Soumlderman (left) with Managing Director Michael Nilsson and Deputy Managing Director Krister Soumlderholm

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983110983141983137983156983157983154983141983140 983137983154983156

The story behind the discovery of the Laivamine is an interesting one During a hunt-

ing trip in the remote forests of Laivakan-

gas in 1979 Pentti Jaumlmbaumlck found an inter-esting-looking piece of stone Although hecould not see the gold hidden inside the

rock Pentti noticed the striking weight

and somewhat different look of the stone

Upon returning home Pentti sent thesample to Outokumpu which at the time

was the leading state-owned mining com-

pany in Finland After testing a high gold

content of 15 grams per ton was found

Gold deposit founded by a hunter

The founder of the Laiva gold deposit Mr Pentti

Jaumlmbaumlck was the guest of honor during theinauguration

Lennart Schoumlnning Chairman of the Board ofNordic Mines holding a gold doreacute bar worthsome EUR 320000

Outokumpu registered a mining claimon the area and conducted a series of

exploration drilling from 1981 to 1987 Due

to the low price level for gold no mine wasstarted at the time Other mining compa-nies such as Endomines held the mining

rights later

Nordic Mines with its sights set on

locating and exploiting gold in Swedenand Finland was founded in 2005 During

the same year the company purchased its

first mining rights at Laiva

Nordic Minesrsquo Laiva gold mine

LOCATION near the city of Raahe

northwestern Finland

GOLD ORE CONTENT average 16 gt

ORE EXTRACTED PER YEAR

12 million tons (present)

20 million tons (planned)

GOLD RECOVERY 85

TOTAL KNOWN ORE RESERVES

169 million tons

MINING METHOD

Selective open-pit benchingNUMBER OF EMPLOYEES

130 including contractors

METSO MAIN EQUIPMENT

2 Metso VF and 6 EMEG EME

vibrating feeders

8 Screens 1 MF 1 CVB and 6 KS

1 RCS Flash flotation unit

1 Metso SRR ball mill 18 x 4 m

1 Nordberg C160 jaw crusher

1 Nordberg HP100 cone crusher

1 Nordberg HP200 cone crusher

5 Nordberg NB series conveyors

73 Metso Slurry pumps ofvarious types and sizes

8132019 Results Minerals Aggregates 3 2012ENG

httpslidepdfcomreaderfullresults-minerals-aggregates-3-2012eng 16426983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155

The newest member of the proven GP series cone crushers ndash theNordberg GP220 ndash offers a versatile alternative for any demanding

tertiary or quaternary or even secondary crushing operation fulfill-

ing all crushing needs and maximizing customersrsquo profitability

High-quality components and optimized castings and forgings

contribute to the GP220rsquos enhanced reliability and help to ensurethe highest level of crusher uptime

Thanks to the 200 kW (270 hp) power draw the GP220 performs

at a 20 to 30 percent higher capacity than other cone crusherbrands with an equal head diameter The large feed openingenables the feeding jaw crusher to run at 110 mm css Operational

flexibility is ensured by multiple strokes and six different cavities

Secondary crushing possible

thanks to cavity and stroke options

Thanks to the GP220rsquos cavity and stroke options secondary crush-

ing in addition to tertiary and quaternary stages is also possible

using cavities with a greater intake opening With the GP220 a suit-

able solution for producing excellent end-product gradations

can always be found

With advanced automation using IC50 or IC5000 operation

is safe and trouble-free The low height thanks to the patented

piston design makes replacement installations much easierA dynamic setting adjustment enables a fast response to process

optimization needs

The Nordberg GP220 weighs 10500 kg (23150 lbs) and hasa maximum real feed size of +200 mm (8rdquo) with strokes from

18ndash40 mm (57rdquondash1 47rdquo) The cavity options are EF F MF M C

and EC

A complete modular crusher steel structure is available for allGP series stationary installations including GP220 The platform

includes places for the lubrication unit motor automation or

pressure accumulator and pressurized sealing The only things

left to add are the feed and discharge conveyors

Main new features of the GP220 Large feed opening allows for secondary stage operation

Longer setting range of main shaft for better wear parts utilization

Stronger main components to carry high loads with a powerdraw as high as 200kW

More info

Hannu Vakkuri

Tel +358 50 317 0638

hannuvakkurimetsocom

Thanks to the large feed opening and wide selection of strokes and cavitiesthe new Nordberg GP220 cone crusher is a highly versatile cone novelty

More versatility with the newNordberg GP220 cone crusher

Reinforced head and frame castings combined with a 200kW power

draw make the GP220 cone a reliable crusher with maximum productivity

8132019 Results Minerals Aggregates 3 2012ENG

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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156

Metsorsquos HRCtrade takes high pressure grinding roll technology to the next level

The new Lokotrack mobile conveyors come as tracked and wheeled models

Metsorsquos latest development in comminution equipment the HRCtradeis a major step in the profitable application of high-pressure grind-

ing roll (HPGR) technology Metso has made several key innova-

tions in order to increase throughput and decrease the total cost

of operation

Metsorsquos patented Arch frame creates an even gap setting acrossthe width of the tires limiting skewing that can result in downtime

for mining operations This anti-skewing Arch frame also prevents

damage to the roller bearings (caused by misalignment) that canoccur with the traditional HPGR design

Flanges maximize wear life and increase throughput

Used in place of spring-loaded cheek plates the flanges keep thebed of material within the crushing zone and prevent material

from bypassing the tires This enables greater circuit capacity and

increases the overall crushing efficiency

In addition by preventing material from bypassing the tires

even pressure across the width of the tire is better maintained

Distributing the pressure more evenly maximizes the tire life bypreventing a ldquobath tub effectrdquo in which the center of the tire wears

faster than the edgesVictoria Herman Metsorsquos Product Manager for the HRC notes

that this breakthrough design is a response to the growing needs

in the mining industry ldquoEnergy efficiency has been attracting our

customers to HPGR technology for yearsrdquo she says ldquoBut our design

concept increases capacity and crushing efficiency ndash and thatrsquossomething mining companies are always looking to improve onrdquo

The track-mounted Lokotrack CT32 and wheel-mounted Lokotrack

CW32 mobile conveyors offer an ideal solution for applications

that require high stockpile capacity and excellent material transfer

capabilities They also add flexibility to multi-stage crushing andscreening applications enabling easy and fast closed-circuit opera-

tion of mobile units

The conveyor novelties can be used in both mobile and station-

ary installations providing extra stockpiling capacity in situationswhere for example fewer wheel loaders are available

The HRC is ideal for high-tonnage hard rock applications andcan be used as a tertiary quaternary or pebble crusher Currently

several HRC units are in operation around the world ndash with a total

of 6500 operating hours including over 3800 hours in a mininghard rock application The machine does have range within hardrock applications itrsquos been designed for use in diamond iron ore

copper gold platinum and various industrial minerals

More info

Victoria Herman

Tel +1 717 309 1150

victoriahermanmetsocom

Several optional features such as hydraulic folding of tail sections

and dual hydraulic drive for increased throughput are available

The capacity of the CT32 and CW32 is 400 mtph (440 stph)feed size up to 150 mm (6rdquo) belt width 1050 mm (42rdquo) and dis-charge height 9120 mm (29rsquo 11rdquo) The CT32 is fitted with a Caterpil-

lar C2 diesel engine with 38kw (51 HP) power The CW32 is avail-

able for hydraulic or electric use

More info

Kimmo Anttila

Tel +358 50 433 3745

kimmoanttilametsocom

The new HRCtrade combines high crushing pressure and a low circulatingload resulting in the most efficient comminution

When flexibility in stockpiling capacityis required the answer can be foundin the new Lokotrack CT32 and

CW32 mobile conveyors

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Service creates value in ChinaChinarsquos most important gold producing area Yantai in northeastern China supplies more than 16 of the countryrsquos goldproduction each year With the gold market thriving the scale of gold production in Yantai has been expanding constantly

Zhongjia Mining Industry Co Ltd is one of the beneficiaries of this thriving industryTEXT amp PHOTOS Yan Xin

Inspection and maintenance of the HP500 cone crusher conducted by Metsorsquos service engineers

In 2011 Zhongjia Mining Industry pur-

chased a modular crushing and screen-ing system from Metso for its new gold

production project With the cooperation

between the two companies continuously

intensifying Zhongjia Mining Industry

signed an additional one-year Life CycleService (LCS) contract with Metso incorpo-

rating Metsorsquos global knowledge in equip-

ment processes and services

ldquoMetso customized a series of reason-

able service solutions also referred toas Metso Performance Solutions for us

including preventive maintenance services

process improvement personnel training

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155

and a procurement plan for wear parts

These really suit our needs perfectlyrdquo saysShen Yidong the Manager of ZhongjiaMining Industry

Effective preventive maintenanceFor mining corporations the biggestconcern is the economic losses caused by

the shutdown of equipment As a result

preventative maintenance is of vital impor-

tance During the contract period Metsoservice engineers offered 7-day tracking

service on the production site every month

to eliminate potential problems and thus

ensured the stability of the system

parts caused pressure on our working capi-tal which was not favorable for our long-

term developmentrdquo Shen explains

To solve this problem Metso designed

a rational stock plan of wear parts and built

a field warehouse In accordance with theuse and consumption of the liners the field

service engineers complement the stock tomake production and operations run more

smoothlyldquoNow when we need to replace the

wear parts we can use them before pay-

ment This not only simplifies the procure-

ment process but also liberates a largesum of our operating capital which can

be used for other business development

purposesrdquo says Shen

Best partner

ldquoAlthough the LCS contract incurs some

early purchase costs in the long run Metsorsquosprofessional and quality service will improve

the equipment efficiency reduce ourenergy consumption and ensure stable

operations thus generating more prof-

its This is the greatest value for us so the

investment is really worthwhile overall Inthe future we will choose more Metso prod-

ucts and services Taking all aspects into

consideration we believe Metso is the best

partner for usrdquo Shen Yidong concludes

More info

Thomas Bai Tel +86 13801009114

thomasbaimetsocom

ldquoIn the eight months since the contract

came into effect our corporation has notsuffered any financial losses due to equip-

ment breakdown The regular maintenance

has greatly improved the efficiency of our

entire crushing system In addition the

experienced engineers from Metso also

provided onsite training and guidancefor our staff and the tailored training has

greatly enhanced the operating abilities of

our employees and upgraded their overalllevel of competencerdquo says Shen Yidong

More productivity with

less consumption

Metsorsquos service contract focuses on real-

izing the optimum performance of each

process flow After analyzing Zhongjiarsquos

production system Metsorsquos techniciansproposed an adjustment to the closed side

setting of the HP500 for tertiary crushingin order to improve the efficiency of the

downstream fine crushing and milling pro-

cessing by over 10ldquoThe process flow improvement solu-

tions provided by Metso not only increased

the output of our gold concentrates but

also reduced our energy consumption andcostsrdquo says Shen

In the past wear parts procurement

took up a larger proportion of Zhongjiarsquos

total production costsldquoTo avoid downtime caused by the

shortage of wear parts we had to keepeight sets of various wear parts in place

However the cost of having so many wear

Zhongjia Mining Industryrsquos gold concentrates processing plant in China

8132019 Results Minerals Aggregates 3 2012ENG

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0983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

Safe quarrying high-

quality aggregates

8132019 Results Minerals Aggregates 3 2012ENG

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ldquoWe share a similar zero-accident strategy and target with Metso and have successfullyfollowed it Metso has also helped us to meet the strictest end-product quality andcubicity requirements set in Spainrdquo This is how Managing Director Intildeigo Ajuria ofOfitas de San Felices the leading hard rock quarrying company in Spain describesthe cooperation with MetsoTEXT Eero Haumlmaumllaumlinen PHOTOS Ofitas and Eero Haumlmaumllaumlinen

The San Felices quarry is situated in a picturesque mountainous landscapebetween the companyrsquos Rioja vineyards and the Bilbao-Madrid motorway

8132019 Results Minerals Aggregates 3 2012ENG

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Ofitas has pioneered the implementation

of several Metso novelties in the Spanish

market The company was the first to use

efficient large track-mounted Lokotrack jaw plants the unique mobile conveying

system and also the new-generation HP4

cone crushers

Today the company operates twomodern Metso stationary plants one in

Guadix near Granada and the newest one

in San Felices Haro Rioja community Both

quarries focus on refining hard rock by pro-cessing ophite rock into the highest quality

railway ballast asphalt and concrete mix

grades The company has a satellite quarry

near Vitoria in PentildeacerradaBeing situated next to a highway and

the famous Rioja vineyards Ofitas must pay

special attention to environmental issues

To minimize dust problems all conveyors

have special covers attached

Quality durability and service

The cooperation between Ofitas de San

Felices and Metso started back in 1973when the Ajuria family bought the com-

pany whose quarrying activities began in

1919 Intildeigo Ajuria has a clear vision of why

the cooperation has continued withoutinterruption for almost 40 years

long-standing personal relationshipsrdquoAjuria adds

Serving railways asphalt

and concrete producers

The year-old San Felices stationary instal-lation lies hidden in a mountainous area

south of the city of Vitoria in NorthernSpain The new plant replaces an old one

that complicated the extraction of ophiterock Both plants are delivered by Metso

With its two separate production lines

the new plant is able to produce all the

end products required ndash from railway bal-last to the finer grades needed for asphalt

and concrete

Due to lower demand the quarry cur-

rently produces some 4000 tons per day

At full capacity however the plant canreach 8000 tons of production per day

30ndash35 of which consists of railway ballastfor high-speed trains and 65ndash70 of chips

and sand Thanks to the versatile two-line con-

cept connected by transverse conveyors

up to 12 different end products can be pro-

duced Depending on the demand for endproducts the material can be guided either

to the HP4 cone or HP400 cone followed

by a Barmac vertical shaft impactor

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

The ophite feed is fed to the C125 jaw crusher by a sturdy dump truck

The key people running the new San Felicesquarry Mine Engineer Carlos Fernandez (left)Managing Director Intildeigo Ajuria with ProductionManager Julian Perez

ldquoThrough the years Metso machinery

has proven its production capacity and

durability resulting in high-quality end

products A big plus for us has also beenthe quick response time to our process

challenges or servicerdquo

ldquoIn fact our cooperation extends

beyond day-to-day business matters to

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155

Meeting the strictest cubicity demands

The Spanish regulations concerning end-product cubicity are becoming more

demanding The flakiness percentage of

railway ballast must be below 10 and for

asphalt and concrete aggregates less than

15

ldquoWith Metsorsquos HP4 cone and the Barmacvertical shaft impactor we can meet even

the strictest cubicity demands We believe

that our high quality is helping us to sur-vive in the present recessionrdquo notes Mine

Engineer Carlos Fernandez

ldquoWe hope to increase the total extrac-

tion of the three quarries from the present15 million tons per year because our plant

capacity allows more than double thatrdquo

Fernandez adds

More info

Angel Luis Garcia Tel +34 686 94 35 30

angelluisgarciametsocom

In addition to being the leading Spanish

quarry to process hard rock Ofitas de SanFelices also cultivates 34 hectares of vine-yards next to the quarry which is situated

in the famous Rioja wine area

The company has previously sold a

harvest of over 200000 kg of Tempranillo

grapes to local red-wine makers Recentlythe company built its own wine process-

ing plant to process 10000ndash15000 kg of

grapes themselves

Aggregates and wine production

Andoni Ajuria the founder of Ofitas de san Felices (left) with Intildeigo Ajuria the present ManagingDirector tasting wine from the companyrsquos own vineyards

The first vintage wine of Ofitas har-

vested in autumn 2010 is now maturingin oak barrels After maturing for 12 to 15months the wine is called crianza and after

two years it will be granted the classifica-

tion reserva

ldquoWinemaking is not a business but

a hobby for us We give our wine out aspresents and drink it when we meet

our suppliers and friendsrdquo Intildeigo Ajuria

comments

For environmental protectionall of San Felicesrsquos plantconveyors are covered

Ofitas de San Felices quarry

LOCATION Haro near the city

of Vitoria northern Spain

SIZE 100 hectares

ROCK TYPE Ophite with Los Angeles

index of 9ndash10

PRESENT DAILY EXTRACTION 3000 tons

of ophiteNUMBER OF PERSONNEL 30

RESERVES 10 million tons

MAIN END PRODUCTS 0ndash2 mm

2ndash4 mm 4ndash10 mm 10ndash16 mm

16ndash22 mm 25ndash60 mm (ballast)

METSO MAIN EQUIPMENT

VF feeder

C125 jaw crusher

ndash feed size 0ndash800 mm

ndash css 130ndash140 mm

HP400 cone crusher

ndash feed size 80ndash250 mm

ndash css 40 mm HP4 cone crusher

ndash feed size 40ndash80 mm

ndash css 15 mm

Barmac 6150 VSI crusher

4 CVB2060 screens

2 TS32 screens

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Metso Distribution Centers he

Europe (Tongeren Belgium)

France (Macon)

Czech Republic (Přerov)

Austria (Vienna)

2271 d

Brazil (Sorocaba SP)

1014 d

USA (Columbia SC)

1690 d

USA (Waukesha WI)

434 d

South Africa (Vereeniging)

Ghana (Tarkwa)

Meacutexico (Irapuato)

Peru (Lima)

Chile (Concoacuten)

788 d

Sweden ( Trelleborg)

Finland (Tampere)

UK (Rugby)

865 d

Russia (St Petersburg)

Brazil (Parauapebas PA)

206 d

4983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983122983141983152983151983154983156983145983150983143 983154983141983155

In the case of an equipment failure or

a planned service shutdown resuming

production as quickly as possible is crucialEach hour spent waiting for a spare part to

arrive equals money lost Whether the right

part takes 12 or 48 hours to arrive really

makes a difference

The comprehensive and global Metsospare and wear parts service network pro-

vides you with the right part in the right

place and at the right time Our strategi-

cally located Distribution Centers and

Satellite Warehouses are on call 24 hoursa day 7 days a week ensuring efficient

parts replacement near you

Check out the locations of the MetsoDistribution Centers and how many parts

pass through them each day

More info

Marcelo Farah

Tel +55 15 2102 1315

marcelofarahmetsocom

you minimize downtime

Australia (Perth)

746 d

China (Tianjin)

China (Kunming)

China (Shanghai)

393 d

India (Faridabad)

India (Ahmedabad)

India (Hyderabad)

India (Bhubaneswar)

India (Bangalore)

419 d

Russia (Yekaterinburg)

Australia (Newcastle)

New Zealand (Matamata)

983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088

TEXT Sofia Williams

Singapore (Singapore)

Distribution Center Satellite Warehouse

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Following a large investment

in Metso crushing equipmentand services Buena Vista del

Cobre is now expanding the

mine site to include even more

equipment ndash and with thatexpansion comes the need for

more local service resources

Metso and Buena Vista del

Cobre have entered into a Life

Cycle Service agreement forthe plant and construction of a

brand new Metso service hub

is under way in Cananea

New facility new

level of service

The Cananea service hub

which will be up and running in early 2013will support the recent expansion and resur-

gence of Buena Vista del Cobre Initially it

will be a major repair and assembly center

for pumps crushers and screens and will

provide for rubber covering capabilitiesBut the 8000-square-meter facilityrsquos service

offering will be expansive including a con-

signment stock inventory to help serve theminersquos varying needs Metso currently has

50 service team members on site

Although Buena Vista del Cobre was a

key influencer in building the new servicehub this location will also enable Metso to

expand its capabilities and provide local

support to the entire mining community

in northwest Mexico The Cananea hub

will serve a number of major copper and

gold mines in the region including MineraFriscorsquos San Felipe Fresnillorsquos Milpillas and

Grupo Mexicorsquos Mexicana de Cobre

ldquoBuena Vista del Cobre is the biggestcustomer we have in Mexico today and

with this expansion project itrsquos only going

to grow and be strongerrdquo says Felix Forna-

guera Director of Services Mexico CentralAmerica and Caribbean ldquoWith that said the

idea behind the Cananea service hub is to

provide a central location for local support

for all our major customers in the areardquo

Establishing safety

ldquoIt was key to have our support here in

Cananea because the Buena Vista delCobre started from the ground uprdquo saysFelix ldquoWersquove been able to help the cus-

tomer to establish the best in support

service and operations from the very

beginningrdquo And this ground-up approachincluded a major focus on safety

Metso worked closely with Buena Vista

del Cobre to establish the safety proto-

col by which the mine operates Basedon Metsorsquos expertise the safety measures

put in place have enabled the mine to

become strict and efficient in its operations

and maintenance procedures To achievethis Metso worked closely with local andnational authorities to ensure the safety

plan was comprehensive and in accord-

ance with all established legal bodies

The best in regional support

The service hub in Cananea is a prime

example of Metsorsquos focus on providing local

service and support to its customers all

Service shines in Cananea MexicoAfter three years of inactivity the Buena Vista del Cobre mine in Cananea Sonora Mexico has been operational since 2010A mine that was inactive for such a significant amount of time however requires a great deal of support to successfullyrestart the plant and bring it back to an operational and profitable state

TEXT Deanna Lee PHOTO Metso

over the world ldquoWe are the first

company developing this kindof service in northwest Mexicordquo

adds Felix ldquoOur people have

developed a close relationship

with the team at the mine Itrsquosmore than a supplier relation-

ship our guys are inside the

mine living and working thererdquo

In fact this is the model

that Metso is using in servicehubs all over the globe build-

ing modern facilities bringing

teams on site and workinghand in hand with mine

operators The Cananea Service

hub is only the most recent

example of Metsorsquos commit-ment to service and northwest Mexico is

yet another mining hotbed thatrsquos going to

benefit from the companyrsquos support

More info

Felix Fornaguera Tel +52 4621079227

felixfornaguerametsocom

A mining cone serviced by Metso at the Buena Vista del Cobre mine inSonora Mexico

ldquoThe new Cananea service center will be a majorrepair and assembly center for pumps crushersand screensrdquo says Felix Fornaguera Director ofServices Mexico Central America and Caribbean

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

8132019 Results Minerals Aggregates 3 2012ENG

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During the MINExpo exhibition over 1300 people visited the Metso stand

983122983141983152983151983154983156983145983150983143 983154983141983155

Held every four years MIN-Expo consistently grows so

perennial exhibitors like Metso

are challenged with elevating

their presence and drawingin new (and greater numbers

of ) visitors each year ldquoItrsquos not

necessarily a challenge to lsquotoprsquo

our last showingrdquo says Keith

Ference Vice President ofmarketing and communica-

tions North America ldquoThere

are four years between eachMINExpo so we always have

a lot to say and reveal to our

customersrdquo The real challenge

he says is finding an exciting

and dynamic way to deliverthe message ldquoTherersquos so much

to see here so your booth has

to be compelling from the

outside-in and thatrsquos what

we always try to dordquo

Service sets the stage

The Metso booth created buzzin a number of ways and per-

haps the most striking (partly

due to its size) was the live

theater presentation As visitorspassed through the aisles of the show-

room the sights and sounds from Metsorsquos

theater were hard to miss And once guests

entered they were captivated by a short

high-energy video presentation focused

on Metsorsquos service capabilities The message was simple Metso is ldquoyour

local service partner rdquo for all mining and

construction needs The video showed ourservice teams in action all over the world

and the audience came away with an

understanding about Metsorsquos commitment

to service Customers can count on morethan 70 local service centers run by more

than 1700 expert technicians delivering

Metso makes an impact at MINExpo 2012At this yearrsquos MINExpo International nearly 60000 attendees flocked to Las Vegas Nevada the largest turnout in showhistory The visitors ndash mining professionals from all over the globe ndash explored 850000 square feet of showroom spacefeaturing the industry rsquos latest technology equipment products and services They toured the show for three days

seeking the latest and greatest from more than 1800 exhibitorsTEXT Keith Ference PHOTOS Tracey Ford Perry

detailed descriptions andphotos of all of Metsorsquos mining

and construction products and

services The app also provides

digital access to Results and asearchable database of sales

contacts By day three of the

show MetsoMAP had been

downloaded by more than

500 usersIn addition to the app the

booth was equipped with

several LCD screens each con-trolled by Metso experts who

used their iPads to present new

products like the Megalinertrade

and the HRCtrade A featured

presentation on Metsorsquos lineupof energy-efficient comminu-

tion equipment including the

VERTIMILLreg SMD and MP-1250

cone crusher was also avail-

able letting customers seehow Metso technology delivers

some of the worldrsquos most effi-

cient size reduction

Measuring MINExpo success

After a very busy three days

(on top of months of prepara-tion leading up to the show) everyone

involved with MINExpo ndash from the North

American marketing team responsible for

the booth to the product managers and

sales force that worked the floor ndash is view-

ing the show as a success ldquoTherersquos alwaysa sigh of relief after each (MINExpo)rdquo says

Keith ldquoAnd overall the initial feedback

and response has been very positiverdquoWith more than 1300 visitors to the

booth Metso certainly made an impact

ldquoWe learn a lot from each show and with

some time wersquoll have a better understand-ing of the tangible results of our effortsrdquo

Keith adds

reliable service for mining equipment as

well as customized cost-effective life-cycle

services contracts

Technology ndash MetsoMAP

is an industry firstMINExpo provided the industry with its firstglimpse of Metsorsquos revolutionary iPad app

MetsoMAP The app was demoed to the

boothrsquos visitors via ldquothe worldrsquos largest iPadrdquo

a custom-made 80-inch screen that show-cased all of its capabilities most of which are

groundbreaking in the industry MetsoMAPrsquos

simple interface is highly intuitive making

it easy to view process animations videos

The presentation of the new HP cone crusher attracted a large audience

8132019 Results Minerals Aggregates 3 2012ENG

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When yoursquore allowed less than a dozen days per year for breakdowns repair andmaintenance every single hour during a service shutdown counts There simplyisnrsquot any room for surprises Thatrsquos why Boliden counts on MetsoTEXT amp PHOTOS Sofia Williams

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Kurt Kalla Site Managerof Metso Gaumlllivare ServiceCenter is responsible forthe maintenance of Aitik

Metso and Boliden Strivingtogether for 97 uptime

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One of the biggest copper mines in

Europe Bolidenrsquos Aitik is located deep inthe wilderness of Swedish Lapland next to

the small town of Gaumlllivare The mine has

been operating since 1968 and a recent

expansion has increased its annual ore

production to 36 million tons

But the ambitious Swedes are not will-ing to lay back and relax just yet Bolidenrsquos

new aim is to reach a production rate of

45 million tons of ore per year in AitikAfter that Perhaps more than 55 million

tons The ore concentration in Aitik is very

low-grade with a mere 022 copper con-

tent hence the need for high capacityAchieving the ambitious production

goal requires maximum plant availability

This means that everything from the crush-

ers to the filters must be up and runningfor approximately 97 percent of the time

Thatrsquos where Metso comes into play

A cost-per-ton contract in action

The maximum uptime requirement allowsless than a dozen days per year for break-

downs repair and maintenance at Aitik

Every single hour during a service shut-

down counts There simply isnrsquot any roomfor surprises

Executing a successful shutdown under

such conditions requires a reliable service

partner not afraid of challenges and this iswhy Boliden has entrusted Aitikrsquos services

operations to Metso Boliden and Metsohave worked together since the 1960s

and the collaboration took another step

forward in September 2012 when the twocompanies signed a three-year extension

of the services contract for Boliden Aitik

ldquoThe new contract is a cost-per-ton

agreement We get paid based on Aitikrsquos

production Itrsquos a win-win deal for both par-

ties but also a new mindset for usrdquo explainsKurt Kalla Site Manager of Metso Gaumlllivare

Service Center responsible for serving Aitik

From now on the duration of the shut-down is what matters the most According

to Kalla the Metso service organization in

Gaumlllivare is now streamlining its operations

to fit the bill and has already witnessed thestrategy working In August 2012 Metso

carried out a 188-hour service shutdown in

Aitik which turned out to be a success

Zero tolerance for injury

One key factor to the success was theextensive planning of precautionary health

safety and environment procedures under-

taken by Metso prior to the shutdown Thanks to strict measures applied no

injuries or accidents occurred during the

shutdown and the work could easily be

finished on scheduleMats Johansson Health Safety

and Environment Manager for Metso in

Sweden explains how this was achieved

rdquoPlanning of the shutdown included arisk analysis for all new tasks participating

in Bolidenrsquos safety coordination meetingsmeeting with both Metso supervisors and

subcontractor supervisors and finally a

meeting with the entire staff participating

in the shutdown where everyone had to

sign a document stating their commitmentto the information providedrdquo he says

During the actual shutdown plenty of

new barriers signs and awareness cones

were put in place as a result of observa-tions from previous audits and safety plans

and risk analyses were readily available

in the work area Metso and Boliden also

introduced a Mill Inching permit a certifi-cate for completing a mandatory course for

those involved in the process In addition

Metso carried out random safety audits

during the shutdown to make sure thestrict policy was followed

According to Boliden Metsorsquos way of

working is a good example of how health

and safety precautions should be handled

ldquoMetso is a good example of how towork with safety and health plans risk

analysis permits and welding permits

Their table with all binders in the second-

ary mill area was exemplaryrdquo says Kjell-Arne

Johansson a technician from Boliden

The use of the new Metso Megalinertrade

system in the lining of Aitikrsquos Metso AG

mills has also improved the safety of main-tenance staff The Metso Megalinertrade con-

sists of larger-than-average liners bolted

in position from outside the mill Mainte-

nance technicians no longer need to go

inside the mill and stand in the dangerousdrop-zone of the liners gt

Boliden aims to reach a production rate of 45 million tons of ore per yearin the Aitik mine site

ldquoA complete risk analysis was conducted during the planningof the shutdownrdquo comments Mats Johansson Health Safetyand Environment Manager for Metso in Sweden

8132019 Results Minerals Aggregates 3 2012ENG

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Service the Metso way

24 hours a day 365 days a year

In addition to paying close attention to

health and safety issues executing an effi-

cient shutdown requires careful planning

and timing of every step in the mainte-

nance process Wear and spare parts have

to be available on time and a repair shoplarge enough to accommodate equipment

located close by

ldquoTo keep maintenance breaks as short

as possible we aim to replace the pump on

site and bring the old one for repair to our

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

nearby facilities This method gives us the

peace to do a good job and keep the cus-

tomerrsquos operations runningrdquo Kalla describes

the Metso way of handling Aitikrsquos pump

maintenance

Metso is currently expanding its Gaumllli-

vare service center to include a distribu-

tion center for wear and spare parts andalso concentrating its previously scattered

operations under one roof in its Vuoskon-

jaumlrvivaumlgen facility The expansion is due to

be completed by 2014

Metso equipment

delivered to Aitik36

bull 2 AG mills diameter 116 x

137 m gearless 22-MW motor

bull 2 Pebble mills diameter 91 x

113m dual 5-MW pinion drive

bull 3 VPA pressure filters VPA 1540-54

bull 12 sample pumps and pipes

VF50

bull 60 Various slurry pumps up to

MR500 modelbull Appr 5000 m rubber-lined slurry

pipes up to 600 mm diameter

bull Appr 5000 m rubber-lined by

gravity pipes up to 600 mm

diameter

bull Appr 5000 m rubber hoses

up to 600 mm diameter

Not only does the expansion make ser-

vice shutdowns at Aitik run more smoothly

it guarantees a more comprehensive

on-call emergency service response in the

region ndash thanks to the spare and wear parts

inventory available 24 hours a day 365

days a year

More info

Lars Rosenling

Tel +46 70 107 45 90

larsrosenlingmetsocom

Metso grinding equipment dominates the view in the concentrator

Safety on site is made up of small things like

making sure that everyone remembers to secure

the hoses in place

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Pebbles have always been a

challenge for producers of sandsince they cannot be returned

to rivers after extraction For

decades the processing of this

material resulted in a huge

environmental liability with alarge amount of pebbles hav-

ing to be stored away and left

unused

Transforming problems into

business opportunities

Areia amp Cia (areia = sand) has

operated in this market forover 20 years and decided to

enlist the help of Metso to find

a profitable solution for the

processing of pebbles

In July 2011 analyses werebegun to assess the abrasive-

ness and crushability of the

material Four alternatives wereidentified for processing and

transforming pebbles into sand

Initially Areia amp Cia was

interested in acquiring an

impactor for its reason-able price level However the

customer wanted to process

all the pebbles that were col-

lected daily in addition to some of the

material that it had stored In weighing theresults expected by the customer and the

excessive abrasiveness of the material the

HP200 cone crusher was decided on as thebest alternative

Areia amp Cia made the required invest-

ment and after using the HP200 for just

six months the company has already beenreporting outstanding results The HP200

not only transforms pebbles into sand but

also produces sand of excellent quality

with high yield and low maintenanceWith minor adjustments the HP200

also enables the production of sand withspecific particle size distribution for special

applications such as filtering sand blasting

and foundry sand adding value to the prod-

uct and increasing the types of sand offeredldquoMetso is pleased that the HP200 not

only enabled the processing of a product

that had been set aside as unusable but

HP200 cone transforms pebblesinto high-quality sandOver the last few decades Brazilian economic growth has been driving demand for construction aggregates The market

for sand in turn has been experiencing major difficulties in maintaining a consistent supply Presently one of the mainchallenges the industry faces is the large amount of pebbles that are obtained in the process of extracting sand at timesconstituting nearly 50 of the volume of material dredged from riverbeds

TEXT Sheila Ivers PHOTO Areia amp Cia

also that it opened up new

market opportunities for Areiaamp Cia Thatrsquos the standard we

seek to deliver to our custom-

ersrdquo states Luiz Oliveira Techni-

cal Salesperson of Metso Brazil

HP cones entering the

Brazilian sand-making

market

Todayrsquos cones such as theHP200 have high resistance

to impacts and abrasiveness

more efficient crushing cham-

bers low maintenance costsand excellent productivity

Following the acquisition of

the HP200 Areia amp Cia is now

also producing special sands

that command a price that is100 higher than common

sand The entire stockpile of

pebbles accumulated through-out the companyrsquos 20 years of

operations has already been

transformed into sand and the

stock of pebbles held by com-

petitors is also being purchasedfor processing

Cristiane Brizolari the

owner of Areia amp Cia confirms

the transformation that has taken place in

the production and commercial processldquoThe HP200 opened up new niches in

the market enabling the production of dif-

ferent types of sand with added valuerdquo

More info

Luiz Oliveira

Tel +55 011 9971 3603

luizoliveirametsocom

After the pebbles are crushed into sand with the HP200 cone crusherdifferent grades are screened for various end uses

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Where therersquos a will we dig a wayAFCONS-Strabag and Metso embark on tunnel project together

When the joint venture AFCONS-Strabag initiated work on the Rohtang bypass tunnel project at an altitude of 3980 metersabove sea level in Himachal Pradesh India they deliberated each aspect with clockwork precision The project involved anumber of surprises and challenges and required technology and project management skills that were second to none

TEXT amp PHOTOS Monisha Majumdar

Cutting a 10-meter-wide and nearly 9-kilo-

meter-long tunnel through the Himalayas

in one of the toughest terrains and cli-mates in India makes for quite a challengeResults set out to find out how AFCONS-

Strabag and Metso are making their way in

one of their most critical projects to date

The only road connection to the north-Indian border region of the province

Himachal-Pradesh and beyond the Manali-

Leh highway leads across the Rohtang

pass Due to the heavy snowfall and high-

velocity winds in this region the towns

located north of the pass are cut off from

the rest of the country during winter for atleast four often even six months each year

A tunnel with strategic importance

With the construction of the tunnel at

3100 m above sea level the Manali-Lehhighway will become an all-weather road

thereby enabling a significant improve-

ment in the economic development of

northern Himachal-Pradesh and an alter-

nate route to the strategically important

Ladakh region

Manali south of the pass is an alreadywell-developed tourist location that is

becoming more and more popular Upon

completion of the tunnel it is likely that

tourist activities will extend to the areanorth of the pass Moreover the tunnel

shortens the distance between the towns

of Manali and Leh by approximately 45 km

thus saving several hours on the small dan-gerous pass road

The Rohtang pass in the Western Himalaya

region of Northern India with its altitude ofalmost four kilometers ranks among thehighest trafficable passes in the world

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The 88-km long horse-shoe-shaped

tunnel provides space for a two-lane8-m-wide carriageway as well as a one-

meter-wide footpath on both sides A

22-m-high and 36-m-wide emergency

tunnel will be integrated in the tun-

nel cross-section Altogether more than

800000 msup3 of rock will be moved Tunneling works started around spring

2010 with excavation driven from both por-

tals As the north portal is inaccessible dur-ing winter closure the excavation focused

on the south After a planned construction

period of 55 years the tunnel is scheduled

to be completed by the end of 2015

Best man for the job

The BRO (Border Road Organization)

wanted to roll out a global tender for theproject due to the challenges that such a

project involves and also considering thatitrsquos the first time in India that a project of

this scale was to be carried out This imme-

diately triggered the need to roll out aglobal tender All major Indian construction

companies bid for it some individually and

some in partnerships

Strabag an Austrian tunnel specialistwas one of the companies who bid for the

project along with AFCONS a Mumbai-

based infrastructure company In Septem-

ber 2009 AFCONS-Strabag was awardedthe contract

Mr Sunil Tyagi Deputy Project Man-ager at AFCONS had this to say about the

unique projectldquoThis project is located in the Himalayas

and as far as we understand the terrain

there is among the toughest We came out

with a new technology and to be honestit is a fairly simple one We would generally

start with the traditional technology of drill-

ing and blasting and then obtain our muck

feed from the inwardbottom of the tunnelrdquo

ldquoThe technology is supplied by Rowa Tunneling Logistics and this is the first

time it is being used in Asia A jaw crusheris placed at a distance of about 40-45

meters behind the face The blasted muckextracted from the face is fed to the crusher

to reduce the lump size and then through

an overhead conveyor transport system

it is then transported out of the tunnelrdquoldquoThis enables free movement of man

and machinery in the lower area or spe-

cifically on the ground area If we were to

conforms to the Indian standard for fines amp

coarse aggregates as prescribed in IS383-1970

The plant was up and running in good

condition and performing to AFCONSrsquos

satisfactionldquoWe have worked with Metso in earlier

projects and are quite impressed by thekind of technology amp services they provide

We have a history together so the trust fac-tor also comes inrdquo explains Dhiman on their

choice of Metso as a partner

Service makes the difference

ldquoMetsorsquos services have made a big dif-ference in the project Without them we

would still be struggling with the machin-

ery and production The service is really

good and the service engineers are knowl-edgeable prompt and quick to act Any

problem can be solved by Metso We donrsquothave to wait until a service engineer turns

up ndash they have the capacity to solve prob-lems over the phone as wellrdquo says Dhiman

ldquoThe Metso plant didnrsquot create any prob-

lems for us We had problems in logistics

the feed was sticky and the weather condi-tions were bad but thankfully we did not

face any problems with production and

efficiency as the Metso plant is performing

very wellrdquo Dhiman concludes

More info

Amol Sinha Tel +91 9811 671 924

amolsinhametsocom

use the old conventional technology this

wouldnrsquot have worked for us in the stipu-lated timerdquo Mr Tyagi adds

When the going gets tough

partner with the toughest

Sensitive projects require the best technol-

ogy After AFCONS-Strabag landed theproject Metso was an obvious choice as a

technology provider not only because of

the long-standing business relationshipbut also for the sheer consistency in prod-

uct quality and service deliverance Metso

strives for

ldquoAfter signing the project we faced alot of road blocks including extreme cold

avalanches roadblocks less oxygen ndash you

name it we faced itrdquo explains Ankit Dhi-

man Plant Manager at AFCONS-Strabag The Rohtang valley is known for its

notorious avalanches and landslides SoAFCONS had to take extra steps and safety

precautions against hazards on the site

ldquoIn this freezing cold not just us humansbut also the machines are at increased risk

of damage I remember when we used

to run the plant during winter the diesel

engines would freeze We had to constantlyheat up the fuel container to get the plant

running And even the sand in the sand

trap would freeze so we had to clean it on

a daily basis to stop the pipes from mal-functioningrdquo Dhiman adds

Plant designed for difficult terrain

Difficult terrain coupled with space con-straints led Metso engineers to put their

minds together to come up with a suitable

plant configuration After studying the

requirements of the project Metso sug-

gested a 150-tons-per-hour three-stagemodular plant using a C106 jaw crusher

a GP11F secondary cone crusher and a

B7150 tertiary vertical shaft impact crusher

In addition considering the unpredict-ability of the feed the plant was about

to reach a point where the amount offines to be handled could be increased

dramatically Metso strongly suggested the TK11-27-3V grizzly scalper and this became

the first-ever TK scalper to be supplied by

Metso to an Indian customer Also in order

to get better products a sand trap SF2360was added to the configuration

The sand trap is important equipment

for this project as it washes the sand thatMr Sunil Tyagi Deputy Project ManagerAFCONS-Strabag

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Smooth transition to new-generation jaw crusher in Germany

Roumlhrig is a German company with a rich heritage The company has been quarrying granite at its plant in Bergstrasse inthe Sonderbach district of Heppenheim for three generations

TEXT amp PHOTOS Ralf Goffin

Roumlhrigrsquos superior product variety is onereason why the companyrsquos proximity to its

customers can be understood in more than

just physical terms The companyrsquos high

level of innovation has allowed it to estab-lish itself as a reliable supplier of materials

both regionally and internationally This

operational and technical expertise always

manages to keep in step with growing

market requirements

In terms of technical processing equip-

ment Roumlhrig has used a Nordberg C160stationary jaw crusher from Metso since

1992 At the start of 2012 it was finally

exchanged for a more up-to-date version

from the same model range

Metsorsquos C Series is specifically designed

to pre-crush hard rock and can cope effort-

lessly with even the hardest of materials

The dimensions of the new stationary jawcrusher are identical to those of the old

one which means that it could simply be

slotted into the housing vacated by the

previous version

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983122983141983152983151983154983156983145983150983143 983154983141983155

Third-generation Managing DirectorMarco Roumlhrig expects the new machinersquos

service life to be just as long as the previ-

ous model due to the product upgrades

that have been implemented The integral motor base is another plus

point in models made by other manu-

facturers it is located outside the crusher

This element of good fortune ensured that

Roumlhrig could reuse the housing withoutany additional rebuilding

Another advantage lies in the revision

of the guards for the C160rsquos drivetrain andflywheel The sturdier construction method

used for the crusher requires fewer parts

which facilitates easier installation andmaintenance and it makes it simpler to

access the motor

Under the watchful eye of Metsorsquos

Assembly Manager Maik Engelstaumltterthe entire project including removal and

installation was successfully completed

within two weeks

Installation making the most

of the available space

Roumlhrig will likely remember the day the

new crusher was installed for a long time

the pitman and main frame were deliveredseparately prior to installation and assem-

bled on site It took just one hour to replace

the old stationary crusher with the new

model A lorry-mounted crane was used toposition the 85-ton crusher with millimeter

precision in the crushing plant Once the

new crusher had been positioned in theexisting steel structure the next task wasto fix it into place as securely as possible

despite the limited space Special vibration

dampers were installed at a height of two

meters to prevent the crusher from sliding

Norbert Ried (fourth from left) installed thenew C160rsquos predecessor 20 years ago and isdelighted at the durability of the powerfulcrusher that is now making way for a newermodel Also pictured from left to right ManagerVolker Angermann Assembly Manager Maik

Engelstaumltter Technical Manager Stefan

Koob Project Manager Dominic SchoumlnhardtManaging Director Marco Roumlhrig Service

Technician Stefan Kolze and employees ofthe installation company Stafemo

On the hook after theold C160 was liftedout by crane the newcrusher was installedin almost no timeOnly the roof of thehousing had to beremoved

sideways off its mount An initial test run

with materials was carried out around oneweek later after all the electrical cables had

been installed

Simultaneously with the installation

of the C160 which is the first of the latest

generation of crushers to be installed in

Germany a new Nordberg GP100 conecrusher was also being installed in Roumlhrigrsquos

chipping plant Roumlhrig is convinced that

the technical improvements made tothe new Metso crusher can only be an

advantage worldwide

Roumlhrig places great value on consistent

product quality maximum added valueand optimum refinement of its product

range Bearing in mind that Roumlhrig has

enough reserves of raw material to last

for the next 150 years the company canconfidently continue to develop with an

emphasis on quality rather than quantity

More info

Dominic Schoenhardt

Tel +49 (0)621 727 00 610

dominicschoenhardtmetsocom

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Groupe Charier Carriegravere de la Mariais France

Quarrying with certi1047297ed quality The Charier Group with its 1600-strong workforce is a family business thatthis year celebrates 115 years of quarrying The company pursues a long-termdevelopment policy that since 2007 has seen processing installations upgradedat 4 of its 9 extraction sites

TEXT Liliane Boutin (with extracts from Mines amp Carriegraveres and Terrassements amp Carriegraveres magazines)PHOTO Baloon photo

The processing installation is of the horizontal type with a primary station located 56 meters below the site access road to keep it hidden from view

The crushing and screening installation at

Charierrsquos CM La Mariais quarry (at Donges

on the Loire estuary) has been in opera-tion since September 2011 Based on theoperatorrsquos ideas it was designed by Metso

to replace a worn-out installation installed

right on top of the seam being extracted

Since its commissioning it has becomethe second quarry in the company to

receive ISO 14 001 certification

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155

tertiary material of sand and gravel for the

local market to use in concrete surfacingprefabrication etcrdquo

Incorporation of a screening station

The stone extracted from La Mariais is

according to the quarry granitic gneiss

sound and homogeneous with a LosAngeles index of 15 good wear resist-

ance with an MDE of 10 a true density of

265 and a certain abrasiveness (2000 gt)ldquoCharacteristically it has a tendency to form

blocksrdquo Leblin points out

The main criteria in designing the instal-

lation was to provide an output of 600000metric tons from one station (38 hours

week) to produce materials aimed at the

concrete and surfacing markets ldquowhich

involved providing a tertiary station withscreening plantrdquo he adds

With this new unit the operating com-pany expands its product range through

the addition of fine materials obtained

from the tertiary screening station This unitis capable of producing 170 tonshour of

020

Preserving the environment

and optimizing safety

The screens have motorized bogies and

retractable walkways to facilitate access

when the screens are opened for main-tenance Other walkways provide access

to the tunnel input feeders The feederscan be isolated with hydraulic rod gate

bars this hydraulic assistance eliminatesthe need to use a heavy hammer to lodge

these metal bars

All conveyors transporting fines (02

and 04) are covered with a tarpaulin to

avoid flying dust and all the screens arehooded (metal cover with Trellex seal-

ing) The Brunone company has installed

dust-tight containment at the outlet of the

tertiary station crushers (HP300 and HP4)on the belt located under the screens

and under the hoppers located belowthe tertiary screens The crushers are put

under negative pressure and the finesare extracted through sleeve filters (7000

m3 h) with declogging which deposits the

dust back onto the conveyor belt

A high-pressure 100 bar water mist sys-tem has been installed at the primary sta-

tion discharge at the secondary crusherrsquos

discharge chutes (Omnicone) and at the

transfer points on the belt

Designed to last

ldquoThis type of new installation can easily last

thirty yearsrdquo affirms Project Leader Bruno

Peix of Metso ldquoIt quite simply depends on

how well it is maintained Thatrsquos why weprovide maintenance contracts that call for

our technicians to make regular inspection

visits and carry out preventive mainte-nance and any necessary repairsrdquo

In 2011 Metso commissioned about

10 new processing units in France like

the one at La Mariais quarry

More info

Frederic Bazire

Tel +33 (0)681442804

fredericbaziremetsocom

Key figures

DURATION OF WORKS 15 months

DRAWING OFFICE TIME 7800 hours

HEIGHT OF SILOS AND GRINDER BUILDINGS

15 m

TOTAL LENGTH OF CONVEYORS 14 km

WEIGHT OF THE INSTALLATION

1200 metric tons

CONCRETE POURED 1800 cubic meters

PROJECT SITE WORKFORCE 30

INSTALLED POWER 2200 kW(not including pumps 200 kW)

METSO EQUIPMENT

Primary

Vibrating feeder PF561-2V

Primary grizzly VG540-3V

Grizzly feeder TK13-20-3V

Jaw crusher C145 with

hydraulic setting

Secondary

Vibrating screen CVB 2050

refurbished

Cone crusher Omnicocircne 1352 SX

with Metso IC7000 controller Ellivar 16 (16 msup2 3 decks) screen

refurbished by Metso

Tertiary

Cone crusher HP300

Cone crusher HP4

2 Ellivar 20 screens (20 m23 decks) for final products

Expanding the production range

ldquoSince the mid-1990s when we became

owners of La Mariais we had used mobilemachinery with an assembly of beltconveyorsrdquo recalls Daniel Leblin Charierrsquos

Technical Manager for site construction

and maintenance

ldquoIt became clear that we needed ahigher performance tool to achieve the

dual goals of reaching one million metric

tonsrsquo maximum production and producing

8132019 Results Minerals Aggregates 3 2012ENG

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Big Lokotrack LT550GPF boostsquarrying productivity by a thirdMaximizing the productivity of operations is a key issue when striving for cost-effective quarrying Big Lokotracks are oneway to achieve improved operational efficiency The Lokotrack LT550GPF equipped with the high-volume GP550 conecrusher and a large screen is popular in the Nordic countries and in Germany and Australia ndash countries all known for theirhigh quarrying volumes

TEXT amp PHOTOS Eero Haumlmaumllaumlinen

Kone-Kostamorsquos new mobile coneplant has reached an averagecapacity of 300 tons per hour

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983122983141983152983151983154983156983145983150983143 983154983141983155

ldquoWith the same number of employees we

can achieve 30 more productivity with

our new LT550GPF unit The high-capacityFS screen has also eliminated the bottle-neck often seen at fine screeningrdquo says

Aarno Kostamo Managing Director of

Kone-Kostamo Oy one of Finlandrsquos biggest

crushing contractorsAccording to Kostamo the high capacity

of the GP550 gyratory cone crusher easily

handles feed from the C120 and C125 jaw

crushers For the contract with the Talvivaara

nickel mine the LT550GPF is being fed bythe brand new Lokotrack LT120 jaw plant

Average capacity 300 tons per hour

Talvivaara Europersquos largest nickel mine uti-

lizes large quantities of aggregates Kone-Kostamo has contracted several million

tons of different end products for the mineIn August 75000 tons of 0ndash63 mm

road gravel was crushed Smaller amountsof finer 0ndash6 mm 0ndash16 mm and 0ndash32 mm

aggregates are also being produced

The rainy summer increased the need

for road gravel along the muddy roadswhich must endure dump trucks weighing

as much as 260 tons

ldquoThe mobile process consisting of the

LT120 jaw plant and LT550GPF cone plant

is cost-effective while aggregates of vari-ous sizes can be produced in a two-stage

operation and with high capacity The con-trolled stroke and elliptical movement of

the FS screen secure big passing throughcapacitiesrdquo Kostamo explains

Operated in two shifts for a total of 16

hours per day the LT550GPF has logged

more than 600 working hours over a two-month period

Managing Director Aarno Kostamo (left) and foreman Karri Maumlenpaumlauml studying the cavity optionsavailable for the new Lokotrack LT550GPF

Longer perspective than

a single quarter needed

Kone-Kostamo Oy was founded as an

earth-moving company in Kemijaumlrvi

Northern Finland in 1956 The company

expanded its operations to include crush-

ing contracting in 1964 and later on

switched to concentrating fully on crush-ing activities

Kone-Kostamo consistently crushes

and screens around 28 million tons ofaggregates annually and has net sales of

between EUR 8ndash9 million

ldquoWe believe that issues within the crush-

ing industry including the purchasing ofmachinery must be studied with a longer

perspective than a single quarter The

secret to our success has always been our

solid work ethic and professional employ-eesrdquo Kostamo sums up

More info

Esa Berg

Tel + 358 40 837 8692

esabergmetsocom

8132019 Results Minerals Aggregates 3 2012ENG

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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155

Monitoring-based reporting is vital for

assessing the performance of a mobile

crushing plant Metso provides suchreporting tools through its plant-wideautomation system Metso DNA (Dynamic

Network of Applications) with its infor-

mation platform that links all the mobile

crushing and screen units together as oneentity Basically there is a lot of measured

real-time information available in every

crushing plant On-line information is

obtained either from each Metso crusherrsquosmachine automation system IC (Intelligent

Controller) or from separately installed

additional sensors and belt scales

All the collected data is sent to a motorhome using wireless communication

based on WLAN technology The motor

home is a purpose-built environment

inside an on-site container In this environ-ment selected variables can be monitored

for assessing the plantrsquos performance And

to make all this even more flexible the

data can be transmitted to a crushing plant

company office using GPRS3G mobile

data communication technologies Thismakes all the last-minute reports acces-sible to the crushing plant managerial staff

at anytime and basically anywhere within

reach of the cell phone network

Production and fuel economics reports

Essentially monitoring and reporting can

be customized to fit the customerrsquos needs

However there are certain off-the-shelf

reports that provide a lot of useful informa-tion for plant supervision The production

report is one of these Requiring at least one

belt scale for measuring the total produc-tion the production report shows the pro-duction rate (tons per hour) for a selected

reporting period eg a day or a week The

production report constantly keeps track of

the plantrsquos production storing all the datathroughout the plantrsquos life cycle

Performance monitoring and reportingfor a mobile crushing plantTEXT Pasi Airikka PHOTOS Metso

unit during which the unit is running By

storing the availability times between start-ups and shutdowns the crushing plant

operation time (hours per dayshift) can be

recorded analyzed and reported In addi-

tion the availability report can be tailored

to evaluate efficient crushing hours during

which the plant is really working and pro-ducing aggregates Consequently the ratio

(0-100) between efficient crushing time

and total running time can be reported forany selected period of time This boosts

the efficiency of the plantrsquos operations

and results in better productivity

Reports on non-choke

or inadequate feeding

Non-choke feeding to crushers is avoid-

able through smart plant-wide crushingplant controls But estimating its severity in

a systematic manner is not straight-forwardwithout constant monitoring and reporting

The crusher choke feeding report makes

use of the crusher cavity level sensors byanalyzing their level measurements By

calculating average and min-max values

and deviations from the average it can be

shown how often the single crusher suffersfrom non-choke feeding to it

In some cases the bottleneck in the

crushing plantrsquos productivity is the material

feeding to the process In mobile plants thefeeding is human operated and therefore

subject to variations Occasionally the sizeof the human-operated machine simply

does not allow for adequate feeding to thecrushing plant There are specific reports

indicating time periods when the crushing

plant suffers from inadequate feeding

Condition monitoring for

crushers and screens

Machine-specific condition monitoring

focuses on vibrating components in

crushers and screens such as drive shaftbearings safety plate wearings and gears

The low middle and high frequencies ofmonitored components are measured and

supervised in real-time to detect abnor-malities due to slow or fast wear looseness

or imbalance

More info

Pasi Airikka

Tel +358 40 587 2730

pasiairikkametsocom

Condition monitoring provides a view tovibrating crusher and screen components forpredictive equipment maintenance

The daily production report shows the hour-by-hour production trend and distribution chartfor a selected day with min-max average andvariation statistics for comparison

Fuel consumption is always an interest-ing concern The fuel consumption reportgives the fuel consumption of each crush-

ing unit (liters per hour) and their total

consumption (liters per hour) for a selected

reporting period and can track fuel con-

sumption changes over timeCrushing plant availability can be

assessed as well The availability report

calculates time periods for each crushing

8132019 Results Minerals Aggregates 3 2012ENG

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983149983141983156983155983151 983150

for tissue machines The record of 2210

mmin was set on June 1 2012 during a

24-hour production run by the TM 2 tissue

machine at the companyrsquos mill in Yenikoumlynear the city of Izmit in Turkey

ldquoThe cooperation with Metso has been

beyond excellent and both parties did

their utmost to make the project success-ful The results clearly show that the efforts

were worthwhile on both sides This coop-

eration will extend to cover new projects

in the futurerdquo says Luumlt1047297 Aydin Paper GroupDirector Hayat Kimya

ldquoWe are not surprised that Hayat K imya

managed to break the world speed record

We have had great confidence in the capa-bility of the Hayat team since our project

started in 2009 We certainly know our

machine very well its stability production

efficiency and speed capabilityrdquo says Jan

Erikson Vice President Sales Metso

PowerThe worldrsquos first eco-gas fueled

power plant is up and running

Lahti Energy Ltdrsquos new Kymijaumlrvi II gasifica-

tion plant was officially inaugurated on

May 8 2012 It is the first of its kind in the

RecyclingRecycling with Lokotrack LT106

jaw plant in New York

A brand-new Lokotrack LT106 jaw plant is

used in the city area of New York USA to

recycle demolition materials The crushing

site faces the skyscrapers of ManhattanIsland

Paper amp FiberHayat Kimyarsquos Metso-supplied tissue

machine sets world speed record

Thanks to a skilled crew and dedicated

efforts Hayat Kimya AS in Turkey has suc-

ceeded in breaking the world speed record

world This CHP plant runs on clean eco-

gas that is gasified cleaned and cooled

from recycled waste with Metsorsquos innova-tive technology

ldquoItrsquos actually eco-gas that we combust

in the boilerrdquo comments Lahti EnergyrsquosProduction Director Jukka Manskinen

ldquoWe convert unwanted waste material into

energy in an efficient and environmentally

friendly wayrdquoNever before has any plant gasified

waste on such a large scale In the gasifier

recycled waste is turned into combustible

product gas which is cleaned cooled and

combusted in a high-efficiency gas boiler

to produce steam for the steam turbine The plant produces 50 MW of electricity

and 90 MW of district heat for the city of

Lahti and its neighboring areasMetso delivered the circulating fluidized

bed (CFB) gasification process gas cleaning

and cooling steam boiler environmental

protection system and automation systemto the entire plant The production of elec-

tricity and heat is kept even with the Metso

DNA automation system that covers the

whole plant starting from fuel reception

AutomationMetso develops and supplies plant-

wide crushing control solutions for

crushing plants

Metso has recently signed contracts on

delivering plant-wide automation systems

for mobile and portable rock crushing

plants The key objective of these deliveries

is to stabilize and to increase productivityand efficiency of the plants using one sin-

gle automation and information platform

for integrating crusher-specific IC machinecontrols

Furthermore the plant-wide system

with its information management tools not

only increases plant availability and opera-

tional safety it also makes troubleshoot-ing quicker and performance monitoring

easier The control room for plant-wide

operability is located either in an excavator

cabin or a purpose-built container

Metso around the world

The new LT106 jaw plant is suitable for crushing both hard rock and all rock-based demolition materials

The new world speed record for tissue setby Hayat Kimyarsquos Metso-supplied TM 2 is2210 mmin

8132019 Results Minerals Aggregates 3 2012ENG

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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 13: Results Minerals Aggregates 3 2012.ENG

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983110983141983137983156983157983154983141983140 983137983154983156

Just one year after starting the gold recov-

ery process Nordic Mines is on track toreaching a capacity of 5 kg of gold per day

At present the operations are averaging 3

to 4 kg of gold daily

The ore in the Laiva Gold Mine consists

of packages of gold-bearing quartz-filled

shear structures The deposit is more thana kilometer long and 700 meters wide The

total depth is still unknown but dr illings

carried out thus far have shown gold-bear-ing shear structures 300 meters below the

surface

A typical ore zone includes a large num-

ber of thin shear structures from 5 to 30per meter The ore zones are commonly 50

to 100 meters long several are 10 meters

deep and they range from a few meters to

20 meters cross strike The minimum min-ing width is 25 meters which means that

even a minor ore zone consists of at least10 to 50 shear structures

Conventional pattern blasting

with selective loading

Prior to mining Nordic Mines conducts

grade control drilling which provides

dense gold grade information and makes

it possible to outline the boundaries

between ore and waste The mining

technique applied is conventional pattern

blasting with selective loading This is oneof the most commonly used techniques in

large-scale open-pit mining

A typical blast in the Laiva mine is 50

meters long 100 meters wide and 5 metersdeep After blasting ore and waste aremined by selective loading

After investing some EUR 100 million

the Laiva mine now comprises an open-pit

mine with a modern complete crushinggrinding and processing circuit that ends

with the casting of gold doreacute bars

With a number of mine staff partners

sub-suppliers city and state officials inattendance the Laiva gold mine was offi-

cially inaugurated on August 16 2012

Michael Nilsson Managing Director

of Nordic Mines stressed in his speechthe importance of overcoming challenges

during the building of the mine

ldquoObviously the whole development

took us longer than expected Today weare pleasantly surprised by the size of our

operation We are becoming much bigger

than expectedrdquo gt

Chief Geologist Kimmo Lahtinen presenting narrow gold veins twisting at the Laiva North open-pit mine

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An international process package

The Metso package for the Laiva gold mine

included the main crushing screening

conveying regrinding leaching and pump-ing elements Metsorsquos office in Sala Swe-

den has served as the main project office

with Metso manufacturing units in FranceGermany Sweden and Finland responsiblefor the equipment supply

At Laiva the gold ore is classified after

selective excavating into two gold con-

tent classes All class A gold ore is takento Metsorsquos sturdy jaw crusher for primary

crushing while the class B ore is stocked for

possible future use After primary grinding

utilizing autogenous technology the ore is

screened and two Metso cones crush the

oversized pebbles For regrinding Metsorsquosball mill is used

During high- and low-grade leaching

processes a number of Metso pumps and

dewatering screens are used The whole

minerals processing system is controlled byMetsoDNA automation

Active exploration drilling going on

According to Mine Manager Tom Soumlder-

man the known gold ore reserves at the

Laiva gold mine amount to 169 million

tons but the potential for additional find-

ings looks good

ldquoWorking at the level of two million tonsper year our expected lifetime is about nine

years We carry out active exploration drill-

ing in Kaukainen Musunneva and Oltava

to locate nearby satellite ore bodies Anupdated detailed mine life plan will be pre-

pared during the autumnrdquo Soumlderman saysNordic Minesrsquo other exploration areas

include Tormua in Finland and Fjaumllltuna

and Vassbo in Sweden

More info

Alf Rydberg

Tel +46 70524 5837

alfrydbergmetsocom

Happy faces during the minersquos inaugural ceremony Mine Manager Tom Soumlderman (left) with Managing Director Michael Nilsson and Deputy Managing Director Krister Soumlderholm

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983110983141983137983156983157983154983141983140 983137983154983156

The story behind the discovery of the Laivamine is an interesting one During a hunt-

ing trip in the remote forests of Laivakan-

gas in 1979 Pentti Jaumlmbaumlck found an inter-esting-looking piece of stone Although hecould not see the gold hidden inside the

rock Pentti noticed the striking weight

and somewhat different look of the stone

Upon returning home Pentti sent thesample to Outokumpu which at the time

was the leading state-owned mining com-

pany in Finland After testing a high gold

content of 15 grams per ton was found

Gold deposit founded by a hunter

The founder of the Laiva gold deposit Mr Pentti

Jaumlmbaumlck was the guest of honor during theinauguration

Lennart Schoumlnning Chairman of the Board ofNordic Mines holding a gold doreacute bar worthsome EUR 320000

Outokumpu registered a mining claimon the area and conducted a series of

exploration drilling from 1981 to 1987 Due

to the low price level for gold no mine wasstarted at the time Other mining compa-nies such as Endomines held the mining

rights later

Nordic Mines with its sights set on

locating and exploiting gold in Swedenand Finland was founded in 2005 During

the same year the company purchased its

first mining rights at Laiva

Nordic Minesrsquo Laiva gold mine

LOCATION near the city of Raahe

northwestern Finland

GOLD ORE CONTENT average 16 gt

ORE EXTRACTED PER YEAR

12 million tons (present)

20 million tons (planned)

GOLD RECOVERY 85

TOTAL KNOWN ORE RESERVES

169 million tons

MINING METHOD

Selective open-pit benchingNUMBER OF EMPLOYEES

130 including contractors

METSO MAIN EQUIPMENT

2 Metso VF and 6 EMEG EME

vibrating feeders

8 Screens 1 MF 1 CVB and 6 KS

1 RCS Flash flotation unit

1 Metso SRR ball mill 18 x 4 m

1 Nordberg C160 jaw crusher

1 Nordberg HP100 cone crusher

1 Nordberg HP200 cone crusher

5 Nordberg NB series conveyors

73 Metso Slurry pumps ofvarious types and sizes

8132019 Results Minerals Aggregates 3 2012ENG

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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155

The newest member of the proven GP series cone crushers ndash theNordberg GP220 ndash offers a versatile alternative for any demanding

tertiary or quaternary or even secondary crushing operation fulfill-

ing all crushing needs and maximizing customersrsquo profitability

High-quality components and optimized castings and forgings

contribute to the GP220rsquos enhanced reliability and help to ensurethe highest level of crusher uptime

Thanks to the 200 kW (270 hp) power draw the GP220 performs

at a 20 to 30 percent higher capacity than other cone crusherbrands with an equal head diameter The large feed openingenables the feeding jaw crusher to run at 110 mm css Operational

flexibility is ensured by multiple strokes and six different cavities

Secondary crushing possible

thanks to cavity and stroke options

Thanks to the GP220rsquos cavity and stroke options secondary crush-

ing in addition to tertiary and quaternary stages is also possible

using cavities with a greater intake opening With the GP220 a suit-

able solution for producing excellent end-product gradations

can always be found

With advanced automation using IC50 or IC5000 operation

is safe and trouble-free The low height thanks to the patented

piston design makes replacement installations much easierA dynamic setting adjustment enables a fast response to process

optimization needs

The Nordberg GP220 weighs 10500 kg (23150 lbs) and hasa maximum real feed size of +200 mm (8rdquo) with strokes from

18ndash40 mm (57rdquondash1 47rdquo) The cavity options are EF F MF M C

and EC

A complete modular crusher steel structure is available for allGP series stationary installations including GP220 The platform

includes places for the lubrication unit motor automation or

pressure accumulator and pressurized sealing The only things

left to add are the feed and discharge conveyors

Main new features of the GP220 Large feed opening allows for secondary stage operation

Longer setting range of main shaft for better wear parts utilization

Stronger main components to carry high loads with a powerdraw as high as 200kW

More info

Hannu Vakkuri

Tel +358 50 317 0638

hannuvakkurimetsocom

Thanks to the large feed opening and wide selection of strokes and cavitiesthe new Nordberg GP220 cone crusher is a highly versatile cone novelty

More versatility with the newNordberg GP220 cone crusher

Reinforced head and frame castings combined with a 200kW power

draw make the GP220 cone a reliable crusher with maximum productivity

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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156

Metsorsquos HRCtrade takes high pressure grinding roll technology to the next level

The new Lokotrack mobile conveyors come as tracked and wheeled models

Metsorsquos latest development in comminution equipment the HRCtradeis a major step in the profitable application of high-pressure grind-

ing roll (HPGR) technology Metso has made several key innova-

tions in order to increase throughput and decrease the total cost

of operation

Metsorsquos patented Arch frame creates an even gap setting acrossthe width of the tires limiting skewing that can result in downtime

for mining operations This anti-skewing Arch frame also prevents

damage to the roller bearings (caused by misalignment) that canoccur with the traditional HPGR design

Flanges maximize wear life and increase throughput

Used in place of spring-loaded cheek plates the flanges keep thebed of material within the crushing zone and prevent material

from bypassing the tires This enables greater circuit capacity and

increases the overall crushing efficiency

In addition by preventing material from bypassing the tires

even pressure across the width of the tire is better maintained

Distributing the pressure more evenly maximizes the tire life bypreventing a ldquobath tub effectrdquo in which the center of the tire wears

faster than the edgesVictoria Herman Metsorsquos Product Manager for the HRC notes

that this breakthrough design is a response to the growing needs

in the mining industry ldquoEnergy efficiency has been attracting our

customers to HPGR technology for yearsrdquo she says ldquoBut our design

concept increases capacity and crushing efficiency ndash and thatrsquossomething mining companies are always looking to improve onrdquo

The track-mounted Lokotrack CT32 and wheel-mounted Lokotrack

CW32 mobile conveyors offer an ideal solution for applications

that require high stockpile capacity and excellent material transfer

capabilities They also add flexibility to multi-stage crushing andscreening applications enabling easy and fast closed-circuit opera-

tion of mobile units

The conveyor novelties can be used in both mobile and station-

ary installations providing extra stockpiling capacity in situationswhere for example fewer wheel loaders are available

The HRC is ideal for high-tonnage hard rock applications andcan be used as a tertiary quaternary or pebble crusher Currently

several HRC units are in operation around the world ndash with a total

of 6500 operating hours including over 3800 hours in a mininghard rock application The machine does have range within hardrock applications itrsquos been designed for use in diamond iron ore

copper gold platinum and various industrial minerals

More info

Victoria Herman

Tel +1 717 309 1150

victoriahermanmetsocom

Several optional features such as hydraulic folding of tail sections

and dual hydraulic drive for increased throughput are available

The capacity of the CT32 and CW32 is 400 mtph (440 stph)feed size up to 150 mm (6rdquo) belt width 1050 mm (42rdquo) and dis-charge height 9120 mm (29rsquo 11rdquo) The CT32 is fitted with a Caterpil-

lar C2 diesel engine with 38kw (51 HP) power The CW32 is avail-

able for hydraulic or electric use

More info

Kimmo Anttila

Tel +358 50 433 3745

kimmoanttilametsocom

The new HRCtrade combines high crushing pressure and a low circulatingload resulting in the most efficient comminution

When flexibility in stockpiling capacityis required the answer can be foundin the new Lokotrack CT32 and

CW32 mobile conveyors

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Service creates value in ChinaChinarsquos most important gold producing area Yantai in northeastern China supplies more than 16 of the countryrsquos goldproduction each year With the gold market thriving the scale of gold production in Yantai has been expanding constantly

Zhongjia Mining Industry Co Ltd is one of the beneficiaries of this thriving industryTEXT amp PHOTOS Yan Xin

Inspection and maintenance of the HP500 cone crusher conducted by Metsorsquos service engineers

In 2011 Zhongjia Mining Industry pur-

chased a modular crushing and screen-ing system from Metso for its new gold

production project With the cooperation

between the two companies continuously

intensifying Zhongjia Mining Industry

signed an additional one-year Life CycleService (LCS) contract with Metso incorpo-

rating Metsorsquos global knowledge in equip-

ment processes and services

ldquoMetso customized a series of reason-

able service solutions also referred toas Metso Performance Solutions for us

including preventive maintenance services

process improvement personnel training

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155

and a procurement plan for wear parts

These really suit our needs perfectlyrdquo saysShen Yidong the Manager of ZhongjiaMining Industry

Effective preventive maintenanceFor mining corporations the biggestconcern is the economic losses caused by

the shutdown of equipment As a result

preventative maintenance is of vital impor-

tance During the contract period Metsoservice engineers offered 7-day tracking

service on the production site every month

to eliminate potential problems and thus

ensured the stability of the system

parts caused pressure on our working capi-tal which was not favorable for our long-

term developmentrdquo Shen explains

To solve this problem Metso designed

a rational stock plan of wear parts and built

a field warehouse In accordance with theuse and consumption of the liners the field

service engineers complement the stock tomake production and operations run more

smoothlyldquoNow when we need to replace the

wear parts we can use them before pay-

ment This not only simplifies the procure-

ment process but also liberates a largesum of our operating capital which can

be used for other business development

purposesrdquo says Shen

Best partner

ldquoAlthough the LCS contract incurs some

early purchase costs in the long run Metsorsquosprofessional and quality service will improve

the equipment efficiency reduce ourenergy consumption and ensure stable

operations thus generating more prof-

its This is the greatest value for us so the

investment is really worthwhile overall Inthe future we will choose more Metso prod-

ucts and services Taking all aspects into

consideration we believe Metso is the best

partner for usrdquo Shen Yidong concludes

More info

Thomas Bai Tel +86 13801009114

thomasbaimetsocom

ldquoIn the eight months since the contract

came into effect our corporation has notsuffered any financial losses due to equip-

ment breakdown The regular maintenance

has greatly improved the efficiency of our

entire crushing system In addition the

experienced engineers from Metso also

provided onsite training and guidancefor our staff and the tailored training has

greatly enhanced the operating abilities of

our employees and upgraded their overalllevel of competencerdquo says Shen Yidong

More productivity with

less consumption

Metsorsquos service contract focuses on real-

izing the optimum performance of each

process flow After analyzing Zhongjiarsquos

production system Metsorsquos techniciansproposed an adjustment to the closed side

setting of the HP500 for tertiary crushingin order to improve the efficiency of the

downstream fine crushing and milling pro-

cessing by over 10ldquoThe process flow improvement solu-

tions provided by Metso not only increased

the output of our gold concentrates but

also reduced our energy consumption andcostsrdquo says Shen

In the past wear parts procurement

took up a larger proportion of Zhongjiarsquos

total production costsldquoTo avoid downtime caused by the

shortage of wear parts we had to keepeight sets of various wear parts in place

However the cost of having so many wear

Zhongjia Mining Industryrsquos gold concentrates processing plant in China

8132019 Results Minerals Aggregates 3 2012ENG

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0983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

Safe quarrying high-

quality aggregates

8132019 Results Minerals Aggregates 3 2012ENG

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ldquoWe share a similar zero-accident strategy and target with Metso and have successfullyfollowed it Metso has also helped us to meet the strictest end-product quality andcubicity requirements set in Spainrdquo This is how Managing Director Intildeigo Ajuria ofOfitas de San Felices the leading hard rock quarrying company in Spain describesthe cooperation with MetsoTEXT Eero Haumlmaumllaumlinen PHOTOS Ofitas and Eero Haumlmaumllaumlinen

The San Felices quarry is situated in a picturesque mountainous landscapebetween the companyrsquos Rioja vineyards and the Bilbao-Madrid motorway

8132019 Results Minerals Aggregates 3 2012ENG

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Ofitas has pioneered the implementation

of several Metso novelties in the Spanish

market The company was the first to use

efficient large track-mounted Lokotrack jaw plants the unique mobile conveying

system and also the new-generation HP4

cone crushers

Today the company operates twomodern Metso stationary plants one in

Guadix near Granada and the newest one

in San Felices Haro Rioja community Both

quarries focus on refining hard rock by pro-cessing ophite rock into the highest quality

railway ballast asphalt and concrete mix

grades The company has a satellite quarry

near Vitoria in PentildeacerradaBeing situated next to a highway and

the famous Rioja vineyards Ofitas must pay

special attention to environmental issues

To minimize dust problems all conveyors

have special covers attached

Quality durability and service

The cooperation between Ofitas de San

Felices and Metso started back in 1973when the Ajuria family bought the com-

pany whose quarrying activities began in

1919 Intildeigo Ajuria has a clear vision of why

the cooperation has continued withoutinterruption for almost 40 years

long-standing personal relationshipsrdquoAjuria adds

Serving railways asphalt

and concrete producers

The year-old San Felices stationary instal-lation lies hidden in a mountainous area

south of the city of Vitoria in NorthernSpain The new plant replaces an old one

that complicated the extraction of ophiterock Both plants are delivered by Metso

With its two separate production lines

the new plant is able to produce all the

end products required ndash from railway bal-last to the finer grades needed for asphalt

and concrete

Due to lower demand the quarry cur-

rently produces some 4000 tons per day

At full capacity however the plant canreach 8000 tons of production per day

30ndash35 of which consists of railway ballastfor high-speed trains and 65ndash70 of chips

and sand Thanks to the versatile two-line con-

cept connected by transverse conveyors

up to 12 different end products can be pro-

duced Depending on the demand for endproducts the material can be guided either

to the HP4 cone or HP400 cone followed

by a Barmac vertical shaft impactor

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

The ophite feed is fed to the C125 jaw crusher by a sturdy dump truck

The key people running the new San Felicesquarry Mine Engineer Carlos Fernandez (left)Managing Director Intildeigo Ajuria with ProductionManager Julian Perez

ldquoThrough the years Metso machinery

has proven its production capacity and

durability resulting in high-quality end

products A big plus for us has also beenthe quick response time to our process

challenges or servicerdquo

ldquoIn fact our cooperation extends

beyond day-to-day business matters to

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155

Meeting the strictest cubicity demands

The Spanish regulations concerning end-product cubicity are becoming more

demanding The flakiness percentage of

railway ballast must be below 10 and for

asphalt and concrete aggregates less than

15

ldquoWith Metsorsquos HP4 cone and the Barmacvertical shaft impactor we can meet even

the strictest cubicity demands We believe

that our high quality is helping us to sur-vive in the present recessionrdquo notes Mine

Engineer Carlos Fernandez

ldquoWe hope to increase the total extrac-

tion of the three quarries from the present15 million tons per year because our plant

capacity allows more than double thatrdquo

Fernandez adds

More info

Angel Luis Garcia Tel +34 686 94 35 30

angelluisgarciametsocom

In addition to being the leading Spanish

quarry to process hard rock Ofitas de SanFelices also cultivates 34 hectares of vine-yards next to the quarry which is situated

in the famous Rioja wine area

The company has previously sold a

harvest of over 200000 kg of Tempranillo

grapes to local red-wine makers Recentlythe company built its own wine process-

ing plant to process 10000ndash15000 kg of

grapes themselves

Aggregates and wine production

Andoni Ajuria the founder of Ofitas de san Felices (left) with Intildeigo Ajuria the present ManagingDirector tasting wine from the companyrsquos own vineyards

The first vintage wine of Ofitas har-

vested in autumn 2010 is now maturingin oak barrels After maturing for 12 to 15months the wine is called crianza and after

two years it will be granted the classifica-

tion reserva

ldquoWinemaking is not a business but

a hobby for us We give our wine out aspresents and drink it when we meet

our suppliers and friendsrdquo Intildeigo Ajuria

comments

For environmental protectionall of San Felicesrsquos plantconveyors are covered

Ofitas de San Felices quarry

LOCATION Haro near the city

of Vitoria northern Spain

SIZE 100 hectares

ROCK TYPE Ophite with Los Angeles

index of 9ndash10

PRESENT DAILY EXTRACTION 3000 tons

of ophiteNUMBER OF PERSONNEL 30

RESERVES 10 million tons

MAIN END PRODUCTS 0ndash2 mm

2ndash4 mm 4ndash10 mm 10ndash16 mm

16ndash22 mm 25ndash60 mm (ballast)

METSO MAIN EQUIPMENT

VF feeder

C125 jaw crusher

ndash feed size 0ndash800 mm

ndash css 130ndash140 mm

HP400 cone crusher

ndash feed size 80ndash250 mm

ndash css 40 mm HP4 cone crusher

ndash feed size 40ndash80 mm

ndash css 15 mm

Barmac 6150 VSI crusher

4 CVB2060 screens

2 TS32 screens

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Metso Distribution Centers he

Europe (Tongeren Belgium)

France (Macon)

Czech Republic (Přerov)

Austria (Vienna)

2271 d

Brazil (Sorocaba SP)

1014 d

USA (Columbia SC)

1690 d

USA (Waukesha WI)

434 d

South Africa (Vereeniging)

Ghana (Tarkwa)

Meacutexico (Irapuato)

Peru (Lima)

Chile (Concoacuten)

788 d

Sweden ( Trelleborg)

Finland (Tampere)

UK (Rugby)

865 d

Russia (St Petersburg)

Brazil (Parauapebas PA)

206 d

4983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983122983141983152983151983154983156983145983150983143 983154983141983155

In the case of an equipment failure or

a planned service shutdown resuming

production as quickly as possible is crucialEach hour spent waiting for a spare part to

arrive equals money lost Whether the right

part takes 12 or 48 hours to arrive really

makes a difference

The comprehensive and global Metsospare and wear parts service network pro-

vides you with the right part in the right

place and at the right time Our strategi-

cally located Distribution Centers and

Satellite Warehouses are on call 24 hoursa day 7 days a week ensuring efficient

parts replacement near you

Check out the locations of the MetsoDistribution Centers and how many parts

pass through them each day

More info

Marcelo Farah

Tel +55 15 2102 1315

marcelofarahmetsocom

you minimize downtime

Australia (Perth)

746 d

China (Tianjin)

China (Kunming)

China (Shanghai)

393 d

India (Faridabad)

India (Ahmedabad)

India (Hyderabad)

India (Bhubaneswar)

India (Bangalore)

419 d

Russia (Yekaterinburg)

Australia (Newcastle)

New Zealand (Matamata)

983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088

TEXT Sofia Williams

Singapore (Singapore)

Distribution Center Satellite Warehouse

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Following a large investment

in Metso crushing equipmentand services Buena Vista del

Cobre is now expanding the

mine site to include even more

equipment ndash and with thatexpansion comes the need for

more local service resources

Metso and Buena Vista del

Cobre have entered into a Life

Cycle Service agreement forthe plant and construction of a

brand new Metso service hub

is under way in Cananea

New facility new

level of service

The Cananea service hub

which will be up and running in early 2013will support the recent expansion and resur-

gence of Buena Vista del Cobre Initially it

will be a major repair and assembly center

for pumps crushers and screens and will

provide for rubber covering capabilitiesBut the 8000-square-meter facilityrsquos service

offering will be expansive including a con-

signment stock inventory to help serve theminersquos varying needs Metso currently has

50 service team members on site

Although Buena Vista del Cobre was a

key influencer in building the new servicehub this location will also enable Metso to

expand its capabilities and provide local

support to the entire mining community

in northwest Mexico The Cananea hub

will serve a number of major copper and

gold mines in the region including MineraFriscorsquos San Felipe Fresnillorsquos Milpillas and

Grupo Mexicorsquos Mexicana de Cobre

ldquoBuena Vista del Cobre is the biggestcustomer we have in Mexico today and

with this expansion project itrsquos only going

to grow and be strongerrdquo says Felix Forna-

guera Director of Services Mexico CentralAmerica and Caribbean ldquoWith that said the

idea behind the Cananea service hub is to

provide a central location for local support

for all our major customers in the areardquo

Establishing safety

ldquoIt was key to have our support here in

Cananea because the Buena Vista delCobre started from the ground uprdquo saysFelix ldquoWersquove been able to help the cus-

tomer to establish the best in support

service and operations from the very

beginningrdquo And this ground-up approachincluded a major focus on safety

Metso worked closely with Buena Vista

del Cobre to establish the safety proto-

col by which the mine operates Basedon Metsorsquos expertise the safety measures

put in place have enabled the mine to

become strict and efficient in its operations

and maintenance procedures To achievethis Metso worked closely with local andnational authorities to ensure the safety

plan was comprehensive and in accord-

ance with all established legal bodies

The best in regional support

The service hub in Cananea is a prime

example of Metsorsquos focus on providing local

service and support to its customers all

Service shines in Cananea MexicoAfter three years of inactivity the Buena Vista del Cobre mine in Cananea Sonora Mexico has been operational since 2010A mine that was inactive for such a significant amount of time however requires a great deal of support to successfullyrestart the plant and bring it back to an operational and profitable state

TEXT Deanna Lee PHOTO Metso

over the world ldquoWe are the first

company developing this kindof service in northwest Mexicordquo

adds Felix ldquoOur people have

developed a close relationship

with the team at the mine Itrsquosmore than a supplier relation-

ship our guys are inside the

mine living and working thererdquo

In fact this is the model

that Metso is using in servicehubs all over the globe build-

ing modern facilities bringing

teams on site and workinghand in hand with mine

operators The Cananea Service

hub is only the most recent

example of Metsorsquos commit-ment to service and northwest Mexico is

yet another mining hotbed thatrsquos going to

benefit from the companyrsquos support

More info

Felix Fornaguera Tel +52 4621079227

felixfornaguerametsocom

A mining cone serviced by Metso at the Buena Vista del Cobre mine inSonora Mexico

ldquoThe new Cananea service center will be a majorrepair and assembly center for pumps crushersand screensrdquo says Felix Fornaguera Director ofServices Mexico Central America and Caribbean

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

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During the MINExpo exhibition over 1300 people visited the Metso stand

983122983141983152983151983154983156983145983150983143 983154983141983155

Held every four years MIN-Expo consistently grows so

perennial exhibitors like Metso

are challenged with elevating

their presence and drawingin new (and greater numbers

of ) visitors each year ldquoItrsquos not

necessarily a challenge to lsquotoprsquo

our last showingrdquo says Keith

Ference Vice President ofmarketing and communica-

tions North America ldquoThere

are four years between eachMINExpo so we always have

a lot to say and reveal to our

customersrdquo The real challenge

he says is finding an exciting

and dynamic way to deliverthe message ldquoTherersquos so much

to see here so your booth has

to be compelling from the

outside-in and thatrsquos what

we always try to dordquo

Service sets the stage

The Metso booth created buzzin a number of ways and per-

haps the most striking (partly

due to its size) was the live

theater presentation As visitorspassed through the aisles of the show-

room the sights and sounds from Metsorsquos

theater were hard to miss And once guests

entered they were captivated by a short

high-energy video presentation focused

on Metsorsquos service capabilities The message was simple Metso is ldquoyour

local service partner rdquo for all mining and

construction needs The video showed ourservice teams in action all over the world

and the audience came away with an

understanding about Metsorsquos commitment

to service Customers can count on morethan 70 local service centers run by more

than 1700 expert technicians delivering

Metso makes an impact at MINExpo 2012At this yearrsquos MINExpo International nearly 60000 attendees flocked to Las Vegas Nevada the largest turnout in showhistory The visitors ndash mining professionals from all over the globe ndash explored 850000 square feet of showroom spacefeaturing the industry rsquos latest technology equipment products and services They toured the show for three days

seeking the latest and greatest from more than 1800 exhibitorsTEXT Keith Ference PHOTOS Tracey Ford Perry

detailed descriptions andphotos of all of Metsorsquos mining

and construction products and

services The app also provides

digital access to Results and asearchable database of sales

contacts By day three of the

show MetsoMAP had been

downloaded by more than

500 usersIn addition to the app the

booth was equipped with

several LCD screens each con-trolled by Metso experts who

used their iPads to present new

products like the Megalinertrade

and the HRCtrade A featured

presentation on Metsorsquos lineupof energy-efficient comminu-

tion equipment including the

VERTIMILLreg SMD and MP-1250

cone crusher was also avail-

able letting customers seehow Metso technology delivers

some of the worldrsquos most effi-

cient size reduction

Measuring MINExpo success

After a very busy three days

(on top of months of prepara-tion leading up to the show) everyone

involved with MINExpo ndash from the North

American marketing team responsible for

the booth to the product managers and

sales force that worked the floor ndash is view-

ing the show as a success ldquoTherersquos alwaysa sigh of relief after each (MINExpo)rdquo says

Keith ldquoAnd overall the initial feedback

and response has been very positiverdquoWith more than 1300 visitors to the

booth Metso certainly made an impact

ldquoWe learn a lot from each show and with

some time wersquoll have a better understand-ing of the tangible results of our effortsrdquo

Keith adds

reliable service for mining equipment as

well as customized cost-effective life-cycle

services contracts

Technology ndash MetsoMAP

is an industry firstMINExpo provided the industry with its firstglimpse of Metsorsquos revolutionary iPad app

MetsoMAP The app was demoed to the

boothrsquos visitors via ldquothe worldrsquos largest iPadrdquo

a custom-made 80-inch screen that show-cased all of its capabilities most of which are

groundbreaking in the industry MetsoMAPrsquos

simple interface is highly intuitive making

it easy to view process animations videos

The presentation of the new HP cone crusher attracted a large audience

8132019 Results Minerals Aggregates 3 2012ENG

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When yoursquore allowed less than a dozen days per year for breakdowns repair andmaintenance every single hour during a service shutdown counts There simplyisnrsquot any room for surprises Thatrsquos why Boliden counts on MetsoTEXT amp PHOTOS Sofia Williams

8983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

Kurt Kalla Site Managerof Metso Gaumlllivare ServiceCenter is responsible forthe maintenance of Aitik

Metso and Boliden Strivingtogether for 97 uptime

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155

One of the biggest copper mines in

Europe Bolidenrsquos Aitik is located deep inthe wilderness of Swedish Lapland next to

the small town of Gaumlllivare The mine has

been operating since 1968 and a recent

expansion has increased its annual ore

production to 36 million tons

But the ambitious Swedes are not will-ing to lay back and relax just yet Bolidenrsquos

new aim is to reach a production rate of

45 million tons of ore per year in AitikAfter that Perhaps more than 55 million

tons The ore concentration in Aitik is very

low-grade with a mere 022 copper con-

tent hence the need for high capacityAchieving the ambitious production

goal requires maximum plant availability

This means that everything from the crush-

ers to the filters must be up and runningfor approximately 97 percent of the time

Thatrsquos where Metso comes into play

A cost-per-ton contract in action

The maximum uptime requirement allowsless than a dozen days per year for break-

downs repair and maintenance at Aitik

Every single hour during a service shut-

down counts There simply isnrsquot any roomfor surprises

Executing a successful shutdown under

such conditions requires a reliable service

partner not afraid of challenges and this iswhy Boliden has entrusted Aitikrsquos services

operations to Metso Boliden and Metsohave worked together since the 1960s

and the collaboration took another step

forward in September 2012 when the twocompanies signed a three-year extension

of the services contract for Boliden Aitik

ldquoThe new contract is a cost-per-ton

agreement We get paid based on Aitikrsquos

production Itrsquos a win-win deal for both par-

ties but also a new mindset for usrdquo explainsKurt Kalla Site Manager of Metso Gaumlllivare

Service Center responsible for serving Aitik

From now on the duration of the shut-down is what matters the most According

to Kalla the Metso service organization in

Gaumlllivare is now streamlining its operations

to fit the bill and has already witnessed thestrategy working In August 2012 Metso

carried out a 188-hour service shutdown in

Aitik which turned out to be a success

Zero tolerance for injury

One key factor to the success was theextensive planning of precautionary health

safety and environment procedures under-

taken by Metso prior to the shutdown Thanks to strict measures applied no

injuries or accidents occurred during the

shutdown and the work could easily be

finished on scheduleMats Johansson Health Safety

and Environment Manager for Metso in

Sweden explains how this was achieved

rdquoPlanning of the shutdown included arisk analysis for all new tasks participating

in Bolidenrsquos safety coordination meetingsmeeting with both Metso supervisors and

subcontractor supervisors and finally a

meeting with the entire staff participating

in the shutdown where everyone had to

sign a document stating their commitmentto the information providedrdquo he says

During the actual shutdown plenty of

new barriers signs and awareness cones

were put in place as a result of observa-tions from previous audits and safety plans

and risk analyses were readily available

in the work area Metso and Boliden also

introduced a Mill Inching permit a certifi-cate for completing a mandatory course for

those involved in the process In addition

Metso carried out random safety audits

during the shutdown to make sure thestrict policy was followed

According to Boliden Metsorsquos way of

working is a good example of how health

and safety precautions should be handled

ldquoMetso is a good example of how towork with safety and health plans risk

analysis permits and welding permits

Their table with all binders in the second-

ary mill area was exemplaryrdquo says Kjell-Arne

Johansson a technician from Boliden

The use of the new Metso Megalinertrade

system in the lining of Aitikrsquos Metso AG

mills has also improved the safety of main-tenance staff The Metso Megalinertrade con-

sists of larger-than-average liners bolted

in position from outside the mill Mainte-

nance technicians no longer need to go

inside the mill and stand in the dangerousdrop-zone of the liners gt

Boliden aims to reach a production rate of 45 million tons of ore per yearin the Aitik mine site

ldquoA complete risk analysis was conducted during the planningof the shutdownrdquo comments Mats Johansson Health Safetyand Environment Manager for Metso in Sweden

8132019 Results Minerals Aggregates 3 2012ENG

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Service the Metso way

24 hours a day 365 days a year

In addition to paying close attention to

health and safety issues executing an effi-

cient shutdown requires careful planning

and timing of every step in the mainte-

nance process Wear and spare parts have

to be available on time and a repair shoplarge enough to accommodate equipment

located close by

ldquoTo keep maintenance breaks as short

as possible we aim to replace the pump on

site and bring the old one for repair to our

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

nearby facilities This method gives us the

peace to do a good job and keep the cus-

tomerrsquos operations runningrdquo Kalla describes

the Metso way of handling Aitikrsquos pump

maintenance

Metso is currently expanding its Gaumllli-

vare service center to include a distribu-

tion center for wear and spare parts andalso concentrating its previously scattered

operations under one roof in its Vuoskon-

jaumlrvivaumlgen facility The expansion is due to

be completed by 2014

Metso equipment

delivered to Aitik36

bull 2 AG mills diameter 116 x

137 m gearless 22-MW motor

bull 2 Pebble mills diameter 91 x

113m dual 5-MW pinion drive

bull 3 VPA pressure filters VPA 1540-54

bull 12 sample pumps and pipes

VF50

bull 60 Various slurry pumps up to

MR500 modelbull Appr 5000 m rubber-lined slurry

pipes up to 600 mm diameter

bull Appr 5000 m rubber-lined by

gravity pipes up to 600 mm

diameter

bull Appr 5000 m rubber hoses

up to 600 mm diameter

Not only does the expansion make ser-

vice shutdowns at Aitik run more smoothly

it guarantees a more comprehensive

on-call emergency service response in the

region ndash thanks to the spare and wear parts

inventory available 24 hours a day 365

days a year

More info

Lars Rosenling

Tel +46 70 107 45 90

larsrosenlingmetsocom

Metso grinding equipment dominates the view in the concentrator

Safety on site is made up of small things like

making sure that everyone remembers to secure

the hoses in place

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Pebbles have always been a

challenge for producers of sandsince they cannot be returned

to rivers after extraction For

decades the processing of this

material resulted in a huge

environmental liability with alarge amount of pebbles hav-

ing to be stored away and left

unused

Transforming problems into

business opportunities

Areia amp Cia (areia = sand) has

operated in this market forover 20 years and decided to

enlist the help of Metso to find

a profitable solution for the

processing of pebbles

In July 2011 analyses werebegun to assess the abrasive-

ness and crushability of the

material Four alternatives wereidentified for processing and

transforming pebbles into sand

Initially Areia amp Cia was

interested in acquiring an

impactor for its reason-able price level However the

customer wanted to process

all the pebbles that were col-

lected daily in addition to some of the

material that it had stored In weighing theresults expected by the customer and the

excessive abrasiveness of the material the

HP200 cone crusher was decided on as thebest alternative

Areia amp Cia made the required invest-

ment and after using the HP200 for just

six months the company has already beenreporting outstanding results The HP200

not only transforms pebbles into sand but

also produces sand of excellent quality

with high yield and low maintenanceWith minor adjustments the HP200

also enables the production of sand withspecific particle size distribution for special

applications such as filtering sand blasting

and foundry sand adding value to the prod-

uct and increasing the types of sand offeredldquoMetso is pleased that the HP200 not

only enabled the processing of a product

that had been set aside as unusable but

HP200 cone transforms pebblesinto high-quality sandOver the last few decades Brazilian economic growth has been driving demand for construction aggregates The market

for sand in turn has been experiencing major difficulties in maintaining a consistent supply Presently one of the mainchallenges the industry faces is the large amount of pebbles that are obtained in the process of extracting sand at timesconstituting nearly 50 of the volume of material dredged from riverbeds

TEXT Sheila Ivers PHOTO Areia amp Cia

also that it opened up new

market opportunities for Areiaamp Cia Thatrsquos the standard we

seek to deliver to our custom-

ersrdquo states Luiz Oliveira Techni-

cal Salesperson of Metso Brazil

HP cones entering the

Brazilian sand-making

market

Todayrsquos cones such as theHP200 have high resistance

to impacts and abrasiveness

more efficient crushing cham-

bers low maintenance costsand excellent productivity

Following the acquisition of

the HP200 Areia amp Cia is now

also producing special sands

that command a price that is100 higher than common

sand The entire stockpile of

pebbles accumulated through-out the companyrsquos 20 years of

operations has already been

transformed into sand and the

stock of pebbles held by com-

petitors is also being purchasedfor processing

Cristiane Brizolari the

owner of Areia amp Cia confirms

the transformation that has taken place in

the production and commercial processldquoThe HP200 opened up new niches in

the market enabling the production of dif-

ferent types of sand with added valuerdquo

More info

Luiz Oliveira

Tel +55 011 9971 3603

luizoliveirametsocom

After the pebbles are crushed into sand with the HP200 cone crusherdifferent grades are screened for various end uses

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Where therersquos a will we dig a wayAFCONS-Strabag and Metso embark on tunnel project together

When the joint venture AFCONS-Strabag initiated work on the Rohtang bypass tunnel project at an altitude of 3980 metersabove sea level in Himachal Pradesh India they deliberated each aspect with clockwork precision The project involved anumber of surprises and challenges and required technology and project management skills that were second to none

TEXT amp PHOTOS Monisha Majumdar

Cutting a 10-meter-wide and nearly 9-kilo-

meter-long tunnel through the Himalayas

in one of the toughest terrains and cli-mates in India makes for quite a challengeResults set out to find out how AFCONS-

Strabag and Metso are making their way in

one of their most critical projects to date

The only road connection to the north-Indian border region of the province

Himachal-Pradesh and beyond the Manali-

Leh highway leads across the Rohtang

pass Due to the heavy snowfall and high-

velocity winds in this region the towns

located north of the pass are cut off from

the rest of the country during winter for atleast four often even six months each year

A tunnel with strategic importance

With the construction of the tunnel at

3100 m above sea level the Manali-Lehhighway will become an all-weather road

thereby enabling a significant improve-

ment in the economic development of

northern Himachal-Pradesh and an alter-

nate route to the strategically important

Ladakh region

Manali south of the pass is an alreadywell-developed tourist location that is

becoming more and more popular Upon

completion of the tunnel it is likely that

tourist activities will extend to the areanorth of the pass Moreover the tunnel

shortens the distance between the towns

of Manali and Leh by approximately 45 km

thus saving several hours on the small dan-gerous pass road

The Rohtang pass in the Western Himalaya

region of Northern India with its altitude ofalmost four kilometers ranks among thehighest trafficable passes in the world

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The 88-km long horse-shoe-shaped

tunnel provides space for a two-lane8-m-wide carriageway as well as a one-

meter-wide footpath on both sides A

22-m-high and 36-m-wide emergency

tunnel will be integrated in the tun-

nel cross-section Altogether more than

800000 msup3 of rock will be moved Tunneling works started around spring

2010 with excavation driven from both por-

tals As the north portal is inaccessible dur-ing winter closure the excavation focused

on the south After a planned construction

period of 55 years the tunnel is scheduled

to be completed by the end of 2015

Best man for the job

The BRO (Border Road Organization)

wanted to roll out a global tender for theproject due to the challenges that such a

project involves and also considering thatitrsquos the first time in India that a project of

this scale was to be carried out This imme-

diately triggered the need to roll out aglobal tender All major Indian construction

companies bid for it some individually and

some in partnerships

Strabag an Austrian tunnel specialistwas one of the companies who bid for the

project along with AFCONS a Mumbai-

based infrastructure company In Septem-

ber 2009 AFCONS-Strabag was awardedthe contract

Mr Sunil Tyagi Deputy Project Man-ager at AFCONS had this to say about the

unique projectldquoThis project is located in the Himalayas

and as far as we understand the terrain

there is among the toughest We came out

with a new technology and to be honestit is a fairly simple one We would generally

start with the traditional technology of drill-

ing and blasting and then obtain our muck

feed from the inwardbottom of the tunnelrdquo

ldquoThe technology is supplied by Rowa Tunneling Logistics and this is the first

time it is being used in Asia A jaw crusheris placed at a distance of about 40-45

meters behind the face The blasted muckextracted from the face is fed to the crusher

to reduce the lump size and then through

an overhead conveyor transport system

it is then transported out of the tunnelrdquoldquoThis enables free movement of man

and machinery in the lower area or spe-

cifically on the ground area If we were to

conforms to the Indian standard for fines amp

coarse aggregates as prescribed in IS383-1970

The plant was up and running in good

condition and performing to AFCONSrsquos

satisfactionldquoWe have worked with Metso in earlier

projects and are quite impressed by thekind of technology amp services they provide

We have a history together so the trust fac-tor also comes inrdquo explains Dhiman on their

choice of Metso as a partner

Service makes the difference

ldquoMetsorsquos services have made a big dif-ference in the project Without them we

would still be struggling with the machin-

ery and production The service is really

good and the service engineers are knowl-edgeable prompt and quick to act Any

problem can be solved by Metso We donrsquothave to wait until a service engineer turns

up ndash they have the capacity to solve prob-lems over the phone as wellrdquo says Dhiman

ldquoThe Metso plant didnrsquot create any prob-

lems for us We had problems in logistics

the feed was sticky and the weather condi-tions were bad but thankfully we did not

face any problems with production and

efficiency as the Metso plant is performing

very wellrdquo Dhiman concludes

More info

Amol Sinha Tel +91 9811 671 924

amolsinhametsocom

use the old conventional technology this

wouldnrsquot have worked for us in the stipu-lated timerdquo Mr Tyagi adds

When the going gets tough

partner with the toughest

Sensitive projects require the best technol-

ogy After AFCONS-Strabag landed theproject Metso was an obvious choice as a

technology provider not only because of

the long-standing business relationshipbut also for the sheer consistency in prod-

uct quality and service deliverance Metso

strives for

ldquoAfter signing the project we faced alot of road blocks including extreme cold

avalanches roadblocks less oxygen ndash you

name it we faced itrdquo explains Ankit Dhi-

man Plant Manager at AFCONS-Strabag The Rohtang valley is known for its

notorious avalanches and landslides SoAFCONS had to take extra steps and safety

precautions against hazards on the site

ldquoIn this freezing cold not just us humansbut also the machines are at increased risk

of damage I remember when we used

to run the plant during winter the diesel

engines would freeze We had to constantlyheat up the fuel container to get the plant

running And even the sand in the sand

trap would freeze so we had to clean it on

a daily basis to stop the pipes from mal-functioningrdquo Dhiman adds

Plant designed for difficult terrain

Difficult terrain coupled with space con-straints led Metso engineers to put their

minds together to come up with a suitable

plant configuration After studying the

requirements of the project Metso sug-

gested a 150-tons-per-hour three-stagemodular plant using a C106 jaw crusher

a GP11F secondary cone crusher and a

B7150 tertiary vertical shaft impact crusher

In addition considering the unpredict-ability of the feed the plant was about

to reach a point where the amount offines to be handled could be increased

dramatically Metso strongly suggested the TK11-27-3V grizzly scalper and this became

the first-ever TK scalper to be supplied by

Metso to an Indian customer Also in order

to get better products a sand trap SF2360was added to the configuration

The sand trap is important equipment

for this project as it washes the sand thatMr Sunil Tyagi Deputy Project ManagerAFCONS-Strabag

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Smooth transition to new-generation jaw crusher in Germany

Roumlhrig is a German company with a rich heritage The company has been quarrying granite at its plant in Bergstrasse inthe Sonderbach district of Heppenheim for three generations

TEXT amp PHOTOS Ralf Goffin

Roumlhrigrsquos superior product variety is onereason why the companyrsquos proximity to its

customers can be understood in more than

just physical terms The companyrsquos high

level of innovation has allowed it to estab-lish itself as a reliable supplier of materials

both regionally and internationally This

operational and technical expertise always

manages to keep in step with growing

market requirements

In terms of technical processing equip-

ment Roumlhrig has used a Nordberg C160stationary jaw crusher from Metso since

1992 At the start of 2012 it was finally

exchanged for a more up-to-date version

from the same model range

Metsorsquos C Series is specifically designed

to pre-crush hard rock and can cope effort-

lessly with even the hardest of materials

The dimensions of the new stationary jawcrusher are identical to those of the old

one which means that it could simply be

slotted into the housing vacated by the

previous version

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983122983141983152983151983154983156983145983150983143 983154983141983155

Third-generation Managing DirectorMarco Roumlhrig expects the new machinersquos

service life to be just as long as the previ-

ous model due to the product upgrades

that have been implemented The integral motor base is another plus

point in models made by other manu-

facturers it is located outside the crusher

This element of good fortune ensured that

Roumlhrig could reuse the housing withoutany additional rebuilding

Another advantage lies in the revision

of the guards for the C160rsquos drivetrain andflywheel The sturdier construction method

used for the crusher requires fewer parts

which facilitates easier installation andmaintenance and it makes it simpler to

access the motor

Under the watchful eye of Metsorsquos

Assembly Manager Maik Engelstaumltterthe entire project including removal and

installation was successfully completed

within two weeks

Installation making the most

of the available space

Roumlhrig will likely remember the day the

new crusher was installed for a long time

the pitman and main frame were deliveredseparately prior to installation and assem-

bled on site It took just one hour to replace

the old stationary crusher with the new

model A lorry-mounted crane was used toposition the 85-ton crusher with millimeter

precision in the crushing plant Once the

new crusher had been positioned in theexisting steel structure the next task wasto fix it into place as securely as possible

despite the limited space Special vibration

dampers were installed at a height of two

meters to prevent the crusher from sliding

Norbert Ried (fourth from left) installed thenew C160rsquos predecessor 20 years ago and isdelighted at the durability of the powerfulcrusher that is now making way for a newermodel Also pictured from left to right ManagerVolker Angermann Assembly Manager Maik

Engelstaumltter Technical Manager Stefan

Koob Project Manager Dominic SchoumlnhardtManaging Director Marco Roumlhrig Service

Technician Stefan Kolze and employees ofthe installation company Stafemo

On the hook after theold C160 was liftedout by crane the newcrusher was installedin almost no timeOnly the roof of thehousing had to beremoved

sideways off its mount An initial test run

with materials was carried out around oneweek later after all the electrical cables had

been installed

Simultaneously with the installation

of the C160 which is the first of the latest

generation of crushers to be installed in

Germany a new Nordberg GP100 conecrusher was also being installed in Roumlhrigrsquos

chipping plant Roumlhrig is convinced that

the technical improvements made tothe new Metso crusher can only be an

advantage worldwide

Roumlhrig places great value on consistent

product quality maximum added valueand optimum refinement of its product

range Bearing in mind that Roumlhrig has

enough reserves of raw material to last

for the next 150 years the company canconfidently continue to develop with an

emphasis on quality rather than quantity

More info

Dominic Schoenhardt

Tel +49 (0)621 727 00 610

dominicschoenhardtmetsocom

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Groupe Charier Carriegravere de la Mariais France

Quarrying with certi1047297ed quality The Charier Group with its 1600-strong workforce is a family business thatthis year celebrates 115 years of quarrying The company pursues a long-termdevelopment policy that since 2007 has seen processing installations upgradedat 4 of its 9 extraction sites

TEXT Liliane Boutin (with extracts from Mines amp Carriegraveres and Terrassements amp Carriegraveres magazines)PHOTO Baloon photo

The processing installation is of the horizontal type with a primary station located 56 meters below the site access road to keep it hidden from view

The crushing and screening installation at

Charierrsquos CM La Mariais quarry (at Donges

on the Loire estuary) has been in opera-tion since September 2011 Based on theoperatorrsquos ideas it was designed by Metso

to replace a worn-out installation installed

right on top of the seam being extracted

Since its commissioning it has becomethe second quarry in the company to

receive ISO 14 001 certification

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983122983141983152983151983154983156983145983150983143 983154983141983155

tertiary material of sand and gravel for the

local market to use in concrete surfacingprefabrication etcrdquo

Incorporation of a screening station

The stone extracted from La Mariais is

according to the quarry granitic gneiss

sound and homogeneous with a LosAngeles index of 15 good wear resist-

ance with an MDE of 10 a true density of

265 and a certain abrasiveness (2000 gt)ldquoCharacteristically it has a tendency to form

blocksrdquo Leblin points out

The main criteria in designing the instal-

lation was to provide an output of 600000metric tons from one station (38 hours

week) to produce materials aimed at the

concrete and surfacing markets ldquowhich

involved providing a tertiary station withscreening plantrdquo he adds

With this new unit the operating com-pany expands its product range through

the addition of fine materials obtained

from the tertiary screening station This unitis capable of producing 170 tonshour of

020

Preserving the environment

and optimizing safety

The screens have motorized bogies and

retractable walkways to facilitate access

when the screens are opened for main-tenance Other walkways provide access

to the tunnel input feeders The feederscan be isolated with hydraulic rod gate

bars this hydraulic assistance eliminatesthe need to use a heavy hammer to lodge

these metal bars

All conveyors transporting fines (02

and 04) are covered with a tarpaulin to

avoid flying dust and all the screens arehooded (metal cover with Trellex seal-

ing) The Brunone company has installed

dust-tight containment at the outlet of the

tertiary station crushers (HP300 and HP4)on the belt located under the screens

and under the hoppers located belowthe tertiary screens The crushers are put

under negative pressure and the finesare extracted through sleeve filters (7000

m3 h) with declogging which deposits the

dust back onto the conveyor belt

A high-pressure 100 bar water mist sys-tem has been installed at the primary sta-

tion discharge at the secondary crusherrsquos

discharge chutes (Omnicone) and at the

transfer points on the belt

Designed to last

ldquoThis type of new installation can easily last

thirty yearsrdquo affirms Project Leader Bruno

Peix of Metso ldquoIt quite simply depends on

how well it is maintained Thatrsquos why weprovide maintenance contracts that call for

our technicians to make regular inspection

visits and carry out preventive mainte-nance and any necessary repairsrdquo

In 2011 Metso commissioned about

10 new processing units in France like

the one at La Mariais quarry

More info

Frederic Bazire

Tel +33 (0)681442804

fredericbaziremetsocom

Key figures

DURATION OF WORKS 15 months

DRAWING OFFICE TIME 7800 hours

HEIGHT OF SILOS AND GRINDER BUILDINGS

15 m

TOTAL LENGTH OF CONVEYORS 14 km

WEIGHT OF THE INSTALLATION

1200 metric tons

CONCRETE POURED 1800 cubic meters

PROJECT SITE WORKFORCE 30

INSTALLED POWER 2200 kW(not including pumps 200 kW)

METSO EQUIPMENT

Primary

Vibrating feeder PF561-2V

Primary grizzly VG540-3V

Grizzly feeder TK13-20-3V

Jaw crusher C145 with

hydraulic setting

Secondary

Vibrating screen CVB 2050

refurbished

Cone crusher Omnicocircne 1352 SX

with Metso IC7000 controller Ellivar 16 (16 msup2 3 decks) screen

refurbished by Metso

Tertiary

Cone crusher HP300

Cone crusher HP4

2 Ellivar 20 screens (20 m23 decks) for final products

Expanding the production range

ldquoSince the mid-1990s when we became

owners of La Mariais we had used mobilemachinery with an assembly of beltconveyorsrdquo recalls Daniel Leblin Charierrsquos

Technical Manager for site construction

and maintenance

ldquoIt became clear that we needed ahigher performance tool to achieve the

dual goals of reaching one million metric

tonsrsquo maximum production and producing

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Big Lokotrack LT550GPF boostsquarrying productivity by a thirdMaximizing the productivity of operations is a key issue when striving for cost-effective quarrying Big Lokotracks are oneway to achieve improved operational efficiency The Lokotrack LT550GPF equipped with the high-volume GP550 conecrusher and a large screen is popular in the Nordic countries and in Germany and Australia ndash countries all known for theirhigh quarrying volumes

TEXT amp PHOTOS Eero Haumlmaumllaumlinen

Kone-Kostamorsquos new mobile coneplant has reached an averagecapacity of 300 tons per hour

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ldquoWith the same number of employees we

can achieve 30 more productivity with

our new LT550GPF unit The high-capacityFS screen has also eliminated the bottle-neck often seen at fine screeningrdquo says

Aarno Kostamo Managing Director of

Kone-Kostamo Oy one of Finlandrsquos biggest

crushing contractorsAccording to Kostamo the high capacity

of the GP550 gyratory cone crusher easily

handles feed from the C120 and C125 jaw

crushers For the contract with the Talvivaara

nickel mine the LT550GPF is being fed bythe brand new Lokotrack LT120 jaw plant

Average capacity 300 tons per hour

Talvivaara Europersquos largest nickel mine uti-

lizes large quantities of aggregates Kone-Kostamo has contracted several million

tons of different end products for the mineIn August 75000 tons of 0ndash63 mm

road gravel was crushed Smaller amountsof finer 0ndash6 mm 0ndash16 mm and 0ndash32 mm

aggregates are also being produced

The rainy summer increased the need

for road gravel along the muddy roadswhich must endure dump trucks weighing

as much as 260 tons

ldquoThe mobile process consisting of the

LT120 jaw plant and LT550GPF cone plant

is cost-effective while aggregates of vari-ous sizes can be produced in a two-stage

operation and with high capacity The con-trolled stroke and elliptical movement of

the FS screen secure big passing throughcapacitiesrdquo Kostamo explains

Operated in two shifts for a total of 16

hours per day the LT550GPF has logged

more than 600 working hours over a two-month period

Managing Director Aarno Kostamo (left) and foreman Karri Maumlenpaumlauml studying the cavity optionsavailable for the new Lokotrack LT550GPF

Longer perspective than

a single quarter needed

Kone-Kostamo Oy was founded as an

earth-moving company in Kemijaumlrvi

Northern Finland in 1956 The company

expanded its operations to include crush-

ing contracting in 1964 and later on

switched to concentrating fully on crush-ing activities

Kone-Kostamo consistently crushes

and screens around 28 million tons ofaggregates annually and has net sales of

between EUR 8ndash9 million

ldquoWe believe that issues within the crush-

ing industry including the purchasing ofmachinery must be studied with a longer

perspective than a single quarter The

secret to our success has always been our

solid work ethic and professional employ-eesrdquo Kostamo sums up

More info

Esa Berg

Tel + 358 40 837 8692

esabergmetsocom

8132019 Results Minerals Aggregates 3 2012ENG

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Monitoring-based reporting is vital for

assessing the performance of a mobile

crushing plant Metso provides suchreporting tools through its plant-wideautomation system Metso DNA (Dynamic

Network of Applications) with its infor-

mation platform that links all the mobile

crushing and screen units together as oneentity Basically there is a lot of measured

real-time information available in every

crushing plant On-line information is

obtained either from each Metso crusherrsquosmachine automation system IC (Intelligent

Controller) or from separately installed

additional sensors and belt scales

All the collected data is sent to a motorhome using wireless communication

based on WLAN technology The motor

home is a purpose-built environment

inside an on-site container In this environ-ment selected variables can be monitored

for assessing the plantrsquos performance And

to make all this even more flexible the

data can be transmitted to a crushing plant

company office using GPRS3G mobile

data communication technologies Thismakes all the last-minute reports acces-sible to the crushing plant managerial staff

at anytime and basically anywhere within

reach of the cell phone network

Production and fuel economics reports

Essentially monitoring and reporting can

be customized to fit the customerrsquos needs

However there are certain off-the-shelf

reports that provide a lot of useful informa-tion for plant supervision The production

report is one of these Requiring at least one

belt scale for measuring the total produc-tion the production report shows the pro-duction rate (tons per hour) for a selected

reporting period eg a day or a week The

production report constantly keeps track of

the plantrsquos production storing all the datathroughout the plantrsquos life cycle

Performance monitoring and reportingfor a mobile crushing plantTEXT Pasi Airikka PHOTOS Metso

unit during which the unit is running By

storing the availability times between start-ups and shutdowns the crushing plant

operation time (hours per dayshift) can be

recorded analyzed and reported In addi-

tion the availability report can be tailored

to evaluate efficient crushing hours during

which the plant is really working and pro-ducing aggregates Consequently the ratio

(0-100) between efficient crushing time

and total running time can be reported forany selected period of time This boosts

the efficiency of the plantrsquos operations

and results in better productivity

Reports on non-choke

or inadequate feeding

Non-choke feeding to crushers is avoid-

able through smart plant-wide crushingplant controls But estimating its severity in

a systematic manner is not straight-forwardwithout constant monitoring and reporting

The crusher choke feeding report makes

use of the crusher cavity level sensors byanalyzing their level measurements By

calculating average and min-max values

and deviations from the average it can be

shown how often the single crusher suffersfrom non-choke feeding to it

In some cases the bottleneck in the

crushing plantrsquos productivity is the material

feeding to the process In mobile plants thefeeding is human operated and therefore

subject to variations Occasionally the sizeof the human-operated machine simply

does not allow for adequate feeding to thecrushing plant There are specific reports

indicating time periods when the crushing

plant suffers from inadequate feeding

Condition monitoring for

crushers and screens

Machine-specific condition monitoring

focuses on vibrating components in

crushers and screens such as drive shaftbearings safety plate wearings and gears

The low middle and high frequencies ofmonitored components are measured and

supervised in real-time to detect abnor-malities due to slow or fast wear looseness

or imbalance

More info

Pasi Airikka

Tel +358 40 587 2730

pasiairikkametsocom

Condition monitoring provides a view tovibrating crusher and screen components forpredictive equipment maintenance

The daily production report shows the hour-by-hour production trend and distribution chartfor a selected day with min-max average andvariation statistics for comparison

Fuel consumption is always an interest-ing concern The fuel consumption reportgives the fuel consumption of each crush-

ing unit (liters per hour) and their total

consumption (liters per hour) for a selected

reporting period and can track fuel con-

sumption changes over timeCrushing plant availability can be

assessed as well The availability report

calculates time periods for each crushing

8132019 Results Minerals Aggregates 3 2012ENG

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983149983141983156983155983151 983150

for tissue machines The record of 2210

mmin was set on June 1 2012 during a

24-hour production run by the TM 2 tissue

machine at the companyrsquos mill in Yenikoumlynear the city of Izmit in Turkey

ldquoThe cooperation with Metso has been

beyond excellent and both parties did

their utmost to make the project success-ful The results clearly show that the efforts

were worthwhile on both sides This coop-

eration will extend to cover new projects

in the futurerdquo says Luumlt1047297 Aydin Paper GroupDirector Hayat Kimya

ldquoWe are not surprised that Hayat K imya

managed to break the world speed record

We have had great confidence in the capa-bility of the Hayat team since our project

started in 2009 We certainly know our

machine very well its stability production

efficiency and speed capabilityrdquo says Jan

Erikson Vice President Sales Metso

PowerThe worldrsquos first eco-gas fueled

power plant is up and running

Lahti Energy Ltdrsquos new Kymijaumlrvi II gasifica-

tion plant was officially inaugurated on

May 8 2012 It is the first of its kind in the

RecyclingRecycling with Lokotrack LT106

jaw plant in New York

A brand-new Lokotrack LT106 jaw plant is

used in the city area of New York USA to

recycle demolition materials The crushing

site faces the skyscrapers of ManhattanIsland

Paper amp FiberHayat Kimyarsquos Metso-supplied tissue

machine sets world speed record

Thanks to a skilled crew and dedicated

efforts Hayat Kimya AS in Turkey has suc-

ceeded in breaking the world speed record

world This CHP plant runs on clean eco-

gas that is gasified cleaned and cooled

from recycled waste with Metsorsquos innova-tive technology

ldquoItrsquos actually eco-gas that we combust

in the boilerrdquo comments Lahti EnergyrsquosProduction Director Jukka Manskinen

ldquoWe convert unwanted waste material into

energy in an efficient and environmentally

friendly wayrdquoNever before has any plant gasified

waste on such a large scale In the gasifier

recycled waste is turned into combustible

product gas which is cleaned cooled and

combusted in a high-efficiency gas boiler

to produce steam for the steam turbine The plant produces 50 MW of electricity

and 90 MW of district heat for the city of

Lahti and its neighboring areasMetso delivered the circulating fluidized

bed (CFB) gasification process gas cleaning

and cooling steam boiler environmental

protection system and automation systemto the entire plant The production of elec-

tricity and heat is kept even with the Metso

DNA automation system that covers the

whole plant starting from fuel reception

AutomationMetso develops and supplies plant-

wide crushing control solutions for

crushing plants

Metso has recently signed contracts on

delivering plant-wide automation systems

for mobile and portable rock crushing

plants The key objective of these deliveries

is to stabilize and to increase productivityand efficiency of the plants using one sin-

gle automation and information platform

for integrating crusher-specific IC machinecontrols

Furthermore the plant-wide system

with its information management tools not

only increases plant availability and opera-

tional safety it also makes troubleshoot-ing quicker and performance monitoring

easier The control room for plant-wide

operability is located either in an excavator

cabin or a purpose-built container

Metso around the world

The new LT106 jaw plant is suitable for crushing both hard rock and all rock-based demolition materials

The new world speed record for tissue setby Hayat Kimyarsquos Metso-supplied TM 2 is2210 mmin

8132019 Results Minerals Aggregates 3 2012ENG

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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 14: Results Minerals Aggregates 3 2012.ENG

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156983145983139983148983141

An international process package

The Metso package for the Laiva gold mine

included the main crushing screening

conveying regrinding leaching and pump-ing elements Metsorsquos office in Sala Swe-

den has served as the main project office

with Metso manufacturing units in FranceGermany Sweden and Finland responsiblefor the equipment supply

At Laiva the gold ore is classified after

selective excavating into two gold con-

tent classes All class A gold ore is takento Metsorsquos sturdy jaw crusher for primary

crushing while the class B ore is stocked for

possible future use After primary grinding

utilizing autogenous technology the ore is

screened and two Metso cones crush the

oversized pebbles For regrinding Metsorsquosball mill is used

During high- and low-grade leaching

processes a number of Metso pumps and

dewatering screens are used The whole

minerals processing system is controlled byMetsoDNA automation

Active exploration drilling going on

According to Mine Manager Tom Soumlder-

man the known gold ore reserves at the

Laiva gold mine amount to 169 million

tons but the potential for additional find-

ings looks good

ldquoWorking at the level of two million tonsper year our expected lifetime is about nine

years We carry out active exploration drill-

ing in Kaukainen Musunneva and Oltava

to locate nearby satellite ore bodies Anupdated detailed mine life plan will be pre-

pared during the autumnrdquo Soumlderman saysNordic Minesrsquo other exploration areas

include Tormua in Finland and Fjaumllltuna

and Vassbo in Sweden

More info

Alf Rydberg

Tel +46 70524 5837

alfrydbergmetsocom

Happy faces during the minersquos inaugural ceremony Mine Manager Tom Soumlderman (left) with Managing Director Michael Nilsson and Deputy Managing Director Krister Soumlderholm

8132019 Results Minerals Aggregates 3 2012ENG

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983110983141983137983156983157983154983141983140 983137983154983156

The story behind the discovery of the Laivamine is an interesting one During a hunt-

ing trip in the remote forests of Laivakan-

gas in 1979 Pentti Jaumlmbaumlck found an inter-esting-looking piece of stone Although hecould not see the gold hidden inside the

rock Pentti noticed the striking weight

and somewhat different look of the stone

Upon returning home Pentti sent thesample to Outokumpu which at the time

was the leading state-owned mining com-

pany in Finland After testing a high gold

content of 15 grams per ton was found

Gold deposit founded by a hunter

The founder of the Laiva gold deposit Mr Pentti

Jaumlmbaumlck was the guest of honor during theinauguration

Lennart Schoumlnning Chairman of the Board ofNordic Mines holding a gold doreacute bar worthsome EUR 320000

Outokumpu registered a mining claimon the area and conducted a series of

exploration drilling from 1981 to 1987 Due

to the low price level for gold no mine wasstarted at the time Other mining compa-nies such as Endomines held the mining

rights later

Nordic Mines with its sights set on

locating and exploiting gold in Swedenand Finland was founded in 2005 During

the same year the company purchased its

first mining rights at Laiva

Nordic Minesrsquo Laiva gold mine

LOCATION near the city of Raahe

northwestern Finland

GOLD ORE CONTENT average 16 gt

ORE EXTRACTED PER YEAR

12 million tons (present)

20 million tons (planned)

GOLD RECOVERY 85

TOTAL KNOWN ORE RESERVES

169 million tons

MINING METHOD

Selective open-pit benchingNUMBER OF EMPLOYEES

130 including contractors

METSO MAIN EQUIPMENT

2 Metso VF and 6 EMEG EME

vibrating feeders

8 Screens 1 MF 1 CVB and 6 KS

1 RCS Flash flotation unit

1 Metso SRR ball mill 18 x 4 m

1 Nordberg C160 jaw crusher

1 Nordberg HP100 cone crusher

1 Nordberg HP200 cone crusher

5 Nordberg NB series conveyors

73 Metso Slurry pumps ofvarious types and sizes

8132019 Results Minerals Aggregates 3 2012ENG

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The newest member of the proven GP series cone crushers ndash theNordberg GP220 ndash offers a versatile alternative for any demanding

tertiary or quaternary or even secondary crushing operation fulfill-

ing all crushing needs and maximizing customersrsquo profitability

High-quality components and optimized castings and forgings

contribute to the GP220rsquos enhanced reliability and help to ensurethe highest level of crusher uptime

Thanks to the 200 kW (270 hp) power draw the GP220 performs

at a 20 to 30 percent higher capacity than other cone crusherbrands with an equal head diameter The large feed openingenables the feeding jaw crusher to run at 110 mm css Operational

flexibility is ensured by multiple strokes and six different cavities

Secondary crushing possible

thanks to cavity and stroke options

Thanks to the GP220rsquos cavity and stroke options secondary crush-

ing in addition to tertiary and quaternary stages is also possible

using cavities with a greater intake opening With the GP220 a suit-

able solution for producing excellent end-product gradations

can always be found

With advanced automation using IC50 or IC5000 operation

is safe and trouble-free The low height thanks to the patented

piston design makes replacement installations much easierA dynamic setting adjustment enables a fast response to process

optimization needs

The Nordberg GP220 weighs 10500 kg (23150 lbs) and hasa maximum real feed size of +200 mm (8rdquo) with strokes from

18ndash40 mm (57rdquondash1 47rdquo) The cavity options are EF F MF M C

and EC

A complete modular crusher steel structure is available for allGP series stationary installations including GP220 The platform

includes places for the lubrication unit motor automation or

pressure accumulator and pressurized sealing The only things

left to add are the feed and discharge conveyors

Main new features of the GP220 Large feed opening allows for secondary stage operation

Longer setting range of main shaft for better wear parts utilization

Stronger main components to carry high loads with a powerdraw as high as 200kW

More info

Hannu Vakkuri

Tel +358 50 317 0638

hannuvakkurimetsocom

Thanks to the large feed opening and wide selection of strokes and cavitiesthe new Nordberg GP220 cone crusher is a highly versatile cone novelty

More versatility with the newNordberg GP220 cone crusher

Reinforced head and frame castings combined with a 200kW power

draw make the GP220 cone a reliable crusher with maximum productivity

8132019 Results Minerals Aggregates 3 2012ENG

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Metsorsquos HRCtrade takes high pressure grinding roll technology to the next level

The new Lokotrack mobile conveyors come as tracked and wheeled models

Metsorsquos latest development in comminution equipment the HRCtradeis a major step in the profitable application of high-pressure grind-

ing roll (HPGR) technology Metso has made several key innova-

tions in order to increase throughput and decrease the total cost

of operation

Metsorsquos patented Arch frame creates an even gap setting acrossthe width of the tires limiting skewing that can result in downtime

for mining operations This anti-skewing Arch frame also prevents

damage to the roller bearings (caused by misalignment) that canoccur with the traditional HPGR design

Flanges maximize wear life and increase throughput

Used in place of spring-loaded cheek plates the flanges keep thebed of material within the crushing zone and prevent material

from bypassing the tires This enables greater circuit capacity and

increases the overall crushing efficiency

In addition by preventing material from bypassing the tires

even pressure across the width of the tire is better maintained

Distributing the pressure more evenly maximizes the tire life bypreventing a ldquobath tub effectrdquo in which the center of the tire wears

faster than the edgesVictoria Herman Metsorsquos Product Manager for the HRC notes

that this breakthrough design is a response to the growing needs

in the mining industry ldquoEnergy efficiency has been attracting our

customers to HPGR technology for yearsrdquo she says ldquoBut our design

concept increases capacity and crushing efficiency ndash and thatrsquossomething mining companies are always looking to improve onrdquo

The track-mounted Lokotrack CT32 and wheel-mounted Lokotrack

CW32 mobile conveyors offer an ideal solution for applications

that require high stockpile capacity and excellent material transfer

capabilities They also add flexibility to multi-stage crushing andscreening applications enabling easy and fast closed-circuit opera-

tion of mobile units

The conveyor novelties can be used in both mobile and station-

ary installations providing extra stockpiling capacity in situationswhere for example fewer wheel loaders are available

The HRC is ideal for high-tonnage hard rock applications andcan be used as a tertiary quaternary or pebble crusher Currently

several HRC units are in operation around the world ndash with a total

of 6500 operating hours including over 3800 hours in a mininghard rock application The machine does have range within hardrock applications itrsquos been designed for use in diamond iron ore

copper gold platinum and various industrial minerals

More info

Victoria Herman

Tel +1 717 309 1150

victoriahermanmetsocom

Several optional features such as hydraulic folding of tail sections

and dual hydraulic drive for increased throughput are available

The capacity of the CT32 and CW32 is 400 mtph (440 stph)feed size up to 150 mm (6rdquo) belt width 1050 mm (42rdquo) and dis-charge height 9120 mm (29rsquo 11rdquo) The CT32 is fitted with a Caterpil-

lar C2 diesel engine with 38kw (51 HP) power The CW32 is avail-

able for hydraulic or electric use

More info

Kimmo Anttila

Tel +358 50 433 3745

kimmoanttilametsocom

The new HRCtrade combines high crushing pressure and a low circulatingload resulting in the most efficient comminution

When flexibility in stockpiling capacityis required the answer can be foundin the new Lokotrack CT32 and

CW32 mobile conveyors

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Service creates value in ChinaChinarsquos most important gold producing area Yantai in northeastern China supplies more than 16 of the countryrsquos goldproduction each year With the gold market thriving the scale of gold production in Yantai has been expanding constantly

Zhongjia Mining Industry Co Ltd is one of the beneficiaries of this thriving industryTEXT amp PHOTOS Yan Xin

Inspection and maintenance of the HP500 cone crusher conducted by Metsorsquos service engineers

In 2011 Zhongjia Mining Industry pur-

chased a modular crushing and screen-ing system from Metso for its new gold

production project With the cooperation

between the two companies continuously

intensifying Zhongjia Mining Industry

signed an additional one-year Life CycleService (LCS) contract with Metso incorpo-

rating Metsorsquos global knowledge in equip-

ment processes and services

ldquoMetso customized a series of reason-

able service solutions also referred toas Metso Performance Solutions for us

including preventive maintenance services

process improvement personnel training

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155

and a procurement plan for wear parts

These really suit our needs perfectlyrdquo saysShen Yidong the Manager of ZhongjiaMining Industry

Effective preventive maintenanceFor mining corporations the biggestconcern is the economic losses caused by

the shutdown of equipment As a result

preventative maintenance is of vital impor-

tance During the contract period Metsoservice engineers offered 7-day tracking

service on the production site every month

to eliminate potential problems and thus

ensured the stability of the system

parts caused pressure on our working capi-tal which was not favorable for our long-

term developmentrdquo Shen explains

To solve this problem Metso designed

a rational stock plan of wear parts and built

a field warehouse In accordance with theuse and consumption of the liners the field

service engineers complement the stock tomake production and operations run more

smoothlyldquoNow when we need to replace the

wear parts we can use them before pay-

ment This not only simplifies the procure-

ment process but also liberates a largesum of our operating capital which can

be used for other business development

purposesrdquo says Shen

Best partner

ldquoAlthough the LCS contract incurs some

early purchase costs in the long run Metsorsquosprofessional and quality service will improve

the equipment efficiency reduce ourenergy consumption and ensure stable

operations thus generating more prof-

its This is the greatest value for us so the

investment is really worthwhile overall Inthe future we will choose more Metso prod-

ucts and services Taking all aspects into

consideration we believe Metso is the best

partner for usrdquo Shen Yidong concludes

More info

Thomas Bai Tel +86 13801009114

thomasbaimetsocom

ldquoIn the eight months since the contract

came into effect our corporation has notsuffered any financial losses due to equip-

ment breakdown The regular maintenance

has greatly improved the efficiency of our

entire crushing system In addition the

experienced engineers from Metso also

provided onsite training and guidancefor our staff and the tailored training has

greatly enhanced the operating abilities of

our employees and upgraded their overalllevel of competencerdquo says Shen Yidong

More productivity with

less consumption

Metsorsquos service contract focuses on real-

izing the optimum performance of each

process flow After analyzing Zhongjiarsquos

production system Metsorsquos techniciansproposed an adjustment to the closed side

setting of the HP500 for tertiary crushingin order to improve the efficiency of the

downstream fine crushing and milling pro-

cessing by over 10ldquoThe process flow improvement solu-

tions provided by Metso not only increased

the output of our gold concentrates but

also reduced our energy consumption andcostsrdquo says Shen

In the past wear parts procurement

took up a larger proportion of Zhongjiarsquos

total production costsldquoTo avoid downtime caused by the

shortage of wear parts we had to keepeight sets of various wear parts in place

However the cost of having so many wear

Zhongjia Mining Industryrsquos gold concentrates processing plant in China

8132019 Results Minerals Aggregates 3 2012ENG

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0983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

Safe quarrying high-

quality aggregates

8132019 Results Minerals Aggregates 3 2012ENG

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ldquoWe share a similar zero-accident strategy and target with Metso and have successfullyfollowed it Metso has also helped us to meet the strictest end-product quality andcubicity requirements set in Spainrdquo This is how Managing Director Intildeigo Ajuria ofOfitas de San Felices the leading hard rock quarrying company in Spain describesthe cooperation with MetsoTEXT Eero Haumlmaumllaumlinen PHOTOS Ofitas and Eero Haumlmaumllaumlinen

The San Felices quarry is situated in a picturesque mountainous landscapebetween the companyrsquos Rioja vineyards and the Bilbao-Madrid motorway

8132019 Results Minerals Aggregates 3 2012ENG

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Ofitas has pioneered the implementation

of several Metso novelties in the Spanish

market The company was the first to use

efficient large track-mounted Lokotrack jaw plants the unique mobile conveying

system and also the new-generation HP4

cone crushers

Today the company operates twomodern Metso stationary plants one in

Guadix near Granada and the newest one

in San Felices Haro Rioja community Both

quarries focus on refining hard rock by pro-cessing ophite rock into the highest quality

railway ballast asphalt and concrete mix

grades The company has a satellite quarry

near Vitoria in PentildeacerradaBeing situated next to a highway and

the famous Rioja vineyards Ofitas must pay

special attention to environmental issues

To minimize dust problems all conveyors

have special covers attached

Quality durability and service

The cooperation between Ofitas de San

Felices and Metso started back in 1973when the Ajuria family bought the com-

pany whose quarrying activities began in

1919 Intildeigo Ajuria has a clear vision of why

the cooperation has continued withoutinterruption for almost 40 years

long-standing personal relationshipsrdquoAjuria adds

Serving railways asphalt

and concrete producers

The year-old San Felices stationary instal-lation lies hidden in a mountainous area

south of the city of Vitoria in NorthernSpain The new plant replaces an old one

that complicated the extraction of ophiterock Both plants are delivered by Metso

With its two separate production lines

the new plant is able to produce all the

end products required ndash from railway bal-last to the finer grades needed for asphalt

and concrete

Due to lower demand the quarry cur-

rently produces some 4000 tons per day

At full capacity however the plant canreach 8000 tons of production per day

30ndash35 of which consists of railway ballastfor high-speed trains and 65ndash70 of chips

and sand Thanks to the versatile two-line con-

cept connected by transverse conveyors

up to 12 different end products can be pro-

duced Depending on the demand for endproducts the material can be guided either

to the HP4 cone or HP400 cone followed

by a Barmac vertical shaft impactor

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

The ophite feed is fed to the C125 jaw crusher by a sturdy dump truck

The key people running the new San Felicesquarry Mine Engineer Carlos Fernandez (left)Managing Director Intildeigo Ajuria with ProductionManager Julian Perez

ldquoThrough the years Metso machinery

has proven its production capacity and

durability resulting in high-quality end

products A big plus for us has also beenthe quick response time to our process

challenges or servicerdquo

ldquoIn fact our cooperation extends

beyond day-to-day business matters to

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983122983141983152983151983154983156983145983150983143 983154983141983155

Meeting the strictest cubicity demands

The Spanish regulations concerning end-product cubicity are becoming more

demanding The flakiness percentage of

railway ballast must be below 10 and for

asphalt and concrete aggregates less than

15

ldquoWith Metsorsquos HP4 cone and the Barmacvertical shaft impactor we can meet even

the strictest cubicity demands We believe

that our high quality is helping us to sur-vive in the present recessionrdquo notes Mine

Engineer Carlos Fernandez

ldquoWe hope to increase the total extrac-

tion of the three quarries from the present15 million tons per year because our plant

capacity allows more than double thatrdquo

Fernandez adds

More info

Angel Luis Garcia Tel +34 686 94 35 30

angelluisgarciametsocom

In addition to being the leading Spanish

quarry to process hard rock Ofitas de SanFelices also cultivates 34 hectares of vine-yards next to the quarry which is situated

in the famous Rioja wine area

The company has previously sold a

harvest of over 200000 kg of Tempranillo

grapes to local red-wine makers Recentlythe company built its own wine process-

ing plant to process 10000ndash15000 kg of

grapes themselves

Aggregates and wine production

Andoni Ajuria the founder of Ofitas de san Felices (left) with Intildeigo Ajuria the present ManagingDirector tasting wine from the companyrsquos own vineyards

The first vintage wine of Ofitas har-

vested in autumn 2010 is now maturingin oak barrels After maturing for 12 to 15months the wine is called crianza and after

two years it will be granted the classifica-

tion reserva

ldquoWinemaking is not a business but

a hobby for us We give our wine out aspresents and drink it when we meet

our suppliers and friendsrdquo Intildeigo Ajuria

comments

For environmental protectionall of San Felicesrsquos plantconveyors are covered

Ofitas de San Felices quarry

LOCATION Haro near the city

of Vitoria northern Spain

SIZE 100 hectares

ROCK TYPE Ophite with Los Angeles

index of 9ndash10

PRESENT DAILY EXTRACTION 3000 tons

of ophiteNUMBER OF PERSONNEL 30

RESERVES 10 million tons

MAIN END PRODUCTS 0ndash2 mm

2ndash4 mm 4ndash10 mm 10ndash16 mm

16ndash22 mm 25ndash60 mm (ballast)

METSO MAIN EQUIPMENT

VF feeder

C125 jaw crusher

ndash feed size 0ndash800 mm

ndash css 130ndash140 mm

HP400 cone crusher

ndash feed size 80ndash250 mm

ndash css 40 mm HP4 cone crusher

ndash feed size 40ndash80 mm

ndash css 15 mm

Barmac 6150 VSI crusher

4 CVB2060 screens

2 TS32 screens

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Metso Distribution Centers he

Europe (Tongeren Belgium)

France (Macon)

Czech Republic (Přerov)

Austria (Vienna)

2271 d

Brazil (Sorocaba SP)

1014 d

USA (Columbia SC)

1690 d

USA (Waukesha WI)

434 d

South Africa (Vereeniging)

Ghana (Tarkwa)

Meacutexico (Irapuato)

Peru (Lima)

Chile (Concoacuten)

788 d

Sweden ( Trelleborg)

Finland (Tampere)

UK (Rugby)

865 d

Russia (St Petersburg)

Brazil (Parauapebas PA)

206 d

4983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

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In the case of an equipment failure or

a planned service shutdown resuming

production as quickly as possible is crucialEach hour spent waiting for a spare part to

arrive equals money lost Whether the right

part takes 12 or 48 hours to arrive really

makes a difference

The comprehensive and global Metsospare and wear parts service network pro-

vides you with the right part in the right

place and at the right time Our strategi-

cally located Distribution Centers and

Satellite Warehouses are on call 24 hoursa day 7 days a week ensuring efficient

parts replacement near you

Check out the locations of the MetsoDistribution Centers and how many parts

pass through them each day

More info

Marcelo Farah

Tel +55 15 2102 1315

marcelofarahmetsocom

you minimize downtime

Australia (Perth)

746 d

China (Tianjin)

China (Kunming)

China (Shanghai)

393 d

India (Faridabad)

India (Ahmedabad)

India (Hyderabad)

India (Bhubaneswar)

India (Bangalore)

419 d

Russia (Yekaterinburg)

Australia (Newcastle)

New Zealand (Matamata)

983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088

TEXT Sofia Williams

Singapore (Singapore)

Distribution Center Satellite Warehouse

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Following a large investment

in Metso crushing equipmentand services Buena Vista del

Cobre is now expanding the

mine site to include even more

equipment ndash and with thatexpansion comes the need for

more local service resources

Metso and Buena Vista del

Cobre have entered into a Life

Cycle Service agreement forthe plant and construction of a

brand new Metso service hub

is under way in Cananea

New facility new

level of service

The Cananea service hub

which will be up and running in early 2013will support the recent expansion and resur-

gence of Buena Vista del Cobre Initially it

will be a major repair and assembly center

for pumps crushers and screens and will

provide for rubber covering capabilitiesBut the 8000-square-meter facilityrsquos service

offering will be expansive including a con-

signment stock inventory to help serve theminersquos varying needs Metso currently has

50 service team members on site

Although Buena Vista del Cobre was a

key influencer in building the new servicehub this location will also enable Metso to

expand its capabilities and provide local

support to the entire mining community

in northwest Mexico The Cananea hub

will serve a number of major copper and

gold mines in the region including MineraFriscorsquos San Felipe Fresnillorsquos Milpillas and

Grupo Mexicorsquos Mexicana de Cobre

ldquoBuena Vista del Cobre is the biggestcustomer we have in Mexico today and

with this expansion project itrsquos only going

to grow and be strongerrdquo says Felix Forna-

guera Director of Services Mexico CentralAmerica and Caribbean ldquoWith that said the

idea behind the Cananea service hub is to

provide a central location for local support

for all our major customers in the areardquo

Establishing safety

ldquoIt was key to have our support here in

Cananea because the Buena Vista delCobre started from the ground uprdquo saysFelix ldquoWersquove been able to help the cus-

tomer to establish the best in support

service and operations from the very

beginningrdquo And this ground-up approachincluded a major focus on safety

Metso worked closely with Buena Vista

del Cobre to establish the safety proto-

col by which the mine operates Basedon Metsorsquos expertise the safety measures

put in place have enabled the mine to

become strict and efficient in its operations

and maintenance procedures To achievethis Metso worked closely with local andnational authorities to ensure the safety

plan was comprehensive and in accord-

ance with all established legal bodies

The best in regional support

The service hub in Cananea is a prime

example of Metsorsquos focus on providing local

service and support to its customers all

Service shines in Cananea MexicoAfter three years of inactivity the Buena Vista del Cobre mine in Cananea Sonora Mexico has been operational since 2010A mine that was inactive for such a significant amount of time however requires a great deal of support to successfullyrestart the plant and bring it back to an operational and profitable state

TEXT Deanna Lee PHOTO Metso

over the world ldquoWe are the first

company developing this kindof service in northwest Mexicordquo

adds Felix ldquoOur people have

developed a close relationship

with the team at the mine Itrsquosmore than a supplier relation-

ship our guys are inside the

mine living and working thererdquo

In fact this is the model

that Metso is using in servicehubs all over the globe build-

ing modern facilities bringing

teams on site and workinghand in hand with mine

operators The Cananea Service

hub is only the most recent

example of Metsorsquos commit-ment to service and northwest Mexico is

yet another mining hotbed thatrsquos going to

benefit from the companyrsquos support

More info

Felix Fornaguera Tel +52 4621079227

felixfornaguerametsocom

A mining cone serviced by Metso at the Buena Vista del Cobre mine inSonora Mexico

ldquoThe new Cananea service center will be a majorrepair and assembly center for pumps crushersand screensrdquo says Felix Fornaguera Director ofServices Mexico Central America and Caribbean

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

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During the MINExpo exhibition over 1300 people visited the Metso stand

983122983141983152983151983154983156983145983150983143 983154983141983155

Held every four years MIN-Expo consistently grows so

perennial exhibitors like Metso

are challenged with elevating

their presence and drawingin new (and greater numbers

of ) visitors each year ldquoItrsquos not

necessarily a challenge to lsquotoprsquo

our last showingrdquo says Keith

Ference Vice President ofmarketing and communica-

tions North America ldquoThere

are four years between eachMINExpo so we always have

a lot to say and reveal to our

customersrdquo The real challenge

he says is finding an exciting

and dynamic way to deliverthe message ldquoTherersquos so much

to see here so your booth has

to be compelling from the

outside-in and thatrsquos what

we always try to dordquo

Service sets the stage

The Metso booth created buzzin a number of ways and per-

haps the most striking (partly

due to its size) was the live

theater presentation As visitorspassed through the aisles of the show-

room the sights and sounds from Metsorsquos

theater were hard to miss And once guests

entered they were captivated by a short

high-energy video presentation focused

on Metsorsquos service capabilities The message was simple Metso is ldquoyour

local service partner rdquo for all mining and

construction needs The video showed ourservice teams in action all over the world

and the audience came away with an

understanding about Metsorsquos commitment

to service Customers can count on morethan 70 local service centers run by more

than 1700 expert technicians delivering

Metso makes an impact at MINExpo 2012At this yearrsquos MINExpo International nearly 60000 attendees flocked to Las Vegas Nevada the largest turnout in showhistory The visitors ndash mining professionals from all over the globe ndash explored 850000 square feet of showroom spacefeaturing the industry rsquos latest technology equipment products and services They toured the show for three days

seeking the latest and greatest from more than 1800 exhibitorsTEXT Keith Ference PHOTOS Tracey Ford Perry

detailed descriptions andphotos of all of Metsorsquos mining

and construction products and

services The app also provides

digital access to Results and asearchable database of sales

contacts By day three of the

show MetsoMAP had been

downloaded by more than

500 usersIn addition to the app the

booth was equipped with

several LCD screens each con-trolled by Metso experts who

used their iPads to present new

products like the Megalinertrade

and the HRCtrade A featured

presentation on Metsorsquos lineupof energy-efficient comminu-

tion equipment including the

VERTIMILLreg SMD and MP-1250

cone crusher was also avail-

able letting customers seehow Metso technology delivers

some of the worldrsquos most effi-

cient size reduction

Measuring MINExpo success

After a very busy three days

(on top of months of prepara-tion leading up to the show) everyone

involved with MINExpo ndash from the North

American marketing team responsible for

the booth to the product managers and

sales force that worked the floor ndash is view-

ing the show as a success ldquoTherersquos alwaysa sigh of relief after each (MINExpo)rdquo says

Keith ldquoAnd overall the initial feedback

and response has been very positiverdquoWith more than 1300 visitors to the

booth Metso certainly made an impact

ldquoWe learn a lot from each show and with

some time wersquoll have a better understand-ing of the tangible results of our effortsrdquo

Keith adds

reliable service for mining equipment as

well as customized cost-effective life-cycle

services contracts

Technology ndash MetsoMAP

is an industry firstMINExpo provided the industry with its firstglimpse of Metsorsquos revolutionary iPad app

MetsoMAP The app was demoed to the

boothrsquos visitors via ldquothe worldrsquos largest iPadrdquo

a custom-made 80-inch screen that show-cased all of its capabilities most of which are

groundbreaking in the industry MetsoMAPrsquos

simple interface is highly intuitive making

it easy to view process animations videos

The presentation of the new HP cone crusher attracted a large audience

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When yoursquore allowed less than a dozen days per year for breakdowns repair andmaintenance every single hour during a service shutdown counts There simplyisnrsquot any room for surprises Thatrsquos why Boliden counts on MetsoTEXT amp PHOTOS Sofia Williams

8983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

Kurt Kalla Site Managerof Metso Gaumlllivare ServiceCenter is responsible forthe maintenance of Aitik

Metso and Boliden Strivingtogether for 97 uptime

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983122983141983152983151983154983156983145983150983143 983154983141983155

One of the biggest copper mines in

Europe Bolidenrsquos Aitik is located deep inthe wilderness of Swedish Lapland next to

the small town of Gaumlllivare The mine has

been operating since 1968 and a recent

expansion has increased its annual ore

production to 36 million tons

But the ambitious Swedes are not will-ing to lay back and relax just yet Bolidenrsquos

new aim is to reach a production rate of

45 million tons of ore per year in AitikAfter that Perhaps more than 55 million

tons The ore concentration in Aitik is very

low-grade with a mere 022 copper con-

tent hence the need for high capacityAchieving the ambitious production

goal requires maximum plant availability

This means that everything from the crush-

ers to the filters must be up and runningfor approximately 97 percent of the time

Thatrsquos where Metso comes into play

A cost-per-ton contract in action

The maximum uptime requirement allowsless than a dozen days per year for break-

downs repair and maintenance at Aitik

Every single hour during a service shut-

down counts There simply isnrsquot any roomfor surprises

Executing a successful shutdown under

such conditions requires a reliable service

partner not afraid of challenges and this iswhy Boliden has entrusted Aitikrsquos services

operations to Metso Boliden and Metsohave worked together since the 1960s

and the collaboration took another step

forward in September 2012 when the twocompanies signed a three-year extension

of the services contract for Boliden Aitik

ldquoThe new contract is a cost-per-ton

agreement We get paid based on Aitikrsquos

production Itrsquos a win-win deal for both par-

ties but also a new mindset for usrdquo explainsKurt Kalla Site Manager of Metso Gaumlllivare

Service Center responsible for serving Aitik

From now on the duration of the shut-down is what matters the most According

to Kalla the Metso service organization in

Gaumlllivare is now streamlining its operations

to fit the bill and has already witnessed thestrategy working In August 2012 Metso

carried out a 188-hour service shutdown in

Aitik which turned out to be a success

Zero tolerance for injury

One key factor to the success was theextensive planning of precautionary health

safety and environment procedures under-

taken by Metso prior to the shutdown Thanks to strict measures applied no

injuries or accidents occurred during the

shutdown and the work could easily be

finished on scheduleMats Johansson Health Safety

and Environment Manager for Metso in

Sweden explains how this was achieved

rdquoPlanning of the shutdown included arisk analysis for all new tasks participating

in Bolidenrsquos safety coordination meetingsmeeting with both Metso supervisors and

subcontractor supervisors and finally a

meeting with the entire staff participating

in the shutdown where everyone had to

sign a document stating their commitmentto the information providedrdquo he says

During the actual shutdown plenty of

new barriers signs and awareness cones

were put in place as a result of observa-tions from previous audits and safety plans

and risk analyses were readily available

in the work area Metso and Boliden also

introduced a Mill Inching permit a certifi-cate for completing a mandatory course for

those involved in the process In addition

Metso carried out random safety audits

during the shutdown to make sure thestrict policy was followed

According to Boliden Metsorsquos way of

working is a good example of how health

and safety precautions should be handled

ldquoMetso is a good example of how towork with safety and health plans risk

analysis permits and welding permits

Their table with all binders in the second-

ary mill area was exemplaryrdquo says Kjell-Arne

Johansson a technician from Boliden

The use of the new Metso Megalinertrade

system in the lining of Aitikrsquos Metso AG

mills has also improved the safety of main-tenance staff The Metso Megalinertrade con-

sists of larger-than-average liners bolted

in position from outside the mill Mainte-

nance technicians no longer need to go

inside the mill and stand in the dangerousdrop-zone of the liners gt

Boliden aims to reach a production rate of 45 million tons of ore per yearin the Aitik mine site

ldquoA complete risk analysis was conducted during the planningof the shutdownrdquo comments Mats Johansson Health Safetyand Environment Manager for Metso in Sweden

8132019 Results Minerals Aggregates 3 2012ENG

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Service the Metso way

24 hours a day 365 days a year

In addition to paying close attention to

health and safety issues executing an effi-

cient shutdown requires careful planning

and timing of every step in the mainte-

nance process Wear and spare parts have

to be available on time and a repair shoplarge enough to accommodate equipment

located close by

ldquoTo keep maintenance breaks as short

as possible we aim to replace the pump on

site and bring the old one for repair to our

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

nearby facilities This method gives us the

peace to do a good job and keep the cus-

tomerrsquos operations runningrdquo Kalla describes

the Metso way of handling Aitikrsquos pump

maintenance

Metso is currently expanding its Gaumllli-

vare service center to include a distribu-

tion center for wear and spare parts andalso concentrating its previously scattered

operations under one roof in its Vuoskon-

jaumlrvivaumlgen facility The expansion is due to

be completed by 2014

Metso equipment

delivered to Aitik36

bull 2 AG mills diameter 116 x

137 m gearless 22-MW motor

bull 2 Pebble mills diameter 91 x

113m dual 5-MW pinion drive

bull 3 VPA pressure filters VPA 1540-54

bull 12 sample pumps and pipes

VF50

bull 60 Various slurry pumps up to

MR500 modelbull Appr 5000 m rubber-lined slurry

pipes up to 600 mm diameter

bull Appr 5000 m rubber-lined by

gravity pipes up to 600 mm

diameter

bull Appr 5000 m rubber hoses

up to 600 mm diameter

Not only does the expansion make ser-

vice shutdowns at Aitik run more smoothly

it guarantees a more comprehensive

on-call emergency service response in the

region ndash thanks to the spare and wear parts

inventory available 24 hours a day 365

days a year

More info

Lars Rosenling

Tel +46 70 107 45 90

larsrosenlingmetsocom

Metso grinding equipment dominates the view in the concentrator

Safety on site is made up of small things like

making sure that everyone remembers to secure

the hoses in place

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983122983141983152983151983154983156983145983150983143 983154983141983155

Pebbles have always been a

challenge for producers of sandsince they cannot be returned

to rivers after extraction For

decades the processing of this

material resulted in a huge

environmental liability with alarge amount of pebbles hav-

ing to be stored away and left

unused

Transforming problems into

business opportunities

Areia amp Cia (areia = sand) has

operated in this market forover 20 years and decided to

enlist the help of Metso to find

a profitable solution for the

processing of pebbles

In July 2011 analyses werebegun to assess the abrasive-

ness and crushability of the

material Four alternatives wereidentified for processing and

transforming pebbles into sand

Initially Areia amp Cia was

interested in acquiring an

impactor for its reason-able price level However the

customer wanted to process

all the pebbles that were col-

lected daily in addition to some of the

material that it had stored In weighing theresults expected by the customer and the

excessive abrasiveness of the material the

HP200 cone crusher was decided on as thebest alternative

Areia amp Cia made the required invest-

ment and after using the HP200 for just

six months the company has already beenreporting outstanding results The HP200

not only transforms pebbles into sand but

also produces sand of excellent quality

with high yield and low maintenanceWith minor adjustments the HP200

also enables the production of sand withspecific particle size distribution for special

applications such as filtering sand blasting

and foundry sand adding value to the prod-

uct and increasing the types of sand offeredldquoMetso is pleased that the HP200 not

only enabled the processing of a product

that had been set aside as unusable but

HP200 cone transforms pebblesinto high-quality sandOver the last few decades Brazilian economic growth has been driving demand for construction aggregates The market

for sand in turn has been experiencing major difficulties in maintaining a consistent supply Presently one of the mainchallenges the industry faces is the large amount of pebbles that are obtained in the process of extracting sand at timesconstituting nearly 50 of the volume of material dredged from riverbeds

TEXT Sheila Ivers PHOTO Areia amp Cia

also that it opened up new

market opportunities for Areiaamp Cia Thatrsquos the standard we

seek to deliver to our custom-

ersrdquo states Luiz Oliveira Techni-

cal Salesperson of Metso Brazil

HP cones entering the

Brazilian sand-making

market

Todayrsquos cones such as theHP200 have high resistance

to impacts and abrasiveness

more efficient crushing cham-

bers low maintenance costsand excellent productivity

Following the acquisition of

the HP200 Areia amp Cia is now

also producing special sands

that command a price that is100 higher than common

sand The entire stockpile of

pebbles accumulated through-out the companyrsquos 20 years of

operations has already been

transformed into sand and the

stock of pebbles held by com-

petitors is also being purchasedfor processing

Cristiane Brizolari the

owner of Areia amp Cia confirms

the transformation that has taken place in

the production and commercial processldquoThe HP200 opened up new niches in

the market enabling the production of dif-

ferent types of sand with added valuerdquo

More info

Luiz Oliveira

Tel +55 011 9971 3603

luizoliveirametsocom

After the pebbles are crushed into sand with the HP200 cone crusherdifferent grades are screened for various end uses

8132019 Results Minerals Aggregates 3 2012ENG

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Where therersquos a will we dig a wayAFCONS-Strabag and Metso embark on tunnel project together

When the joint venture AFCONS-Strabag initiated work on the Rohtang bypass tunnel project at an altitude of 3980 metersabove sea level in Himachal Pradesh India they deliberated each aspect with clockwork precision The project involved anumber of surprises and challenges and required technology and project management skills that were second to none

TEXT amp PHOTOS Monisha Majumdar

Cutting a 10-meter-wide and nearly 9-kilo-

meter-long tunnel through the Himalayas

in one of the toughest terrains and cli-mates in India makes for quite a challengeResults set out to find out how AFCONS-

Strabag and Metso are making their way in

one of their most critical projects to date

The only road connection to the north-Indian border region of the province

Himachal-Pradesh and beyond the Manali-

Leh highway leads across the Rohtang

pass Due to the heavy snowfall and high-

velocity winds in this region the towns

located north of the pass are cut off from

the rest of the country during winter for atleast four often even six months each year

A tunnel with strategic importance

With the construction of the tunnel at

3100 m above sea level the Manali-Lehhighway will become an all-weather road

thereby enabling a significant improve-

ment in the economic development of

northern Himachal-Pradesh and an alter-

nate route to the strategically important

Ladakh region

Manali south of the pass is an alreadywell-developed tourist location that is

becoming more and more popular Upon

completion of the tunnel it is likely that

tourist activities will extend to the areanorth of the pass Moreover the tunnel

shortens the distance between the towns

of Manali and Leh by approximately 45 km

thus saving several hours on the small dan-gerous pass road

The Rohtang pass in the Western Himalaya

region of Northern India with its altitude ofalmost four kilometers ranks among thehighest trafficable passes in the world

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The 88-km long horse-shoe-shaped

tunnel provides space for a two-lane8-m-wide carriageway as well as a one-

meter-wide footpath on both sides A

22-m-high and 36-m-wide emergency

tunnel will be integrated in the tun-

nel cross-section Altogether more than

800000 msup3 of rock will be moved Tunneling works started around spring

2010 with excavation driven from both por-

tals As the north portal is inaccessible dur-ing winter closure the excavation focused

on the south After a planned construction

period of 55 years the tunnel is scheduled

to be completed by the end of 2015

Best man for the job

The BRO (Border Road Organization)

wanted to roll out a global tender for theproject due to the challenges that such a

project involves and also considering thatitrsquos the first time in India that a project of

this scale was to be carried out This imme-

diately triggered the need to roll out aglobal tender All major Indian construction

companies bid for it some individually and

some in partnerships

Strabag an Austrian tunnel specialistwas one of the companies who bid for the

project along with AFCONS a Mumbai-

based infrastructure company In Septem-

ber 2009 AFCONS-Strabag was awardedthe contract

Mr Sunil Tyagi Deputy Project Man-ager at AFCONS had this to say about the

unique projectldquoThis project is located in the Himalayas

and as far as we understand the terrain

there is among the toughest We came out

with a new technology and to be honestit is a fairly simple one We would generally

start with the traditional technology of drill-

ing and blasting and then obtain our muck

feed from the inwardbottom of the tunnelrdquo

ldquoThe technology is supplied by Rowa Tunneling Logistics and this is the first

time it is being used in Asia A jaw crusheris placed at a distance of about 40-45

meters behind the face The blasted muckextracted from the face is fed to the crusher

to reduce the lump size and then through

an overhead conveyor transport system

it is then transported out of the tunnelrdquoldquoThis enables free movement of man

and machinery in the lower area or spe-

cifically on the ground area If we were to

conforms to the Indian standard for fines amp

coarse aggregates as prescribed in IS383-1970

The plant was up and running in good

condition and performing to AFCONSrsquos

satisfactionldquoWe have worked with Metso in earlier

projects and are quite impressed by thekind of technology amp services they provide

We have a history together so the trust fac-tor also comes inrdquo explains Dhiman on their

choice of Metso as a partner

Service makes the difference

ldquoMetsorsquos services have made a big dif-ference in the project Without them we

would still be struggling with the machin-

ery and production The service is really

good and the service engineers are knowl-edgeable prompt and quick to act Any

problem can be solved by Metso We donrsquothave to wait until a service engineer turns

up ndash they have the capacity to solve prob-lems over the phone as wellrdquo says Dhiman

ldquoThe Metso plant didnrsquot create any prob-

lems for us We had problems in logistics

the feed was sticky and the weather condi-tions were bad but thankfully we did not

face any problems with production and

efficiency as the Metso plant is performing

very wellrdquo Dhiman concludes

More info

Amol Sinha Tel +91 9811 671 924

amolsinhametsocom

use the old conventional technology this

wouldnrsquot have worked for us in the stipu-lated timerdquo Mr Tyagi adds

When the going gets tough

partner with the toughest

Sensitive projects require the best technol-

ogy After AFCONS-Strabag landed theproject Metso was an obvious choice as a

technology provider not only because of

the long-standing business relationshipbut also for the sheer consistency in prod-

uct quality and service deliverance Metso

strives for

ldquoAfter signing the project we faced alot of road blocks including extreme cold

avalanches roadblocks less oxygen ndash you

name it we faced itrdquo explains Ankit Dhi-

man Plant Manager at AFCONS-Strabag The Rohtang valley is known for its

notorious avalanches and landslides SoAFCONS had to take extra steps and safety

precautions against hazards on the site

ldquoIn this freezing cold not just us humansbut also the machines are at increased risk

of damage I remember when we used

to run the plant during winter the diesel

engines would freeze We had to constantlyheat up the fuel container to get the plant

running And even the sand in the sand

trap would freeze so we had to clean it on

a daily basis to stop the pipes from mal-functioningrdquo Dhiman adds

Plant designed for difficult terrain

Difficult terrain coupled with space con-straints led Metso engineers to put their

minds together to come up with a suitable

plant configuration After studying the

requirements of the project Metso sug-

gested a 150-tons-per-hour three-stagemodular plant using a C106 jaw crusher

a GP11F secondary cone crusher and a

B7150 tertiary vertical shaft impact crusher

In addition considering the unpredict-ability of the feed the plant was about

to reach a point where the amount offines to be handled could be increased

dramatically Metso strongly suggested the TK11-27-3V grizzly scalper and this became

the first-ever TK scalper to be supplied by

Metso to an Indian customer Also in order

to get better products a sand trap SF2360was added to the configuration

The sand trap is important equipment

for this project as it washes the sand thatMr Sunil Tyagi Deputy Project ManagerAFCONS-Strabag

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Smooth transition to new-generation jaw crusher in Germany

Roumlhrig is a German company with a rich heritage The company has been quarrying granite at its plant in Bergstrasse inthe Sonderbach district of Heppenheim for three generations

TEXT amp PHOTOS Ralf Goffin

Roumlhrigrsquos superior product variety is onereason why the companyrsquos proximity to its

customers can be understood in more than

just physical terms The companyrsquos high

level of innovation has allowed it to estab-lish itself as a reliable supplier of materials

both regionally and internationally This

operational and technical expertise always

manages to keep in step with growing

market requirements

In terms of technical processing equip-

ment Roumlhrig has used a Nordberg C160stationary jaw crusher from Metso since

1992 At the start of 2012 it was finally

exchanged for a more up-to-date version

from the same model range

Metsorsquos C Series is specifically designed

to pre-crush hard rock and can cope effort-

lessly with even the hardest of materials

The dimensions of the new stationary jawcrusher are identical to those of the old

one which means that it could simply be

slotted into the housing vacated by the

previous version

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983122983141983152983151983154983156983145983150983143 983154983141983155

Third-generation Managing DirectorMarco Roumlhrig expects the new machinersquos

service life to be just as long as the previ-

ous model due to the product upgrades

that have been implemented The integral motor base is another plus

point in models made by other manu-

facturers it is located outside the crusher

This element of good fortune ensured that

Roumlhrig could reuse the housing withoutany additional rebuilding

Another advantage lies in the revision

of the guards for the C160rsquos drivetrain andflywheel The sturdier construction method

used for the crusher requires fewer parts

which facilitates easier installation andmaintenance and it makes it simpler to

access the motor

Under the watchful eye of Metsorsquos

Assembly Manager Maik Engelstaumltterthe entire project including removal and

installation was successfully completed

within two weeks

Installation making the most

of the available space

Roumlhrig will likely remember the day the

new crusher was installed for a long time

the pitman and main frame were deliveredseparately prior to installation and assem-

bled on site It took just one hour to replace

the old stationary crusher with the new

model A lorry-mounted crane was used toposition the 85-ton crusher with millimeter

precision in the crushing plant Once the

new crusher had been positioned in theexisting steel structure the next task wasto fix it into place as securely as possible

despite the limited space Special vibration

dampers were installed at a height of two

meters to prevent the crusher from sliding

Norbert Ried (fourth from left) installed thenew C160rsquos predecessor 20 years ago and isdelighted at the durability of the powerfulcrusher that is now making way for a newermodel Also pictured from left to right ManagerVolker Angermann Assembly Manager Maik

Engelstaumltter Technical Manager Stefan

Koob Project Manager Dominic SchoumlnhardtManaging Director Marco Roumlhrig Service

Technician Stefan Kolze and employees ofthe installation company Stafemo

On the hook after theold C160 was liftedout by crane the newcrusher was installedin almost no timeOnly the roof of thehousing had to beremoved

sideways off its mount An initial test run

with materials was carried out around oneweek later after all the electrical cables had

been installed

Simultaneously with the installation

of the C160 which is the first of the latest

generation of crushers to be installed in

Germany a new Nordberg GP100 conecrusher was also being installed in Roumlhrigrsquos

chipping plant Roumlhrig is convinced that

the technical improvements made tothe new Metso crusher can only be an

advantage worldwide

Roumlhrig places great value on consistent

product quality maximum added valueand optimum refinement of its product

range Bearing in mind that Roumlhrig has

enough reserves of raw material to last

for the next 150 years the company canconfidently continue to develop with an

emphasis on quality rather than quantity

More info

Dominic Schoenhardt

Tel +49 (0)621 727 00 610

dominicschoenhardtmetsocom

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Groupe Charier Carriegravere de la Mariais France

Quarrying with certi1047297ed quality The Charier Group with its 1600-strong workforce is a family business thatthis year celebrates 115 years of quarrying The company pursues a long-termdevelopment policy that since 2007 has seen processing installations upgradedat 4 of its 9 extraction sites

TEXT Liliane Boutin (with extracts from Mines amp Carriegraveres and Terrassements amp Carriegraveres magazines)PHOTO Baloon photo

The processing installation is of the horizontal type with a primary station located 56 meters below the site access road to keep it hidden from view

The crushing and screening installation at

Charierrsquos CM La Mariais quarry (at Donges

on the Loire estuary) has been in opera-tion since September 2011 Based on theoperatorrsquos ideas it was designed by Metso

to replace a worn-out installation installed

right on top of the seam being extracted

Since its commissioning it has becomethe second quarry in the company to

receive ISO 14 001 certification

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983122983141983152983151983154983156983145983150983143 983154983141983155

tertiary material of sand and gravel for the

local market to use in concrete surfacingprefabrication etcrdquo

Incorporation of a screening station

The stone extracted from La Mariais is

according to the quarry granitic gneiss

sound and homogeneous with a LosAngeles index of 15 good wear resist-

ance with an MDE of 10 a true density of

265 and a certain abrasiveness (2000 gt)ldquoCharacteristically it has a tendency to form

blocksrdquo Leblin points out

The main criteria in designing the instal-

lation was to provide an output of 600000metric tons from one station (38 hours

week) to produce materials aimed at the

concrete and surfacing markets ldquowhich

involved providing a tertiary station withscreening plantrdquo he adds

With this new unit the operating com-pany expands its product range through

the addition of fine materials obtained

from the tertiary screening station This unitis capable of producing 170 tonshour of

020

Preserving the environment

and optimizing safety

The screens have motorized bogies and

retractable walkways to facilitate access

when the screens are opened for main-tenance Other walkways provide access

to the tunnel input feeders The feederscan be isolated with hydraulic rod gate

bars this hydraulic assistance eliminatesthe need to use a heavy hammer to lodge

these metal bars

All conveyors transporting fines (02

and 04) are covered with a tarpaulin to

avoid flying dust and all the screens arehooded (metal cover with Trellex seal-

ing) The Brunone company has installed

dust-tight containment at the outlet of the

tertiary station crushers (HP300 and HP4)on the belt located under the screens

and under the hoppers located belowthe tertiary screens The crushers are put

under negative pressure and the finesare extracted through sleeve filters (7000

m3 h) with declogging which deposits the

dust back onto the conveyor belt

A high-pressure 100 bar water mist sys-tem has been installed at the primary sta-

tion discharge at the secondary crusherrsquos

discharge chutes (Omnicone) and at the

transfer points on the belt

Designed to last

ldquoThis type of new installation can easily last

thirty yearsrdquo affirms Project Leader Bruno

Peix of Metso ldquoIt quite simply depends on

how well it is maintained Thatrsquos why weprovide maintenance contracts that call for

our technicians to make regular inspection

visits and carry out preventive mainte-nance and any necessary repairsrdquo

In 2011 Metso commissioned about

10 new processing units in France like

the one at La Mariais quarry

More info

Frederic Bazire

Tel +33 (0)681442804

fredericbaziremetsocom

Key figures

DURATION OF WORKS 15 months

DRAWING OFFICE TIME 7800 hours

HEIGHT OF SILOS AND GRINDER BUILDINGS

15 m

TOTAL LENGTH OF CONVEYORS 14 km

WEIGHT OF THE INSTALLATION

1200 metric tons

CONCRETE POURED 1800 cubic meters

PROJECT SITE WORKFORCE 30

INSTALLED POWER 2200 kW(not including pumps 200 kW)

METSO EQUIPMENT

Primary

Vibrating feeder PF561-2V

Primary grizzly VG540-3V

Grizzly feeder TK13-20-3V

Jaw crusher C145 with

hydraulic setting

Secondary

Vibrating screen CVB 2050

refurbished

Cone crusher Omnicocircne 1352 SX

with Metso IC7000 controller Ellivar 16 (16 msup2 3 decks) screen

refurbished by Metso

Tertiary

Cone crusher HP300

Cone crusher HP4

2 Ellivar 20 screens (20 m23 decks) for final products

Expanding the production range

ldquoSince the mid-1990s when we became

owners of La Mariais we had used mobilemachinery with an assembly of beltconveyorsrdquo recalls Daniel Leblin Charierrsquos

Technical Manager for site construction

and maintenance

ldquoIt became clear that we needed ahigher performance tool to achieve the

dual goals of reaching one million metric

tonsrsquo maximum production and producing

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Big Lokotrack LT550GPF boostsquarrying productivity by a thirdMaximizing the productivity of operations is a key issue when striving for cost-effective quarrying Big Lokotracks are oneway to achieve improved operational efficiency The Lokotrack LT550GPF equipped with the high-volume GP550 conecrusher and a large screen is popular in the Nordic countries and in Germany and Australia ndash countries all known for theirhigh quarrying volumes

TEXT amp PHOTOS Eero Haumlmaumllaumlinen

Kone-Kostamorsquos new mobile coneplant has reached an averagecapacity of 300 tons per hour

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983122983141983152983151983154983156983145983150983143 983154983141983155

ldquoWith the same number of employees we

can achieve 30 more productivity with

our new LT550GPF unit The high-capacityFS screen has also eliminated the bottle-neck often seen at fine screeningrdquo says

Aarno Kostamo Managing Director of

Kone-Kostamo Oy one of Finlandrsquos biggest

crushing contractorsAccording to Kostamo the high capacity

of the GP550 gyratory cone crusher easily

handles feed from the C120 and C125 jaw

crushers For the contract with the Talvivaara

nickel mine the LT550GPF is being fed bythe brand new Lokotrack LT120 jaw plant

Average capacity 300 tons per hour

Talvivaara Europersquos largest nickel mine uti-

lizes large quantities of aggregates Kone-Kostamo has contracted several million

tons of different end products for the mineIn August 75000 tons of 0ndash63 mm

road gravel was crushed Smaller amountsof finer 0ndash6 mm 0ndash16 mm and 0ndash32 mm

aggregates are also being produced

The rainy summer increased the need

for road gravel along the muddy roadswhich must endure dump trucks weighing

as much as 260 tons

ldquoThe mobile process consisting of the

LT120 jaw plant and LT550GPF cone plant

is cost-effective while aggregates of vari-ous sizes can be produced in a two-stage

operation and with high capacity The con-trolled stroke and elliptical movement of

the FS screen secure big passing throughcapacitiesrdquo Kostamo explains

Operated in two shifts for a total of 16

hours per day the LT550GPF has logged

more than 600 working hours over a two-month period

Managing Director Aarno Kostamo (left) and foreman Karri Maumlenpaumlauml studying the cavity optionsavailable for the new Lokotrack LT550GPF

Longer perspective than

a single quarter needed

Kone-Kostamo Oy was founded as an

earth-moving company in Kemijaumlrvi

Northern Finland in 1956 The company

expanded its operations to include crush-

ing contracting in 1964 and later on

switched to concentrating fully on crush-ing activities

Kone-Kostamo consistently crushes

and screens around 28 million tons ofaggregates annually and has net sales of

between EUR 8ndash9 million

ldquoWe believe that issues within the crush-

ing industry including the purchasing ofmachinery must be studied with a longer

perspective than a single quarter The

secret to our success has always been our

solid work ethic and professional employ-eesrdquo Kostamo sums up

More info

Esa Berg

Tel + 358 40 837 8692

esabergmetsocom

8132019 Results Minerals Aggregates 3 2012ENG

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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155

Monitoring-based reporting is vital for

assessing the performance of a mobile

crushing plant Metso provides suchreporting tools through its plant-wideautomation system Metso DNA (Dynamic

Network of Applications) with its infor-

mation platform that links all the mobile

crushing and screen units together as oneentity Basically there is a lot of measured

real-time information available in every

crushing plant On-line information is

obtained either from each Metso crusherrsquosmachine automation system IC (Intelligent

Controller) or from separately installed

additional sensors and belt scales

All the collected data is sent to a motorhome using wireless communication

based on WLAN technology The motor

home is a purpose-built environment

inside an on-site container In this environ-ment selected variables can be monitored

for assessing the plantrsquos performance And

to make all this even more flexible the

data can be transmitted to a crushing plant

company office using GPRS3G mobile

data communication technologies Thismakes all the last-minute reports acces-sible to the crushing plant managerial staff

at anytime and basically anywhere within

reach of the cell phone network

Production and fuel economics reports

Essentially monitoring and reporting can

be customized to fit the customerrsquos needs

However there are certain off-the-shelf

reports that provide a lot of useful informa-tion for plant supervision The production

report is one of these Requiring at least one

belt scale for measuring the total produc-tion the production report shows the pro-duction rate (tons per hour) for a selected

reporting period eg a day or a week The

production report constantly keeps track of

the plantrsquos production storing all the datathroughout the plantrsquos life cycle

Performance monitoring and reportingfor a mobile crushing plantTEXT Pasi Airikka PHOTOS Metso

unit during which the unit is running By

storing the availability times between start-ups and shutdowns the crushing plant

operation time (hours per dayshift) can be

recorded analyzed and reported In addi-

tion the availability report can be tailored

to evaluate efficient crushing hours during

which the plant is really working and pro-ducing aggregates Consequently the ratio

(0-100) between efficient crushing time

and total running time can be reported forany selected period of time This boosts

the efficiency of the plantrsquos operations

and results in better productivity

Reports on non-choke

or inadequate feeding

Non-choke feeding to crushers is avoid-

able through smart plant-wide crushingplant controls But estimating its severity in

a systematic manner is not straight-forwardwithout constant monitoring and reporting

The crusher choke feeding report makes

use of the crusher cavity level sensors byanalyzing their level measurements By

calculating average and min-max values

and deviations from the average it can be

shown how often the single crusher suffersfrom non-choke feeding to it

In some cases the bottleneck in the

crushing plantrsquos productivity is the material

feeding to the process In mobile plants thefeeding is human operated and therefore

subject to variations Occasionally the sizeof the human-operated machine simply

does not allow for adequate feeding to thecrushing plant There are specific reports

indicating time periods when the crushing

plant suffers from inadequate feeding

Condition monitoring for

crushers and screens

Machine-specific condition monitoring

focuses on vibrating components in

crushers and screens such as drive shaftbearings safety plate wearings and gears

The low middle and high frequencies ofmonitored components are measured and

supervised in real-time to detect abnor-malities due to slow or fast wear looseness

or imbalance

More info

Pasi Airikka

Tel +358 40 587 2730

pasiairikkametsocom

Condition monitoring provides a view tovibrating crusher and screen components forpredictive equipment maintenance

The daily production report shows the hour-by-hour production trend and distribution chartfor a selected day with min-max average andvariation statistics for comparison

Fuel consumption is always an interest-ing concern The fuel consumption reportgives the fuel consumption of each crush-

ing unit (liters per hour) and their total

consumption (liters per hour) for a selected

reporting period and can track fuel con-

sumption changes over timeCrushing plant availability can be

assessed as well The availability report

calculates time periods for each crushing

8132019 Results Minerals Aggregates 3 2012ENG

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983149983141983156983155983151 983150

for tissue machines The record of 2210

mmin was set on June 1 2012 during a

24-hour production run by the TM 2 tissue

machine at the companyrsquos mill in Yenikoumlynear the city of Izmit in Turkey

ldquoThe cooperation with Metso has been

beyond excellent and both parties did

their utmost to make the project success-ful The results clearly show that the efforts

were worthwhile on both sides This coop-

eration will extend to cover new projects

in the futurerdquo says Luumlt1047297 Aydin Paper GroupDirector Hayat Kimya

ldquoWe are not surprised that Hayat K imya

managed to break the world speed record

We have had great confidence in the capa-bility of the Hayat team since our project

started in 2009 We certainly know our

machine very well its stability production

efficiency and speed capabilityrdquo says Jan

Erikson Vice President Sales Metso

PowerThe worldrsquos first eco-gas fueled

power plant is up and running

Lahti Energy Ltdrsquos new Kymijaumlrvi II gasifica-

tion plant was officially inaugurated on

May 8 2012 It is the first of its kind in the

RecyclingRecycling with Lokotrack LT106

jaw plant in New York

A brand-new Lokotrack LT106 jaw plant is

used in the city area of New York USA to

recycle demolition materials The crushing

site faces the skyscrapers of ManhattanIsland

Paper amp FiberHayat Kimyarsquos Metso-supplied tissue

machine sets world speed record

Thanks to a skilled crew and dedicated

efforts Hayat Kimya AS in Turkey has suc-

ceeded in breaking the world speed record

world This CHP plant runs on clean eco-

gas that is gasified cleaned and cooled

from recycled waste with Metsorsquos innova-tive technology

ldquoItrsquos actually eco-gas that we combust

in the boilerrdquo comments Lahti EnergyrsquosProduction Director Jukka Manskinen

ldquoWe convert unwanted waste material into

energy in an efficient and environmentally

friendly wayrdquoNever before has any plant gasified

waste on such a large scale In the gasifier

recycled waste is turned into combustible

product gas which is cleaned cooled and

combusted in a high-efficiency gas boiler

to produce steam for the steam turbine The plant produces 50 MW of electricity

and 90 MW of district heat for the city of

Lahti and its neighboring areasMetso delivered the circulating fluidized

bed (CFB) gasification process gas cleaning

and cooling steam boiler environmental

protection system and automation systemto the entire plant The production of elec-

tricity and heat is kept even with the Metso

DNA automation system that covers the

whole plant starting from fuel reception

AutomationMetso develops and supplies plant-

wide crushing control solutions for

crushing plants

Metso has recently signed contracts on

delivering plant-wide automation systems

for mobile and portable rock crushing

plants The key objective of these deliveries

is to stabilize and to increase productivityand efficiency of the plants using one sin-

gle automation and information platform

for integrating crusher-specific IC machinecontrols

Furthermore the plant-wide system

with its information management tools not

only increases plant availability and opera-

tional safety it also makes troubleshoot-ing quicker and performance monitoring

easier The control room for plant-wide

operability is located either in an excavator

cabin or a purpose-built container

Metso around the world

The new LT106 jaw plant is suitable for crushing both hard rock and all rock-based demolition materials

The new world speed record for tissue setby Hayat Kimyarsquos Metso-supplied TM 2 is2210 mmin

8132019 Results Minerals Aggregates 3 2012ENG

httpslidepdfcomreaderfullresults-minerals-aggregates-3-2012eng 4242

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: Results Minerals Aggregates 3 2012.ENG

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983110983141983137983156983157983154983141983140 983137983154983156

The story behind the discovery of the Laivamine is an interesting one During a hunt-

ing trip in the remote forests of Laivakan-

gas in 1979 Pentti Jaumlmbaumlck found an inter-esting-looking piece of stone Although hecould not see the gold hidden inside the

rock Pentti noticed the striking weight

and somewhat different look of the stone

Upon returning home Pentti sent thesample to Outokumpu which at the time

was the leading state-owned mining com-

pany in Finland After testing a high gold

content of 15 grams per ton was found

Gold deposit founded by a hunter

The founder of the Laiva gold deposit Mr Pentti

Jaumlmbaumlck was the guest of honor during theinauguration

Lennart Schoumlnning Chairman of the Board ofNordic Mines holding a gold doreacute bar worthsome EUR 320000

Outokumpu registered a mining claimon the area and conducted a series of

exploration drilling from 1981 to 1987 Due

to the low price level for gold no mine wasstarted at the time Other mining compa-nies such as Endomines held the mining

rights later

Nordic Mines with its sights set on

locating and exploiting gold in Swedenand Finland was founded in 2005 During

the same year the company purchased its

first mining rights at Laiva

Nordic Minesrsquo Laiva gold mine

LOCATION near the city of Raahe

northwestern Finland

GOLD ORE CONTENT average 16 gt

ORE EXTRACTED PER YEAR

12 million tons (present)

20 million tons (planned)

GOLD RECOVERY 85

TOTAL KNOWN ORE RESERVES

169 million tons

MINING METHOD

Selective open-pit benchingNUMBER OF EMPLOYEES

130 including contractors

METSO MAIN EQUIPMENT

2 Metso VF and 6 EMEG EME

vibrating feeders

8 Screens 1 MF 1 CVB and 6 KS

1 RCS Flash flotation unit

1 Metso SRR ball mill 18 x 4 m

1 Nordberg C160 jaw crusher

1 Nordberg HP100 cone crusher

1 Nordberg HP200 cone crusher

5 Nordberg NB series conveyors

73 Metso Slurry pumps ofvarious types and sizes

8132019 Results Minerals Aggregates 3 2012ENG

httpslidepdfcomreaderfullresults-minerals-aggregates-3-2012eng 16426983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155

The newest member of the proven GP series cone crushers ndash theNordberg GP220 ndash offers a versatile alternative for any demanding

tertiary or quaternary or even secondary crushing operation fulfill-

ing all crushing needs and maximizing customersrsquo profitability

High-quality components and optimized castings and forgings

contribute to the GP220rsquos enhanced reliability and help to ensurethe highest level of crusher uptime

Thanks to the 200 kW (270 hp) power draw the GP220 performs

at a 20 to 30 percent higher capacity than other cone crusherbrands with an equal head diameter The large feed openingenables the feeding jaw crusher to run at 110 mm css Operational

flexibility is ensured by multiple strokes and six different cavities

Secondary crushing possible

thanks to cavity and stroke options

Thanks to the GP220rsquos cavity and stroke options secondary crush-

ing in addition to tertiary and quaternary stages is also possible

using cavities with a greater intake opening With the GP220 a suit-

able solution for producing excellent end-product gradations

can always be found

With advanced automation using IC50 or IC5000 operation

is safe and trouble-free The low height thanks to the patented

piston design makes replacement installations much easierA dynamic setting adjustment enables a fast response to process

optimization needs

The Nordberg GP220 weighs 10500 kg (23150 lbs) and hasa maximum real feed size of +200 mm (8rdquo) with strokes from

18ndash40 mm (57rdquondash1 47rdquo) The cavity options are EF F MF M C

and EC

A complete modular crusher steel structure is available for allGP series stationary installations including GP220 The platform

includes places for the lubrication unit motor automation or

pressure accumulator and pressurized sealing The only things

left to add are the feed and discharge conveyors

Main new features of the GP220 Large feed opening allows for secondary stage operation

Longer setting range of main shaft for better wear parts utilization

Stronger main components to carry high loads with a powerdraw as high as 200kW

More info

Hannu Vakkuri

Tel +358 50 317 0638

hannuvakkurimetsocom

Thanks to the large feed opening and wide selection of strokes and cavitiesthe new Nordberg GP220 cone crusher is a highly versatile cone novelty

More versatility with the newNordberg GP220 cone crusher

Reinforced head and frame castings combined with a 200kW power

draw make the GP220 cone a reliable crusher with maximum productivity

8132019 Results Minerals Aggregates 3 2012ENG

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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156

Metsorsquos HRCtrade takes high pressure grinding roll technology to the next level

The new Lokotrack mobile conveyors come as tracked and wheeled models

Metsorsquos latest development in comminution equipment the HRCtradeis a major step in the profitable application of high-pressure grind-

ing roll (HPGR) technology Metso has made several key innova-

tions in order to increase throughput and decrease the total cost

of operation

Metsorsquos patented Arch frame creates an even gap setting acrossthe width of the tires limiting skewing that can result in downtime

for mining operations This anti-skewing Arch frame also prevents

damage to the roller bearings (caused by misalignment) that canoccur with the traditional HPGR design

Flanges maximize wear life and increase throughput

Used in place of spring-loaded cheek plates the flanges keep thebed of material within the crushing zone and prevent material

from bypassing the tires This enables greater circuit capacity and

increases the overall crushing efficiency

In addition by preventing material from bypassing the tires

even pressure across the width of the tire is better maintained

Distributing the pressure more evenly maximizes the tire life bypreventing a ldquobath tub effectrdquo in which the center of the tire wears

faster than the edgesVictoria Herman Metsorsquos Product Manager for the HRC notes

that this breakthrough design is a response to the growing needs

in the mining industry ldquoEnergy efficiency has been attracting our

customers to HPGR technology for yearsrdquo she says ldquoBut our design

concept increases capacity and crushing efficiency ndash and thatrsquossomething mining companies are always looking to improve onrdquo

The track-mounted Lokotrack CT32 and wheel-mounted Lokotrack

CW32 mobile conveyors offer an ideal solution for applications

that require high stockpile capacity and excellent material transfer

capabilities They also add flexibility to multi-stage crushing andscreening applications enabling easy and fast closed-circuit opera-

tion of mobile units

The conveyor novelties can be used in both mobile and station-

ary installations providing extra stockpiling capacity in situationswhere for example fewer wheel loaders are available

The HRC is ideal for high-tonnage hard rock applications andcan be used as a tertiary quaternary or pebble crusher Currently

several HRC units are in operation around the world ndash with a total

of 6500 operating hours including over 3800 hours in a mininghard rock application The machine does have range within hardrock applications itrsquos been designed for use in diamond iron ore

copper gold platinum and various industrial minerals

More info

Victoria Herman

Tel +1 717 309 1150

victoriahermanmetsocom

Several optional features such as hydraulic folding of tail sections

and dual hydraulic drive for increased throughput are available

The capacity of the CT32 and CW32 is 400 mtph (440 stph)feed size up to 150 mm (6rdquo) belt width 1050 mm (42rdquo) and dis-charge height 9120 mm (29rsquo 11rdquo) The CT32 is fitted with a Caterpil-

lar C2 diesel engine with 38kw (51 HP) power The CW32 is avail-

able for hydraulic or electric use

More info

Kimmo Anttila

Tel +358 50 433 3745

kimmoanttilametsocom

The new HRCtrade combines high crushing pressure and a low circulatingload resulting in the most efficient comminution

When flexibility in stockpiling capacityis required the answer can be foundin the new Lokotrack CT32 and

CW32 mobile conveyors

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Service creates value in ChinaChinarsquos most important gold producing area Yantai in northeastern China supplies more than 16 of the countryrsquos goldproduction each year With the gold market thriving the scale of gold production in Yantai has been expanding constantly

Zhongjia Mining Industry Co Ltd is one of the beneficiaries of this thriving industryTEXT amp PHOTOS Yan Xin

Inspection and maintenance of the HP500 cone crusher conducted by Metsorsquos service engineers

In 2011 Zhongjia Mining Industry pur-

chased a modular crushing and screen-ing system from Metso for its new gold

production project With the cooperation

between the two companies continuously

intensifying Zhongjia Mining Industry

signed an additional one-year Life CycleService (LCS) contract with Metso incorpo-

rating Metsorsquos global knowledge in equip-

ment processes and services

ldquoMetso customized a series of reason-

able service solutions also referred toas Metso Performance Solutions for us

including preventive maintenance services

process improvement personnel training

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155

and a procurement plan for wear parts

These really suit our needs perfectlyrdquo saysShen Yidong the Manager of ZhongjiaMining Industry

Effective preventive maintenanceFor mining corporations the biggestconcern is the economic losses caused by

the shutdown of equipment As a result

preventative maintenance is of vital impor-

tance During the contract period Metsoservice engineers offered 7-day tracking

service on the production site every month

to eliminate potential problems and thus

ensured the stability of the system

parts caused pressure on our working capi-tal which was not favorable for our long-

term developmentrdquo Shen explains

To solve this problem Metso designed

a rational stock plan of wear parts and built

a field warehouse In accordance with theuse and consumption of the liners the field

service engineers complement the stock tomake production and operations run more

smoothlyldquoNow when we need to replace the

wear parts we can use them before pay-

ment This not only simplifies the procure-

ment process but also liberates a largesum of our operating capital which can

be used for other business development

purposesrdquo says Shen

Best partner

ldquoAlthough the LCS contract incurs some

early purchase costs in the long run Metsorsquosprofessional and quality service will improve

the equipment efficiency reduce ourenergy consumption and ensure stable

operations thus generating more prof-

its This is the greatest value for us so the

investment is really worthwhile overall Inthe future we will choose more Metso prod-

ucts and services Taking all aspects into

consideration we believe Metso is the best

partner for usrdquo Shen Yidong concludes

More info

Thomas Bai Tel +86 13801009114

thomasbaimetsocom

ldquoIn the eight months since the contract

came into effect our corporation has notsuffered any financial losses due to equip-

ment breakdown The regular maintenance

has greatly improved the efficiency of our

entire crushing system In addition the

experienced engineers from Metso also

provided onsite training and guidancefor our staff and the tailored training has

greatly enhanced the operating abilities of

our employees and upgraded their overalllevel of competencerdquo says Shen Yidong

More productivity with

less consumption

Metsorsquos service contract focuses on real-

izing the optimum performance of each

process flow After analyzing Zhongjiarsquos

production system Metsorsquos techniciansproposed an adjustment to the closed side

setting of the HP500 for tertiary crushingin order to improve the efficiency of the

downstream fine crushing and milling pro-

cessing by over 10ldquoThe process flow improvement solu-

tions provided by Metso not only increased

the output of our gold concentrates but

also reduced our energy consumption andcostsrdquo says Shen

In the past wear parts procurement

took up a larger proportion of Zhongjiarsquos

total production costsldquoTo avoid downtime caused by the

shortage of wear parts we had to keepeight sets of various wear parts in place

However the cost of having so many wear

Zhongjia Mining Industryrsquos gold concentrates processing plant in China

8132019 Results Minerals Aggregates 3 2012ENG

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0983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

Safe quarrying high-

quality aggregates

8132019 Results Minerals Aggregates 3 2012ENG

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ldquoWe share a similar zero-accident strategy and target with Metso and have successfullyfollowed it Metso has also helped us to meet the strictest end-product quality andcubicity requirements set in Spainrdquo This is how Managing Director Intildeigo Ajuria ofOfitas de San Felices the leading hard rock quarrying company in Spain describesthe cooperation with MetsoTEXT Eero Haumlmaumllaumlinen PHOTOS Ofitas and Eero Haumlmaumllaumlinen

The San Felices quarry is situated in a picturesque mountainous landscapebetween the companyrsquos Rioja vineyards and the Bilbao-Madrid motorway

8132019 Results Minerals Aggregates 3 2012ENG

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Ofitas has pioneered the implementation

of several Metso novelties in the Spanish

market The company was the first to use

efficient large track-mounted Lokotrack jaw plants the unique mobile conveying

system and also the new-generation HP4

cone crushers

Today the company operates twomodern Metso stationary plants one in

Guadix near Granada and the newest one

in San Felices Haro Rioja community Both

quarries focus on refining hard rock by pro-cessing ophite rock into the highest quality

railway ballast asphalt and concrete mix

grades The company has a satellite quarry

near Vitoria in PentildeacerradaBeing situated next to a highway and

the famous Rioja vineyards Ofitas must pay

special attention to environmental issues

To minimize dust problems all conveyors

have special covers attached

Quality durability and service

The cooperation between Ofitas de San

Felices and Metso started back in 1973when the Ajuria family bought the com-

pany whose quarrying activities began in

1919 Intildeigo Ajuria has a clear vision of why

the cooperation has continued withoutinterruption for almost 40 years

long-standing personal relationshipsrdquoAjuria adds

Serving railways asphalt

and concrete producers

The year-old San Felices stationary instal-lation lies hidden in a mountainous area

south of the city of Vitoria in NorthernSpain The new plant replaces an old one

that complicated the extraction of ophiterock Both plants are delivered by Metso

With its two separate production lines

the new plant is able to produce all the

end products required ndash from railway bal-last to the finer grades needed for asphalt

and concrete

Due to lower demand the quarry cur-

rently produces some 4000 tons per day

At full capacity however the plant canreach 8000 tons of production per day

30ndash35 of which consists of railway ballastfor high-speed trains and 65ndash70 of chips

and sand Thanks to the versatile two-line con-

cept connected by transverse conveyors

up to 12 different end products can be pro-

duced Depending on the demand for endproducts the material can be guided either

to the HP4 cone or HP400 cone followed

by a Barmac vertical shaft impactor

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

The ophite feed is fed to the C125 jaw crusher by a sturdy dump truck

The key people running the new San Felicesquarry Mine Engineer Carlos Fernandez (left)Managing Director Intildeigo Ajuria with ProductionManager Julian Perez

ldquoThrough the years Metso machinery

has proven its production capacity and

durability resulting in high-quality end

products A big plus for us has also beenthe quick response time to our process

challenges or servicerdquo

ldquoIn fact our cooperation extends

beyond day-to-day business matters to

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155

Meeting the strictest cubicity demands

The Spanish regulations concerning end-product cubicity are becoming more

demanding The flakiness percentage of

railway ballast must be below 10 and for

asphalt and concrete aggregates less than

15

ldquoWith Metsorsquos HP4 cone and the Barmacvertical shaft impactor we can meet even

the strictest cubicity demands We believe

that our high quality is helping us to sur-vive in the present recessionrdquo notes Mine

Engineer Carlos Fernandez

ldquoWe hope to increase the total extrac-

tion of the three quarries from the present15 million tons per year because our plant

capacity allows more than double thatrdquo

Fernandez adds

More info

Angel Luis Garcia Tel +34 686 94 35 30

angelluisgarciametsocom

In addition to being the leading Spanish

quarry to process hard rock Ofitas de SanFelices also cultivates 34 hectares of vine-yards next to the quarry which is situated

in the famous Rioja wine area

The company has previously sold a

harvest of over 200000 kg of Tempranillo

grapes to local red-wine makers Recentlythe company built its own wine process-

ing plant to process 10000ndash15000 kg of

grapes themselves

Aggregates and wine production

Andoni Ajuria the founder of Ofitas de san Felices (left) with Intildeigo Ajuria the present ManagingDirector tasting wine from the companyrsquos own vineyards

The first vintage wine of Ofitas har-

vested in autumn 2010 is now maturingin oak barrels After maturing for 12 to 15months the wine is called crianza and after

two years it will be granted the classifica-

tion reserva

ldquoWinemaking is not a business but

a hobby for us We give our wine out aspresents and drink it when we meet

our suppliers and friendsrdquo Intildeigo Ajuria

comments

For environmental protectionall of San Felicesrsquos plantconveyors are covered

Ofitas de San Felices quarry

LOCATION Haro near the city

of Vitoria northern Spain

SIZE 100 hectares

ROCK TYPE Ophite with Los Angeles

index of 9ndash10

PRESENT DAILY EXTRACTION 3000 tons

of ophiteNUMBER OF PERSONNEL 30

RESERVES 10 million tons

MAIN END PRODUCTS 0ndash2 mm

2ndash4 mm 4ndash10 mm 10ndash16 mm

16ndash22 mm 25ndash60 mm (ballast)

METSO MAIN EQUIPMENT

VF feeder

C125 jaw crusher

ndash feed size 0ndash800 mm

ndash css 130ndash140 mm

HP400 cone crusher

ndash feed size 80ndash250 mm

ndash css 40 mm HP4 cone crusher

ndash feed size 40ndash80 mm

ndash css 15 mm

Barmac 6150 VSI crusher

4 CVB2060 screens

2 TS32 screens

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Metso Distribution Centers he

Europe (Tongeren Belgium)

France (Macon)

Czech Republic (Přerov)

Austria (Vienna)

2271 d

Brazil (Sorocaba SP)

1014 d

USA (Columbia SC)

1690 d

USA (Waukesha WI)

434 d

South Africa (Vereeniging)

Ghana (Tarkwa)

Meacutexico (Irapuato)

Peru (Lima)

Chile (Concoacuten)

788 d

Sweden ( Trelleborg)

Finland (Tampere)

UK (Rugby)

865 d

Russia (St Petersburg)

Brazil (Parauapebas PA)

206 d

4983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983122983141983152983151983154983156983145983150983143 983154983141983155

In the case of an equipment failure or

a planned service shutdown resuming

production as quickly as possible is crucialEach hour spent waiting for a spare part to

arrive equals money lost Whether the right

part takes 12 or 48 hours to arrive really

makes a difference

The comprehensive and global Metsospare and wear parts service network pro-

vides you with the right part in the right

place and at the right time Our strategi-

cally located Distribution Centers and

Satellite Warehouses are on call 24 hoursa day 7 days a week ensuring efficient

parts replacement near you

Check out the locations of the MetsoDistribution Centers and how many parts

pass through them each day

More info

Marcelo Farah

Tel +55 15 2102 1315

marcelofarahmetsocom

you minimize downtime

Australia (Perth)

746 d

China (Tianjin)

China (Kunming)

China (Shanghai)

393 d

India (Faridabad)

India (Ahmedabad)

India (Hyderabad)

India (Bhubaneswar)

India (Bangalore)

419 d

Russia (Yekaterinburg)

Australia (Newcastle)

New Zealand (Matamata)

983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088

TEXT Sofia Williams

Singapore (Singapore)

Distribution Center Satellite Warehouse

8132019 Results Minerals Aggregates 3 2012ENG

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Following a large investment

in Metso crushing equipmentand services Buena Vista del

Cobre is now expanding the

mine site to include even more

equipment ndash and with thatexpansion comes the need for

more local service resources

Metso and Buena Vista del

Cobre have entered into a Life

Cycle Service agreement forthe plant and construction of a

brand new Metso service hub

is under way in Cananea

New facility new

level of service

The Cananea service hub

which will be up and running in early 2013will support the recent expansion and resur-

gence of Buena Vista del Cobre Initially it

will be a major repair and assembly center

for pumps crushers and screens and will

provide for rubber covering capabilitiesBut the 8000-square-meter facilityrsquos service

offering will be expansive including a con-

signment stock inventory to help serve theminersquos varying needs Metso currently has

50 service team members on site

Although Buena Vista del Cobre was a

key influencer in building the new servicehub this location will also enable Metso to

expand its capabilities and provide local

support to the entire mining community

in northwest Mexico The Cananea hub

will serve a number of major copper and

gold mines in the region including MineraFriscorsquos San Felipe Fresnillorsquos Milpillas and

Grupo Mexicorsquos Mexicana de Cobre

ldquoBuena Vista del Cobre is the biggestcustomer we have in Mexico today and

with this expansion project itrsquos only going

to grow and be strongerrdquo says Felix Forna-

guera Director of Services Mexico CentralAmerica and Caribbean ldquoWith that said the

idea behind the Cananea service hub is to

provide a central location for local support

for all our major customers in the areardquo

Establishing safety

ldquoIt was key to have our support here in

Cananea because the Buena Vista delCobre started from the ground uprdquo saysFelix ldquoWersquove been able to help the cus-

tomer to establish the best in support

service and operations from the very

beginningrdquo And this ground-up approachincluded a major focus on safety

Metso worked closely with Buena Vista

del Cobre to establish the safety proto-

col by which the mine operates Basedon Metsorsquos expertise the safety measures

put in place have enabled the mine to

become strict and efficient in its operations

and maintenance procedures To achievethis Metso worked closely with local andnational authorities to ensure the safety

plan was comprehensive and in accord-

ance with all established legal bodies

The best in regional support

The service hub in Cananea is a prime

example of Metsorsquos focus on providing local

service and support to its customers all

Service shines in Cananea MexicoAfter three years of inactivity the Buena Vista del Cobre mine in Cananea Sonora Mexico has been operational since 2010A mine that was inactive for such a significant amount of time however requires a great deal of support to successfullyrestart the plant and bring it back to an operational and profitable state

TEXT Deanna Lee PHOTO Metso

over the world ldquoWe are the first

company developing this kindof service in northwest Mexicordquo

adds Felix ldquoOur people have

developed a close relationship

with the team at the mine Itrsquosmore than a supplier relation-

ship our guys are inside the

mine living and working thererdquo

In fact this is the model

that Metso is using in servicehubs all over the globe build-

ing modern facilities bringing

teams on site and workinghand in hand with mine

operators The Cananea Service

hub is only the most recent

example of Metsorsquos commit-ment to service and northwest Mexico is

yet another mining hotbed thatrsquos going to

benefit from the companyrsquos support

More info

Felix Fornaguera Tel +52 4621079227

felixfornaguerametsocom

A mining cone serviced by Metso at the Buena Vista del Cobre mine inSonora Mexico

ldquoThe new Cananea service center will be a majorrepair and assembly center for pumps crushersand screensrdquo says Felix Fornaguera Director ofServices Mexico Central America and Caribbean

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

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During the MINExpo exhibition over 1300 people visited the Metso stand

983122983141983152983151983154983156983145983150983143 983154983141983155

Held every four years MIN-Expo consistently grows so

perennial exhibitors like Metso

are challenged with elevating

their presence and drawingin new (and greater numbers

of ) visitors each year ldquoItrsquos not

necessarily a challenge to lsquotoprsquo

our last showingrdquo says Keith

Ference Vice President ofmarketing and communica-

tions North America ldquoThere

are four years between eachMINExpo so we always have

a lot to say and reveal to our

customersrdquo The real challenge

he says is finding an exciting

and dynamic way to deliverthe message ldquoTherersquos so much

to see here so your booth has

to be compelling from the

outside-in and thatrsquos what

we always try to dordquo

Service sets the stage

The Metso booth created buzzin a number of ways and per-

haps the most striking (partly

due to its size) was the live

theater presentation As visitorspassed through the aisles of the show-

room the sights and sounds from Metsorsquos

theater were hard to miss And once guests

entered they were captivated by a short

high-energy video presentation focused

on Metsorsquos service capabilities The message was simple Metso is ldquoyour

local service partner rdquo for all mining and

construction needs The video showed ourservice teams in action all over the world

and the audience came away with an

understanding about Metsorsquos commitment

to service Customers can count on morethan 70 local service centers run by more

than 1700 expert technicians delivering

Metso makes an impact at MINExpo 2012At this yearrsquos MINExpo International nearly 60000 attendees flocked to Las Vegas Nevada the largest turnout in showhistory The visitors ndash mining professionals from all over the globe ndash explored 850000 square feet of showroom spacefeaturing the industry rsquos latest technology equipment products and services They toured the show for three days

seeking the latest and greatest from more than 1800 exhibitorsTEXT Keith Ference PHOTOS Tracey Ford Perry

detailed descriptions andphotos of all of Metsorsquos mining

and construction products and

services The app also provides

digital access to Results and asearchable database of sales

contacts By day three of the

show MetsoMAP had been

downloaded by more than

500 usersIn addition to the app the

booth was equipped with

several LCD screens each con-trolled by Metso experts who

used their iPads to present new

products like the Megalinertrade

and the HRCtrade A featured

presentation on Metsorsquos lineupof energy-efficient comminu-

tion equipment including the

VERTIMILLreg SMD and MP-1250

cone crusher was also avail-

able letting customers seehow Metso technology delivers

some of the worldrsquos most effi-

cient size reduction

Measuring MINExpo success

After a very busy three days

(on top of months of prepara-tion leading up to the show) everyone

involved with MINExpo ndash from the North

American marketing team responsible for

the booth to the product managers and

sales force that worked the floor ndash is view-

ing the show as a success ldquoTherersquos alwaysa sigh of relief after each (MINExpo)rdquo says

Keith ldquoAnd overall the initial feedback

and response has been very positiverdquoWith more than 1300 visitors to the

booth Metso certainly made an impact

ldquoWe learn a lot from each show and with

some time wersquoll have a better understand-ing of the tangible results of our effortsrdquo

Keith adds

reliable service for mining equipment as

well as customized cost-effective life-cycle

services contracts

Technology ndash MetsoMAP

is an industry firstMINExpo provided the industry with its firstglimpse of Metsorsquos revolutionary iPad app

MetsoMAP The app was demoed to the

boothrsquos visitors via ldquothe worldrsquos largest iPadrdquo

a custom-made 80-inch screen that show-cased all of its capabilities most of which are

groundbreaking in the industry MetsoMAPrsquos

simple interface is highly intuitive making

it easy to view process animations videos

The presentation of the new HP cone crusher attracted a large audience

8132019 Results Minerals Aggregates 3 2012ENG

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When yoursquore allowed less than a dozen days per year for breakdowns repair andmaintenance every single hour during a service shutdown counts There simplyisnrsquot any room for surprises Thatrsquos why Boliden counts on MetsoTEXT amp PHOTOS Sofia Williams

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Kurt Kalla Site Managerof Metso Gaumlllivare ServiceCenter is responsible forthe maintenance of Aitik

Metso and Boliden Strivingtogether for 97 uptime

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983122983141983152983151983154983156983145983150983143 983154983141983155

One of the biggest copper mines in

Europe Bolidenrsquos Aitik is located deep inthe wilderness of Swedish Lapland next to

the small town of Gaumlllivare The mine has

been operating since 1968 and a recent

expansion has increased its annual ore

production to 36 million tons

But the ambitious Swedes are not will-ing to lay back and relax just yet Bolidenrsquos

new aim is to reach a production rate of

45 million tons of ore per year in AitikAfter that Perhaps more than 55 million

tons The ore concentration in Aitik is very

low-grade with a mere 022 copper con-

tent hence the need for high capacityAchieving the ambitious production

goal requires maximum plant availability

This means that everything from the crush-

ers to the filters must be up and runningfor approximately 97 percent of the time

Thatrsquos where Metso comes into play

A cost-per-ton contract in action

The maximum uptime requirement allowsless than a dozen days per year for break-

downs repair and maintenance at Aitik

Every single hour during a service shut-

down counts There simply isnrsquot any roomfor surprises

Executing a successful shutdown under

such conditions requires a reliable service

partner not afraid of challenges and this iswhy Boliden has entrusted Aitikrsquos services

operations to Metso Boliden and Metsohave worked together since the 1960s

and the collaboration took another step

forward in September 2012 when the twocompanies signed a three-year extension

of the services contract for Boliden Aitik

ldquoThe new contract is a cost-per-ton

agreement We get paid based on Aitikrsquos

production Itrsquos a win-win deal for both par-

ties but also a new mindset for usrdquo explainsKurt Kalla Site Manager of Metso Gaumlllivare

Service Center responsible for serving Aitik

From now on the duration of the shut-down is what matters the most According

to Kalla the Metso service organization in

Gaumlllivare is now streamlining its operations

to fit the bill and has already witnessed thestrategy working In August 2012 Metso

carried out a 188-hour service shutdown in

Aitik which turned out to be a success

Zero tolerance for injury

One key factor to the success was theextensive planning of precautionary health

safety and environment procedures under-

taken by Metso prior to the shutdown Thanks to strict measures applied no

injuries or accidents occurred during the

shutdown and the work could easily be

finished on scheduleMats Johansson Health Safety

and Environment Manager for Metso in

Sweden explains how this was achieved

rdquoPlanning of the shutdown included arisk analysis for all new tasks participating

in Bolidenrsquos safety coordination meetingsmeeting with both Metso supervisors and

subcontractor supervisors and finally a

meeting with the entire staff participating

in the shutdown where everyone had to

sign a document stating their commitmentto the information providedrdquo he says

During the actual shutdown plenty of

new barriers signs and awareness cones

were put in place as a result of observa-tions from previous audits and safety plans

and risk analyses were readily available

in the work area Metso and Boliden also

introduced a Mill Inching permit a certifi-cate for completing a mandatory course for

those involved in the process In addition

Metso carried out random safety audits

during the shutdown to make sure thestrict policy was followed

According to Boliden Metsorsquos way of

working is a good example of how health

and safety precautions should be handled

ldquoMetso is a good example of how towork with safety and health plans risk

analysis permits and welding permits

Their table with all binders in the second-

ary mill area was exemplaryrdquo says Kjell-Arne

Johansson a technician from Boliden

The use of the new Metso Megalinertrade

system in the lining of Aitikrsquos Metso AG

mills has also improved the safety of main-tenance staff The Metso Megalinertrade con-

sists of larger-than-average liners bolted

in position from outside the mill Mainte-

nance technicians no longer need to go

inside the mill and stand in the dangerousdrop-zone of the liners gt

Boliden aims to reach a production rate of 45 million tons of ore per yearin the Aitik mine site

ldquoA complete risk analysis was conducted during the planningof the shutdownrdquo comments Mats Johansson Health Safetyand Environment Manager for Metso in Sweden

8132019 Results Minerals Aggregates 3 2012ENG

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Service the Metso way

24 hours a day 365 days a year

In addition to paying close attention to

health and safety issues executing an effi-

cient shutdown requires careful planning

and timing of every step in the mainte-

nance process Wear and spare parts have

to be available on time and a repair shoplarge enough to accommodate equipment

located close by

ldquoTo keep maintenance breaks as short

as possible we aim to replace the pump on

site and bring the old one for repair to our

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

nearby facilities This method gives us the

peace to do a good job and keep the cus-

tomerrsquos operations runningrdquo Kalla describes

the Metso way of handling Aitikrsquos pump

maintenance

Metso is currently expanding its Gaumllli-

vare service center to include a distribu-

tion center for wear and spare parts andalso concentrating its previously scattered

operations under one roof in its Vuoskon-

jaumlrvivaumlgen facility The expansion is due to

be completed by 2014

Metso equipment

delivered to Aitik36

bull 2 AG mills diameter 116 x

137 m gearless 22-MW motor

bull 2 Pebble mills diameter 91 x

113m dual 5-MW pinion drive

bull 3 VPA pressure filters VPA 1540-54

bull 12 sample pumps and pipes

VF50

bull 60 Various slurry pumps up to

MR500 modelbull Appr 5000 m rubber-lined slurry

pipes up to 600 mm diameter

bull Appr 5000 m rubber-lined by

gravity pipes up to 600 mm

diameter

bull Appr 5000 m rubber hoses

up to 600 mm diameter

Not only does the expansion make ser-

vice shutdowns at Aitik run more smoothly

it guarantees a more comprehensive

on-call emergency service response in the

region ndash thanks to the spare and wear parts

inventory available 24 hours a day 365

days a year

More info

Lars Rosenling

Tel +46 70 107 45 90

larsrosenlingmetsocom

Metso grinding equipment dominates the view in the concentrator

Safety on site is made up of small things like

making sure that everyone remembers to secure

the hoses in place

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983122983141983152983151983154983156983145983150983143 983154983141983155

Pebbles have always been a

challenge for producers of sandsince they cannot be returned

to rivers after extraction For

decades the processing of this

material resulted in a huge

environmental liability with alarge amount of pebbles hav-

ing to be stored away and left

unused

Transforming problems into

business opportunities

Areia amp Cia (areia = sand) has

operated in this market forover 20 years and decided to

enlist the help of Metso to find

a profitable solution for the

processing of pebbles

In July 2011 analyses werebegun to assess the abrasive-

ness and crushability of the

material Four alternatives wereidentified for processing and

transforming pebbles into sand

Initially Areia amp Cia was

interested in acquiring an

impactor for its reason-able price level However the

customer wanted to process

all the pebbles that were col-

lected daily in addition to some of the

material that it had stored In weighing theresults expected by the customer and the

excessive abrasiveness of the material the

HP200 cone crusher was decided on as thebest alternative

Areia amp Cia made the required invest-

ment and after using the HP200 for just

six months the company has already beenreporting outstanding results The HP200

not only transforms pebbles into sand but

also produces sand of excellent quality

with high yield and low maintenanceWith minor adjustments the HP200

also enables the production of sand withspecific particle size distribution for special

applications such as filtering sand blasting

and foundry sand adding value to the prod-

uct and increasing the types of sand offeredldquoMetso is pleased that the HP200 not

only enabled the processing of a product

that had been set aside as unusable but

HP200 cone transforms pebblesinto high-quality sandOver the last few decades Brazilian economic growth has been driving demand for construction aggregates The market

for sand in turn has been experiencing major difficulties in maintaining a consistent supply Presently one of the mainchallenges the industry faces is the large amount of pebbles that are obtained in the process of extracting sand at timesconstituting nearly 50 of the volume of material dredged from riverbeds

TEXT Sheila Ivers PHOTO Areia amp Cia

also that it opened up new

market opportunities for Areiaamp Cia Thatrsquos the standard we

seek to deliver to our custom-

ersrdquo states Luiz Oliveira Techni-

cal Salesperson of Metso Brazil

HP cones entering the

Brazilian sand-making

market

Todayrsquos cones such as theHP200 have high resistance

to impacts and abrasiveness

more efficient crushing cham-

bers low maintenance costsand excellent productivity

Following the acquisition of

the HP200 Areia amp Cia is now

also producing special sands

that command a price that is100 higher than common

sand The entire stockpile of

pebbles accumulated through-out the companyrsquos 20 years of

operations has already been

transformed into sand and the

stock of pebbles held by com-

petitors is also being purchasedfor processing

Cristiane Brizolari the

owner of Areia amp Cia confirms

the transformation that has taken place in

the production and commercial processldquoThe HP200 opened up new niches in

the market enabling the production of dif-

ferent types of sand with added valuerdquo

More info

Luiz Oliveira

Tel +55 011 9971 3603

luizoliveirametsocom

After the pebbles are crushed into sand with the HP200 cone crusherdifferent grades are screened for various end uses

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Where therersquos a will we dig a wayAFCONS-Strabag and Metso embark on tunnel project together

When the joint venture AFCONS-Strabag initiated work on the Rohtang bypass tunnel project at an altitude of 3980 metersabove sea level in Himachal Pradesh India they deliberated each aspect with clockwork precision The project involved anumber of surprises and challenges and required technology and project management skills that were second to none

TEXT amp PHOTOS Monisha Majumdar

Cutting a 10-meter-wide and nearly 9-kilo-

meter-long tunnel through the Himalayas

in one of the toughest terrains and cli-mates in India makes for quite a challengeResults set out to find out how AFCONS-

Strabag and Metso are making their way in

one of their most critical projects to date

The only road connection to the north-Indian border region of the province

Himachal-Pradesh and beyond the Manali-

Leh highway leads across the Rohtang

pass Due to the heavy snowfall and high-

velocity winds in this region the towns

located north of the pass are cut off from

the rest of the country during winter for atleast four often even six months each year

A tunnel with strategic importance

With the construction of the tunnel at

3100 m above sea level the Manali-Lehhighway will become an all-weather road

thereby enabling a significant improve-

ment in the economic development of

northern Himachal-Pradesh and an alter-

nate route to the strategically important

Ladakh region

Manali south of the pass is an alreadywell-developed tourist location that is

becoming more and more popular Upon

completion of the tunnel it is likely that

tourist activities will extend to the areanorth of the pass Moreover the tunnel

shortens the distance between the towns

of Manali and Leh by approximately 45 km

thus saving several hours on the small dan-gerous pass road

The Rohtang pass in the Western Himalaya

region of Northern India with its altitude ofalmost four kilometers ranks among thehighest trafficable passes in the world

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983122983141983152983151983154983156983145983150983143 983154983141983155

The 88-km long horse-shoe-shaped

tunnel provides space for a two-lane8-m-wide carriageway as well as a one-

meter-wide footpath on both sides A

22-m-high and 36-m-wide emergency

tunnel will be integrated in the tun-

nel cross-section Altogether more than

800000 msup3 of rock will be moved Tunneling works started around spring

2010 with excavation driven from both por-

tals As the north portal is inaccessible dur-ing winter closure the excavation focused

on the south After a planned construction

period of 55 years the tunnel is scheduled

to be completed by the end of 2015

Best man for the job

The BRO (Border Road Organization)

wanted to roll out a global tender for theproject due to the challenges that such a

project involves and also considering thatitrsquos the first time in India that a project of

this scale was to be carried out This imme-

diately triggered the need to roll out aglobal tender All major Indian construction

companies bid for it some individually and

some in partnerships

Strabag an Austrian tunnel specialistwas one of the companies who bid for the

project along with AFCONS a Mumbai-

based infrastructure company In Septem-

ber 2009 AFCONS-Strabag was awardedthe contract

Mr Sunil Tyagi Deputy Project Man-ager at AFCONS had this to say about the

unique projectldquoThis project is located in the Himalayas

and as far as we understand the terrain

there is among the toughest We came out

with a new technology and to be honestit is a fairly simple one We would generally

start with the traditional technology of drill-

ing and blasting and then obtain our muck

feed from the inwardbottom of the tunnelrdquo

ldquoThe technology is supplied by Rowa Tunneling Logistics and this is the first

time it is being used in Asia A jaw crusheris placed at a distance of about 40-45

meters behind the face The blasted muckextracted from the face is fed to the crusher

to reduce the lump size and then through

an overhead conveyor transport system

it is then transported out of the tunnelrdquoldquoThis enables free movement of man

and machinery in the lower area or spe-

cifically on the ground area If we were to

conforms to the Indian standard for fines amp

coarse aggregates as prescribed in IS383-1970

The plant was up and running in good

condition and performing to AFCONSrsquos

satisfactionldquoWe have worked with Metso in earlier

projects and are quite impressed by thekind of technology amp services they provide

We have a history together so the trust fac-tor also comes inrdquo explains Dhiman on their

choice of Metso as a partner

Service makes the difference

ldquoMetsorsquos services have made a big dif-ference in the project Without them we

would still be struggling with the machin-

ery and production The service is really

good and the service engineers are knowl-edgeable prompt and quick to act Any

problem can be solved by Metso We donrsquothave to wait until a service engineer turns

up ndash they have the capacity to solve prob-lems over the phone as wellrdquo says Dhiman

ldquoThe Metso plant didnrsquot create any prob-

lems for us We had problems in logistics

the feed was sticky and the weather condi-tions were bad but thankfully we did not

face any problems with production and

efficiency as the Metso plant is performing

very wellrdquo Dhiman concludes

More info

Amol Sinha Tel +91 9811 671 924

amolsinhametsocom

use the old conventional technology this

wouldnrsquot have worked for us in the stipu-lated timerdquo Mr Tyagi adds

When the going gets tough

partner with the toughest

Sensitive projects require the best technol-

ogy After AFCONS-Strabag landed theproject Metso was an obvious choice as a

technology provider not only because of

the long-standing business relationshipbut also for the sheer consistency in prod-

uct quality and service deliverance Metso

strives for

ldquoAfter signing the project we faced alot of road blocks including extreme cold

avalanches roadblocks less oxygen ndash you

name it we faced itrdquo explains Ankit Dhi-

man Plant Manager at AFCONS-Strabag The Rohtang valley is known for its

notorious avalanches and landslides SoAFCONS had to take extra steps and safety

precautions against hazards on the site

ldquoIn this freezing cold not just us humansbut also the machines are at increased risk

of damage I remember when we used

to run the plant during winter the diesel

engines would freeze We had to constantlyheat up the fuel container to get the plant

running And even the sand in the sand

trap would freeze so we had to clean it on

a daily basis to stop the pipes from mal-functioningrdquo Dhiman adds

Plant designed for difficult terrain

Difficult terrain coupled with space con-straints led Metso engineers to put their

minds together to come up with a suitable

plant configuration After studying the

requirements of the project Metso sug-

gested a 150-tons-per-hour three-stagemodular plant using a C106 jaw crusher

a GP11F secondary cone crusher and a

B7150 tertiary vertical shaft impact crusher

In addition considering the unpredict-ability of the feed the plant was about

to reach a point where the amount offines to be handled could be increased

dramatically Metso strongly suggested the TK11-27-3V grizzly scalper and this became

the first-ever TK scalper to be supplied by

Metso to an Indian customer Also in order

to get better products a sand trap SF2360was added to the configuration

The sand trap is important equipment

for this project as it washes the sand thatMr Sunil Tyagi Deputy Project ManagerAFCONS-Strabag

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Smooth transition to new-generation jaw crusher in Germany

Roumlhrig is a German company with a rich heritage The company has been quarrying granite at its plant in Bergstrasse inthe Sonderbach district of Heppenheim for three generations

TEXT amp PHOTOS Ralf Goffin

Roumlhrigrsquos superior product variety is onereason why the companyrsquos proximity to its

customers can be understood in more than

just physical terms The companyrsquos high

level of innovation has allowed it to estab-lish itself as a reliable supplier of materials

both regionally and internationally This

operational and technical expertise always

manages to keep in step with growing

market requirements

In terms of technical processing equip-

ment Roumlhrig has used a Nordberg C160stationary jaw crusher from Metso since

1992 At the start of 2012 it was finally

exchanged for a more up-to-date version

from the same model range

Metsorsquos C Series is specifically designed

to pre-crush hard rock and can cope effort-

lessly with even the hardest of materials

The dimensions of the new stationary jawcrusher are identical to those of the old

one which means that it could simply be

slotted into the housing vacated by the

previous version

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155

Third-generation Managing DirectorMarco Roumlhrig expects the new machinersquos

service life to be just as long as the previ-

ous model due to the product upgrades

that have been implemented The integral motor base is another plus

point in models made by other manu-

facturers it is located outside the crusher

This element of good fortune ensured that

Roumlhrig could reuse the housing withoutany additional rebuilding

Another advantage lies in the revision

of the guards for the C160rsquos drivetrain andflywheel The sturdier construction method

used for the crusher requires fewer parts

which facilitates easier installation andmaintenance and it makes it simpler to

access the motor

Under the watchful eye of Metsorsquos

Assembly Manager Maik Engelstaumltterthe entire project including removal and

installation was successfully completed

within two weeks

Installation making the most

of the available space

Roumlhrig will likely remember the day the

new crusher was installed for a long time

the pitman and main frame were deliveredseparately prior to installation and assem-

bled on site It took just one hour to replace

the old stationary crusher with the new

model A lorry-mounted crane was used toposition the 85-ton crusher with millimeter

precision in the crushing plant Once the

new crusher had been positioned in theexisting steel structure the next task wasto fix it into place as securely as possible

despite the limited space Special vibration

dampers were installed at a height of two

meters to prevent the crusher from sliding

Norbert Ried (fourth from left) installed thenew C160rsquos predecessor 20 years ago and isdelighted at the durability of the powerfulcrusher that is now making way for a newermodel Also pictured from left to right ManagerVolker Angermann Assembly Manager Maik

Engelstaumltter Technical Manager Stefan

Koob Project Manager Dominic SchoumlnhardtManaging Director Marco Roumlhrig Service

Technician Stefan Kolze and employees ofthe installation company Stafemo

On the hook after theold C160 was liftedout by crane the newcrusher was installedin almost no timeOnly the roof of thehousing had to beremoved

sideways off its mount An initial test run

with materials was carried out around oneweek later after all the electrical cables had

been installed

Simultaneously with the installation

of the C160 which is the first of the latest

generation of crushers to be installed in

Germany a new Nordberg GP100 conecrusher was also being installed in Roumlhrigrsquos

chipping plant Roumlhrig is convinced that

the technical improvements made tothe new Metso crusher can only be an

advantage worldwide

Roumlhrig places great value on consistent

product quality maximum added valueand optimum refinement of its product

range Bearing in mind that Roumlhrig has

enough reserves of raw material to last

for the next 150 years the company canconfidently continue to develop with an

emphasis on quality rather than quantity

More info

Dominic Schoenhardt

Tel +49 (0)621 727 00 610

dominicschoenhardtmetsocom

8132019 Results Minerals Aggregates 3 2012ENG

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Groupe Charier Carriegravere de la Mariais France

Quarrying with certi1047297ed quality The Charier Group with its 1600-strong workforce is a family business thatthis year celebrates 115 years of quarrying The company pursues a long-termdevelopment policy that since 2007 has seen processing installations upgradedat 4 of its 9 extraction sites

TEXT Liliane Boutin (with extracts from Mines amp Carriegraveres and Terrassements amp Carriegraveres magazines)PHOTO Baloon photo

The processing installation is of the horizontal type with a primary station located 56 meters below the site access road to keep it hidden from view

The crushing and screening installation at

Charierrsquos CM La Mariais quarry (at Donges

on the Loire estuary) has been in opera-tion since September 2011 Based on theoperatorrsquos ideas it was designed by Metso

to replace a worn-out installation installed

right on top of the seam being extracted

Since its commissioning it has becomethe second quarry in the company to

receive ISO 14 001 certification

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983122983141983152983151983154983156983145983150983143 983154983141983155

tertiary material of sand and gravel for the

local market to use in concrete surfacingprefabrication etcrdquo

Incorporation of a screening station

The stone extracted from La Mariais is

according to the quarry granitic gneiss

sound and homogeneous with a LosAngeles index of 15 good wear resist-

ance with an MDE of 10 a true density of

265 and a certain abrasiveness (2000 gt)ldquoCharacteristically it has a tendency to form

blocksrdquo Leblin points out

The main criteria in designing the instal-

lation was to provide an output of 600000metric tons from one station (38 hours

week) to produce materials aimed at the

concrete and surfacing markets ldquowhich

involved providing a tertiary station withscreening plantrdquo he adds

With this new unit the operating com-pany expands its product range through

the addition of fine materials obtained

from the tertiary screening station This unitis capable of producing 170 tonshour of

020

Preserving the environment

and optimizing safety

The screens have motorized bogies and

retractable walkways to facilitate access

when the screens are opened for main-tenance Other walkways provide access

to the tunnel input feeders The feederscan be isolated with hydraulic rod gate

bars this hydraulic assistance eliminatesthe need to use a heavy hammer to lodge

these metal bars

All conveyors transporting fines (02

and 04) are covered with a tarpaulin to

avoid flying dust and all the screens arehooded (metal cover with Trellex seal-

ing) The Brunone company has installed

dust-tight containment at the outlet of the

tertiary station crushers (HP300 and HP4)on the belt located under the screens

and under the hoppers located belowthe tertiary screens The crushers are put

under negative pressure and the finesare extracted through sleeve filters (7000

m3 h) with declogging which deposits the

dust back onto the conveyor belt

A high-pressure 100 bar water mist sys-tem has been installed at the primary sta-

tion discharge at the secondary crusherrsquos

discharge chutes (Omnicone) and at the

transfer points on the belt

Designed to last

ldquoThis type of new installation can easily last

thirty yearsrdquo affirms Project Leader Bruno

Peix of Metso ldquoIt quite simply depends on

how well it is maintained Thatrsquos why weprovide maintenance contracts that call for

our technicians to make regular inspection

visits and carry out preventive mainte-nance and any necessary repairsrdquo

In 2011 Metso commissioned about

10 new processing units in France like

the one at La Mariais quarry

More info

Frederic Bazire

Tel +33 (0)681442804

fredericbaziremetsocom

Key figures

DURATION OF WORKS 15 months

DRAWING OFFICE TIME 7800 hours

HEIGHT OF SILOS AND GRINDER BUILDINGS

15 m

TOTAL LENGTH OF CONVEYORS 14 km

WEIGHT OF THE INSTALLATION

1200 metric tons

CONCRETE POURED 1800 cubic meters

PROJECT SITE WORKFORCE 30

INSTALLED POWER 2200 kW(not including pumps 200 kW)

METSO EQUIPMENT

Primary

Vibrating feeder PF561-2V

Primary grizzly VG540-3V

Grizzly feeder TK13-20-3V

Jaw crusher C145 with

hydraulic setting

Secondary

Vibrating screen CVB 2050

refurbished

Cone crusher Omnicocircne 1352 SX

with Metso IC7000 controller Ellivar 16 (16 msup2 3 decks) screen

refurbished by Metso

Tertiary

Cone crusher HP300

Cone crusher HP4

2 Ellivar 20 screens (20 m23 decks) for final products

Expanding the production range

ldquoSince the mid-1990s when we became

owners of La Mariais we had used mobilemachinery with an assembly of beltconveyorsrdquo recalls Daniel Leblin Charierrsquos

Technical Manager for site construction

and maintenance

ldquoIt became clear that we needed ahigher performance tool to achieve the

dual goals of reaching one million metric

tonsrsquo maximum production and producing

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Big Lokotrack LT550GPF boostsquarrying productivity by a thirdMaximizing the productivity of operations is a key issue when striving for cost-effective quarrying Big Lokotracks are oneway to achieve improved operational efficiency The Lokotrack LT550GPF equipped with the high-volume GP550 conecrusher and a large screen is popular in the Nordic countries and in Germany and Australia ndash countries all known for theirhigh quarrying volumes

TEXT amp PHOTOS Eero Haumlmaumllaumlinen

Kone-Kostamorsquos new mobile coneplant has reached an averagecapacity of 300 tons per hour

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155

ldquoWith the same number of employees we

can achieve 30 more productivity with

our new LT550GPF unit The high-capacityFS screen has also eliminated the bottle-neck often seen at fine screeningrdquo says

Aarno Kostamo Managing Director of

Kone-Kostamo Oy one of Finlandrsquos biggest

crushing contractorsAccording to Kostamo the high capacity

of the GP550 gyratory cone crusher easily

handles feed from the C120 and C125 jaw

crushers For the contract with the Talvivaara

nickel mine the LT550GPF is being fed bythe brand new Lokotrack LT120 jaw plant

Average capacity 300 tons per hour

Talvivaara Europersquos largest nickel mine uti-

lizes large quantities of aggregates Kone-Kostamo has contracted several million

tons of different end products for the mineIn August 75000 tons of 0ndash63 mm

road gravel was crushed Smaller amountsof finer 0ndash6 mm 0ndash16 mm and 0ndash32 mm

aggregates are also being produced

The rainy summer increased the need

for road gravel along the muddy roadswhich must endure dump trucks weighing

as much as 260 tons

ldquoThe mobile process consisting of the

LT120 jaw plant and LT550GPF cone plant

is cost-effective while aggregates of vari-ous sizes can be produced in a two-stage

operation and with high capacity The con-trolled stroke and elliptical movement of

the FS screen secure big passing throughcapacitiesrdquo Kostamo explains

Operated in two shifts for a total of 16

hours per day the LT550GPF has logged

more than 600 working hours over a two-month period

Managing Director Aarno Kostamo (left) and foreman Karri Maumlenpaumlauml studying the cavity optionsavailable for the new Lokotrack LT550GPF

Longer perspective than

a single quarter needed

Kone-Kostamo Oy was founded as an

earth-moving company in Kemijaumlrvi

Northern Finland in 1956 The company

expanded its operations to include crush-

ing contracting in 1964 and later on

switched to concentrating fully on crush-ing activities

Kone-Kostamo consistently crushes

and screens around 28 million tons ofaggregates annually and has net sales of

between EUR 8ndash9 million

ldquoWe believe that issues within the crush-

ing industry including the purchasing ofmachinery must be studied with a longer

perspective than a single quarter The

secret to our success has always been our

solid work ethic and professional employ-eesrdquo Kostamo sums up

More info

Esa Berg

Tel + 358 40 837 8692

esabergmetsocom

8132019 Results Minerals Aggregates 3 2012ENG

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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155

Monitoring-based reporting is vital for

assessing the performance of a mobile

crushing plant Metso provides suchreporting tools through its plant-wideautomation system Metso DNA (Dynamic

Network of Applications) with its infor-

mation platform that links all the mobile

crushing and screen units together as oneentity Basically there is a lot of measured

real-time information available in every

crushing plant On-line information is

obtained either from each Metso crusherrsquosmachine automation system IC (Intelligent

Controller) or from separately installed

additional sensors and belt scales

All the collected data is sent to a motorhome using wireless communication

based on WLAN technology The motor

home is a purpose-built environment

inside an on-site container In this environ-ment selected variables can be monitored

for assessing the plantrsquos performance And

to make all this even more flexible the

data can be transmitted to a crushing plant

company office using GPRS3G mobile

data communication technologies Thismakes all the last-minute reports acces-sible to the crushing plant managerial staff

at anytime and basically anywhere within

reach of the cell phone network

Production and fuel economics reports

Essentially monitoring and reporting can

be customized to fit the customerrsquos needs

However there are certain off-the-shelf

reports that provide a lot of useful informa-tion for plant supervision The production

report is one of these Requiring at least one

belt scale for measuring the total produc-tion the production report shows the pro-duction rate (tons per hour) for a selected

reporting period eg a day or a week The

production report constantly keeps track of

the plantrsquos production storing all the datathroughout the plantrsquos life cycle

Performance monitoring and reportingfor a mobile crushing plantTEXT Pasi Airikka PHOTOS Metso

unit during which the unit is running By

storing the availability times between start-ups and shutdowns the crushing plant

operation time (hours per dayshift) can be

recorded analyzed and reported In addi-

tion the availability report can be tailored

to evaluate efficient crushing hours during

which the plant is really working and pro-ducing aggregates Consequently the ratio

(0-100) between efficient crushing time

and total running time can be reported forany selected period of time This boosts

the efficiency of the plantrsquos operations

and results in better productivity

Reports on non-choke

or inadequate feeding

Non-choke feeding to crushers is avoid-

able through smart plant-wide crushingplant controls But estimating its severity in

a systematic manner is not straight-forwardwithout constant monitoring and reporting

The crusher choke feeding report makes

use of the crusher cavity level sensors byanalyzing their level measurements By

calculating average and min-max values

and deviations from the average it can be

shown how often the single crusher suffersfrom non-choke feeding to it

In some cases the bottleneck in the

crushing plantrsquos productivity is the material

feeding to the process In mobile plants thefeeding is human operated and therefore

subject to variations Occasionally the sizeof the human-operated machine simply

does not allow for adequate feeding to thecrushing plant There are specific reports

indicating time periods when the crushing

plant suffers from inadequate feeding

Condition monitoring for

crushers and screens

Machine-specific condition monitoring

focuses on vibrating components in

crushers and screens such as drive shaftbearings safety plate wearings and gears

The low middle and high frequencies ofmonitored components are measured and

supervised in real-time to detect abnor-malities due to slow or fast wear looseness

or imbalance

More info

Pasi Airikka

Tel +358 40 587 2730

pasiairikkametsocom

Condition monitoring provides a view tovibrating crusher and screen components forpredictive equipment maintenance

The daily production report shows the hour-by-hour production trend and distribution chartfor a selected day with min-max average andvariation statistics for comparison

Fuel consumption is always an interest-ing concern The fuel consumption reportgives the fuel consumption of each crush-

ing unit (liters per hour) and their total

consumption (liters per hour) for a selected

reporting period and can track fuel con-

sumption changes over timeCrushing plant availability can be

assessed as well The availability report

calculates time periods for each crushing

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983149983141983156983155983151 983150

for tissue machines The record of 2210

mmin was set on June 1 2012 during a

24-hour production run by the TM 2 tissue

machine at the companyrsquos mill in Yenikoumlynear the city of Izmit in Turkey

ldquoThe cooperation with Metso has been

beyond excellent and both parties did

their utmost to make the project success-ful The results clearly show that the efforts

were worthwhile on both sides This coop-

eration will extend to cover new projects

in the futurerdquo says Luumlt1047297 Aydin Paper GroupDirector Hayat Kimya

ldquoWe are not surprised that Hayat K imya

managed to break the world speed record

We have had great confidence in the capa-bility of the Hayat team since our project

started in 2009 We certainly know our

machine very well its stability production

efficiency and speed capabilityrdquo says Jan

Erikson Vice President Sales Metso

PowerThe worldrsquos first eco-gas fueled

power plant is up and running

Lahti Energy Ltdrsquos new Kymijaumlrvi II gasifica-

tion plant was officially inaugurated on

May 8 2012 It is the first of its kind in the

RecyclingRecycling with Lokotrack LT106

jaw plant in New York

A brand-new Lokotrack LT106 jaw plant is

used in the city area of New York USA to

recycle demolition materials The crushing

site faces the skyscrapers of ManhattanIsland

Paper amp FiberHayat Kimyarsquos Metso-supplied tissue

machine sets world speed record

Thanks to a skilled crew and dedicated

efforts Hayat Kimya AS in Turkey has suc-

ceeded in breaking the world speed record

world This CHP plant runs on clean eco-

gas that is gasified cleaned and cooled

from recycled waste with Metsorsquos innova-tive technology

ldquoItrsquos actually eco-gas that we combust

in the boilerrdquo comments Lahti EnergyrsquosProduction Director Jukka Manskinen

ldquoWe convert unwanted waste material into

energy in an efficient and environmentally

friendly wayrdquoNever before has any plant gasified

waste on such a large scale In the gasifier

recycled waste is turned into combustible

product gas which is cleaned cooled and

combusted in a high-efficiency gas boiler

to produce steam for the steam turbine The plant produces 50 MW of electricity

and 90 MW of district heat for the city of

Lahti and its neighboring areasMetso delivered the circulating fluidized

bed (CFB) gasification process gas cleaning

and cooling steam boiler environmental

protection system and automation systemto the entire plant The production of elec-

tricity and heat is kept even with the Metso

DNA automation system that covers the

whole plant starting from fuel reception

AutomationMetso develops and supplies plant-

wide crushing control solutions for

crushing plants

Metso has recently signed contracts on

delivering plant-wide automation systems

for mobile and portable rock crushing

plants The key objective of these deliveries

is to stabilize and to increase productivityand efficiency of the plants using one sin-

gle automation and information platform

for integrating crusher-specific IC machinecontrols

Furthermore the plant-wide system

with its information management tools not

only increases plant availability and opera-

tional safety it also makes troubleshoot-ing quicker and performance monitoring

easier The control room for plant-wide

operability is located either in an excavator

cabin or a purpose-built container

Metso around the world

The new LT106 jaw plant is suitable for crushing both hard rock and all rock-based demolition materials

The new world speed record for tissue setby Hayat Kimyarsquos Metso-supplied TM 2 is2210 mmin

8132019 Results Minerals Aggregates 3 2012ENG

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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: Results Minerals Aggregates 3 2012.ENG

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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155

The newest member of the proven GP series cone crushers ndash theNordberg GP220 ndash offers a versatile alternative for any demanding

tertiary or quaternary or even secondary crushing operation fulfill-

ing all crushing needs and maximizing customersrsquo profitability

High-quality components and optimized castings and forgings

contribute to the GP220rsquos enhanced reliability and help to ensurethe highest level of crusher uptime

Thanks to the 200 kW (270 hp) power draw the GP220 performs

at a 20 to 30 percent higher capacity than other cone crusherbrands with an equal head diameter The large feed openingenables the feeding jaw crusher to run at 110 mm css Operational

flexibility is ensured by multiple strokes and six different cavities

Secondary crushing possible

thanks to cavity and stroke options

Thanks to the GP220rsquos cavity and stroke options secondary crush-

ing in addition to tertiary and quaternary stages is also possible

using cavities with a greater intake opening With the GP220 a suit-

able solution for producing excellent end-product gradations

can always be found

With advanced automation using IC50 or IC5000 operation

is safe and trouble-free The low height thanks to the patented

piston design makes replacement installations much easierA dynamic setting adjustment enables a fast response to process

optimization needs

The Nordberg GP220 weighs 10500 kg (23150 lbs) and hasa maximum real feed size of +200 mm (8rdquo) with strokes from

18ndash40 mm (57rdquondash1 47rdquo) The cavity options are EF F MF M C

and EC

A complete modular crusher steel structure is available for allGP series stationary installations including GP220 The platform

includes places for the lubrication unit motor automation or

pressure accumulator and pressurized sealing The only things

left to add are the feed and discharge conveyors

Main new features of the GP220 Large feed opening allows for secondary stage operation

Longer setting range of main shaft for better wear parts utilization

Stronger main components to carry high loads with a powerdraw as high as 200kW

More info

Hannu Vakkuri

Tel +358 50 317 0638

hannuvakkurimetsocom

Thanks to the large feed opening and wide selection of strokes and cavitiesthe new Nordberg GP220 cone crusher is a highly versatile cone novelty

More versatility with the newNordberg GP220 cone crusher

Reinforced head and frame castings combined with a 200kW power

draw make the GP220 cone a reliable crusher with maximum productivity

8132019 Results Minerals Aggregates 3 2012ENG

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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156

Metsorsquos HRCtrade takes high pressure grinding roll technology to the next level

The new Lokotrack mobile conveyors come as tracked and wheeled models

Metsorsquos latest development in comminution equipment the HRCtradeis a major step in the profitable application of high-pressure grind-

ing roll (HPGR) technology Metso has made several key innova-

tions in order to increase throughput and decrease the total cost

of operation

Metsorsquos patented Arch frame creates an even gap setting acrossthe width of the tires limiting skewing that can result in downtime

for mining operations This anti-skewing Arch frame also prevents

damage to the roller bearings (caused by misalignment) that canoccur with the traditional HPGR design

Flanges maximize wear life and increase throughput

Used in place of spring-loaded cheek plates the flanges keep thebed of material within the crushing zone and prevent material

from bypassing the tires This enables greater circuit capacity and

increases the overall crushing efficiency

In addition by preventing material from bypassing the tires

even pressure across the width of the tire is better maintained

Distributing the pressure more evenly maximizes the tire life bypreventing a ldquobath tub effectrdquo in which the center of the tire wears

faster than the edgesVictoria Herman Metsorsquos Product Manager for the HRC notes

that this breakthrough design is a response to the growing needs

in the mining industry ldquoEnergy efficiency has been attracting our

customers to HPGR technology for yearsrdquo she says ldquoBut our design

concept increases capacity and crushing efficiency ndash and thatrsquossomething mining companies are always looking to improve onrdquo

The track-mounted Lokotrack CT32 and wheel-mounted Lokotrack

CW32 mobile conveyors offer an ideal solution for applications

that require high stockpile capacity and excellent material transfer

capabilities They also add flexibility to multi-stage crushing andscreening applications enabling easy and fast closed-circuit opera-

tion of mobile units

The conveyor novelties can be used in both mobile and station-

ary installations providing extra stockpiling capacity in situationswhere for example fewer wheel loaders are available

The HRC is ideal for high-tonnage hard rock applications andcan be used as a tertiary quaternary or pebble crusher Currently

several HRC units are in operation around the world ndash with a total

of 6500 operating hours including over 3800 hours in a mininghard rock application The machine does have range within hardrock applications itrsquos been designed for use in diamond iron ore

copper gold platinum and various industrial minerals

More info

Victoria Herman

Tel +1 717 309 1150

victoriahermanmetsocom

Several optional features such as hydraulic folding of tail sections

and dual hydraulic drive for increased throughput are available

The capacity of the CT32 and CW32 is 400 mtph (440 stph)feed size up to 150 mm (6rdquo) belt width 1050 mm (42rdquo) and dis-charge height 9120 mm (29rsquo 11rdquo) The CT32 is fitted with a Caterpil-

lar C2 diesel engine with 38kw (51 HP) power The CW32 is avail-

able for hydraulic or electric use

More info

Kimmo Anttila

Tel +358 50 433 3745

kimmoanttilametsocom

The new HRCtrade combines high crushing pressure and a low circulatingload resulting in the most efficient comminution

When flexibility in stockpiling capacityis required the answer can be foundin the new Lokotrack CT32 and

CW32 mobile conveyors

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Service creates value in ChinaChinarsquos most important gold producing area Yantai in northeastern China supplies more than 16 of the countryrsquos goldproduction each year With the gold market thriving the scale of gold production in Yantai has been expanding constantly

Zhongjia Mining Industry Co Ltd is one of the beneficiaries of this thriving industryTEXT amp PHOTOS Yan Xin

Inspection and maintenance of the HP500 cone crusher conducted by Metsorsquos service engineers

In 2011 Zhongjia Mining Industry pur-

chased a modular crushing and screen-ing system from Metso for its new gold

production project With the cooperation

between the two companies continuously

intensifying Zhongjia Mining Industry

signed an additional one-year Life CycleService (LCS) contract with Metso incorpo-

rating Metsorsquos global knowledge in equip-

ment processes and services

ldquoMetso customized a series of reason-

able service solutions also referred toas Metso Performance Solutions for us

including preventive maintenance services

process improvement personnel training

8132019 Results Minerals Aggregates 3 2012ENG

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and a procurement plan for wear parts

These really suit our needs perfectlyrdquo saysShen Yidong the Manager of ZhongjiaMining Industry

Effective preventive maintenanceFor mining corporations the biggestconcern is the economic losses caused by

the shutdown of equipment As a result

preventative maintenance is of vital impor-

tance During the contract period Metsoservice engineers offered 7-day tracking

service on the production site every month

to eliminate potential problems and thus

ensured the stability of the system

parts caused pressure on our working capi-tal which was not favorable for our long-

term developmentrdquo Shen explains

To solve this problem Metso designed

a rational stock plan of wear parts and built

a field warehouse In accordance with theuse and consumption of the liners the field

service engineers complement the stock tomake production and operations run more

smoothlyldquoNow when we need to replace the

wear parts we can use them before pay-

ment This not only simplifies the procure-

ment process but also liberates a largesum of our operating capital which can

be used for other business development

purposesrdquo says Shen

Best partner

ldquoAlthough the LCS contract incurs some

early purchase costs in the long run Metsorsquosprofessional and quality service will improve

the equipment efficiency reduce ourenergy consumption and ensure stable

operations thus generating more prof-

its This is the greatest value for us so the

investment is really worthwhile overall Inthe future we will choose more Metso prod-

ucts and services Taking all aspects into

consideration we believe Metso is the best

partner for usrdquo Shen Yidong concludes

More info

Thomas Bai Tel +86 13801009114

thomasbaimetsocom

ldquoIn the eight months since the contract

came into effect our corporation has notsuffered any financial losses due to equip-

ment breakdown The regular maintenance

has greatly improved the efficiency of our

entire crushing system In addition the

experienced engineers from Metso also

provided onsite training and guidancefor our staff and the tailored training has

greatly enhanced the operating abilities of

our employees and upgraded their overalllevel of competencerdquo says Shen Yidong

More productivity with

less consumption

Metsorsquos service contract focuses on real-

izing the optimum performance of each

process flow After analyzing Zhongjiarsquos

production system Metsorsquos techniciansproposed an adjustment to the closed side

setting of the HP500 for tertiary crushingin order to improve the efficiency of the

downstream fine crushing and milling pro-

cessing by over 10ldquoThe process flow improvement solu-

tions provided by Metso not only increased

the output of our gold concentrates but

also reduced our energy consumption andcostsrdquo says Shen

In the past wear parts procurement

took up a larger proportion of Zhongjiarsquos

total production costsldquoTo avoid downtime caused by the

shortage of wear parts we had to keepeight sets of various wear parts in place

However the cost of having so many wear

Zhongjia Mining Industryrsquos gold concentrates processing plant in China

8132019 Results Minerals Aggregates 3 2012ENG

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0983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

Safe quarrying high-

quality aggregates

8132019 Results Minerals Aggregates 3 2012ENG

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ldquoWe share a similar zero-accident strategy and target with Metso and have successfullyfollowed it Metso has also helped us to meet the strictest end-product quality andcubicity requirements set in Spainrdquo This is how Managing Director Intildeigo Ajuria ofOfitas de San Felices the leading hard rock quarrying company in Spain describesthe cooperation with MetsoTEXT Eero Haumlmaumllaumlinen PHOTOS Ofitas and Eero Haumlmaumllaumlinen

The San Felices quarry is situated in a picturesque mountainous landscapebetween the companyrsquos Rioja vineyards and the Bilbao-Madrid motorway

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Ofitas has pioneered the implementation

of several Metso novelties in the Spanish

market The company was the first to use

efficient large track-mounted Lokotrack jaw plants the unique mobile conveying

system and also the new-generation HP4

cone crushers

Today the company operates twomodern Metso stationary plants one in

Guadix near Granada and the newest one

in San Felices Haro Rioja community Both

quarries focus on refining hard rock by pro-cessing ophite rock into the highest quality

railway ballast asphalt and concrete mix

grades The company has a satellite quarry

near Vitoria in PentildeacerradaBeing situated next to a highway and

the famous Rioja vineyards Ofitas must pay

special attention to environmental issues

To minimize dust problems all conveyors

have special covers attached

Quality durability and service

The cooperation between Ofitas de San

Felices and Metso started back in 1973when the Ajuria family bought the com-

pany whose quarrying activities began in

1919 Intildeigo Ajuria has a clear vision of why

the cooperation has continued withoutinterruption for almost 40 years

long-standing personal relationshipsrdquoAjuria adds

Serving railways asphalt

and concrete producers

The year-old San Felices stationary instal-lation lies hidden in a mountainous area

south of the city of Vitoria in NorthernSpain The new plant replaces an old one

that complicated the extraction of ophiterock Both plants are delivered by Metso

With its two separate production lines

the new plant is able to produce all the

end products required ndash from railway bal-last to the finer grades needed for asphalt

and concrete

Due to lower demand the quarry cur-

rently produces some 4000 tons per day

At full capacity however the plant canreach 8000 tons of production per day

30ndash35 of which consists of railway ballastfor high-speed trains and 65ndash70 of chips

and sand Thanks to the versatile two-line con-

cept connected by transverse conveyors

up to 12 different end products can be pro-

duced Depending on the demand for endproducts the material can be guided either

to the HP4 cone or HP400 cone followed

by a Barmac vertical shaft impactor

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

The ophite feed is fed to the C125 jaw crusher by a sturdy dump truck

The key people running the new San Felicesquarry Mine Engineer Carlos Fernandez (left)Managing Director Intildeigo Ajuria with ProductionManager Julian Perez

ldquoThrough the years Metso machinery

has proven its production capacity and

durability resulting in high-quality end

products A big plus for us has also beenthe quick response time to our process

challenges or servicerdquo

ldquoIn fact our cooperation extends

beyond day-to-day business matters to

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983122983141983152983151983154983156983145983150983143 983154983141983155

Meeting the strictest cubicity demands

The Spanish regulations concerning end-product cubicity are becoming more

demanding The flakiness percentage of

railway ballast must be below 10 and for

asphalt and concrete aggregates less than

15

ldquoWith Metsorsquos HP4 cone and the Barmacvertical shaft impactor we can meet even

the strictest cubicity demands We believe

that our high quality is helping us to sur-vive in the present recessionrdquo notes Mine

Engineer Carlos Fernandez

ldquoWe hope to increase the total extrac-

tion of the three quarries from the present15 million tons per year because our plant

capacity allows more than double thatrdquo

Fernandez adds

More info

Angel Luis Garcia Tel +34 686 94 35 30

angelluisgarciametsocom

In addition to being the leading Spanish

quarry to process hard rock Ofitas de SanFelices also cultivates 34 hectares of vine-yards next to the quarry which is situated

in the famous Rioja wine area

The company has previously sold a

harvest of over 200000 kg of Tempranillo

grapes to local red-wine makers Recentlythe company built its own wine process-

ing plant to process 10000ndash15000 kg of

grapes themselves

Aggregates and wine production

Andoni Ajuria the founder of Ofitas de san Felices (left) with Intildeigo Ajuria the present ManagingDirector tasting wine from the companyrsquos own vineyards

The first vintage wine of Ofitas har-

vested in autumn 2010 is now maturingin oak barrels After maturing for 12 to 15months the wine is called crianza and after

two years it will be granted the classifica-

tion reserva

ldquoWinemaking is not a business but

a hobby for us We give our wine out aspresents and drink it when we meet

our suppliers and friendsrdquo Intildeigo Ajuria

comments

For environmental protectionall of San Felicesrsquos plantconveyors are covered

Ofitas de San Felices quarry

LOCATION Haro near the city

of Vitoria northern Spain

SIZE 100 hectares

ROCK TYPE Ophite with Los Angeles

index of 9ndash10

PRESENT DAILY EXTRACTION 3000 tons

of ophiteNUMBER OF PERSONNEL 30

RESERVES 10 million tons

MAIN END PRODUCTS 0ndash2 mm

2ndash4 mm 4ndash10 mm 10ndash16 mm

16ndash22 mm 25ndash60 mm (ballast)

METSO MAIN EQUIPMENT

VF feeder

C125 jaw crusher

ndash feed size 0ndash800 mm

ndash css 130ndash140 mm

HP400 cone crusher

ndash feed size 80ndash250 mm

ndash css 40 mm HP4 cone crusher

ndash feed size 40ndash80 mm

ndash css 15 mm

Barmac 6150 VSI crusher

4 CVB2060 screens

2 TS32 screens

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Metso Distribution Centers he

Europe (Tongeren Belgium)

France (Macon)

Czech Republic (Přerov)

Austria (Vienna)

2271 d

Brazil (Sorocaba SP)

1014 d

USA (Columbia SC)

1690 d

USA (Waukesha WI)

434 d

South Africa (Vereeniging)

Ghana (Tarkwa)

Meacutexico (Irapuato)

Peru (Lima)

Chile (Concoacuten)

788 d

Sweden ( Trelleborg)

Finland (Tampere)

UK (Rugby)

865 d

Russia (St Petersburg)

Brazil (Parauapebas PA)

206 d

4983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

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In the case of an equipment failure or

a planned service shutdown resuming

production as quickly as possible is crucialEach hour spent waiting for a spare part to

arrive equals money lost Whether the right

part takes 12 or 48 hours to arrive really

makes a difference

The comprehensive and global Metsospare and wear parts service network pro-

vides you with the right part in the right

place and at the right time Our strategi-

cally located Distribution Centers and

Satellite Warehouses are on call 24 hoursa day 7 days a week ensuring efficient

parts replacement near you

Check out the locations of the MetsoDistribution Centers and how many parts

pass through them each day

More info

Marcelo Farah

Tel +55 15 2102 1315

marcelofarahmetsocom

you minimize downtime

Australia (Perth)

746 d

China (Tianjin)

China (Kunming)

China (Shanghai)

393 d

India (Faridabad)

India (Ahmedabad)

India (Hyderabad)

India (Bhubaneswar)

India (Bangalore)

419 d

Russia (Yekaterinburg)

Australia (Newcastle)

New Zealand (Matamata)

983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088

TEXT Sofia Williams

Singapore (Singapore)

Distribution Center Satellite Warehouse

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Following a large investment

in Metso crushing equipmentand services Buena Vista del

Cobre is now expanding the

mine site to include even more

equipment ndash and with thatexpansion comes the need for

more local service resources

Metso and Buena Vista del

Cobre have entered into a Life

Cycle Service agreement forthe plant and construction of a

brand new Metso service hub

is under way in Cananea

New facility new

level of service

The Cananea service hub

which will be up and running in early 2013will support the recent expansion and resur-

gence of Buena Vista del Cobre Initially it

will be a major repair and assembly center

for pumps crushers and screens and will

provide for rubber covering capabilitiesBut the 8000-square-meter facilityrsquos service

offering will be expansive including a con-

signment stock inventory to help serve theminersquos varying needs Metso currently has

50 service team members on site

Although Buena Vista del Cobre was a

key influencer in building the new servicehub this location will also enable Metso to

expand its capabilities and provide local

support to the entire mining community

in northwest Mexico The Cananea hub

will serve a number of major copper and

gold mines in the region including MineraFriscorsquos San Felipe Fresnillorsquos Milpillas and

Grupo Mexicorsquos Mexicana de Cobre

ldquoBuena Vista del Cobre is the biggestcustomer we have in Mexico today and

with this expansion project itrsquos only going

to grow and be strongerrdquo says Felix Forna-

guera Director of Services Mexico CentralAmerica and Caribbean ldquoWith that said the

idea behind the Cananea service hub is to

provide a central location for local support

for all our major customers in the areardquo

Establishing safety

ldquoIt was key to have our support here in

Cananea because the Buena Vista delCobre started from the ground uprdquo saysFelix ldquoWersquove been able to help the cus-

tomer to establish the best in support

service and operations from the very

beginningrdquo And this ground-up approachincluded a major focus on safety

Metso worked closely with Buena Vista

del Cobre to establish the safety proto-

col by which the mine operates Basedon Metsorsquos expertise the safety measures

put in place have enabled the mine to

become strict and efficient in its operations

and maintenance procedures To achievethis Metso worked closely with local andnational authorities to ensure the safety

plan was comprehensive and in accord-

ance with all established legal bodies

The best in regional support

The service hub in Cananea is a prime

example of Metsorsquos focus on providing local

service and support to its customers all

Service shines in Cananea MexicoAfter three years of inactivity the Buena Vista del Cobre mine in Cananea Sonora Mexico has been operational since 2010A mine that was inactive for such a significant amount of time however requires a great deal of support to successfullyrestart the plant and bring it back to an operational and profitable state

TEXT Deanna Lee PHOTO Metso

over the world ldquoWe are the first

company developing this kindof service in northwest Mexicordquo

adds Felix ldquoOur people have

developed a close relationship

with the team at the mine Itrsquosmore than a supplier relation-

ship our guys are inside the

mine living and working thererdquo

In fact this is the model

that Metso is using in servicehubs all over the globe build-

ing modern facilities bringing

teams on site and workinghand in hand with mine

operators The Cananea Service

hub is only the most recent

example of Metsorsquos commit-ment to service and northwest Mexico is

yet another mining hotbed thatrsquos going to

benefit from the companyrsquos support

More info

Felix Fornaguera Tel +52 4621079227

felixfornaguerametsocom

A mining cone serviced by Metso at the Buena Vista del Cobre mine inSonora Mexico

ldquoThe new Cananea service center will be a majorrepair and assembly center for pumps crushersand screensrdquo says Felix Fornaguera Director ofServices Mexico Central America and Caribbean

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

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During the MINExpo exhibition over 1300 people visited the Metso stand

983122983141983152983151983154983156983145983150983143 983154983141983155

Held every four years MIN-Expo consistently grows so

perennial exhibitors like Metso

are challenged with elevating

their presence and drawingin new (and greater numbers

of ) visitors each year ldquoItrsquos not

necessarily a challenge to lsquotoprsquo

our last showingrdquo says Keith

Ference Vice President ofmarketing and communica-

tions North America ldquoThere

are four years between eachMINExpo so we always have

a lot to say and reveal to our

customersrdquo The real challenge

he says is finding an exciting

and dynamic way to deliverthe message ldquoTherersquos so much

to see here so your booth has

to be compelling from the

outside-in and thatrsquos what

we always try to dordquo

Service sets the stage

The Metso booth created buzzin a number of ways and per-

haps the most striking (partly

due to its size) was the live

theater presentation As visitorspassed through the aisles of the show-

room the sights and sounds from Metsorsquos

theater were hard to miss And once guests

entered they were captivated by a short

high-energy video presentation focused

on Metsorsquos service capabilities The message was simple Metso is ldquoyour

local service partner rdquo for all mining and

construction needs The video showed ourservice teams in action all over the world

and the audience came away with an

understanding about Metsorsquos commitment

to service Customers can count on morethan 70 local service centers run by more

than 1700 expert technicians delivering

Metso makes an impact at MINExpo 2012At this yearrsquos MINExpo International nearly 60000 attendees flocked to Las Vegas Nevada the largest turnout in showhistory The visitors ndash mining professionals from all over the globe ndash explored 850000 square feet of showroom spacefeaturing the industry rsquos latest technology equipment products and services They toured the show for three days

seeking the latest and greatest from more than 1800 exhibitorsTEXT Keith Ference PHOTOS Tracey Ford Perry

detailed descriptions andphotos of all of Metsorsquos mining

and construction products and

services The app also provides

digital access to Results and asearchable database of sales

contacts By day three of the

show MetsoMAP had been

downloaded by more than

500 usersIn addition to the app the

booth was equipped with

several LCD screens each con-trolled by Metso experts who

used their iPads to present new

products like the Megalinertrade

and the HRCtrade A featured

presentation on Metsorsquos lineupof energy-efficient comminu-

tion equipment including the

VERTIMILLreg SMD and MP-1250

cone crusher was also avail-

able letting customers seehow Metso technology delivers

some of the worldrsquos most effi-

cient size reduction

Measuring MINExpo success

After a very busy three days

(on top of months of prepara-tion leading up to the show) everyone

involved with MINExpo ndash from the North

American marketing team responsible for

the booth to the product managers and

sales force that worked the floor ndash is view-

ing the show as a success ldquoTherersquos alwaysa sigh of relief after each (MINExpo)rdquo says

Keith ldquoAnd overall the initial feedback

and response has been very positiverdquoWith more than 1300 visitors to the

booth Metso certainly made an impact

ldquoWe learn a lot from each show and with

some time wersquoll have a better understand-ing of the tangible results of our effortsrdquo

Keith adds

reliable service for mining equipment as

well as customized cost-effective life-cycle

services contracts

Technology ndash MetsoMAP

is an industry firstMINExpo provided the industry with its firstglimpse of Metsorsquos revolutionary iPad app

MetsoMAP The app was demoed to the

boothrsquos visitors via ldquothe worldrsquos largest iPadrdquo

a custom-made 80-inch screen that show-cased all of its capabilities most of which are

groundbreaking in the industry MetsoMAPrsquos

simple interface is highly intuitive making

it easy to view process animations videos

The presentation of the new HP cone crusher attracted a large audience

8132019 Results Minerals Aggregates 3 2012ENG

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When yoursquore allowed less than a dozen days per year for breakdowns repair andmaintenance every single hour during a service shutdown counts There simplyisnrsquot any room for surprises Thatrsquos why Boliden counts on MetsoTEXT amp PHOTOS Sofia Williams

8983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

Kurt Kalla Site Managerof Metso Gaumlllivare ServiceCenter is responsible forthe maintenance of Aitik

Metso and Boliden Strivingtogether for 97 uptime

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983122983141983152983151983154983156983145983150983143 983154983141983155

One of the biggest copper mines in

Europe Bolidenrsquos Aitik is located deep inthe wilderness of Swedish Lapland next to

the small town of Gaumlllivare The mine has

been operating since 1968 and a recent

expansion has increased its annual ore

production to 36 million tons

But the ambitious Swedes are not will-ing to lay back and relax just yet Bolidenrsquos

new aim is to reach a production rate of

45 million tons of ore per year in AitikAfter that Perhaps more than 55 million

tons The ore concentration in Aitik is very

low-grade with a mere 022 copper con-

tent hence the need for high capacityAchieving the ambitious production

goal requires maximum plant availability

This means that everything from the crush-

ers to the filters must be up and runningfor approximately 97 percent of the time

Thatrsquos where Metso comes into play

A cost-per-ton contract in action

The maximum uptime requirement allowsless than a dozen days per year for break-

downs repair and maintenance at Aitik

Every single hour during a service shut-

down counts There simply isnrsquot any roomfor surprises

Executing a successful shutdown under

such conditions requires a reliable service

partner not afraid of challenges and this iswhy Boliden has entrusted Aitikrsquos services

operations to Metso Boliden and Metsohave worked together since the 1960s

and the collaboration took another step

forward in September 2012 when the twocompanies signed a three-year extension

of the services contract for Boliden Aitik

ldquoThe new contract is a cost-per-ton

agreement We get paid based on Aitikrsquos

production Itrsquos a win-win deal for both par-

ties but also a new mindset for usrdquo explainsKurt Kalla Site Manager of Metso Gaumlllivare

Service Center responsible for serving Aitik

From now on the duration of the shut-down is what matters the most According

to Kalla the Metso service organization in

Gaumlllivare is now streamlining its operations

to fit the bill and has already witnessed thestrategy working In August 2012 Metso

carried out a 188-hour service shutdown in

Aitik which turned out to be a success

Zero tolerance for injury

One key factor to the success was theextensive planning of precautionary health

safety and environment procedures under-

taken by Metso prior to the shutdown Thanks to strict measures applied no

injuries or accidents occurred during the

shutdown and the work could easily be

finished on scheduleMats Johansson Health Safety

and Environment Manager for Metso in

Sweden explains how this was achieved

rdquoPlanning of the shutdown included arisk analysis for all new tasks participating

in Bolidenrsquos safety coordination meetingsmeeting with both Metso supervisors and

subcontractor supervisors and finally a

meeting with the entire staff participating

in the shutdown where everyone had to

sign a document stating their commitmentto the information providedrdquo he says

During the actual shutdown plenty of

new barriers signs and awareness cones

were put in place as a result of observa-tions from previous audits and safety plans

and risk analyses were readily available

in the work area Metso and Boliden also

introduced a Mill Inching permit a certifi-cate for completing a mandatory course for

those involved in the process In addition

Metso carried out random safety audits

during the shutdown to make sure thestrict policy was followed

According to Boliden Metsorsquos way of

working is a good example of how health

and safety precautions should be handled

ldquoMetso is a good example of how towork with safety and health plans risk

analysis permits and welding permits

Their table with all binders in the second-

ary mill area was exemplaryrdquo says Kjell-Arne

Johansson a technician from Boliden

The use of the new Metso Megalinertrade

system in the lining of Aitikrsquos Metso AG

mills has also improved the safety of main-tenance staff The Metso Megalinertrade con-

sists of larger-than-average liners bolted

in position from outside the mill Mainte-

nance technicians no longer need to go

inside the mill and stand in the dangerousdrop-zone of the liners gt

Boliden aims to reach a production rate of 45 million tons of ore per yearin the Aitik mine site

ldquoA complete risk analysis was conducted during the planningof the shutdownrdquo comments Mats Johansson Health Safetyand Environment Manager for Metso in Sweden

8132019 Results Minerals Aggregates 3 2012ENG

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Service the Metso way

24 hours a day 365 days a year

In addition to paying close attention to

health and safety issues executing an effi-

cient shutdown requires careful planning

and timing of every step in the mainte-

nance process Wear and spare parts have

to be available on time and a repair shoplarge enough to accommodate equipment

located close by

ldquoTo keep maintenance breaks as short

as possible we aim to replace the pump on

site and bring the old one for repair to our

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

nearby facilities This method gives us the

peace to do a good job and keep the cus-

tomerrsquos operations runningrdquo Kalla describes

the Metso way of handling Aitikrsquos pump

maintenance

Metso is currently expanding its Gaumllli-

vare service center to include a distribu-

tion center for wear and spare parts andalso concentrating its previously scattered

operations under one roof in its Vuoskon-

jaumlrvivaumlgen facility The expansion is due to

be completed by 2014

Metso equipment

delivered to Aitik36

bull 2 AG mills diameter 116 x

137 m gearless 22-MW motor

bull 2 Pebble mills diameter 91 x

113m dual 5-MW pinion drive

bull 3 VPA pressure filters VPA 1540-54

bull 12 sample pumps and pipes

VF50

bull 60 Various slurry pumps up to

MR500 modelbull Appr 5000 m rubber-lined slurry

pipes up to 600 mm diameter

bull Appr 5000 m rubber-lined by

gravity pipes up to 600 mm

diameter

bull Appr 5000 m rubber hoses

up to 600 mm diameter

Not only does the expansion make ser-

vice shutdowns at Aitik run more smoothly

it guarantees a more comprehensive

on-call emergency service response in the

region ndash thanks to the spare and wear parts

inventory available 24 hours a day 365

days a year

More info

Lars Rosenling

Tel +46 70 107 45 90

larsrosenlingmetsocom

Metso grinding equipment dominates the view in the concentrator

Safety on site is made up of small things like

making sure that everyone remembers to secure

the hoses in place

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Pebbles have always been a

challenge for producers of sandsince they cannot be returned

to rivers after extraction For

decades the processing of this

material resulted in a huge

environmental liability with alarge amount of pebbles hav-

ing to be stored away and left

unused

Transforming problems into

business opportunities

Areia amp Cia (areia = sand) has

operated in this market forover 20 years and decided to

enlist the help of Metso to find

a profitable solution for the

processing of pebbles

In July 2011 analyses werebegun to assess the abrasive-

ness and crushability of the

material Four alternatives wereidentified for processing and

transforming pebbles into sand

Initially Areia amp Cia was

interested in acquiring an

impactor for its reason-able price level However the

customer wanted to process

all the pebbles that were col-

lected daily in addition to some of the

material that it had stored In weighing theresults expected by the customer and the

excessive abrasiveness of the material the

HP200 cone crusher was decided on as thebest alternative

Areia amp Cia made the required invest-

ment and after using the HP200 for just

six months the company has already beenreporting outstanding results The HP200

not only transforms pebbles into sand but

also produces sand of excellent quality

with high yield and low maintenanceWith minor adjustments the HP200

also enables the production of sand withspecific particle size distribution for special

applications such as filtering sand blasting

and foundry sand adding value to the prod-

uct and increasing the types of sand offeredldquoMetso is pleased that the HP200 not

only enabled the processing of a product

that had been set aside as unusable but

HP200 cone transforms pebblesinto high-quality sandOver the last few decades Brazilian economic growth has been driving demand for construction aggregates The market

for sand in turn has been experiencing major difficulties in maintaining a consistent supply Presently one of the mainchallenges the industry faces is the large amount of pebbles that are obtained in the process of extracting sand at timesconstituting nearly 50 of the volume of material dredged from riverbeds

TEXT Sheila Ivers PHOTO Areia amp Cia

also that it opened up new

market opportunities for Areiaamp Cia Thatrsquos the standard we

seek to deliver to our custom-

ersrdquo states Luiz Oliveira Techni-

cal Salesperson of Metso Brazil

HP cones entering the

Brazilian sand-making

market

Todayrsquos cones such as theHP200 have high resistance

to impacts and abrasiveness

more efficient crushing cham-

bers low maintenance costsand excellent productivity

Following the acquisition of

the HP200 Areia amp Cia is now

also producing special sands

that command a price that is100 higher than common

sand The entire stockpile of

pebbles accumulated through-out the companyrsquos 20 years of

operations has already been

transformed into sand and the

stock of pebbles held by com-

petitors is also being purchasedfor processing

Cristiane Brizolari the

owner of Areia amp Cia confirms

the transformation that has taken place in

the production and commercial processldquoThe HP200 opened up new niches in

the market enabling the production of dif-

ferent types of sand with added valuerdquo

More info

Luiz Oliveira

Tel +55 011 9971 3603

luizoliveirametsocom

After the pebbles are crushed into sand with the HP200 cone crusherdifferent grades are screened for various end uses

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Where therersquos a will we dig a wayAFCONS-Strabag and Metso embark on tunnel project together

When the joint venture AFCONS-Strabag initiated work on the Rohtang bypass tunnel project at an altitude of 3980 metersabove sea level in Himachal Pradesh India they deliberated each aspect with clockwork precision The project involved anumber of surprises and challenges and required technology and project management skills that were second to none

TEXT amp PHOTOS Monisha Majumdar

Cutting a 10-meter-wide and nearly 9-kilo-

meter-long tunnel through the Himalayas

in one of the toughest terrains and cli-mates in India makes for quite a challengeResults set out to find out how AFCONS-

Strabag and Metso are making their way in

one of their most critical projects to date

The only road connection to the north-Indian border region of the province

Himachal-Pradesh and beyond the Manali-

Leh highway leads across the Rohtang

pass Due to the heavy snowfall and high-

velocity winds in this region the towns

located north of the pass are cut off from

the rest of the country during winter for atleast four often even six months each year

A tunnel with strategic importance

With the construction of the tunnel at

3100 m above sea level the Manali-Lehhighway will become an all-weather road

thereby enabling a significant improve-

ment in the economic development of

northern Himachal-Pradesh and an alter-

nate route to the strategically important

Ladakh region

Manali south of the pass is an alreadywell-developed tourist location that is

becoming more and more popular Upon

completion of the tunnel it is likely that

tourist activities will extend to the areanorth of the pass Moreover the tunnel

shortens the distance between the towns

of Manali and Leh by approximately 45 km

thus saving several hours on the small dan-gerous pass road

The Rohtang pass in the Western Himalaya

region of Northern India with its altitude ofalmost four kilometers ranks among thehighest trafficable passes in the world

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The 88-km long horse-shoe-shaped

tunnel provides space for a two-lane8-m-wide carriageway as well as a one-

meter-wide footpath on both sides A

22-m-high and 36-m-wide emergency

tunnel will be integrated in the tun-

nel cross-section Altogether more than

800000 msup3 of rock will be moved Tunneling works started around spring

2010 with excavation driven from both por-

tals As the north portal is inaccessible dur-ing winter closure the excavation focused

on the south After a planned construction

period of 55 years the tunnel is scheduled

to be completed by the end of 2015

Best man for the job

The BRO (Border Road Organization)

wanted to roll out a global tender for theproject due to the challenges that such a

project involves and also considering thatitrsquos the first time in India that a project of

this scale was to be carried out This imme-

diately triggered the need to roll out aglobal tender All major Indian construction

companies bid for it some individually and

some in partnerships

Strabag an Austrian tunnel specialistwas one of the companies who bid for the

project along with AFCONS a Mumbai-

based infrastructure company In Septem-

ber 2009 AFCONS-Strabag was awardedthe contract

Mr Sunil Tyagi Deputy Project Man-ager at AFCONS had this to say about the

unique projectldquoThis project is located in the Himalayas

and as far as we understand the terrain

there is among the toughest We came out

with a new technology and to be honestit is a fairly simple one We would generally

start with the traditional technology of drill-

ing and blasting and then obtain our muck

feed from the inwardbottom of the tunnelrdquo

ldquoThe technology is supplied by Rowa Tunneling Logistics and this is the first

time it is being used in Asia A jaw crusheris placed at a distance of about 40-45

meters behind the face The blasted muckextracted from the face is fed to the crusher

to reduce the lump size and then through

an overhead conveyor transport system

it is then transported out of the tunnelrdquoldquoThis enables free movement of man

and machinery in the lower area or spe-

cifically on the ground area If we were to

conforms to the Indian standard for fines amp

coarse aggregates as prescribed in IS383-1970

The plant was up and running in good

condition and performing to AFCONSrsquos

satisfactionldquoWe have worked with Metso in earlier

projects and are quite impressed by thekind of technology amp services they provide

We have a history together so the trust fac-tor also comes inrdquo explains Dhiman on their

choice of Metso as a partner

Service makes the difference

ldquoMetsorsquos services have made a big dif-ference in the project Without them we

would still be struggling with the machin-

ery and production The service is really

good and the service engineers are knowl-edgeable prompt and quick to act Any

problem can be solved by Metso We donrsquothave to wait until a service engineer turns

up ndash they have the capacity to solve prob-lems over the phone as wellrdquo says Dhiman

ldquoThe Metso plant didnrsquot create any prob-

lems for us We had problems in logistics

the feed was sticky and the weather condi-tions were bad but thankfully we did not

face any problems with production and

efficiency as the Metso plant is performing

very wellrdquo Dhiman concludes

More info

Amol Sinha Tel +91 9811 671 924

amolsinhametsocom

use the old conventional technology this

wouldnrsquot have worked for us in the stipu-lated timerdquo Mr Tyagi adds

When the going gets tough

partner with the toughest

Sensitive projects require the best technol-

ogy After AFCONS-Strabag landed theproject Metso was an obvious choice as a

technology provider not only because of

the long-standing business relationshipbut also for the sheer consistency in prod-

uct quality and service deliverance Metso

strives for

ldquoAfter signing the project we faced alot of road blocks including extreme cold

avalanches roadblocks less oxygen ndash you

name it we faced itrdquo explains Ankit Dhi-

man Plant Manager at AFCONS-Strabag The Rohtang valley is known for its

notorious avalanches and landslides SoAFCONS had to take extra steps and safety

precautions against hazards on the site

ldquoIn this freezing cold not just us humansbut also the machines are at increased risk

of damage I remember when we used

to run the plant during winter the diesel

engines would freeze We had to constantlyheat up the fuel container to get the plant

running And even the sand in the sand

trap would freeze so we had to clean it on

a daily basis to stop the pipes from mal-functioningrdquo Dhiman adds

Plant designed for difficult terrain

Difficult terrain coupled with space con-straints led Metso engineers to put their

minds together to come up with a suitable

plant configuration After studying the

requirements of the project Metso sug-

gested a 150-tons-per-hour three-stagemodular plant using a C106 jaw crusher

a GP11F secondary cone crusher and a

B7150 tertiary vertical shaft impact crusher

In addition considering the unpredict-ability of the feed the plant was about

to reach a point where the amount offines to be handled could be increased

dramatically Metso strongly suggested the TK11-27-3V grizzly scalper and this became

the first-ever TK scalper to be supplied by

Metso to an Indian customer Also in order

to get better products a sand trap SF2360was added to the configuration

The sand trap is important equipment

for this project as it washes the sand thatMr Sunil Tyagi Deputy Project ManagerAFCONS-Strabag

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Smooth transition to new-generation jaw crusher in Germany

Roumlhrig is a German company with a rich heritage The company has been quarrying granite at its plant in Bergstrasse inthe Sonderbach district of Heppenheim for three generations

TEXT amp PHOTOS Ralf Goffin

Roumlhrigrsquos superior product variety is onereason why the companyrsquos proximity to its

customers can be understood in more than

just physical terms The companyrsquos high

level of innovation has allowed it to estab-lish itself as a reliable supplier of materials

both regionally and internationally This

operational and technical expertise always

manages to keep in step with growing

market requirements

In terms of technical processing equip-

ment Roumlhrig has used a Nordberg C160stationary jaw crusher from Metso since

1992 At the start of 2012 it was finally

exchanged for a more up-to-date version

from the same model range

Metsorsquos C Series is specifically designed

to pre-crush hard rock and can cope effort-

lessly with even the hardest of materials

The dimensions of the new stationary jawcrusher are identical to those of the old

one which means that it could simply be

slotted into the housing vacated by the

previous version

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Third-generation Managing DirectorMarco Roumlhrig expects the new machinersquos

service life to be just as long as the previ-

ous model due to the product upgrades

that have been implemented The integral motor base is another plus

point in models made by other manu-

facturers it is located outside the crusher

This element of good fortune ensured that

Roumlhrig could reuse the housing withoutany additional rebuilding

Another advantage lies in the revision

of the guards for the C160rsquos drivetrain andflywheel The sturdier construction method

used for the crusher requires fewer parts

which facilitates easier installation andmaintenance and it makes it simpler to

access the motor

Under the watchful eye of Metsorsquos

Assembly Manager Maik Engelstaumltterthe entire project including removal and

installation was successfully completed

within two weeks

Installation making the most

of the available space

Roumlhrig will likely remember the day the

new crusher was installed for a long time

the pitman and main frame were deliveredseparately prior to installation and assem-

bled on site It took just one hour to replace

the old stationary crusher with the new

model A lorry-mounted crane was used toposition the 85-ton crusher with millimeter

precision in the crushing plant Once the

new crusher had been positioned in theexisting steel structure the next task wasto fix it into place as securely as possible

despite the limited space Special vibration

dampers were installed at a height of two

meters to prevent the crusher from sliding

Norbert Ried (fourth from left) installed thenew C160rsquos predecessor 20 years ago and isdelighted at the durability of the powerfulcrusher that is now making way for a newermodel Also pictured from left to right ManagerVolker Angermann Assembly Manager Maik

Engelstaumltter Technical Manager Stefan

Koob Project Manager Dominic SchoumlnhardtManaging Director Marco Roumlhrig Service

Technician Stefan Kolze and employees ofthe installation company Stafemo

On the hook after theold C160 was liftedout by crane the newcrusher was installedin almost no timeOnly the roof of thehousing had to beremoved

sideways off its mount An initial test run

with materials was carried out around oneweek later after all the electrical cables had

been installed

Simultaneously with the installation

of the C160 which is the first of the latest

generation of crushers to be installed in

Germany a new Nordberg GP100 conecrusher was also being installed in Roumlhrigrsquos

chipping plant Roumlhrig is convinced that

the technical improvements made tothe new Metso crusher can only be an

advantage worldwide

Roumlhrig places great value on consistent

product quality maximum added valueand optimum refinement of its product

range Bearing in mind that Roumlhrig has

enough reserves of raw material to last

for the next 150 years the company canconfidently continue to develop with an

emphasis on quality rather than quantity

More info

Dominic Schoenhardt

Tel +49 (0)621 727 00 610

dominicschoenhardtmetsocom

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Groupe Charier Carriegravere de la Mariais France

Quarrying with certi1047297ed quality The Charier Group with its 1600-strong workforce is a family business thatthis year celebrates 115 years of quarrying The company pursues a long-termdevelopment policy that since 2007 has seen processing installations upgradedat 4 of its 9 extraction sites

TEXT Liliane Boutin (with extracts from Mines amp Carriegraveres and Terrassements amp Carriegraveres magazines)PHOTO Baloon photo

The processing installation is of the horizontal type with a primary station located 56 meters below the site access road to keep it hidden from view

The crushing and screening installation at

Charierrsquos CM La Mariais quarry (at Donges

on the Loire estuary) has been in opera-tion since September 2011 Based on theoperatorrsquos ideas it was designed by Metso

to replace a worn-out installation installed

right on top of the seam being extracted

Since its commissioning it has becomethe second quarry in the company to

receive ISO 14 001 certification

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983122983141983152983151983154983156983145983150983143 983154983141983155

tertiary material of sand and gravel for the

local market to use in concrete surfacingprefabrication etcrdquo

Incorporation of a screening station

The stone extracted from La Mariais is

according to the quarry granitic gneiss

sound and homogeneous with a LosAngeles index of 15 good wear resist-

ance with an MDE of 10 a true density of

265 and a certain abrasiveness (2000 gt)ldquoCharacteristically it has a tendency to form

blocksrdquo Leblin points out

The main criteria in designing the instal-

lation was to provide an output of 600000metric tons from one station (38 hours

week) to produce materials aimed at the

concrete and surfacing markets ldquowhich

involved providing a tertiary station withscreening plantrdquo he adds

With this new unit the operating com-pany expands its product range through

the addition of fine materials obtained

from the tertiary screening station This unitis capable of producing 170 tonshour of

020

Preserving the environment

and optimizing safety

The screens have motorized bogies and

retractable walkways to facilitate access

when the screens are opened for main-tenance Other walkways provide access

to the tunnel input feeders The feederscan be isolated with hydraulic rod gate

bars this hydraulic assistance eliminatesthe need to use a heavy hammer to lodge

these metal bars

All conveyors transporting fines (02

and 04) are covered with a tarpaulin to

avoid flying dust and all the screens arehooded (metal cover with Trellex seal-

ing) The Brunone company has installed

dust-tight containment at the outlet of the

tertiary station crushers (HP300 and HP4)on the belt located under the screens

and under the hoppers located belowthe tertiary screens The crushers are put

under negative pressure and the finesare extracted through sleeve filters (7000

m3 h) with declogging which deposits the

dust back onto the conveyor belt

A high-pressure 100 bar water mist sys-tem has been installed at the primary sta-

tion discharge at the secondary crusherrsquos

discharge chutes (Omnicone) and at the

transfer points on the belt

Designed to last

ldquoThis type of new installation can easily last

thirty yearsrdquo affirms Project Leader Bruno

Peix of Metso ldquoIt quite simply depends on

how well it is maintained Thatrsquos why weprovide maintenance contracts that call for

our technicians to make regular inspection

visits and carry out preventive mainte-nance and any necessary repairsrdquo

In 2011 Metso commissioned about

10 new processing units in France like

the one at La Mariais quarry

More info

Frederic Bazire

Tel +33 (0)681442804

fredericbaziremetsocom

Key figures

DURATION OF WORKS 15 months

DRAWING OFFICE TIME 7800 hours

HEIGHT OF SILOS AND GRINDER BUILDINGS

15 m

TOTAL LENGTH OF CONVEYORS 14 km

WEIGHT OF THE INSTALLATION

1200 metric tons

CONCRETE POURED 1800 cubic meters

PROJECT SITE WORKFORCE 30

INSTALLED POWER 2200 kW(not including pumps 200 kW)

METSO EQUIPMENT

Primary

Vibrating feeder PF561-2V

Primary grizzly VG540-3V

Grizzly feeder TK13-20-3V

Jaw crusher C145 with

hydraulic setting

Secondary

Vibrating screen CVB 2050

refurbished

Cone crusher Omnicocircne 1352 SX

with Metso IC7000 controller Ellivar 16 (16 msup2 3 decks) screen

refurbished by Metso

Tertiary

Cone crusher HP300

Cone crusher HP4

2 Ellivar 20 screens (20 m23 decks) for final products

Expanding the production range

ldquoSince the mid-1990s when we became

owners of La Mariais we had used mobilemachinery with an assembly of beltconveyorsrdquo recalls Daniel Leblin Charierrsquos

Technical Manager for site construction

and maintenance

ldquoIt became clear that we needed ahigher performance tool to achieve the

dual goals of reaching one million metric

tonsrsquo maximum production and producing

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Big Lokotrack LT550GPF boostsquarrying productivity by a thirdMaximizing the productivity of operations is a key issue when striving for cost-effective quarrying Big Lokotracks are oneway to achieve improved operational efficiency The Lokotrack LT550GPF equipped with the high-volume GP550 conecrusher and a large screen is popular in the Nordic countries and in Germany and Australia ndash countries all known for theirhigh quarrying volumes

TEXT amp PHOTOS Eero Haumlmaumllaumlinen

Kone-Kostamorsquos new mobile coneplant has reached an averagecapacity of 300 tons per hour

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983122983141983152983151983154983156983145983150983143 983154983141983155

ldquoWith the same number of employees we

can achieve 30 more productivity with

our new LT550GPF unit The high-capacityFS screen has also eliminated the bottle-neck often seen at fine screeningrdquo says

Aarno Kostamo Managing Director of

Kone-Kostamo Oy one of Finlandrsquos biggest

crushing contractorsAccording to Kostamo the high capacity

of the GP550 gyratory cone crusher easily

handles feed from the C120 and C125 jaw

crushers For the contract with the Talvivaara

nickel mine the LT550GPF is being fed bythe brand new Lokotrack LT120 jaw plant

Average capacity 300 tons per hour

Talvivaara Europersquos largest nickel mine uti-

lizes large quantities of aggregates Kone-Kostamo has contracted several million

tons of different end products for the mineIn August 75000 tons of 0ndash63 mm

road gravel was crushed Smaller amountsof finer 0ndash6 mm 0ndash16 mm and 0ndash32 mm

aggregates are also being produced

The rainy summer increased the need

for road gravel along the muddy roadswhich must endure dump trucks weighing

as much as 260 tons

ldquoThe mobile process consisting of the

LT120 jaw plant and LT550GPF cone plant

is cost-effective while aggregates of vari-ous sizes can be produced in a two-stage

operation and with high capacity The con-trolled stroke and elliptical movement of

the FS screen secure big passing throughcapacitiesrdquo Kostamo explains

Operated in two shifts for a total of 16

hours per day the LT550GPF has logged

more than 600 working hours over a two-month period

Managing Director Aarno Kostamo (left) and foreman Karri Maumlenpaumlauml studying the cavity optionsavailable for the new Lokotrack LT550GPF

Longer perspective than

a single quarter needed

Kone-Kostamo Oy was founded as an

earth-moving company in Kemijaumlrvi

Northern Finland in 1956 The company

expanded its operations to include crush-

ing contracting in 1964 and later on

switched to concentrating fully on crush-ing activities

Kone-Kostamo consistently crushes

and screens around 28 million tons ofaggregates annually and has net sales of

between EUR 8ndash9 million

ldquoWe believe that issues within the crush-

ing industry including the purchasing ofmachinery must be studied with a longer

perspective than a single quarter The

secret to our success has always been our

solid work ethic and professional employ-eesrdquo Kostamo sums up

More info

Esa Berg

Tel + 358 40 837 8692

esabergmetsocom

8132019 Results Minerals Aggregates 3 2012ENG

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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155

Monitoring-based reporting is vital for

assessing the performance of a mobile

crushing plant Metso provides suchreporting tools through its plant-wideautomation system Metso DNA (Dynamic

Network of Applications) with its infor-

mation platform that links all the mobile

crushing and screen units together as oneentity Basically there is a lot of measured

real-time information available in every

crushing plant On-line information is

obtained either from each Metso crusherrsquosmachine automation system IC (Intelligent

Controller) or from separately installed

additional sensors and belt scales

All the collected data is sent to a motorhome using wireless communication

based on WLAN technology The motor

home is a purpose-built environment

inside an on-site container In this environ-ment selected variables can be monitored

for assessing the plantrsquos performance And

to make all this even more flexible the

data can be transmitted to a crushing plant

company office using GPRS3G mobile

data communication technologies Thismakes all the last-minute reports acces-sible to the crushing plant managerial staff

at anytime and basically anywhere within

reach of the cell phone network

Production and fuel economics reports

Essentially monitoring and reporting can

be customized to fit the customerrsquos needs

However there are certain off-the-shelf

reports that provide a lot of useful informa-tion for plant supervision The production

report is one of these Requiring at least one

belt scale for measuring the total produc-tion the production report shows the pro-duction rate (tons per hour) for a selected

reporting period eg a day or a week The

production report constantly keeps track of

the plantrsquos production storing all the datathroughout the plantrsquos life cycle

Performance monitoring and reportingfor a mobile crushing plantTEXT Pasi Airikka PHOTOS Metso

unit during which the unit is running By

storing the availability times between start-ups and shutdowns the crushing plant

operation time (hours per dayshift) can be

recorded analyzed and reported In addi-

tion the availability report can be tailored

to evaluate efficient crushing hours during

which the plant is really working and pro-ducing aggregates Consequently the ratio

(0-100) between efficient crushing time

and total running time can be reported forany selected period of time This boosts

the efficiency of the plantrsquos operations

and results in better productivity

Reports on non-choke

or inadequate feeding

Non-choke feeding to crushers is avoid-

able through smart plant-wide crushingplant controls But estimating its severity in

a systematic manner is not straight-forwardwithout constant monitoring and reporting

The crusher choke feeding report makes

use of the crusher cavity level sensors byanalyzing their level measurements By

calculating average and min-max values

and deviations from the average it can be

shown how often the single crusher suffersfrom non-choke feeding to it

In some cases the bottleneck in the

crushing plantrsquos productivity is the material

feeding to the process In mobile plants thefeeding is human operated and therefore

subject to variations Occasionally the sizeof the human-operated machine simply

does not allow for adequate feeding to thecrushing plant There are specific reports

indicating time periods when the crushing

plant suffers from inadequate feeding

Condition monitoring for

crushers and screens

Machine-specific condition monitoring

focuses on vibrating components in

crushers and screens such as drive shaftbearings safety plate wearings and gears

The low middle and high frequencies ofmonitored components are measured and

supervised in real-time to detect abnor-malities due to slow or fast wear looseness

or imbalance

More info

Pasi Airikka

Tel +358 40 587 2730

pasiairikkametsocom

Condition monitoring provides a view tovibrating crusher and screen components forpredictive equipment maintenance

The daily production report shows the hour-by-hour production trend and distribution chartfor a selected day with min-max average andvariation statistics for comparison

Fuel consumption is always an interest-ing concern The fuel consumption reportgives the fuel consumption of each crush-

ing unit (liters per hour) and their total

consumption (liters per hour) for a selected

reporting period and can track fuel con-

sumption changes over timeCrushing plant availability can be

assessed as well The availability report

calculates time periods for each crushing

8132019 Results Minerals Aggregates 3 2012ENG

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983149983141983156983155983151 983150

for tissue machines The record of 2210

mmin was set on June 1 2012 during a

24-hour production run by the TM 2 tissue

machine at the companyrsquos mill in Yenikoumlynear the city of Izmit in Turkey

ldquoThe cooperation with Metso has been

beyond excellent and both parties did

their utmost to make the project success-ful The results clearly show that the efforts

were worthwhile on both sides This coop-

eration will extend to cover new projects

in the futurerdquo says Luumlt1047297 Aydin Paper GroupDirector Hayat Kimya

ldquoWe are not surprised that Hayat K imya

managed to break the world speed record

We have had great confidence in the capa-bility of the Hayat team since our project

started in 2009 We certainly know our

machine very well its stability production

efficiency and speed capabilityrdquo says Jan

Erikson Vice President Sales Metso

PowerThe worldrsquos first eco-gas fueled

power plant is up and running

Lahti Energy Ltdrsquos new Kymijaumlrvi II gasifica-

tion plant was officially inaugurated on

May 8 2012 It is the first of its kind in the

RecyclingRecycling with Lokotrack LT106

jaw plant in New York

A brand-new Lokotrack LT106 jaw plant is

used in the city area of New York USA to

recycle demolition materials The crushing

site faces the skyscrapers of ManhattanIsland

Paper amp FiberHayat Kimyarsquos Metso-supplied tissue

machine sets world speed record

Thanks to a skilled crew and dedicated

efforts Hayat Kimya AS in Turkey has suc-

ceeded in breaking the world speed record

world This CHP plant runs on clean eco-

gas that is gasified cleaned and cooled

from recycled waste with Metsorsquos innova-tive technology

ldquoItrsquos actually eco-gas that we combust

in the boilerrdquo comments Lahti EnergyrsquosProduction Director Jukka Manskinen

ldquoWe convert unwanted waste material into

energy in an efficient and environmentally

friendly wayrdquoNever before has any plant gasified

waste on such a large scale In the gasifier

recycled waste is turned into combustible

product gas which is cleaned cooled and

combusted in a high-efficiency gas boiler

to produce steam for the steam turbine The plant produces 50 MW of electricity

and 90 MW of district heat for the city of

Lahti and its neighboring areasMetso delivered the circulating fluidized

bed (CFB) gasification process gas cleaning

and cooling steam boiler environmental

protection system and automation systemto the entire plant The production of elec-

tricity and heat is kept even with the Metso

DNA automation system that covers the

whole plant starting from fuel reception

AutomationMetso develops and supplies plant-

wide crushing control solutions for

crushing plants

Metso has recently signed contracts on

delivering plant-wide automation systems

for mobile and portable rock crushing

plants The key objective of these deliveries

is to stabilize and to increase productivityand efficiency of the plants using one sin-

gle automation and information platform

for integrating crusher-specific IC machinecontrols

Furthermore the plant-wide system

with its information management tools not

only increases plant availability and opera-

tional safety it also makes troubleshoot-ing quicker and performance monitoring

easier The control room for plant-wide

operability is located either in an excavator

cabin or a purpose-built container

Metso around the world

The new LT106 jaw plant is suitable for crushing both hard rock and all rock-based demolition materials

The new world speed record for tissue setby Hayat Kimyarsquos Metso-supplied TM 2 is2210 mmin

8132019 Results Minerals Aggregates 3 2012ENG

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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: Results Minerals Aggregates 3 2012.ENG

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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156

Metsorsquos HRCtrade takes high pressure grinding roll technology to the next level

The new Lokotrack mobile conveyors come as tracked and wheeled models

Metsorsquos latest development in comminution equipment the HRCtradeis a major step in the profitable application of high-pressure grind-

ing roll (HPGR) technology Metso has made several key innova-

tions in order to increase throughput and decrease the total cost

of operation

Metsorsquos patented Arch frame creates an even gap setting acrossthe width of the tires limiting skewing that can result in downtime

for mining operations This anti-skewing Arch frame also prevents

damage to the roller bearings (caused by misalignment) that canoccur with the traditional HPGR design

Flanges maximize wear life and increase throughput

Used in place of spring-loaded cheek plates the flanges keep thebed of material within the crushing zone and prevent material

from bypassing the tires This enables greater circuit capacity and

increases the overall crushing efficiency

In addition by preventing material from bypassing the tires

even pressure across the width of the tire is better maintained

Distributing the pressure more evenly maximizes the tire life bypreventing a ldquobath tub effectrdquo in which the center of the tire wears

faster than the edgesVictoria Herman Metsorsquos Product Manager for the HRC notes

that this breakthrough design is a response to the growing needs

in the mining industry ldquoEnergy efficiency has been attracting our

customers to HPGR technology for yearsrdquo she says ldquoBut our design

concept increases capacity and crushing efficiency ndash and thatrsquossomething mining companies are always looking to improve onrdquo

The track-mounted Lokotrack CT32 and wheel-mounted Lokotrack

CW32 mobile conveyors offer an ideal solution for applications

that require high stockpile capacity and excellent material transfer

capabilities They also add flexibility to multi-stage crushing andscreening applications enabling easy and fast closed-circuit opera-

tion of mobile units

The conveyor novelties can be used in both mobile and station-

ary installations providing extra stockpiling capacity in situationswhere for example fewer wheel loaders are available

The HRC is ideal for high-tonnage hard rock applications andcan be used as a tertiary quaternary or pebble crusher Currently

several HRC units are in operation around the world ndash with a total

of 6500 operating hours including over 3800 hours in a mininghard rock application The machine does have range within hardrock applications itrsquos been designed for use in diamond iron ore

copper gold platinum and various industrial minerals

More info

Victoria Herman

Tel +1 717 309 1150

victoriahermanmetsocom

Several optional features such as hydraulic folding of tail sections

and dual hydraulic drive for increased throughput are available

The capacity of the CT32 and CW32 is 400 mtph (440 stph)feed size up to 150 mm (6rdquo) belt width 1050 mm (42rdquo) and dis-charge height 9120 mm (29rsquo 11rdquo) The CT32 is fitted with a Caterpil-

lar C2 diesel engine with 38kw (51 HP) power The CW32 is avail-

able for hydraulic or electric use

More info

Kimmo Anttila

Tel +358 50 433 3745

kimmoanttilametsocom

The new HRCtrade combines high crushing pressure and a low circulatingload resulting in the most efficient comminution

When flexibility in stockpiling capacityis required the answer can be foundin the new Lokotrack CT32 and

CW32 mobile conveyors

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Service creates value in ChinaChinarsquos most important gold producing area Yantai in northeastern China supplies more than 16 of the countryrsquos goldproduction each year With the gold market thriving the scale of gold production in Yantai has been expanding constantly

Zhongjia Mining Industry Co Ltd is one of the beneficiaries of this thriving industryTEXT amp PHOTOS Yan Xin

Inspection and maintenance of the HP500 cone crusher conducted by Metsorsquos service engineers

In 2011 Zhongjia Mining Industry pur-

chased a modular crushing and screen-ing system from Metso for its new gold

production project With the cooperation

between the two companies continuously

intensifying Zhongjia Mining Industry

signed an additional one-year Life CycleService (LCS) contract with Metso incorpo-

rating Metsorsquos global knowledge in equip-

ment processes and services

ldquoMetso customized a series of reason-

able service solutions also referred toas Metso Performance Solutions for us

including preventive maintenance services

process improvement personnel training

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155

and a procurement plan for wear parts

These really suit our needs perfectlyrdquo saysShen Yidong the Manager of ZhongjiaMining Industry

Effective preventive maintenanceFor mining corporations the biggestconcern is the economic losses caused by

the shutdown of equipment As a result

preventative maintenance is of vital impor-

tance During the contract period Metsoservice engineers offered 7-day tracking

service on the production site every month

to eliminate potential problems and thus

ensured the stability of the system

parts caused pressure on our working capi-tal which was not favorable for our long-

term developmentrdquo Shen explains

To solve this problem Metso designed

a rational stock plan of wear parts and built

a field warehouse In accordance with theuse and consumption of the liners the field

service engineers complement the stock tomake production and operations run more

smoothlyldquoNow when we need to replace the

wear parts we can use them before pay-

ment This not only simplifies the procure-

ment process but also liberates a largesum of our operating capital which can

be used for other business development

purposesrdquo says Shen

Best partner

ldquoAlthough the LCS contract incurs some

early purchase costs in the long run Metsorsquosprofessional and quality service will improve

the equipment efficiency reduce ourenergy consumption and ensure stable

operations thus generating more prof-

its This is the greatest value for us so the

investment is really worthwhile overall Inthe future we will choose more Metso prod-

ucts and services Taking all aspects into

consideration we believe Metso is the best

partner for usrdquo Shen Yidong concludes

More info

Thomas Bai Tel +86 13801009114

thomasbaimetsocom

ldquoIn the eight months since the contract

came into effect our corporation has notsuffered any financial losses due to equip-

ment breakdown The regular maintenance

has greatly improved the efficiency of our

entire crushing system In addition the

experienced engineers from Metso also

provided onsite training and guidancefor our staff and the tailored training has

greatly enhanced the operating abilities of

our employees and upgraded their overalllevel of competencerdquo says Shen Yidong

More productivity with

less consumption

Metsorsquos service contract focuses on real-

izing the optimum performance of each

process flow After analyzing Zhongjiarsquos

production system Metsorsquos techniciansproposed an adjustment to the closed side

setting of the HP500 for tertiary crushingin order to improve the efficiency of the

downstream fine crushing and milling pro-

cessing by over 10ldquoThe process flow improvement solu-

tions provided by Metso not only increased

the output of our gold concentrates but

also reduced our energy consumption andcostsrdquo says Shen

In the past wear parts procurement

took up a larger proportion of Zhongjiarsquos

total production costsldquoTo avoid downtime caused by the

shortage of wear parts we had to keepeight sets of various wear parts in place

However the cost of having so many wear

Zhongjia Mining Industryrsquos gold concentrates processing plant in China

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0983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

Safe quarrying high-

quality aggregates

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ldquoWe share a similar zero-accident strategy and target with Metso and have successfullyfollowed it Metso has also helped us to meet the strictest end-product quality andcubicity requirements set in Spainrdquo This is how Managing Director Intildeigo Ajuria ofOfitas de San Felices the leading hard rock quarrying company in Spain describesthe cooperation with MetsoTEXT Eero Haumlmaumllaumlinen PHOTOS Ofitas and Eero Haumlmaumllaumlinen

The San Felices quarry is situated in a picturesque mountainous landscapebetween the companyrsquos Rioja vineyards and the Bilbao-Madrid motorway

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Ofitas has pioneered the implementation

of several Metso novelties in the Spanish

market The company was the first to use

efficient large track-mounted Lokotrack jaw plants the unique mobile conveying

system and also the new-generation HP4

cone crushers

Today the company operates twomodern Metso stationary plants one in

Guadix near Granada and the newest one

in San Felices Haro Rioja community Both

quarries focus on refining hard rock by pro-cessing ophite rock into the highest quality

railway ballast asphalt and concrete mix

grades The company has a satellite quarry

near Vitoria in PentildeacerradaBeing situated next to a highway and

the famous Rioja vineyards Ofitas must pay

special attention to environmental issues

To minimize dust problems all conveyors

have special covers attached

Quality durability and service

The cooperation between Ofitas de San

Felices and Metso started back in 1973when the Ajuria family bought the com-

pany whose quarrying activities began in

1919 Intildeigo Ajuria has a clear vision of why

the cooperation has continued withoutinterruption for almost 40 years

long-standing personal relationshipsrdquoAjuria adds

Serving railways asphalt

and concrete producers

The year-old San Felices stationary instal-lation lies hidden in a mountainous area

south of the city of Vitoria in NorthernSpain The new plant replaces an old one

that complicated the extraction of ophiterock Both plants are delivered by Metso

With its two separate production lines

the new plant is able to produce all the

end products required ndash from railway bal-last to the finer grades needed for asphalt

and concrete

Due to lower demand the quarry cur-

rently produces some 4000 tons per day

At full capacity however the plant canreach 8000 tons of production per day

30ndash35 of which consists of railway ballastfor high-speed trains and 65ndash70 of chips

and sand Thanks to the versatile two-line con-

cept connected by transverse conveyors

up to 12 different end products can be pro-

duced Depending on the demand for endproducts the material can be guided either

to the HP4 cone or HP400 cone followed

by a Barmac vertical shaft impactor

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

The ophite feed is fed to the C125 jaw crusher by a sturdy dump truck

The key people running the new San Felicesquarry Mine Engineer Carlos Fernandez (left)Managing Director Intildeigo Ajuria with ProductionManager Julian Perez

ldquoThrough the years Metso machinery

has proven its production capacity and

durability resulting in high-quality end

products A big plus for us has also beenthe quick response time to our process

challenges or servicerdquo

ldquoIn fact our cooperation extends

beyond day-to-day business matters to

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983122983141983152983151983154983156983145983150983143 983154983141983155

Meeting the strictest cubicity demands

The Spanish regulations concerning end-product cubicity are becoming more

demanding The flakiness percentage of

railway ballast must be below 10 and for

asphalt and concrete aggregates less than

15

ldquoWith Metsorsquos HP4 cone and the Barmacvertical shaft impactor we can meet even

the strictest cubicity demands We believe

that our high quality is helping us to sur-vive in the present recessionrdquo notes Mine

Engineer Carlos Fernandez

ldquoWe hope to increase the total extrac-

tion of the three quarries from the present15 million tons per year because our plant

capacity allows more than double thatrdquo

Fernandez adds

More info

Angel Luis Garcia Tel +34 686 94 35 30

angelluisgarciametsocom

In addition to being the leading Spanish

quarry to process hard rock Ofitas de SanFelices also cultivates 34 hectares of vine-yards next to the quarry which is situated

in the famous Rioja wine area

The company has previously sold a

harvest of over 200000 kg of Tempranillo

grapes to local red-wine makers Recentlythe company built its own wine process-

ing plant to process 10000ndash15000 kg of

grapes themselves

Aggregates and wine production

Andoni Ajuria the founder of Ofitas de san Felices (left) with Intildeigo Ajuria the present ManagingDirector tasting wine from the companyrsquos own vineyards

The first vintage wine of Ofitas har-

vested in autumn 2010 is now maturingin oak barrels After maturing for 12 to 15months the wine is called crianza and after

two years it will be granted the classifica-

tion reserva

ldquoWinemaking is not a business but

a hobby for us We give our wine out aspresents and drink it when we meet

our suppliers and friendsrdquo Intildeigo Ajuria

comments

For environmental protectionall of San Felicesrsquos plantconveyors are covered

Ofitas de San Felices quarry

LOCATION Haro near the city

of Vitoria northern Spain

SIZE 100 hectares

ROCK TYPE Ophite with Los Angeles

index of 9ndash10

PRESENT DAILY EXTRACTION 3000 tons

of ophiteNUMBER OF PERSONNEL 30

RESERVES 10 million tons

MAIN END PRODUCTS 0ndash2 mm

2ndash4 mm 4ndash10 mm 10ndash16 mm

16ndash22 mm 25ndash60 mm (ballast)

METSO MAIN EQUIPMENT

VF feeder

C125 jaw crusher

ndash feed size 0ndash800 mm

ndash css 130ndash140 mm

HP400 cone crusher

ndash feed size 80ndash250 mm

ndash css 40 mm HP4 cone crusher

ndash feed size 40ndash80 mm

ndash css 15 mm

Barmac 6150 VSI crusher

4 CVB2060 screens

2 TS32 screens

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Metso Distribution Centers he

Europe (Tongeren Belgium)

France (Macon)

Czech Republic (Přerov)

Austria (Vienna)

2271 d

Brazil (Sorocaba SP)

1014 d

USA (Columbia SC)

1690 d

USA (Waukesha WI)

434 d

South Africa (Vereeniging)

Ghana (Tarkwa)

Meacutexico (Irapuato)

Peru (Lima)

Chile (Concoacuten)

788 d

Sweden ( Trelleborg)

Finland (Tampere)

UK (Rugby)

865 d

Russia (St Petersburg)

Brazil (Parauapebas PA)

206 d

4983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983122983141983152983151983154983156983145983150983143 983154983141983155

In the case of an equipment failure or

a planned service shutdown resuming

production as quickly as possible is crucialEach hour spent waiting for a spare part to

arrive equals money lost Whether the right

part takes 12 or 48 hours to arrive really

makes a difference

The comprehensive and global Metsospare and wear parts service network pro-

vides you with the right part in the right

place and at the right time Our strategi-

cally located Distribution Centers and

Satellite Warehouses are on call 24 hoursa day 7 days a week ensuring efficient

parts replacement near you

Check out the locations of the MetsoDistribution Centers and how many parts

pass through them each day

More info

Marcelo Farah

Tel +55 15 2102 1315

marcelofarahmetsocom

you minimize downtime

Australia (Perth)

746 d

China (Tianjin)

China (Kunming)

China (Shanghai)

393 d

India (Faridabad)

India (Ahmedabad)

India (Hyderabad)

India (Bhubaneswar)

India (Bangalore)

419 d

Russia (Yekaterinburg)

Australia (Newcastle)

New Zealand (Matamata)

983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088

TEXT Sofia Williams

Singapore (Singapore)

Distribution Center Satellite Warehouse

8132019 Results Minerals Aggregates 3 2012ENG

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Following a large investment

in Metso crushing equipmentand services Buena Vista del

Cobre is now expanding the

mine site to include even more

equipment ndash and with thatexpansion comes the need for

more local service resources

Metso and Buena Vista del

Cobre have entered into a Life

Cycle Service agreement forthe plant and construction of a

brand new Metso service hub

is under way in Cananea

New facility new

level of service

The Cananea service hub

which will be up and running in early 2013will support the recent expansion and resur-

gence of Buena Vista del Cobre Initially it

will be a major repair and assembly center

for pumps crushers and screens and will

provide for rubber covering capabilitiesBut the 8000-square-meter facilityrsquos service

offering will be expansive including a con-

signment stock inventory to help serve theminersquos varying needs Metso currently has

50 service team members on site

Although Buena Vista del Cobre was a

key influencer in building the new servicehub this location will also enable Metso to

expand its capabilities and provide local

support to the entire mining community

in northwest Mexico The Cananea hub

will serve a number of major copper and

gold mines in the region including MineraFriscorsquos San Felipe Fresnillorsquos Milpillas and

Grupo Mexicorsquos Mexicana de Cobre

ldquoBuena Vista del Cobre is the biggestcustomer we have in Mexico today and

with this expansion project itrsquos only going

to grow and be strongerrdquo says Felix Forna-

guera Director of Services Mexico CentralAmerica and Caribbean ldquoWith that said the

idea behind the Cananea service hub is to

provide a central location for local support

for all our major customers in the areardquo

Establishing safety

ldquoIt was key to have our support here in

Cananea because the Buena Vista delCobre started from the ground uprdquo saysFelix ldquoWersquove been able to help the cus-

tomer to establish the best in support

service and operations from the very

beginningrdquo And this ground-up approachincluded a major focus on safety

Metso worked closely with Buena Vista

del Cobre to establish the safety proto-

col by which the mine operates Basedon Metsorsquos expertise the safety measures

put in place have enabled the mine to

become strict and efficient in its operations

and maintenance procedures To achievethis Metso worked closely with local andnational authorities to ensure the safety

plan was comprehensive and in accord-

ance with all established legal bodies

The best in regional support

The service hub in Cananea is a prime

example of Metsorsquos focus on providing local

service and support to its customers all

Service shines in Cananea MexicoAfter three years of inactivity the Buena Vista del Cobre mine in Cananea Sonora Mexico has been operational since 2010A mine that was inactive for such a significant amount of time however requires a great deal of support to successfullyrestart the plant and bring it back to an operational and profitable state

TEXT Deanna Lee PHOTO Metso

over the world ldquoWe are the first

company developing this kindof service in northwest Mexicordquo

adds Felix ldquoOur people have

developed a close relationship

with the team at the mine Itrsquosmore than a supplier relation-

ship our guys are inside the

mine living and working thererdquo

In fact this is the model

that Metso is using in servicehubs all over the globe build-

ing modern facilities bringing

teams on site and workinghand in hand with mine

operators The Cananea Service

hub is only the most recent

example of Metsorsquos commit-ment to service and northwest Mexico is

yet another mining hotbed thatrsquos going to

benefit from the companyrsquos support

More info

Felix Fornaguera Tel +52 4621079227

felixfornaguerametsocom

A mining cone serviced by Metso at the Buena Vista del Cobre mine inSonora Mexico

ldquoThe new Cananea service center will be a majorrepair and assembly center for pumps crushersand screensrdquo says Felix Fornaguera Director ofServices Mexico Central America and Caribbean

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

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During the MINExpo exhibition over 1300 people visited the Metso stand

983122983141983152983151983154983156983145983150983143 983154983141983155

Held every four years MIN-Expo consistently grows so

perennial exhibitors like Metso

are challenged with elevating

their presence and drawingin new (and greater numbers

of ) visitors each year ldquoItrsquos not

necessarily a challenge to lsquotoprsquo

our last showingrdquo says Keith

Ference Vice President ofmarketing and communica-

tions North America ldquoThere

are four years between eachMINExpo so we always have

a lot to say and reveal to our

customersrdquo The real challenge

he says is finding an exciting

and dynamic way to deliverthe message ldquoTherersquos so much

to see here so your booth has

to be compelling from the

outside-in and thatrsquos what

we always try to dordquo

Service sets the stage

The Metso booth created buzzin a number of ways and per-

haps the most striking (partly

due to its size) was the live

theater presentation As visitorspassed through the aisles of the show-

room the sights and sounds from Metsorsquos

theater were hard to miss And once guests

entered they were captivated by a short

high-energy video presentation focused

on Metsorsquos service capabilities The message was simple Metso is ldquoyour

local service partner rdquo for all mining and

construction needs The video showed ourservice teams in action all over the world

and the audience came away with an

understanding about Metsorsquos commitment

to service Customers can count on morethan 70 local service centers run by more

than 1700 expert technicians delivering

Metso makes an impact at MINExpo 2012At this yearrsquos MINExpo International nearly 60000 attendees flocked to Las Vegas Nevada the largest turnout in showhistory The visitors ndash mining professionals from all over the globe ndash explored 850000 square feet of showroom spacefeaturing the industry rsquos latest technology equipment products and services They toured the show for three days

seeking the latest and greatest from more than 1800 exhibitorsTEXT Keith Ference PHOTOS Tracey Ford Perry

detailed descriptions andphotos of all of Metsorsquos mining

and construction products and

services The app also provides

digital access to Results and asearchable database of sales

contacts By day three of the

show MetsoMAP had been

downloaded by more than

500 usersIn addition to the app the

booth was equipped with

several LCD screens each con-trolled by Metso experts who

used their iPads to present new

products like the Megalinertrade

and the HRCtrade A featured

presentation on Metsorsquos lineupof energy-efficient comminu-

tion equipment including the

VERTIMILLreg SMD and MP-1250

cone crusher was also avail-

able letting customers seehow Metso technology delivers

some of the worldrsquos most effi-

cient size reduction

Measuring MINExpo success

After a very busy three days

(on top of months of prepara-tion leading up to the show) everyone

involved with MINExpo ndash from the North

American marketing team responsible for

the booth to the product managers and

sales force that worked the floor ndash is view-

ing the show as a success ldquoTherersquos alwaysa sigh of relief after each (MINExpo)rdquo says

Keith ldquoAnd overall the initial feedback

and response has been very positiverdquoWith more than 1300 visitors to the

booth Metso certainly made an impact

ldquoWe learn a lot from each show and with

some time wersquoll have a better understand-ing of the tangible results of our effortsrdquo

Keith adds

reliable service for mining equipment as

well as customized cost-effective life-cycle

services contracts

Technology ndash MetsoMAP

is an industry firstMINExpo provided the industry with its firstglimpse of Metsorsquos revolutionary iPad app

MetsoMAP The app was demoed to the

boothrsquos visitors via ldquothe worldrsquos largest iPadrdquo

a custom-made 80-inch screen that show-cased all of its capabilities most of which are

groundbreaking in the industry MetsoMAPrsquos

simple interface is highly intuitive making

it easy to view process animations videos

The presentation of the new HP cone crusher attracted a large audience

8132019 Results Minerals Aggregates 3 2012ENG

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When yoursquore allowed less than a dozen days per year for breakdowns repair andmaintenance every single hour during a service shutdown counts There simplyisnrsquot any room for surprises Thatrsquos why Boliden counts on MetsoTEXT amp PHOTOS Sofia Williams

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Kurt Kalla Site Managerof Metso Gaumlllivare ServiceCenter is responsible forthe maintenance of Aitik

Metso and Boliden Strivingtogether for 97 uptime

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983122983141983152983151983154983156983145983150983143 983154983141983155

One of the biggest copper mines in

Europe Bolidenrsquos Aitik is located deep inthe wilderness of Swedish Lapland next to

the small town of Gaumlllivare The mine has

been operating since 1968 and a recent

expansion has increased its annual ore

production to 36 million tons

But the ambitious Swedes are not will-ing to lay back and relax just yet Bolidenrsquos

new aim is to reach a production rate of

45 million tons of ore per year in AitikAfter that Perhaps more than 55 million

tons The ore concentration in Aitik is very

low-grade with a mere 022 copper con-

tent hence the need for high capacityAchieving the ambitious production

goal requires maximum plant availability

This means that everything from the crush-

ers to the filters must be up and runningfor approximately 97 percent of the time

Thatrsquos where Metso comes into play

A cost-per-ton contract in action

The maximum uptime requirement allowsless than a dozen days per year for break-

downs repair and maintenance at Aitik

Every single hour during a service shut-

down counts There simply isnrsquot any roomfor surprises

Executing a successful shutdown under

such conditions requires a reliable service

partner not afraid of challenges and this iswhy Boliden has entrusted Aitikrsquos services

operations to Metso Boliden and Metsohave worked together since the 1960s

and the collaboration took another step

forward in September 2012 when the twocompanies signed a three-year extension

of the services contract for Boliden Aitik

ldquoThe new contract is a cost-per-ton

agreement We get paid based on Aitikrsquos

production Itrsquos a win-win deal for both par-

ties but also a new mindset for usrdquo explainsKurt Kalla Site Manager of Metso Gaumlllivare

Service Center responsible for serving Aitik

From now on the duration of the shut-down is what matters the most According

to Kalla the Metso service organization in

Gaumlllivare is now streamlining its operations

to fit the bill and has already witnessed thestrategy working In August 2012 Metso

carried out a 188-hour service shutdown in

Aitik which turned out to be a success

Zero tolerance for injury

One key factor to the success was theextensive planning of precautionary health

safety and environment procedures under-

taken by Metso prior to the shutdown Thanks to strict measures applied no

injuries or accidents occurred during the

shutdown and the work could easily be

finished on scheduleMats Johansson Health Safety

and Environment Manager for Metso in

Sweden explains how this was achieved

rdquoPlanning of the shutdown included arisk analysis for all new tasks participating

in Bolidenrsquos safety coordination meetingsmeeting with both Metso supervisors and

subcontractor supervisors and finally a

meeting with the entire staff participating

in the shutdown where everyone had to

sign a document stating their commitmentto the information providedrdquo he says

During the actual shutdown plenty of

new barriers signs and awareness cones

were put in place as a result of observa-tions from previous audits and safety plans

and risk analyses were readily available

in the work area Metso and Boliden also

introduced a Mill Inching permit a certifi-cate for completing a mandatory course for

those involved in the process In addition

Metso carried out random safety audits

during the shutdown to make sure thestrict policy was followed

According to Boliden Metsorsquos way of

working is a good example of how health

and safety precautions should be handled

ldquoMetso is a good example of how towork with safety and health plans risk

analysis permits and welding permits

Their table with all binders in the second-

ary mill area was exemplaryrdquo says Kjell-Arne

Johansson a technician from Boliden

The use of the new Metso Megalinertrade

system in the lining of Aitikrsquos Metso AG

mills has also improved the safety of main-tenance staff The Metso Megalinertrade con-

sists of larger-than-average liners bolted

in position from outside the mill Mainte-

nance technicians no longer need to go

inside the mill and stand in the dangerousdrop-zone of the liners gt

Boliden aims to reach a production rate of 45 million tons of ore per yearin the Aitik mine site

ldquoA complete risk analysis was conducted during the planningof the shutdownrdquo comments Mats Johansson Health Safetyand Environment Manager for Metso in Sweden

8132019 Results Minerals Aggregates 3 2012ENG

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Service the Metso way

24 hours a day 365 days a year

In addition to paying close attention to

health and safety issues executing an effi-

cient shutdown requires careful planning

and timing of every step in the mainte-

nance process Wear and spare parts have

to be available on time and a repair shoplarge enough to accommodate equipment

located close by

ldquoTo keep maintenance breaks as short

as possible we aim to replace the pump on

site and bring the old one for repair to our

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

nearby facilities This method gives us the

peace to do a good job and keep the cus-

tomerrsquos operations runningrdquo Kalla describes

the Metso way of handling Aitikrsquos pump

maintenance

Metso is currently expanding its Gaumllli-

vare service center to include a distribu-

tion center for wear and spare parts andalso concentrating its previously scattered

operations under one roof in its Vuoskon-

jaumlrvivaumlgen facility The expansion is due to

be completed by 2014

Metso equipment

delivered to Aitik36

bull 2 AG mills diameter 116 x

137 m gearless 22-MW motor

bull 2 Pebble mills diameter 91 x

113m dual 5-MW pinion drive

bull 3 VPA pressure filters VPA 1540-54

bull 12 sample pumps and pipes

VF50

bull 60 Various slurry pumps up to

MR500 modelbull Appr 5000 m rubber-lined slurry

pipes up to 600 mm diameter

bull Appr 5000 m rubber-lined by

gravity pipes up to 600 mm

diameter

bull Appr 5000 m rubber hoses

up to 600 mm diameter

Not only does the expansion make ser-

vice shutdowns at Aitik run more smoothly

it guarantees a more comprehensive

on-call emergency service response in the

region ndash thanks to the spare and wear parts

inventory available 24 hours a day 365

days a year

More info

Lars Rosenling

Tel +46 70 107 45 90

larsrosenlingmetsocom

Metso grinding equipment dominates the view in the concentrator

Safety on site is made up of small things like

making sure that everyone remembers to secure

the hoses in place

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983122983141983152983151983154983156983145983150983143 983154983141983155

Pebbles have always been a

challenge for producers of sandsince they cannot be returned

to rivers after extraction For

decades the processing of this

material resulted in a huge

environmental liability with alarge amount of pebbles hav-

ing to be stored away and left

unused

Transforming problems into

business opportunities

Areia amp Cia (areia = sand) has

operated in this market forover 20 years and decided to

enlist the help of Metso to find

a profitable solution for the

processing of pebbles

In July 2011 analyses werebegun to assess the abrasive-

ness and crushability of the

material Four alternatives wereidentified for processing and

transforming pebbles into sand

Initially Areia amp Cia was

interested in acquiring an

impactor for its reason-able price level However the

customer wanted to process

all the pebbles that were col-

lected daily in addition to some of the

material that it had stored In weighing theresults expected by the customer and the

excessive abrasiveness of the material the

HP200 cone crusher was decided on as thebest alternative

Areia amp Cia made the required invest-

ment and after using the HP200 for just

six months the company has already beenreporting outstanding results The HP200

not only transforms pebbles into sand but

also produces sand of excellent quality

with high yield and low maintenanceWith minor adjustments the HP200

also enables the production of sand withspecific particle size distribution for special

applications such as filtering sand blasting

and foundry sand adding value to the prod-

uct and increasing the types of sand offeredldquoMetso is pleased that the HP200 not

only enabled the processing of a product

that had been set aside as unusable but

HP200 cone transforms pebblesinto high-quality sandOver the last few decades Brazilian economic growth has been driving demand for construction aggregates The market

for sand in turn has been experiencing major difficulties in maintaining a consistent supply Presently one of the mainchallenges the industry faces is the large amount of pebbles that are obtained in the process of extracting sand at timesconstituting nearly 50 of the volume of material dredged from riverbeds

TEXT Sheila Ivers PHOTO Areia amp Cia

also that it opened up new

market opportunities for Areiaamp Cia Thatrsquos the standard we

seek to deliver to our custom-

ersrdquo states Luiz Oliveira Techni-

cal Salesperson of Metso Brazil

HP cones entering the

Brazilian sand-making

market

Todayrsquos cones such as theHP200 have high resistance

to impacts and abrasiveness

more efficient crushing cham-

bers low maintenance costsand excellent productivity

Following the acquisition of

the HP200 Areia amp Cia is now

also producing special sands

that command a price that is100 higher than common

sand The entire stockpile of

pebbles accumulated through-out the companyrsquos 20 years of

operations has already been

transformed into sand and the

stock of pebbles held by com-

petitors is also being purchasedfor processing

Cristiane Brizolari the

owner of Areia amp Cia confirms

the transformation that has taken place in

the production and commercial processldquoThe HP200 opened up new niches in

the market enabling the production of dif-

ferent types of sand with added valuerdquo

More info

Luiz Oliveira

Tel +55 011 9971 3603

luizoliveirametsocom

After the pebbles are crushed into sand with the HP200 cone crusherdifferent grades are screened for various end uses

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Where therersquos a will we dig a wayAFCONS-Strabag and Metso embark on tunnel project together

When the joint venture AFCONS-Strabag initiated work on the Rohtang bypass tunnel project at an altitude of 3980 metersabove sea level in Himachal Pradesh India they deliberated each aspect with clockwork precision The project involved anumber of surprises and challenges and required technology and project management skills that were second to none

TEXT amp PHOTOS Monisha Majumdar

Cutting a 10-meter-wide and nearly 9-kilo-

meter-long tunnel through the Himalayas

in one of the toughest terrains and cli-mates in India makes for quite a challengeResults set out to find out how AFCONS-

Strabag and Metso are making their way in

one of their most critical projects to date

The only road connection to the north-Indian border region of the province

Himachal-Pradesh and beyond the Manali-

Leh highway leads across the Rohtang

pass Due to the heavy snowfall and high-

velocity winds in this region the towns

located north of the pass are cut off from

the rest of the country during winter for atleast four often even six months each year

A tunnel with strategic importance

With the construction of the tunnel at

3100 m above sea level the Manali-Lehhighway will become an all-weather road

thereby enabling a significant improve-

ment in the economic development of

northern Himachal-Pradesh and an alter-

nate route to the strategically important

Ladakh region

Manali south of the pass is an alreadywell-developed tourist location that is

becoming more and more popular Upon

completion of the tunnel it is likely that

tourist activities will extend to the areanorth of the pass Moreover the tunnel

shortens the distance between the towns

of Manali and Leh by approximately 45 km

thus saving several hours on the small dan-gerous pass road

The Rohtang pass in the Western Himalaya

region of Northern India with its altitude ofalmost four kilometers ranks among thehighest trafficable passes in the world

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983122983141983152983151983154983156983145983150983143 983154983141983155

The 88-km long horse-shoe-shaped

tunnel provides space for a two-lane8-m-wide carriageway as well as a one-

meter-wide footpath on both sides A

22-m-high and 36-m-wide emergency

tunnel will be integrated in the tun-

nel cross-section Altogether more than

800000 msup3 of rock will be moved Tunneling works started around spring

2010 with excavation driven from both por-

tals As the north portal is inaccessible dur-ing winter closure the excavation focused

on the south After a planned construction

period of 55 years the tunnel is scheduled

to be completed by the end of 2015

Best man for the job

The BRO (Border Road Organization)

wanted to roll out a global tender for theproject due to the challenges that such a

project involves and also considering thatitrsquos the first time in India that a project of

this scale was to be carried out This imme-

diately triggered the need to roll out aglobal tender All major Indian construction

companies bid for it some individually and

some in partnerships

Strabag an Austrian tunnel specialistwas one of the companies who bid for the

project along with AFCONS a Mumbai-

based infrastructure company In Septem-

ber 2009 AFCONS-Strabag was awardedthe contract

Mr Sunil Tyagi Deputy Project Man-ager at AFCONS had this to say about the

unique projectldquoThis project is located in the Himalayas

and as far as we understand the terrain

there is among the toughest We came out

with a new technology and to be honestit is a fairly simple one We would generally

start with the traditional technology of drill-

ing and blasting and then obtain our muck

feed from the inwardbottom of the tunnelrdquo

ldquoThe technology is supplied by Rowa Tunneling Logistics and this is the first

time it is being used in Asia A jaw crusheris placed at a distance of about 40-45

meters behind the face The blasted muckextracted from the face is fed to the crusher

to reduce the lump size and then through

an overhead conveyor transport system

it is then transported out of the tunnelrdquoldquoThis enables free movement of man

and machinery in the lower area or spe-

cifically on the ground area If we were to

conforms to the Indian standard for fines amp

coarse aggregates as prescribed in IS383-1970

The plant was up and running in good

condition and performing to AFCONSrsquos

satisfactionldquoWe have worked with Metso in earlier

projects and are quite impressed by thekind of technology amp services they provide

We have a history together so the trust fac-tor also comes inrdquo explains Dhiman on their

choice of Metso as a partner

Service makes the difference

ldquoMetsorsquos services have made a big dif-ference in the project Without them we

would still be struggling with the machin-

ery and production The service is really

good and the service engineers are knowl-edgeable prompt and quick to act Any

problem can be solved by Metso We donrsquothave to wait until a service engineer turns

up ndash they have the capacity to solve prob-lems over the phone as wellrdquo says Dhiman

ldquoThe Metso plant didnrsquot create any prob-

lems for us We had problems in logistics

the feed was sticky and the weather condi-tions were bad but thankfully we did not

face any problems with production and

efficiency as the Metso plant is performing

very wellrdquo Dhiman concludes

More info

Amol Sinha Tel +91 9811 671 924

amolsinhametsocom

use the old conventional technology this

wouldnrsquot have worked for us in the stipu-lated timerdquo Mr Tyagi adds

When the going gets tough

partner with the toughest

Sensitive projects require the best technol-

ogy After AFCONS-Strabag landed theproject Metso was an obvious choice as a

technology provider not only because of

the long-standing business relationshipbut also for the sheer consistency in prod-

uct quality and service deliverance Metso

strives for

ldquoAfter signing the project we faced alot of road blocks including extreme cold

avalanches roadblocks less oxygen ndash you

name it we faced itrdquo explains Ankit Dhi-

man Plant Manager at AFCONS-Strabag The Rohtang valley is known for its

notorious avalanches and landslides SoAFCONS had to take extra steps and safety

precautions against hazards on the site

ldquoIn this freezing cold not just us humansbut also the machines are at increased risk

of damage I remember when we used

to run the plant during winter the diesel

engines would freeze We had to constantlyheat up the fuel container to get the plant

running And even the sand in the sand

trap would freeze so we had to clean it on

a daily basis to stop the pipes from mal-functioningrdquo Dhiman adds

Plant designed for difficult terrain

Difficult terrain coupled with space con-straints led Metso engineers to put their

minds together to come up with a suitable

plant configuration After studying the

requirements of the project Metso sug-

gested a 150-tons-per-hour three-stagemodular plant using a C106 jaw crusher

a GP11F secondary cone crusher and a

B7150 tertiary vertical shaft impact crusher

In addition considering the unpredict-ability of the feed the plant was about

to reach a point where the amount offines to be handled could be increased

dramatically Metso strongly suggested the TK11-27-3V grizzly scalper and this became

the first-ever TK scalper to be supplied by

Metso to an Indian customer Also in order

to get better products a sand trap SF2360was added to the configuration

The sand trap is important equipment

for this project as it washes the sand thatMr Sunil Tyagi Deputy Project ManagerAFCONS-Strabag

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Smooth transition to new-generation jaw crusher in Germany

Roumlhrig is a German company with a rich heritage The company has been quarrying granite at its plant in Bergstrasse inthe Sonderbach district of Heppenheim for three generations

TEXT amp PHOTOS Ralf Goffin

Roumlhrigrsquos superior product variety is onereason why the companyrsquos proximity to its

customers can be understood in more than

just physical terms The companyrsquos high

level of innovation has allowed it to estab-lish itself as a reliable supplier of materials

both regionally and internationally This

operational and technical expertise always

manages to keep in step with growing

market requirements

In terms of technical processing equip-

ment Roumlhrig has used a Nordberg C160stationary jaw crusher from Metso since

1992 At the start of 2012 it was finally

exchanged for a more up-to-date version

from the same model range

Metsorsquos C Series is specifically designed

to pre-crush hard rock and can cope effort-

lessly with even the hardest of materials

The dimensions of the new stationary jawcrusher are identical to those of the old

one which means that it could simply be

slotted into the housing vacated by the

previous version

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983122983141983152983151983154983156983145983150983143 983154983141983155

Third-generation Managing DirectorMarco Roumlhrig expects the new machinersquos

service life to be just as long as the previ-

ous model due to the product upgrades

that have been implemented The integral motor base is another plus

point in models made by other manu-

facturers it is located outside the crusher

This element of good fortune ensured that

Roumlhrig could reuse the housing withoutany additional rebuilding

Another advantage lies in the revision

of the guards for the C160rsquos drivetrain andflywheel The sturdier construction method

used for the crusher requires fewer parts

which facilitates easier installation andmaintenance and it makes it simpler to

access the motor

Under the watchful eye of Metsorsquos

Assembly Manager Maik Engelstaumltterthe entire project including removal and

installation was successfully completed

within two weeks

Installation making the most

of the available space

Roumlhrig will likely remember the day the

new crusher was installed for a long time

the pitman and main frame were deliveredseparately prior to installation and assem-

bled on site It took just one hour to replace

the old stationary crusher with the new

model A lorry-mounted crane was used toposition the 85-ton crusher with millimeter

precision in the crushing plant Once the

new crusher had been positioned in theexisting steel structure the next task wasto fix it into place as securely as possible

despite the limited space Special vibration

dampers were installed at a height of two

meters to prevent the crusher from sliding

Norbert Ried (fourth from left) installed thenew C160rsquos predecessor 20 years ago and isdelighted at the durability of the powerfulcrusher that is now making way for a newermodel Also pictured from left to right ManagerVolker Angermann Assembly Manager Maik

Engelstaumltter Technical Manager Stefan

Koob Project Manager Dominic SchoumlnhardtManaging Director Marco Roumlhrig Service

Technician Stefan Kolze and employees ofthe installation company Stafemo

On the hook after theold C160 was liftedout by crane the newcrusher was installedin almost no timeOnly the roof of thehousing had to beremoved

sideways off its mount An initial test run

with materials was carried out around oneweek later after all the electrical cables had

been installed

Simultaneously with the installation

of the C160 which is the first of the latest

generation of crushers to be installed in

Germany a new Nordberg GP100 conecrusher was also being installed in Roumlhrigrsquos

chipping plant Roumlhrig is convinced that

the technical improvements made tothe new Metso crusher can only be an

advantage worldwide

Roumlhrig places great value on consistent

product quality maximum added valueand optimum refinement of its product

range Bearing in mind that Roumlhrig has

enough reserves of raw material to last

for the next 150 years the company canconfidently continue to develop with an

emphasis on quality rather than quantity

More info

Dominic Schoenhardt

Tel +49 (0)621 727 00 610

dominicschoenhardtmetsocom

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Groupe Charier Carriegravere de la Mariais France

Quarrying with certi1047297ed quality The Charier Group with its 1600-strong workforce is a family business thatthis year celebrates 115 years of quarrying The company pursues a long-termdevelopment policy that since 2007 has seen processing installations upgradedat 4 of its 9 extraction sites

TEXT Liliane Boutin (with extracts from Mines amp Carriegraveres and Terrassements amp Carriegraveres magazines)PHOTO Baloon photo

The processing installation is of the horizontal type with a primary station located 56 meters below the site access road to keep it hidden from view

The crushing and screening installation at

Charierrsquos CM La Mariais quarry (at Donges

on the Loire estuary) has been in opera-tion since September 2011 Based on theoperatorrsquos ideas it was designed by Metso

to replace a worn-out installation installed

right on top of the seam being extracted

Since its commissioning it has becomethe second quarry in the company to

receive ISO 14 001 certification

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983122983141983152983151983154983156983145983150983143 983154983141983155

tertiary material of sand and gravel for the

local market to use in concrete surfacingprefabrication etcrdquo

Incorporation of a screening station

The stone extracted from La Mariais is

according to the quarry granitic gneiss

sound and homogeneous with a LosAngeles index of 15 good wear resist-

ance with an MDE of 10 a true density of

265 and a certain abrasiveness (2000 gt)ldquoCharacteristically it has a tendency to form

blocksrdquo Leblin points out

The main criteria in designing the instal-

lation was to provide an output of 600000metric tons from one station (38 hours

week) to produce materials aimed at the

concrete and surfacing markets ldquowhich

involved providing a tertiary station withscreening plantrdquo he adds

With this new unit the operating com-pany expands its product range through

the addition of fine materials obtained

from the tertiary screening station This unitis capable of producing 170 tonshour of

020

Preserving the environment

and optimizing safety

The screens have motorized bogies and

retractable walkways to facilitate access

when the screens are opened for main-tenance Other walkways provide access

to the tunnel input feeders The feederscan be isolated with hydraulic rod gate

bars this hydraulic assistance eliminatesthe need to use a heavy hammer to lodge

these metal bars

All conveyors transporting fines (02

and 04) are covered with a tarpaulin to

avoid flying dust and all the screens arehooded (metal cover with Trellex seal-

ing) The Brunone company has installed

dust-tight containment at the outlet of the

tertiary station crushers (HP300 and HP4)on the belt located under the screens

and under the hoppers located belowthe tertiary screens The crushers are put

under negative pressure and the finesare extracted through sleeve filters (7000

m3 h) with declogging which deposits the

dust back onto the conveyor belt

A high-pressure 100 bar water mist sys-tem has been installed at the primary sta-

tion discharge at the secondary crusherrsquos

discharge chutes (Omnicone) and at the

transfer points on the belt

Designed to last

ldquoThis type of new installation can easily last

thirty yearsrdquo affirms Project Leader Bruno

Peix of Metso ldquoIt quite simply depends on

how well it is maintained Thatrsquos why weprovide maintenance contracts that call for

our technicians to make regular inspection

visits and carry out preventive mainte-nance and any necessary repairsrdquo

In 2011 Metso commissioned about

10 new processing units in France like

the one at La Mariais quarry

More info

Frederic Bazire

Tel +33 (0)681442804

fredericbaziremetsocom

Key figures

DURATION OF WORKS 15 months

DRAWING OFFICE TIME 7800 hours

HEIGHT OF SILOS AND GRINDER BUILDINGS

15 m

TOTAL LENGTH OF CONVEYORS 14 km

WEIGHT OF THE INSTALLATION

1200 metric tons

CONCRETE POURED 1800 cubic meters

PROJECT SITE WORKFORCE 30

INSTALLED POWER 2200 kW(not including pumps 200 kW)

METSO EQUIPMENT

Primary

Vibrating feeder PF561-2V

Primary grizzly VG540-3V

Grizzly feeder TK13-20-3V

Jaw crusher C145 with

hydraulic setting

Secondary

Vibrating screen CVB 2050

refurbished

Cone crusher Omnicocircne 1352 SX

with Metso IC7000 controller Ellivar 16 (16 msup2 3 decks) screen

refurbished by Metso

Tertiary

Cone crusher HP300

Cone crusher HP4

2 Ellivar 20 screens (20 m23 decks) for final products

Expanding the production range

ldquoSince the mid-1990s when we became

owners of La Mariais we had used mobilemachinery with an assembly of beltconveyorsrdquo recalls Daniel Leblin Charierrsquos

Technical Manager for site construction

and maintenance

ldquoIt became clear that we needed ahigher performance tool to achieve the

dual goals of reaching one million metric

tonsrsquo maximum production and producing

8132019 Results Minerals Aggregates 3 2012ENG

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Big Lokotrack LT550GPF boostsquarrying productivity by a thirdMaximizing the productivity of operations is a key issue when striving for cost-effective quarrying Big Lokotracks are oneway to achieve improved operational efficiency The Lokotrack LT550GPF equipped with the high-volume GP550 conecrusher and a large screen is popular in the Nordic countries and in Germany and Australia ndash countries all known for theirhigh quarrying volumes

TEXT amp PHOTOS Eero Haumlmaumllaumlinen

Kone-Kostamorsquos new mobile coneplant has reached an averagecapacity of 300 tons per hour

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983122983141983152983151983154983156983145983150983143 983154983141983155

ldquoWith the same number of employees we

can achieve 30 more productivity with

our new LT550GPF unit The high-capacityFS screen has also eliminated the bottle-neck often seen at fine screeningrdquo says

Aarno Kostamo Managing Director of

Kone-Kostamo Oy one of Finlandrsquos biggest

crushing contractorsAccording to Kostamo the high capacity

of the GP550 gyratory cone crusher easily

handles feed from the C120 and C125 jaw

crushers For the contract with the Talvivaara

nickel mine the LT550GPF is being fed bythe brand new Lokotrack LT120 jaw plant

Average capacity 300 tons per hour

Talvivaara Europersquos largest nickel mine uti-

lizes large quantities of aggregates Kone-Kostamo has contracted several million

tons of different end products for the mineIn August 75000 tons of 0ndash63 mm

road gravel was crushed Smaller amountsof finer 0ndash6 mm 0ndash16 mm and 0ndash32 mm

aggregates are also being produced

The rainy summer increased the need

for road gravel along the muddy roadswhich must endure dump trucks weighing

as much as 260 tons

ldquoThe mobile process consisting of the

LT120 jaw plant and LT550GPF cone plant

is cost-effective while aggregates of vari-ous sizes can be produced in a two-stage

operation and with high capacity The con-trolled stroke and elliptical movement of

the FS screen secure big passing throughcapacitiesrdquo Kostamo explains

Operated in two shifts for a total of 16

hours per day the LT550GPF has logged

more than 600 working hours over a two-month period

Managing Director Aarno Kostamo (left) and foreman Karri Maumlenpaumlauml studying the cavity optionsavailable for the new Lokotrack LT550GPF

Longer perspective than

a single quarter needed

Kone-Kostamo Oy was founded as an

earth-moving company in Kemijaumlrvi

Northern Finland in 1956 The company

expanded its operations to include crush-

ing contracting in 1964 and later on

switched to concentrating fully on crush-ing activities

Kone-Kostamo consistently crushes

and screens around 28 million tons ofaggregates annually and has net sales of

between EUR 8ndash9 million

ldquoWe believe that issues within the crush-

ing industry including the purchasing ofmachinery must be studied with a longer

perspective than a single quarter The

secret to our success has always been our

solid work ethic and professional employ-eesrdquo Kostamo sums up

More info

Esa Berg

Tel + 358 40 837 8692

esabergmetsocom

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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155

Monitoring-based reporting is vital for

assessing the performance of a mobile

crushing plant Metso provides suchreporting tools through its plant-wideautomation system Metso DNA (Dynamic

Network of Applications) with its infor-

mation platform that links all the mobile

crushing and screen units together as oneentity Basically there is a lot of measured

real-time information available in every

crushing plant On-line information is

obtained either from each Metso crusherrsquosmachine automation system IC (Intelligent

Controller) or from separately installed

additional sensors and belt scales

All the collected data is sent to a motorhome using wireless communication

based on WLAN technology The motor

home is a purpose-built environment

inside an on-site container In this environ-ment selected variables can be monitored

for assessing the plantrsquos performance And

to make all this even more flexible the

data can be transmitted to a crushing plant

company office using GPRS3G mobile

data communication technologies Thismakes all the last-minute reports acces-sible to the crushing plant managerial staff

at anytime and basically anywhere within

reach of the cell phone network

Production and fuel economics reports

Essentially monitoring and reporting can

be customized to fit the customerrsquos needs

However there are certain off-the-shelf

reports that provide a lot of useful informa-tion for plant supervision The production

report is one of these Requiring at least one

belt scale for measuring the total produc-tion the production report shows the pro-duction rate (tons per hour) for a selected

reporting period eg a day or a week The

production report constantly keeps track of

the plantrsquos production storing all the datathroughout the plantrsquos life cycle

Performance monitoring and reportingfor a mobile crushing plantTEXT Pasi Airikka PHOTOS Metso

unit during which the unit is running By

storing the availability times between start-ups and shutdowns the crushing plant

operation time (hours per dayshift) can be

recorded analyzed and reported In addi-

tion the availability report can be tailored

to evaluate efficient crushing hours during

which the plant is really working and pro-ducing aggregates Consequently the ratio

(0-100) between efficient crushing time

and total running time can be reported forany selected period of time This boosts

the efficiency of the plantrsquos operations

and results in better productivity

Reports on non-choke

or inadequate feeding

Non-choke feeding to crushers is avoid-

able through smart plant-wide crushingplant controls But estimating its severity in

a systematic manner is not straight-forwardwithout constant monitoring and reporting

The crusher choke feeding report makes

use of the crusher cavity level sensors byanalyzing their level measurements By

calculating average and min-max values

and deviations from the average it can be

shown how often the single crusher suffersfrom non-choke feeding to it

In some cases the bottleneck in the

crushing plantrsquos productivity is the material

feeding to the process In mobile plants thefeeding is human operated and therefore

subject to variations Occasionally the sizeof the human-operated machine simply

does not allow for adequate feeding to thecrushing plant There are specific reports

indicating time periods when the crushing

plant suffers from inadequate feeding

Condition monitoring for

crushers and screens

Machine-specific condition monitoring

focuses on vibrating components in

crushers and screens such as drive shaftbearings safety plate wearings and gears

The low middle and high frequencies ofmonitored components are measured and

supervised in real-time to detect abnor-malities due to slow or fast wear looseness

or imbalance

More info

Pasi Airikka

Tel +358 40 587 2730

pasiairikkametsocom

Condition monitoring provides a view tovibrating crusher and screen components forpredictive equipment maintenance

The daily production report shows the hour-by-hour production trend and distribution chartfor a selected day with min-max average andvariation statistics for comparison

Fuel consumption is always an interest-ing concern The fuel consumption reportgives the fuel consumption of each crush-

ing unit (liters per hour) and their total

consumption (liters per hour) for a selected

reporting period and can track fuel con-

sumption changes over timeCrushing plant availability can be

assessed as well The availability report

calculates time periods for each crushing

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983149983141983156983155983151 983150

for tissue machines The record of 2210

mmin was set on June 1 2012 during a

24-hour production run by the TM 2 tissue

machine at the companyrsquos mill in Yenikoumlynear the city of Izmit in Turkey

ldquoThe cooperation with Metso has been

beyond excellent and both parties did

their utmost to make the project success-ful The results clearly show that the efforts

were worthwhile on both sides This coop-

eration will extend to cover new projects

in the futurerdquo says Luumlt1047297 Aydin Paper GroupDirector Hayat Kimya

ldquoWe are not surprised that Hayat K imya

managed to break the world speed record

We have had great confidence in the capa-bility of the Hayat team since our project

started in 2009 We certainly know our

machine very well its stability production

efficiency and speed capabilityrdquo says Jan

Erikson Vice President Sales Metso

PowerThe worldrsquos first eco-gas fueled

power plant is up and running

Lahti Energy Ltdrsquos new Kymijaumlrvi II gasifica-

tion plant was officially inaugurated on

May 8 2012 It is the first of its kind in the

RecyclingRecycling with Lokotrack LT106

jaw plant in New York

A brand-new Lokotrack LT106 jaw plant is

used in the city area of New York USA to

recycle demolition materials The crushing

site faces the skyscrapers of ManhattanIsland

Paper amp FiberHayat Kimyarsquos Metso-supplied tissue

machine sets world speed record

Thanks to a skilled crew and dedicated

efforts Hayat Kimya AS in Turkey has suc-

ceeded in breaking the world speed record

world This CHP plant runs on clean eco-

gas that is gasified cleaned and cooled

from recycled waste with Metsorsquos innova-tive technology

ldquoItrsquos actually eco-gas that we combust

in the boilerrdquo comments Lahti EnergyrsquosProduction Director Jukka Manskinen

ldquoWe convert unwanted waste material into

energy in an efficient and environmentally

friendly wayrdquoNever before has any plant gasified

waste on such a large scale In the gasifier

recycled waste is turned into combustible

product gas which is cleaned cooled and

combusted in a high-efficiency gas boiler

to produce steam for the steam turbine The plant produces 50 MW of electricity

and 90 MW of district heat for the city of

Lahti and its neighboring areasMetso delivered the circulating fluidized

bed (CFB) gasification process gas cleaning

and cooling steam boiler environmental

protection system and automation systemto the entire plant The production of elec-

tricity and heat is kept even with the Metso

DNA automation system that covers the

whole plant starting from fuel reception

AutomationMetso develops and supplies plant-

wide crushing control solutions for

crushing plants

Metso has recently signed contracts on

delivering plant-wide automation systems

for mobile and portable rock crushing

plants The key objective of these deliveries

is to stabilize and to increase productivityand efficiency of the plants using one sin-

gle automation and information platform

for integrating crusher-specific IC machinecontrols

Furthermore the plant-wide system

with its information management tools not

only increases plant availability and opera-

tional safety it also makes troubleshoot-ing quicker and performance monitoring

easier The control room for plant-wide

operability is located either in an excavator

cabin or a purpose-built container

Metso around the world

The new LT106 jaw plant is suitable for crushing both hard rock and all rock-based demolition materials

The new world speed record for tissue setby Hayat Kimyarsquos Metso-supplied TM 2 is2210 mmin

8132019 Results Minerals Aggregates 3 2012ENG

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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: Results Minerals Aggregates 3 2012.ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Service creates value in ChinaChinarsquos most important gold producing area Yantai in northeastern China supplies more than 16 of the countryrsquos goldproduction each year With the gold market thriving the scale of gold production in Yantai has been expanding constantly

Zhongjia Mining Industry Co Ltd is one of the beneficiaries of this thriving industryTEXT amp PHOTOS Yan Xin

Inspection and maintenance of the HP500 cone crusher conducted by Metsorsquos service engineers

In 2011 Zhongjia Mining Industry pur-

chased a modular crushing and screen-ing system from Metso for its new gold

production project With the cooperation

between the two companies continuously

intensifying Zhongjia Mining Industry

signed an additional one-year Life CycleService (LCS) contract with Metso incorpo-

rating Metsorsquos global knowledge in equip-

ment processes and services

ldquoMetso customized a series of reason-

able service solutions also referred toas Metso Performance Solutions for us

including preventive maintenance services

process improvement personnel training

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983122983141983152983151983154983156983145983150983143 983154983141983155

and a procurement plan for wear parts

These really suit our needs perfectlyrdquo saysShen Yidong the Manager of ZhongjiaMining Industry

Effective preventive maintenanceFor mining corporations the biggestconcern is the economic losses caused by

the shutdown of equipment As a result

preventative maintenance is of vital impor-

tance During the contract period Metsoservice engineers offered 7-day tracking

service on the production site every month

to eliminate potential problems and thus

ensured the stability of the system

parts caused pressure on our working capi-tal which was not favorable for our long-

term developmentrdquo Shen explains

To solve this problem Metso designed

a rational stock plan of wear parts and built

a field warehouse In accordance with theuse and consumption of the liners the field

service engineers complement the stock tomake production and operations run more

smoothlyldquoNow when we need to replace the

wear parts we can use them before pay-

ment This not only simplifies the procure-

ment process but also liberates a largesum of our operating capital which can

be used for other business development

purposesrdquo says Shen

Best partner

ldquoAlthough the LCS contract incurs some

early purchase costs in the long run Metsorsquosprofessional and quality service will improve

the equipment efficiency reduce ourenergy consumption and ensure stable

operations thus generating more prof-

its This is the greatest value for us so the

investment is really worthwhile overall Inthe future we will choose more Metso prod-

ucts and services Taking all aspects into

consideration we believe Metso is the best

partner for usrdquo Shen Yidong concludes

More info

Thomas Bai Tel +86 13801009114

thomasbaimetsocom

ldquoIn the eight months since the contract

came into effect our corporation has notsuffered any financial losses due to equip-

ment breakdown The regular maintenance

has greatly improved the efficiency of our

entire crushing system In addition the

experienced engineers from Metso also

provided onsite training and guidancefor our staff and the tailored training has

greatly enhanced the operating abilities of

our employees and upgraded their overalllevel of competencerdquo says Shen Yidong

More productivity with

less consumption

Metsorsquos service contract focuses on real-

izing the optimum performance of each

process flow After analyzing Zhongjiarsquos

production system Metsorsquos techniciansproposed an adjustment to the closed side

setting of the HP500 for tertiary crushingin order to improve the efficiency of the

downstream fine crushing and milling pro-

cessing by over 10ldquoThe process flow improvement solu-

tions provided by Metso not only increased

the output of our gold concentrates but

also reduced our energy consumption andcostsrdquo says Shen

In the past wear parts procurement

took up a larger proportion of Zhongjiarsquos

total production costsldquoTo avoid downtime caused by the

shortage of wear parts we had to keepeight sets of various wear parts in place

However the cost of having so many wear

Zhongjia Mining Industryrsquos gold concentrates processing plant in China

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0983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

Safe quarrying high-

quality aggregates

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ldquoWe share a similar zero-accident strategy and target with Metso and have successfullyfollowed it Metso has also helped us to meet the strictest end-product quality andcubicity requirements set in Spainrdquo This is how Managing Director Intildeigo Ajuria ofOfitas de San Felices the leading hard rock quarrying company in Spain describesthe cooperation with MetsoTEXT Eero Haumlmaumllaumlinen PHOTOS Ofitas and Eero Haumlmaumllaumlinen

The San Felices quarry is situated in a picturesque mountainous landscapebetween the companyrsquos Rioja vineyards and the Bilbao-Madrid motorway

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Ofitas has pioneered the implementation

of several Metso novelties in the Spanish

market The company was the first to use

efficient large track-mounted Lokotrack jaw plants the unique mobile conveying

system and also the new-generation HP4

cone crushers

Today the company operates twomodern Metso stationary plants one in

Guadix near Granada and the newest one

in San Felices Haro Rioja community Both

quarries focus on refining hard rock by pro-cessing ophite rock into the highest quality

railway ballast asphalt and concrete mix

grades The company has a satellite quarry

near Vitoria in PentildeacerradaBeing situated next to a highway and

the famous Rioja vineyards Ofitas must pay

special attention to environmental issues

To minimize dust problems all conveyors

have special covers attached

Quality durability and service

The cooperation between Ofitas de San

Felices and Metso started back in 1973when the Ajuria family bought the com-

pany whose quarrying activities began in

1919 Intildeigo Ajuria has a clear vision of why

the cooperation has continued withoutinterruption for almost 40 years

long-standing personal relationshipsrdquoAjuria adds

Serving railways asphalt

and concrete producers

The year-old San Felices stationary instal-lation lies hidden in a mountainous area

south of the city of Vitoria in NorthernSpain The new plant replaces an old one

that complicated the extraction of ophiterock Both plants are delivered by Metso

With its two separate production lines

the new plant is able to produce all the

end products required ndash from railway bal-last to the finer grades needed for asphalt

and concrete

Due to lower demand the quarry cur-

rently produces some 4000 tons per day

At full capacity however the plant canreach 8000 tons of production per day

30ndash35 of which consists of railway ballastfor high-speed trains and 65ndash70 of chips

and sand Thanks to the versatile two-line con-

cept connected by transverse conveyors

up to 12 different end products can be pro-

duced Depending on the demand for endproducts the material can be guided either

to the HP4 cone or HP400 cone followed

by a Barmac vertical shaft impactor

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

The ophite feed is fed to the C125 jaw crusher by a sturdy dump truck

The key people running the new San Felicesquarry Mine Engineer Carlos Fernandez (left)Managing Director Intildeigo Ajuria with ProductionManager Julian Perez

ldquoThrough the years Metso machinery

has proven its production capacity and

durability resulting in high-quality end

products A big plus for us has also beenthe quick response time to our process

challenges or servicerdquo

ldquoIn fact our cooperation extends

beyond day-to-day business matters to

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155

Meeting the strictest cubicity demands

The Spanish regulations concerning end-product cubicity are becoming more

demanding The flakiness percentage of

railway ballast must be below 10 and for

asphalt and concrete aggregates less than

15

ldquoWith Metsorsquos HP4 cone and the Barmacvertical shaft impactor we can meet even

the strictest cubicity demands We believe

that our high quality is helping us to sur-vive in the present recessionrdquo notes Mine

Engineer Carlos Fernandez

ldquoWe hope to increase the total extrac-

tion of the three quarries from the present15 million tons per year because our plant

capacity allows more than double thatrdquo

Fernandez adds

More info

Angel Luis Garcia Tel +34 686 94 35 30

angelluisgarciametsocom

In addition to being the leading Spanish

quarry to process hard rock Ofitas de SanFelices also cultivates 34 hectares of vine-yards next to the quarry which is situated

in the famous Rioja wine area

The company has previously sold a

harvest of over 200000 kg of Tempranillo

grapes to local red-wine makers Recentlythe company built its own wine process-

ing plant to process 10000ndash15000 kg of

grapes themselves

Aggregates and wine production

Andoni Ajuria the founder of Ofitas de san Felices (left) with Intildeigo Ajuria the present ManagingDirector tasting wine from the companyrsquos own vineyards

The first vintage wine of Ofitas har-

vested in autumn 2010 is now maturingin oak barrels After maturing for 12 to 15months the wine is called crianza and after

two years it will be granted the classifica-

tion reserva

ldquoWinemaking is not a business but

a hobby for us We give our wine out aspresents and drink it when we meet

our suppliers and friendsrdquo Intildeigo Ajuria

comments

For environmental protectionall of San Felicesrsquos plantconveyors are covered

Ofitas de San Felices quarry

LOCATION Haro near the city

of Vitoria northern Spain

SIZE 100 hectares

ROCK TYPE Ophite with Los Angeles

index of 9ndash10

PRESENT DAILY EXTRACTION 3000 tons

of ophiteNUMBER OF PERSONNEL 30

RESERVES 10 million tons

MAIN END PRODUCTS 0ndash2 mm

2ndash4 mm 4ndash10 mm 10ndash16 mm

16ndash22 mm 25ndash60 mm (ballast)

METSO MAIN EQUIPMENT

VF feeder

C125 jaw crusher

ndash feed size 0ndash800 mm

ndash css 130ndash140 mm

HP400 cone crusher

ndash feed size 80ndash250 mm

ndash css 40 mm HP4 cone crusher

ndash feed size 40ndash80 mm

ndash css 15 mm

Barmac 6150 VSI crusher

4 CVB2060 screens

2 TS32 screens

8132019 Results Minerals Aggregates 3 2012ENG

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Metso Distribution Centers he

Europe (Tongeren Belgium)

France (Macon)

Czech Republic (Přerov)

Austria (Vienna)

2271 d

Brazil (Sorocaba SP)

1014 d

USA (Columbia SC)

1690 d

USA (Waukesha WI)

434 d

South Africa (Vereeniging)

Ghana (Tarkwa)

Meacutexico (Irapuato)

Peru (Lima)

Chile (Concoacuten)

788 d

Sweden ( Trelleborg)

Finland (Tampere)

UK (Rugby)

865 d

Russia (St Petersburg)

Brazil (Parauapebas PA)

206 d

4983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

8132019 Results Minerals Aggregates 3 2012ENG

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In the case of an equipment failure or

a planned service shutdown resuming

production as quickly as possible is crucialEach hour spent waiting for a spare part to

arrive equals money lost Whether the right

part takes 12 or 48 hours to arrive really

makes a difference

The comprehensive and global Metsospare and wear parts service network pro-

vides you with the right part in the right

place and at the right time Our strategi-

cally located Distribution Centers and

Satellite Warehouses are on call 24 hoursa day 7 days a week ensuring efficient

parts replacement near you

Check out the locations of the MetsoDistribution Centers and how many parts

pass through them each day

More info

Marcelo Farah

Tel +55 15 2102 1315

marcelofarahmetsocom

you minimize downtime

Australia (Perth)

746 d

China (Tianjin)

China (Kunming)

China (Shanghai)

393 d

India (Faridabad)

India (Ahmedabad)

India (Hyderabad)

India (Bhubaneswar)

India (Bangalore)

419 d

Russia (Yekaterinburg)

Australia (Newcastle)

New Zealand (Matamata)

983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088

TEXT Sofia Williams

Singapore (Singapore)

Distribution Center Satellite Warehouse

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Following a large investment

in Metso crushing equipmentand services Buena Vista del

Cobre is now expanding the

mine site to include even more

equipment ndash and with thatexpansion comes the need for

more local service resources

Metso and Buena Vista del

Cobre have entered into a Life

Cycle Service agreement forthe plant and construction of a

brand new Metso service hub

is under way in Cananea

New facility new

level of service

The Cananea service hub

which will be up and running in early 2013will support the recent expansion and resur-

gence of Buena Vista del Cobre Initially it

will be a major repair and assembly center

for pumps crushers and screens and will

provide for rubber covering capabilitiesBut the 8000-square-meter facilityrsquos service

offering will be expansive including a con-

signment stock inventory to help serve theminersquos varying needs Metso currently has

50 service team members on site

Although Buena Vista del Cobre was a

key influencer in building the new servicehub this location will also enable Metso to

expand its capabilities and provide local

support to the entire mining community

in northwest Mexico The Cananea hub

will serve a number of major copper and

gold mines in the region including MineraFriscorsquos San Felipe Fresnillorsquos Milpillas and

Grupo Mexicorsquos Mexicana de Cobre

ldquoBuena Vista del Cobre is the biggestcustomer we have in Mexico today and

with this expansion project itrsquos only going

to grow and be strongerrdquo says Felix Forna-

guera Director of Services Mexico CentralAmerica and Caribbean ldquoWith that said the

idea behind the Cananea service hub is to

provide a central location for local support

for all our major customers in the areardquo

Establishing safety

ldquoIt was key to have our support here in

Cananea because the Buena Vista delCobre started from the ground uprdquo saysFelix ldquoWersquove been able to help the cus-

tomer to establish the best in support

service and operations from the very

beginningrdquo And this ground-up approachincluded a major focus on safety

Metso worked closely with Buena Vista

del Cobre to establish the safety proto-

col by which the mine operates Basedon Metsorsquos expertise the safety measures

put in place have enabled the mine to

become strict and efficient in its operations

and maintenance procedures To achievethis Metso worked closely with local andnational authorities to ensure the safety

plan was comprehensive and in accord-

ance with all established legal bodies

The best in regional support

The service hub in Cananea is a prime

example of Metsorsquos focus on providing local

service and support to its customers all

Service shines in Cananea MexicoAfter three years of inactivity the Buena Vista del Cobre mine in Cananea Sonora Mexico has been operational since 2010A mine that was inactive for such a significant amount of time however requires a great deal of support to successfullyrestart the plant and bring it back to an operational and profitable state

TEXT Deanna Lee PHOTO Metso

over the world ldquoWe are the first

company developing this kindof service in northwest Mexicordquo

adds Felix ldquoOur people have

developed a close relationship

with the team at the mine Itrsquosmore than a supplier relation-

ship our guys are inside the

mine living and working thererdquo

In fact this is the model

that Metso is using in servicehubs all over the globe build-

ing modern facilities bringing

teams on site and workinghand in hand with mine

operators The Cananea Service

hub is only the most recent

example of Metsorsquos commit-ment to service and northwest Mexico is

yet another mining hotbed thatrsquos going to

benefit from the companyrsquos support

More info

Felix Fornaguera Tel +52 4621079227

felixfornaguerametsocom

A mining cone serviced by Metso at the Buena Vista del Cobre mine inSonora Mexico

ldquoThe new Cananea service center will be a majorrepair and assembly center for pumps crushersand screensrdquo says Felix Fornaguera Director ofServices Mexico Central America and Caribbean

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

8132019 Results Minerals Aggregates 3 2012ENG

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During the MINExpo exhibition over 1300 people visited the Metso stand

983122983141983152983151983154983156983145983150983143 983154983141983155

Held every four years MIN-Expo consistently grows so

perennial exhibitors like Metso

are challenged with elevating

their presence and drawingin new (and greater numbers

of ) visitors each year ldquoItrsquos not

necessarily a challenge to lsquotoprsquo

our last showingrdquo says Keith

Ference Vice President ofmarketing and communica-

tions North America ldquoThere

are four years between eachMINExpo so we always have

a lot to say and reveal to our

customersrdquo The real challenge

he says is finding an exciting

and dynamic way to deliverthe message ldquoTherersquos so much

to see here so your booth has

to be compelling from the

outside-in and thatrsquos what

we always try to dordquo

Service sets the stage

The Metso booth created buzzin a number of ways and per-

haps the most striking (partly

due to its size) was the live

theater presentation As visitorspassed through the aisles of the show-

room the sights and sounds from Metsorsquos

theater were hard to miss And once guests

entered they were captivated by a short

high-energy video presentation focused

on Metsorsquos service capabilities The message was simple Metso is ldquoyour

local service partner rdquo for all mining and

construction needs The video showed ourservice teams in action all over the world

and the audience came away with an

understanding about Metsorsquos commitment

to service Customers can count on morethan 70 local service centers run by more

than 1700 expert technicians delivering

Metso makes an impact at MINExpo 2012At this yearrsquos MINExpo International nearly 60000 attendees flocked to Las Vegas Nevada the largest turnout in showhistory The visitors ndash mining professionals from all over the globe ndash explored 850000 square feet of showroom spacefeaturing the industry rsquos latest technology equipment products and services They toured the show for three days

seeking the latest and greatest from more than 1800 exhibitorsTEXT Keith Ference PHOTOS Tracey Ford Perry

detailed descriptions andphotos of all of Metsorsquos mining

and construction products and

services The app also provides

digital access to Results and asearchable database of sales

contacts By day three of the

show MetsoMAP had been

downloaded by more than

500 usersIn addition to the app the

booth was equipped with

several LCD screens each con-trolled by Metso experts who

used their iPads to present new

products like the Megalinertrade

and the HRCtrade A featured

presentation on Metsorsquos lineupof energy-efficient comminu-

tion equipment including the

VERTIMILLreg SMD and MP-1250

cone crusher was also avail-

able letting customers seehow Metso technology delivers

some of the worldrsquos most effi-

cient size reduction

Measuring MINExpo success

After a very busy three days

(on top of months of prepara-tion leading up to the show) everyone

involved with MINExpo ndash from the North

American marketing team responsible for

the booth to the product managers and

sales force that worked the floor ndash is view-

ing the show as a success ldquoTherersquos alwaysa sigh of relief after each (MINExpo)rdquo says

Keith ldquoAnd overall the initial feedback

and response has been very positiverdquoWith more than 1300 visitors to the

booth Metso certainly made an impact

ldquoWe learn a lot from each show and with

some time wersquoll have a better understand-ing of the tangible results of our effortsrdquo

Keith adds

reliable service for mining equipment as

well as customized cost-effective life-cycle

services contracts

Technology ndash MetsoMAP

is an industry firstMINExpo provided the industry with its firstglimpse of Metsorsquos revolutionary iPad app

MetsoMAP The app was demoed to the

boothrsquos visitors via ldquothe worldrsquos largest iPadrdquo

a custom-made 80-inch screen that show-cased all of its capabilities most of which are

groundbreaking in the industry MetsoMAPrsquos

simple interface is highly intuitive making

it easy to view process animations videos

The presentation of the new HP cone crusher attracted a large audience

8132019 Results Minerals Aggregates 3 2012ENG

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When yoursquore allowed less than a dozen days per year for breakdowns repair andmaintenance every single hour during a service shutdown counts There simplyisnrsquot any room for surprises Thatrsquos why Boliden counts on MetsoTEXT amp PHOTOS Sofia Williams

8983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

Kurt Kalla Site Managerof Metso Gaumlllivare ServiceCenter is responsible forthe maintenance of Aitik

Metso and Boliden Strivingtogether for 97 uptime

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983122983141983152983151983154983156983145983150983143 983154983141983155

One of the biggest copper mines in

Europe Bolidenrsquos Aitik is located deep inthe wilderness of Swedish Lapland next to

the small town of Gaumlllivare The mine has

been operating since 1968 and a recent

expansion has increased its annual ore

production to 36 million tons

But the ambitious Swedes are not will-ing to lay back and relax just yet Bolidenrsquos

new aim is to reach a production rate of

45 million tons of ore per year in AitikAfter that Perhaps more than 55 million

tons The ore concentration in Aitik is very

low-grade with a mere 022 copper con-

tent hence the need for high capacityAchieving the ambitious production

goal requires maximum plant availability

This means that everything from the crush-

ers to the filters must be up and runningfor approximately 97 percent of the time

Thatrsquos where Metso comes into play

A cost-per-ton contract in action

The maximum uptime requirement allowsless than a dozen days per year for break-

downs repair and maintenance at Aitik

Every single hour during a service shut-

down counts There simply isnrsquot any roomfor surprises

Executing a successful shutdown under

such conditions requires a reliable service

partner not afraid of challenges and this iswhy Boliden has entrusted Aitikrsquos services

operations to Metso Boliden and Metsohave worked together since the 1960s

and the collaboration took another step

forward in September 2012 when the twocompanies signed a three-year extension

of the services contract for Boliden Aitik

ldquoThe new contract is a cost-per-ton

agreement We get paid based on Aitikrsquos

production Itrsquos a win-win deal for both par-

ties but also a new mindset for usrdquo explainsKurt Kalla Site Manager of Metso Gaumlllivare

Service Center responsible for serving Aitik

From now on the duration of the shut-down is what matters the most According

to Kalla the Metso service organization in

Gaumlllivare is now streamlining its operations

to fit the bill and has already witnessed thestrategy working In August 2012 Metso

carried out a 188-hour service shutdown in

Aitik which turned out to be a success

Zero tolerance for injury

One key factor to the success was theextensive planning of precautionary health

safety and environment procedures under-

taken by Metso prior to the shutdown Thanks to strict measures applied no

injuries or accidents occurred during the

shutdown and the work could easily be

finished on scheduleMats Johansson Health Safety

and Environment Manager for Metso in

Sweden explains how this was achieved

rdquoPlanning of the shutdown included arisk analysis for all new tasks participating

in Bolidenrsquos safety coordination meetingsmeeting with both Metso supervisors and

subcontractor supervisors and finally a

meeting with the entire staff participating

in the shutdown where everyone had to

sign a document stating their commitmentto the information providedrdquo he says

During the actual shutdown plenty of

new barriers signs and awareness cones

were put in place as a result of observa-tions from previous audits and safety plans

and risk analyses were readily available

in the work area Metso and Boliden also

introduced a Mill Inching permit a certifi-cate for completing a mandatory course for

those involved in the process In addition

Metso carried out random safety audits

during the shutdown to make sure thestrict policy was followed

According to Boliden Metsorsquos way of

working is a good example of how health

and safety precautions should be handled

ldquoMetso is a good example of how towork with safety and health plans risk

analysis permits and welding permits

Their table with all binders in the second-

ary mill area was exemplaryrdquo says Kjell-Arne

Johansson a technician from Boliden

The use of the new Metso Megalinertrade

system in the lining of Aitikrsquos Metso AG

mills has also improved the safety of main-tenance staff The Metso Megalinertrade con-

sists of larger-than-average liners bolted

in position from outside the mill Mainte-

nance technicians no longer need to go

inside the mill and stand in the dangerousdrop-zone of the liners gt

Boliden aims to reach a production rate of 45 million tons of ore per yearin the Aitik mine site

ldquoA complete risk analysis was conducted during the planningof the shutdownrdquo comments Mats Johansson Health Safetyand Environment Manager for Metso in Sweden

8132019 Results Minerals Aggregates 3 2012ENG

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Service the Metso way

24 hours a day 365 days a year

In addition to paying close attention to

health and safety issues executing an effi-

cient shutdown requires careful planning

and timing of every step in the mainte-

nance process Wear and spare parts have

to be available on time and a repair shoplarge enough to accommodate equipment

located close by

ldquoTo keep maintenance breaks as short

as possible we aim to replace the pump on

site and bring the old one for repair to our

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

nearby facilities This method gives us the

peace to do a good job and keep the cus-

tomerrsquos operations runningrdquo Kalla describes

the Metso way of handling Aitikrsquos pump

maintenance

Metso is currently expanding its Gaumllli-

vare service center to include a distribu-

tion center for wear and spare parts andalso concentrating its previously scattered

operations under one roof in its Vuoskon-

jaumlrvivaumlgen facility The expansion is due to

be completed by 2014

Metso equipment

delivered to Aitik36

bull 2 AG mills diameter 116 x

137 m gearless 22-MW motor

bull 2 Pebble mills diameter 91 x

113m dual 5-MW pinion drive

bull 3 VPA pressure filters VPA 1540-54

bull 12 sample pumps and pipes

VF50

bull 60 Various slurry pumps up to

MR500 modelbull Appr 5000 m rubber-lined slurry

pipes up to 600 mm diameter

bull Appr 5000 m rubber-lined by

gravity pipes up to 600 mm

diameter

bull Appr 5000 m rubber hoses

up to 600 mm diameter

Not only does the expansion make ser-

vice shutdowns at Aitik run more smoothly

it guarantees a more comprehensive

on-call emergency service response in the

region ndash thanks to the spare and wear parts

inventory available 24 hours a day 365

days a year

More info

Lars Rosenling

Tel +46 70 107 45 90

larsrosenlingmetsocom

Metso grinding equipment dominates the view in the concentrator

Safety on site is made up of small things like

making sure that everyone remembers to secure

the hoses in place

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155

Pebbles have always been a

challenge for producers of sandsince they cannot be returned

to rivers after extraction For

decades the processing of this

material resulted in a huge

environmental liability with alarge amount of pebbles hav-

ing to be stored away and left

unused

Transforming problems into

business opportunities

Areia amp Cia (areia = sand) has

operated in this market forover 20 years and decided to

enlist the help of Metso to find

a profitable solution for the

processing of pebbles

In July 2011 analyses werebegun to assess the abrasive-

ness and crushability of the

material Four alternatives wereidentified for processing and

transforming pebbles into sand

Initially Areia amp Cia was

interested in acquiring an

impactor for its reason-able price level However the

customer wanted to process

all the pebbles that were col-

lected daily in addition to some of the

material that it had stored In weighing theresults expected by the customer and the

excessive abrasiveness of the material the

HP200 cone crusher was decided on as thebest alternative

Areia amp Cia made the required invest-

ment and after using the HP200 for just

six months the company has already beenreporting outstanding results The HP200

not only transforms pebbles into sand but

also produces sand of excellent quality

with high yield and low maintenanceWith minor adjustments the HP200

also enables the production of sand withspecific particle size distribution for special

applications such as filtering sand blasting

and foundry sand adding value to the prod-

uct and increasing the types of sand offeredldquoMetso is pleased that the HP200 not

only enabled the processing of a product

that had been set aside as unusable but

HP200 cone transforms pebblesinto high-quality sandOver the last few decades Brazilian economic growth has been driving demand for construction aggregates The market

for sand in turn has been experiencing major difficulties in maintaining a consistent supply Presently one of the mainchallenges the industry faces is the large amount of pebbles that are obtained in the process of extracting sand at timesconstituting nearly 50 of the volume of material dredged from riverbeds

TEXT Sheila Ivers PHOTO Areia amp Cia

also that it opened up new

market opportunities for Areiaamp Cia Thatrsquos the standard we

seek to deliver to our custom-

ersrdquo states Luiz Oliveira Techni-

cal Salesperson of Metso Brazil

HP cones entering the

Brazilian sand-making

market

Todayrsquos cones such as theHP200 have high resistance

to impacts and abrasiveness

more efficient crushing cham-

bers low maintenance costsand excellent productivity

Following the acquisition of

the HP200 Areia amp Cia is now

also producing special sands

that command a price that is100 higher than common

sand The entire stockpile of

pebbles accumulated through-out the companyrsquos 20 years of

operations has already been

transformed into sand and the

stock of pebbles held by com-

petitors is also being purchasedfor processing

Cristiane Brizolari the

owner of Areia amp Cia confirms

the transformation that has taken place in

the production and commercial processldquoThe HP200 opened up new niches in

the market enabling the production of dif-

ferent types of sand with added valuerdquo

More info

Luiz Oliveira

Tel +55 011 9971 3603

luizoliveirametsocom

After the pebbles are crushed into sand with the HP200 cone crusherdifferent grades are screened for various end uses

8132019 Results Minerals Aggregates 3 2012ENG

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Where therersquos a will we dig a wayAFCONS-Strabag and Metso embark on tunnel project together

When the joint venture AFCONS-Strabag initiated work on the Rohtang bypass tunnel project at an altitude of 3980 metersabove sea level in Himachal Pradesh India they deliberated each aspect with clockwork precision The project involved anumber of surprises and challenges and required technology and project management skills that were second to none

TEXT amp PHOTOS Monisha Majumdar

Cutting a 10-meter-wide and nearly 9-kilo-

meter-long tunnel through the Himalayas

in one of the toughest terrains and cli-mates in India makes for quite a challengeResults set out to find out how AFCONS-

Strabag and Metso are making their way in

one of their most critical projects to date

The only road connection to the north-Indian border region of the province

Himachal-Pradesh and beyond the Manali-

Leh highway leads across the Rohtang

pass Due to the heavy snowfall and high-

velocity winds in this region the towns

located north of the pass are cut off from

the rest of the country during winter for atleast four often even six months each year

A tunnel with strategic importance

With the construction of the tunnel at

3100 m above sea level the Manali-Lehhighway will become an all-weather road

thereby enabling a significant improve-

ment in the economic development of

northern Himachal-Pradesh and an alter-

nate route to the strategically important

Ladakh region

Manali south of the pass is an alreadywell-developed tourist location that is

becoming more and more popular Upon

completion of the tunnel it is likely that

tourist activities will extend to the areanorth of the pass Moreover the tunnel

shortens the distance between the towns

of Manali and Leh by approximately 45 km

thus saving several hours on the small dan-gerous pass road

The Rohtang pass in the Western Himalaya

region of Northern India with its altitude ofalmost four kilometers ranks among thehighest trafficable passes in the world

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The 88-km long horse-shoe-shaped

tunnel provides space for a two-lane8-m-wide carriageway as well as a one-

meter-wide footpath on both sides A

22-m-high and 36-m-wide emergency

tunnel will be integrated in the tun-

nel cross-section Altogether more than

800000 msup3 of rock will be moved Tunneling works started around spring

2010 with excavation driven from both por-

tals As the north portal is inaccessible dur-ing winter closure the excavation focused

on the south After a planned construction

period of 55 years the tunnel is scheduled

to be completed by the end of 2015

Best man for the job

The BRO (Border Road Organization)

wanted to roll out a global tender for theproject due to the challenges that such a

project involves and also considering thatitrsquos the first time in India that a project of

this scale was to be carried out This imme-

diately triggered the need to roll out aglobal tender All major Indian construction

companies bid for it some individually and

some in partnerships

Strabag an Austrian tunnel specialistwas one of the companies who bid for the

project along with AFCONS a Mumbai-

based infrastructure company In Septem-

ber 2009 AFCONS-Strabag was awardedthe contract

Mr Sunil Tyagi Deputy Project Man-ager at AFCONS had this to say about the

unique projectldquoThis project is located in the Himalayas

and as far as we understand the terrain

there is among the toughest We came out

with a new technology and to be honestit is a fairly simple one We would generally

start with the traditional technology of drill-

ing and blasting and then obtain our muck

feed from the inwardbottom of the tunnelrdquo

ldquoThe technology is supplied by Rowa Tunneling Logistics and this is the first

time it is being used in Asia A jaw crusheris placed at a distance of about 40-45

meters behind the face The blasted muckextracted from the face is fed to the crusher

to reduce the lump size and then through

an overhead conveyor transport system

it is then transported out of the tunnelrdquoldquoThis enables free movement of man

and machinery in the lower area or spe-

cifically on the ground area If we were to

conforms to the Indian standard for fines amp

coarse aggregates as prescribed in IS383-1970

The plant was up and running in good

condition and performing to AFCONSrsquos

satisfactionldquoWe have worked with Metso in earlier

projects and are quite impressed by thekind of technology amp services they provide

We have a history together so the trust fac-tor also comes inrdquo explains Dhiman on their

choice of Metso as a partner

Service makes the difference

ldquoMetsorsquos services have made a big dif-ference in the project Without them we

would still be struggling with the machin-

ery and production The service is really

good and the service engineers are knowl-edgeable prompt and quick to act Any

problem can be solved by Metso We donrsquothave to wait until a service engineer turns

up ndash they have the capacity to solve prob-lems over the phone as wellrdquo says Dhiman

ldquoThe Metso plant didnrsquot create any prob-

lems for us We had problems in logistics

the feed was sticky and the weather condi-tions were bad but thankfully we did not

face any problems with production and

efficiency as the Metso plant is performing

very wellrdquo Dhiman concludes

More info

Amol Sinha Tel +91 9811 671 924

amolsinhametsocom

use the old conventional technology this

wouldnrsquot have worked for us in the stipu-lated timerdquo Mr Tyagi adds

When the going gets tough

partner with the toughest

Sensitive projects require the best technol-

ogy After AFCONS-Strabag landed theproject Metso was an obvious choice as a

technology provider not only because of

the long-standing business relationshipbut also for the sheer consistency in prod-

uct quality and service deliverance Metso

strives for

ldquoAfter signing the project we faced alot of road blocks including extreme cold

avalanches roadblocks less oxygen ndash you

name it we faced itrdquo explains Ankit Dhi-

man Plant Manager at AFCONS-Strabag The Rohtang valley is known for its

notorious avalanches and landslides SoAFCONS had to take extra steps and safety

precautions against hazards on the site

ldquoIn this freezing cold not just us humansbut also the machines are at increased risk

of damage I remember when we used

to run the plant during winter the diesel

engines would freeze We had to constantlyheat up the fuel container to get the plant

running And even the sand in the sand

trap would freeze so we had to clean it on

a daily basis to stop the pipes from mal-functioningrdquo Dhiman adds

Plant designed for difficult terrain

Difficult terrain coupled with space con-straints led Metso engineers to put their

minds together to come up with a suitable

plant configuration After studying the

requirements of the project Metso sug-

gested a 150-tons-per-hour three-stagemodular plant using a C106 jaw crusher

a GP11F secondary cone crusher and a

B7150 tertiary vertical shaft impact crusher

In addition considering the unpredict-ability of the feed the plant was about

to reach a point where the amount offines to be handled could be increased

dramatically Metso strongly suggested the TK11-27-3V grizzly scalper and this became

the first-ever TK scalper to be supplied by

Metso to an Indian customer Also in order

to get better products a sand trap SF2360was added to the configuration

The sand trap is important equipment

for this project as it washes the sand thatMr Sunil Tyagi Deputy Project ManagerAFCONS-Strabag

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Smooth transition to new-generation jaw crusher in Germany

Roumlhrig is a German company with a rich heritage The company has been quarrying granite at its plant in Bergstrasse inthe Sonderbach district of Heppenheim for three generations

TEXT amp PHOTOS Ralf Goffin

Roumlhrigrsquos superior product variety is onereason why the companyrsquos proximity to its

customers can be understood in more than

just physical terms The companyrsquos high

level of innovation has allowed it to estab-lish itself as a reliable supplier of materials

both regionally and internationally This

operational and technical expertise always

manages to keep in step with growing

market requirements

In terms of technical processing equip-

ment Roumlhrig has used a Nordberg C160stationary jaw crusher from Metso since

1992 At the start of 2012 it was finally

exchanged for a more up-to-date version

from the same model range

Metsorsquos C Series is specifically designed

to pre-crush hard rock and can cope effort-

lessly with even the hardest of materials

The dimensions of the new stationary jawcrusher are identical to those of the old

one which means that it could simply be

slotted into the housing vacated by the

previous version

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983122983141983152983151983154983156983145983150983143 983154983141983155

Third-generation Managing DirectorMarco Roumlhrig expects the new machinersquos

service life to be just as long as the previ-

ous model due to the product upgrades

that have been implemented The integral motor base is another plus

point in models made by other manu-

facturers it is located outside the crusher

This element of good fortune ensured that

Roumlhrig could reuse the housing withoutany additional rebuilding

Another advantage lies in the revision

of the guards for the C160rsquos drivetrain andflywheel The sturdier construction method

used for the crusher requires fewer parts

which facilitates easier installation andmaintenance and it makes it simpler to

access the motor

Under the watchful eye of Metsorsquos

Assembly Manager Maik Engelstaumltterthe entire project including removal and

installation was successfully completed

within two weeks

Installation making the most

of the available space

Roumlhrig will likely remember the day the

new crusher was installed for a long time

the pitman and main frame were deliveredseparately prior to installation and assem-

bled on site It took just one hour to replace

the old stationary crusher with the new

model A lorry-mounted crane was used toposition the 85-ton crusher with millimeter

precision in the crushing plant Once the

new crusher had been positioned in theexisting steel structure the next task wasto fix it into place as securely as possible

despite the limited space Special vibration

dampers were installed at a height of two

meters to prevent the crusher from sliding

Norbert Ried (fourth from left) installed thenew C160rsquos predecessor 20 years ago and isdelighted at the durability of the powerfulcrusher that is now making way for a newermodel Also pictured from left to right ManagerVolker Angermann Assembly Manager Maik

Engelstaumltter Technical Manager Stefan

Koob Project Manager Dominic SchoumlnhardtManaging Director Marco Roumlhrig Service

Technician Stefan Kolze and employees ofthe installation company Stafemo

On the hook after theold C160 was liftedout by crane the newcrusher was installedin almost no timeOnly the roof of thehousing had to beremoved

sideways off its mount An initial test run

with materials was carried out around oneweek later after all the electrical cables had

been installed

Simultaneously with the installation

of the C160 which is the first of the latest

generation of crushers to be installed in

Germany a new Nordberg GP100 conecrusher was also being installed in Roumlhrigrsquos

chipping plant Roumlhrig is convinced that

the technical improvements made tothe new Metso crusher can only be an

advantage worldwide

Roumlhrig places great value on consistent

product quality maximum added valueand optimum refinement of its product

range Bearing in mind that Roumlhrig has

enough reserves of raw material to last

for the next 150 years the company canconfidently continue to develop with an

emphasis on quality rather than quantity

More info

Dominic Schoenhardt

Tel +49 (0)621 727 00 610

dominicschoenhardtmetsocom

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Groupe Charier Carriegravere de la Mariais France

Quarrying with certi1047297ed quality The Charier Group with its 1600-strong workforce is a family business thatthis year celebrates 115 years of quarrying The company pursues a long-termdevelopment policy that since 2007 has seen processing installations upgradedat 4 of its 9 extraction sites

TEXT Liliane Boutin (with extracts from Mines amp Carriegraveres and Terrassements amp Carriegraveres magazines)PHOTO Baloon photo

The processing installation is of the horizontal type with a primary station located 56 meters below the site access road to keep it hidden from view

The crushing and screening installation at

Charierrsquos CM La Mariais quarry (at Donges

on the Loire estuary) has been in opera-tion since September 2011 Based on theoperatorrsquos ideas it was designed by Metso

to replace a worn-out installation installed

right on top of the seam being extracted

Since its commissioning it has becomethe second quarry in the company to

receive ISO 14 001 certification

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983122983141983152983151983154983156983145983150983143 983154983141983155

tertiary material of sand and gravel for the

local market to use in concrete surfacingprefabrication etcrdquo

Incorporation of a screening station

The stone extracted from La Mariais is

according to the quarry granitic gneiss

sound and homogeneous with a LosAngeles index of 15 good wear resist-

ance with an MDE of 10 a true density of

265 and a certain abrasiveness (2000 gt)ldquoCharacteristically it has a tendency to form

blocksrdquo Leblin points out

The main criteria in designing the instal-

lation was to provide an output of 600000metric tons from one station (38 hours

week) to produce materials aimed at the

concrete and surfacing markets ldquowhich

involved providing a tertiary station withscreening plantrdquo he adds

With this new unit the operating com-pany expands its product range through

the addition of fine materials obtained

from the tertiary screening station This unitis capable of producing 170 tonshour of

020

Preserving the environment

and optimizing safety

The screens have motorized bogies and

retractable walkways to facilitate access

when the screens are opened for main-tenance Other walkways provide access

to the tunnel input feeders The feederscan be isolated with hydraulic rod gate

bars this hydraulic assistance eliminatesthe need to use a heavy hammer to lodge

these metal bars

All conveyors transporting fines (02

and 04) are covered with a tarpaulin to

avoid flying dust and all the screens arehooded (metal cover with Trellex seal-

ing) The Brunone company has installed

dust-tight containment at the outlet of the

tertiary station crushers (HP300 and HP4)on the belt located under the screens

and under the hoppers located belowthe tertiary screens The crushers are put

under negative pressure and the finesare extracted through sleeve filters (7000

m3 h) with declogging which deposits the

dust back onto the conveyor belt

A high-pressure 100 bar water mist sys-tem has been installed at the primary sta-

tion discharge at the secondary crusherrsquos

discharge chutes (Omnicone) and at the

transfer points on the belt

Designed to last

ldquoThis type of new installation can easily last

thirty yearsrdquo affirms Project Leader Bruno

Peix of Metso ldquoIt quite simply depends on

how well it is maintained Thatrsquos why weprovide maintenance contracts that call for

our technicians to make regular inspection

visits and carry out preventive mainte-nance and any necessary repairsrdquo

In 2011 Metso commissioned about

10 new processing units in France like

the one at La Mariais quarry

More info

Frederic Bazire

Tel +33 (0)681442804

fredericbaziremetsocom

Key figures

DURATION OF WORKS 15 months

DRAWING OFFICE TIME 7800 hours

HEIGHT OF SILOS AND GRINDER BUILDINGS

15 m

TOTAL LENGTH OF CONVEYORS 14 km

WEIGHT OF THE INSTALLATION

1200 metric tons

CONCRETE POURED 1800 cubic meters

PROJECT SITE WORKFORCE 30

INSTALLED POWER 2200 kW(not including pumps 200 kW)

METSO EQUIPMENT

Primary

Vibrating feeder PF561-2V

Primary grizzly VG540-3V

Grizzly feeder TK13-20-3V

Jaw crusher C145 with

hydraulic setting

Secondary

Vibrating screen CVB 2050

refurbished

Cone crusher Omnicocircne 1352 SX

with Metso IC7000 controller Ellivar 16 (16 msup2 3 decks) screen

refurbished by Metso

Tertiary

Cone crusher HP300

Cone crusher HP4

2 Ellivar 20 screens (20 m23 decks) for final products

Expanding the production range

ldquoSince the mid-1990s when we became

owners of La Mariais we had used mobilemachinery with an assembly of beltconveyorsrdquo recalls Daniel Leblin Charierrsquos

Technical Manager for site construction

and maintenance

ldquoIt became clear that we needed ahigher performance tool to achieve the

dual goals of reaching one million metric

tonsrsquo maximum production and producing

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Big Lokotrack LT550GPF boostsquarrying productivity by a thirdMaximizing the productivity of operations is a key issue when striving for cost-effective quarrying Big Lokotracks are oneway to achieve improved operational efficiency The Lokotrack LT550GPF equipped with the high-volume GP550 conecrusher and a large screen is popular in the Nordic countries and in Germany and Australia ndash countries all known for theirhigh quarrying volumes

TEXT amp PHOTOS Eero Haumlmaumllaumlinen

Kone-Kostamorsquos new mobile coneplant has reached an averagecapacity of 300 tons per hour

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983122983141983152983151983154983156983145983150983143 983154983141983155

ldquoWith the same number of employees we

can achieve 30 more productivity with

our new LT550GPF unit The high-capacityFS screen has also eliminated the bottle-neck often seen at fine screeningrdquo says

Aarno Kostamo Managing Director of

Kone-Kostamo Oy one of Finlandrsquos biggest

crushing contractorsAccording to Kostamo the high capacity

of the GP550 gyratory cone crusher easily

handles feed from the C120 and C125 jaw

crushers For the contract with the Talvivaara

nickel mine the LT550GPF is being fed bythe brand new Lokotrack LT120 jaw plant

Average capacity 300 tons per hour

Talvivaara Europersquos largest nickel mine uti-

lizes large quantities of aggregates Kone-Kostamo has contracted several million

tons of different end products for the mineIn August 75000 tons of 0ndash63 mm

road gravel was crushed Smaller amountsof finer 0ndash6 mm 0ndash16 mm and 0ndash32 mm

aggregates are also being produced

The rainy summer increased the need

for road gravel along the muddy roadswhich must endure dump trucks weighing

as much as 260 tons

ldquoThe mobile process consisting of the

LT120 jaw plant and LT550GPF cone plant

is cost-effective while aggregates of vari-ous sizes can be produced in a two-stage

operation and with high capacity The con-trolled stroke and elliptical movement of

the FS screen secure big passing throughcapacitiesrdquo Kostamo explains

Operated in two shifts for a total of 16

hours per day the LT550GPF has logged

more than 600 working hours over a two-month period

Managing Director Aarno Kostamo (left) and foreman Karri Maumlenpaumlauml studying the cavity optionsavailable for the new Lokotrack LT550GPF

Longer perspective than

a single quarter needed

Kone-Kostamo Oy was founded as an

earth-moving company in Kemijaumlrvi

Northern Finland in 1956 The company

expanded its operations to include crush-

ing contracting in 1964 and later on

switched to concentrating fully on crush-ing activities

Kone-Kostamo consistently crushes

and screens around 28 million tons ofaggregates annually and has net sales of

between EUR 8ndash9 million

ldquoWe believe that issues within the crush-

ing industry including the purchasing ofmachinery must be studied with a longer

perspective than a single quarter The

secret to our success has always been our

solid work ethic and professional employ-eesrdquo Kostamo sums up

More info

Esa Berg

Tel + 358 40 837 8692

esabergmetsocom

8132019 Results Minerals Aggregates 3 2012ENG

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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155

Monitoring-based reporting is vital for

assessing the performance of a mobile

crushing plant Metso provides suchreporting tools through its plant-wideautomation system Metso DNA (Dynamic

Network of Applications) with its infor-

mation platform that links all the mobile

crushing and screen units together as oneentity Basically there is a lot of measured

real-time information available in every

crushing plant On-line information is

obtained either from each Metso crusherrsquosmachine automation system IC (Intelligent

Controller) or from separately installed

additional sensors and belt scales

All the collected data is sent to a motorhome using wireless communication

based on WLAN technology The motor

home is a purpose-built environment

inside an on-site container In this environ-ment selected variables can be monitored

for assessing the plantrsquos performance And

to make all this even more flexible the

data can be transmitted to a crushing plant

company office using GPRS3G mobile

data communication technologies Thismakes all the last-minute reports acces-sible to the crushing plant managerial staff

at anytime and basically anywhere within

reach of the cell phone network

Production and fuel economics reports

Essentially monitoring and reporting can

be customized to fit the customerrsquos needs

However there are certain off-the-shelf

reports that provide a lot of useful informa-tion for plant supervision The production

report is one of these Requiring at least one

belt scale for measuring the total produc-tion the production report shows the pro-duction rate (tons per hour) for a selected

reporting period eg a day or a week The

production report constantly keeps track of

the plantrsquos production storing all the datathroughout the plantrsquos life cycle

Performance monitoring and reportingfor a mobile crushing plantTEXT Pasi Airikka PHOTOS Metso

unit during which the unit is running By

storing the availability times between start-ups and shutdowns the crushing plant

operation time (hours per dayshift) can be

recorded analyzed and reported In addi-

tion the availability report can be tailored

to evaluate efficient crushing hours during

which the plant is really working and pro-ducing aggregates Consequently the ratio

(0-100) between efficient crushing time

and total running time can be reported forany selected period of time This boosts

the efficiency of the plantrsquos operations

and results in better productivity

Reports on non-choke

or inadequate feeding

Non-choke feeding to crushers is avoid-

able through smart plant-wide crushingplant controls But estimating its severity in

a systematic manner is not straight-forwardwithout constant monitoring and reporting

The crusher choke feeding report makes

use of the crusher cavity level sensors byanalyzing their level measurements By

calculating average and min-max values

and deviations from the average it can be

shown how often the single crusher suffersfrom non-choke feeding to it

In some cases the bottleneck in the

crushing plantrsquos productivity is the material

feeding to the process In mobile plants thefeeding is human operated and therefore

subject to variations Occasionally the sizeof the human-operated machine simply

does not allow for adequate feeding to thecrushing plant There are specific reports

indicating time periods when the crushing

plant suffers from inadequate feeding

Condition monitoring for

crushers and screens

Machine-specific condition monitoring

focuses on vibrating components in

crushers and screens such as drive shaftbearings safety plate wearings and gears

The low middle and high frequencies ofmonitored components are measured and

supervised in real-time to detect abnor-malities due to slow or fast wear looseness

or imbalance

More info

Pasi Airikka

Tel +358 40 587 2730

pasiairikkametsocom

Condition monitoring provides a view tovibrating crusher and screen components forpredictive equipment maintenance

The daily production report shows the hour-by-hour production trend and distribution chartfor a selected day with min-max average andvariation statistics for comparison

Fuel consumption is always an interest-ing concern The fuel consumption reportgives the fuel consumption of each crush-

ing unit (liters per hour) and their total

consumption (liters per hour) for a selected

reporting period and can track fuel con-

sumption changes over timeCrushing plant availability can be

assessed as well The availability report

calculates time periods for each crushing

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983149983141983156983155983151 983150

for tissue machines The record of 2210

mmin was set on June 1 2012 during a

24-hour production run by the TM 2 tissue

machine at the companyrsquos mill in Yenikoumlynear the city of Izmit in Turkey

ldquoThe cooperation with Metso has been

beyond excellent and both parties did

their utmost to make the project success-ful The results clearly show that the efforts

were worthwhile on both sides This coop-

eration will extend to cover new projects

in the futurerdquo says Luumlt1047297 Aydin Paper GroupDirector Hayat Kimya

ldquoWe are not surprised that Hayat K imya

managed to break the world speed record

We have had great confidence in the capa-bility of the Hayat team since our project

started in 2009 We certainly know our

machine very well its stability production

efficiency and speed capabilityrdquo says Jan

Erikson Vice President Sales Metso

PowerThe worldrsquos first eco-gas fueled

power plant is up and running

Lahti Energy Ltdrsquos new Kymijaumlrvi II gasifica-

tion plant was officially inaugurated on

May 8 2012 It is the first of its kind in the

RecyclingRecycling with Lokotrack LT106

jaw plant in New York

A brand-new Lokotrack LT106 jaw plant is

used in the city area of New York USA to

recycle demolition materials The crushing

site faces the skyscrapers of ManhattanIsland

Paper amp FiberHayat Kimyarsquos Metso-supplied tissue

machine sets world speed record

Thanks to a skilled crew and dedicated

efforts Hayat Kimya AS in Turkey has suc-

ceeded in breaking the world speed record

world This CHP plant runs on clean eco-

gas that is gasified cleaned and cooled

from recycled waste with Metsorsquos innova-tive technology

ldquoItrsquos actually eco-gas that we combust

in the boilerrdquo comments Lahti EnergyrsquosProduction Director Jukka Manskinen

ldquoWe convert unwanted waste material into

energy in an efficient and environmentally

friendly wayrdquoNever before has any plant gasified

waste on such a large scale In the gasifier

recycled waste is turned into combustible

product gas which is cleaned cooled and

combusted in a high-efficiency gas boiler

to produce steam for the steam turbine The plant produces 50 MW of electricity

and 90 MW of district heat for the city of

Lahti and its neighboring areasMetso delivered the circulating fluidized

bed (CFB) gasification process gas cleaning

and cooling steam boiler environmental

protection system and automation systemto the entire plant The production of elec-

tricity and heat is kept even with the Metso

DNA automation system that covers the

whole plant starting from fuel reception

AutomationMetso develops and supplies plant-

wide crushing control solutions for

crushing plants

Metso has recently signed contracts on

delivering plant-wide automation systems

for mobile and portable rock crushing

plants The key objective of these deliveries

is to stabilize and to increase productivityand efficiency of the plants using one sin-

gle automation and information platform

for integrating crusher-specific IC machinecontrols

Furthermore the plant-wide system

with its information management tools not

only increases plant availability and opera-

tional safety it also makes troubleshoot-ing quicker and performance monitoring

easier The control room for plant-wide

operability is located either in an excavator

cabin or a purpose-built container

Metso around the world

The new LT106 jaw plant is suitable for crushing both hard rock and all rock-based demolition materials

The new world speed record for tissue setby Hayat Kimyarsquos Metso-supplied TM 2 is2210 mmin

8132019 Results Minerals Aggregates 3 2012ENG

httpslidepdfcomreaderfullresults-minerals-aggregates-3-2012eng 4242

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: Results Minerals Aggregates 3 2012.ENG

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and a procurement plan for wear parts

These really suit our needs perfectlyrdquo saysShen Yidong the Manager of ZhongjiaMining Industry

Effective preventive maintenanceFor mining corporations the biggestconcern is the economic losses caused by

the shutdown of equipment As a result

preventative maintenance is of vital impor-

tance During the contract period Metsoservice engineers offered 7-day tracking

service on the production site every month

to eliminate potential problems and thus

ensured the stability of the system

parts caused pressure on our working capi-tal which was not favorable for our long-

term developmentrdquo Shen explains

To solve this problem Metso designed

a rational stock plan of wear parts and built

a field warehouse In accordance with theuse and consumption of the liners the field

service engineers complement the stock tomake production and operations run more

smoothlyldquoNow when we need to replace the

wear parts we can use them before pay-

ment This not only simplifies the procure-

ment process but also liberates a largesum of our operating capital which can

be used for other business development

purposesrdquo says Shen

Best partner

ldquoAlthough the LCS contract incurs some

early purchase costs in the long run Metsorsquosprofessional and quality service will improve

the equipment efficiency reduce ourenergy consumption and ensure stable

operations thus generating more prof-

its This is the greatest value for us so the

investment is really worthwhile overall Inthe future we will choose more Metso prod-

ucts and services Taking all aspects into

consideration we believe Metso is the best

partner for usrdquo Shen Yidong concludes

More info

Thomas Bai Tel +86 13801009114

thomasbaimetsocom

ldquoIn the eight months since the contract

came into effect our corporation has notsuffered any financial losses due to equip-

ment breakdown The regular maintenance

has greatly improved the efficiency of our

entire crushing system In addition the

experienced engineers from Metso also

provided onsite training and guidancefor our staff and the tailored training has

greatly enhanced the operating abilities of

our employees and upgraded their overalllevel of competencerdquo says Shen Yidong

More productivity with

less consumption

Metsorsquos service contract focuses on real-

izing the optimum performance of each

process flow After analyzing Zhongjiarsquos

production system Metsorsquos techniciansproposed an adjustment to the closed side

setting of the HP500 for tertiary crushingin order to improve the efficiency of the

downstream fine crushing and milling pro-

cessing by over 10ldquoThe process flow improvement solu-

tions provided by Metso not only increased

the output of our gold concentrates but

also reduced our energy consumption andcostsrdquo says Shen

In the past wear parts procurement

took up a larger proportion of Zhongjiarsquos

total production costsldquoTo avoid downtime caused by the

shortage of wear parts we had to keepeight sets of various wear parts in place

However the cost of having so many wear

Zhongjia Mining Industryrsquos gold concentrates processing plant in China

8132019 Results Minerals Aggregates 3 2012ENG

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0983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

Safe quarrying high-

quality aggregates

8132019 Results Minerals Aggregates 3 2012ENG

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ldquoWe share a similar zero-accident strategy and target with Metso and have successfullyfollowed it Metso has also helped us to meet the strictest end-product quality andcubicity requirements set in Spainrdquo This is how Managing Director Intildeigo Ajuria ofOfitas de San Felices the leading hard rock quarrying company in Spain describesthe cooperation with MetsoTEXT Eero Haumlmaumllaumlinen PHOTOS Ofitas and Eero Haumlmaumllaumlinen

The San Felices quarry is situated in a picturesque mountainous landscapebetween the companyrsquos Rioja vineyards and the Bilbao-Madrid motorway

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Ofitas has pioneered the implementation

of several Metso novelties in the Spanish

market The company was the first to use

efficient large track-mounted Lokotrack jaw plants the unique mobile conveying

system and also the new-generation HP4

cone crushers

Today the company operates twomodern Metso stationary plants one in

Guadix near Granada and the newest one

in San Felices Haro Rioja community Both

quarries focus on refining hard rock by pro-cessing ophite rock into the highest quality

railway ballast asphalt and concrete mix

grades The company has a satellite quarry

near Vitoria in PentildeacerradaBeing situated next to a highway and

the famous Rioja vineyards Ofitas must pay

special attention to environmental issues

To minimize dust problems all conveyors

have special covers attached

Quality durability and service

The cooperation between Ofitas de San

Felices and Metso started back in 1973when the Ajuria family bought the com-

pany whose quarrying activities began in

1919 Intildeigo Ajuria has a clear vision of why

the cooperation has continued withoutinterruption for almost 40 years

long-standing personal relationshipsrdquoAjuria adds

Serving railways asphalt

and concrete producers

The year-old San Felices stationary instal-lation lies hidden in a mountainous area

south of the city of Vitoria in NorthernSpain The new plant replaces an old one

that complicated the extraction of ophiterock Both plants are delivered by Metso

With its two separate production lines

the new plant is able to produce all the

end products required ndash from railway bal-last to the finer grades needed for asphalt

and concrete

Due to lower demand the quarry cur-

rently produces some 4000 tons per day

At full capacity however the plant canreach 8000 tons of production per day

30ndash35 of which consists of railway ballastfor high-speed trains and 65ndash70 of chips

and sand Thanks to the versatile two-line con-

cept connected by transverse conveyors

up to 12 different end products can be pro-

duced Depending on the demand for endproducts the material can be guided either

to the HP4 cone or HP400 cone followed

by a Barmac vertical shaft impactor

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

The ophite feed is fed to the C125 jaw crusher by a sturdy dump truck

The key people running the new San Felicesquarry Mine Engineer Carlos Fernandez (left)Managing Director Intildeigo Ajuria with ProductionManager Julian Perez

ldquoThrough the years Metso machinery

has proven its production capacity and

durability resulting in high-quality end

products A big plus for us has also beenthe quick response time to our process

challenges or servicerdquo

ldquoIn fact our cooperation extends

beyond day-to-day business matters to

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983122983141983152983151983154983156983145983150983143 983154983141983155

Meeting the strictest cubicity demands

The Spanish regulations concerning end-product cubicity are becoming more

demanding The flakiness percentage of

railway ballast must be below 10 and for

asphalt and concrete aggregates less than

15

ldquoWith Metsorsquos HP4 cone and the Barmacvertical shaft impactor we can meet even

the strictest cubicity demands We believe

that our high quality is helping us to sur-vive in the present recessionrdquo notes Mine

Engineer Carlos Fernandez

ldquoWe hope to increase the total extrac-

tion of the three quarries from the present15 million tons per year because our plant

capacity allows more than double thatrdquo

Fernandez adds

More info

Angel Luis Garcia Tel +34 686 94 35 30

angelluisgarciametsocom

In addition to being the leading Spanish

quarry to process hard rock Ofitas de SanFelices also cultivates 34 hectares of vine-yards next to the quarry which is situated

in the famous Rioja wine area

The company has previously sold a

harvest of over 200000 kg of Tempranillo

grapes to local red-wine makers Recentlythe company built its own wine process-

ing plant to process 10000ndash15000 kg of

grapes themselves

Aggregates and wine production

Andoni Ajuria the founder of Ofitas de san Felices (left) with Intildeigo Ajuria the present ManagingDirector tasting wine from the companyrsquos own vineyards

The first vintage wine of Ofitas har-

vested in autumn 2010 is now maturingin oak barrels After maturing for 12 to 15months the wine is called crianza and after

two years it will be granted the classifica-

tion reserva

ldquoWinemaking is not a business but

a hobby for us We give our wine out aspresents and drink it when we meet

our suppliers and friendsrdquo Intildeigo Ajuria

comments

For environmental protectionall of San Felicesrsquos plantconveyors are covered

Ofitas de San Felices quarry

LOCATION Haro near the city

of Vitoria northern Spain

SIZE 100 hectares

ROCK TYPE Ophite with Los Angeles

index of 9ndash10

PRESENT DAILY EXTRACTION 3000 tons

of ophiteNUMBER OF PERSONNEL 30

RESERVES 10 million tons

MAIN END PRODUCTS 0ndash2 mm

2ndash4 mm 4ndash10 mm 10ndash16 mm

16ndash22 mm 25ndash60 mm (ballast)

METSO MAIN EQUIPMENT

VF feeder

C125 jaw crusher

ndash feed size 0ndash800 mm

ndash css 130ndash140 mm

HP400 cone crusher

ndash feed size 80ndash250 mm

ndash css 40 mm HP4 cone crusher

ndash feed size 40ndash80 mm

ndash css 15 mm

Barmac 6150 VSI crusher

4 CVB2060 screens

2 TS32 screens

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Metso Distribution Centers he

Europe (Tongeren Belgium)

France (Macon)

Czech Republic (Přerov)

Austria (Vienna)

2271 d

Brazil (Sorocaba SP)

1014 d

USA (Columbia SC)

1690 d

USA (Waukesha WI)

434 d

South Africa (Vereeniging)

Ghana (Tarkwa)

Meacutexico (Irapuato)

Peru (Lima)

Chile (Concoacuten)

788 d

Sweden ( Trelleborg)

Finland (Tampere)

UK (Rugby)

865 d

Russia (St Petersburg)

Brazil (Parauapebas PA)

206 d

4983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

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In the case of an equipment failure or

a planned service shutdown resuming

production as quickly as possible is crucialEach hour spent waiting for a spare part to

arrive equals money lost Whether the right

part takes 12 or 48 hours to arrive really

makes a difference

The comprehensive and global Metsospare and wear parts service network pro-

vides you with the right part in the right

place and at the right time Our strategi-

cally located Distribution Centers and

Satellite Warehouses are on call 24 hoursa day 7 days a week ensuring efficient

parts replacement near you

Check out the locations of the MetsoDistribution Centers and how many parts

pass through them each day

More info

Marcelo Farah

Tel +55 15 2102 1315

marcelofarahmetsocom

you minimize downtime

Australia (Perth)

746 d

China (Tianjin)

China (Kunming)

China (Shanghai)

393 d

India (Faridabad)

India (Ahmedabad)

India (Hyderabad)

India (Bhubaneswar)

India (Bangalore)

419 d

Russia (Yekaterinburg)

Australia (Newcastle)

New Zealand (Matamata)

983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088

TEXT Sofia Williams

Singapore (Singapore)

Distribution Center Satellite Warehouse

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Following a large investment

in Metso crushing equipmentand services Buena Vista del

Cobre is now expanding the

mine site to include even more

equipment ndash and with thatexpansion comes the need for

more local service resources

Metso and Buena Vista del

Cobre have entered into a Life

Cycle Service agreement forthe plant and construction of a

brand new Metso service hub

is under way in Cananea

New facility new

level of service

The Cananea service hub

which will be up and running in early 2013will support the recent expansion and resur-

gence of Buena Vista del Cobre Initially it

will be a major repair and assembly center

for pumps crushers and screens and will

provide for rubber covering capabilitiesBut the 8000-square-meter facilityrsquos service

offering will be expansive including a con-

signment stock inventory to help serve theminersquos varying needs Metso currently has

50 service team members on site

Although Buena Vista del Cobre was a

key influencer in building the new servicehub this location will also enable Metso to

expand its capabilities and provide local

support to the entire mining community

in northwest Mexico The Cananea hub

will serve a number of major copper and

gold mines in the region including MineraFriscorsquos San Felipe Fresnillorsquos Milpillas and

Grupo Mexicorsquos Mexicana de Cobre

ldquoBuena Vista del Cobre is the biggestcustomer we have in Mexico today and

with this expansion project itrsquos only going

to grow and be strongerrdquo says Felix Forna-

guera Director of Services Mexico CentralAmerica and Caribbean ldquoWith that said the

idea behind the Cananea service hub is to

provide a central location for local support

for all our major customers in the areardquo

Establishing safety

ldquoIt was key to have our support here in

Cananea because the Buena Vista delCobre started from the ground uprdquo saysFelix ldquoWersquove been able to help the cus-

tomer to establish the best in support

service and operations from the very

beginningrdquo And this ground-up approachincluded a major focus on safety

Metso worked closely with Buena Vista

del Cobre to establish the safety proto-

col by which the mine operates Basedon Metsorsquos expertise the safety measures

put in place have enabled the mine to

become strict and efficient in its operations

and maintenance procedures To achievethis Metso worked closely with local andnational authorities to ensure the safety

plan was comprehensive and in accord-

ance with all established legal bodies

The best in regional support

The service hub in Cananea is a prime

example of Metsorsquos focus on providing local

service and support to its customers all

Service shines in Cananea MexicoAfter three years of inactivity the Buena Vista del Cobre mine in Cananea Sonora Mexico has been operational since 2010A mine that was inactive for such a significant amount of time however requires a great deal of support to successfullyrestart the plant and bring it back to an operational and profitable state

TEXT Deanna Lee PHOTO Metso

over the world ldquoWe are the first

company developing this kindof service in northwest Mexicordquo

adds Felix ldquoOur people have

developed a close relationship

with the team at the mine Itrsquosmore than a supplier relation-

ship our guys are inside the

mine living and working thererdquo

In fact this is the model

that Metso is using in servicehubs all over the globe build-

ing modern facilities bringing

teams on site and workinghand in hand with mine

operators The Cananea Service

hub is only the most recent

example of Metsorsquos commit-ment to service and northwest Mexico is

yet another mining hotbed thatrsquos going to

benefit from the companyrsquos support

More info

Felix Fornaguera Tel +52 4621079227

felixfornaguerametsocom

A mining cone serviced by Metso at the Buena Vista del Cobre mine inSonora Mexico

ldquoThe new Cananea service center will be a majorrepair and assembly center for pumps crushersand screensrdquo says Felix Fornaguera Director ofServices Mexico Central America and Caribbean

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

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During the MINExpo exhibition over 1300 people visited the Metso stand

983122983141983152983151983154983156983145983150983143 983154983141983155

Held every four years MIN-Expo consistently grows so

perennial exhibitors like Metso

are challenged with elevating

their presence and drawingin new (and greater numbers

of ) visitors each year ldquoItrsquos not

necessarily a challenge to lsquotoprsquo

our last showingrdquo says Keith

Ference Vice President ofmarketing and communica-

tions North America ldquoThere

are four years between eachMINExpo so we always have

a lot to say and reveal to our

customersrdquo The real challenge

he says is finding an exciting

and dynamic way to deliverthe message ldquoTherersquos so much

to see here so your booth has

to be compelling from the

outside-in and thatrsquos what

we always try to dordquo

Service sets the stage

The Metso booth created buzzin a number of ways and per-

haps the most striking (partly

due to its size) was the live

theater presentation As visitorspassed through the aisles of the show-

room the sights and sounds from Metsorsquos

theater were hard to miss And once guests

entered they were captivated by a short

high-energy video presentation focused

on Metsorsquos service capabilities The message was simple Metso is ldquoyour

local service partner rdquo for all mining and

construction needs The video showed ourservice teams in action all over the world

and the audience came away with an

understanding about Metsorsquos commitment

to service Customers can count on morethan 70 local service centers run by more

than 1700 expert technicians delivering

Metso makes an impact at MINExpo 2012At this yearrsquos MINExpo International nearly 60000 attendees flocked to Las Vegas Nevada the largest turnout in showhistory The visitors ndash mining professionals from all over the globe ndash explored 850000 square feet of showroom spacefeaturing the industry rsquos latest technology equipment products and services They toured the show for three days

seeking the latest and greatest from more than 1800 exhibitorsTEXT Keith Ference PHOTOS Tracey Ford Perry

detailed descriptions andphotos of all of Metsorsquos mining

and construction products and

services The app also provides

digital access to Results and asearchable database of sales

contacts By day three of the

show MetsoMAP had been

downloaded by more than

500 usersIn addition to the app the

booth was equipped with

several LCD screens each con-trolled by Metso experts who

used their iPads to present new

products like the Megalinertrade

and the HRCtrade A featured

presentation on Metsorsquos lineupof energy-efficient comminu-

tion equipment including the

VERTIMILLreg SMD and MP-1250

cone crusher was also avail-

able letting customers seehow Metso technology delivers

some of the worldrsquos most effi-

cient size reduction

Measuring MINExpo success

After a very busy three days

(on top of months of prepara-tion leading up to the show) everyone

involved with MINExpo ndash from the North

American marketing team responsible for

the booth to the product managers and

sales force that worked the floor ndash is view-

ing the show as a success ldquoTherersquos alwaysa sigh of relief after each (MINExpo)rdquo says

Keith ldquoAnd overall the initial feedback

and response has been very positiverdquoWith more than 1300 visitors to the

booth Metso certainly made an impact

ldquoWe learn a lot from each show and with

some time wersquoll have a better understand-ing of the tangible results of our effortsrdquo

Keith adds

reliable service for mining equipment as

well as customized cost-effective life-cycle

services contracts

Technology ndash MetsoMAP

is an industry firstMINExpo provided the industry with its firstglimpse of Metsorsquos revolutionary iPad app

MetsoMAP The app was demoed to the

boothrsquos visitors via ldquothe worldrsquos largest iPadrdquo

a custom-made 80-inch screen that show-cased all of its capabilities most of which are

groundbreaking in the industry MetsoMAPrsquos

simple interface is highly intuitive making

it easy to view process animations videos

The presentation of the new HP cone crusher attracted a large audience

8132019 Results Minerals Aggregates 3 2012ENG

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When yoursquore allowed less than a dozen days per year for breakdowns repair andmaintenance every single hour during a service shutdown counts There simplyisnrsquot any room for surprises Thatrsquos why Boliden counts on MetsoTEXT amp PHOTOS Sofia Williams

8983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

Kurt Kalla Site Managerof Metso Gaumlllivare ServiceCenter is responsible forthe maintenance of Aitik

Metso and Boliden Strivingtogether for 97 uptime

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983122983141983152983151983154983156983145983150983143 983154983141983155

One of the biggest copper mines in

Europe Bolidenrsquos Aitik is located deep inthe wilderness of Swedish Lapland next to

the small town of Gaumlllivare The mine has

been operating since 1968 and a recent

expansion has increased its annual ore

production to 36 million tons

But the ambitious Swedes are not will-ing to lay back and relax just yet Bolidenrsquos

new aim is to reach a production rate of

45 million tons of ore per year in AitikAfter that Perhaps more than 55 million

tons The ore concentration in Aitik is very

low-grade with a mere 022 copper con-

tent hence the need for high capacityAchieving the ambitious production

goal requires maximum plant availability

This means that everything from the crush-

ers to the filters must be up and runningfor approximately 97 percent of the time

Thatrsquos where Metso comes into play

A cost-per-ton contract in action

The maximum uptime requirement allowsless than a dozen days per year for break-

downs repair and maintenance at Aitik

Every single hour during a service shut-

down counts There simply isnrsquot any roomfor surprises

Executing a successful shutdown under

such conditions requires a reliable service

partner not afraid of challenges and this iswhy Boliden has entrusted Aitikrsquos services

operations to Metso Boliden and Metsohave worked together since the 1960s

and the collaboration took another step

forward in September 2012 when the twocompanies signed a three-year extension

of the services contract for Boliden Aitik

ldquoThe new contract is a cost-per-ton

agreement We get paid based on Aitikrsquos

production Itrsquos a win-win deal for both par-

ties but also a new mindset for usrdquo explainsKurt Kalla Site Manager of Metso Gaumlllivare

Service Center responsible for serving Aitik

From now on the duration of the shut-down is what matters the most According

to Kalla the Metso service organization in

Gaumlllivare is now streamlining its operations

to fit the bill and has already witnessed thestrategy working In August 2012 Metso

carried out a 188-hour service shutdown in

Aitik which turned out to be a success

Zero tolerance for injury

One key factor to the success was theextensive planning of precautionary health

safety and environment procedures under-

taken by Metso prior to the shutdown Thanks to strict measures applied no

injuries or accidents occurred during the

shutdown and the work could easily be

finished on scheduleMats Johansson Health Safety

and Environment Manager for Metso in

Sweden explains how this was achieved

rdquoPlanning of the shutdown included arisk analysis for all new tasks participating

in Bolidenrsquos safety coordination meetingsmeeting with both Metso supervisors and

subcontractor supervisors and finally a

meeting with the entire staff participating

in the shutdown where everyone had to

sign a document stating their commitmentto the information providedrdquo he says

During the actual shutdown plenty of

new barriers signs and awareness cones

were put in place as a result of observa-tions from previous audits and safety plans

and risk analyses were readily available

in the work area Metso and Boliden also

introduced a Mill Inching permit a certifi-cate for completing a mandatory course for

those involved in the process In addition

Metso carried out random safety audits

during the shutdown to make sure thestrict policy was followed

According to Boliden Metsorsquos way of

working is a good example of how health

and safety precautions should be handled

ldquoMetso is a good example of how towork with safety and health plans risk

analysis permits and welding permits

Their table with all binders in the second-

ary mill area was exemplaryrdquo says Kjell-Arne

Johansson a technician from Boliden

The use of the new Metso Megalinertrade

system in the lining of Aitikrsquos Metso AG

mills has also improved the safety of main-tenance staff The Metso Megalinertrade con-

sists of larger-than-average liners bolted

in position from outside the mill Mainte-

nance technicians no longer need to go

inside the mill and stand in the dangerousdrop-zone of the liners gt

Boliden aims to reach a production rate of 45 million tons of ore per yearin the Aitik mine site

ldquoA complete risk analysis was conducted during the planningof the shutdownrdquo comments Mats Johansson Health Safetyand Environment Manager for Metso in Sweden

8132019 Results Minerals Aggregates 3 2012ENG

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Service the Metso way

24 hours a day 365 days a year

In addition to paying close attention to

health and safety issues executing an effi-

cient shutdown requires careful planning

and timing of every step in the mainte-

nance process Wear and spare parts have

to be available on time and a repair shoplarge enough to accommodate equipment

located close by

ldquoTo keep maintenance breaks as short

as possible we aim to replace the pump on

site and bring the old one for repair to our

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

nearby facilities This method gives us the

peace to do a good job and keep the cus-

tomerrsquos operations runningrdquo Kalla describes

the Metso way of handling Aitikrsquos pump

maintenance

Metso is currently expanding its Gaumllli-

vare service center to include a distribu-

tion center for wear and spare parts andalso concentrating its previously scattered

operations under one roof in its Vuoskon-

jaumlrvivaumlgen facility The expansion is due to

be completed by 2014

Metso equipment

delivered to Aitik36

bull 2 AG mills diameter 116 x

137 m gearless 22-MW motor

bull 2 Pebble mills diameter 91 x

113m dual 5-MW pinion drive

bull 3 VPA pressure filters VPA 1540-54

bull 12 sample pumps and pipes

VF50

bull 60 Various slurry pumps up to

MR500 modelbull Appr 5000 m rubber-lined slurry

pipes up to 600 mm diameter

bull Appr 5000 m rubber-lined by

gravity pipes up to 600 mm

diameter

bull Appr 5000 m rubber hoses

up to 600 mm diameter

Not only does the expansion make ser-

vice shutdowns at Aitik run more smoothly

it guarantees a more comprehensive

on-call emergency service response in the

region ndash thanks to the spare and wear parts

inventory available 24 hours a day 365

days a year

More info

Lars Rosenling

Tel +46 70 107 45 90

larsrosenlingmetsocom

Metso grinding equipment dominates the view in the concentrator

Safety on site is made up of small things like

making sure that everyone remembers to secure

the hoses in place

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Pebbles have always been a

challenge for producers of sandsince they cannot be returned

to rivers after extraction For

decades the processing of this

material resulted in a huge

environmental liability with alarge amount of pebbles hav-

ing to be stored away and left

unused

Transforming problems into

business opportunities

Areia amp Cia (areia = sand) has

operated in this market forover 20 years and decided to

enlist the help of Metso to find

a profitable solution for the

processing of pebbles

In July 2011 analyses werebegun to assess the abrasive-

ness and crushability of the

material Four alternatives wereidentified for processing and

transforming pebbles into sand

Initially Areia amp Cia was

interested in acquiring an

impactor for its reason-able price level However the

customer wanted to process

all the pebbles that were col-

lected daily in addition to some of the

material that it had stored In weighing theresults expected by the customer and the

excessive abrasiveness of the material the

HP200 cone crusher was decided on as thebest alternative

Areia amp Cia made the required invest-

ment and after using the HP200 for just

six months the company has already beenreporting outstanding results The HP200

not only transforms pebbles into sand but

also produces sand of excellent quality

with high yield and low maintenanceWith minor adjustments the HP200

also enables the production of sand withspecific particle size distribution for special

applications such as filtering sand blasting

and foundry sand adding value to the prod-

uct and increasing the types of sand offeredldquoMetso is pleased that the HP200 not

only enabled the processing of a product

that had been set aside as unusable but

HP200 cone transforms pebblesinto high-quality sandOver the last few decades Brazilian economic growth has been driving demand for construction aggregates The market

for sand in turn has been experiencing major difficulties in maintaining a consistent supply Presently one of the mainchallenges the industry faces is the large amount of pebbles that are obtained in the process of extracting sand at timesconstituting nearly 50 of the volume of material dredged from riverbeds

TEXT Sheila Ivers PHOTO Areia amp Cia

also that it opened up new

market opportunities for Areiaamp Cia Thatrsquos the standard we

seek to deliver to our custom-

ersrdquo states Luiz Oliveira Techni-

cal Salesperson of Metso Brazil

HP cones entering the

Brazilian sand-making

market

Todayrsquos cones such as theHP200 have high resistance

to impacts and abrasiveness

more efficient crushing cham-

bers low maintenance costsand excellent productivity

Following the acquisition of

the HP200 Areia amp Cia is now

also producing special sands

that command a price that is100 higher than common

sand The entire stockpile of

pebbles accumulated through-out the companyrsquos 20 years of

operations has already been

transformed into sand and the

stock of pebbles held by com-

petitors is also being purchasedfor processing

Cristiane Brizolari the

owner of Areia amp Cia confirms

the transformation that has taken place in

the production and commercial processldquoThe HP200 opened up new niches in

the market enabling the production of dif-

ferent types of sand with added valuerdquo

More info

Luiz Oliveira

Tel +55 011 9971 3603

luizoliveirametsocom

After the pebbles are crushed into sand with the HP200 cone crusherdifferent grades are screened for various end uses

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Where therersquos a will we dig a wayAFCONS-Strabag and Metso embark on tunnel project together

When the joint venture AFCONS-Strabag initiated work on the Rohtang bypass tunnel project at an altitude of 3980 metersabove sea level in Himachal Pradesh India they deliberated each aspect with clockwork precision The project involved anumber of surprises and challenges and required technology and project management skills that were second to none

TEXT amp PHOTOS Monisha Majumdar

Cutting a 10-meter-wide and nearly 9-kilo-

meter-long tunnel through the Himalayas

in one of the toughest terrains and cli-mates in India makes for quite a challengeResults set out to find out how AFCONS-

Strabag and Metso are making their way in

one of their most critical projects to date

The only road connection to the north-Indian border region of the province

Himachal-Pradesh and beyond the Manali-

Leh highway leads across the Rohtang

pass Due to the heavy snowfall and high-

velocity winds in this region the towns

located north of the pass are cut off from

the rest of the country during winter for atleast four often even six months each year

A tunnel with strategic importance

With the construction of the tunnel at

3100 m above sea level the Manali-Lehhighway will become an all-weather road

thereby enabling a significant improve-

ment in the economic development of

northern Himachal-Pradesh and an alter-

nate route to the strategically important

Ladakh region

Manali south of the pass is an alreadywell-developed tourist location that is

becoming more and more popular Upon

completion of the tunnel it is likely that

tourist activities will extend to the areanorth of the pass Moreover the tunnel

shortens the distance between the towns

of Manali and Leh by approximately 45 km

thus saving several hours on the small dan-gerous pass road

The Rohtang pass in the Western Himalaya

region of Northern India with its altitude ofalmost four kilometers ranks among thehighest trafficable passes in the world

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The 88-km long horse-shoe-shaped

tunnel provides space for a two-lane8-m-wide carriageway as well as a one-

meter-wide footpath on both sides A

22-m-high and 36-m-wide emergency

tunnel will be integrated in the tun-

nel cross-section Altogether more than

800000 msup3 of rock will be moved Tunneling works started around spring

2010 with excavation driven from both por-

tals As the north portal is inaccessible dur-ing winter closure the excavation focused

on the south After a planned construction

period of 55 years the tunnel is scheduled

to be completed by the end of 2015

Best man for the job

The BRO (Border Road Organization)

wanted to roll out a global tender for theproject due to the challenges that such a

project involves and also considering thatitrsquos the first time in India that a project of

this scale was to be carried out This imme-

diately triggered the need to roll out aglobal tender All major Indian construction

companies bid for it some individually and

some in partnerships

Strabag an Austrian tunnel specialistwas one of the companies who bid for the

project along with AFCONS a Mumbai-

based infrastructure company In Septem-

ber 2009 AFCONS-Strabag was awardedthe contract

Mr Sunil Tyagi Deputy Project Man-ager at AFCONS had this to say about the

unique projectldquoThis project is located in the Himalayas

and as far as we understand the terrain

there is among the toughest We came out

with a new technology and to be honestit is a fairly simple one We would generally

start with the traditional technology of drill-

ing and blasting and then obtain our muck

feed from the inwardbottom of the tunnelrdquo

ldquoThe technology is supplied by Rowa Tunneling Logistics and this is the first

time it is being used in Asia A jaw crusheris placed at a distance of about 40-45

meters behind the face The blasted muckextracted from the face is fed to the crusher

to reduce the lump size and then through

an overhead conveyor transport system

it is then transported out of the tunnelrdquoldquoThis enables free movement of man

and machinery in the lower area or spe-

cifically on the ground area If we were to

conforms to the Indian standard for fines amp

coarse aggregates as prescribed in IS383-1970

The plant was up and running in good

condition and performing to AFCONSrsquos

satisfactionldquoWe have worked with Metso in earlier

projects and are quite impressed by thekind of technology amp services they provide

We have a history together so the trust fac-tor also comes inrdquo explains Dhiman on their

choice of Metso as a partner

Service makes the difference

ldquoMetsorsquos services have made a big dif-ference in the project Without them we

would still be struggling with the machin-

ery and production The service is really

good and the service engineers are knowl-edgeable prompt and quick to act Any

problem can be solved by Metso We donrsquothave to wait until a service engineer turns

up ndash they have the capacity to solve prob-lems over the phone as wellrdquo says Dhiman

ldquoThe Metso plant didnrsquot create any prob-

lems for us We had problems in logistics

the feed was sticky and the weather condi-tions were bad but thankfully we did not

face any problems with production and

efficiency as the Metso plant is performing

very wellrdquo Dhiman concludes

More info

Amol Sinha Tel +91 9811 671 924

amolsinhametsocom

use the old conventional technology this

wouldnrsquot have worked for us in the stipu-lated timerdquo Mr Tyagi adds

When the going gets tough

partner with the toughest

Sensitive projects require the best technol-

ogy After AFCONS-Strabag landed theproject Metso was an obvious choice as a

technology provider not only because of

the long-standing business relationshipbut also for the sheer consistency in prod-

uct quality and service deliverance Metso

strives for

ldquoAfter signing the project we faced alot of road blocks including extreme cold

avalanches roadblocks less oxygen ndash you

name it we faced itrdquo explains Ankit Dhi-

man Plant Manager at AFCONS-Strabag The Rohtang valley is known for its

notorious avalanches and landslides SoAFCONS had to take extra steps and safety

precautions against hazards on the site

ldquoIn this freezing cold not just us humansbut also the machines are at increased risk

of damage I remember when we used

to run the plant during winter the diesel

engines would freeze We had to constantlyheat up the fuel container to get the plant

running And even the sand in the sand

trap would freeze so we had to clean it on

a daily basis to stop the pipes from mal-functioningrdquo Dhiman adds

Plant designed for difficult terrain

Difficult terrain coupled with space con-straints led Metso engineers to put their

minds together to come up with a suitable

plant configuration After studying the

requirements of the project Metso sug-

gested a 150-tons-per-hour three-stagemodular plant using a C106 jaw crusher

a GP11F secondary cone crusher and a

B7150 tertiary vertical shaft impact crusher

In addition considering the unpredict-ability of the feed the plant was about

to reach a point where the amount offines to be handled could be increased

dramatically Metso strongly suggested the TK11-27-3V grizzly scalper and this became

the first-ever TK scalper to be supplied by

Metso to an Indian customer Also in order

to get better products a sand trap SF2360was added to the configuration

The sand trap is important equipment

for this project as it washes the sand thatMr Sunil Tyagi Deputy Project ManagerAFCONS-Strabag

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Smooth transition to new-generation jaw crusher in Germany

Roumlhrig is a German company with a rich heritage The company has been quarrying granite at its plant in Bergstrasse inthe Sonderbach district of Heppenheim for three generations

TEXT amp PHOTOS Ralf Goffin

Roumlhrigrsquos superior product variety is onereason why the companyrsquos proximity to its

customers can be understood in more than

just physical terms The companyrsquos high

level of innovation has allowed it to estab-lish itself as a reliable supplier of materials

both regionally and internationally This

operational and technical expertise always

manages to keep in step with growing

market requirements

In terms of technical processing equip-

ment Roumlhrig has used a Nordberg C160stationary jaw crusher from Metso since

1992 At the start of 2012 it was finally

exchanged for a more up-to-date version

from the same model range

Metsorsquos C Series is specifically designed

to pre-crush hard rock and can cope effort-

lessly with even the hardest of materials

The dimensions of the new stationary jawcrusher are identical to those of the old

one which means that it could simply be

slotted into the housing vacated by the

previous version

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Third-generation Managing DirectorMarco Roumlhrig expects the new machinersquos

service life to be just as long as the previ-

ous model due to the product upgrades

that have been implemented The integral motor base is another plus

point in models made by other manu-

facturers it is located outside the crusher

This element of good fortune ensured that

Roumlhrig could reuse the housing withoutany additional rebuilding

Another advantage lies in the revision

of the guards for the C160rsquos drivetrain andflywheel The sturdier construction method

used for the crusher requires fewer parts

which facilitates easier installation andmaintenance and it makes it simpler to

access the motor

Under the watchful eye of Metsorsquos

Assembly Manager Maik Engelstaumltterthe entire project including removal and

installation was successfully completed

within two weeks

Installation making the most

of the available space

Roumlhrig will likely remember the day the

new crusher was installed for a long time

the pitman and main frame were deliveredseparately prior to installation and assem-

bled on site It took just one hour to replace

the old stationary crusher with the new

model A lorry-mounted crane was used toposition the 85-ton crusher with millimeter

precision in the crushing plant Once the

new crusher had been positioned in theexisting steel structure the next task wasto fix it into place as securely as possible

despite the limited space Special vibration

dampers were installed at a height of two

meters to prevent the crusher from sliding

Norbert Ried (fourth from left) installed thenew C160rsquos predecessor 20 years ago and isdelighted at the durability of the powerfulcrusher that is now making way for a newermodel Also pictured from left to right ManagerVolker Angermann Assembly Manager Maik

Engelstaumltter Technical Manager Stefan

Koob Project Manager Dominic SchoumlnhardtManaging Director Marco Roumlhrig Service

Technician Stefan Kolze and employees ofthe installation company Stafemo

On the hook after theold C160 was liftedout by crane the newcrusher was installedin almost no timeOnly the roof of thehousing had to beremoved

sideways off its mount An initial test run

with materials was carried out around oneweek later after all the electrical cables had

been installed

Simultaneously with the installation

of the C160 which is the first of the latest

generation of crushers to be installed in

Germany a new Nordberg GP100 conecrusher was also being installed in Roumlhrigrsquos

chipping plant Roumlhrig is convinced that

the technical improvements made tothe new Metso crusher can only be an

advantage worldwide

Roumlhrig places great value on consistent

product quality maximum added valueand optimum refinement of its product

range Bearing in mind that Roumlhrig has

enough reserves of raw material to last

for the next 150 years the company canconfidently continue to develop with an

emphasis on quality rather than quantity

More info

Dominic Schoenhardt

Tel +49 (0)621 727 00 610

dominicschoenhardtmetsocom

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Groupe Charier Carriegravere de la Mariais France

Quarrying with certi1047297ed quality The Charier Group with its 1600-strong workforce is a family business thatthis year celebrates 115 years of quarrying The company pursues a long-termdevelopment policy that since 2007 has seen processing installations upgradedat 4 of its 9 extraction sites

TEXT Liliane Boutin (with extracts from Mines amp Carriegraveres and Terrassements amp Carriegraveres magazines)PHOTO Baloon photo

The processing installation is of the horizontal type with a primary station located 56 meters below the site access road to keep it hidden from view

The crushing and screening installation at

Charierrsquos CM La Mariais quarry (at Donges

on the Loire estuary) has been in opera-tion since September 2011 Based on theoperatorrsquos ideas it was designed by Metso

to replace a worn-out installation installed

right on top of the seam being extracted

Since its commissioning it has becomethe second quarry in the company to

receive ISO 14 001 certification

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983122983141983152983151983154983156983145983150983143 983154983141983155

tertiary material of sand and gravel for the

local market to use in concrete surfacingprefabrication etcrdquo

Incorporation of a screening station

The stone extracted from La Mariais is

according to the quarry granitic gneiss

sound and homogeneous with a LosAngeles index of 15 good wear resist-

ance with an MDE of 10 a true density of

265 and a certain abrasiveness (2000 gt)ldquoCharacteristically it has a tendency to form

blocksrdquo Leblin points out

The main criteria in designing the instal-

lation was to provide an output of 600000metric tons from one station (38 hours

week) to produce materials aimed at the

concrete and surfacing markets ldquowhich

involved providing a tertiary station withscreening plantrdquo he adds

With this new unit the operating com-pany expands its product range through

the addition of fine materials obtained

from the tertiary screening station This unitis capable of producing 170 tonshour of

020

Preserving the environment

and optimizing safety

The screens have motorized bogies and

retractable walkways to facilitate access

when the screens are opened for main-tenance Other walkways provide access

to the tunnel input feeders The feederscan be isolated with hydraulic rod gate

bars this hydraulic assistance eliminatesthe need to use a heavy hammer to lodge

these metal bars

All conveyors transporting fines (02

and 04) are covered with a tarpaulin to

avoid flying dust and all the screens arehooded (metal cover with Trellex seal-

ing) The Brunone company has installed

dust-tight containment at the outlet of the

tertiary station crushers (HP300 and HP4)on the belt located under the screens

and under the hoppers located belowthe tertiary screens The crushers are put

under negative pressure and the finesare extracted through sleeve filters (7000

m3 h) with declogging which deposits the

dust back onto the conveyor belt

A high-pressure 100 bar water mist sys-tem has been installed at the primary sta-

tion discharge at the secondary crusherrsquos

discharge chutes (Omnicone) and at the

transfer points on the belt

Designed to last

ldquoThis type of new installation can easily last

thirty yearsrdquo affirms Project Leader Bruno

Peix of Metso ldquoIt quite simply depends on

how well it is maintained Thatrsquos why weprovide maintenance contracts that call for

our technicians to make regular inspection

visits and carry out preventive mainte-nance and any necessary repairsrdquo

In 2011 Metso commissioned about

10 new processing units in France like

the one at La Mariais quarry

More info

Frederic Bazire

Tel +33 (0)681442804

fredericbaziremetsocom

Key figures

DURATION OF WORKS 15 months

DRAWING OFFICE TIME 7800 hours

HEIGHT OF SILOS AND GRINDER BUILDINGS

15 m

TOTAL LENGTH OF CONVEYORS 14 km

WEIGHT OF THE INSTALLATION

1200 metric tons

CONCRETE POURED 1800 cubic meters

PROJECT SITE WORKFORCE 30

INSTALLED POWER 2200 kW(not including pumps 200 kW)

METSO EQUIPMENT

Primary

Vibrating feeder PF561-2V

Primary grizzly VG540-3V

Grizzly feeder TK13-20-3V

Jaw crusher C145 with

hydraulic setting

Secondary

Vibrating screen CVB 2050

refurbished

Cone crusher Omnicocircne 1352 SX

with Metso IC7000 controller Ellivar 16 (16 msup2 3 decks) screen

refurbished by Metso

Tertiary

Cone crusher HP300

Cone crusher HP4

2 Ellivar 20 screens (20 m23 decks) for final products

Expanding the production range

ldquoSince the mid-1990s when we became

owners of La Mariais we had used mobilemachinery with an assembly of beltconveyorsrdquo recalls Daniel Leblin Charierrsquos

Technical Manager for site construction

and maintenance

ldquoIt became clear that we needed ahigher performance tool to achieve the

dual goals of reaching one million metric

tonsrsquo maximum production and producing

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Big Lokotrack LT550GPF boostsquarrying productivity by a thirdMaximizing the productivity of operations is a key issue when striving for cost-effective quarrying Big Lokotracks are oneway to achieve improved operational efficiency The Lokotrack LT550GPF equipped with the high-volume GP550 conecrusher and a large screen is popular in the Nordic countries and in Germany and Australia ndash countries all known for theirhigh quarrying volumes

TEXT amp PHOTOS Eero Haumlmaumllaumlinen

Kone-Kostamorsquos new mobile coneplant has reached an averagecapacity of 300 tons per hour

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983122983141983152983151983154983156983145983150983143 983154983141983155

ldquoWith the same number of employees we

can achieve 30 more productivity with

our new LT550GPF unit The high-capacityFS screen has also eliminated the bottle-neck often seen at fine screeningrdquo says

Aarno Kostamo Managing Director of

Kone-Kostamo Oy one of Finlandrsquos biggest

crushing contractorsAccording to Kostamo the high capacity

of the GP550 gyratory cone crusher easily

handles feed from the C120 and C125 jaw

crushers For the contract with the Talvivaara

nickel mine the LT550GPF is being fed bythe brand new Lokotrack LT120 jaw plant

Average capacity 300 tons per hour

Talvivaara Europersquos largest nickel mine uti-

lizes large quantities of aggregates Kone-Kostamo has contracted several million

tons of different end products for the mineIn August 75000 tons of 0ndash63 mm

road gravel was crushed Smaller amountsof finer 0ndash6 mm 0ndash16 mm and 0ndash32 mm

aggregates are also being produced

The rainy summer increased the need

for road gravel along the muddy roadswhich must endure dump trucks weighing

as much as 260 tons

ldquoThe mobile process consisting of the

LT120 jaw plant and LT550GPF cone plant

is cost-effective while aggregates of vari-ous sizes can be produced in a two-stage

operation and with high capacity The con-trolled stroke and elliptical movement of

the FS screen secure big passing throughcapacitiesrdquo Kostamo explains

Operated in two shifts for a total of 16

hours per day the LT550GPF has logged

more than 600 working hours over a two-month period

Managing Director Aarno Kostamo (left) and foreman Karri Maumlenpaumlauml studying the cavity optionsavailable for the new Lokotrack LT550GPF

Longer perspective than

a single quarter needed

Kone-Kostamo Oy was founded as an

earth-moving company in Kemijaumlrvi

Northern Finland in 1956 The company

expanded its operations to include crush-

ing contracting in 1964 and later on

switched to concentrating fully on crush-ing activities

Kone-Kostamo consistently crushes

and screens around 28 million tons ofaggregates annually and has net sales of

between EUR 8ndash9 million

ldquoWe believe that issues within the crush-

ing industry including the purchasing ofmachinery must be studied with a longer

perspective than a single quarter The

secret to our success has always been our

solid work ethic and professional employ-eesrdquo Kostamo sums up

More info

Esa Berg

Tel + 358 40 837 8692

esabergmetsocom

8132019 Results Minerals Aggregates 3 2012ENG

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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155

Monitoring-based reporting is vital for

assessing the performance of a mobile

crushing plant Metso provides suchreporting tools through its plant-wideautomation system Metso DNA (Dynamic

Network of Applications) with its infor-

mation platform that links all the mobile

crushing and screen units together as oneentity Basically there is a lot of measured

real-time information available in every

crushing plant On-line information is

obtained either from each Metso crusherrsquosmachine automation system IC (Intelligent

Controller) or from separately installed

additional sensors and belt scales

All the collected data is sent to a motorhome using wireless communication

based on WLAN technology The motor

home is a purpose-built environment

inside an on-site container In this environ-ment selected variables can be monitored

for assessing the plantrsquos performance And

to make all this even more flexible the

data can be transmitted to a crushing plant

company office using GPRS3G mobile

data communication technologies Thismakes all the last-minute reports acces-sible to the crushing plant managerial staff

at anytime and basically anywhere within

reach of the cell phone network

Production and fuel economics reports

Essentially monitoring and reporting can

be customized to fit the customerrsquos needs

However there are certain off-the-shelf

reports that provide a lot of useful informa-tion for plant supervision The production

report is one of these Requiring at least one

belt scale for measuring the total produc-tion the production report shows the pro-duction rate (tons per hour) for a selected

reporting period eg a day or a week The

production report constantly keeps track of

the plantrsquos production storing all the datathroughout the plantrsquos life cycle

Performance monitoring and reportingfor a mobile crushing plantTEXT Pasi Airikka PHOTOS Metso

unit during which the unit is running By

storing the availability times between start-ups and shutdowns the crushing plant

operation time (hours per dayshift) can be

recorded analyzed and reported In addi-

tion the availability report can be tailored

to evaluate efficient crushing hours during

which the plant is really working and pro-ducing aggregates Consequently the ratio

(0-100) between efficient crushing time

and total running time can be reported forany selected period of time This boosts

the efficiency of the plantrsquos operations

and results in better productivity

Reports on non-choke

or inadequate feeding

Non-choke feeding to crushers is avoid-

able through smart plant-wide crushingplant controls But estimating its severity in

a systematic manner is not straight-forwardwithout constant monitoring and reporting

The crusher choke feeding report makes

use of the crusher cavity level sensors byanalyzing their level measurements By

calculating average and min-max values

and deviations from the average it can be

shown how often the single crusher suffersfrom non-choke feeding to it

In some cases the bottleneck in the

crushing plantrsquos productivity is the material

feeding to the process In mobile plants thefeeding is human operated and therefore

subject to variations Occasionally the sizeof the human-operated machine simply

does not allow for adequate feeding to thecrushing plant There are specific reports

indicating time periods when the crushing

plant suffers from inadequate feeding

Condition monitoring for

crushers and screens

Machine-specific condition monitoring

focuses on vibrating components in

crushers and screens such as drive shaftbearings safety plate wearings and gears

The low middle and high frequencies ofmonitored components are measured and

supervised in real-time to detect abnor-malities due to slow or fast wear looseness

or imbalance

More info

Pasi Airikka

Tel +358 40 587 2730

pasiairikkametsocom

Condition monitoring provides a view tovibrating crusher and screen components forpredictive equipment maintenance

The daily production report shows the hour-by-hour production trend and distribution chartfor a selected day with min-max average andvariation statistics for comparison

Fuel consumption is always an interest-ing concern The fuel consumption reportgives the fuel consumption of each crush-

ing unit (liters per hour) and their total

consumption (liters per hour) for a selected

reporting period and can track fuel con-

sumption changes over timeCrushing plant availability can be

assessed as well The availability report

calculates time periods for each crushing

8132019 Results Minerals Aggregates 3 2012ENG

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983149983141983156983155983151 983150

for tissue machines The record of 2210

mmin was set on June 1 2012 during a

24-hour production run by the TM 2 tissue

machine at the companyrsquos mill in Yenikoumlynear the city of Izmit in Turkey

ldquoThe cooperation with Metso has been

beyond excellent and both parties did

their utmost to make the project success-ful The results clearly show that the efforts

were worthwhile on both sides This coop-

eration will extend to cover new projects

in the futurerdquo says Luumlt1047297 Aydin Paper GroupDirector Hayat Kimya

ldquoWe are not surprised that Hayat K imya

managed to break the world speed record

We have had great confidence in the capa-bility of the Hayat team since our project

started in 2009 We certainly know our

machine very well its stability production

efficiency and speed capabilityrdquo says Jan

Erikson Vice President Sales Metso

PowerThe worldrsquos first eco-gas fueled

power plant is up and running

Lahti Energy Ltdrsquos new Kymijaumlrvi II gasifica-

tion plant was officially inaugurated on

May 8 2012 It is the first of its kind in the

RecyclingRecycling with Lokotrack LT106

jaw plant in New York

A brand-new Lokotrack LT106 jaw plant is

used in the city area of New York USA to

recycle demolition materials The crushing

site faces the skyscrapers of ManhattanIsland

Paper amp FiberHayat Kimyarsquos Metso-supplied tissue

machine sets world speed record

Thanks to a skilled crew and dedicated

efforts Hayat Kimya AS in Turkey has suc-

ceeded in breaking the world speed record

world This CHP plant runs on clean eco-

gas that is gasified cleaned and cooled

from recycled waste with Metsorsquos innova-tive technology

ldquoItrsquos actually eco-gas that we combust

in the boilerrdquo comments Lahti EnergyrsquosProduction Director Jukka Manskinen

ldquoWe convert unwanted waste material into

energy in an efficient and environmentally

friendly wayrdquoNever before has any plant gasified

waste on such a large scale In the gasifier

recycled waste is turned into combustible

product gas which is cleaned cooled and

combusted in a high-efficiency gas boiler

to produce steam for the steam turbine The plant produces 50 MW of electricity

and 90 MW of district heat for the city of

Lahti and its neighboring areasMetso delivered the circulating fluidized

bed (CFB) gasification process gas cleaning

and cooling steam boiler environmental

protection system and automation systemto the entire plant The production of elec-

tricity and heat is kept even with the Metso

DNA automation system that covers the

whole plant starting from fuel reception

AutomationMetso develops and supplies plant-

wide crushing control solutions for

crushing plants

Metso has recently signed contracts on

delivering plant-wide automation systems

for mobile and portable rock crushing

plants The key objective of these deliveries

is to stabilize and to increase productivityand efficiency of the plants using one sin-

gle automation and information platform

for integrating crusher-specific IC machinecontrols

Furthermore the plant-wide system

with its information management tools not

only increases plant availability and opera-

tional safety it also makes troubleshoot-ing quicker and performance monitoring

easier The control room for plant-wide

operability is located either in an excavator

cabin or a purpose-built container

Metso around the world

The new LT106 jaw plant is suitable for crushing both hard rock and all rock-based demolition materials

The new world speed record for tissue setby Hayat Kimyarsquos Metso-supplied TM 2 is2210 mmin

8132019 Results Minerals Aggregates 3 2012ENG

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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: Results Minerals Aggregates 3 2012.ENG

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0983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

Safe quarrying high-

quality aggregates

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ldquoWe share a similar zero-accident strategy and target with Metso and have successfullyfollowed it Metso has also helped us to meet the strictest end-product quality andcubicity requirements set in Spainrdquo This is how Managing Director Intildeigo Ajuria ofOfitas de San Felices the leading hard rock quarrying company in Spain describesthe cooperation with MetsoTEXT Eero Haumlmaumllaumlinen PHOTOS Ofitas and Eero Haumlmaumllaumlinen

The San Felices quarry is situated in a picturesque mountainous landscapebetween the companyrsquos Rioja vineyards and the Bilbao-Madrid motorway

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Ofitas has pioneered the implementation

of several Metso novelties in the Spanish

market The company was the first to use

efficient large track-mounted Lokotrack jaw plants the unique mobile conveying

system and also the new-generation HP4

cone crushers

Today the company operates twomodern Metso stationary plants one in

Guadix near Granada and the newest one

in San Felices Haro Rioja community Both

quarries focus on refining hard rock by pro-cessing ophite rock into the highest quality

railway ballast asphalt and concrete mix

grades The company has a satellite quarry

near Vitoria in PentildeacerradaBeing situated next to a highway and

the famous Rioja vineyards Ofitas must pay

special attention to environmental issues

To minimize dust problems all conveyors

have special covers attached

Quality durability and service

The cooperation between Ofitas de San

Felices and Metso started back in 1973when the Ajuria family bought the com-

pany whose quarrying activities began in

1919 Intildeigo Ajuria has a clear vision of why

the cooperation has continued withoutinterruption for almost 40 years

long-standing personal relationshipsrdquoAjuria adds

Serving railways asphalt

and concrete producers

The year-old San Felices stationary instal-lation lies hidden in a mountainous area

south of the city of Vitoria in NorthernSpain The new plant replaces an old one

that complicated the extraction of ophiterock Both plants are delivered by Metso

With its two separate production lines

the new plant is able to produce all the

end products required ndash from railway bal-last to the finer grades needed for asphalt

and concrete

Due to lower demand the quarry cur-

rently produces some 4000 tons per day

At full capacity however the plant canreach 8000 tons of production per day

30ndash35 of which consists of railway ballastfor high-speed trains and 65ndash70 of chips

and sand Thanks to the versatile two-line con-

cept connected by transverse conveyors

up to 12 different end products can be pro-

duced Depending on the demand for endproducts the material can be guided either

to the HP4 cone or HP400 cone followed

by a Barmac vertical shaft impactor

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

The ophite feed is fed to the C125 jaw crusher by a sturdy dump truck

The key people running the new San Felicesquarry Mine Engineer Carlos Fernandez (left)Managing Director Intildeigo Ajuria with ProductionManager Julian Perez

ldquoThrough the years Metso machinery

has proven its production capacity and

durability resulting in high-quality end

products A big plus for us has also beenthe quick response time to our process

challenges or servicerdquo

ldquoIn fact our cooperation extends

beyond day-to-day business matters to

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983122983141983152983151983154983156983145983150983143 983154983141983155

Meeting the strictest cubicity demands

The Spanish regulations concerning end-product cubicity are becoming more

demanding The flakiness percentage of

railway ballast must be below 10 and for

asphalt and concrete aggregates less than

15

ldquoWith Metsorsquos HP4 cone and the Barmacvertical shaft impactor we can meet even

the strictest cubicity demands We believe

that our high quality is helping us to sur-vive in the present recessionrdquo notes Mine

Engineer Carlos Fernandez

ldquoWe hope to increase the total extrac-

tion of the three quarries from the present15 million tons per year because our plant

capacity allows more than double thatrdquo

Fernandez adds

More info

Angel Luis Garcia Tel +34 686 94 35 30

angelluisgarciametsocom

In addition to being the leading Spanish

quarry to process hard rock Ofitas de SanFelices also cultivates 34 hectares of vine-yards next to the quarry which is situated

in the famous Rioja wine area

The company has previously sold a

harvest of over 200000 kg of Tempranillo

grapes to local red-wine makers Recentlythe company built its own wine process-

ing plant to process 10000ndash15000 kg of

grapes themselves

Aggregates and wine production

Andoni Ajuria the founder of Ofitas de san Felices (left) with Intildeigo Ajuria the present ManagingDirector tasting wine from the companyrsquos own vineyards

The first vintage wine of Ofitas har-

vested in autumn 2010 is now maturingin oak barrels After maturing for 12 to 15months the wine is called crianza and after

two years it will be granted the classifica-

tion reserva

ldquoWinemaking is not a business but

a hobby for us We give our wine out aspresents and drink it when we meet

our suppliers and friendsrdquo Intildeigo Ajuria

comments

For environmental protectionall of San Felicesrsquos plantconveyors are covered

Ofitas de San Felices quarry

LOCATION Haro near the city

of Vitoria northern Spain

SIZE 100 hectares

ROCK TYPE Ophite with Los Angeles

index of 9ndash10

PRESENT DAILY EXTRACTION 3000 tons

of ophiteNUMBER OF PERSONNEL 30

RESERVES 10 million tons

MAIN END PRODUCTS 0ndash2 mm

2ndash4 mm 4ndash10 mm 10ndash16 mm

16ndash22 mm 25ndash60 mm (ballast)

METSO MAIN EQUIPMENT

VF feeder

C125 jaw crusher

ndash feed size 0ndash800 mm

ndash css 130ndash140 mm

HP400 cone crusher

ndash feed size 80ndash250 mm

ndash css 40 mm HP4 cone crusher

ndash feed size 40ndash80 mm

ndash css 15 mm

Barmac 6150 VSI crusher

4 CVB2060 screens

2 TS32 screens

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Metso Distribution Centers he

Europe (Tongeren Belgium)

France (Macon)

Czech Republic (Přerov)

Austria (Vienna)

2271 d

Brazil (Sorocaba SP)

1014 d

USA (Columbia SC)

1690 d

USA (Waukesha WI)

434 d

South Africa (Vereeniging)

Ghana (Tarkwa)

Meacutexico (Irapuato)

Peru (Lima)

Chile (Concoacuten)

788 d

Sweden ( Trelleborg)

Finland (Tampere)

UK (Rugby)

865 d

Russia (St Petersburg)

Brazil (Parauapebas PA)

206 d

4983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

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983122983141983152983151983154983156983145983150983143 983154983141983155983122983141983152983151983154983156983145983150983143 983154983141983155

In the case of an equipment failure or

a planned service shutdown resuming

production as quickly as possible is crucialEach hour spent waiting for a spare part to

arrive equals money lost Whether the right

part takes 12 or 48 hours to arrive really

makes a difference

The comprehensive and global Metsospare and wear parts service network pro-

vides you with the right part in the right

place and at the right time Our strategi-

cally located Distribution Centers and

Satellite Warehouses are on call 24 hoursa day 7 days a week ensuring efficient

parts replacement near you

Check out the locations of the MetsoDistribution Centers and how many parts

pass through them each day

More info

Marcelo Farah

Tel +55 15 2102 1315

marcelofarahmetsocom

you minimize downtime

Australia (Perth)

746 d

China (Tianjin)

China (Kunming)

China (Shanghai)

393 d

India (Faridabad)

India (Ahmedabad)

India (Hyderabad)

India (Bhubaneswar)

India (Bangalore)

419 d

Russia (Yekaterinburg)

Australia (Newcastle)

New Zealand (Matamata)

983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088

TEXT Sofia Williams

Singapore (Singapore)

Distribution Center Satellite Warehouse

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Following a large investment

in Metso crushing equipmentand services Buena Vista del

Cobre is now expanding the

mine site to include even more

equipment ndash and with thatexpansion comes the need for

more local service resources

Metso and Buena Vista del

Cobre have entered into a Life

Cycle Service agreement forthe plant and construction of a

brand new Metso service hub

is under way in Cananea

New facility new

level of service

The Cananea service hub

which will be up and running in early 2013will support the recent expansion and resur-

gence of Buena Vista del Cobre Initially it

will be a major repair and assembly center

for pumps crushers and screens and will

provide for rubber covering capabilitiesBut the 8000-square-meter facilityrsquos service

offering will be expansive including a con-

signment stock inventory to help serve theminersquos varying needs Metso currently has

50 service team members on site

Although Buena Vista del Cobre was a

key influencer in building the new servicehub this location will also enable Metso to

expand its capabilities and provide local

support to the entire mining community

in northwest Mexico The Cananea hub

will serve a number of major copper and

gold mines in the region including MineraFriscorsquos San Felipe Fresnillorsquos Milpillas and

Grupo Mexicorsquos Mexicana de Cobre

ldquoBuena Vista del Cobre is the biggestcustomer we have in Mexico today and

with this expansion project itrsquos only going

to grow and be strongerrdquo says Felix Forna-

guera Director of Services Mexico CentralAmerica and Caribbean ldquoWith that said the

idea behind the Cananea service hub is to

provide a central location for local support

for all our major customers in the areardquo

Establishing safety

ldquoIt was key to have our support here in

Cananea because the Buena Vista delCobre started from the ground uprdquo saysFelix ldquoWersquove been able to help the cus-

tomer to establish the best in support

service and operations from the very

beginningrdquo And this ground-up approachincluded a major focus on safety

Metso worked closely with Buena Vista

del Cobre to establish the safety proto-

col by which the mine operates Basedon Metsorsquos expertise the safety measures

put in place have enabled the mine to

become strict and efficient in its operations

and maintenance procedures To achievethis Metso worked closely with local andnational authorities to ensure the safety

plan was comprehensive and in accord-

ance with all established legal bodies

The best in regional support

The service hub in Cananea is a prime

example of Metsorsquos focus on providing local

service and support to its customers all

Service shines in Cananea MexicoAfter three years of inactivity the Buena Vista del Cobre mine in Cananea Sonora Mexico has been operational since 2010A mine that was inactive for such a significant amount of time however requires a great deal of support to successfullyrestart the plant and bring it back to an operational and profitable state

TEXT Deanna Lee PHOTO Metso

over the world ldquoWe are the first

company developing this kindof service in northwest Mexicordquo

adds Felix ldquoOur people have

developed a close relationship

with the team at the mine Itrsquosmore than a supplier relation-

ship our guys are inside the

mine living and working thererdquo

In fact this is the model

that Metso is using in servicehubs all over the globe build-

ing modern facilities bringing

teams on site and workinghand in hand with mine

operators The Cananea Service

hub is only the most recent

example of Metsorsquos commit-ment to service and northwest Mexico is

yet another mining hotbed thatrsquos going to

benefit from the companyrsquos support

More info

Felix Fornaguera Tel +52 4621079227

felixfornaguerametsocom

A mining cone serviced by Metso at the Buena Vista del Cobre mine inSonora Mexico

ldquoThe new Cananea service center will be a majorrepair and assembly center for pumps crushersand screensrdquo says Felix Fornaguera Director ofServices Mexico Central America and Caribbean

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

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During the MINExpo exhibition over 1300 people visited the Metso stand

983122983141983152983151983154983156983145983150983143 983154983141983155

Held every four years MIN-Expo consistently grows so

perennial exhibitors like Metso

are challenged with elevating

their presence and drawingin new (and greater numbers

of ) visitors each year ldquoItrsquos not

necessarily a challenge to lsquotoprsquo

our last showingrdquo says Keith

Ference Vice President ofmarketing and communica-

tions North America ldquoThere

are four years between eachMINExpo so we always have

a lot to say and reveal to our

customersrdquo The real challenge

he says is finding an exciting

and dynamic way to deliverthe message ldquoTherersquos so much

to see here so your booth has

to be compelling from the

outside-in and thatrsquos what

we always try to dordquo

Service sets the stage

The Metso booth created buzzin a number of ways and per-

haps the most striking (partly

due to its size) was the live

theater presentation As visitorspassed through the aisles of the show-

room the sights and sounds from Metsorsquos

theater were hard to miss And once guests

entered they were captivated by a short

high-energy video presentation focused

on Metsorsquos service capabilities The message was simple Metso is ldquoyour

local service partner rdquo for all mining and

construction needs The video showed ourservice teams in action all over the world

and the audience came away with an

understanding about Metsorsquos commitment

to service Customers can count on morethan 70 local service centers run by more

than 1700 expert technicians delivering

Metso makes an impact at MINExpo 2012At this yearrsquos MINExpo International nearly 60000 attendees flocked to Las Vegas Nevada the largest turnout in showhistory The visitors ndash mining professionals from all over the globe ndash explored 850000 square feet of showroom spacefeaturing the industry rsquos latest technology equipment products and services They toured the show for three days

seeking the latest and greatest from more than 1800 exhibitorsTEXT Keith Ference PHOTOS Tracey Ford Perry

detailed descriptions andphotos of all of Metsorsquos mining

and construction products and

services The app also provides

digital access to Results and asearchable database of sales

contacts By day three of the

show MetsoMAP had been

downloaded by more than

500 usersIn addition to the app the

booth was equipped with

several LCD screens each con-trolled by Metso experts who

used their iPads to present new

products like the Megalinertrade

and the HRCtrade A featured

presentation on Metsorsquos lineupof energy-efficient comminu-

tion equipment including the

VERTIMILLreg SMD and MP-1250

cone crusher was also avail-

able letting customers seehow Metso technology delivers

some of the worldrsquos most effi-

cient size reduction

Measuring MINExpo success

After a very busy three days

(on top of months of prepara-tion leading up to the show) everyone

involved with MINExpo ndash from the North

American marketing team responsible for

the booth to the product managers and

sales force that worked the floor ndash is view-

ing the show as a success ldquoTherersquos alwaysa sigh of relief after each (MINExpo)rdquo says

Keith ldquoAnd overall the initial feedback

and response has been very positiverdquoWith more than 1300 visitors to the

booth Metso certainly made an impact

ldquoWe learn a lot from each show and with

some time wersquoll have a better understand-ing of the tangible results of our effortsrdquo

Keith adds

reliable service for mining equipment as

well as customized cost-effective life-cycle

services contracts

Technology ndash MetsoMAP

is an industry firstMINExpo provided the industry with its firstglimpse of Metsorsquos revolutionary iPad app

MetsoMAP The app was demoed to the

boothrsquos visitors via ldquothe worldrsquos largest iPadrdquo

a custom-made 80-inch screen that show-cased all of its capabilities most of which are

groundbreaking in the industry MetsoMAPrsquos

simple interface is highly intuitive making

it easy to view process animations videos

The presentation of the new HP cone crusher attracted a large audience

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When yoursquore allowed less than a dozen days per year for breakdowns repair andmaintenance every single hour during a service shutdown counts There simplyisnrsquot any room for surprises Thatrsquos why Boliden counts on MetsoTEXT amp PHOTOS Sofia Williams

8983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

Kurt Kalla Site Managerof Metso Gaumlllivare ServiceCenter is responsible forthe maintenance of Aitik

Metso and Boliden Strivingtogether for 97 uptime

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983122983141983152983151983154983156983145983150983143 983154983141983155

One of the biggest copper mines in

Europe Bolidenrsquos Aitik is located deep inthe wilderness of Swedish Lapland next to

the small town of Gaumlllivare The mine has

been operating since 1968 and a recent

expansion has increased its annual ore

production to 36 million tons

But the ambitious Swedes are not will-ing to lay back and relax just yet Bolidenrsquos

new aim is to reach a production rate of

45 million tons of ore per year in AitikAfter that Perhaps more than 55 million

tons The ore concentration in Aitik is very

low-grade with a mere 022 copper con-

tent hence the need for high capacityAchieving the ambitious production

goal requires maximum plant availability

This means that everything from the crush-

ers to the filters must be up and runningfor approximately 97 percent of the time

Thatrsquos where Metso comes into play

A cost-per-ton contract in action

The maximum uptime requirement allowsless than a dozen days per year for break-

downs repair and maintenance at Aitik

Every single hour during a service shut-

down counts There simply isnrsquot any roomfor surprises

Executing a successful shutdown under

such conditions requires a reliable service

partner not afraid of challenges and this iswhy Boliden has entrusted Aitikrsquos services

operations to Metso Boliden and Metsohave worked together since the 1960s

and the collaboration took another step

forward in September 2012 when the twocompanies signed a three-year extension

of the services contract for Boliden Aitik

ldquoThe new contract is a cost-per-ton

agreement We get paid based on Aitikrsquos

production Itrsquos a win-win deal for both par-

ties but also a new mindset for usrdquo explainsKurt Kalla Site Manager of Metso Gaumlllivare

Service Center responsible for serving Aitik

From now on the duration of the shut-down is what matters the most According

to Kalla the Metso service organization in

Gaumlllivare is now streamlining its operations

to fit the bill and has already witnessed thestrategy working In August 2012 Metso

carried out a 188-hour service shutdown in

Aitik which turned out to be a success

Zero tolerance for injury

One key factor to the success was theextensive planning of precautionary health

safety and environment procedures under-

taken by Metso prior to the shutdown Thanks to strict measures applied no

injuries or accidents occurred during the

shutdown and the work could easily be

finished on scheduleMats Johansson Health Safety

and Environment Manager for Metso in

Sweden explains how this was achieved

rdquoPlanning of the shutdown included arisk analysis for all new tasks participating

in Bolidenrsquos safety coordination meetingsmeeting with both Metso supervisors and

subcontractor supervisors and finally a

meeting with the entire staff participating

in the shutdown where everyone had to

sign a document stating their commitmentto the information providedrdquo he says

During the actual shutdown plenty of

new barriers signs and awareness cones

were put in place as a result of observa-tions from previous audits and safety plans

and risk analyses were readily available

in the work area Metso and Boliden also

introduced a Mill Inching permit a certifi-cate for completing a mandatory course for

those involved in the process In addition

Metso carried out random safety audits

during the shutdown to make sure thestrict policy was followed

According to Boliden Metsorsquos way of

working is a good example of how health

and safety precautions should be handled

ldquoMetso is a good example of how towork with safety and health plans risk

analysis permits and welding permits

Their table with all binders in the second-

ary mill area was exemplaryrdquo says Kjell-Arne

Johansson a technician from Boliden

The use of the new Metso Megalinertrade

system in the lining of Aitikrsquos Metso AG

mills has also improved the safety of main-tenance staff The Metso Megalinertrade con-

sists of larger-than-average liners bolted

in position from outside the mill Mainte-

nance technicians no longer need to go

inside the mill and stand in the dangerousdrop-zone of the liners gt

Boliden aims to reach a production rate of 45 million tons of ore per yearin the Aitik mine site

ldquoA complete risk analysis was conducted during the planningof the shutdownrdquo comments Mats Johansson Health Safetyand Environment Manager for Metso in Sweden

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Service the Metso way

24 hours a day 365 days a year

In addition to paying close attention to

health and safety issues executing an effi-

cient shutdown requires careful planning

and timing of every step in the mainte-

nance process Wear and spare parts have

to be available on time and a repair shoplarge enough to accommodate equipment

located close by

ldquoTo keep maintenance breaks as short

as possible we aim to replace the pump on

site and bring the old one for repair to our

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

nearby facilities This method gives us the

peace to do a good job and keep the cus-

tomerrsquos operations runningrdquo Kalla describes

the Metso way of handling Aitikrsquos pump

maintenance

Metso is currently expanding its Gaumllli-

vare service center to include a distribu-

tion center for wear and spare parts andalso concentrating its previously scattered

operations under one roof in its Vuoskon-

jaumlrvivaumlgen facility The expansion is due to

be completed by 2014

Metso equipment

delivered to Aitik36

bull 2 AG mills diameter 116 x

137 m gearless 22-MW motor

bull 2 Pebble mills diameter 91 x

113m dual 5-MW pinion drive

bull 3 VPA pressure filters VPA 1540-54

bull 12 sample pumps and pipes

VF50

bull 60 Various slurry pumps up to

MR500 modelbull Appr 5000 m rubber-lined slurry

pipes up to 600 mm diameter

bull Appr 5000 m rubber-lined by

gravity pipes up to 600 mm

diameter

bull Appr 5000 m rubber hoses

up to 600 mm diameter

Not only does the expansion make ser-

vice shutdowns at Aitik run more smoothly

it guarantees a more comprehensive

on-call emergency service response in the

region ndash thanks to the spare and wear parts

inventory available 24 hours a day 365

days a year

More info

Lars Rosenling

Tel +46 70 107 45 90

larsrosenlingmetsocom

Metso grinding equipment dominates the view in the concentrator

Safety on site is made up of small things like

making sure that everyone remembers to secure

the hoses in place

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Pebbles have always been a

challenge for producers of sandsince they cannot be returned

to rivers after extraction For

decades the processing of this

material resulted in a huge

environmental liability with alarge amount of pebbles hav-

ing to be stored away and left

unused

Transforming problems into

business opportunities

Areia amp Cia (areia = sand) has

operated in this market forover 20 years and decided to

enlist the help of Metso to find

a profitable solution for the

processing of pebbles

In July 2011 analyses werebegun to assess the abrasive-

ness and crushability of the

material Four alternatives wereidentified for processing and

transforming pebbles into sand

Initially Areia amp Cia was

interested in acquiring an

impactor for its reason-able price level However the

customer wanted to process

all the pebbles that were col-

lected daily in addition to some of the

material that it had stored In weighing theresults expected by the customer and the

excessive abrasiveness of the material the

HP200 cone crusher was decided on as thebest alternative

Areia amp Cia made the required invest-

ment and after using the HP200 for just

six months the company has already beenreporting outstanding results The HP200

not only transforms pebbles into sand but

also produces sand of excellent quality

with high yield and low maintenanceWith minor adjustments the HP200

also enables the production of sand withspecific particle size distribution for special

applications such as filtering sand blasting

and foundry sand adding value to the prod-

uct and increasing the types of sand offeredldquoMetso is pleased that the HP200 not

only enabled the processing of a product

that had been set aside as unusable but

HP200 cone transforms pebblesinto high-quality sandOver the last few decades Brazilian economic growth has been driving demand for construction aggregates The market

for sand in turn has been experiencing major difficulties in maintaining a consistent supply Presently one of the mainchallenges the industry faces is the large amount of pebbles that are obtained in the process of extracting sand at timesconstituting nearly 50 of the volume of material dredged from riverbeds

TEXT Sheila Ivers PHOTO Areia amp Cia

also that it opened up new

market opportunities for Areiaamp Cia Thatrsquos the standard we

seek to deliver to our custom-

ersrdquo states Luiz Oliveira Techni-

cal Salesperson of Metso Brazil

HP cones entering the

Brazilian sand-making

market

Todayrsquos cones such as theHP200 have high resistance

to impacts and abrasiveness

more efficient crushing cham-

bers low maintenance costsand excellent productivity

Following the acquisition of

the HP200 Areia amp Cia is now

also producing special sands

that command a price that is100 higher than common

sand The entire stockpile of

pebbles accumulated through-out the companyrsquos 20 years of

operations has already been

transformed into sand and the

stock of pebbles held by com-

petitors is also being purchasedfor processing

Cristiane Brizolari the

owner of Areia amp Cia confirms

the transformation that has taken place in

the production and commercial processldquoThe HP200 opened up new niches in

the market enabling the production of dif-

ferent types of sand with added valuerdquo

More info

Luiz Oliveira

Tel +55 011 9971 3603

luizoliveirametsocom

After the pebbles are crushed into sand with the HP200 cone crusherdifferent grades are screened for various end uses

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Where therersquos a will we dig a wayAFCONS-Strabag and Metso embark on tunnel project together

When the joint venture AFCONS-Strabag initiated work on the Rohtang bypass tunnel project at an altitude of 3980 metersabove sea level in Himachal Pradesh India they deliberated each aspect with clockwork precision The project involved anumber of surprises and challenges and required technology and project management skills that were second to none

TEXT amp PHOTOS Monisha Majumdar

Cutting a 10-meter-wide and nearly 9-kilo-

meter-long tunnel through the Himalayas

in one of the toughest terrains and cli-mates in India makes for quite a challengeResults set out to find out how AFCONS-

Strabag and Metso are making their way in

one of their most critical projects to date

The only road connection to the north-Indian border region of the province

Himachal-Pradesh and beyond the Manali-

Leh highway leads across the Rohtang

pass Due to the heavy snowfall and high-

velocity winds in this region the towns

located north of the pass are cut off from

the rest of the country during winter for atleast four often even six months each year

A tunnel with strategic importance

With the construction of the tunnel at

3100 m above sea level the Manali-Lehhighway will become an all-weather road

thereby enabling a significant improve-

ment in the economic development of

northern Himachal-Pradesh and an alter-

nate route to the strategically important

Ladakh region

Manali south of the pass is an alreadywell-developed tourist location that is

becoming more and more popular Upon

completion of the tunnel it is likely that

tourist activities will extend to the areanorth of the pass Moreover the tunnel

shortens the distance between the towns

of Manali and Leh by approximately 45 km

thus saving several hours on the small dan-gerous pass road

The Rohtang pass in the Western Himalaya

region of Northern India with its altitude ofalmost four kilometers ranks among thehighest trafficable passes in the world

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983122983141983152983151983154983156983145983150983143 983154983141983155

The 88-km long horse-shoe-shaped

tunnel provides space for a two-lane8-m-wide carriageway as well as a one-

meter-wide footpath on both sides A

22-m-high and 36-m-wide emergency

tunnel will be integrated in the tun-

nel cross-section Altogether more than

800000 msup3 of rock will be moved Tunneling works started around spring

2010 with excavation driven from both por-

tals As the north portal is inaccessible dur-ing winter closure the excavation focused

on the south After a planned construction

period of 55 years the tunnel is scheduled

to be completed by the end of 2015

Best man for the job

The BRO (Border Road Organization)

wanted to roll out a global tender for theproject due to the challenges that such a

project involves and also considering thatitrsquos the first time in India that a project of

this scale was to be carried out This imme-

diately triggered the need to roll out aglobal tender All major Indian construction

companies bid for it some individually and

some in partnerships

Strabag an Austrian tunnel specialistwas one of the companies who bid for the

project along with AFCONS a Mumbai-

based infrastructure company In Septem-

ber 2009 AFCONS-Strabag was awardedthe contract

Mr Sunil Tyagi Deputy Project Man-ager at AFCONS had this to say about the

unique projectldquoThis project is located in the Himalayas

and as far as we understand the terrain

there is among the toughest We came out

with a new technology and to be honestit is a fairly simple one We would generally

start with the traditional technology of drill-

ing and blasting and then obtain our muck

feed from the inwardbottom of the tunnelrdquo

ldquoThe technology is supplied by Rowa Tunneling Logistics and this is the first

time it is being used in Asia A jaw crusheris placed at a distance of about 40-45

meters behind the face The blasted muckextracted from the face is fed to the crusher

to reduce the lump size and then through

an overhead conveyor transport system

it is then transported out of the tunnelrdquoldquoThis enables free movement of man

and machinery in the lower area or spe-

cifically on the ground area If we were to

conforms to the Indian standard for fines amp

coarse aggregates as prescribed in IS383-1970

The plant was up and running in good

condition and performing to AFCONSrsquos

satisfactionldquoWe have worked with Metso in earlier

projects and are quite impressed by thekind of technology amp services they provide

We have a history together so the trust fac-tor also comes inrdquo explains Dhiman on their

choice of Metso as a partner

Service makes the difference

ldquoMetsorsquos services have made a big dif-ference in the project Without them we

would still be struggling with the machin-

ery and production The service is really

good and the service engineers are knowl-edgeable prompt and quick to act Any

problem can be solved by Metso We donrsquothave to wait until a service engineer turns

up ndash they have the capacity to solve prob-lems over the phone as wellrdquo says Dhiman

ldquoThe Metso plant didnrsquot create any prob-

lems for us We had problems in logistics

the feed was sticky and the weather condi-tions were bad but thankfully we did not

face any problems with production and

efficiency as the Metso plant is performing

very wellrdquo Dhiman concludes

More info

Amol Sinha Tel +91 9811 671 924

amolsinhametsocom

use the old conventional technology this

wouldnrsquot have worked for us in the stipu-lated timerdquo Mr Tyagi adds

When the going gets tough

partner with the toughest

Sensitive projects require the best technol-

ogy After AFCONS-Strabag landed theproject Metso was an obvious choice as a

technology provider not only because of

the long-standing business relationshipbut also for the sheer consistency in prod-

uct quality and service deliverance Metso

strives for

ldquoAfter signing the project we faced alot of road blocks including extreme cold

avalanches roadblocks less oxygen ndash you

name it we faced itrdquo explains Ankit Dhi-

man Plant Manager at AFCONS-Strabag The Rohtang valley is known for its

notorious avalanches and landslides SoAFCONS had to take extra steps and safety

precautions against hazards on the site

ldquoIn this freezing cold not just us humansbut also the machines are at increased risk

of damage I remember when we used

to run the plant during winter the diesel

engines would freeze We had to constantlyheat up the fuel container to get the plant

running And even the sand in the sand

trap would freeze so we had to clean it on

a daily basis to stop the pipes from mal-functioningrdquo Dhiman adds

Plant designed for difficult terrain

Difficult terrain coupled with space con-straints led Metso engineers to put their

minds together to come up with a suitable

plant configuration After studying the

requirements of the project Metso sug-

gested a 150-tons-per-hour three-stagemodular plant using a C106 jaw crusher

a GP11F secondary cone crusher and a

B7150 tertiary vertical shaft impact crusher

In addition considering the unpredict-ability of the feed the plant was about

to reach a point where the amount offines to be handled could be increased

dramatically Metso strongly suggested the TK11-27-3V grizzly scalper and this became

the first-ever TK scalper to be supplied by

Metso to an Indian customer Also in order

to get better products a sand trap SF2360was added to the configuration

The sand trap is important equipment

for this project as it washes the sand thatMr Sunil Tyagi Deputy Project ManagerAFCONS-Strabag

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Smooth transition to new-generation jaw crusher in Germany

Roumlhrig is a German company with a rich heritage The company has been quarrying granite at its plant in Bergstrasse inthe Sonderbach district of Heppenheim for three generations

TEXT amp PHOTOS Ralf Goffin

Roumlhrigrsquos superior product variety is onereason why the companyrsquos proximity to its

customers can be understood in more than

just physical terms The companyrsquos high

level of innovation has allowed it to estab-lish itself as a reliable supplier of materials

both regionally and internationally This

operational and technical expertise always

manages to keep in step with growing

market requirements

In terms of technical processing equip-

ment Roumlhrig has used a Nordberg C160stationary jaw crusher from Metso since

1992 At the start of 2012 it was finally

exchanged for a more up-to-date version

from the same model range

Metsorsquos C Series is specifically designed

to pre-crush hard rock and can cope effort-

lessly with even the hardest of materials

The dimensions of the new stationary jawcrusher are identical to those of the old

one which means that it could simply be

slotted into the housing vacated by the

previous version

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983122983141983152983151983154983156983145983150983143 983154983141983155

Third-generation Managing DirectorMarco Roumlhrig expects the new machinersquos

service life to be just as long as the previ-

ous model due to the product upgrades

that have been implemented The integral motor base is another plus

point in models made by other manu-

facturers it is located outside the crusher

This element of good fortune ensured that

Roumlhrig could reuse the housing withoutany additional rebuilding

Another advantage lies in the revision

of the guards for the C160rsquos drivetrain andflywheel The sturdier construction method

used for the crusher requires fewer parts

which facilitates easier installation andmaintenance and it makes it simpler to

access the motor

Under the watchful eye of Metsorsquos

Assembly Manager Maik Engelstaumltterthe entire project including removal and

installation was successfully completed

within two weeks

Installation making the most

of the available space

Roumlhrig will likely remember the day the

new crusher was installed for a long time

the pitman and main frame were deliveredseparately prior to installation and assem-

bled on site It took just one hour to replace

the old stationary crusher with the new

model A lorry-mounted crane was used toposition the 85-ton crusher with millimeter

precision in the crushing plant Once the

new crusher had been positioned in theexisting steel structure the next task wasto fix it into place as securely as possible

despite the limited space Special vibration

dampers were installed at a height of two

meters to prevent the crusher from sliding

Norbert Ried (fourth from left) installed thenew C160rsquos predecessor 20 years ago and isdelighted at the durability of the powerfulcrusher that is now making way for a newermodel Also pictured from left to right ManagerVolker Angermann Assembly Manager Maik

Engelstaumltter Technical Manager Stefan

Koob Project Manager Dominic SchoumlnhardtManaging Director Marco Roumlhrig Service

Technician Stefan Kolze and employees ofthe installation company Stafemo

On the hook after theold C160 was liftedout by crane the newcrusher was installedin almost no timeOnly the roof of thehousing had to beremoved

sideways off its mount An initial test run

with materials was carried out around oneweek later after all the electrical cables had

been installed

Simultaneously with the installation

of the C160 which is the first of the latest

generation of crushers to be installed in

Germany a new Nordberg GP100 conecrusher was also being installed in Roumlhrigrsquos

chipping plant Roumlhrig is convinced that

the technical improvements made tothe new Metso crusher can only be an

advantage worldwide

Roumlhrig places great value on consistent

product quality maximum added valueand optimum refinement of its product

range Bearing in mind that Roumlhrig has

enough reserves of raw material to last

for the next 150 years the company canconfidently continue to develop with an

emphasis on quality rather than quantity

More info

Dominic Schoenhardt

Tel +49 (0)621 727 00 610

dominicschoenhardtmetsocom

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Groupe Charier Carriegravere de la Mariais France

Quarrying with certi1047297ed quality The Charier Group with its 1600-strong workforce is a family business thatthis year celebrates 115 years of quarrying The company pursues a long-termdevelopment policy that since 2007 has seen processing installations upgradedat 4 of its 9 extraction sites

TEXT Liliane Boutin (with extracts from Mines amp Carriegraveres and Terrassements amp Carriegraveres magazines)PHOTO Baloon photo

The processing installation is of the horizontal type with a primary station located 56 meters below the site access road to keep it hidden from view

The crushing and screening installation at

Charierrsquos CM La Mariais quarry (at Donges

on the Loire estuary) has been in opera-tion since September 2011 Based on theoperatorrsquos ideas it was designed by Metso

to replace a worn-out installation installed

right on top of the seam being extracted

Since its commissioning it has becomethe second quarry in the company to

receive ISO 14 001 certification

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983122983141983152983151983154983156983145983150983143 983154983141983155

tertiary material of sand and gravel for the

local market to use in concrete surfacingprefabrication etcrdquo

Incorporation of a screening station

The stone extracted from La Mariais is

according to the quarry granitic gneiss

sound and homogeneous with a LosAngeles index of 15 good wear resist-

ance with an MDE of 10 a true density of

265 and a certain abrasiveness (2000 gt)ldquoCharacteristically it has a tendency to form

blocksrdquo Leblin points out

The main criteria in designing the instal-

lation was to provide an output of 600000metric tons from one station (38 hours

week) to produce materials aimed at the

concrete and surfacing markets ldquowhich

involved providing a tertiary station withscreening plantrdquo he adds

With this new unit the operating com-pany expands its product range through

the addition of fine materials obtained

from the tertiary screening station This unitis capable of producing 170 tonshour of

020

Preserving the environment

and optimizing safety

The screens have motorized bogies and

retractable walkways to facilitate access

when the screens are opened for main-tenance Other walkways provide access

to the tunnel input feeders The feederscan be isolated with hydraulic rod gate

bars this hydraulic assistance eliminatesthe need to use a heavy hammer to lodge

these metal bars

All conveyors transporting fines (02

and 04) are covered with a tarpaulin to

avoid flying dust and all the screens arehooded (metal cover with Trellex seal-

ing) The Brunone company has installed

dust-tight containment at the outlet of the

tertiary station crushers (HP300 and HP4)on the belt located under the screens

and under the hoppers located belowthe tertiary screens The crushers are put

under negative pressure and the finesare extracted through sleeve filters (7000

m3 h) with declogging which deposits the

dust back onto the conveyor belt

A high-pressure 100 bar water mist sys-tem has been installed at the primary sta-

tion discharge at the secondary crusherrsquos

discharge chutes (Omnicone) and at the

transfer points on the belt

Designed to last

ldquoThis type of new installation can easily last

thirty yearsrdquo affirms Project Leader Bruno

Peix of Metso ldquoIt quite simply depends on

how well it is maintained Thatrsquos why weprovide maintenance contracts that call for

our technicians to make regular inspection

visits and carry out preventive mainte-nance and any necessary repairsrdquo

In 2011 Metso commissioned about

10 new processing units in France like

the one at La Mariais quarry

More info

Frederic Bazire

Tel +33 (0)681442804

fredericbaziremetsocom

Key figures

DURATION OF WORKS 15 months

DRAWING OFFICE TIME 7800 hours

HEIGHT OF SILOS AND GRINDER BUILDINGS

15 m

TOTAL LENGTH OF CONVEYORS 14 km

WEIGHT OF THE INSTALLATION

1200 metric tons

CONCRETE POURED 1800 cubic meters

PROJECT SITE WORKFORCE 30

INSTALLED POWER 2200 kW(not including pumps 200 kW)

METSO EQUIPMENT

Primary

Vibrating feeder PF561-2V

Primary grizzly VG540-3V

Grizzly feeder TK13-20-3V

Jaw crusher C145 with

hydraulic setting

Secondary

Vibrating screen CVB 2050

refurbished

Cone crusher Omnicocircne 1352 SX

with Metso IC7000 controller Ellivar 16 (16 msup2 3 decks) screen

refurbished by Metso

Tertiary

Cone crusher HP300

Cone crusher HP4

2 Ellivar 20 screens (20 m23 decks) for final products

Expanding the production range

ldquoSince the mid-1990s when we became

owners of La Mariais we had used mobilemachinery with an assembly of beltconveyorsrdquo recalls Daniel Leblin Charierrsquos

Technical Manager for site construction

and maintenance

ldquoIt became clear that we needed ahigher performance tool to achieve the

dual goals of reaching one million metric

tonsrsquo maximum production and producing

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Big Lokotrack LT550GPF boostsquarrying productivity by a thirdMaximizing the productivity of operations is a key issue when striving for cost-effective quarrying Big Lokotracks are oneway to achieve improved operational efficiency The Lokotrack LT550GPF equipped with the high-volume GP550 conecrusher and a large screen is popular in the Nordic countries and in Germany and Australia ndash countries all known for theirhigh quarrying volumes

TEXT amp PHOTOS Eero Haumlmaumllaumlinen

Kone-Kostamorsquos new mobile coneplant has reached an averagecapacity of 300 tons per hour

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155

ldquoWith the same number of employees we

can achieve 30 more productivity with

our new LT550GPF unit The high-capacityFS screen has also eliminated the bottle-neck often seen at fine screeningrdquo says

Aarno Kostamo Managing Director of

Kone-Kostamo Oy one of Finlandrsquos biggest

crushing contractorsAccording to Kostamo the high capacity

of the GP550 gyratory cone crusher easily

handles feed from the C120 and C125 jaw

crushers For the contract with the Talvivaara

nickel mine the LT550GPF is being fed bythe brand new Lokotrack LT120 jaw plant

Average capacity 300 tons per hour

Talvivaara Europersquos largest nickel mine uti-

lizes large quantities of aggregates Kone-Kostamo has contracted several million

tons of different end products for the mineIn August 75000 tons of 0ndash63 mm

road gravel was crushed Smaller amountsof finer 0ndash6 mm 0ndash16 mm and 0ndash32 mm

aggregates are also being produced

The rainy summer increased the need

for road gravel along the muddy roadswhich must endure dump trucks weighing

as much as 260 tons

ldquoThe mobile process consisting of the

LT120 jaw plant and LT550GPF cone plant

is cost-effective while aggregates of vari-ous sizes can be produced in a two-stage

operation and with high capacity The con-trolled stroke and elliptical movement of

the FS screen secure big passing throughcapacitiesrdquo Kostamo explains

Operated in two shifts for a total of 16

hours per day the LT550GPF has logged

more than 600 working hours over a two-month period

Managing Director Aarno Kostamo (left) and foreman Karri Maumlenpaumlauml studying the cavity optionsavailable for the new Lokotrack LT550GPF

Longer perspective than

a single quarter needed

Kone-Kostamo Oy was founded as an

earth-moving company in Kemijaumlrvi

Northern Finland in 1956 The company

expanded its operations to include crush-

ing contracting in 1964 and later on

switched to concentrating fully on crush-ing activities

Kone-Kostamo consistently crushes

and screens around 28 million tons ofaggregates annually and has net sales of

between EUR 8ndash9 million

ldquoWe believe that issues within the crush-

ing industry including the purchasing ofmachinery must be studied with a longer

perspective than a single quarter The

secret to our success has always been our

solid work ethic and professional employ-eesrdquo Kostamo sums up

More info

Esa Berg

Tel + 358 40 837 8692

esabergmetsocom

8132019 Results Minerals Aggregates 3 2012ENG

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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155

Monitoring-based reporting is vital for

assessing the performance of a mobile

crushing plant Metso provides suchreporting tools through its plant-wideautomation system Metso DNA (Dynamic

Network of Applications) with its infor-

mation platform that links all the mobile

crushing and screen units together as oneentity Basically there is a lot of measured

real-time information available in every

crushing plant On-line information is

obtained either from each Metso crusherrsquosmachine automation system IC (Intelligent

Controller) or from separately installed

additional sensors and belt scales

All the collected data is sent to a motorhome using wireless communication

based on WLAN technology The motor

home is a purpose-built environment

inside an on-site container In this environ-ment selected variables can be monitored

for assessing the plantrsquos performance And

to make all this even more flexible the

data can be transmitted to a crushing plant

company office using GPRS3G mobile

data communication technologies Thismakes all the last-minute reports acces-sible to the crushing plant managerial staff

at anytime and basically anywhere within

reach of the cell phone network

Production and fuel economics reports

Essentially monitoring and reporting can

be customized to fit the customerrsquos needs

However there are certain off-the-shelf

reports that provide a lot of useful informa-tion for plant supervision The production

report is one of these Requiring at least one

belt scale for measuring the total produc-tion the production report shows the pro-duction rate (tons per hour) for a selected

reporting period eg a day or a week The

production report constantly keeps track of

the plantrsquos production storing all the datathroughout the plantrsquos life cycle

Performance monitoring and reportingfor a mobile crushing plantTEXT Pasi Airikka PHOTOS Metso

unit during which the unit is running By

storing the availability times between start-ups and shutdowns the crushing plant

operation time (hours per dayshift) can be

recorded analyzed and reported In addi-

tion the availability report can be tailored

to evaluate efficient crushing hours during

which the plant is really working and pro-ducing aggregates Consequently the ratio

(0-100) between efficient crushing time

and total running time can be reported forany selected period of time This boosts

the efficiency of the plantrsquos operations

and results in better productivity

Reports on non-choke

or inadequate feeding

Non-choke feeding to crushers is avoid-

able through smart plant-wide crushingplant controls But estimating its severity in

a systematic manner is not straight-forwardwithout constant monitoring and reporting

The crusher choke feeding report makes

use of the crusher cavity level sensors byanalyzing their level measurements By

calculating average and min-max values

and deviations from the average it can be

shown how often the single crusher suffersfrom non-choke feeding to it

In some cases the bottleneck in the

crushing plantrsquos productivity is the material

feeding to the process In mobile plants thefeeding is human operated and therefore

subject to variations Occasionally the sizeof the human-operated machine simply

does not allow for adequate feeding to thecrushing plant There are specific reports

indicating time periods when the crushing

plant suffers from inadequate feeding

Condition monitoring for

crushers and screens

Machine-specific condition monitoring

focuses on vibrating components in

crushers and screens such as drive shaftbearings safety plate wearings and gears

The low middle and high frequencies ofmonitored components are measured and

supervised in real-time to detect abnor-malities due to slow or fast wear looseness

or imbalance

More info

Pasi Airikka

Tel +358 40 587 2730

pasiairikkametsocom

Condition monitoring provides a view tovibrating crusher and screen components forpredictive equipment maintenance

The daily production report shows the hour-by-hour production trend and distribution chartfor a selected day with min-max average andvariation statistics for comparison

Fuel consumption is always an interest-ing concern The fuel consumption reportgives the fuel consumption of each crush-

ing unit (liters per hour) and their total

consumption (liters per hour) for a selected

reporting period and can track fuel con-

sumption changes over timeCrushing plant availability can be

assessed as well The availability report

calculates time periods for each crushing

8132019 Results Minerals Aggregates 3 2012ENG

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983149983141983156983155983151 983150

for tissue machines The record of 2210

mmin was set on June 1 2012 during a

24-hour production run by the TM 2 tissue

machine at the companyrsquos mill in Yenikoumlynear the city of Izmit in Turkey

ldquoThe cooperation with Metso has been

beyond excellent and both parties did

their utmost to make the project success-ful The results clearly show that the efforts

were worthwhile on both sides This coop-

eration will extend to cover new projects

in the futurerdquo says Luumlt1047297 Aydin Paper GroupDirector Hayat Kimya

ldquoWe are not surprised that Hayat K imya

managed to break the world speed record

We have had great confidence in the capa-bility of the Hayat team since our project

started in 2009 We certainly know our

machine very well its stability production

efficiency and speed capabilityrdquo says Jan

Erikson Vice President Sales Metso

PowerThe worldrsquos first eco-gas fueled

power plant is up and running

Lahti Energy Ltdrsquos new Kymijaumlrvi II gasifica-

tion plant was officially inaugurated on

May 8 2012 It is the first of its kind in the

RecyclingRecycling with Lokotrack LT106

jaw plant in New York

A brand-new Lokotrack LT106 jaw plant is

used in the city area of New York USA to

recycle demolition materials The crushing

site faces the skyscrapers of ManhattanIsland

Paper amp FiberHayat Kimyarsquos Metso-supplied tissue

machine sets world speed record

Thanks to a skilled crew and dedicated

efforts Hayat Kimya AS in Turkey has suc-

ceeded in breaking the world speed record

world This CHP plant runs on clean eco-

gas that is gasified cleaned and cooled

from recycled waste with Metsorsquos innova-tive technology

ldquoItrsquos actually eco-gas that we combust

in the boilerrdquo comments Lahti EnergyrsquosProduction Director Jukka Manskinen

ldquoWe convert unwanted waste material into

energy in an efficient and environmentally

friendly wayrdquoNever before has any plant gasified

waste on such a large scale In the gasifier

recycled waste is turned into combustible

product gas which is cleaned cooled and

combusted in a high-efficiency gas boiler

to produce steam for the steam turbine The plant produces 50 MW of electricity

and 90 MW of district heat for the city of

Lahti and its neighboring areasMetso delivered the circulating fluidized

bed (CFB) gasification process gas cleaning

and cooling steam boiler environmental

protection system and automation systemto the entire plant The production of elec-

tricity and heat is kept even with the Metso

DNA automation system that covers the

whole plant starting from fuel reception

AutomationMetso develops and supplies plant-

wide crushing control solutions for

crushing plants

Metso has recently signed contracts on

delivering plant-wide automation systems

for mobile and portable rock crushing

plants The key objective of these deliveries

is to stabilize and to increase productivityand efficiency of the plants using one sin-

gle automation and information platform

for integrating crusher-specific IC machinecontrols

Furthermore the plant-wide system

with its information management tools not

only increases plant availability and opera-

tional safety it also makes troubleshoot-ing quicker and performance monitoring

easier The control room for plant-wide

operability is located either in an excavator

cabin or a purpose-built container

Metso around the world

The new LT106 jaw plant is suitable for crushing both hard rock and all rock-based demolition materials

The new world speed record for tissue setby Hayat Kimyarsquos Metso-supplied TM 2 is2210 mmin

8132019 Results Minerals Aggregates 3 2012ENG

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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 21: Results Minerals Aggregates 3 2012.ENG

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ldquoWe share a similar zero-accident strategy and target with Metso and have successfullyfollowed it Metso has also helped us to meet the strictest end-product quality andcubicity requirements set in Spainrdquo This is how Managing Director Intildeigo Ajuria ofOfitas de San Felices the leading hard rock quarrying company in Spain describesthe cooperation with MetsoTEXT Eero Haumlmaumllaumlinen PHOTOS Ofitas and Eero Haumlmaumllaumlinen

The San Felices quarry is situated in a picturesque mountainous landscapebetween the companyrsquos Rioja vineyards and the Bilbao-Madrid motorway

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Ofitas has pioneered the implementation

of several Metso novelties in the Spanish

market The company was the first to use

efficient large track-mounted Lokotrack jaw plants the unique mobile conveying

system and also the new-generation HP4

cone crushers

Today the company operates twomodern Metso stationary plants one in

Guadix near Granada and the newest one

in San Felices Haro Rioja community Both

quarries focus on refining hard rock by pro-cessing ophite rock into the highest quality

railway ballast asphalt and concrete mix

grades The company has a satellite quarry

near Vitoria in PentildeacerradaBeing situated next to a highway and

the famous Rioja vineyards Ofitas must pay

special attention to environmental issues

To minimize dust problems all conveyors

have special covers attached

Quality durability and service

The cooperation between Ofitas de San

Felices and Metso started back in 1973when the Ajuria family bought the com-

pany whose quarrying activities began in

1919 Intildeigo Ajuria has a clear vision of why

the cooperation has continued withoutinterruption for almost 40 years

long-standing personal relationshipsrdquoAjuria adds

Serving railways asphalt

and concrete producers

The year-old San Felices stationary instal-lation lies hidden in a mountainous area

south of the city of Vitoria in NorthernSpain The new plant replaces an old one

that complicated the extraction of ophiterock Both plants are delivered by Metso

With its two separate production lines

the new plant is able to produce all the

end products required ndash from railway bal-last to the finer grades needed for asphalt

and concrete

Due to lower demand the quarry cur-

rently produces some 4000 tons per day

At full capacity however the plant canreach 8000 tons of production per day

30ndash35 of which consists of railway ballastfor high-speed trains and 65ndash70 of chips

and sand Thanks to the versatile two-line con-

cept connected by transverse conveyors

up to 12 different end products can be pro-

duced Depending on the demand for endproducts the material can be guided either

to the HP4 cone or HP400 cone followed

by a Barmac vertical shaft impactor

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

The ophite feed is fed to the C125 jaw crusher by a sturdy dump truck

The key people running the new San Felicesquarry Mine Engineer Carlos Fernandez (left)Managing Director Intildeigo Ajuria with ProductionManager Julian Perez

ldquoThrough the years Metso machinery

has proven its production capacity and

durability resulting in high-quality end

products A big plus for us has also beenthe quick response time to our process

challenges or servicerdquo

ldquoIn fact our cooperation extends

beyond day-to-day business matters to

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983122983141983152983151983154983156983145983150983143 983154983141983155

Meeting the strictest cubicity demands

The Spanish regulations concerning end-product cubicity are becoming more

demanding The flakiness percentage of

railway ballast must be below 10 and for

asphalt and concrete aggregates less than

15

ldquoWith Metsorsquos HP4 cone and the Barmacvertical shaft impactor we can meet even

the strictest cubicity demands We believe

that our high quality is helping us to sur-vive in the present recessionrdquo notes Mine

Engineer Carlos Fernandez

ldquoWe hope to increase the total extrac-

tion of the three quarries from the present15 million tons per year because our plant

capacity allows more than double thatrdquo

Fernandez adds

More info

Angel Luis Garcia Tel +34 686 94 35 30

angelluisgarciametsocom

In addition to being the leading Spanish

quarry to process hard rock Ofitas de SanFelices also cultivates 34 hectares of vine-yards next to the quarry which is situated

in the famous Rioja wine area

The company has previously sold a

harvest of over 200000 kg of Tempranillo

grapes to local red-wine makers Recentlythe company built its own wine process-

ing plant to process 10000ndash15000 kg of

grapes themselves

Aggregates and wine production

Andoni Ajuria the founder of Ofitas de san Felices (left) with Intildeigo Ajuria the present ManagingDirector tasting wine from the companyrsquos own vineyards

The first vintage wine of Ofitas har-

vested in autumn 2010 is now maturingin oak barrels After maturing for 12 to 15months the wine is called crianza and after

two years it will be granted the classifica-

tion reserva

ldquoWinemaking is not a business but

a hobby for us We give our wine out aspresents and drink it when we meet

our suppliers and friendsrdquo Intildeigo Ajuria

comments

For environmental protectionall of San Felicesrsquos plantconveyors are covered

Ofitas de San Felices quarry

LOCATION Haro near the city

of Vitoria northern Spain

SIZE 100 hectares

ROCK TYPE Ophite with Los Angeles

index of 9ndash10

PRESENT DAILY EXTRACTION 3000 tons

of ophiteNUMBER OF PERSONNEL 30

RESERVES 10 million tons

MAIN END PRODUCTS 0ndash2 mm

2ndash4 mm 4ndash10 mm 10ndash16 mm

16ndash22 mm 25ndash60 mm (ballast)

METSO MAIN EQUIPMENT

VF feeder

C125 jaw crusher

ndash feed size 0ndash800 mm

ndash css 130ndash140 mm

HP400 cone crusher

ndash feed size 80ndash250 mm

ndash css 40 mm HP4 cone crusher

ndash feed size 40ndash80 mm

ndash css 15 mm

Barmac 6150 VSI crusher

4 CVB2060 screens

2 TS32 screens

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Metso Distribution Centers he

Europe (Tongeren Belgium)

France (Macon)

Czech Republic (Přerov)

Austria (Vienna)

2271 d

Brazil (Sorocaba SP)

1014 d

USA (Columbia SC)

1690 d

USA (Waukesha WI)

434 d

South Africa (Vereeniging)

Ghana (Tarkwa)

Meacutexico (Irapuato)

Peru (Lima)

Chile (Concoacuten)

788 d

Sweden ( Trelleborg)

Finland (Tampere)

UK (Rugby)

865 d

Russia (St Petersburg)

Brazil (Parauapebas PA)

206 d

4983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983122983141983152983151983154983156983145983150983143 983154983141983155

In the case of an equipment failure or

a planned service shutdown resuming

production as quickly as possible is crucialEach hour spent waiting for a spare part to

arrive equals money lost Whether the right

part takes 12 or 48 hours to arrive really

makes a difference

The comprehensive and global Metsospare and wear parts service network pro-

vides you with the right part in the right

place and at the right time Our strategi-

cally located Distribution Centers and

Satellite Warehouses are on call 24 hoursa day 7 days a week ensuring efficient

parts replacement near you

Check out the locations of the MetsoDistribution Centers and how many parts

pass through them each day

More info

Marcelo Farah

Tel +55 15 2102 1315

marcelofarahmetsocom

you minimize downtime

Australia (Perth)

746 d

China (Tianjin)

China (Kunming)

China (Shanghai)

393 d

India (Faridabad)

India (Ahmedabad)

India (Hyderabad)

India (Bhubaneswar)

India (Bangalore)

419 d

Russia (Yekaterinburg)

Australia (Newcastle)

New Zealand (Matamata)

983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088

TEXT Sofia Williams

Singapore (Singapore)

Distribution Center Satellite Warehouse

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Following a large investment

in Metso crushing equipmentand services Buena Vista del

Cobre is now expanding the

mine site to include even more

equipment ndash and with thatexpansion comes the need for

more local service resources

Metso and Buena Vista del

Cobre have entered into a Life

Cycle Service agreement forthe plant and construction of a

brand new Metso service hub

is under way in Cananea

New facility new

level of service

The Cananea service hub

which will be up and running in early 2013will support the recent expansion and resur-

gence of Buena Vista del Cobre Initially it

will be a major repair and assembly center

for pumps crushers and screens and will

provide for rubber covering capabilitiesBut the 8000-square-meter facilityrsquos service

offering will be expansive including a con-

signment stock inventory to help serve theminersquos varying needs Metso currently has

50 service team members on site

Although Buena Vista del Cobre was a

key influencer in building the new servicehub this location will also enable Metso to

expand its capabilities and provide local

support to the entire mining community

in northwest Mexico The Cananea hub

will serve a number of major copper and

gold mines in the region including MineraFriscorsquos San Felipe Fresnillorsquos Milpillas and

Grupo Mexicorsquos Mexicana de Cobre

ldquoBuena Vista del Cobre is the biggestcustomer we have in Mexico today and

with this expansion project itrsquos only going

to grow and be strongerrdquo says Felix Forna-

guera Director of Services Mexico CentralAmerica and Caribbean ldquoWith that said the

idea behind the Cananea service hub is to

provide a central location for local support

for all our major customers in the areardquo

Establishing safety

ldquoIt was key to have our support here in

Cananea because the Buena Vista delCobre started from the ground uprdquo saysFelix ldquoWersquove been able to help the cus-

tomer to establish the best in support

service and operations from the very

beginningrdquo And this ground-up approachincluded a major focus on safety

Metso worked closely with Buena Vista

del Cobre to establish the safety proto-

col by which the mine operates Basedon Metsorsquos expertise the safety measures

put in place have enabled the mine to

become strict and efficient in its operations

and maintenance procedures To achievethis Metso worked closely with local andnational authorities to ensure the safety

plan was comprehensive and in accord-

ance with all established legal bodies

The best in regional support

The service hub in Cananea is a prime

example of Metsorsquos focus on providing local

service and support to its customers all

Service shines in Cananea MexicoAfter three years of inactivity the Buena Vista del Cobre mine in Cananea Sonora Mexico has been operational since 2010A mine that was inactive for such a significant amount of time however requires a great deal of support to successfullyrestart the plant and bring it back to an operational and profitable state

TEXT Deanna Lee PHOTO Metso

over the world ldquoWe are the first

company developing this kindof service in northwest Mexicordquo

adds Felix ldquoOur people have

developed a close relationship

with the team at the mine Itrsquosmore than a supplier relation-

ship our guys are inside the

mine living and working thererdquo

In fact this is the model

that Metso is using in servicehubs all over the globe build-

ing modern facilities bringing

teams on site and workinghand in hand with mine

operators The Cananea Service

hub is only the most recent

example of Metsorsquos commit-ment to service and northwest Mexico is

yet another mining hotbed thatrsquos going to

benefit from the companyrsquos support

More info

Felix Fornaguera Tel +52 4621079227

felixfornaguerametsocom

A mining cone serviced by Metso at the Buena Vista del Cobre mine inSonora Mexico

ldquoThe new Cananea service center will be a majorrepair and assembly center for pumps crushersand screensrdquo says Felix Fornaguera Director ofServices Mexico Central America and Caribbean

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

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During the MINExpo exhibition over 1300 people visited the Metso stand

983122983141983152983151983154983156983145983150983143 983154983141983155

Held every four years MIN-Expo consistently grows so

perennial exhibitors like Metso

are challenged with elevating

their presence and drawingin new (and greater numbers

of ) visitors each year ldquoItrsquos not

necessarily a challenge to lsquotoprsquo

our last showingrdquo says Keith

Ference Vice President ofmarketing and communica-

tions North America ldquoThere

are four years between eachMINExpo so we always have

a lot to say and reveal to our

customersrdquo The real challenge

he says is finding an exciting

and dynamic way to deliverthe message ldquoTherersquos so much

to see here so your booth has

to be compelling from the

outside-in and thatrsquos what

we always try to dordquo

Service sets the stage

The Metso booth created buzzin a number of ways and per-

haps the most striking (partly

due to its size) was the live

theater presentation As visitorspassed through the aisles of the show-

room the sights and sounds from Metsorsquos

theater were hard to miss And once guests

entered they were captivated by a short

high-energy video presentation focused

on Metsorsquos service capabilities The message was simple Metso is ldquoyour

local service partner rdquo for all mining and

construction needs The video showed ourservice teams in action all over the world

and the audience came away with an

understanding about Metsorsquos commitment

to service Customers can count on morethan 70 local service centers run by more

than 1700 expert technicians delivering

Metso makes an impact at MINExpo 2012At this yearrsquos MINExpo International nearly 60000 attendees flocked to Las Vegas Nevada the largest turnout in showhistory The visitors ndash mining professionals from all over the globe ndash explored 850000 square feet of showroom spacefeaturing the industry rsquos latest technology equipment products and services They toured the show for three days

seeking the latest and greatest from more than 1800 exhibitorsTEXT Keith Ference PHOTOS Tracey Ford Perry

detailed descriptions andphotos of all of Metsorsquos mining

and construction products and

services The app also provides

digital access to Results and asearchable database of sales

contacts By day three of the

show MetsoMAP had been

downloaded by more than

500 usersIn addition to the app the

booth was equipped with

several LCD screens each con-trolled by Metso experts who

used their iPads to present new

products like the Megalinertrade

and the HRCtrade A featured

presentation on Metsorsquos lineupof energy-efficient comminu-

tion equipment including the

VERTIMILLreg SMD and MP-1250

cone crusher was also avail-

able letting customers seehow Metso technology delivers

some of the worldrsquos most effi-

cient size reduction

Measuring MINExpo success

After a very busy three days

(on top of months of prepara-tion leading up to the show) everyone

involved with MINExpo ndash from the North

American marketing team responsible for

the booth to the product managers and

sales force that worked the floor ndash is view-

ing the show as a success ldquoTherersquos alwaysa sigh of relief after each (MINExpo)rdquo says

Keith ldquoAnd overall the initial feedback

and response has been very positiverdquoWith more than 1300 visitors to the

booth Metso certainly made an impact

ldquoWe learn a lot from each show and with

some time wersquoll have a better understand-ing of the tangible results of our effortsrdquo

Keith adds

reliable service for mining equipment as

well as customized cost-effective life-cycle

services contracts

Technology ndash MetsoMAP

is an industry firstMINExpo provided the industry with its firstglimpse of Metsorsquos revolutionary iPad app

MetsoMAP The app was demoed to the

boothrsquos visitors via ldquothe worldrsquos largest iPadrdquo

a custom-made 80-inch screen that show-cased all of its capabilities most of which are

groundbreaking in the industry MetsoMAPrsquos

simple interface is highly intuitive making

it easy to view process animations videos

The presentation of the new HP cone crusher attracted a large audience

8132019 Results Minerals Aggregates 3 2012ENG

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When yoursquore allowed less than a dozen days per year for breakdowns repair andmaintenance every single hour during a service shutdown counts There simplyisnrsquot any room for surprises Thatrsquos why Boliden counts on MetsoTEXT amp PHOTOS Sofia Williams

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Kurt Kalla Site Managerof Metso Gaumlllivare ServiceCenter is responsible forthe maintenance of Aitik

Metso and Boliden Strivingtogether for 97 uptime

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983122983141983152983151983154983156983145983150983143 983154983141983155

One of the biggest copper mines in

Europe Bolidenrsquos Aitik is located deep inthe wilderness of Swedish Lapland next to

the small town of Gaumlllivare The mine has

been operating since 1968 and a recent

expansion has increased its annual ore

production to 36 million tons

But the ambitious Swedes are not will-ing to lay back and relax just yet Bolidenrsquos

new aim is to reach a production rate of

45 million tons of ore per year in AitikAfter that Perhaps more than 55 million

tons The ore concentration in Aitik is very

low-grade with a mere 022 copper con-

tent hence the need for high capacityAchieving the ambitious production

goal requires maximum plant availability

This means that everything from the crush-

ers to the filters must be up and runningfor approximately 97 percent of the time

Thatrsquos where Metso comes into play

A cost-per-ton contract in action

The maximum uptime requirement allowsless than a dozen days per year for break-

downs repair and maintenance at Aitik

Every single hour during a service shut-

down counts There simply isnrsquot any roomfor surprises

Executing a successful shutdown under

such conditions requires a reliable service

partner not afraid of challenges and this iswhy Boliden has entrusted Aitikrsquos services

operations to Metso Boliden and Metsohave worked together since the 1960s

and the collaboration took another step

forward in September 2012 when the twocompanies signed a three-year extension

of the services contract for Boliden Aitik

ldquoThe new contract is a cost-per-ton

agreement We get paid based on Aitikrsquos

production Itrsquos a win-win deal for both par-

ties but also a new mindset for usrdquo explainsKurt Kalla Site Manager of Metso Gaumlllivare

Service Center responsible for serving Aitik

From now on the duration of the shut-down is what matters the most According

to Kalla the Metso service organization in

Gaumlllivare is now streamlining its operations

to fit the bill and has already witnessed thestrategy working In August 2012 Metso

carried out a 188-hour service shutdown in

Aitik which turned out to be a success

Zero tolerance for injury

One key factor to the success was theextensive planning of precautionary health

safety and environment procedures under-

taken by Metso prior to the shutdown Thanks to strict measures applied no

injuries or accidents occurred during the

shutdown and the work could easily be

finished on scheduleMats Johansson Health Safety

and Environment Manager for Metso in

Sweden explains how this was achieved

rdquoPlanning of the shutdown included arisk analysis for all new tasks participating

in Bolidenrsquos safety coordination meetingsmeeting with both Metso supervisors and

subcontractor supervisors and finally a

meeting with the entire staff participating

in the shutdown where everyone had to

sign a document stating their commitmentto the information providedrdquo he says

During the actual shutdown plenty of

new barriers signs and awareness cones

were put in place as a result of observa-tions from previous audits and safety plans

and risk analyses were readily available

in the work area Metso and Boliden also

introduced a Mill Inching permit a certifi-cate for completing a mandatory course for

those involved in the process In addition

Metso carried out random safety audits

during the shutdown to make sure thestrict policy was followed

According to Boliden Metsorsquos way of

working is a good example of how health

and safety precautions should be handled

ldquoMetso is a good example of how towork with safety and health plans risk

analysis permits and welding permits

Their table with all binders in the second-

ary mill area was exemplaryrdquo says Kjell-Arne

Johansson a technician from Boliden

The use of the new Metso Megalinertrade

system in the lining of Aitikrsquos Metso AG

mills has also improved the safety of main-tenance staff The Metso Megalinertrade con-

sists of larger-than-average liners bolted

in position from outside the mill Mainte-

nance technicians no longer need to go

inside the mill and stand in the dangerousdrop-zone of the liners gt

Boliden aims to reach a production rate of 45 million tons of ore per yearin the Aitik mine site

ldquoA complete risk analysis was conducted during the planningof the shutdownrdquo comments Mats Johansson Health Safetyand Environment Manager for Metso in Sweden

8132019 Results Minerals Aggregates 3 2012ENG

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Service the Metso way

24 hours a day 365 days a year

In addition to paying close attention to

health and safety issues executing an effi-

cient shutdown requires careful planning

and timing of every step in the mainte-

nance process Wear and spare parts have

to be available on time and a repair shoplarge enough to accommodate equipment

located close by

ldquoTo keep maintenance breaks as short

as possible we aim to replace the pump on

site and bring the old one for repair to our

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

nearby facilities This method gives us the

peace to do a good job and keep the cus-

tomerrsquos operations runningrdquo Kalla describes

the Metso way of handling Aitikrsquos pump

maintenance

Metso is currently expanding its Gaumllli-

vare service center to include a distribu-

tion center for wear and spare parts andalso concentrating its previously scattered

operations under one roof in its Vuoskon-

jaumlrvivaumlgen facility The expansion is due to

be completed by 2014

Metso equipment

delivered to Aitik36

bull 2 AG mills diameter 116 x

137 m gearless 22-MW motor

bull 2 Pebble mills diameter 91 x

113m dual 5-MW pinion drive

bull 3 VPA pressure filters VPA 1540-54

bull 12 sample pumps and pipes

VF50

bull 60 Various slurry pumps up to

MR500 modelbull Appr 5000 m rubber-lined slurry

pipes up to 600 mm diameter

bull Appr 5000 m rubber-lined by

gravity pipes up to 600 mm

diameter

bull Appr 5000 m rubber hoses

up to 600 mm diameter

Not only does the expansion make ser-

vice shutdowns at Aitik run more smoothly

it guarantees a more comprehensive

on-call emergency service response in the

region ndash thanks to the spare and wear parts

inventory available 24 hours a day 365

days a year

More info

Lars Rosenling

Tel +46 70 107 45 90

larsrosenlingmetsocom

Metso grinding equipment dominates the view in the concentrator

Safety on site is made up of small things like

making sure that everyone remembers to secure

the hoses in place

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983122983141983152983151983154983156983145983150983143 983154983141983155

Pebbles have always been a

challenge for producers of sandsince they cannot be returned

to rivers after extraction For

decades the processing of this

material resulted in a huge

environmental liability with alarge amount of pebbles hav-

ing to be stored away and left

unused

Transforming problems into

business opportunities

Areia amp Cia (areia = sand) has

operated in this market forover 20 years and decided to

enlist the help of Metso to find

a profitable solution for the

processing of pebbles

In July 2011 analyses werebegun to assess the abrasive-

ness and crushability of the

material Four alternatives wereidentified for processing and

transforming pebbles into sand

Initially Areia amp Cia was

interested in acquiring an

impactor for its reason-able price level However the

customer wanted to process

all the pebbles that were col-

lected daily in addition to some of the

material that it had stored In weighing theresults expected by the customer and the

excessive abrasiveness of the material the

HP200 cone crusher was decided on as thebest alternative

Areia amp Cia made the required invest-

ment and after using the HP200 for just

six months the company has already beenreporting outstanding results The HP200

not only transforms pebbles into sand but

also produces sand of excellent quality

with high yield and low maintenanceWith minor adjustments the HP200

also enables the production of sand withspecific particle size distribution for special

applications such as filtering sand blasting

and foundry sand adding value to the prod-

uct and increasing the types of sand offeredldquoMetso is pleased that the HP200 not

only enabled the processing of a product

that had been set aside as unusable but

HP200 cone transforms pebblesinto high-quality sandOver the last few decades Brazilian economic growth has been driving demand for construction aggregates The market

for sand in turn has been experiencing major difficulties in maintaining a consistent supply Presently one of the mainchallenges the industry faces is the large amount of pebbles that are obtained in the process of extracting sand at timesconstituting nearly 50 of the volume of material dredged from riverbeds

TEXT Sheila Ivers PHOTO Areia amp Cia

also that it opened up new

market opportunities for Areiaamp Cia Thatrsquos the standard we

seek to deliver to our custom-

ersrdquo states Luiz Oliveira Techni-

cal Salesperson of Metso Brazil

HP cones entering the

Brazilian sand-making

market

Todayrsquos cones such as theHP200 have high resistance

to impacts and abrasiveness

more efficient crushing cham-

bers low maintenance costsand excellent productivity

Following the acquisition of

the HP200 Areia amp Cia is now

also producing special sands

that command a price that is100 higher than common

sand The entire stockpile of

pebbles accumulated through-out the companyrsquos 20 years of

operations has already been

transformed into sand and the

stock of pebbles held by com-

petitors is also being purchasedfor processing

Cristiane Brizolari the

owner of Areia amp Cia confirms

the transformation that has taken place in

the production and commercial processldquoThe HP200 opened up new niches in

the market enabling the production of dif-

ferent types of sand with added valuerdquo

More info

Luiz Oliveira

Tel +55 011 9971 3603

luizoliveirametsocom

After the pebbles are crushed into sand with the HP200 cone crusherdifferent grades are screened for various end uses

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Where therersquos a will we dig a wayAFCONS-Strabag and Metso embark on tunnel project together

When the joint venture AFCONS-Strabag initiated work on the Rohtang bypass tunnel project at an altitude of 3980 metersabove sea level in Himachal Pradesh India they deliberated each aspect with clockwork precision The project involved anumber of surprises and challenges and required technology and project management skills that were second to none

TEXT amp PHOTOS Monisha Majumdar

Cutting a 10-meter-wide and nearly 9-kilo-

meter-long tunnel through the Himalayas

in one of the toughest terrains and cli-mates in India makes for quite a challengeResults set out to find out how AFCONS-

Strabag and Metso are making their way in

one of their most critical projects to date

The only road connection to the north-Indian border region of the province

Himachal-Pradesh and beyond the Manali-

Leh highway leads across the Rohtang

pass Due to the heavy snowfall and high-

velocity winds in this region the towns

located north of the pass are cut off from

the rest of the country during winter for atleast four often even six months each year

A tunnel with strategic importance

With the construction of the tunnel at

3100 m above sea level the Manali-Lehhighway will become an all-weather road

thereby enabling a significant improve-

ment in the economic development of

northern Himachal-Pradesh and an alter-

nate route to the strategically important

Ladakh region

Manali south of the pass is an alreadywell-developed tourist location that is

becoming more and more popular Upon

completion of the tunnel it is likely that

tourist activities will extend to the areanorth of the pass Moreover the tunnel

shortens the distance between the towns

of Manali and Leh by approximately 45 km

thus saving several hours on the small dan-gerous pass road

The Rohtang pass in the Western Himalaya

region of Northern India with its altitude ofalmost four kilometers ranks among thehighest trafficable passes in the world

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983122983141983152983151983154983156983145983150983143 983154983141983155

The 88-km long horse-shoe-shaped

tunnel provides space for a two-lane8-m-wide carriageway as well as a one-

meter-wide footpath on both sides A

22-m-high and 36-m-wide emergency

tunnel will be integrated in the tun-

nel cross-section Altogether more than

800000 msup3 of rock will be moved Tunneling works started around spring

2010 with excavation driven from both por-

tals As the north portal is inaccessible dur-ing winter closure the excavation focused

on the south After a planned construction

period of 55 years the tunnel is scheduled

to be completed by the end of 2015

Best man for the job

The BRO (Border Road Organization)

wanted to roll out a global tender for theproject due to the challenges that such a

project involves and also considering thatitrsquos the first time in India that a project of

this scale was to be carried out This imme-

diately triggered the need to roll out aglobal tender All major Indian construction

companies bid for it some individually and

some in partnerships

Strabag an Austrian tunnel specialistwas one of the companies who bid for the

project along with AFCONS a Mumbai-

based infrastructure company In Septem-

ber 2009 AFCONS-Strabag was awardedthe contract

Mr Sunil Tyagi Deputy Project Man-ager at AFCONS had this to say about the

unique projectldquoThis project is located in the Himalayas

and as far as we understand the terrain

there is among the toughest We came out

with a new technology and to be honestit is a fairly simple one We would generally

start with the traditional technology of drill-

ing and blasting and then obtain our muck

feed from the inwardbottom of the tunnelrdquo

ldquoThe technology is supplied by Rowa Tunneling Logistics and this is the first

time it is being used in Asia A jaw crusheris placed at a distance of about 40-45

meters behind the face The blasted muckextracted from the face is fed to the crusher

to reduce the lump size and then through

an overhead conveyor transport system

it is then transported out of the tunnelrdquoldquoThis enables free movement of man

and machinery in the lower area or spe-

cifically on the ground area If we were to

conforms to the Indian standard for fines amp

coarse aggregates as prescribed in IS383-1970

The plant was up and running in good

condition and performing to AFCONSrsquos

satisfactionldquoWe have worked with Metso in earlier

projects and are quite impressed by thekind of technology amp services they provide

We have a history together so the trust fac-tor also comes inrdquo explains Dhiman on their

choice of Metso as a partner

Service makes the difference

ldquoMetsorsquos services have made a big dif-ference in the project Without them we

would still be struggling with the machin-

ery and production The service is really

good and the service engineers are knowl-edgeable prompt and quick to act Any

problem can be solved by Metso We donrsquothave to wait until a service engineer turns

up ndash they have the capacity to solve prob-lems over the phone as wellrdquo says Dhiman

ldquoThe Metso plant didnrsquot create any prob-

lems for us We had problems in logistics

the feed was sticky and the weather condi-tions were bad but thankfully we did not

face any problems with production and

efficiency as the Metso plant is performing

very wellrdquo Dhiman concludes

More info

Amol Sinha Tel +91 9811 671 924

amolsinhametsocom

use the old conventional technology this

wouldnrsquot have worked for us in the stipu-lated timerdquo Mr Tyagi adds

When the going gets tough

partner with the toughest

Sensitive projects require the best technol-

ogy After AFCONS-Strabag landed theproject Metso was an obvious choice as a

technology provider not only because of

the long-standing business relationshipbut also for the sheer consistency in prod-

uct quality and service deliverance Metso

strives for

ldquoAfter signing the project we faced alot of road blocks including extreme cold

avalanches roadblocks less oxygen ndash you

name it we faced itrdquo explains Ankit Dhi-

man Plant Manager at AFCONS-Strabag The Rohtang valley is known for its

notorious avalanches and landslides SoAFCONS had to take extra steps and safety

precautions against hazards on the site

ldquoIn this freezing cold not just us humansbut also the machines are at increased risk

of damage I remember when we used

to run the plant during winter the diesel

engines would freeze We had to constantlyheat up the fuel container to get the plant

running And even the sand in the sand

trap would freeze so we had to clean it on

a daily basis to stop the pipes from mal-functioningrdquo Dhiman adds

Plant designed for difficult terrain

Difficult terrain coupled with space con-straints led Metso engineers to put their

minds together to come up with a suitable

plant configuration After studying the

requirements of the project Metso sug-

gested a 150-tons-per-hour three-stagemodular plant using a C106 jaw crusher

a GP11F secondary cone crusher and a

B7150 tertiary vertical shaft impact crusher

In addition considering the unpredict-ability of the feed the plant was about

to reach a point where the amount offines to be handled could be increased

dramatically Metso strongly suggested the TK11-27-3V grizzly scalper and this became

the first-ever TK scalper to be supplied by

Metso to an Indian customer Also in order

to get better products a sand trap SF2360was added to the configuration

The sand trap is important equipment

for this project as it washes the sand thatMr Sunil Tyagi Deputy Project ManagerAFCONS-Strabag

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Smooth transition to new-generation jaw crusher in Germany

Roumlhrig is a German company with a rich heritage The company has been quarrying granite at its plant in Bergstrasse inthe Sonderbach district of Heppenheim for three generations

TEXT amp PHOTOS Ralf Goffin

Roumlhrigrsquos superior product variety is onereason why the companyrsquos proximity to its

customers can be understood in more than

just physical terms The companyrsquos high

level of innovation has allowed it to estab-lish itself as a reliable supplier of materials

both regionally and internationally This

operational and technical expertise always

manages to keep in step with growing

market requirements

In terms of technical processing equip-

ment Roumlhrig has used a Nordberg C160stationary jaw crusher from Metso since

1992 At the start of 2012 it was finally

exchanged for a more up-to-date version

from the same model range

Metsorsquos C Series is specifically designed

to pre-crush hard rock and can cope effort-

lessly with even the hardest of materials

The dimensions of the new stationary jawcrusher are identical to those of the old

one which means that it could simply be

slotted into the housing vacated by the

previous version

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983122983141983152983151983154983156983145983150983143 983154983141983155

Third-generation Managing DirectorMarco Roumlhrig expects the new machinersquos

service life to be just as long as the previ-

ous model due to the product upgrades

that have been implemented The integral motor base is another plus

point in models made by other manu-

facturers it is located outside the crusher

This element of good fortune ensured that

Roumlhrig could reuse the housing withoutany additional rebuilding

Another advantage lies in the revision

of the guards for the C160rsquos drivetrain andflywheel The sturdier construction method

used for the crusher requires fewer parts

which facilitates easier installation andmaintenance and it makes it simpler to

access the motor

Under the watchful eye of Metsorsquos

Assembly Manager Maik Engelstaumltterthe entire project including removal and

installation was successfully completed

within two weeks

Installation making the most

of the available space

Roumlhrig will likely remember the day the

new crusher was installed for a long time

the pitman and main frame were deliveredseparately prior to installation and assem-

bled on site It took just one hour to replace

the old stationary crusher with the new

model A lorry-mounted crane was used toposition the 85-ton crusher with millimeter

precision in the crushing plant Once the

new crusher had been positioned in theexisting steel structure the next task wasto fix it into place as securely as possible

despite the limited space Special vibration

dampers were installed at a height of two

meters to prevent the crusher from sliding

Norbert Ried (fourth from left) installed thenew C160rsquos predecessor 20 years ago and isdelighted at the durability of the powerfulcrusher that is now making way for a newermodel Also pictured from left to right ManagerVolker Angermann Assembly Manager Maik

Engelstaumltter Technical Manager Stefan

Koob Project Manager Dominic SchoumlnhardtManaging Director Marco Roumlhrig Service

Technician Stefan Kolze and employees ofthe installation company Stafemo

On the hook after theold C160 was liftedout by crane the newcrusher was installedin almost no timeOnly the roof of thehousing had to beremoved

sideways off its mount An initial test run

with materials was carried out around oneweek later after all the electrical cables had

been installed

Simultaneously with the installation

of the C160 which is the first of the latest

generation of crushers to be installed in

Germany a new Nordberg GP100 conecrusher was also being installed in Roumlhrigrsquos

chipping plant Roumlhrig is convinced that

the technical improvements made tothe new Metso crusher can only be an

advantage worldwide

Roumlhrig places great value on consistent

product quality maximum added valueand optimum refinement of its product

range Bearing in mind that Roumlhrig has

enough reserves of raw material to last

for the next 150 years the company canconfidently continue to develop with an

emphasis on quality rather than quantity

More info

Dominic Schoenhardt

Tel +49 (0)621 727 00 610

dominicschoenhardtmetsocom

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Groupe Charier Carriegravere de la Mariais France

Quarrying with certi1047297ed quality The Charier Group with its 1600-strong workforce is a family business thatthis year celebrates 115 years of quarrying The company pursues a long-termdevelopment policy that since 2007 has seen processing installations upgradedat 4 of its 9 extraction sites

TEXT Liliane Boutin (with extracts from Mines amp Carriegraveres and Terrassements amp Carriegraveres magazines)PHOTO Baloon photo

The processing installation is of the horizontal type with a primary station located 56 meters below the site access road to keep it hidden from view

The crushing and screening installation at

Charierrsquos CM La Mariais quarry (at Donges

on the Loire estuary) has been in opera-tion since September 2011 Based on theoperatorrsquos ideas it was designed by Metso

to replace a worn-out installation installed

right on top of the seam being extracted

Since its commissioning it has becomethe second quarry in the company to

receive ISO 14 001 certification

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983122983141983152983151983154983156983145983150983143 983154983141983155

tertiary material of sand and gravel for the

local market to use in concrete surfacingprefabrication etcrdquo

Incorporation of a screening station

The stone extracted from La Mariais is

according to the quarry granitic gneiss

sound and homogeneous with a LosAngeles index of 15 good wear resist-

ance with an MDE of 10 a true density of

265 and a certain abrasiveness (2000 gt)ldquoCharacteristically it has a tendency to form

blocksrdquo Leblin points out

The main criteria in designing the instal-

lation was to provide an output of 600000metric tons from one station (38 hours

week) to produce materials aimed at the

concrete and surfacing markets ldquowhich

involved providing a tertiary station withscreening plantrdquo he adds

With this new unit the operating com-pany expands its product range through

the addition of fine materials obtained

from the tertiary screening station This unitis capable of producing 170 tonshour of

020

Preserving the environment

and optimizing safety

The screens have motorized bogies and

retractable walkways to facilitate access

when the screens are opened for main-tenance Other walkways provide access

to the tunnel input feeders The feederscan be isolated with hydraulic rod gate

bars this hydraulic assistance eliminatesthe need to use a heavy hammer to lodge

these metal bars

All conveyors transporting fines (02

and 04) are covered with a tarpaulin to

avoid flying dust and all the screens arehooded (metal cover with Trellex seal-

ing) The Brunone company has installed

dust-tight containment at the outlet of the

tertiary station crushers (HP300 and HP4)on the belt located under the screens

and under the hoppers located belowthe tertiary screens The crushers are put

under negative pressure and the finesare extracted through sleeve filters (7000

m3 h) with declogging which deposits the

dust back onto the conveyor belt

A high-pressure 100 bar water mist sys-tem has been installed at the primary sta-

tion discharge at the secondary crusherrsquos

discharge chutes (Omnicone) and at the

transfer points on the belt

Designed to last

ldquoThis type of new installation can easily last

thirty yearsrdquo affirms Project Leader Bruno

Peix of Metso ldquoIt quite simply depends on

how well it is maintained Thatrsquos why weprovide maintenance contracts that call for

our technicians to make regular inspection

visits and carry out preventive mainte-nance and any necessary repairsrdquo

In 2011 Metso commissioned about

10 new processing units in France like

the one at La Mariais quarry

More info

Frederic Bazire

Tel +33 (0)681442804

fredericbaziremetsocom

Key figures

DURATION OF WORKS 15 months

DRAWING OFFICE TIME 7800 hours

HEIGHT OF SILOS AND GRINDER BUILDINGS

15 m

TOTAL LENGTH OF CONVEYORS 14 km

WEIGHT OF THE INSTALLATION

1200 metric tons

CONCRETE POURED 1800 cubic meters

PROJECT SITE WORKFORCE 30

INSTALLED POWER 2200 kW(not including pumps 200 kW)

METSO EQUIPMENT

Primary

Vibrating feeder PF561-2V

Primary grizzly VG540-3V

Grizzly feeder TK13-20-3V

Jaw crusher C145 with

hydraulic setting

Secondary

Vibrating screen CVB 2050

refurbished

Cone crusher Omnicocircne 1352 SX

with Metso IC7000 controller Ellivar 16 (16 msup2 3 decks) screen

refurbished by Metso

Tertiary

Cone crusher HP300

Cone crusher HP4

2 Ellivar 20 screens (20 m23 decks) for final products

Expanding the production range

ldquoSince the mid-1990s when we became

owners of La Mariais we had used mobilemachinery with an assembly of beltconveyorsrdquo recalls Daniel Leblin Charierrsquos

Technical Manager for site construction

and maintenance

ldquoIt became clear that we needed ahigher performance tool to achieve the

dual goals of reaching one million metric

tonsrsquo maximum production and producing

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Big Lokotrack LT550GPF boostsquarrying productivity by a thirdMaximizing the productivity of operations is a key issue when striving for cost-effective quarrying Big Lokotracks are oneway to achieve improved operational efficiency The Lokotrack LT550GPF equipped with the high-volume GP550 conecrusher and a large screen is popular in the Nordic countries and in Germany and Australia ndash countries all known for theirhigh quarrying volumes

TEXT amp PHOTOS Eero Haumlmaumllaumlinen

Kone-Kostamorsquos new mobile coneplant has reached an averagecapacity of 300 tons per hour

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983122983141983152983151983154983156983145983150983143 983154983141983155

ldquoWith the same number of employees we

can achieve 30 more productivity with

our new LT550GPF unit The high-capacityFS screen has also eliminated the bottle-neck often seen at fine screeningrdquo says

Aarno Kostamo Managing Director of

Kone-Kostamo Oy one of Finlandrsquos biggest

crushing contractorsAccording to Kostamo the high capacity

of the GP550 gyratory cone crusher easily

handles feed from the C120 and C125 jaw

crushers For the contract with the Talvivaara

nickel mine the LT550GPF is being fed bythe brand new Lokotrack LT120 jaw plant

Average capacity 300 tons per hour

Talvivaara Europersquos largest nickel mine uti-

lizes large quantities of aggregates Kone-Kostamo has contracted several million

tons of different end products for the mineIn August 75000 tons of 0ndash63 mm

road gravel was crushed Smaller amountsof finer 0ndash6 mm 0ndash16 mm and 0ndash32 mm

aggregates are also being produced

The rainy summer increased the need

for road gravel along the muddy roadswhich must endure dump trucks weighing

as much as 260 tons

ldquoThe mobile process consisting of the

LT120 jaw plant and LT550GPF cone plant

is cost-effective while aggregates of vari-ous sizes can be produced in a two-stage

operation and with high capacity The con-trolled stroke and elliptical movement of

the FS screen secure big passing throughcapacitiesrdquo Kostamo explains

Operated in two shifts for a total of 16

hours per day the LT550GPF has logged

more than 600 working hours over a two-month period

Managing Director Aarno Kostamo (left) and foreman Karri Maumlenpaumlauml studying the cavity optionsavailable for the new Lokotrack LT550GPF

Longer perspective than

a single quarter needed

Kone-Kostamo Oy was founded as an

earth-moving company in Kemijaumlrvi

Northern Finland in 1956 The company

expanded its operations to include crush-

ing contracting in 1964 and later on

switched to concentrating fully on crush-ing activities

Kone-Kostamo consistently crushes

and screens around 28 million tons ofaggregates annually and has net sales of

between EUR 8ndash9 million

ldquoWe believe that issues within the crush-

ing industry including the purchasing ofmachinery must be studied with a longer

perspective than a single quarter The

secret to our success has always been our

solid work ethic and professional employ-eesrdquo Kostamo sums up

More info

Esa Berg

Tel + 358 40 837 8692

esabergmetsocom

8132019 Results Minerals Aggregates 3 2012ENG

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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155

Monitoring-based reporting is vital for

assessing the performance of a mobile

crushing plant Metso provides suchreporting tools through its plant-wideautomation system Metso DNA (Dynamic

Network of Applications) with its infor-

mation platform that links all the mobile

crushing and screen units together as oneentity Basically there is a lot of measured

real-time information available in every

crushing plant On-line information is

obtained either from each Metso crusherrsquosmachine automation system IC (Intelligent

Controller) or from separately installed

additional sensors and belt scales

All the collected data is sent to a motorhome using wireless communication

based on WLAN technology The motor

home is a purpose-built environment

inside an on-site container In this environ-ment selected variables can be monitored

for assessing the plantrsquos performance And

to make all this even more flexible the

data can be transmitted to a crushing plant

company office using GPRS3G mobile

data communication technologies Thismakes all the last-minute reports acces-sible to the crushing plant managerial staff

at anytime and basically anywhere within

reach of the cell phone network

Production and fuel economics reports

Essentially monitoring and reporting can

be customized to fit the customerrsquos needs

However there are certain off-the-shelf

reports that provide a lot of useful informa-tion for plant supervision The production

report is one of these Requiring at least one

belt scale for measuring the total produc-tion the production report shows the pro-duction rate (tons per hour) for a selected

reporting period eg a day or a week The

production report constantly keeps track of

the plantrsquos production storing all the datathroughout the plantrsquos life cycle

Performance monitoring and reportingfor a mobile crushing plantTEXT Pasi Airikka PHOTOS Metso

unit during which the unit is running By

storing the availability times between start-ups and shutdowns the crushing plant

operation time (hours per dayshift) can be

recorded analyzed and reported In addi-

tion the availability report can be tailored

to evaluate efficient crushing hours during

which the plant is really working and pro-ducing aggregates Consequently the ratio

(0-100) between efficient crushing time

and total running time can be reported forany selected period of time This boosts

the efficiency of the plantrsquos operations

and results in better productivity

Reports on non-choke

or inadequate feeding

Non-choke feeding to crushers is avoid-

able through smart plant-wide crushingplant controls But estimating its severity in

a systematic manner is not straight-forwardwithout constant monitoring and reporting

The crusher choke feeding report makes

use of the crusher cavity level sensors byanalyzing their level measurements By

calculating average and min-max values

and deviations from the average it can be

shown how often the single crusher suffersfrom non-choke feeding to it

In some cases the bottleneck in the

crushing plantrsquos productivity is the material

feeding to the process In mobile plants thefeeding is human operated and therefore

subject to variations Occasionally the sizeof the human-operated machine simply

does not allow for adequate feeding to thecrushing plant There are specific reports

indicating time periods when the crushing

plant suffers from inadequate feeding

Condition monitoring for

crushers and screens

Machine-specific condition monitoring

focuses on vibrating components in

crushers and screens such as drive shaftbearings safety plate wearings and gears

The low middle and high frequencies ofmonitored components are measured and

supervised in real-time to detect abnor-malities due to slow or fast wear looseness

or imbalance

More info

Pasi Airikka

Tel +358 40 587 2730

pasiairikkametsocom

Condition monitoring provides a view tovibrating crusher and screen components forpredictive equipment maintenance

The daily production report shows the hour-by-hour production trend and distribution chartfor a selected day with min-max average andvariation statistics for comparison

Fuel consumption is always an interest-ing concern The fuel consumption reportgives the fuel consumption of each crush-

ing unit (liters per hour) and their total

consumption (liters per hour) for a selected

reporting period and can track fuel con-

sumption changes over timeCrushing plant availability can be

assessed as well The availability report

calculates time periods for each crushing

8132019 Results Minerals Aggregates 3 2012ENG

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983149983141983156983155983151 983150

for tissue machines The record of 2210

mmin was set on June 1 2012 during a

24-hour production run by the TM 2 tissue

machine at the companyrsquos mill in Yenikoumlynear the city of Izmit in Turkey

ldquoThe cooperation with Metso has been

beyond excellent and both parties did

their utmost to make the project success-ful The results clearly show that the efforts

were worthwhile on both sides This coop-

eration will extend to cover new projects

in the futurerdquo says Luumlt1047297 Aydin Paper GroupDirector Hayat Kimya

ldquoWe are not surprised that Hayat K imya

managed to break the world speed record

We have had great confidence in the capa-bility of the Hayat team since our project

started in 2009 We certainly know our

machine very well its stability production

efficiency and speed capabilityrdquo says Jan

Erikson Vice President Sales Metso

PowerThe worldrsquos first eco-gas fueled

power plant is up and running

Lahti Energy Ltdrsquos new Kymijaumlrvi II gasifica-

tion plant was officially inaugurated on

May 8 2012 It is the first of its kind in the

RecyclingRecycling with Lokotrack LT106

jaw plant in New York

A brand-new Lokotrack LT106 jaw plant is

used in the city area of New York USA to

recycle demolition materials The crushing

site faces the skyscrapers of ManhattanIsland

Paper amp FiberHayat Kimyarsquos Metso-supplied tissue

machine sets world speed record

Thanks to a skilled crew and dedicated

efforts Hayat Kimya AS in Turkey has suc-

ceeded in breaking the world speed record

world This CHP plant runs on clean eco-

gas that is gasified cleaned and cooled

from recycled waste with Metsorsquos innova-tive technology

ldquoItrsquos actually eco-gas that we combust

in the boilerrdquo comments Lahti EnergyrsquosProduction Director Jukka Manskinen

ldquoWe convert unwanted waste material into

energy in an efficient and environmentally

friendly wayrdquoNever before has any plant gasified

waste on such a large scale In the gasifier

recycled waste is turned into combustible

product gas which is cleaned cooled and

combusted in a high-efficiency gas boiler

to produce steam for the steam turbine The plant produces 50 MW of electricity

and 90 MW of district heat for the city of

Lahti and its neighboring areasMetso delivered the circulating fluidized

bed (CFB) gasification process gas cleaning

and cooling steam boiler environmental

protection system and automation systemto the entire plant The production of elec-

tricity and heat is kept even with the Metso

DNA automation system that covers the

whole plant starting from fuel reception

AutomationMetso develops and supplies plant-

wide crushing control solutions for

crushing plants

Metso has recently signed contracts on

delivering plant-wide automation systems

for mobile and portable rock crushing

plants The key objective of these deliveries

is to stabilize and to increase productivityand efficiency of the plants using one sin-

gle automation and information platform

for integrating crusher-specific IC machinecontrols

Furthermore the plant-wide system

with its information management tools not

only increases plant availability and opera-

tional safety it also makes troubleshoot-ing quicker and performance monitoring

easier The control room for plant-wide

operability is located either in an excavator

cabin or a purpose-built container

Metso around the world

The new LT106 jaw plant is suitable for crushing both hard rock and all rock-based demolition materials

The new world speed record for tissue setby Hayat Kimyarsquos Metso-supplied TM 2 is2210 mmin

8132019 Results Minerals Aggregates 3 2012ENG

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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 22: Results Minerals Aggregates 3 2012.ENG

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Ofitas has pioneered the implementation

of several Metso novelties in the Spanish

market The company was the first to use

efficient large track-mounted Lokotrack jaw plants the unique mobile conveying

system and also the new-generation HP4

cone crushers

Today the company operates twomodern Metso stationary plants one in

Guadix near Granada and the newest one

in San Felices Haro Rioja community Both

quarries focus on refining hard rock by pro-cessing ophite rock into the highest quality

railway ballast asphalt and concrete mix

grades The company has a satellite quarry

near Vitoria in PentildeacerradaBeing situated next to a highway and

the famous Rioja vineyards Ofitas must pay

special attention to environmental issues

To minimize dust problems all conveyors

have special covers attached

Quality durability and service

The cooperation between Ofitas de San

Felices and Metso started back in 1973when the Ajuria family bought the com-

pany whose quarrying activities began in

1919 Intildeigo Ajuria has a clear vision of why

the cooperation has continued withoutinterruption for almost 40 years

long-standing personal relationshipsrdquoAjuria adds

Serving railways asphalt

and concrete producers

The year-old San Felices stationary instal-lation lies hidden in a mountainous area

south of the city of Vitoria in NorthernSpain The new plant replaces an old one

that complicated the extraction of ophiterock Both plants are delivered by Metso

With its two separate production lines

the new plant is able to produce all the

end products required ndash from railway bal-last to the finer grades needed for asphalt

and concrete

Due to lower demand the quarry cur-

rently produces some 4000 tons per day

At full capacity however the plant canreach 8000 tons of production per day

30ndash35 of which consists of railway ballastfor high-speed trains and 65ndash70 of chips

and sand Thanks to the versatile two-line con-

cept connected by transverse conveyors

up to 12 different end products can be pro-

duced Depending on the demand for endproducts the material can be guided either

to the HP4 cone or HP400 cone followed

by a Barmac vertical shaft impactor

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

The ophite feed is fed to the C125 jaw crusher by a sturdy dump truck

The key people running the new San Felicesquarry Mine Engineer Carlos Fernandez (left)Managing Director Intildeigo Ajuria with ProductionManager Julian Perez

ldquoThrough the years Metso machinery

has proven its production capacity and

durability resulting in high-quality end

products A big plus for us has also beenthe quick response time to our process

challenges or servicerdquo

ldquoIn fact our cooperation extends

beyond day-to-day business matters to

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983122983141983152983151983154983156983145983150983143 983154983141983155

Meeting the strictest cubicity demands

The Spanish regulations concerning end-product cubicity are becoming more

demanding The flakiness percentage of

railway ballast must be below 10 and for

asphalt and concrete aggregates less than

15

ldquoWith Metsorsquos HP4 cone and the Barmacvertical shaft impactor we can meet even

the strictest cubicity demands We believe

that our high quality is helping us to sur-vive in the present recessionrdquo notes Mine

Engineer Carlos Fernandez

ldquoWe hope to increase the total extrac-

tion of the three quarries from the present15 million tons per year because our plant

capacity allows more than double thatrdquo

Fernandez adds

More info

Angel Luis Garcia Tel +34 686 94 35 30

angelluisgarciametsocom

In addition to being the leading Spanish

quarry to process hard rock Ofitas de SanFelices also cultivates 34 hectares of vine-yards next to the quarry which is situated

in the famous Rioja wine area

The company has previously sold a

harvest of over 200000 kg of Tempranillo

grapes to local red-wine makers Recentlythe company built its own wine process-

ing plant to process 10000ndash15000 kg of

grapes themselves

Aggregates and wine production

Andoni Ajuria the founder of Ofitas de san Felices (left) with Intildeigo Ajuria the present ManagingDirector tasting wine from the companyrsquos own vineyards

The first vintage wine of Ofitas har-

vested in autumn 2010 is now maturingin oak barrels After maturing for 12 to 15months the wine is called crianza and after

two years it will be granted the classifica-

tion reserva

ldquoWinemaking is not a business but

a hobby for us We give our wine out aspresents and drink it when we meet

our suppliers and friendsrdquo Intildeigo Ajuria

comments

For environmental protectionall of San Felicesrsquos plantconveyors are covered

Ofitas de San Felices quarry

LOCATION Haro near the city

of Vitoria northern Spain

SIZE 100 hectares

ROCK TYPE Ophite with Los Angeles

index of 9ndash10

PRESENT DAILY EXTRACTION 3000 tons

of ophiteNUMBER OF PERSONNEL 30

RESERVES 10 million tons

MAIN END PRODUCTS 0ndash2 mm

2ndash4 mm 4ndash10 mm 10ndash16 mm

16ndash22 mm 25ndash60 mm (ballast)

METSO MAIN EQUIPMENT

VF feeder

C125 jaw crusher

ndash feed size 0ndash800 mm

ndash css 130ndash140 mm

HP400 cone crusher

ndash feed size 80ndash250 mm

ndash css 40 mm HP4 cone crusher

ndash feed size 40ndash80 mm

ndash css 15 mm

Barmac 6150 VSI crusher

4 CVB2060 screens

2 TS32 screens

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Metso Distribution Centers he

Europe (Tongeren Belgium)

France (Macon)

Czech Republic (Přerov)

Austria (Vienna)

2271 d

Brazil (Sorocaba SP)

1014 d

USA (Columbia SC)

1690 d

USA (Waukesha WI)

434 d

South Africa (Vereeniging)

Ghana (Tarkwa)

Meacutexico (Irapuato)

Peru (Lima)

Chile (Concoacuten)

788 d

Sweden ( Trelleborg)

Finland (Tampere)

UK (Rugby)

865 d

Russia (St Petersburg)

Brazil (Parauapebas PA)

206 d

4983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

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983122983141983152983151983154983156983145983150983143 983154983141983155983122983141983152983151983154983156983145983150983143 983154983141983155

In the case of an equipment failure or

a planned service shutdown resuming

production as quickly as possible is crucialEach hour spent waiting for a spare part to

arrive equals money lost Whether the right

part takes 12 or 48 hours to arrive really

makes a difference

The comprehensive and global Metsospare and wear parts service network pro-

vides you with the right part in the right

place and at the right time Our strategi-

cally located Distribution Centers and

Satellite Warehouses are on call 24 hoursa day 7 days a week ensuring efficient

parts replacement near you

Check out the locations of the MetsoDistribution Centers and how many parts

pass through them each day

More info

Marcelo Farah

Tel +55 15 2102 1315

marcelofarahmetsocom

you minimize downtime

Australia (Perth)

746 d

China (Tianjin)

China (Kunming)

China (Shanghai)

393 d

India (Faridabad)

India (Ahmedabad)

India (Hyderabad)

India (Bhubaneswar)

India (Bangalore)

419 d

Russia (Yekaterinburg)

Australia (Newcastle)

New Zealand (Matamata)

983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088

TEXT Sofia Williams

Singapore (Singapore)

Distribution Center Satellite Warehouse

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Following a large investment

in Metso crushing equipmentand services Buena Vista del

Cobre is now expanding the

mine site to include even more

equipment ndash and with thatexpansion comes the need for

more local service resources

Metso and Buena Vista del

Cobre have entered into a Life

Cycle Service agreement forthe plant and construction of a

brand new Metso service hub

is under way in Cananea

New facility new

level of service

The Cananea service hub

which will be up and running in early 2013will support the recent expansion and resur-

gence of Buena Vista del Cobre Initially it

will be a major repair and assembly center

for pumps crushers and screens and will

provide for rubber covering capabilitiesBut the 8000-square-meter facilityrsquos service

offering will be expansive including a con-

signment stock inventory to help serve theminersquos varying needs Metso currently has

50 service team members on site

Although Buena Vista del Cobre was a

key influencer in building the new servicehub this location will also enable Metso to

expand its capabilities and provide local

support to the entire mining community

in northwest Mexico The Cananea hub

will serve a number of major copper and

gold mines in the region including MineraFriscorsquos San Felipe Fresnillorsquos Milpillas and

Grupo Mexicorsquos Mexicana de Cobre

ldquoBuena Vista del Cobre is the biggestcustomer we have in Mexico today and

with this expansion project itrsquos only going

to grow and be strongerrdquo says Felix Forna-

guera Director of Services Mexico CentralAmerica and Caribbean ldquoWith that said the

idea behind the Cananea service hub is to

provide a central location for local support

for all our major customers in the areardquo

Establishing safety

ldquoIt was key to have our support here in

Cananea because the Buena Vista delCobre started from the ground uprdquo saysFelix ldquoWersquove been able to help the cus-

tomer to establish the best in support

service and operations from the very

beginningrdquo And this ground-up approachincluded a major focus on safety

Metso worked closely with Buena Vista

del Cobre to establish the safety proto-

col by which the mine operates Basedon Metsorsquos expertise the safety measures

put in place have enabled the mine to

become strict and efficient in its operations

and maintenance procedures To achievethis Metso worked closely with local andnational authorities to ensure the safety

plan was comprehensive and in accord-

ance with all established legal bodies

The best in regional support

The service hub in Cananea is a prime

example of Metsorsquos focus on providing local

service and support to its customers all

Service shines in Cananea MexicoAfter three years of inactivity the Buena Vista del Cobre mine in Cananea Sonora Mexico has been operational since 2010A mine that was inactive for such a significant amount of time however requires a great deal of support to successfullyrestart the plant and bring it back to an operational and profitable state

TEXT Deanna Lee PHOTO Metso

over the world ldquoWe are the first

company developing this kindof service in northwest Mexicordquo

adds Felix ldquoOur people have

developed a close relationship

with the team at the mine Itrsquosmore than a supplier relation-

ship our guys are inside the

mine living and working thererdquo

In fact this is the model

that Metso is using in servicehubs all over the globe build-

ing modern facilities bringing

teams on site and workinghand in hand with mine

operators The Cananea Service

hub is only the most recent

example of Metsorsquos commit-ment to service and northwest Mexico is

yet another mining hotbed thatrsquos going to

benefit from the companyrsquos support

More info

Felix Fornaguera Tel +52 4621079227

felixfornaguerametsocom

A mining cone serviced by Metso at the Buena Vista del Cobre mine inSonora Mexico

ldquoThe new Cananea service center will be a majorrepair and assembly center for pumps crushersand screensrdquo says Felix Fornaguera Director ofServices Mexico Central America and Caribbean

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

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During the MINExpo exhibition over 1300 people visited the Metso stand

983122983141983152983151983154983156983145983150983143 983154983141983155

Held every four years MIN-Expo consistently grows so

perennial exhibitors like Metso

are challenged with elevating

their presence and drawingin new (and greater numbers

of ) visitors each year ldquoItrsquos not

necessarily a challenge to lsquotoprsquo

our last showingrdquo says Keith

Ference Vice President ofmarketing and communica-

tions North America ldquoThere

are four years between eachMINExpo so we always have

a lot to say and reveal to our

customersrdquo The real challenge

he says is finding an exciting

and dynamic way to deliverthe message ldquoTherersquos so much

to see here so your booth has

to be compelling from the

outside-in and thatrsquos what

we always try to dordquo

Service sets the stage

The Metso booth created buzzin a number of ways and per-

haps the most striking (partly

due to its size) was the live

theater presentation As visitorspassed through the aisles of the show-

room the sights and sounds from Metsorsquos

theater were hard to miss And once guests

entered they were captivated by a short

high-energy video presentation focused

on Metsorsquos service capabilities The message was simple Metso is ldquoyour

local service partner rdquo for all mining and

construction needs The video showed ourservice teams in action all over the world

and the audience came away with an

understanding about Metsorsquos commitment

to service Customers can count on morethan 70 local service centers run by more

than 1700 expert technicians delivering

Metso makes an impact at MINExpo 2012At this yearrsquos MINExpo International nearly 60000 attendees flocked to Las Vegas Nevada the largest turnout in showhistory The visitors ndash mining professionals from all over the globe ndash explored 850000 square feet of showroom spacefeaturing the industry rsquos latest technology equipment products and services They toured the show for three days

seeking the latest and greatest from more than 1800 exhibitorsTEXT Keith Ference PHOTOS Tracey Ford Perry

detailed descriptions andphotos of all of Metsorsquos mining

and construction products and

services The app also provides

digital access to Results and asearchable database of sales

contacts By day three of the

show MetsoMAP had been

downloaded by more than

500 usersIn addition to the app the

booth was equipped with

several LCD screens each con-trolled by Metso experts who

used their iPads to present new

products like the Megalinertrade

and the HRCtrade A featured

presentation on Metsorsquos lineupof energy-efficient comminu-

tion equipment including the

VERTIMILLreg SMD and MP-1250

cone crusher was also avail-

able letting customers seehow Metso technology delivers

some of the worldrsquos most effi-

cient size reduction

Measuring MINExpo success

After a very busy three days

(on top of months of prepara-tion leading up to the show) everyone

involved with MINExpo ndash from the North

American marketing team responsible for

the booth to the product managers and

sales force that worked the floor ndash is view-

ing the show as a success ldquoTherersquos alwaysa sigh of relief after each (MINExpo)rdquo says

Keith ldquoAnd overall the initial feedback

and response has been very positiverdquoWith more than 1300 visitors to the

booth Metso certainly made an impact

ldquoWe learn a lot from each show and with

some time wersquoll have a better understand-ing of the tangible results of our effortsrdquo

Keith adds

reliable service for mining equipment as

well as customized cost-effective life-cycle

services contracts

Technology ndash MetsoMAP

is an industry firstMINExpo provided the industry with its firstglimpse of Metsorsquos revolutionary iPad app

MetsoMAP The app was demoed to the

boothrsquos visitors via ldquothe worldrsquos largest iPadrdquo

a custom-made 80-inch screen that show-cased all of its capabilities most of which are

groundbreaking in the industry MetsoMAPrsquos

simple interface is highly intuitive making

it easy to view process animations videos

The presentation of the new HP cone crusher attracted a large audience

8132019 Results Minerals Aggregates 3 2012ENG

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When yoursquore allowed less than a dozen days per year for breakdowns repair andmaintenance every single hour during a service shutdown counts There simplyisnrsquot any room for surprises Thatrsquos why Boliden counts on MetsoTEXT amp PHOTOS Sofia Williams

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Kurt Kalla Site Managerof Metso Gaumlllivare ServiceCenter is responsible forthe maintenance of Aitik

Metso and Boliden Strivingtogether for 97 uptime

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983122983141983152983151983154983156983145983150983143 983154983141983155

One of the biggest copper mines in

Europe Bolidenrsquos Aitik is located deep inthe wilderness of Swedish Lapland next to

the small town of Gaumlllivare The mine has

been operating since 1968 and a recent

expansion has increased its annual ore

production to 36 million tons

But the ambitious Swedes are not will-ing to lay back and relax just yet Bolidenrsquos

new aim is to reach a production rate of

45 million tons of ore per year in AitikAfter that Perhaps more than 55 million

tons The ore concentration in Aitik is very

low-grade with a mere 022 copper con-

tent hence the need for high capacityAchieving the ambitious production

goal requires maximum plant availability

This means that everything from the crush-

ers to the filters must be up and runningfor approximately 97 percent of the time

Thatrsquos where Metso comes into play

A cost-per-ton contract in action

The maximum uptime requirement allowsless than a dozen days per year for break-

downs repair and maintenance at Aitik

Every single hour during a service shut-

down counts There simply isnrsquot any roomfor surprises

Executing a successful shutdown under

such conditions requires a reliable service

partner not afraid of challenges and this iswhy Boliden has entrusted Aitikrsquos services

operations to Metso Boliden and Metsohave worked together since the 1960s

and the collaboration took another step

forward in September 2012 when the twocompanies signed a three-year extension

of the services contract for Boliden Aitik

ldquoThe new contract is a cost-per-ton

agreement We get paid based on Aitikrsquos

production Itrsquos a win-win deal for both par-

ties but also a new mindset for usrdquo explainsKurt Kalla Site Manager of Metso Gaumlllivare

Service Center responsible for serving Aitik

From now on the duration of the shut-down is what matters the most According

to Kalla the Metso service organization in

Gaumlllivare is now streamlining its operations

to fit the bill and has already witnessed thestrategy working In August 2012 Metso

carried out a 188-hour service shutdown in

Aitik which turned out to be a success

Zero tolerance for injury

One key factor to the success was theextensive planning of precautionary health

safety and environment procedures under-

taken by Metso prior to the shutdown Thanks to strict measures applied no

injuries or accidents occurred during the

shutdown and the work could easily be

finished on scheduleMats Johansson Health Safety

and Environment Manager for Metso in

Sweden explains how this was achieved

rdquoPlanning of the shutdown included arisk analysis for all new tasks participating

in Bolidenrsquos safety coordination meetingsmeeting with both Metso supervisors and

subcontractor supervisors and finally a

meeting with the entire staff participating

in the shutdown where everyone had to

sign a document stating their commitmentto the information providedrdquo he says

During the actual shutdown plenty of

new barriers signs and awareness cones

were put in place as a result of observa-tions from previous audits and safety plans

and risk analyses were readily available

in the work area Metso and Boliden also

introduced a Mill Inching permit a certifi-cate for completing a mandatory course for

those involved in the process In addition

Metso carried out random safety audits

during the shutdown to make sure thestrict policy was followed

According to Boliden Metsorsquos way of

working is a good example of how health

and safety precautions should be handled

ldquoMetso is a good example of how towork with safety and health plans risk

analysis permits and welding permits

Their table with all binders in the second-

ary mill area was exemplaryrdquo says Kjell-Arne

Johansson a technician from Boliden

The use of the new Metso Megalinertrade

system in the lining of Aitikrsquos Metso AG

mills has also improved the safety of main-tenance staff The Metso Megalinertrade con-

sists of larger-than-average liners bolted

in position from outside the mill Mainte-

nance technicians no longer need to go

inside the mill and stand in the dangerousdrop-zone of the liners gt

Boliden aims to reach a production rate of 45 million tons of ore per yearin the Aitik mine site

ldquoA complete risk analysis was conducted during the planningof the shutdownrdquo comments Mats Johansson Health Safetyand Environment Manager for Metso in Sweden

8132019 Results Minerals Aggregates 3 2012ENG

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Service the Metso way

24 hours a day 365 days a year

In addition to paying close attention to

health and safety issues executing an effi-

cient shutdown requires careful planning

and timing of every step in the mainte-

nance process Wear and spare parts have

to be available on time and a repair shoplarge enough to accommodate equipment

located close by

ldquoTo keep maintenance breaks as short

as possible we aim to replace the pump on

site and bring the old one for repair to our

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

nearby facilities This method gives us the

peace to do a good job and keep the cus-

tomerrsquos operations runningrdquo Kalla describes

the Metso way of handling Aitikrsquos pump

maintenance

Metso is currently expanding its Gaumllli-

vare service center to include a distribu-

tion center for wear and spare parts andalso concentrating its previously scattered

operations under one roof in its Vuoskon-

jaumlrvivaumlgen facility The expansion is due to

be completed by 2014

Metso equipment

delivered to Aitik36

bull 2 AG mills diameter 116 x

137 m gearless 22-MW motor

bull 2 Pebble mills diameter 91 x

113m dual 5-MW pinion drive

bull 3 VPA pressure filters VPA 1540-54

bull 12 sample pumps and pipes

VF50

bull 60 Various slurry pumps up to

MR500 modelbull Appr 5000 m rubber-lined slurry

pipes up to 600 mm diameter

bull Appr 5000 m rubber-lined by

gravity pipes up to 600 mm

diameter

bull Appr 5000 m rubber hoses

up to 600 mm diameter

Not only does the expansion make ser-

vice shutdowns at Aitik run more smoothly

it guarantees a more comprehensive

on-call emergency service response in the

region ndash thanks to the spare and wear parts

inventory available 24 hours a day 365

days a year

More info

Lars Rosenling

Tel +46 70 107 45 90

larsrosenlingmetsocom

Metso grinding equipment dominates the view in the concentrator

Safety on site is made up of small things like

making sure that everyone remembers to secure

the hoses in place

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983122983141983152983151983154983156983145983150983143 983154983141983155

Pebbles have always been a

challenge for producers of sandsince they cannot be returned

to rivers after extraction For

decades the processing of this

material resulted in a huge

environmental liability with alarge amount of pebbles hav-

ing to be stored away and left

unused

Transforming problems into

business opportunities

Areia amp Cia (areia = sand) has

operated in this market forover 20 years and decided to

enlist the help of Metso to find

a profitable solution for the

processing of pebbles

In July 2011 analyses werebegun to assess the abrasive-

ness and crushability of the

material Four alternatives wereidentified for processing and

transforming pebbles into sand

Initially Areia amp Cia was

interested in acquiring an

impactor for its reason-able price level However the

customer wanted to process

all the pebbles that were col-

lected daily in addition to some of the

material that it had stored In weighing theresults expected by the customer and the

excessive abrasiveness of the material the

HP200 cone crusher was decided on as thebest alternative

Areia amp Cia made the required invest-

ment and after using the HP200 for just

six months the company has already beenreporting outstanding results The HP200

not only transforms pebbles into sand but

also produces sand of excellent quality

with high yield and low maintenanceWith minor adjustments the HP200

also enables the production of sand withspecific particle size distribution for special

applications such as filtering sand blasting

and foundry sand adding value to the prod-

uct and increasing the types of sand offeredldquoMetso is pleased that the HP200 not

only enabled the processing of a product

that had been set aside as unusable but

HP200 cone transforms pebblesinto high-quality sandOver the last few decades Brazilian economic growth has been driving demand for construction aggregates The market

for sand in turn has been experiencing major difficulties in maintaining a consistent supply Presently one of the mainchallenges the industry faces is the large amount of pebbles that are obtained in the process of extracting sand at timesconstituting nearly 50 of the volume of material dredged from riverbeds

TEXT Sheila Ivers PHOTO Areia amp Cia

also that it opened up new

market opportunities for Areiaamp Cia Thatrsquos the standard we

seek to deliver to our custom-

ersrdquo states Luiz Oliveira Techni-

cal Salesperson of Metso Brazil

HP cones entering the

Brazilian sand-making

market

Todayrsquos cones such as theHP200 have high resistance

to impacts and abrasiveness

more efficient crushing cham-

bers low maintenance costsand excellent productivity

Following the acquisition of

the HP200 Areia amp Cia is now

also producing special sands

that command a price that is100 higher than common

sand The entire stockpile of

pebbles accumulated through-out the companyrsquos 20 years of

operations has already been

transformed into sand and the

stock of pebbles held by com-

petitors is also being purchasedfor processing

Cristiane Brizolari the

owner of Areia amp Cia confirms

the transformation that has taken place in

the production and commercial processldquoThe HP200 opened up new niches in

the market enabling the production of dif-

ferent types of sand with added valuerdquo

More info

Luiz Oliveira

Tel +55 011 9971 3603

luizoliveirametsocom

After the pebbles are crushed into sand with the HP200 cone crusherdifferent grades are screened for various end uses

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Where therersquos a will we dig a wayAFCONS-Strabag and Metso embark on tunnel project together

When the joint venture AFCONS-Strabag initiated work on the Rohtang bypass tunnel project at an altitude of 3980 metersabove sea level in Himachal Pradesh India they deliberated each aspect with clockwork precision The project involved anumber of surprises and challenges and required technology and project management skills that were second to none

TEXT amp PHOTOS Monisha Majumdar

Cutting a 10-meter-wide and nearly 9-kilo-

meter-long tunnel through the Himalayas

in one of the toughest terrains and cli-mates in India makes for quite a challengeResults set out to find out how AFCONS-

Strabag and Metso are making their way in

one of their most critical projects to date

The only road connection to the north-Indian border region of the province

Himachal-Pradesh and beyond the Manali-

Leh highway leads across the Rohtang

pass Due to the heavy snowfall and high-

velocity winds in this region the towns

located north of the pass are cut off from

the rest of the country during winter for atleast four often even six months each year

A tunnel with strategic importance

With the construction of the tunnel at

3100 m above sea level the Manali-Lehhighway will become an all-weather road

thereby enabling a significant improve-

ment in the economic development of

northern Himachal-Pradesh and an alter-

nate route to the strategically important

Ladakh region

Manali south of the pass is an alreadywell-developed tourist location that is

becoming more and more popular Upon

completion of the tunnel it is likely that

tourist activities will extend to the areanorth of the pass Moreover the tunnel

shortens the distance between the towns

of Manali and Leh by approximately 45 km

thus saving several hours on the small dan-gerous pass road

The Rohtang pass in the Western Himalaya

region of Northern India with its altitude ofalmost four kilometers ranks among thehighest trafficable passes in the world

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983122983141983152983151983154983156983145983150983143 983154983141983155

The 88-km long horse-shoe-shaped

tunnel provides space for a two-lane8-m-wide carriageway as well as a one-

meter-wide footpath on both sides A

22-m-high and 36-m-wide emergency

tunnel will be integrated in the tun-

nel cross-section Altogether more than

800000 msup3 of rock will be moved Tunneling works started around spring

2010 with excavation driven from both por-

tals As the north portal is inaccessible dur-ing winter closure the excavation focused

on the south After a planned construction

period of 55 years the tunnel is scheduled

to be completed by the end of 2015

Best man for the job

The BRO (Border Road Organization)

wanted to roll out a global tender for theproject due to the challenges that such a

project involves and also considering thatitrsquos the first time in India that a project of

this scale was to be carried out This imme-

diately triggered the need to roll out aglobal tender All major Indian construction

companies bid for it some individually and

some in partnerships

Strabag an Austrian tunnel specialistwas one of the companies who bid for the

project along with AFCONS a Mumbai-

based infrastructure company In Septem-

ber 2009 AFCONS-Strabag was awardedthe contract

Mr Sunil Tyagi Deputy Project Man-ager at AFCONS had this to say about the

unique projectldquoThis project is located in the Himalayas

and as far as we understand the terrain

there is among the toughest We came out

with a new technology and to be honestit is a fairly simple one We would generally

start with the traditional technology of drill-

ing and blasting and then obtain our muck

feed from the inwardbottom of the tunnelrdquo

ldquoThe technology is supplied by Rowa Tunneling Logistics and this is the first

time it is being used in Asia A jaw crusheris placed at a distance of about 40-45

meters behind the face The blasted muckextracted from the face is fed to the crusher

to reduce the lump size and then through

an overhead conveyor transport system

it is then transported out of the tunnelrdquoldquoThis enables free movement of man

and machinery in the lower area or spe-

cifically on the ground area If we were to

conforms to the Indian standard for fines amp

coarse aggregates as prescribed in IS383-1970

The plant was up and running in good

condition and performing to AFCONSrsquos

satisfactionldquoWe have worked with Metso in earlier

projects and are quite impressed by thekind of technology amp services they provide

We have a history together so the trust fac-tor also comes inrdquo explains Dhiman on their

choice of Metso as a partner

Service makes the difference

ldquoMetsorsquos services have made a big dif-ference in the project Without them we

would still be struggling with the machin-

ery and production The service is really

good and the service engineers are knowl-edgeable prompt and quick to act Any

problem can be solved by Metso We donrsquothave to wait until a service engineer turns

up ndash they have the capacity to solve prob-lems over the phone as wellrdquo says Dhiman

ldquoThe Metso plant didnrsquot create any prob-

lems for us We had problems in logistics

the feed was sticky and the weather condi-tions were bad but thankfully we did not

face any problems with production and

efficiency as the Metso plant is performing

very wellrdquo Dhiman concludes

More info

Amol Sinha Tel +91 9811 671 924

amolsinhametsocom

use the old conventional technology this

wouldnrsquot have worked for us in the stipu-lated timerdquo Mr Tyagi adds

When the going gets tough

partner with the toughest

Sensitive projects require the best technol-

ogy After AFCONS-Strabag landed theproject Metso was an obvious choice as a

technology provider not only because of

the long-standing business relationshipbut also for the sheer consistency in prod-

uct quality and service deliverance Metso

strives for

ldquoAfter signing the project we faced alot of road blocks including extreme cold

avalanches roadblocks less oxygen ndash you

name it we faced itrdquo explains Ankit Dhi-

man Plant Manager at AFCONS-Strabag The Rohtang valley is known for its

notorious avalanches and landslides SoAFCONS had to take extra steps and safety

precautions against hazards on the site

ldquoIn this freezing cold not just us humansbut also the machines are at increased risk

of damage I remember when we used

to run the plant during winter the diesel

engines would freeze We had to constantlyheat up the fuel container to get the plant

running And even the sand in the sand

trap would freeze so we had to clean it on

a daily basis to stop the pipes from mal-functioningrdquo Dhiman adds

Plant designed for difficult terrain

Difficult terrain coupled with space con-straints led Metso engineers to put their

minds together to come up with a suitable

plant configuration After studying the

requirements of the project Metso sug-

gested a 150-tons-per-hour three-stagemodular plant using a C106 jaw crusher

a GP11F secondary cone crusher and a

B7150 tertiary vertical shaft impact crusher

In addition considering the unpredict-ability of the feed the plant was about

to reach a point where the amount offines to be handled could be increased

dramatically Metso strongly suggested the TK11-27-3V grizzly scalper and this became

the first-ever TK scalper to be supplied by

Metso to an Indian customer Also in order

to get better products a sand trap SF2360was added to the configuration

The sand trap is important equipment

for this project as it washes the sand thatMr Sunil Tyagi Deputy Project ManagerAFCONS-Strabag

8132019 Results Minerals Aggregates 3 2012ENG

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Smooth transition to new-generation jaw crusher in Germany

Roumlhrig is a German company with a rich heritage The company has been quarrying granite at its plant in Bergstrasse inthe Sonderbach district of Heppenheim for three generations

TEXT amp PHOTOS Ralf Goffin

Roumlhrigrsquos superior product variety is onereason why the companyrsquos proximity to its

customers can be understood in more than

just physical terms The companyrsquos high

level of innovation has allowed it to estab-lish itself as a reliable supplier of materials

both regionally and internationally This

operational and technical expertise always

manages to keep in step with growing

market requirements

In terms of technical processing equip-

ment Roumlhrig has used a Nordberg C160stationary jaw crusher from Metso since

1992 At the start of 2012 it was finally

exchanged for a more up-to-date version

from the same model range

Metsorsquos C Series is specifically designed

to pre-crush hard rock and can cope effort-

lessly with even the hardest of materials

The dimensions of the new stationary jawcrusher are identical to those of the old

one which means that it could simply be

slotted into the housing vacated by the

previous version

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Third-generation Managing DirectorMarco Roumlhrig expects the new machinersquos

service life to be just as long as the previ-

ous model due to the product upgrades

that have been implemented The integral motor base is another plus

point in models made by other manu-

facturers it is located outside the crusher

This element of good fortune ensured that

Roumlhrig could reuse the housing withoutany additional rebuilding

Another advantage lies in the revision

of the guards for the C160rsquos drivetrain andflywheel The sturdier construction method

used for the crusher requires fewer parts

which facilitates easier installation andmaintenance and it makes it simpler to

access the motor

Under the watchful eye of Metsorsquos

Assembly Manager Maik Engelstaumltterthe entire project including removal and

installation was successfully completed

within two weeks

Installation making the most

of the available space

Roumlhrig will likely remember the day the

new crusher was installed for a long time

the pitman and main frame were deliveredseparately prior to installation and assem-

bled on site It took just one hour to replace

the old stationary crusher with the new

model A lorry-mounted crane was used toposition the 85-ton crusher with millimeter

precision in the crushing plant Once the

new crusher had been positioned in theexisting steel structure the next task wasto fix it into place as securely as possible

despite the limited space Special vibration

dampers were installed at a height of two

meters to prevent the crusher from sliding

Norbert Ried (fourth from left) installed thenew C160rsquos predecessor 20 years ago and isdelighted at the durability of the powerfulcrusher that is now making way for a newermodel Also pictured from left to right ManagerVolker Angermann Assembly Manager Maik

Engelstaumltter Technical Manager Stefan

Koob Project Manager Dominic SchoumlnhardtManaging Director Marco Roumlhrig Service

Technician Stefan Kolze and employees ofthe installation company Stafemo

On the hook after theold C160 was liftedout by crane the newcrusher was installedin almost no timeOnly the roof of thehousing had to beremoved

sideways off its mount An initial test run

with materials was carried out around oneweek later after all the electrical cables had

been installed

Simultaneously with the installation

of the C160 which is the first of the latest

generation of crushers to be installed in

Germany a new Nordberg GP100 conecrusher was also being installed in Roumlhrigrsquos

chipping plant Roumlhrig is convinced that

the technical improvements made tothe new Metso crusher can only be an

advantage worldwide

Roumlhrig places great value on consistent

product quality maximum added valueand optimum refinement of its product

range Bearing in mind that Roumlhrig has

enough reserves of raw material to last

for the next 150 years the company canconfidently continue to develop with an

emphasis on quality rather than quantity

More info

Dominic Schoenhardt

Tel +49 (0)621 727 00 610

dominicschoenhardtmetsocom

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Groupe Charier Carriegravere de la Mariais France

Quarrying with certi1047297ed quality The Charier Group with its 1600-strong workforce is a family business thatthis year celebrates 115 years of quarrying The company pursues a long-termdevelopment policy that since 2007 has seen processing installations upgradedat 4 of its 9 extraction sites

TEXT Liliane Boutin (with extracts from Mines amp Carriegraveres and Terrassements amp Carriegraveres magazines)PHOTO Baloon photo

The processing installation is of the horizontal type with a primary station located 56 meters below the site access road to keep it hidden from view

The crushing and screening installation at

Charierrsquos CM La Mariais quarry (at Donges

on the Loire estuary) has been in opera-tion since September 2011 Based on theoperatorrsquos ideas it was designed by Metso

to replace a worn-out installation installed

right on top of the seam being extracted

Since its commissioning it has becomethe second quarry in the company to

receive ISO 14 001 certification

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tertiary material of sand and gravel for the

local market to use in concrete surfacingprefabrication etcrdquo

Incorporation of a screening station

The stone extracted from La Mariais is

according to the quarry granitic gneiss

sound and homogeneous with a LosAngeles index of 15 good wear resist-

ance with an MDE of 10 a true density of

265 and a certain abrasiveness (2000 gt)ldquoCharacteristically it has a tendency to form

blocksrdquo Leblin points out

The main criteria in designing the instal-

lation was to provide an output of 600000metric tons from one station (38 hours

week) to produce materials aimed at the

concrete and surfacing markets ldquowhich

involved providing a tertiary station withscreening plantrdquo he adds

With this new unit the operating com-pany expands its product range through

the addition of fine materials obtained

from the tertiary screening station This unitis capable of producing 170 tonshour of

020

Preserving the environment

and optimizing safety

The screens have motorized bogies and

retractable walkways to facilitate access

when the screens are opened for main-tenance Other walkways provide access

to the tunnel input feeders The feederscan be isolated with hydraulic rod gate

bars this hydraulic assistance eliminatesthe need to use a heavy hammer to lodge

these metal bars

All conveyors transporting fines (02

and 04) are covered with a tarpaulin to

avoid flying dust and all the screens arehooded (metal cover with Trellex seal-

ing) The Brunone company has installed

dust-tight containment at the outlet of the

tertiary station crushers (HP300 and HP4)on the belt located under the screens

and under the hoppers located belowthe tertiary screens The crushers are put

under negative pressure and the finesare extracted through sleeve filters (7000

m3 h) with declogging which deposits the

dust back onto the conveyor belt

A high-pressure 100 bar water mist sys-tem has been installed at the primary sta-

tion discharge at the secondary crusherrsquos

discharge chutes (Omnicone) and at the

transfer points on the belt

Designed to last

ldquoThis type of new installation can easily last

thirty yearsrdquo affirms Project Leader Bruno

Peix of Metso ldquoIt quite simply depends on

how well it is maintained Thatrsquos why weprovide maintenance contracts that call for

our technicians to make regular inspection

visits and carry out preventive mainte-nance and any necessary repairsrdquo

In 2011 Metso commissioned about

10 new processing units in France like

the one at La Mariais quarry

More info

Frederic Bazire

Tel +33 (0)681442804

fredericbaziremetsocom

Key figures

DURATION OF WORKS 15 months

DRAWING OFFICE TIME 7800 hours

HEIGHT OF SILOS AND GRINDER BUILDINGS

15 m

TOTAL LENGTH OF CONVEYORS 14 km

WEIGHT OF THE INSTALLATION

1200 metric tons

CONCRETE POURED 1800 cubic meters

PROJECT SITE WORKFORCE 30

INSTALLED POWER 2200 kW(not including pumps 200 kW)

METSO EQUIPMENT

Primary

Vibrating feeder PF561-2V

Primary grizzly VG540-3V

Grizzly feeder TK13-20-3V

Jaw crusher C145 with

hydraulic setting

Secondary

Vibrating screen CVB 2050

refurbished

Cone crusher Omnicocircne 1352 SX

with Metso IC7000 controller Ellivar 16 (16 msup2 3 decks) screen

refurbished by Metso

Tertiary

Cone crusher HP300

Cone crusher HP4

2 Ellivar 20 screens (20 m23 decks) for final products

Expanding the production range

ldquoSince the mid-1990s when we became

owners of La Mariais we had used mobilemachinery with an assembly of beltconveyorsrdquo recalls Daniel Leblin Charierrsquos

Technical Manager for site construction

and maintenance

ldquoIt became clear that we needed ahigher performance tool to achieve the

dual goals of reaching one million metric

tonsrsquo maximum production and producing

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Big Lokotrack LT550GPF boostsquarrying productivity by a thirdMaximizing the productivity of operations is a key issue when striving for cost-effective quarrying Big Lokotracks are oneway to achieve improved operational efficiency The Lokotrack LT550GPF equipped with the high-volume GP550 conecrusher and a large screen is popular in the Nordic countries and in Germany and Australia ndash countries all known for theirhigh quarrying volumes

TEXT amp PHOTOS Eero Haumlmaumllaumlinen

Kone-Kostamorsquos new mobile coneplant has reached an averagecapacity of 300 tons per hour

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ldquoWith the same number of employees we

can achieve 30 more productivity with

our new LT550GPF unit The high-capacityFS screen has also eliminated the bottle-neck often seen at fine screeningrdquo says

Aarno Kostamo Managing Director of

Kone-Kostamo Oy one of Finlandrsquos biggest

crushing contractorsAccording to Kostamo the high capacity

of the GP550 gyratory cone crusher easily

handles feed from the C120 and C125 jaw

crushers For the contract with the Talvivaara

nickel mine the LT550GPF is being fed bythe brand new Lokotrack LT120 jaw plant

Average capacity 300 tons per hour

Talvivaara Europersquos largest nickel mine uti-

lizes large quantities of aggregates Kone-Kostamo has contracted several million

tons of different end products for the mineIn August 75000 tons of 0ndash63 mm

road gravel was crushed Smaller amountsof finer 0ndash6 mm 0ndash16 mm and 0ndash32 mm

aggregates are also being produced

The rainy summer increased the need

for road gravel along the muddy roadswhich must endure dump trucks weighing

as much as 260 tons

ldquoThe mobile process consisting of the

LT120 jaw plant and LT550GPF cone plant

is cost-effective while aggregates of vari-ous sizes can be produced in a two-stage

operation and with high capacity The con-trolled stroke and elliptical movement of

the FS screen secure big passing throughcapacitiesrdquo Kostamo explains

Operated in two shifts for a total of 16

hours per day the LT550GPF has logged

more than 600 working hours over a two-month period

Managing Director Aarno Kostamo (left) and foreman Karri Maumlenpaumlauml studying the cavity optionsavailable for the new Lokotrack LT550GPF

Longer perspective than

a single quarter needed

Kone-Kostamo Oy was founded as an

earth-moving company in Kemijaumlrvi

Northern Finland in 1956 The company

expanded its operations to include crush-

ing contracting in 1964 and later on

switched to concentrating fully on crush-ing activities

Kone-Kostamo consistently crushes

and screens around 28 million tons ofaggregates annually and has net sales of

between EUR 8ndash9 million

ldquoWe believe that issues within the crush-

ing industry including the purchasing ofmachinery must be studied with a longer

perspective than a single quarter The

secret to our success has always been our

solid work ethic and professional employ-eesrdquo Kostamo sums up

More info

Esa Berg

Tel + 358 40 837 8692

esabergmetsocom

8132019 Results Minerals Aggregates 3 2012ENG

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Monitoring-based reporting is vital for

assessing the performance of a mobile

crushing plant Metso provides suchreporting tools through its plant-wideautomation system Metso DNA (Dynamic

Network of Applications) with its infor-

mation platform that links all the mobile

crushing and screen units together as oneentity Basically there is a lot of measured

real-time information available in every

crushing plant On-line information is

obtained either from each Metso crusherrsquosmachine automation system IC (Intelligent

Controller) or from separately installed

additional sensors and belt scales

All the collected data is sent to a motorhome using wireless communication

based on WLAN technology The motor

home is a purpose-built environment

inside an on-site container In this environ-ment selected variables can be monitored

for assessing the plantrsquos performance And

to make all this even more flexible the

data can be transmitted to a crushing plant

company office using GPRS3G mobile

data communication technologies Thismakes all the last-minute reports acces-sible to the crushing plant managerial staff

at anytime and basically anywhere within

reach of the cell phone network

Production and fuel economics reports

Essentially monitoring and reporting can

be customized to fit the customerrsquos needs

However there are certain off-the-shelf

reports that provide a lot of useful informa-tion for plant supervision The production

report is one of these Requiring at least one

belt scale for measuring the total produc-tion the production report shows the pro-duction rate (tons per hour) for a selected

reporting period eg a day or a week The

production report constantly keeps track of

the plantrsquos production storing all the datathroughout the plantrsquos life cycle

Performance monitoring and reportingfor a mobile crushing plantTEXT Pasi Airikka PHOTOS Metso

unit during which the unit is running By

storing the availability times between start-ups and shutdowns the crushing plant

operation time (hours per dayshift) can be

recorded analyzed and reported In addi-

tion the availability report can be tailored

to evaluate efficient crushing hours during

which the plant is really working and pro-ducing aggregates Consequently the ratio

(0-100) between efficient crushing time

and total running time can be reported forany selected period of time This boosts

the efficiency of the plantrsquos operations

and results in better productivity

Reports on non-choke

or inadequate feeding

Non-choke feeding to crushers is avoid-

able through smart plant-wide crushingplant controls But estimating its severity in

a systematic manner is not straight-forwardwithout constant monitoring and reporting

The crusher choke feeding report makes

use of the crusher cavity level sensors byanalyzing their level measurements By

calculating average and min-max values

and deviations from the average it can be

shown how often the single crusher suffersfrom non-choke feeding to it

In some cases the bottleneck in the

crushing plantrsquos productivity is the material

feeding to the process In mobile plants thefeeding is human operated and therefore

subject to variations Occasionally the sizeof the human-operated machine simply

does not allow for adequate feeding to thecrushing plant There are specific reports

indicating time periods when the crushing

plant suffers from inadequate feeding

Condition monitoring for

crushers and screens

Machine-specific condition monitoring

focuses on vibrating components in

crushers and screens such as drive shaftbearings safety plate wearings and gears

The low middle and high frequencies ofmonitored components are measured and

supervised in real-time to detect abnor-malities due to slow or fast wear looseness

or imbalance

More info

Pasi Airikka

Tel +358 40 587 2730

pasiairikkametsocom

Condition monitoring provides a view tovibrating crusher and screen components forpredictive equipment maintenance

The daily production report shows the hour-by-hour production trend and distribution chartfor a selected day with min-max average andvariation statistics for comparison

Fuel consumption is always an interest-ing concern The fuel consumption reportgives the fuel consumption of each crush-

ing unit (liters per hour) and their total

consumption (liters per hour) for a selected

reporting period and can track fuel con-

sumption changes over timeCrushing plant availability can be

assessed as well The availability report

calculates time periods for each crushing

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983149983141983156983155983151 983150

for tissue machines The record of 2210

mmin was set on June 1 2012 during a

24-hour production run by the TM 2 tissue

machine at the companyrsquos mill in Yenikoumlynear the city of Izmit in Turkey

ldquoThe cooperation with Metso has been

beyond excellent and both parties did

their utmost to make the project success-ful The results clearly show that the efforts

were worthwhile on both sides This coop-

eration will extend to cover new projects

in the futurerdquo says Luumlt1047297 Aydin Paper GroupDirector Hayat Kimya

ldquoWe are not surprised that Hayat K imya

managed to break the world speed record

We have had great confidence in the capa-bility of the Hayat team since our project

started in 2009 We certainly know our

machine very well its stability production

efficiency and speed capabilityrdquo says Jan

Erikson Vice President Sales Metso

PowerThe worldrsquos first eco-gas fueled

power plant is up and running

Lahti Energy Ltdrsquos new Kymijaumlrvi II gasifica-

tion plant was officially inaugurated on

May 8 2012 It is the first of its kind in the

RecyclingRecycling with Lokotrack LT106

jaw plant in New York

A brand-new Lokotrack LT106 jaw plant is

used in the city area of New York USA to

recycle demolition materials The crushing

site faces the skyscrapers of ManhattanIsland

Paper amp FiberHayat Kimyarsquos Metso-supplied tissue

machine sets world speed record

Thanks to a skilled crew and dedicated

efforts Hayat Kimya AS in Turkey has suc-

ceeded in breaking the world speed record

world This CHP plant runs on clean eco-

gas that is gasified cleaned and cooled

from recycled waste with Metsorsquos innova-tive technology

ldquoItrsquos actually eco-gas that we combust

in the boilerrdquo comments Lahti EnergyrsquosProduction Director Jukka Manskinen

ldquoWe convert unwanted waste material into

energy in an efficient and environmentally

friendly wayrdquoNever before has any plant gasified

waste on such a large scale In the gasifier

recycled waste is turned into combustible

product gas which is cleaned cooled and

combusted in a high-efficiency gas boiler

to produce steam for the steam turbine The plant produces 50 MW of electricity

and 90 MW of district heat for the city of

Lahti and its neighboring areasMetso delivered the circulating fluidized

bed (CFB) gasification process gas cleaning

and cooling steam boiler environmental

protection system and automation systemto the entire plant The production of elec-

tricity and heat is kept even with the Metso

DNA automation system that covers the

whole plant starting from fuel reception

AutomationMetso develops and supplies plant-

wide crushing control solutions for

crushing plants

Metso has recently signed contracts on

delivering plant-wide automation systems

for mobile and portable rock crushing

plants The key objective of these deliveries

is to stabilize and to increase productivityand efficiency of the plants using one sin-

gle automation and information platform

for integrating crusher-specific IC machinecontrols

Furthermore the plant-wide system

with its information management tools not

only increases plant availability and opera-

tional safety it also makes troubleshoot-ing quicker and performance monitoring

easier The control room for plant-wide

operability is located either in an excavator

cabin or a purpose-built container

Metso around the world

The new LT106 jaw plant is suitable for crushing both hard rock and all rock-based demolition materials

The new world speed record for tissue setby Hayat Kimyarsquos Metso-supplied TM 2 is2210 mmin

8132019 Results Minerals Aggregates 3 2012ENG

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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 23: Results Minerals Aggregates 3 2012.ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155

Meeting the strictest cubicity demands

The Spanish regulations concerning end-product cubicity are becoming more

demanding The flakiness percentage of

railway ballast must be below 10 and for

asphalt and concrete aggregates less than

15

ldquoWith Metsorsquos HP4 cone and the Barmacvertical shaft impactor we can meet even

the strictest cubicity demands We believe

that our high quality is helping us to sur-vive in the present recessionrdquo notes Mine

Engineer Carlos Fernandez

ldquoWe hope to increase the total extrac-

tion of the three quarries from the present15 million tons per year because our plant

capacity allows more than double thatrdquo

Fernandez adds

More info

Angel Luis Garcia Tel +34 686 94 35 30

angelluisgarciametsocom

In addition to being the leading Spanish

quarry to process hard rock Ofitas de SanFelices also cultivates 34 hectares of vine-yards next to the quarry which is situated

in the famous Rioja wine area

The company has previously sold a

harvest of over 200000 kg of Tempranillo

grapes to local red-wine makers Recentlythe company built its own wine process-

ing plant to process 10000ndash15000 kg of

grapes themselves

Aggregates and wine production

Andoni Ajuria the founder of Ofitas de san Felices (left) with Intildeigo Ajuria the present ManagingDirector tasting wine from the companyrsquos own vineyards

The first vintage wine of Ofitas har-

vested in autumn 2010 is now maturingin oak barrels After maturing for 12 to 15months the wine is called crianza and after

two years it will be granted the classifica-

tion reserva

ldquoWinemaking is not a business but

a hobby for us We give our wine out aspresents and drink it when we meet

our suppliers and friendsrdquo Intildeigo Ajuria

comments

For environmental protectionall of San Felicesrsquos plantconveyors are covered

Ofitas de San Felices quarry

LOCATION Haro near the city

of Vitoria northern Spain

SIZE 100 hectares

ROCK TYPE Ophite with Los Angeles

index of 9ndash10

PRESENT DAILY EXTRACTION 3000 tons

of ophiteNUMBER OF PERSONNEL 30

RESERVES 10 million tons

MAIN END PRODUCTS 0ndash2 mm

2ndash4 mm 4ndash10 mm 10ndash16 mm

16ndash22 mm 25ndash60 mm (ballast)

METSO MAIN EQUIPMENT

VF feeder

C125 jaw crusher

ndash feed size 0ndash800 mm

ndash css 130ndash140 mm

HP400 cone crusher

ndash feed size 80ndash250 mm

ndash css 40 mm HP4 cone crusher

ndash feed size 40ndash80 mm

ndash css 15 mm

Barmac 6150 VSI crusher

4 CVB2060 screens

2 TS32 screens

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Metso Distribution Centers he

Europe (Tongeren Belgium)

France (Macon)

Czech Republic (Přerov)

Austria (Vienna)

2271 d

Brazil (Sorocaba SP)

1014 d

USA (Columbia SC)

1690 d

USA (Waukesha WI)

434 d

South Africa (Vereeniging)

Ghana (Tarkwa)

Meacutexico (Irapuato)

Peru (Lima)

Chile (Concoacuten)

788 d

Sweden ( Trelleborg)

Finland (Tampere)

UK (Rugby)

865 d

Russia (St Petersburg)

Brazil (Parauapebas PA)

206 d

4983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

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983122983141983152983151983154983156983145983150983143 983154983141983155983122983141983152983151983154983156983145983150983143 983154983141983155

In the case of an equipment failure or

a planned service shutdown resuming

production as quickly as possible is crucialEach hour spent waiting for a spare part to

arrive equals money lost Whether the right

part takes 12 or 48 hours to arrive really

makes a difference

The comprehensive and global Metsospare and wear parts service network pro-

vides you with the right part in the right

place and at the right time Our strategi-

cally located Distribution Centers and

Satellite Warehouses are on call 24 hoursa day 7 days a week ensuring efficient

parts replacement near you

Check out the locations of the MetsoDistribution Centers and how many parts

pass through them each day

More info

Marcelo Farah

Tel +55 15 2102 1315

marcelofarahmetsocom

you minimize downtime

Australia (Perth)

746 d

China (Tianjin)

China (Kunming)

China (Shanghai)

393 d

India (Faridabad)

India (Ahmedabad)

India (Hyderabad)

India (Bhubaneswar)

India (Bangalore)

419 d

Russia (Yekaterinburg)

Australia (Newcastle)

New Zealand (Matamata)

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TEXT Sofia Williams

Singapore (Singapore)

Distribution Center Satellite Warehouse

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Following a large investment

in Metso crushing equipmentand services Buena Vista del

Cobre is now expanding the

mine site to include even more

equipment ndash and with thatexpansion comes the need for

more local service resources

Metso and Buena Vista del

Cobre have entered into a Life

Cycle Service agreement forthe plant and construction of a

brand new Metso service hub

is under way in Cananea

New facility new

level of service

The Cananea service hub

which will be up and running in early 2013will support the recent expansion and resur-

gence of Buena Vista del Cobre Initially it

will be a major repair and assembly center

for pumps crushers and screens and will

provide for rubber covering capabilitiesBut the 8000-square-meter facilityrsquos service

offering will be expansive including a con-

signment stock inventory to help serve theminersquos varying needs Metso currently has

50 service team members on site

Although Buena Vista del Cobre was a

key influencer in building the new servicehub this location will also enable Metso to

expand its capabilities and provide local

support to the entire mining community

in northwest Mexico The Cananea hub

will serve a number of major copper and

gold mines in the region including MineraFriscorsquos San Felipe Fresnillorsquos Milpillas and

Grupo Mexicorsquos Mexicana de Cobre

ldquoBuena Vista del Cobre is the biggestcustomer we have in Mexico today and

with this expansion project itrsquos only going

to grow and be strongerrdquo says Felix Forna-

guera Director of Services Mexico CentralAmerica and Caribbean ldquoWith that said the

idea behind the Cananea service hub is to

provide a central location for local support

for all our major customers in the areardquo

Establishing safety

ldquoIt was key to have our support here in

Cananea because the Buena Vista delCobre started from the ground uprdquo saysFelix ldquoWersquove been able to help the cus-

tomer to establish the best in support

service and operations from the very

beginningrdquo And this ground-up approachincluded a major focus on safety

Metso worked closely with Buena Vista

del Cobre to establish the safety proto-

col by which the mine operates Basedon Metsorsquos expertise the safety measures

put in place have enabled the mine to

become strict and efficient in its operations

and maintenance procedures To achievethis Metso worked closely with local andnational authorities to ensure the safety

plan was comprehensive and in accord-

ance with all established legal bodies

The best in regional support

The service hub in Cananea is a prime

example of Metsorsquos focus on providing local

service and support to its customers all

Service shines in Cananea MexicoAfter three years of inactivity the Buena Vista del Cobre mine in Cananea Sonora Mexico has been operational since 2010A mine that was inactive for such a significant amount of time however requires a great deal of support to successfullyrestart the plant and bring it back to an operational and profitable state

TEXT Deanna Lee PHOTO Metso

over the world ldquoWe are the first

company developing this kindof service in northwest Mexicordquo

adds Felix ldquoOur people have

developed a close relationship

with the team at the mine Itrsquosmore than a supplier relation-

ship our guys are inside the

mine living and working thererdquo

In fact this is the model

that Metso is using in servicehubs all over the globe build-

ing modern facilities bringing

teams on site and workinghand in hand with mine

operators The Cananea Service

hub is only the most recent

example of Metsorsquos commit-ment to service and northwest Mexico is

yet another mining hotbed thatrsquos going to

benefit from the companyrsquos support

More info

Felix Fornaguera Tel +52 4621079227

felixfornaguerametsocom

A mining cone serviced by Metso at the Buena Vista del Cobre mine inSonora Mexico

ldquoThe new Cananea service center will be a majorrepair and assembly center for pumps crushersand screensrdquo says Felix Fornaguera Director ofServices Mexico Central America and Caribbean

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

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During the MINExpo exhibition over 1300 people visited the Metso stand

983122983141983152983151983154983156983145983150983143 983154983141983155

Held every four years MIN-Expo consistently grows so

perennial exhibitors like Metso

are challenged with elevating

their presence and drawingin new (and greater numbers

of ) visitors each year ldquoItrsquos not

necessarily a challenge to lsquotoprsquo

our last showingrdquo says Keith

Ference Vice President ofmarketing and communica-

tions North America ldquoThere

are four years between eachMINExpo so we always have

a lot to say and reveal to our

customersrdquo The real challenge

he says is finding an exciting

and dynamic way to deliverthe message ldquoTherersquos so much

to see here so your booth has

to be compelling from the

outside-in and thatrsquos what

we always try to dordquo

Service sets the stage

The Metso booth created buzzin a number of ways and per-

haps the most striking (partly

due to its size) was the live

theater presentation As visitorspassed through the aisles of the show-

room the sights and sounds from Metsorsquos

theater were hard to miss And once guests

entered they were captivated by a short

high-energy video presentation focused

on Metsorsquos service capabilities The message was simple Metso is ldquoyour

local service partner rdquo for all mining and

construction needs The video showed ourservice teams in action all over the world

and the audience came away with an

understanding about Metsorsquos commitment

to service Customers can count on morethan 70 local service centers run by more

than 1700 expert technicians delivering

Metso makes an impact at MINExpo 2012At this yearrsquos MINExpo International nearly 60000 attendees flocked to Las Vegas Nevada the largest turnout in showhistory The visitors ndash mining professionals from all over the globe ndash explored 850000 square feet of showroom spacefeaturing the industry rsquos latest technology equipment products and services They toured the show for three days

seeking the latest and greatest from more than 1800 exhibitorsTEXT Keith Ference PHOTOS Tracey Ford Perry

detailed descriptions andphotos of all of Metsorsquos mining

and construction products and

services The app also provides

digital access to Results and asearchable database of sales

contacts By day three of the

show MetsoMAP had been

downloaded by more than

500 usersIn addition to the app the

booth was equipped with

several LCD screens each con-trolled by Metso experts who

used their iPads to present new

products like the Megalinertrade

and the HRCtrade A featured

presentation on Metsorsquos lineupof energy-efficient comminu-

tion equipment including the

VERTIMILLreg SMD and MP-1250

cone crusher was also avail-

able letting customers seehow Metso technology delivers

some of the worldrsquos most effi-

cient size reduction

Measuring MINExpo success

After a very busy three days

(on top of months of prepara-tion leading up to the show) everyone

involved with MINExpo ndash from the North

American marketing team responsible for

the booth to the product managers and

sales force that worked the floor ndash is view-

ing the show as a success ldquoTherersquos alwaysa sigh of relief after each (MINExpo)rdquo says

Keith ldquoAnd overall the initial feedback

and response has been very positiverdquoWith more than 1300 visitors to the

booth Metso certainly made an impact

ldquoWe learn a lot from each show and with

some time wersquoll have a better understand-ing of the tangible results of our effortsrdquo

Keith adds

reliable service for mining equipment as

well as customized cost-effective life-cycle

services contracts

Technology ndash MetsoMAP

is an industry firstMINExpo provided the industry with its firstglimpse of Metsorsquos revolutionary iPad app

MetsoMAP The app was demoed to the

boothrsquos visitors via ldquothe worldrsquos largest iPadrdquo

a custom-made 80-inch screen that show-cased all of its capabilities most of which are

groundbreaking in the industry MetsoMAPrsquos

simple interface is highly intuitive making

it easy to view process animations videos

The presentation of the new HP cone crusher attracted a large audience

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When yoursquore allowed less than a dozen days per year for breakdowns repair andmaintenance every single hour during a service shutdown counts There simplyisnrsquot any room for surprises Thatrsquos why Boliden counts on MetsoTEXT amp PHOTOS Sofia Williams

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Kurt Kalla Site Managerof Metso Gaumlllivare ServiceCenter is responsible forthe maintenance of Aitik

Metso and Boliden Strivingtogether for 97 uptime

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983122983141983152983151983154983156983145983150983143 983154983141983155

One of the biggest copper mines in

Europe Bolidenrsquos Aitik is located deep inthe wilderness of Swedish Lapland next to

the small town of Gaumlllivare The mine has

been operating since 1968 and a recent

expansion has increased its annual ore

production to 36 million tons

But the ambitious Swedes are not will-ing to lay back and relax just yet Bolidenrsquos

new aim is to reach a production rate of

45 million tons of ore per year in AitikAfter that Perhaps more than 55 million

tons The ore concentration in Aitik is very

low-grade with a mere 022 copper con-

tent hence the need for high capacityAchieving the ambitious production

goal requires maximum plant availability

This means that everything from the crush-

ers to the filters must be up and runningfor approximately 97 percent of the time

Thatrsquos where Metso comes into play

A cost-per-ton contract in action

The maximum uptime requirement allowsless than a dozen days per year for break-

downs repair and maintenance at Aitik

Every single hour during a service shut-

down counts There simply isnrsquot any roomfor surprises

Executing a successful shutdown under

such conditions requires a reliable service

partner not afraid of challenges and this iswhy Boliden has entrusted Aitikrsquos services

operations to Metso Boliden and Metsohave worked together since the 1960s

and the collaboration took another step

forward in September 2012 when the twocompanies signed a three-year extension

of the services contract for Boliden Aitik

ldquoThe new contract is a cost-per-ton

agreement We get paid based on Aitikrsquos

production Itrsquos a win-win deal for both par-

ties but also a new mindset for usrdquo explainsKurt Kalla Site Manager of Metso Gaumlllivare

Service Center responsible for serving Aitik

From now on the duration of the shut-down is what matters the most According

to Kalla the Metso service organization in

Gaumlllivare is now streamlining its operations

to fit the bill and has already witnessed thestrategy working In August 2012 Metso

carried out a 188-hour service shutdown in

Aitik which turned out to be a success

Zero tolerance for injury

One key factor to the success was theextensive planning of precautionary health

safety and environment procedures under-

taken by Metso prior to the shutdown Thanks to strict measures applied no

injuries or accidents occurred during the

shutdown and the work could easily be

finished on scheduleMats Johansson Health Safety

and Environment Manager for Metso in

Sweden explains how this was achieved

rdquoPlanning of the shutdown included arisk analysis for all new tasks participating

in Bolidenrsquos safety coordination meetingsmeeting with both Metso supervisors and

subcontractor supervisors and finally a

meeting with the entire staff participating

in the shutdown where everyone had to

sign a document stating their commitmentto the information providedrdquo he says

During the actual shutdown plenty of

new barriers signs and awareness cones

were put in place as a result of observa-tions from previous audits and safety plans

and risk analyses were readily available

in the work area Metso and Boliden also

introduced a Mill Inching permit a certifi-cate for completing a mandatory course for

those involved in the process In addition

Metso carried out random safety audits

during the shutdown to make sure thestrict policy was followed

According to Boliden Metsorsquos way of

working is a good example of how health

and safety precautions should be handled

ldquoMetso is a good example of how towork with safety and health plans risk

analysis permits and welding permits

Their table with all binders in the second-

ary mill area was exemplaryrdquo says Kjell-Arne

Johansson a technician from Boliden

The use of the new Metso Megalinertrade

system in the lining of Aitikrsquos Metso AG

mills has also improved the safety of main-tenance staff The Metso Megalinertrade con-

sists of larger-than-average liners bolted

in position from outside the mill Mainte-

nance technicians no longer need to go

inside the mill and stand in the dangerousdrop-zone of the liners gt

Boliden aims to reach a production rate of 45 million tons of ore per yearin the Aitik mine site

ldquoA complete risk analysis was conducted during the planningof the shutdownrdquo comments Mats Johansson Health Safetyand Environment Manager for Metso in Sweden

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Service the Metso way

24 hours a day 365 days a year

In addition to paying close attention to

health and safety issues executing an effi-

cient shutdown requires careful planning

and timing of every step in the mainte-

nance process Wear and spare parts have

to be available on time and a repair shoplarge enough to accommodate equipment

located close by

ldquoTo keep maintenance breaks as short

as possible we aim to replace the pump on

site and bring the old one for repair to our

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

nearby facilities This method gives us the

peace to do a good job and keep the cus-

tomerrsquos operations runningrdquo Kalla describes

the Metso way of handling Aitikrsquos pump

maintenance

Metso is currently expanding its Gaumllli-

vare service center to include a distribu-

tion center for wear and spare parts andalso concentrating its previously scattered

operations under one roof in its Vuoskon-

jaumlrvivaumlgen facility The expansion is due to

be completed by 2014

Metso equipment

delivered to Aitik36

bull 2 AG mills diameter 116 x

137 m gearless 22-MW motor

bull 2 Pebble mills diameter 91 x

113m dual 5-MW pinion drive

bull 3 VPA pressure filters VPA 1540-54

bull 12 sample pumps and pipes

VF50

bull 60 Various slurry pumps up to

MR500 modelbull Appr 5000 m rubber-lined slurry

pipes up to 600 mm diameter

bull Appr 5000 m rubber-lined by

gravity pipes up to 600 mm

diameter

bull Appr 5000 m rubber hoses

up to 600 mm diameter

Not only does the expansion make ser-

vice shutdowns at Aitik run more smoothly

it guarantees a more comprehensive

on-call emergency service response in the

region ndash thanks to the spare and wear parts

inventory available 24 hours a day 365

days a year

More info

Lars Rosenling

Tel +46 70 107 45 90

larsrosenlingmetsocom

Metso grinding equipment dominates the view in the concentrator

Safety on site is made up of small things like

making sure that everyone remembers to secure

the hoses in place

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983122983141983152983151983154983156983145983150983143 983154983141983155

Pebbles have always been a

challenge for producers of sandsince they cannot be returned

to rivers after extraction For

decades the processing of this

material resulted in a huge

environmental liability with alarge amount of pebbles hav-

ing to be stored away and left

unused

Transforming problems into

business opportunities

Areia amp Cia (areia = sand) has

operated in this market forover 20 years and decided to

enlist the help of Metso to find

a profitable solution for the

processing of pebbles

In July 2011 analyses werebegun to assess the abrasive-

ness and crushability of the

material Four alternatives wereidentified for processing and

transforming pebbles into sand

Initially Areia amp Cia was

interested in acquiring an

impactor for its reason-able price level However the

customer wanted to process

all the pebbles that were col-

lected daily in addition to some of the

material that it had stored In weighing theresults expected by the customer and the

excessive abrasiveness of the material the

HP200 cone crusher was decided on as thebest alternative

Areia amp Cia made the required invest-

ment and after using the HP200 for just

six months the company has already beenreporting outstanding results The HP200

not only transforms pebbles into sand but

also produces sand of excellent quality

with high yield and low maintenanceWith minor adjustments the HP200

also enables the production of sand withspecific particle size distribution for special

applications such as filtering sand blasting

and foundry sand adding value to the prod-

uct and increasing the types of sand offeredldquoMetso is pleased that the HP200 not

only enabled the processing of a product

that had been set aside as unusable but

HP200 cone transforms pebblesinto high-quality sandOver the last few decades Brazilian economic growth has been driving demand for construction aggregates The market

for sand in turn has been experiencing major difficulties in maintaining a consistent supply Presently one of the mainchallenges the industry faces is the large amount of pebbles that are obtained in the process of extracting sand at timesconstituting nearly 50 of the volume of material dredged from riverbeds

TEXT Sheila Ivers PHOTO Areia amp Cia

also that it opened up new

market opportunities for Areiaamp Cia Thatrsquos the standard we

seek to deliver to our custom-

ersrdquo states Luiz Oliveira Techni-

cal Salesperson of Metso Brazil

HP cones entering the

Brazilian sand-making

market

Todayrsquos cones such as theHP200 have high resistance

to impacts and abrasiveness

more efficient crushing cham-

bers low maintenance costsand excellent productivity

Following the acquisition of

the HP200 Areia amp Cia is now

also producing special sands

that command a price that is100 higher than common

sand The entire stockpile of

pebbles accumulated through-out the companyrsquos 20 years of

operations has already been

transformed into sand and the

stock of pebbles held by com-

petitors is also being purchasedfor processing

Cristiane Brizolari the

owner of Areia amp Cia confirms

the transformation that has taken place in

the production and commercial processldquoThe HP200 opened up new niches in

the market enabling the production of dif-

ferent types of sand with added valuerdquo

More info

Luiz Oliveira

Tel +55 011 9971 3603

luizoliveirametsocom

After the pebbles are crushed into sand with the HP200 cone crusherdifferent grades are screened for various end uses

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Where therersquos a will we dig a wayAFCONS-Strabag and Metso embark on tunnel project together

When the joint venture AFCONS-Strabag initiated work on the Rohtang bypass tunnel project at an altitude of 3980 metersabove sea level in Himachal Pradesh India they deliberated each aspect with clockwork precision The project involved anumber of surprises and challenges and required technology and project management skills that were second to none

TEXT amp PHOTOS Monisha Majumdar

Cutting a 10-meter-wide and nearly 9-kilo-

meter-long tunnel through the Himalayas

in one of the toughest terrains and cli-mates in India makes for quite a challengeResults set out to find out how AFCONS-

Strabag and Metso are making their way in

one of their most critical projects to date

The only road connection to the north-Indian border region of the province

Himachal-Pradesh and beyond the Manali-

Leh highway leads across the Rohtang

pass Due to the heavy snowfall and high-

velocity winds in this region the towns

located north of the pass are cut off from

the rest of the country during winter for atleast four often even six months each year

A tunnel with strategic importance

With the construction of the tunnel at

3100 m above sea level the Manali-Lehhighway will become an all-weather road

thereby enabling a significant improve-

ment in the economic development of

northern Himachal-Pradesh and an alter-

nate route to the strategically important

Ladakh region

Manali south of the pass is an alreadywell-developed tourist location that is

becoming more and more popular Upon

completion of the tunnel it is likely that

tourist activities will extend to the areanorth of the pass Moreover the tunnel

shortens the distance between the towns

of Manali and Leh by approximately 45 km

thus saving several hours on the small dan-gerous pass road

The Rohtang pass in the Western Himalaya

region of Northern India with its altitude ofalmost four kilometers ranks among thehighest trafficable passes in the world

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983122983141983152983151983154983156983145983150983143 983154983141983155

The 88-km long horse-shoe-shaped

tunnel provides space for a two-lane8-m-wide carriageway as well as a one-

meter-wide footpath on both sides A

22-m-high and 36-m-wide emergency

tunnel will be integrated in the tun-

nel cross-section Altogether more than

800000 msup3 of rock will be moved Tunneling works started around spring

2010 with excavation driven from both por-

tals As the north portal is inaccessible dur-ing winter closure the excavation focused

on the south After a planned construction

period of 55 years the tunnel is scheduled

to be completed by the end of 2015

Best man for the job

The BRO (Border Road Organization)

wanted to roll out a global tender for theproject due to the challenges that such a

project involves and also considering thatitrsquos the first time in India that a project of

this scale was to be carried out This imme-

diately triggered the need to roll out aglobal tender All major Indian construction

companies bid for it some individually and

some in partnerships

Strabag an Austrian tunnel specialistwas one of the companies who bid for the

project along with AFCONS a Mumbai-

based infrastructure company In Septem-

ber 2009 AFCONS-Strabag was awardedthe contract

Mr Sunil Tyagi Deputy Project Man-ager at AFCONS had this to say about the

unique projectldquoThis project is located in the Himalayas

and as far as we understand the terrain

there is among the toughest We came out

with a new technology and to be honestit is a fairly simple one We would generally

start with the traditional technology of drill-

ing and blasting and then obtain our muck

feed from the inwardbottom of the tunnelrdquo

ldquoThe technology is supplied by Rowa Tunneling Logistics and this is the first

time it is being used in Asia A jaw crusheris placed at a distance of about 40-45

meters behind the face The blasted muckextracted from the face is fed to the crusher

to reduce the lump size and then through

an overhead conveyor transport system

it is then transported out of the tunnelrdquoldquoThis enables free movement of man

and machinery in the lower area or spe-

cifically on the ground area If we were to

conforms to the Indian standard for fines amp

coarse aggregates as prescribed in IS383-1970

The plant was up and running in good

condition and performing to AFCONSrsquos

satisfactionldquoWe have worked with Metso in earlier

projects and are quite impressed by thekind of technology amp services they provide

We have a history together so the trust fac-tor also comes inrdquo explains Dhiman on their

choice of Metso as a partner

Service makes the difference

ldquoMetsorsquos services have made a big dif-ference in the project Without them we

would still be struggling with the machin-

ery and production The service is really

good and the service engineers are knowl-edgeable prompt and quick to act Any

problem can be solved by Metso We donrsquothave to wait until a service engineer turns

up ndash they have the capacity to solve prob-lems over the phone as wellrdquo says Dhiman

ldquoThe Metso plant didnrsquot create any prob-

lems for us We had problems in logistics

the feed was sticky and the weather condi-tions were bad but thankfully we did not

face any problems with production and

efficiency as the Metso plant is performing

very wellrdquo Dhiman concludes

More info

Amol Sinha Tel +91 9811 671 924

amolsinhametsocom

use the old conventional technology this

wouldnrsquot have worked for us in the stipu-lated timerdquo Mr Tyagi adds

When the going gets tough

partner with the toughest

Sensitive projects require the best technol-

ogy After AFCONS-Strabag landed theproject Metso was an obvious choice as a

technology provider not only because of

the long-standing business relationshipbut also for the sheer consistency in prod-

uct quality and service deliverance Metso

strives for

ldquoAfter signing the project we faced alot of road blocks including extreme cold

avalanches roadblocks less oxygen ndash you

name it we faced itrdquo explains Ankit Dhi-

man Plant Manager at AFCONS-Strabag The Rohtang valley is known for its

notorious avalanches and landslides SoAFCONS had to take extra steps and safety

precautions against hazards on the site

ldquoIn this freezing cold not just us humansbut also the machines are at increased risk

of damage I remember when we used

to run the plant during winter the diesel

engines would freeze We had to constantlyheat up the fuel container to get the plant

running And even the sand in the sand

trap would freeze so we had to clean it on

a daily basis to stop the pipes from mal-functioningrdquo Dhiman adds

Plant designed for difficult terrain

Difficult terrain coupled with space con-straints led Metso engineers to put their

minds together to come up with a suitable

plant configuration After studying the

requirements of the project Metso sug-

gested a 150-tons-per-hour three-stagemodular plant using a C106 jaw crusher

a GP11F secondary cone crusher and a

B7150 tertiary vertical shaft impact crusher

In addition considering the unpredict-ability of the feed the plant was about

to reach a point where the amount offines to be handled could be increased

dramatically Metso strongly suggested the TK11-27-3V grizzly scalper and this became

the first-ever TK scalper to be supplied by

Metso to an Indian customer Also in order

to get better products a sand trap SF2360was added to the configuration

The sand trap is important equipment

for this project as it washes the sand thatMr Sunil Tyagi Deputy Project ManagerAFCONS-Strabag

8132019 Results Minerals Aggregates 3 2012ENG

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Smooth transition to new-generation jaw crusher in Germany

Roumlhrig is a German company with a rich heritage The company has been quarrying granite at its plant in Bergstrasse inthe Sonderbach district of Heppenheim for three generations

TEXT amp PHOTOS Ralf Goffin

Roumlhrigrsquos superior product variety is onereason why the companyrsquos proximity to its

customers can be understood in more than

just physical terms The companyrsquos high

level of innovation has allowed it to estab-lish itself as a reliable supplier of materials

both regionally and internationally This

operational and technical expertise always

manages to keep in step with growing

market requirements

In terms of technical processing equip-

ment Roumlhrig has used a Nordberg C160stationary jaw crusher from Metso since

1992 At the start of 2012 it was finally

exchanged for a more up-to-date version

from the same model range

Metsorsquos C Series is specifically designed

to pre-crush hard rock and can cope effort-

lessly with even the hardest of materials

The dimensions of the new stationary jawcrusher are identical to those of the old

one which means that it could simply be

slotted into the housing vacated by the

previous version

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155

Third-generation Managing DirectorMarco Roumlhrig expects the new machinersquos

service life to be just as long as the previ-

ous model due to the product upgrades

that have been implemented The integral motor base is another plus

point in models made by other manu-

facturers it is located outside the crusher

This element of good fortune ensured that

Roumlhrig could reuse the housing withoutany additional rebuilding

Another advantage lies in the revision

of the guards for the C160rsquos drivetrain andflywheel The sturdier construction method

used for the crusher requires fewer parts

which facilitates easier installation andmaintenance and it makes it simpler to

access the motor

Under the watchful eye of Metsorsquos

Assembly Manager Maik Engelstaumltterthe entire project including removal and

installation was successfully completed

within two weeks

Installation making the most

of the available space

Roumlhrig will likely remember the day the

new crusher was installed for a long time

the pitman and main frame were deliveredseparately prior to installation and assem-

bled on site It took just one hour to replace

the old stationary crusher with the new

model A lorry-mounted crane was used toposition the 85-ton crusher with millimeter

precision in the crushing plant Once the

new crusher had been positioned in theexisting steel structure the next task wasto fix it into place as securely as possible

despite the limited space Special vibration

dampers were installed at a height of two

meters to prevent the crusher from sliding

Norbert Ried (fourth from left) installed thenew C160rsquos predecessor 20 years ago and isdelighted at the durability of the powerfulcrusher that is now making way for a newermodel Also pictured from left to right ManagerVolker Angermann Assembly Manager Maik

Engelstaumltter Technical Manager Stefan

Koob Project Manager Dominic SchoumlnhardtManaging Director Marco Roumlhrig Service

Technician Stefan Kolze and employees ofthe installation company Stafemo

On the hook after theold C160 was liftedout by crane the newcrusher was installedin almost no timeOnly the roof of thehousing had to beremoved

sideways off its mount An initial test run

with materials was carried out around oneweek later after all the electrical cables had

been installed

Simultaneously with the installation

of the C160 which is the first of the latest

generation of crushers to be installed in

Germany a new Nordberg GP100 conecrusher was also being installed in Roumlhrigrsquos

chipping plant Roumlhrig is convinced that

the technical improvements made tothe new Metso crusher can only be an

advantage worldwide

Roumlhrig places great value on consistent

product quality maximum added valueand optimum refinement of its product

range Bearing in mind that Roumlhrig has

enough reserves of raw material to last

for the next 150 years the company canconfidently continue to develop with an

emphasis on quality rather than quantity

More info

Dominic Schoenhardt

Tel +49 (0)621 727 00 610

dominicschoenhardtmetsocom

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Groupe Charier Carriegravere de la Mariais France

Quarrying with certi1047297ed quality The Charier Group with its 1600-strong workforce is a family business thatthis year celebrates 115 years of quarrying The company pursues a long-termdevelopment policy that since 2007 has seen processing installations upgradedat 4 of its 9 extraction sites

TEXT Liliane Boutin (with extracts from Mines amp Carriegraveres and Terrassements amp Carriegraveres magazines)PHOTO Baloon photo

The processing installation is of the horizontal type with a primary station located 56 meters below the site access road to keep it hidden from view

The crushing and screening installation at

Charierrsquos CM La Mariais quarry (at Donges

on the Loire estuary) has been in opera-tion since September 2011 Based on theoperatorrsquos ideas it was designed by Metso

to replace a worn-out installation installed

right on top of the seam being extracted

Since its commissioning it has becomethe second quarry in the company to

receive ISO 14 001 certification

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983122983141983152983151983154983156983145983150983143 983154983141983155

tertiary material of sand and gravel for the

local market to use in concrete surfacingprefabrication etcrdquo

Incorporation of a screening station

The stone extracted from La Mariais is

according to the quarry granitic gneiss

sound and homogeneous with a LosAngeles index of 15 good wear resist-

ance with an MDE of 10 a true density of

265 and a certain abrasiveness (2000 gt)ldquoCharacteristically it has a tendency to form

blocksrdquo Leblin points out

The main criteria in designing the instal-

lation was to provide an output of 600000metric tons from one station (38 hours

week) to produce materials aimed at the

concrete and surfacing markets ldquowhich

involved providing a tertiary station withscreening plantrdquo he adds

With this new unit the operating com-pany expands its product range through

the addition of fine materials obtained

from the tertiary screening station This unitis capable of producing 170 tonshour of

020

Preserving the environment

and optimizing safety

The screens have motorized bogies and

retractable walkways to facilitate access

when the screens are opened for main-tenance Other walkways provide access

to the tunnel input feeders The feederscan be isolated with hydraulic rod gate

bars this hydraulic assistance eliminatesthe need to use a heavy hammer to lodge

these metal bars

All conveyors transporting fines (02

and 04) are covered with a tarpaulin to

avoid flying dust and all the screens arehooded (metal cover with Trellex seal-

ing) The Brunone company has installed

dust-tight containment at the outlet of the

tertiary station crushers (HP300 and HP4)on the belt located under the screens

and under the hoppers located belowthe tertiary screens The crushers are put

under negative pressure and the finesare extracted through sleeve filters (7000

m3 h) with declogging which deposits the

dust back onto the conveyor belt

A high-pressure 100 bar water mist sys-tem has been installed at the primary sta-

tion discharge at the secondary crusherrsquos

discharge chutes (Omnicone) and at the

transfer points on the belt

Designed to last

ldquoThis type of new installation can easily last

thirty yearsrdquo affirms Project Leader Bruno

Peix of Metso ldquoIt quite simply depends on

how well it is maintained Thatrsquos why weprovide maintenance contracts that call for

our technicians to make regular inspection

visits and carry out preventive mainte-nance and any necessary repairsrdquo

In 2011 Metso commissioned about

10 new processing units in France like

the one at La Mariais quarry

More info

Frederic Bazire

Tel +33 (0)681442804

fredericbaziremetsocom

Key figures

DURATION OF WORKS 15 months

DRAWING OFFICE TIME 7800 hours

HEIGHT OF SILOS AND GRINDER BUILDINGS

15 m

TOTAL LENGTH OF CONVEYORS 14 km

WEIGHT OF THE INSTALLATION

1200 metric tons

CONCRETE POURED 1800 cubic meters

PROJECT SITE WORKFORCE 30

INSTALLED POWER 2200 kW(not including pumps 200 kW)

METSO EQUIPMENT

Primary

Vibrating feeder PF561-2V

Primary grizzly VG540-3V

Grizzly feeder TK13-20-3V

Jaw crusher C145 with

hydraulic setting

Secondary

Vibrating screen CVB 2050

refurbished

Cone crusher Omnicocircne 1352 SX

with Metso IC7000 controller Ellivar 16 (16 msup2 3 decks) screen

refurbished by Metso

Tertiary

Cone crusher HP300

Cone crusher HP4

2 Ellivar 20 screens (20 m23 decks) for final products

Expanding the production range

ldquoSince the mid-1990s when we became

owners of La Mariais we had used mobilemachinery with an assembly of beltconveyorsrdquo recalls Daniel Leblin Charierrsquos

Technical Manager for site construction

and maintenance

ldquoIt became clear that we needed ahigher performance tool to achieve the

dual goals of reaching one million metric

tonsrsquo maximum production and producing

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Big Lokotrack LT550GPF boostsquarrying productivity by a thirdMaximizing the productivity of operations is a key issue when striving for cost-effective quarrying Big Lokotracks are oneway to achieve improved operational efficiency The Lokotrack LT550GPF equipped with the high-volume GP550 conecrusher and a large screen is popular in the Nordic countries and in Germany and Australia ndash countries all known for theirhigh quarrying volumes

TEXT amp PHOTOS Eero Haumlmaumllaumlinen

Kone-Kostamorsquos new mobile coneplant has reached an averagecapacity of 300 tons per hour

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983122983141983152983151983154983156983145983150983143 983154983141983155

ldquoWith the same number of employees we

can achieve 30 more productivity with

our new LT550GPF unit The high-capacityFS screen has also eliminated the bottle-neck often seen at fine screeningrdquo says

Aarno Kostamo Managing Director of

Kone-Kostamo Oy one of Finlandrsquos biggest

crushing contractorsAccording to Kostamo the high capacity

of the GP550 gyratory cone crusher easily

handles feed from the C120 and C125 jaw

crushers For the contract with the Talvivaara

nickel mine the LT550GPF is being fed bythe brand new Lokotrack LT120 jaw plant

Average capacity 300 tons per hour

Talvivaara Europersquos largest nickel mine uti-

lizes large quantities of aggregates Kone-Kostamo has contracted several million

tons of different end products for the mineIn August 75000 tons of 0ndash63 mm

road gravel was crushed Smaller amountsof finer 0ndash6 mm 0ndash16 mm and 0ndash32 mm

aggregates are also being produced

The rainy summer increased the need

for road gravel along the muddy roadswhich must endure dump trucks weighing

as much as 260 tons

ldquoThe mobile process consisting of the

LT120 jaw plant and LT550GPF cone plant

is cost-effective while aggregates of vari-ous sizes can be produced in a two-stage

operation and with high capacity The con-trolled stroke and elliptical movement of

the FS screen secure big passing throughcapacitiesrdquo Kostamo explains

Operated in two shifts for a total of 16

hours per day the LT550GPF has logged

more than 600 working hours over a two-month period

Managing Director Aarno Kostamo (left) and foreman Karri Maumlenpaumlauml studying the cavity optionsavailable for the new Lokotrack LT550GPF

Longer perspective than

a single quarter needed

Kone-Kostamo Oy was founded as an

earth-moving company in Kemijaumlrvi

Northern Finland in 1956 The company

expanded its operations to include crush-

ing contracting in 1964 and later on

switched to concentrating fully on crush-ing activities

Kone-Kostamo consistently crushes

and screens around 28 million tons ofaggregates annually and has net sales of

between EUR 8ndash9 million

ldquoWe believe that issues within the crush-

ing industry including the purchasing ofmachinery must be studied with a longer

perspective than a single quarter The

secret to our success has always been our

solid work ethic and professional employ-eesrdquo Kostamo sums up

More info

Esa Berg

Tel + 358 40 837 8692

esabergmetsocom

8132019 Results Minerals Aggregates 3 2012ENG

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Monitoring-based reporting is vital for

assessing the performance of a mobile

crushing plant Metso provides suchreporting tools through its plant-wideautomation system Metso DNA (Dynamic

Network of Applications) with its infor-

mation platform that links all the mobile

crushing and screen units together as oneentity Basically there is a lot of measured

real-time information available in every

crushing plant On-line information is

obtained either from each Metso crusherrsquosmachine automation system IC (Intelligent

Controller) or from separately installed

additional sensors and belt scales

All the collected data is sent to a motorhome using wireless communication

based on WLAN technology The motor

home is a purpose-built environment

inside an on-site container In this environ-ment selected variables can be monitored

for assessing the plantrsquos performance And

to make all this even more flexible the

data can be transmitted to a crushing plant

company office using GPRS3G mobile

data communication technologies Thismakes all the last-minute reports acces-sible to the crushing plant managerial staff

at anytime and basically anywhere within

reach of the cell phone network

Production and fuel economics reports

Essentially monitoring and reporting can

be customized to fit the customerrsquos needs

However there are certain off-the-shelf

reports that provide a lot of useful informa-tion for plant supervision The production

report is one of these Requiring at least one

belt scale for measuring the total produc-tion the production report shows the pro-duction rate (tons per hour) for a selected

reporting period eg a day or a week The

production report constantly keeps track of

the plantrsquos production storing all the datathroughout the plantrsquos life cycle

Performance monitoring and reportingfor a mobile crushing plantTEXT Pasi Airikka PHOTOS Metso

unit during which the unit is running By

storing the availability times between start-ups and shutdowns the crushing plant

operation time (hours per dayshift) can be

recorded analyzed and reported In addi-

tion the availability report can be tailored

to evaluate efficient crushing hours during

which the plant is really working and pro-ducing aggregates Consequently the ratio

(0-100) between efficient crushing time

and total running time can be reported forany selected period of time This boosts

the efficiency of the plantrsquos operations

and results in better productivity

Reports on non-choke

or inadequate feeding

Non-choke feeding to crushers is avoid-

able through smart plant-wide crushingplant controls But estimating its severity in

a systematic manner is not straight-forwardwithout constant monitoring and reporting

The crusher choke feeding report makes

use of the crusher cavity level sensors byanalyzing their level measurements By

calculating average and min-max values

and deviations from the average it can be

shown how often the single crusher suffersfrom non-choke feeding to it

In some cases the bottleneck in the

crushing plantrsquos productivity is the material

feeding to the process In mobile plants thefeeding is human operated and therefore

subject to variations Occasionally the sizeof the human-operated machine simply

does not allow for adequate feeding to thecrushing plant There are specific reports

indicating time periods when the crushing

plant suffers from inadequate feeding

Condition monitoring for

crushers and screens

Machine-specific condition monitoring

focuses on vibrating components in

crushers and screens such as drive shaftbearings safety plate wearings and gears

The low middle and high frequencies ofmonitored components are measured and

supervised in real-time to detect abnor-malities due to slow or fast wear looseness

or imbalance

More info

Pasi Airikka

Tel +358 40 587 2730

pasiairikkametsocom

Condition monitoring provides a view tovibrating crusher and screen components forpredictive equipment maintenance

The daily production report shows the hour-by-hour production trend and distribution chartfor a selected day with min-max average andvariation statistics for comparison

Fuel consumption is always an interest-ing concern The fuel consumption reportgives the fuel consumption of each crush-

ing unit (liters per hour) and their total

consumption (liters per hour) for a selected

reporting period and can track fuel con-

sumption changes over timeCrushing plant availability can be

assessed as well The availability report

calculates time periods for each crushing

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983149983141983156983155983151 983150

for tissue machines The record of 2210

mmin was set on June 1 2012 during a

24-hour production run by the TM 2 tissue

machine at the companyrsquos mill in Yenikoumlynear the city of Izmit in Turkey

ldquoThe cooperation with Metso has been

beyond excellent and both parties did

their utmost to make the project success-ful The results clearly show that the efforts

were worthwhile on both sides This coop-

eration will extend to cover new projects

in the futurerdquo says Luumlt1047297 Aydin Paper GroupDirector Hayat Kimya

ldquoWe are not surprised that Hayat K imya

managed to break the world speed record

We have had great confidence in the capa-bility of the Hayat team since our project

started in 2009 We certainly know our

machine very well its stability production

efficiency and speed capabilityrdquo says Jan

Erikson Vice President Sales Metso

PowerThe worldrsquos first eco-gas fueled

power plant is up and running

Lahti Energy Ltdrsquos new Kymijaumlrvi II gasifica-

tion plant was officially inaugurated on

May 8 2012 It is the first of its kind in the

RecyclingRecycling with Lokotrack LT106

jaw plant in New York

A brand-new Lokotrack LT106 jaw plant is

used in the city area of New York USA to

recycle demolition materials The crushing

site faces the skyscrapers of ManhattanIsland

Paper amp FiberHayat Kimyarsquos Metso-supplied tissue

machine sets world speed record

Thanks to a skilled crew and dedicated

efforts Hayat Kimya AS in Turkey has suc-

ceeded in breaking the world speed record

world This CHP plant runs on clean eco-

gas that is gasified cleaned and cooled

from recycled waste with Metsorsquos innova-tive technology

ldquoItrsquos actually eco-gas that we combust

in the boilerrdquo comments Lahti EnergyrsquosProduction Director Jukka Manskinen

ldquoWe convert unwanted waste material into

energy in an efficient and environmentally

friendly wayrdquoNever before has any plant gasified

waste on such a large scale In the gasifier

recycled waste is turned into combustible

product gas which is cleaned cooled and

combusted in a high-efficiency gas boiler

to produce steam for the steam turbine The plant produces 50 MW of electricity

and 90 MW of district heat for the city of

Lahti and its neighboring areasMetso delivered the circulating fluidized

bed (CFB) gasification process gas cleaning

and cooling steam boiler environmental

protection system and automation systemto the entire plant The production of elec-

tricity and heat is kept even with the Metso

DNA automation system that covers the

whole plant starting from fuel reception

AutomationMetso develops and supplies plant-

wide crushing control solutions for

crushing plants

Metso has recently signed contracts on

delivering plant-wide automation systems

for mobile and portable rock crushing

plants The key objective of these deliveries

is to stabilize and to increase productivityand efficiency of the plants using one sin-

gle automation and information platform

for integrating crusher-specific IC machinecontrols

Furthermore the plant-wide system

with its information management tools not

only increases plant availability and opera-

tional safety it also makes troubleshoot-ing quicker and performance monitoring

easier The control room for plant-wide

operability is located either in an excavator

cabin or a purpose-built container

Metso around the world

The new LT106 jaw plant is suitable for crushing both hard rock and all rock-based demolition materials

The new world speed record for tissue setby Hayat Kimyarsquos Metso-supplied TM 2 is2210 mmin

8132019 Results Minerals Aggregates 3 2012ENG

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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: Results Minerals Aggregates 3 2012.ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Metso Distribution Centers he

Europe (Tongeren Belgium)

France (Macon)

Czech Republic (Přerov)

Austria (Vienna)

2271 d

Brazil (Sorocaba SP)

1014 d

USA (Columbia SC)

1690 d

USA (Waukesha WI)

434 d

South Africa (Vereeniging)

Ghana (Tarkwa)

Meacutexico (Irapuato)

Peru (Lima)

Chile (Concoacuten)

788 d

Sweden ( Trelleborg)

Finland (Tampere)

UK (Rugby)

865 d

Russia (St Petersburg)

Brazil (Parauapebas PA)

206 d

4983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

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983122983141983152983151983154983156983145983150983143 983154983141983155983122983141983152983151983154983156983145983150983143 983154983141983155

In the case of an equipment failure or

a planned service shutdown resuming

production as quickly as possible is crucialEach hour spent waiting for a spare part to

arrive equals money lost Whether the right

part takes 12 or 48 hours to arrive really

makes a difference

The comprehensive and global Metsospare and wear parts service network pro-

vides you with the right part in the right

place and at the right time Our strategi-

cally located Distribution Centers and

Satellite Warehouses are on call 24 hoursa day 7 days a week ensuring efficient

parts replacement near you

Check out the locations of the MetsoDistribution Centers and how many parts

pass through them each day

More info

Marcelo Farah

Tel +55 15 2102 1315

marcelofarahmetsocom

you minimize downtime

Australia (Perth)

746 d

China (Tianjin)

China (Kunming)

China (Shanghai)

393 d

India (Faridabad)

India (Ahmedabad)

India (Hyderabad)

India (Bhubaneswar)

India (Bangalore)

419 d

Russia (Yekaterinburg)

Australia (Newcastle)

New Zealand (Matamata)

983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088

TEXT Sofia Williams

Singapore (Singapore)

Distribution Center Satellite Warehouse

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Following a large investment

in Metso crushing equipmentand services Buena Vista del

Cobre is now expanding the

mine site to include even more

equipment ndash and with thatexpansion comes the need for

more local service resources

Metso and Buena Vista del

Cobre have entered into a Life

Cycle Service agreement forthe plant and construction of a

brand new Metso service hub

is under way in Cananea

New facility new

level of service

The Cananea service hub

which will be up and running in early 2013will support the recent expansion and resur-

gence of Buena Vista del Cobre Initially it

will be a major repair and assembly center

for pumps crushers and screens and will

provide for rubber covering capabilitiesBut the 8000-square-meter facilityrsquos service

offering will be expansive including a con-

signment stock inventory to help serve theminersquos varying needs Metso currently has

50 service team members on site

Although Buena Vista del Cobre was a

key influencer in building the new servicehub this location will also enable Metso to

expand its capabilities and provide local

support to the entire mining community

in northwest Mexico The Cananea hub

will serve a number of major copper and

gold mines in the region including MineraFriscorsquos San Felipe Fresnillorsquos Milpillas and

Grupo Mexicorsquos Mexicana de Cobre

ldquoBuena Vista del Cobre is the biggestcustomer we have in Mexico today and

with this expansion project itrsquos only going

to grow and be strongerrdquo says Felix Forna-

guera Director of Services Mexico CentralAmerica and Caribbean ldquoWith that said the

idea behind the Cananea service hub is to

provide a central location for local support

for all our major customers in the areardquo

Establishing safety

ldquoIt was key to have our support here in

Cananea because the Buena Vista delCobre started from the ground uprdquo saysFelix ldquoWersquove been able to help the cus-

tomer to establish the best in support

service and operations from the very

beginningrdquo And this ground-up approachincluded a major focus on safety

Metso worked closely with Buena Vista

del Cobre to establish the safety proto-

col by which the mine operates Basedon Metsorsquos expertise the safety measures

put in place have enabled the mine to

become strict and efficient in its operations

and maintenance procedures To achievethis Metso worked closely with local andnational authorities to ensure the safety

plan was comprehensive and in accord-

ance with all established legal bodies

The best in regional support

The service hub in Cananea is a prime

example of Metsorsquos focus on providing local

service and support to its customers all

Service shines in Cananea MexicoAfter three years of inactivity the Buena Vista del Cobre mine in Cananea Sonora Mexico has been operational since 2010A mine that was inactive for such a significant amount of time however requires a great deal of support to successfullyrestart the plant and bring it back to an operational and profitable state

TEXT Deanna Lee PHOTO Metso

over the world ldquoWe are the first

company developing this kindof service in northwest Mexicordquo

adds Felix ldquoOur people have

developed a close relationship

with the team at the mine Itrsquosmore than a supplier relation-

ship our guys are inside the

mine living and working thererdquo

In fact this is the model

that Metso is using in servicehubs all over the globe build-

ing modern facilities bringing

teams on site and workinghand in hand with mine

operators The Cananea Service

hub is only the most recent

example of Metsorsquos commit-ment to service and northwest Mexico is

yet another mining hotbed thatrsquos going to

benefit from the companyrsquos support

More info

Felix Fornaguera Tel +52 4621079227

felixfornaguerametsocom

A mining cone serviced by Metso at the Buena Vista del Cobre mine inSonora Mexico

ldquoThe new Cananea service center will be a majorrepair and assembly center for pumps crushersand screensrdquo says Felix Fornaguera Director ofServices Mexico Central America and Caribbean

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

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During the MINExpo exhibition over 1300 people visited the Metso stand

983122983141983152983151983154983156983145983150983143 983154983141983155

Held every four years MIN-Expo consistently grows so

perennial exhibitors like Metso

are challenged with elevating

their presence and drawingin new (and greater numbers

of ) visitors each year ldquoItrsquos not

necessarily a challenge to lsquotoprsquo

our last showingrdquo says Keith

Ference Vice President ofmarketing and communica-

tions North America ldquoThere

are four years between eachMINExpo so we always have

a lot to say and reveal to our

customersrdquo The real challenge

he says is finding an exciting

and dynamic way to deliverthe message ldquoTherersquos so much

to see here so your booth has

to be compelling from the

outside-in and thatrsquos what

we always try to dordquo

Service sets the stage

The Metso booth created buzzin a number of ways and per-

haps the most striking (partly

due to its size) was the live

theater presentation As visitorspassed through the aisles of the show-

room the sights and sounds from Metsorsquos

theater were hard to miss And once guests

entered they were captivated by a short

high-energy video presentation focused

on Metsorsquos service capabilities The message was simple Metso is ldquoyour

local service partner rdquo for all mining and

construction needs The video showed ourservice teams in action all over the world

and the audience came away with an

understanding about Metsorsquos commitment

to service Customers can count on morethan 70 local service centers run by more

than 1700 expert technicians delivering

Metso makes an impact at MINExpo 2012At this yearrsquos MINExpo International nearly 60000 attendees flocked to Las Vegas Nevada the largest turnout in showhistory The visitors ndash mining professionals from all over the globe ndash explored 850000 square feet of showroom spacefeaturing the industry rsquos latest technology equipment products and services They toured the show for three days

seeking the latest and greatest from more than 1800 exhibitorsTEXT Keith Ference PHOTOS Tracey Ford Perry

detailed descriptions andphotos of all of Metsorsquos mining

and construction products and

services The app also provides

digital access to Results and asearchable database of sales

contacts By day three of the

show MetsoMAP had been

downloaded by more than

500 usersIn addition to the app the

booth was equipped with

several LCD screens each con-trolled by Metso experts who

used their iPads to present new

products like the Megalinertrade

and the HRCtrade A featured

presentation on Metsorsquos lineupof energy-efficient comminu-

tion equipment including the

VERTIMILLreg SMD and MP-1250

cone crusher was also avail-

able letting customers seehow Metso technology delivers

some of the worldrsquos most effi-

cient size reduction

Measuring MINExpo success

After a very busy three days

(on top of months of prepara-tion leading up to the show) everyone

involved with MINExpo ndash from the North

American marketing team responsible for

the booth to the product managers and

sales force that worked the floor ndash is view-

ing the show as a success ldquoTherersquos alwaysa sigh of relief after each (MINExpo)rdquo says

Keith ldquoAnd overall the initial feedback

and response has been very positiverdquoWith more than 1300 visitors to the

booth Metso certainly made an impact

ldquoWe learn a lot from each show and with

some time wersquoll have a better understand-ing of the tangible results of our effortsrdquo

Keith adds

reliable service for mining equipment as

well as customized cost-effective life-cycle

services contracts

Technology ndash MetsoMAP

is an industry firstMINExpo provided the industry with its firstglimpse of Metsorsquos revolutionary iPad app

MetsoMAP The app was demoed to the

boothrsquos visitors via ldquothe worldrsquos largest iPadrdquo

a custom-made 80-inch screen that show-cased all of its capabilities most of which are

groundbreaking in the industry MetsoMAPrsquos

simple interface is highly intuitive making

it easy to view process animations videos

The presentation of the new HP cone crusher attracted a large audience

8132019 Results Minerals Aggregates 3 2012ENG

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When yoursquore allowed less than a dozen days per year for breakdowns repair andmaintenance every single hour during a service shutdown counts There simplyisnrsquot any room for surprises Thatrsquos why Boliden counts on MetsoTEXT amp PHOTOS Sofia Williams

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Kurt Kalla Site Managerof Metso Gaumlllivare ServiceCenter is responsible forthe maintenance of Aitik

Metso and Boliden Strivingtogether for 97 uptime

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983122983141983152983151983154983156983145983150983143 983154983141983155

One of the biggest copper mines in

Europe Bolidenrsquos Aitik is located deep inthe wilderness of Swedish Lapland next to

the small town of Gaumlllivare The mine has

been operating since 1968 and a recent

expansion has increased its annual ore

production to 36 million tons

But the ambitious Swedes are not will-ing to lay back and relax just yet Bolidenrsquos

new aim is to reach a production rate of

45 million tons of ore per year in AitikAfter that Perhaps more than 55 million

tons The ore concentration in Aitik is very

low-grade with a mere 022 copper con-

tent hence the need for high capacityAchieving the ambitious production

goal requires maximum plant availability

This means that everything from the crush-

ers to the filters must be up and runningfor approximately 97 percent of the time

Thatrsquos where Metso comes into play

A cost-per-ton contract in action

The maximum uptime requirement allowsless than a dozen days per year for break-

downs repair and maintenance at Aitik

Every single hour during a service shut-

down counts There simply isnrsquot any roomfor surprises

Executing a successful shutdown under

such conditions requires a reliable service

partner not afraid of challenges and this iswhy Boliden has entrusted Aitikrsquos services

operations to Metso Boliden and Metsohave worked together since the 1960s

and the collaboration took another step

forward in September 2012 when the twocompanies signed a three-year extension

of the services contract for Boliden Aitik

ldquoThe new contract is a cost-per-ton

agreement We get paid based on Aitikrsquos

production Itrsquos a win-win deal for both par-

ties but also a new mindset for usrdquo explainsKurt Kalla Site Manager of Metso Gaumlllivare

Service Center responsible for serving Aitik

From now on the duration of the shut-down is what matters the most According

to Kalla the Metso service organization in

Gaumlllivare is now streamlining its operations

to fit the bill and has already witnessed thestrategy working In August 2012 Metso

carried out a 188-hour service shutdown in

Aitik which turned out to be a success

Zero tolerance for injury

One key factor to the success was theextensive planning of precautionary health

safety and environment procedures under-

taken by Metso prior to the shutdown Thanks to strict measures applied no

injuries or accidents occurred during the

shutdown and the work could easily be

finished on scheduleMats Johansson Health Safety

and Environment Manager for Metso in

Sweden explains how this was achieved

rdquoPlanning of the shutdown included arisk analysis for all new tasks participating

in Bolidenrsquos safety coordination meetingsmeeting with both Metso supervisors and

subcontractor supervisors and finally a

meeting with the entire staff participating

in the shutdown where everyone had to

sign a document stating their commitmentto the information providedrdquo he says

During the actual shutdown plenty of

new barriers signs and awareness cones

were put in place as a result of observa-tions from previous audits and safety plans

and risk analyses were readily available

in the work area Metso and Boliden also

introduced a Mill Inching permit a certifi-cate for completing a mandatory course for

those involved in the process In addition

Metso carried out random safety audits

during the shutdown to make sure thestrict policy was followed

According to Boliden Metsorsquos way of

working is a good example of how health

and safety precautions should be handled

ldquoMetso is a good example of how towork with safety and health plans risk

analysis permits and welding permits

Their table with all binders in the second-

ary mill area was exemplaryrdquo says Kjell-Arne

Johansson a technician from Boliden

The use of the new Metso Megalinertrade

system in the lining of Aitikrsquos Metso AG

mills has also improved the safety of main-tenance staff The Metso Megalinertrade con-

sists of larger-than-average liners bolted

in position from outside the mill Mainte-

nance technicians no longer need to go

inside the mill and stand in the dangerousdrop-zone of the liners gt

Boliden aims to reach a production rate of 45 million tons of ore per yearin the Aitik mine site

ldquoA complete risk analysis was conducted during the planningof the shutdownrdquo comments Mats Johansson Health Safetyand Environment Manager for Metso in Sweden

8132019 Results Minerals Aggregates 3 2012ENG

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Service the Metso way

24 hours a day 365 days a year

In addition to paying close attention to

health and safety issues executing an effi-

cient shutdown requires careful planning

and timing of every step in the mainte-

nance process Wear and spare parts have

to be available on time and a repair shoplarge enough to accommodate equipment

located close by

ldquoTo keep maintenance breaks as short

as possible we aim to replace the pump on

site and bring the old one for repair to our

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

nearby facilities This method gives us the

peace to do a good job and keep the cus-

tomerrsquos operations runningrdquo Kalla describes

the Metso way of handling Aitikrsquos pump

maintenance

Metso is currently expanding its Gaumllli-

vare service center to include a distribu-

tion center for wear and spare parts andalso concentrating its previously scattered

operations under one roof in its Vuoskon-

jaumlrvivaumlgen facility The expansion is due to

be completed by 2014

Metso equipment

delivered to Aitik36

bull 2 AG mills diameter 116 x

137 m gearless 22-MW motor

bull 2 Pebble mills diameter 91 x

113m dual 5-MW pinion drive

bull 3 VPA pressure filters VPA 1540-54

bull 12 sample pumps and pipes

VF50

bull 60 Various slurry pumps up to

MR500 modelbull Appr 5000 m rubber-lined slurry

pipes up to 600 mm diameter

bull Appr 5000 m rubber-lined by

gravity pipes up to 600 mm

diameter

bull Appr 5000 m rubber hoses

up to 600 mm diameter

Not only does the expansion make ser-

vice shutdowns at Aitik run more smoothly

it guarantees a more comprehensive

on-call emergency service response in the

region ndash thanks to the spare and wear parts

inventory available 24 hours a day 365

days a year

More info

Lars Rosenling

Tel +46 70 107 45 90

larsrosenlingmetsocom

Metso grinding equipment dominates the view in the concentrator

Safety on site is made up of small things like

making sure that everyone remembers to secure

the hoses in place

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983122983141983152983151983154983156983145983150983143 983154983141983155

Pebbles have always been a

challenge for producers of sandsince they cannot be returned

to rivers after extraction For

decades the processing of this

material resulted in a huge

environmental liability with alarge amount of pebbles hav-

ing to be stored away and left

unused

Transforming problems into

business opportunities

Areia amp Cia (areia = sand) has

operated in this market forover 20 years and decided to

enlist the help of Metso to find

a profitable solution for the

processing of pebbles

In July 2011 analyses werebegun to assess the abrasive-

ness and crushability of the

material Four alternatives wereidentified for processing and

transforming pebbles into sand

Initially Areia amp Cia was

interested in acquiring an

impactor for its reason-able price level However the

customer wanted to process

all the pebbles that were col-

lected daily in addition to some of the

material that it had stored In weighing theresults expected by the customer and the

excessive abrasiveness of the material the

HP200 cone crusher was decided on as thebest alternative

Areia amp Cia made the required invest-

ment and after using the HP200 for just

six months the company has already beenreporting outstanding results The HP200

not only transforms pebbles into sand but

also produces sand of excellent quality

with high yield and low maintenanceWith minor adjustments the HP200

also enables the production of sand withspecific particle size distribution for special

applications such as filtering sand blasting

and foundry sand adding value to the prod-

uct and increasing the types of sand offeredldquoMetso is pleased that the HP200 not

only enabled the processing of a product

that had been set aside as unusable but

HP200 cone transforms pebblesinto high-quality sandOver the last few decades Brazilian economic growth has been driving demand for construction aggregates The market

for sand in turn has been experiencing major difficulties in maintaining a consistent supply Presently one of the mainchallenges the industry faces is the large amount of pebbles that are obtained in the process of extracting sand at timesconstituting nearly 50 of the volume of material dredged from riverbeds

TEXT Sheila Ivers PHOTO Areia amp Cia

also that it opened up new

market opportunities for Areiaamp Cia Thatrsquos the standard we

seek to deliver to our custom-

ersrdquo states Luiz Oliveira Techni-

cal Salesperson of Metso Brazil

HP cones entering the

Brazilian sand-making

market

Todayrsquos cones such as theHP200 have high resistance

to impacts and abrasiveness

more efficient crushing cham-

bers low maintenance costsand excellent productivity

Following the acquisition of

the HP200 Areia amp Cia is now

also producing special sands

that command a price that is100 higher than common

sand The entire stockpile of

pebbles accumulated through-out the companyrsquos 20 years of

operations has already been

transformed into sand and the

stock of pebbles held by com-

petitors is also being purchasedfor processing

Cristiane Brizolari the

owner of Areia amp Cia confirms

the transformation that has taken place in

the production and commercial processldquoThe HP200 opened up new niches in

the market enabling the production of dif-

ferent types of sand with added valuerdquo

More info

Luiz Oliveira

Tel +55 011 9971 3603

luizoliveirametsocom

After the pebbles are crushed into sand with the HP200 cone crusherdifferent grades are screened for various end uses

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Where therersquos a will we dig a wayAFCONS-Strabag and Metso embark on tunnel project together

When the joint venture AFCONS-Strabag initiated work on the Rohtang bypass tunnel project at an altitude of 3980 metersabove sea level in Himachal Pradesh India they deliberated each aspect with clockwork precision The project involved anumber of surprises and challenges and required technology and project management skills that were second to none

TEXT amp PHOTOS Monisha Majumdar

Cutting a 10-meter-wide and nearly 9-kilo-

meter-long tunnel through the Himalayas

in one of the toughest terrains and cli-mates in India makes for quite a challengeResults set out to find out how AFCONS-

Strabag and Metso are making their way in

one of their most critical projects to date

The only road connection to the north-Indian border region of the province

Himachal-Pradesh and beyond the Manali-

Leh highway leads across the Rohtang

pass Due to the heavy snowfall and high-

velocity winds in this region the towns

located north of the pass are cut off from

the rest of the country during winter for atleast four often even six months each year

A tunnel with strategic importance

With the construction of the tunnel at

3100 m above sea level the Manali-Lehhighway will become an all-weather road

thereby enabling a significant improve-

ment in the economic development of

northern Himachal-Pradesh and an alter-

nate route to the strategically important

Ladakh region

Manali south of the pass is an alreadywell-developed tourist location that is

becoming more and more popular Upon

completion of the tunnel it is likely that

tourist activities will extend to the areanorth of the pass Moreover the tunnel

shortens the distance between the towns

of Manali and Leh by approximately 45 km

thus saving several hours on the small dan-gerous pass road

The Rohtang pass in the Western Himalaya

region of Northern India with its altitude ofalmost four kilometers ranks among thehighest trafficable passes in the world

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983122983141983152983151983154983156983145983150983143 983154983141983155

The 88-km long horse-shoe-shaped

tunnel provides space for a two-lane8-m-wide carriageway as well as a one-

meter-wide footpath on both sides A

22-m-high and 36-m-wide emergency

tunnel will be integrated in the tun-

nel cross-section Altogether more than

800000 msup3 of rock will be moved Tunneling works started around spring

2010 with excavation driven from both por-

tals As the north portal is inaccessible dur-ing winter closure the excavation focused

on the south After a planned construction

period of 55 years the tunnel is scheduled

to be completed by the end of 2015

Best man for the job

The BRO (Border Road Organization)

wanted to roll out a global tender for theproject due to the challenges that such a

project involves and also considering thatitrsquos the first time in India that a project of

this scale was to be carried out This imme-

diately triggered the need to roll out aglobal tender All major Indian construction

companies bid for it some individually and

some in partnerships

Strabag an Austrian tunnel specialistwas one of the companies who bid for the

project along with AFCONS a Mumbai-

based infrastructure company In Septem-

ber 2009 AFCONS-Strabag was awardedthe contract

Mr Sunil Tyagi Deputy Project Man-ager at AFCONS had this to say about the

unique projectldquoThis project is located in the Himalayas

and as far as we understand the terrain

there is among the toughest We came out

with a new technology and to be honestit is a fairly simple one We would generally

start with the traditional technology of drill-

ing and blasting and then obtain our muck

feed from the inwardbottom of the tunnelrdquo

ldquoThe technology is supplied by Rowa Tunneling Logistics and this is the first

time it is being used in Asia A jaw crusheris placed at a distance of about 40-45

meters behind the face The blasted muckextracted from the face is fed to the crusher

to reduce the lump size and then through

an overhead conveyor transport system

it is then transported out of the tunnelrdquoldquoThis enables free movement of man

and machinery in the lower area or spe-

cifically on the ground area If we were to

conforms to the Indian standard for fines amp

coarse aggregates as prescribed in IS383-1970

The plant was up and running in good

condition and performing to AFCONSrsquos

satisfactionldquoWe have worked with Metso in earlier

projects and are quite impressed by thekind of technology amp services they provide

We have a history together so the trust fac-tor also comes inrdquo explains Dhiman on their

choice of Metso as a partner

Service makes the difference

ldquoMetsorsquos services have made a big dif-ference in the project Without them we

would still be struggling with the machin-

ery and production The service is really

good and the service engineers are knowl-edgeable prompt and quick to act Any

problem can be solved by Metso We donrsquothave to wait until a service engineer turns

up ndash they have the capacity to solve prob-lems over the phone as wellrdquo says Dhiman

ldquoThe Metso plant didnrsquot create any prob-

lems for us We had problems in logistics

the feed was sticky and the weather condi-tions were bad but thankfully we did not

face any problems with production and

efficiency as the Metso plant is performing

very wellrdquo Dhiman concludes

More info

Amol Sinha Tel +91 9811 671 924

amolsinhametsocom

use the old conventional technology this

wouldnrsquot have worked for us in the stipu-lated timerdquo Mr Tyagi adds

When the going gets tough

partner with the toughest

Sensitive projects require the best technol-

ogy After AFCONS-Strabag landed theproject Metso was an obvious choice as a

technology provider not only because of

the long-standing business relationshipbut also for the sheer consistency in prod-

uct quality and service deliverance Metso

strives for

ldquoAfter signing the project we faced alot of road blocks including extreme cold

avalanches roadblocks less oxygen ndash you

name it we faced itrdquo explains Ankit Dhi-

man Plant Manager at AFCONS-Strabag The Rohtang valley is known for its

notorious avalanches and landslides SoAFCONS had to take extra steps and safety

precautions against hazards on the site

ldquoIn this freezing cold not just us humansbut also the machines are at increased risk

of damage I remember when we used

to run the plant during winter the diesel

engines would freeze We had to constantlyheat up the fuel container to get the plant

running And even the sand in the sand

trap would freeze so we had to clean it on

a daily basis to stop the pipes from mal-functioningrdquo Dhiman adds

Plant designed for difficult terrain

Difficult terrain coupled with space con-straints led Metso engineers to put their

minds together to come up with a suitable

plant configuration After studying the

requirements of the project Metso sug-

gested a 150-tons-per-hour three-stagemodular plant using a C106 jaw crusher

a GP11F secondary cone crusher and a

B7150 tertiary vertical shaft impact crusher

In addition considering the unpredict-ability of the feed the plant was about

to reach a point where the amount offines to be handled could be increased

dramatically Metso strongly suggested the TK11-27-3V grizzly scalper and this became

the first-ever TK scalper to be supplied by

Metso to an Indian customer Also in order

to get better products a sand trap SF2360was added to the configuration

The sand trap is important equipment

for this project as it washes the sand thatMr Sunil Tyagi Deputy Project ManagerAFCONS-Strabag

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Smooth transition to new-generation jaw crusher in Germany

Roumlhrig is a German company with a rich heritage The company has been quarrying granite at its plant in Bergstrasse inthe Sonderbach district of Heppenheim for three generations

TEXT amp PHOTOS Ralf Goffin

Roumlhrigrsquos superior product variety is onereason why the companyrsquos proximity to its

customers can be understood in more than

just physical terms The companyrsquos high

level of innovation has allowed it to estab-lish itself as a reliable supplier of materials

both regionally and internationally This

operational and technical expertise always

manages to keep in step with growing

market requirements

In terms of technical processing equip-

ment Roumlhrig has used a Nordberg C160stationary jaw crusher from Metso since

1992 At the start of 2012 it was finally

exchanged for a more up-to-date version

from the same model range

Metsorsquos C Series is specifically designed

to pre-crush hard rock and can cope effort-

lessly with even the hardest of materials

The dimensions of the new stationary jawcrusher are identical to those of the old

one which means that it could simply be

slotted into the housing vacated by the

previous version

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983122983141983152983151983154983156983145983150983143 983154983141983155

Third-generation Managing DirectorMarco Roumlhrig expects the new machinersquos

service life to be just as long as the previ-

ous model due to the product upgrades

that have been implemented The integral motor base is another plus

point in models made by other manu-

facturers it is located outside the crusher

This element of good fortune ensured that

Roumlhrig could reuse the housing withoutany additional rebuilding

Another advantage lies in the revision

of the guards for the C160rsquos drivetrain andflywheel The sturdier construction method

used for the crusher requires fewer parts

which facilitates easier installation andmaintenance and it makes it simpler to

access the motor

Under the watchful eye of Metsorsquos

Assembly Manager Maik Engelstaumltterthe entire project including removal and

installation was successfully completed

within two weeks

Installation making the most

of the available space

Roumlhrig will likely remember the day the

new crusher was installed for a long time

the pitman and main frame were deliveredseparately prior to installation and assem-

bled on site It took just one hour to replace

the old stationary crusher with the new

model A lorry-mounted crane was used toposition the 85-ton crusher with millimeter

precision in the crushing plant Once the

new crusher had been positioned in theexisting steel structure the next task wasto fix it into place as securely as possible

despite the limited space Special vibration

dampers were installed at a height of two

meters to prevent the crusher from sliding

Norbert Ried (fourth from left) installed thenew C160rsquos predecessor 20 years ago and isdelighted at the durability of the powerfulcrusher that is now making way for a newermodel Also pictured from left to right ManagerVolker Angermann Assembly Manager Maik

Engelstaumltter Technical Manager Stefan

Koob Project Manager Dominic SchoumlnhardtManaging Director Marco Roumlhrig Service

Technician Stefan Kolze and employees ofthe installation company Stafemo

On the hook after theold C160 was liftedout by crane the newcrusher was installedin almost no timeOnly the roof of thehousing had to beremoved

sideways off its mount An initial test run

with materials was carried out around oneweek later after all the electrical cables had

been installed

Simultaneously with the installation

of the C160 which is the first of the latest

generation of crushers to be installed in

Germany a new Nordberg GP100 conecrusher was also being installed in Roumlhrigrsquos

chipping plant Roumlhrig is convinced that

the technical improvements made tothe new Metso crusher can only be an

advantage worldwide

Roumlhrig places great value on consistent

product quality maximum added valueand optimum refinement of its product

range Bearing in mind that Roumlhrig has

enough reserves of raw material to last

for the next 150 years the company canconfidently continue to develop with an

emphasis on quality rather than quantity

More info

Dominic Schoenhardt

Tel +49 (0)621 727 00 610

dominicschoenhardtmetsocom

8132019 Results Minerals Aggregates 3 2012ENG

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Groupe Charier Carriegravere de la Mariais France

Quarrying with certi1047297ed quality The Charier Group with its 1600-strong workforce is a family business thatthis year celebrates 115 years of quarrying The company pursues a long-termdevelopment policy that since 2007 has seen processing installations upgradedat 4 of its 9 extraction sites

TEXT Liliane Boutin (with extracts from Mines amp Carriegraveres and Terrassements amp Carriegraveres magazines)PHOTO Baloon photo

The processing installation is of the horizontal type with a primary station located 56 meters below the site access road to keep it hidden from view

The crushing and screening installation at

Charierrsquos CM La Mariais quarry (at Donges

on the Loire estuary) has been in opera-tion since September 2011 Based on theoperatorrsquos ideas it was designed by Metso

to replace a worn-out installation installed

right on top of the seam being extracted

Since its commissioning it has becomethe second quarry in the company to

receive ISO 14 001 certification

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155

tertiary material of sand and gravel for the

local market to use in concrete surfacingprefabrication etcrdquo

Incorporation of a screening station

The stone extracted from La Mariais is

according to the quarry granitic gneiss

sound and homogeneous with a LosAngeles index of 15 good wear resist-

ance with an MDE of 10 a true density of

265 and a certain abrasiveness (2000 gt)ldquoCharacteristically it has a tendency to form

blocksrdquo Leblin points out

The main criteria in designing the instal-

lation was to provide an output of 600000metric tons from one station (38 hours

week) to produce materials aimed at the

concrete and surfacing markets ldquowhich

involved providing a tertiary station withscreening plantrdquo he adds

With this new unit the operating com-pany expands its product range through

the addition of fine materials obtained

from the tertiary screening station This unitis capable of producing 170 tonshour of

020

Preserving the environment

and optimizing safety

The screens have motorized bogies and

retractable walkways to facilitate access

when the screens are opened for main-tenance Other walkways provide access

to the tunnel input feeders The feederscan be isolated with hydraulic rod gate

bars this hydraulic assistance eliminatesthe need to use a heavy hammer to lodge

these metal bars

All conveyors transporting fines (02

and 04) are covered with a tarpaulin to

avoid flying dust and all the screens arehooded (metal cover with Trellex seal-

ing) The Brunone company has installed

dust-tight containment at the outlet of the

tertiary station crushers (HP300 and HP4)on the belt located under the screens

and under the hoppers located belowthe tertiary screens The crushers are put

under negative pressure and the finesare extracted through sleeve filters (7000

m3 h) with declogging which deposits the

dust back onto the conveyor belt

A high-pressure 100 bar water mist sys-tem has been installed at the primary sta-

tion discharge at the secondary crusherrsquos

discharge chutes (Omnicone) and at the

transfer points on the belt

Designed to last

ldquoThis type of new installation can easily last

thirty yearsrdquo affirms Project Leader Bruno

Peix of Metso ldquoIt quite simply depends on

how well it is maintained Thatrsquos why weprovide maintenance contracts that call for

our technicians to make regular inspection

visits and carry out preventive mainte-nance and any necessary repairsrdquo

In 2011 Metso commissioned about

10 new processing units in France like

the one at La Mariais quarry

More info

Frederic Bazire

Tel +33 (0)681442804

fredericbaziremetsocom

Key figures

DURATION OF WORKS 15 months

DRAWING OFFICE TIME 7800 hours

HEIGHT OF SILOS AND GRINDER BUILDINGS

15 m

TOTAL LENGTH OF CONVEYORS 14 km

WEIGHT OF THE INSTALLATION

1200 metric tons

CONCRETE POURED 1800 cubic meters

PROJECT SITE WORKFORCE 30

INSTALLED POWER 2200 kW(not including pumps 200 kW)

METSO EQUIPMENT

Primary

Vibrating feeder PF561-2V

Primary grizzly VG540-3V

Grizzly feeder TK13-20-3V

Jaw crusher C145 with

hydraulic setting

Secondary

Vibrating screen CVB 2050

refurbished

Cone crusher Omnicocircne 1352 SX

with Metso IC7000 controller Ellivar 16 (16 msup2 3 decks) screen

refurbished by Metso

Tertiary

Cone crusher HP300

Cone crusher HP4

2 Ellivar 20 screens (20 m23 decks) for final products

Expanding the production range

ldquoSince the mid-1990s when we became

owners of La Mariais we had used mobilemachinery with an assembly of beltconveyorsrdquo recalls Daniel Leblin Charierrsquos

Technical Manager for site construction

and maintenance

ldquoIt became clear that we needed ahigher performance tool to achieve the

dual goals of reaching one million metric

tonsrsquo maximum production and producing

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Big Lokotrack LT550GPF boostsquarrying productivity by a thirdMaximizing the productivity of operations is a key issue when striving for cost-effective quarrying Big Lokotracks are oneway to achieve improved operational efficiency The Lokotrack LT550GPF equipped with the high-volume GP550 conecrusher and a large screen is popular in the Nordic countries and in Germany and Australia ndash countries all known for theirhigh quarrying volumes

TEXT amp PHOTOS Eero Haumlmaumllaumlinen

Kone-Kostamorsquos new mobile coneplant has reached an averagecapacity of 300 tons per hour

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155

ldquoWith the same number of employees we

can achieve 30 more productivity with

our new LT550GPF unit The high-capacityFS screen has also eliminated the bottle-neck often seen at fine screeningrdquo says

Aarno Kostamo Managing Director of

Kone-Kostamo Oy one of Finlandrsquos biggest

crushing contractorsAccording to Kostamo the high capacity

of the GP550 gyratory cone crusher easily

handles feed from the C120 and C125 jaw

crushers For the contract with the Talvivaara

nickel mine the LT550GPF is being fed bythe brand new Lokotrack LT120 jaw plant

Average capacity 300 tons per hour

Talvivaara Europersquos largest nickel mine uti-

lizes large quantities of aggregates Kone-Kostamo has contracted several million

tons of different end products for the mineIn August 75000 tons of 0ndash63 mm

road gravel was crushed Smaller amountsof finer 0ndash6 mm 0ndash16 mm and 0ndash32 mm

aggregates are also being produced

The rainy summer increased the need

for road gravel along the muddy roadswhich must endure dump trucks weighing

as much as 260 tons

ldquoThe mobile process consisting of the

LT120 jaw plant and LT550GPF cone plant

is cost-effective while aggregates of vari-ous sizes can be produced in a two-stage

operation and with high capacity The con-trolled stroke and elliptical movement of

the FS screen secure big passing throughcapacitiesrdquo Kostamo explains

Operated in two shifts for a total of 16

hours per day the LT550GPF has logged

more than 600 working hours over a two-month period

Managing Director Aarno Kostamo (left) and foreman Karri Maumlenpaumlauml studying the cavity optionsavailable for the new Lokotrack LT550GPF

Longer perspective than

a single quarter needed

Kone-Kostamo Oy was founded as an

earth-moving company in Kemijaumlrvi

Northern Finland in 1956 The company

expanded its operations to include crush-

ing contracting in 1964 and later on

switched to concentrating fully on crush-ing activities

Kone-Kostamo consistently crushes

and screens around 28 million tons ofaggregates annually and has net sales of

between EUR 8ndash9 million

ldquoWe believe that issues within the crush-

ing industry including the purchasing ofmachinery must be studied with a longer

perspective than a single quarter The

secret to our success has always been our

solid work ethic and professional employ-eesrdquo Kostamo sums up

More info

Esa Berg

Tel + 358 40 837 8692

esabergmetsocom

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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155

Monitoring-based reporting is vital for

assessing the performance of a mobile

crushing plant Metso provides suchreporting tools through its plant-wideautomation system Metso DNA (Dynamic

Network of Applications) with its infor-

mation platform that links all the mobile

crushing and screen units together as oneentity Basically there is a lot of measured

real-time information available in every

crushing plant On-line information is

obtained either from each Metso crusherrsquosmachine automation system IC (Intelligent

Controller) or from separately installed

additional sensors and belt scales

All the collected data is sent to a motorhome using wireless communication

based on WLAN technology The motor

home is a purpose-built environment

inside an on-site container In this environ-ment selected variables can be monitored

for assessing the plantrsquos performance And

to make all this even more flexible the

data can be transmitted to a crushing plant

company office using GPRS3G mobile

data communication technologies Thismakes all the last-minute reports acces-sible to the crushing plant managerial staff

at anytime and basically anywhere within

reach of the cell phone network

Production and fuel economics reports

Essentially monitoring and reporting can

be customized to fit the customerrsquos needs

However there are certain off-the-shelf

reports that provide a lot of useful informa-tion for plant supervision The production

report is one of these Requiring at least one

belt scale for measuring the total produc-tion the production report shows the pro-duction rate (tons per hour) for a selected

reporting period eg a day or a week The

production report constantly keeps track of

the plantrsquos production storing all the datathroughout the plantrsquos life cycle

Performance monitoring and reportingfor a mobile crushing plantTEXT Pasi Airikka PHOTOS Metso

unit during which the unit is running By

storing the availability times between start-ups and shutdowns the crushing plant

operation time (hours per dayshift) can be

recorded analyzed and reported In addi-

tion the availability report can be tailored

to evaluate efficient crushing hours during

which the plant is really working and pro-ducing aggregates Consequently the ratio

(0-100) between efficient crushing time

and total running time can be reported forany selected period of time This boosts

the efficiency of the plantrsquos operations

and results in better productivity

Reports on non-choke

or inadequate feeding

Non-choke feeding to crushers is avoid-

able through smart plant-wide crushingplant controls But estimating its severity in

a systematic manner is not straight-forwardwithout constant monitoring and reporting

The crusher choke feeding report makes

use of the crusher cavity level sensors byanalyzing their level measurements By

calculating average and min-max values

and deviations from the average it can be

shown how often the single crusher suffersfrom non-choke feeding to it

In some cases the bottleneck in the

crushing plantrsquos productivity is the material

feeding to the process In mobile plants thefeeding is human operated and therefore

subject to variations Occasionally the sizeof the human-operated machine simply

does not allow for adequate feeding to thecrushing plant There are specific reports

indicating time periods when the crushing

plant suffers from inadequate feeding

Condition monitoring for

crushers and screens

Machine-specific condition monitoring

focuses on vibrating components in

crushers and screens such as drive shaftbearings safety plate wearings and gears

The low middle and high frequencies ofmonitored components are measured and

supervised in real-time to detect abnor-malities due to slow or fast wear looseness

or imbalance

More info

Pasi Airikka

Tel +358 40 587 2730

pasiairikkametsocom

Condition monitoring provides a view tovibrating crusher and screen components forpredictive equipment maintenance

The daily production report shows the hour-by-hour production trend and distribution chartfor a selected day with min-max average andvariation statistics for comparison

Fuel consumption is always an interest-ing concern The fuel consumption reportgives the fuel consumption of each crush-

ing unit (liters per hour) and their total

consumption (liters per hour) for a selected

reporting period and can track fuel con-

sumption changes over timeCrushing plant availability can be

assessed as well The availability report

calculates time periods for each crushing

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983149983141983156983155983151 983150

for tissue machines The record of 2210

mmin was set on June 1 2012 during a

24-hour production run by the TM 2 tissue

machine at the companyrsquos mill in Yenikoumlynear the city of Izmit in Turkey

ldquoThe cooperation with Metso has been

beyond excellent and both parties did

their utmost to make the project success-ful The results clearly show that the efforts

were worthwhile on both sides This coop-

eration will extend to cover new projects

in the futurerdquo says Luumlt1047297 Aydin Paper GroupDirector Hayat Kimya

ldquoWe are not surprised that Hayat K imya

managed to break the world speed record

We have had great confidence in the capa-bility of the Hayat team since our project

started in 2009 We certainly know our

machine very well its stability production

efficiency and speed capabilityrdquo says Jan

Erikson Vice President Sales Metso

PowerThe worldrsquos first eco-gas fueled

power plant is up and running

Lahti Energy Ltdrsquos new Kymijaumlrvi II gasifica-

tion plant was officially inaugurated on

May 8 2012 It is the first of its kind in the

RecyclingRecycling with Lokotrack LT106

jaw plant in New York

A brand-new Lokotrack LT106 jaw plant is

used in the city area of New York USA to

recycle demolition materials The crushing

site faces the skyscrapers of ManhattanIsland

Paper amp FiberHayat Kimyarsquos Metso-supplied tissue

machine sets world speed record

Thanks to a skilled crew and dedicated

efforts Hayat Kimya AS in Turkey has suc-

ceeded in breaking the world speed record

world This CHP plant runs on clean eco-

gas that is gasified cleaned and cooled

from recycled waste with Metsorsquos innova-tive technology

ldquoItrsquos actually eco-gas that we combust

in the boilerrdquo comments Lahti EnergyrsquosProduction Director Jukka Manskinen

ldquoWe convert unwanted waste material into

energy in an efficient and environmentally

friendly wayrdquoNever before has any plant gasified

waste on such a large scale In the gasifier

recycled waste is turned into combustible

product gas which is cleaned cooled and

combusted in a high-efficiency gas boiler

to produce steam for the steam turbine The plant produces 50 MW of electricity

and 90 MW of district heat for the city of

Lahti and its neighboring areasMetso delivered the circulating fluidized

bed (CFB) gasification process gas cleaning

and cooling steam boiler environmental

protection system and automation systemto the entire plant The production of elec-

tricity and heat is kept even with the Metso

DNA automation system that covers the

whole plant starting from fuel reception

AutomationMetso develops and supplies plant-

wide crushing control solutions for

crushing plants

Metso has recently signed contracts on

delivering plant-wide automation systems

for mobile and portable rock crushing

plants The key objective of these deliveries

is to stabilize and to increase productivityand efficiency of the plants using one sin-

gle automation and information platform

for integrating crusher-specific IC machinecontrols

Furthermore the plant-wide system

with its information management tools not

only increases plant availability and opera-

tional safety it also makes troubleshoot-ing quicker and performance monitoring

easier The control room for plant-wide

operability is located either in an excavator

cabin or a purpose-built container

Metso around the world

The new LT106 jaw plant is suitable for crushing both hard rock and all rock-based demolition materials

The new world speed record for tissue setby Hayat Kimyarsquos Metso-supplied TM 2 is2210 mmin

8132019 Results Minerals Aggregates 3 2012ENG

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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: Results Minerals Aggregates 3 2012.ENG

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In the case of an equipment failure or

a planned service shutdown resuming

production as quickly as possible is crucialEach hour spent waiting for a spare part to

arrive equals money lost Whether the right

part takes 12 or 48 hours to arrive really

makes a difference

The comprehensive and global Metsospare and wear parts service network pro-

vides you with the right part in the right

place and at the right time Our strategi-

cally located Distribution Centers and

Satellite Warehouses are on call 24 hoursa day 7 days a week ensuring efficient

parts replacement near you

Check out the locations of the MetsoDistribution Centers and how many parts

pass through them each day

More info

Marcelo Farah

Tel +55 15 2102 1315

marcelofarahmetsocom

you minimize downtime

Australia (Perth)

746 d

China (Tianjin)

China (Kunming)

China (Shanghai)

393 d

India (Faridabad)

India (Ahmedabad)

India (Hyderabad)

India (Bhubaneswar)

India (Bangalore)

419 d

Russia (Yekaterinburg)

Australia (Newcastle)

New Zealand (Matamata)

983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088

TEXT Sofia Williams

Singapore (Singapore)

Distribution Center Satellite Warehouse

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Following a large investment

in Metso crushing equipmentand services Buena Vista del

Cobre is now expanding the

mine site to include even more

equipment ndash and with thatexpansion comes the need for

more local service resources

Metso and Buena Vista del

Cobre have entered into a Life

Cycle Service agreement forthe plant and construction of a

brand new Metso service hub

is under way in Cananea

New facility new

level of service

The Cananea service hub

which will be up and running in early 2013will support the recent expansion and resur-

gence of Buena Vista del Cobre Initially it

will be a major repair and assembly center

for pumps crushers and screens and will

provide for rubber covering capabilitiesBut the 8000-square-meter facilityrsquos service

offering will be expansive including a con-

signment stock inventory to help serve theminersquos varying needs Metso currently has

50 service team members on site

Although Buena Vista del Cobre was a

key influencer in building the new servicehub this location will also enable Metso to

expand its capabilities and provide local

support to the entire mining community

in northwest Mexico The Cananea hub

will serve a number of major copper and

gold mines in the region including MineraFriscorsquos San Felipe Fresnillorsquos Milpillas and

Grupo Mexicorsquos Mexicana de Cobre

ldquoBuena Vista del Cobre is the biggestcustomer we have in Mexico today and

with this expansion project itrsquos only going

to grow and be strongerrdquo says Felix Forna-

guera Director of Services Mexico CentralAmerica and Caribbean ldquoWith that said the

idea behind the Cananea service hub is to

provide a central location for local support

for all our major customers in the areardquo

Establishing safety

ldquoIt was key to have our support here in

Cananea because the Buena Vista delCobre started from the ground uprdquo saysFelix ldquoWersquove been able to help the cus-

tomer to establish the best in support

service and operations from the very

beginningrdquo And this ground-up approachincluded a major focus on safety

Metso worked closely with Buena Vista

del Cobre to establish the safety proto-

col by which the mine operates Basedon Metsorsquos expertise the safety measures

put in place have enabled the mine to

become strict and efficient in its operations

and maintenance procedures To achievethis Metso worked closely with local andnational authorities to ensure the safety

plan was comprehensive and in accord-

ance with all established legal bodies

The best in regional support

The service hub in Cananea is a prime

example of Metsorsquos focus on providing local

service and support to its customers all

Service shines in Cananea MexicoAfter three years of inactivity the Buena Vista del Cobre mine in Cananea Sonora Mexico has been operational since 2010A mine that was inactive for such a significant amount of time however requires a great deal of support to successfullyrestart the plant and bring it back to an operational and profitable state

TEXT Deanna Lee PHOTO Metso

over the world ldquoWe are the first

company developing this kindof service in northwest Mexicordquo

adds Felix ldquoOur people have

developed a close relationship

with the team at the mine Itrsquosmore than a supplier relation-

ship our guys are inside the

mine living and working thererdquo

In fact this is the model

that Metso is using in servicehubs all over the globe build-

ing modern facilities bringing

teams on site and workinghand in hand with mine

operators The Cananea Service

hub is only the most recent

example of Metsorsquos commit-ment to service and northwest Mexico is

yet another mining hotbed thatrsquos going to

benefit from the companyrsquos support

More info

Felix Fornaguera Tel +52 4621079227

felixfornaguerametsocom

A mining cone serviced by Metso at the Buena Vista del Cobre mine inSonora Mexico

ldquoThe new Cananea service center will be a majorrepair and assembly center for pumps crushersand screensrdquo says Felix Fornaguera Director ofServices Mexico Central America and Caribbean

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

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During the MINExpo exhibition over 1300 people visited the Metso stand

983122983141983152983151983154983156983145983150983143 983154983141983155

Held every four years MIN-Expo consistently grows so

perennial exhibitors like Metso

are challenged with elevating

their presence and drawingin new (and greater numbers

of ) visitors each year ldquoItrsquos not

necessarily a challenge to lsquotoprsquo

our last showingrdquo says Keith

Ference Vice President ofmarketing and communica-

tions North America ldquoThere

are four years between eachMINExpo so we always have

a lot to say and reveal to our

customersrdquo The real challenge

he says is finding an exciting

and dynamic way to deliverthe message ldquoTherersquos so much

to see here so your booth has

to be compelling from the

outside-in and thatrsquos what

we always try to dordquo

Service sets the stage

The Metso booth created buzzin a number of ways and per-

haps the most striking (partly

due to its size) was the live

theater presentation As visitorspassed through the aisles of the show-

room the sights and sounds from Metsorsquos

theater were hard to miss And once guests

entered they were captivated by a short

high-energy video presentation focused

on Metsorsquos service capabilities The message was simple Metso is ldquoyour

local service partner rdquo for all mining and

construction needs The video showed ourservice teams in action all over the world

and the audience came away with an

understanding about Metsorsquos commitment

to service Customers can count on morethan 70 local service centers run by more

than 1700 expert technicians delivering

Metso makes an impact at MINExpo 2012At this yearrsquos MINExpo International nearly 60000 attendees flocked to Las Vegas Nevada the largest turnout in showhistory The visitors ndash mining professionals from all over the globe ndash explored 850000 square feet of showroom spacefeaturing the industry rsquos latest technology equipment products and services They toured the show for three days

seeking the latest and greatest from more than 1800 exhibitorsTEXT Keith Ference PHOTOS Tracey Ford Perry

detailed descriptions andphotos of all of Metsorsquos mining

and construction products and

services The app also provides

digital access to Results and asearchable database of sales

contacts By day three of the

show MetsoMAP had been

downloaded by more than

500 usersIn addition to the app the

booth was equipped with

several LCD screens each con-trolled by Metso experts who

used their iPads to present new

products like the Megalinertrade

and the HRCtrade A featured

presentation on Metsorsquos lineupof energy-efficient comminu-

tion equipment including the

VERTIMILLreg SMD and MP-1250

cone crusher was also avail-

able letting customers seehow Metso technology delivers

some of the worldrsquos most effi-

cient size reduction

Measuring MINExpo success

After a very busy three days

(on top of months of prepara-tion leading up to the show) everyone

involved with MINExpo ndash from the North

American marketing team responsible for

the booth to the product managers and

sales force that worked the floor ndash is view-

ing the show as a success ldquoTherersquos alwaysa sigh of relief after each (MINExpo)rdquo says

Keith ldquoAnd overall the initial feedback

and response has been very positiverdquoWith more than 1300 visitors to the

booth Metso certainly made an impact

ldquoWe learn a lot from each show and with

some time wersquoll have a better understand-ing of the tangible results of our effortsrdquo

Keith adds

reliable service for mining equipment as

well as customized cost-effective life-cycle

services contracts

Technology ndash MetsoMAP

is an industry firstMINExpo provided the industry with its firstglimpse of Metsorsquos revolutionary iPad app

MetsoMAP The app was demoed to the

boothrsquos visitors via ldquothe worldrsquos largest iPadrdquo

a custom-made 80-inch screen that show-cased all of its capabilities most of which are

groundbreaking in the industry MetsoMAPrsquos

simple interface is highly intuitive making

it easy to view process animations videos

The presentation of the new HP cone crusher attracted a large audience

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When yoursquore allowed less than a dozen days per year for breakdowns repair andmaintenance every single hour during a service shutdown counts There simplyisnrsquot any room for surprises Thatrsquos why Boliden counts on MetsoTEXT amp PHOTOS Sofia Williams

8983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

Kurt Kalla Site Managerof Metso Gaumlllivare ServiceCenter is responsible forthe maintenance of Aitik

Metso and Boliden Strivingtogether for 97 uptime

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983122983141983152983151983154983156983145983150983143 983154983141983155

One of the biggest copper mines in

Europe Bolidenrsquos Aitik is located deep inthe wilderness of Swedish Lapland next to

the small town of Gaumlllivare The mine has

been operating since 1968 and a recent

expansion has increased its annual ore

production to 36 million tons

But the ambitious Swedes are not will-ing to lay back and relax just yet Bolidenrsquos

new aim is to reach a production rate of

45 million tons of ore per year in AitikAfter that Perhaps more than 55 million

tons The ore concentration in Aitik is very

low-grade with a mere 022 copper con-

tent hence the need for high capacityAchieving the ambitious production

goal requires maximum plant availability

This means that everything from the crush-

ers to the filters must be up and runningfor approximately 97 percent of the time

Thatrsquos where Metso comes into play

A cost-per-ton contract in action

The maximum uptime requirement allowsless than a dozen days per year for break-

downs repair and maintenance at Aitik

Every single hour during a service shut-

down counts There simply isnrsquot any roomfor surprises

Executing a successful shutdown under

such conditions requires a reliable service

partner not afraid of challenges and this iswhy Boliden has entrusted Aitikrsquos services

operations to Metso Boliden and Metsohave worked together since the 1960s

and the collaboration took another step

forward in September 2012 when the twocompanies signed a three-year extension

of the services contract for Boliden Aitik

ldquoThe new contract is a cost-per-ton

agreement We get paid based on Aitikrsquos

production Itrsquos a win-win deal for both par-

ties but also a new mindset for usrdquo explainsKurt Kalla Site Manager of Metso Gaumlllivare

Service Center responsible for serving Aitik

From now on the duration of the shut-down is what matters the most According

to Kalla the Metso service organization in

Gaumlllivare is now streamlining its operations

to fit the bill and has already witnessed thestrategy working In August 2012 Metso

carried out a 188-hour service shutdown in

Aitik which turned out to be a success

Zero tolerance for injury

One key factor to the success was theextensive planning of precautionary health

safety and environment procedures under-

taken by Metso prior to the shutdown Thanks to strict measures applied no

injuries or accidents occurred during the

shutdown and the work could easily be

finished on scheduleMats Johansson Health Safety

and Environment Manager for Metso in

Sweden explains how this was achieved

rdquoPlanning of the shutdown included arisk analysis for all new tasks participating

in Bolidenrsquos safety coordination meetingsmeeting with both Metso supervisors and

subcontractor supervisors and finally a

meeting with the entire staff participating

in the shutdown where everyone had to

sign a document stating their commitmentto the information providedrdquo he says

During the actual shutdown plenty of

new barriers signs and awareness cones

were put in place as a result of observa-tions from previous audits and safety plans

and risk analyses were readily available

in the work area Metso and Boliden also

introduced a Mill Inching permit a certifi-cate for completing a mandatory course for

those involved in the process In addition

Metso carried out random safety audits

during the shutdown to make sure thestrict policy was followed

According to Boliden Metsorsquos way of

working is a good example of how health

and safety precautions should be handled

ldquoMetso is a good example of how towork with safety and health plans risk

analysis permits and welding permits

Their table with all binders in the second-

ary mill area was exemplaryrdquo says Kjell-Arne

Johansson a technician from Boliden

The use of the new Metso Megalinertrade

system in the lining of Aitikrsquos Metso AG

mills has also improved the safety of main-tenance staff The Metso Megalinertrade con-

sists of larger-than-average liners bolted

in position from outside the mill Mainte-

nance technicians no longer need to go

inside the mill and stand in the dangerousdrop-zone of the liners gt

Boliden aims to reach a production rate of 45 million tons of ore per yearin the Aitik mine site

ldquoA complete risk analysis was conducted during the planningof the shutdownrdquo comments Mats Johansson Health Safetyand Environment Manager for Metso in Sweden

8132019 Results Minerals Aggregates 3 2012ENG

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Service the Metso way

24 hours a day 365 days a year

In addition to paying close attention to

health and safety issues executing an effi-

cient shutdown requires careful planning

and timing of every step in the mainte-

nance process Wear and spare parts have

to be available on time and a repair shoplarge enough to accommodate equipment

located close by

ldquoTo keep maintenance breaks as short

as possible we aim to replace the pump on

site and bring the old one for repair to our

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

nearby facilities This method gives us the

peace to do a good job and keep the cus-

tomerrsquos operations runningrdquo Kalla describes

the Metso way of handling Aitikrsquos pump

maintenance

Metso is currently expanding its Gaumllli-

vare service center to include a distribu-

tion center for wear and spare parts andalso concentrating its previously scattered

operations under one roof in its Vuoskon-

jaumlrvivaumlgen facility The expansion is due to

be completed by 2014

Metso equipment

delivered to Aitik36

bull 2 AG mills diameter 116 x

137 m gearless 22-MW motor

bull 2 Pebble mills diameter 91 x

113m dual 5-MW pinion drive

bull 3 VPA pressure filters VPA 1540-54

bull 12 sample pumps and pipes

VF50

bull 60 Various slurry pumps up to

MR500 modelbull Appr 5000 m rubber-lined slurry

pipes up to 600 mm diameter

bull Appr 5000 m rubber-lined by

gravity pipes up to 600 mm

diameter

bull Appr 5000 m rubber hoses

up to 600 mm diameter

Not only does the expansion make ser-

vice shutdowns at Aitik run more smoothly

it guarantees a more comprehensive

on-call emergency service response in the

region ndash thanks to the spare and wear parts

inventory available 24 hours a day 365

days a year

More info

Lars Rosenling

Tel +46 70 107 45 90

larsrosenlingmetsocom

Metso grinding equipment dominates the view in the concentrator

Safety on site is made up of small things like

making sure that everyone remembers to secure

the hoses in place

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Pebbles have always been a

challenge for producers of sandsince they cannot be returned

to rivers after extraction For

decades the processing of this

material resulted in a huge

environmental liability with alarge amount of pebbles hav-

ing to be stored away and left

unused

Transforming problems into

business opportunities

Areia amp Cia (areia = sand) has

operated in this market forover 20 years and decided to

enlist the help of Metso to find

a profitable solution for the

processing of pebbles

In July 2011 analyses werebegun to assess the abrasive-

ness and crushability of the

material Four alternatives wereidentified for processing and

transforming pebbles into sand

Initially Areia amp Cia was

interested in acquiring an

impactor for its reason-able price level However the

customer wanted to process

all the pebbles that were col-

lected daily in addition to some of the

material that it had stored In weighing theresults expected by the customer and the

excessive abrasiveness of the material the

HP200 cone crusher was decided on as thebest alternative

Areia amp Cia made the required invest-

ment and after using the HP200 for just

six months the company has already beenreporting outstanding results The HP200

not only transforms pebbles into sand but

also produces sand of excellent quality

with high yield and low maintenanceWith minor adjustments the HP200

also enables the production of sand withspecific particle size distribution for special

applications such as filtering sand blasting

and foundry sand adding value to the prod-

uct and increasing the types of sand offeredldquoMetso is pleased that the HP200 not

only enabled the processing of a product

that had been set aside as unusable but

HP200 cone transforms pebblesinto high-quality sandOver the last few decades Brazilian economic growth has been driving demand for construction aggregates The market

for sand in turn has been experiencing major difficulties in maintaining a consistent supply Presently one of the mainchallenges the industry faces is the large amount of pebbles that are obtained in the process of extracting sand at timesconstituting nearly 50 of the volume of material dredged from riverbeds

TEXT Sheila Ivers PHOTO Areia amp Cia

also that it opened up new

market opportunities for Areiaamp Cia Thatrsquos the standard we

seek to deliver to our custom-

ersrdquo states Luiz Oliveira Techni-

cal Salesperson of Metso Brazil

HP cones entering the

Brazilian sand-making

market

Todayrsquos cones such as theHP200 have high resistance

to impacts and abrasiveness

more efficient crushing cham-

bers low maintenance costsand excellent productivity

Following the acquisition of

the HP200 Areia amp Cia is now

also producing special sands

that command a price that is100 higher than common

sand The entire stockpile of

pebbles accumulated through-out the companyrsquos 20 years of

operations has already been

transformed into sand and the

stock of pebbles held by com-

petitors is also being purchasedfor processing

Cristiane Brizolari the

owner of Areia amp Cia confirms

the transformation that has taken place in

the production and commercial processldquoThe HP200 opened up new niches in

the market enabling the production of dif-

ferent types of sand with added valuerdquo

More info

Luiz Oliveira

Tel +55 011 9971 3603

luizoliveirametsocom

After the pebbles are crushed into sand with the HP200 cone crusherdifferent grades are screened for various end uses

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Where therersquos a will we dig a wayAFCONS-Strabag and Metso embark on tunnel project together

When the joint venture AFCONS-Strabag initiated work on the Rohtang bypass tunnel project at an altitude of 3980 metersabove sea level in Himachal Pradesh India they deliberated each aspect with clockwork precision The project involved anumber of surprises and challenges and required technology and project management skills that were second to none

TEXT amp PHOTOS Monisha Majumdar

Cutting a 10-meter-wide and nearly 9-kilo-

meter-long tunnel through the Himalayas

in one of the toughest terrains and cli-mates in India makes for quite a challengeResults set out to find out how AFCONS-

Strabag and Metso are making their way in

one of their most critical projects to date

The only road connection to the north-Indian border region of the province

Himachal-Pradesh and beyond the Manali-

Leh highway leads across the Rohtang

pass Due to the heavy snowfall and high-

velocity winds in this region the towns

located north of the pass are cut off from

the rest of the country during winter for atleast four often even six months each year

A tunnel with strategic importance

With the construction of the tunnel at

3100 m above sea level the Manali-Lehhighway will become an all-weather road

thereby enabling a significant improve-

ment in the economic development of

northern Himachal-Pradesh and an alter-

nate route to the strategically important

Ladakh region

Manali south of the pass is an alreadywell-developed tourist location that is

becoming more and more popular Upon

completion of the tunnel it is likely that

tourist activities will extend to the areanorth of the pass Moreover the tunnel

shortens the distance between the towns

of Manali and Leh by approximately 45 km

thus saving several hours on the small dan-gerous pass road

The Rohtang pass in the Western Himalaya

region of Northern India with its altitude ofalmost four kilometers ranks among thehighest trafficable passes in the world

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983122983141983152983151983154983156983145983150983143 983154983141983155

The 88-km long horse-shoe-shaped

tunnel provides space for a two-lane8-m-wide carriageway as well as a one-

meter-wide footpath on both sides A

22-m-high and 36-m-wide emergency

tunnel will be integrated in the tun-

nel cross-section Altogether more than

800000 msup3 of rock will be moved Tunneling works started around spring

2010 with excavation driven from both por-

tals As the north portal is inaccessible dur-ing winter closure the excavation focused

on the south After a planned construction

period of 55 years the tunnel is scheduled

to be completed by the end of 2015

Best man for the job

The BRO (Border Road Organization)

wanted to roll out a global tender for theproject due to the challenges that such a

project involves and also considering thatitrsquos the first time in India that a project of

this scale was to be carried out This imme-

diately triggered the need to roll out aglobal tender All major Indian construction

companies bid for it some individually and

some in partnerships

Strabag an Austrian tunnel specialistwas one of the companies who bid for the

project along with AFCONS a Mumbai-

based infrastructure company In Septem-

ber 2009 AFCONS-Strabag was awardedthe contract

Mr Sunil Tyagi Deputy Project Man-ager at AFCONS had this to say about the

unique projectldquoThis project is located in the Himalayas

and as far as we understand the terrain

there is among the toughest We came out

with a new technology and to be honestit is a fairly simple one We would generally

start with the traditional technology of drill-

ing and blasting and then obtain our muck

feed from the inwardbottom of the tunnelrdquo

ldquoThe technology is supplied by Rowa Tunneling Logistics and this is the first

time it is being used in Asia A jaw crusheris placed at a distance of about 40-45

meters behind the face The blasted muckextracted from the face is fed to the crusher

to reduce the lump size and then through

an overhead conveyor transport system

it is then transported out of the tunnelrdquoldquoThis enables free movement of man

and machinery in the lower area or spe-

cifically on the ground area If we were to

conforms to the Indian standard for fines amp

coarse aggregates as prescribed in IS383-1970

The plant was up and running in good

condition and performing to AFCONSrsquos

satisfactionldquoWe have worked with Metso in earlier

projects and are quite impressed by thekind of technology amp services they provide

We have a history together so the trust fac-tor also comes inrdquo explains Dhiman on their

choice of Metso as a partner

Service makes the difference

ldquoMetsorsquos services have made a big dif-ference in the project Without them we

would still be struggling with the machin-

ery and production The service is really

good and the service engineers are knowl-edgeable prompt and quick to act Any

problem can be solved by Metso We donrsquothave to wait until a service engineer turns

up ndash they have the capacity to solve prob-lems over the phone as wellrdquo says Dhiman

ldquoThe Metso plant didnrsquot create any prob-

lems for us We had problems in logistics

the feed was sticky and the weather condi-tions were bad but thankfully we did not

face any problems with production and

efficiency as the Metso plant is performing

very wellrdquo Dhiman concludes

More info

Amol Sinha Tel +91 9811 671 924

amolsinhametsocom

use the old conventional technology this

wouldnrsquot have worked for us in the stipu-lated timerdquo Mr Tyagi adds

When the going gets tough

partner with the toughest

Sensitive projects require the best technol-

ogy After AFCONS-Strabag landed theproject Metso was an obvious choice as a

technology provider not only because of

the long-standing business relationshipbut also for the sheer consistency in prod-

uct quality and service deliverance Metso

strives for

ldquoAfter signing the project we faced alot of road blocks including extreme cold

avalanches roadblocks less oxygen ndash you

name it we faced itrdquo explains Ankit Dhi-

man Plant Manager at AFCONS-Strabag The Rohtang valley is known for its

notorious avalanches and landslides SoAFCONS had to take extra steps and safety

precautions against hazards on the site

ldquoIn this freezing cold not just us humansbut also the machines are at increased risk

of damage I remember when we used

to run the plant during winter the diesel

engines would freeze We had to constantlyheat up the fuel container to get the plant

running And even the sand in the sand

trap would freeze so we had to clean it on

a daily basis to stop the pipes from mal-functioningrdquo Dhiman adds

Plant designed for difficult terrain

Difficult terrain coupled with space con-straints led Metso engineers to put their

minds together to come up with a suitable

plant configuration After studying the

requirements of the project Metso sug-

gested a 150-tons-per-hour three-stagemodular plant using a C106 jaw crusher

a GP11F secondary cone crusher and a

B7150 tertiary vertical shaft impact crusher

In addition considering the unpredict-ability of the feed the plant was about

to reach a point where the amount offines to be handled could be increased

dramatically Metso strongly suggested the TK11-27-3V grizzly scalper and this became

the first-ever TK scalper to be supplied by

Metso to an Indian customer Also in order

to get better products a sand trap SF2360was added to the configuration

The sand trap is important equipment

for this project as it washes the sand thatMr Sunil Tyagi Deputy Project ManagerAFCONS-Strabag

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Smooth transition to new-generation jaw crusher in Germany

Roumlhrig is a German company with a rich heritage The company has been quarrying granite at its plant in Bergstrasse inthe Sonderbach district of Heppenheim for three generations

TEXT amp PHOTOS Ralf Goffin

Roumlhrigrsquos superior product variety is onereason why the companyrsquos proximity to its

customers can be understood in more than

just physical terms The companyrsquos high

level of innovation has allowed it to estab-lish itself as a reliable supplier of materials

both regionally and internationally This

operational and technical expertise always

manages to keep in step with growing

market requirements

In terms of technical processing equip-

ment Roumlhrig has used a Nordberg C160stationary jaw crusher from Metso since

1992 At the start of 2012 it was finally

exchanged for a more up-to-date version

from the same model range

Metsorsquos C Series is specifically designed

to pre-crush hard rock and can cope effort-

lessly with even the hardest of materials

The dimensions of the new stationary jawcrusher are identical to those of the old

one which means that it could simply be

slotted into the housing vacated by the

previous version

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983122983141983152983151983154983156983145983150983143 983154983141983155

Third-generation Managing DirectorMarco Roumlhrig expects the new machinersquos

service life to be just as long as the previ-

ous model due to the product upgrades

that have been implemented The integral motor base is another plus

point in models made by other manu-

facturers it is located outside the crusher

This element of good fortune ensured that

Roumlhrig could reuse the housing withoutany additional rebuilding

Another advantage lies in the revision

of the guards for the C160rsquos drivetrain andflywheel The sturdier construction method

used for the crusher requires fewer parts

which facilitates easier installation andmaintenance and it makes it simpler to

access the motor

Under the watchful eye of Metsorsquos

Assembly Manager Maik Engelstaumltterthe entire project including removal and

installation was successfully completed

within two weeks

Installation making the most

of the available space

Roumlhrig will likely remember the day the

new crusher was installed for a long time

the pitman and main frame were deliveredseparately prior to installation and assem-

bled on site It took just one hour to replace

the old stationary crusher with the new

model A lorry-mounted crane was used toposition the 85-ton crusher with millimeter

precision in the crushing plant Once the

new crusher had been positioned in theexisting steel structure the next task wasto fix it into place as securely as possible

despite the limited space Special vibration

dampers were installed at a height of two

meters to prevent the crusher from sliding

Norbert Ried (fourth from left) installed thenew C160rsquos predecessor 20 years ago and isdelighted at the durability of the powerfulcrusher that is now making way for a newermodel Also pictured from left to right ManagerVolker Angermann Assembly Manager Maik

Engelstaumltter Technical Manager Stefan

Koob Project Manager Dominic SchoumlnhardtManaging Director Marco Roumlhrig Service

Technician Stefan Kolze and employees ofthe installation company Stafemo

On the hook after theold C160 was liftedout by crane the newcrusher was installedin almost no timeOnly the roof of thehousing had to beremoved

sideways off its mount An initial test run

with materials was carried out around oneweek later after all the electrical cables had

been installed

Simultaneously with the installation

of the C160 which is the first of the latest

generation of crushers to be installed in

Germany a new Nordberg GP100 conecrusher was also being installed in Roumlhrigrsquos

chipping plant Roumlhrig is convinced that

the technical improvements made tothe new Metso crusher can only be an

advantage worldwide

Roumlhrig places great value on consistent

product quality maximum added valueand optimum refinement of its product

range Bearing in mind that Roumlhrig has

enough reserves of raw material to last

for the next 150 years the company canconfidently continue to develop with an

emphasis on quality rather than quantity

More info

Dominic Schoenhardt

Tel +49 (0)621 727 00 610

dominicschoenhardtmetsocom

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Groupe Charier Carriegravere de la Mariais France

Quarrying with certi1047297ed quality The Charier Group with its 1600-strong workforce is a family business thatthis year celebrates 115 years of quarrying The company pursues a long-termdevelopment policy that since 2007 has seen processing installations upgradedat 4 of its 9 extraction sites

TEXT Liliane Boutin (with extracts from Mines amp Carriegraveres and Terrassements amp Carriegraveres magazines)PHOTO Baloon photo

The processing installation is of the horizontal type with a primary station located 56 meters below the site access road to keep it hidden from view

The crushing and screening installation at

Charierrsquos CM La Mariais quarry (at Donges

on the Loire estuary) has been in opera-tion since September 2011 Based on theoperatorrsquos ideas it was designed by Metso

to replace a worn-out installation installed

right on top of the seam being extracted

Since its commissioning it has becomethe second quarry in the company to

receive ISO 14 001 certification

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983122983141983152983151983154983156983145983150983143 983154983141983155

tertiary material of sand and gravel for the

local market to use in concrete surfacingprefabrication etcrdquo

Incorporation of a screening station

The stone extracted from La Mariais is

according to the quarry granitic gneiss

sound and homogeneous with a LosAngeles index of 15 good wear resist-

ance with an MDE of 10 a true density of

265 and a certain abrasiveness (2000 gt)ldquoCharacteristically it has a tendency to form

blocksrdquo Leblin points out

The main criteria in designing the instal-

lation was to provide an output of 600000metric tons from one station (38 hours

week) to produce materials aimed at the

concrete and surfacing markets ldquowhich

involved providing a tertiary station withscreening plantrdquo he adds

With this new unit the operating com-pany expands its product range through

the addition of fine materials obtained

from the tertiary screening station This unitis capable of producing 170 tonshour of

020

Preserving the environment

and optimizing safety

The screens have motorized bogies and

retractable walkways to facilitate access

when the screens are opened for main-tenance Other walkways provide access

to the tunnel input feeders The feederscan be isolated with hydraulic rod gate

bars this hydraulic assistance eliminatesthe need to use a heavy hammer to lodge

these metal bars

All conveyors transporting fines (02

and 04) are covered with a tarpaulin to

avoid flying dust and all the screens arehooded (metal cover with Trellex seal-

ing) The Brunone company has installed

dust-tight containment at the outlet of the

tertiary station crushers (HP300 and HP4)on the belt located under the screens

and under the hoppers located belowthe tertiary screens The crushers are put

under negative pressure and the finesare extracted through sleeve filters (7000

m3 h) with declogging which deposits the

dust back onto the conveyor belt

A high-pressure 100 bar water mist sys-tem has been installed at the primary sta-

tion discharge at the secondary crusherrsquos

discharge chutes (Omnicone) and at the

transfer points on the belt

Designed to last

ldquoThis type of new installation can easily last

thirty yearsrdquo affirms Project Leader Bruno

Peix of Metso ldquoIt quite simply depends on

how well it is maintained Thatrsquos why weprovide maintenance contracts that call for

our technicians to make regular inspection

visits and carry out preventive mainte-nance and any necessary repairsrdquo

In 2011 Metso commissioned about

10 new processing units in France like

the one at La Mariais quarry

More info

Frederic Bazire

Tel +33 (0)681442804

fredericbaziremetsocom

Key figures

DURATION OF WORKS 15 months

DRAWING OFFICE TIME 7800 hours

HEIGHT OF SILOS AND GRINDER BUILDINGS

15 m

TOTAL LENGTH OF CONVEYORS 14 km

WEIGHT OF THE INSTALLATION

1200 metric tons

CONCRETE POURED 1800 cubic meters

PROJECT SITE WORKFORCE 30

INSTALLED POWER 2200 kW(not including pumps 200 kW)

METSO EQUIPMENT

Primary

Vibrating feeder PF561-2V

Primary grizzly VG540-3V

Grizzly feeder TK13-20-3V

Jaw crusher C145 with

hydraulic setting

Secondary

Vibrating screen CVB 2050

refurbished

Cone crusher Omnicocircne 1352 SX

with Metso IC7000 controller Ellivar 16 (16 msup2 3 decks) screen

refurbished by Metso

Tertiary

Cone crusher HP300

Cone crusher HP4

2 Ellivar 20 screens (20 m23 decks) for final products

Expanding the production range

ldquoSince the mid-1990s when we became

owners of La Mariais we had used mobilemachinery with an assembly of beltconveyorsrdquo recalls Daniel Leblin Charierrsquos

Technical Manager for site construction

and maintenance

ldquoIt became clear that we needed ahigher performance tool to achieve the

dual goals of reaching one million metric

tonsrsquo maximum production and producing

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Big Lokotrack LT550GPF boostsquarrying productivity by a thirdMaximizing the productivity of operations is a key issue when striving for cost-effective quarrying Big Lokotracks are oneway to achieve improved operational efficiency The Lokotrack LT550GPF equipped with the high-volume GP550 conecrusher and a large screen is popular in the Nordic countries and in Germany and Australia ndash countries all known for theirhigh quarrying volumes

TEXT amp PHOTOS Eero Haumlmaumllaumlinen

Kone-Kostamorsquos new mobile coneplant has reached an averagecapacity of 300 tons per hour

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155

ldquoWith the same number of employees we

can achieve 30 more productivity with

our new LT550GPF unit The high-capacityFS screen has also eliminated the bottle-neck often seen at fine screeningrdquo says

Aarno Kostamo Managing Director of

Kone-Kostamo Oy one of Finlandrsquos biggest

crushing contractorsAccording to Kostamo the high capacity

of the GP550 gyratory cone crusher easily

handles feed from the C120 and C125 jaw

crushers For the contract with the Talvivaara

nickel mine the LT550GPF is being fed bythe brand new Lokotrack LT120 jaw plant

Average capacity 300 tons per hour

Talvivaara Europersquos largest nickel mine uti-

lizes large quantities of aggregates Kone-Kostamo has contracted several million

tons of different end products for the mineIn August 75000 tons of 0ndash63 mm

road gravel was crushed Smaller amountsof finer 0ndash6 mm 0ndash16 mm and 0ndash32 mm

aggregates are also being produced

The rainy summer increased the need

for road gravel along the muddy roadswhich must endure dump trucks weighing

as much as 260 tons

ldquoThe mobile process consisting of the

LT120 jaw plant and LT550GPF cone plant

is cost-effective while aggregates of vari-ous sizes can be produced in a two-stage

operation and with high capacity The con-trolled stroke and elliptical movement of

the FS screen secure big passing throughcapacitiesrdquo Kostamo explains

Operated in two shifts for a total of 16

hours per day the LT550GPF has logged

more than 600 working hours over a two-month period

Managing Director Aarno Kostamo (left) and foreman Karri Maumlenpaumlauml studying the cavity optionsavailable for the new Lokotrack LT550GPF

Longer perspective than

a single quarter needed

Kone-Kostamo Oy was founded as an

earth-moving company in Kemijaumlrvi

Northern Finland in 1956 The company

expanded its operations to include crush-

ing contracting in 1964 and later on

switched to concentrating fully on crush-ing activities

Kone-Kostamo consistently crushes

and screens around 28 million tons ofaggregates annually and has net sales of

between EUR 8ndash9 million

ldquoWe believe that issues within the crush-

ing industry including the purchasing ofmachinery must be studied with a longer

perspective than a single quarter The

secret to our success has always been our

solid work ethic and professional employ-eesrdquo Kostamo sums up

More info

Esa Berg

Tel + 358 40 837 8692

esabergmetsocom

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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155

Monitoring-based reporting is vital for

assessing the performance of a mobile

crushing plant Metso provides suchreporting tools through its plant-wideautomation system Metso DNA (Dynamic

Network of Applications) with its infor-

mation platform that links all the mobile

crushing and screen units together as oneentity Basically there is a lot of measured

real-time information available in every

crushing plant On-line information is

obtained either from each Metso crusherrsquosmachine automation system IC (Intelligent

Controller) or from separately installed

additional sensors and belt scales

All the collected data is sent to a motorhome using wireless communication

based on WLAN technology The motor

home is a purpose-built environment

inside an on-site container In this environ-ment selected variables can be monitored

for assessing the plantrsquos performance And

to make all this even more flexible the

data can be transmitted to a crushing plant

company office using GPRS3G mobile

data communication technologies Thismakes all the last-minute reports acces-sible to the crushing plant managerial staff

at anytime and basically anywhere within

reach of the cell phone network

Production and fuel economics reports

Essentially monitoring and reporting can

be customized to fit the customerrsquos needs

However there are certain off-the-shelf

reports that provide a lot of useful informa-tion for plant supervision The production

report is one of these Requiring at least one

belt scale for measuring the total produc-tion the production report shows the pro-duction rate (tons per hour) for a selected

reporting period eg a day or a week The

production report constantly keeps track of

the plantrsquos production storing all the datathroughout the plantrsquos life cycle

Performance monitoring and reportingfor a mobile crushing plantTEXT Pasi Airikka PHOTOS Metso

unit during which the unit is running By

storing the availability times between start-ups and shutdowns the crushing plant

operation time (hours per dayshift) can be

recorded analyzed and reported In addi-

tion the availability report can be tailored

to evaluate efficient crushing hours during

which the plant is really working and pro-ducing aggregates Consequently the ratio

(0-100) between efficient crushing time

and total running time can be reported forany selected period of time This boosts

the efficiency of the plantrsquos operations

and results in better productivity

Reports on non-choke

or inadequate feeding

Non-choke feeding to crushers is avoid-

able through smart plant-wide crushingplant controls But estimating its severity in

a systematic manner is not straight-forwardwithout constant monitoring and reporting

The crusher choke feeding report makes

use of the crusher cavity level sensors byanalyzing their level measurements By

calculating average and min-max values

and deviations from the average it can be

shown how often the single crusher suffersfrom non-choke feeding to it

In some cases the bottleneck in the

crushing plantrsquos productivity is the material

feeding to the process In mobile plants thefeeding is human operated and therefore

subject to variations Occasionally the sizeof the human-operated machine simply

does not allow for adequate feeding to thecrushing plant There are specific reports

indicating time periods when the crushing

plant suffers from inadequate feeding

Condition monitoring for

crushers and screens

Machine-specific condition monitoring

focuses on vibrating components in

crushers and screens such as drive shaftbearings safety plate wearings and gears

The low middle and high frequencies ofmonitored components are measured and

supervised in real-time to detect abnor-malities due to slow or fast wear looseness

or imbalance

More info

Pasi Airikka

Tel +358 40 587 2730

pasiairikkametsocom

Condition monitoring provides a view tovibrating crusher and screen components forpredictive equipment maintenance

The daily production report shows the hour-by-hour production trend and distribution chartfor a selected day with min-max average andvariation statistics for comparison

Fuel consumption is always an interest-ing concern The fuel consumption reportgives the fuel consumption of each crush-

ing unit (liters per hour) and their total

consumption (liters per hour) for a selected

reporting period and can track fuel con-

sumption changes over timeCrushing plant availability can be

assessed as well The availability report

calculates time periods for each crushing

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983149983141983156983155983151 983150

for tissue machines The record of 2210

mmin was set on June 1 2012 during a

24-hour production run by the TM 2 tissue

machine at the companyrsquos mill in Yenikoumlynear the city of Izmit in Turkey

ldquoThe cooperation with Metso has been

beyond excellent and both parties did

their utmost to make the project success-ful The results clearly show that the efforts

were worthwhile on both sides This coop-

eration will extend to cover new projects

in the futurerdquo says Luumlt1047297 Aydin Paper GroupDirector Hayat Kimya

ldquoWe are not surprised that Hayat K imya

managed to break the world speed record

We have had great confidence in the capa-bility of the Hayat team since our project

started in 2009 We certainly know our

machine very well its stability production

efficiency and speed capabilityrdquo says Jan

Erikson Vice President Sales Metso

PowerThe worldrsquos first eco-gas fueled

power plant is up and running

Lahti Energy Ltdrsquos new Kymijaumlrvi II gasifica-

tion plant was officially inaugurated on

May 8 2012 It is the first of its kind in the

RecyclingRecycling with Lokotrack LT106

jaw plant in New York

A brand-new Lokotrack LT106 jaw plant is

used in the city area of New York USA to

recycle demolition materials The crushing

site faces the skyscrapers of ManhattanIsland

Paper amp FiberHayat Kimyarsquos Metso-supplied tissue

machine sets world speed record

Thanks to a skilled crew and dedicated

efforts Hayat Kimya AS in Turkey has suc-

ceeded in breaking the world speed record

world This CHP plant runs on clean eco-

gas that is gasified cleaned and cooled

from recycled waste with Metsorsquos innova-tive technology

ldquoItrsquos actually eco-gas that we combust

in the boilerrdquo comments Lahti EnergyrsquosProduction Director Jukka Manskinen

ldquoWe convert unwanted waste material into

energy in an efficient and environmentally

friendly wayrdquoNever before has any plant gasified

waste on such a large scale In the gasifier

recycled waste is turned into combustible

product gas which is cleaned cooled and

combusted in a high-efficiency gas boiler

to produce steam for the steam turbine The plant produces 50 MW of electricity

and 90 MW of district heat for the city of

Lahti and its neighboring areasMetso delivered the circulating fluidized

bed (CFB) gasification process gas cleaning

and cooling steam boiler environmental

protection system and automation systemto the entire plant The production of elec-

tricity and heat is kept even with the Metso

DNA automation system that covers the

whole plant starting from fuel reception

AutomationMetso develops and supplies plant-

wide crushing control solutions for

crushing plants

Metso has recently signed contracts on

delivering plant-wide automation systems

for mobile and portable rock crushing

plants The key objective of these deliveries

is to stabilize and to increase productivityand efficiency of the plants using one sin-

gle automation and information platform

for integrating crusher-specific IC machinecontrols

Furthermore the plant-wide system

with its information management tools not

only increases plant availability and opera-

tional safety it also makes troubleshoot-ing quicker and performance monitoring

easier The control room for plant-wide

operability is located either in an excavator

cabin or a purpose-built container

Metso around the world

The new LT106 jaw plant is suitable for crushing both hard rock and all rock-based demolition materials

The new world speed record for tissue setby Hayat Kimyarsquos Metso-supplied TM 2 is2210 mmin

8132019 Results Minerals Aggregates 3 2012ENG

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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 26: Results Minerals Aggregates 3 2012.ENG

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Following a large investment

in Metso crushing equipmentand services Buena Vista del

Cobre is now expanding the

mine site to include even more

equipment ndash and with thatexpansion comes the need for

more local service resources

Metso and Buena Vista del

Cobre have entered into a Life

Cycle Service agreement forthe plant and construction of a

brand new Metso service hub

is under way in Cananea

New facility new

level of service

The Cananea service hub

which will be up and running in early 2013will support the recent expansion and resur-

gence of Buena Vista del Cobre Initially it

will be a major repair and assembly center

for pumps crushers and screens and will

provide for rubber covering capabilitiesBut the 8000-square-meter facilityrsquos service

offering will be expansive including a con-

signment stock inventory to help serve theminersquos varying needs Metso currently has

50 service team members on site

Although Buena Vista del Cobre was a

key influencer in building the new servicehub this location will also enable Metso to

expand its capabilities and provide local

support to the entire mining community

in northwest Mexico The Cananea hub

will serve a number of major copper and

gold mines in the region including MineraFriscorsquos San Felipe Fresnillorsquos Milpillas and

Grupo Mexicorsquos Mexicana de Cobre

ldquoBuena Vista del Cobre is the biggestcustomer we have in Mexico today and

with this expansion project itrsquos only going

to grow and be strongerrdquo says Felix Forna-

guera Director of Services Mexico CentralAmerica and Caribbean ldquoWith that said the

idea behind the Cananea service hub is to

provide a central location for local support

for all our major customers in the areardquo

Establishing safety

ldquoIt was key to have our support here in

Cananea because the Buena Vista delCobre started from the ground uprdquo saysFelix ldquoWersquove been able to help the cus-

tomer to establish the best in support

service and operations from the very

beginningrdquo And this ground-up approachincluded a major focus on safety

Metso worked closely with Buena Vista

del Cobre to establish the safety proto-

col by which the mine operates Basedon Metsorsquos expertise the safety measures

put in place have enabled the mine to

become strict and efficient in its operations

and maintenance procedures To achievethis Metso worked closely with local andnational authorities to ensure the safety

plan was comprehensive and in accord-

ance with all established legal bodies

The best in regional support

The service hub in Cananea is a prime

example of Metsorsquos focus on providing local

service and support to its customers all

Service shines in Cananea MexicoAfter three years of inactivity the Buena Vista del Cobre mine in Cananea Sonora Mexico has been operational since 2010A mine that was inactive for such a significant amount of time however requires a great deal of support to successfullyrestart the plant and bring it back to an operational and profitable state

TEXT Deanna Lee PHOTO Metso

over the world ldquoWe are the first

company developing this kindof service in northwest Mexicordquo

adds Felix ldquoOur people have

developed a close relationship

with the team at the mine Itrsquosmore than a supplier relation-

ship our guys are inside the

mine living and working thererdquo

In fact this is the model

that Metso is using in servicehubs all over the globe build-

ing modern facilities bringing

teams on site and workinghand in hand with mine

operators The Cananea Service

hub is only the most recent

example of Metsorsquos commit-ment to service and northwest Mexico is

yet another mining hotbed thatrsquos going to

benefit from the companyrsquos support

More info

Felix Fornaguera Tel +52 4621079227

felixfornaguerametsocom

A mining cone serviced by Metso at the Buena Vista del Cobre mine inSonora Mexico

ldquoThe new Cananea service center will be a majorrepair and assembly center for pumps crushersand screensrdquo says Felix Fornaguera Director ofServices Mexico Central America and Caribbean

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

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During the MINExpo exhibition over 1300 people visited the Metso stand

983122983141983152983151983154983156983145983150983143 983154983141983155

Held every four years MIN-Expo consistently grows so

perennial exhibitors like Metso

are challenged with elevating

their presence and drawingin new (and greater numbers

of ) visitors each year ldquoItrsquos not

necessarily a challenge to lsquotoprsquo

our last showingrdquo says Keith

Ference Vice President ofmarketing and communica-

tions North America ldquoThere

are four years between eachMINExpo so we always have

a lot to say and reveal to our

customersrdquo The real challenge

he says is finding an exciting

and dynamic way to deliverthe message ldquoTherersquos so much

to see here so your booth has

to be compelling from the

outside-in and thatrsquos what

we always try to dordquo

Service sets the stage

The Metso booth created buzzin a number of ways and per-

haps the most striking (partly

due to its size) was the live

theater presentation As visitorspassed through the aisles of the show-

room the sights and sounds from Metsorsquos

theater were hard to miss And once guests

entered they were captivated by a short

high-energy video presentation focused

on Metsorsquos service capabilities The message was simple Metso is ldquoyour

local service partner rdquo for all mining and

construction needs The video showed ourservice teams in action all over the world

and the audience came away with an

understanding about Metsorsquos commitment

to service Customers can count on morethan 70 local service centers run by more

than 1700 expert technicians delivering

Metso makes an impact at MINExpo 2012At this yearrsquos MINExpo International nearly 60000 attendees flocked to Las Vegas Nevada the largest turnout in showhistory The visitors ndash mining professionals from all over the globe ndash explored 850000 square feet of showroom spacefeaturing the industry rsquos latest technology equipment products and services They toured the show for three days

seeking the latest and greatest from more than 1800 exhibitorsTEXT Keith Ference PHOTOS Tracey Ford Perry

detailed descriptions andphotos of all of Metsorsquos mining

and construction products and

services The app also provides

digital access to Results and asearchable database of sales

contacts By day three of the

show MetsoMAP had been

downloaded by more than

500 usersIn addition to the app the

booth was equipped with

several LCD screens each con-trolled by Metso experts who

used their iPads to present new

products like the Megalinertrade

and the HRCtrade A featured

presentation on Metsorsquos lineupof energy-efficient comminu-

tion equipment including the

VERTIMILLreg SMD and MP-1250

cone crusher was also avail-

able letting customers seehow Metso technology delivers

some of the worldrsquos most effi-

cient size reduction

Measuring MINExpo success

After a very busy three days

(on top of months of prepara-tion leading up to the show) everyone

involved with MINExpo ndash from the North

American marketing team responsible for

the booth to the product managers and

sales force that worked the floor ndash is view-

ing the show as a success ldquoTherersquos alwaysa sigh of relief after each (MINExpo)rdquo says

Keith ldquoAnd overall the initial feedback

and response has been very positiverdquoWith more than 1300 visitors to the

booth Metso certainly made an impact

ldquoWe learn a lot from each show and with

some time wersquoll have a better understand-ing of the tangible results of our effortsrdquo

Keith adds

reliable service for mining equipment as

well as customized cost-effective life-cycle

services contracts

Technology ndash MetsoMAP

is an industry firstMINExpo provided the industry with its firstglimpse of Metsorsquos revolutionary iPad app

MetsoMAP The app was demoed to the

boothrsquos visitors via ldquothe worldrsquos largest iPadrdquo

a custom-made 80-inch screen that show-cased all of its capabilities most of which are

groundbreaking in the industry MetsoMAPrsquos

simple interface is highly intuitive making

it easy to view process animations videos

The presentation of the new HP cone crusher attracted a large audience

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When yoursquore allowed less than a dozen days per year for breakdowns repair andmaintenance every single hour during a service shutdown counts There simplyisnrsquot any room for surprises Thatrsquos why Boliden counts on MetsoTEXT amp PHOTOS Sofia Williams

8983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

Kurt Kalla Site Managerof Metso Gaumlllivare ServiceCenter is responsible forthe maintenance of Aitik

Metso and Boliden Strivingtogether for 97 uptime

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983122983141983152983151983154983156983145983150983143 983154983141983155

One of the biggest copper mines in

Europe Bolidenrsquos Aitik is located deep inthe wilderness of Swedish Lapland next to

the small town of Gaumlllivare The mine has

been operating since 1968 and a recent

expansion has increased its annual ore

production to 36 million tons

But the ambitious Swedes are not will-ing to lay back and relax just yet Bolidenrsquos

new aim is to reach a production rate of

45 million tons of ore per year in AitikAfter that Perhaps more than 55 million

tons The ore concentration in Aitik is very

low-grade with a mere 022 copper con-

tent hence the need for high capacityAchieving the ambitious production

goal requires maximum plant availability

This means that everything from the crush-

ers to the filters must be up and runningfor approximately 97 percent of the time

Thatrsquos where Metso comes into play

A cost-per-ton contract in action

The maximum uptime requirement allowsless than a dozen days per year for break-

downs repair and maintenance at Aitik

Every single hour during a service shut-

down counts There simply isnrsquot any roomfor surprises

Executing a successful shutdown under

such conditions requires a reliable service

partner not afraid of challenges and this iswhy Boliden has entrusted Aitikrsquos services

operations to Metso Boliden and Metsohave worked together since the 1960s

and the collaboration took another step

forward in September 2012 when the twocompanies signed a three-year extension

of the services contract for Boliden Aitik

ldquoThe new contract is a cost-per-ton

agreement We get paid based on Aitikrsquos

production Itrsquos a win-win deal for both par-

ties but also a new mindset for usrdquo explainsKurt Kalla Site Manager of Metso Gaumlllivare

Service Center responsible for serving Aitik

From now on the duration of the shut-down is what matters the most According

to Kalla the Metso service organization in

Gaumlllivare is now streamlining its operations

to fit the bill and has already witnessed thestrategy working In August 2012 Metso

carried out a 188-hour service shutdown in

Aitik which turned out to be a success

Zero tolerance for injury

One key factor to the success was theextensive planning of precautionary health

safety and environment procedures under-

taken by Metso prior to the shutdown Thanks to strict measures applied no

injuries or accidents occurred during the

shutdown and the work could easily be

finished on scheduleMats Johansson Health Safety

and Environment Manager for Metso in

Sweden explains how this was achieved

rdquoPlanning of the shutdown included arisk analysis for all new tasks participating

in Bolidenrsquos safety coordination meetingsmeeting with both Metso supervisors and

subcontractor supervisors and finally a

meeting with the entire staff participating

in the shutdown where everyone had to

sign a document stating their commitmentto the information providedrdquo he says

During the actual shutdown plenty of

new barriers signs and awareness cones

were put in place as a result of observa-tions from previous audits and safety plans

and risk analyses were readily available

in the work area Metso and Boliden also

introduced a Mill Inching permit a certifi-cate for completing a mandatory course for

those involved in the process In addition

Metso carried out random safety audits

during the shutdown to make sure thestrict policy was followed

According to Boliden Metsorsquos way of

working is a good example of how health

and safety precautions should be handled

ldquoMetso is a good example of how towork with safety and health plans risk

analysis permits and welding permits

Their table with all binders in the second-

ary mill area was exemplaryrdquo says Kjell-Arne

Johansson a technician from Boliden

The use of the new Metso Megalinertrade

system in the lining of Aitikrsquos Metso AG

mills has also improved the safety of main-tenance staff The Metso Megalinertrade con-

sists of larger-than-average liners bolted

in position from outside the mill Mainte-

nance technicians no longer need to go

inside the mill and stand in the dangerousdrop-zone of the liners gt

Boliden aims to reach a production rate of 45 million tons of ore per yearin the Aitik mine site

ldquoA complete risk analysis was conducted during the planningof the shutdownrdquo comments Mats Johansson Health Safetyand Environment Manager for Metso in Sweden

8132019 Results Minerals Aggregates 3 2012ENG

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Service the Metso way

24 hours a day 365 days a year

In addition to paying close attention to

health and safety issues executing an effi-

cient shutdown requires careful planning

and timing of every step in the mainte-

nance process Wear and spare parts have

to be available on time and a repair shoplarge enough to accommodate equipment

located close by

ldquoTo keep maintenance breaks as short

as possible we aim to replace the pump on

site and bring the old one for repair to our

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

nearby facilities This method gives us the

peace to do a good job and keep the cus-

tomerrsquos operations runningrdquo Kalla describes

the Metso way of handling Aitikrsquos pump

maintenance

Metso is currently expanding its Gaumllli-

vare service center to include a distribu-

tion center for wear and spare parts andalso concentrating its previously scattered

operations under one roof in its Vuoskon-

jaumlrvivaumlgen facility The expansion is due to

be completed by 2014

Metso equipment

delivered to Aitik36

bull 2 AG mills diameter 116 x

137 m gearless 22-MW motor

bull 2 Pebble mills diameter 91 x

113m dual 5-MW pinion drive

bull 3 VPA pressure filters VPA 1540-54

bull 12 sample pumps and pipes

VF50

bull 60 Various slurry pumps up to

MR500 modelbull Appr 5000 m rubber-lined slurry

pipes up to 600 mm diameter

bull Appr 5000 m rubber-lined by

gravity pipes up to 600 mm

diameter

bull Appr 5000 m rubber hoses

up to 600 mm diameter

Not only does the expansion make ser-

vice shutdowns at Aitik run more smoothly

it guarantees a more comprehensive

on-call emergency service response in the

region ndash thanks to the spare and wear parts

inventory available 24 hours a day 365

days a year

More info

Lars Rosenling

Tel +46 70 107 45 90

larsrosenlingmetsocom

Metso grinding equipment dominates the view in the concentrator

Safety on site is made up of small things like

making sure that everyone remembers to secure

the hoses in place

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Pebbles have always been a

challenge for producers of sandsince they cannot be returned

to rivers after extraction For

decades the processing of this

material resulted in a huge

environmental liability with alarge amount of pebbles hav-

ing to be stored away and left

unused

Transforming problems into

business opportunities

Areia amp Cia (areia = sand) has

operated in this market forover 20 years and decided to

enlist the help of Metso to find

a profitable solution for the

processing of pebbles

In July 2011 analyses werebegun to assess the abrasive-

ness and crushability of the

material Four alternatives wereidentified for processing and

transforming pebbles into sand

Initially Areia amp Cia was

interested in acquiring an

impactor for its reason-able price level However the

customer wanted to process

all the pebbles that were col-

lected daily in addition to some of the

material that it had stored In weighing theresults expected by the customer and the

excessive abrasiveness of the material the

HP200 cone crusher was decided on as thebest alternative

Areia amp Cia made the required invest-

ment and after using the HP200 for just

six months the company has already beenreporting outstanding results The HP200

not only transforms pebbles into sand but

also produces sand of excellent quality

with high yield and low maintenanceWith minor adjustments the HP200

also enables the production of sand withspecific particle size distribution for special

applications such as filtering sand blasting

and foundry sand adding value to the prod-

uct and increasing the types of sand offeredldquoMetso is pleased that the HP200 not

only enabled the processing of a product

that had been set aside as unusable but

HP200 cone transforms pebblesinto high-quality sandOver the last few decades Brazilian economic growth has been driving demand for construction aggregates The market

for sand in turn has been experiencing major difficulties in maintaining a consistent supply Presently one of the mainchallenges the industry faces is the large amount of pebbles that are obtained in the process of extracting sand at timesconstituting nearly 50 of the volume of material dredged from riverbeds

TEXT Sheila Ivers PHOTO Areia amp Cia

also that it opened up new

market opportunities for Areiaamp Cia Thatrsquos the standard we

seek to deliver to our custom-

ersrdquo states Luiz Oliveira Techni-

cal Salesperson of Metso Brazil

HP cones entering the

Brazilian sand-making

market

Todayrsquos cones such as theHP200 have high resistance

to impacts and abrasiveness

more efficient crushing cham-

bers low maintenance costsand excellent productivity

Following the acquisition of

the HP200 Areia amp Cia is now

also producing special sands

that command a price that is100 higher than common

sand The entire stockpile of

pebbles accumulated through-out the companyrsquos 20 years of

operations has already been

transformed into sand and the

stock of pebbles held by com-

petitors is also being purchasedfor processing

Cristiane Brizolari the

owner of Areia amp Cia confirms

the transformation that has taken place in

the production and commercial processldquoThe HP200 opened up new niches in

the market enabling the production of dif-

ferent types of sand with added valuerdquo

More info

Luiz Oliveira

Tel +55 011 9971 3603

luizoliveirametsocom

After the pebbles are crushed into sand with the HP200 cone crusherdifferent grades are screened for various end uses

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Where therersquos a will we dig a wayAFCONS-Strabag and Metso embark on tunnel project together

When the joint venture AFCONS-Strabag initiated work on the Rohtang bypass tunnel project at an altitude of 3980 metersabove sea level in Himachal Pradesh India they deliberated each aspect with clockwork precision The project involved anumber of surprises and challenges and required technology and project management skills that were second to none

TEXT amp PHOTOS Monisha Majumdar

Cutting a 10-meter-wide and nearly 9-kilo-

meter-long tunnel through the Himalayas

in one of the toughest terrains and cli-mates in India makes for quite a challengeResults set out to find out how AFCONS-

Strabag and Metso are making their way in

one of their most critical projects to date

The only road connection to the north-Indian border region of the province

Himachal-Pradesh and beyond the Manali-

Leh highway leads across the Rohtang

pass Due to the heavy snowfall and high-

velocity winds in this region the towns

located north of the pass are cut off from

the rest of the country during winter for atleast four often even six months each year

A tunnel with strategic importance

With the construction of the tunnel at

3100 m above sea level the Manali-Lehhighway will become an all-weather road

thereby enabling a significant improve-

ment in the economic development of

northern Himachal-Pradesh and an alter-

nate route to the strategically important

Ladakh region

Manali south of the pass is an alreadywell-developed tourist location that is

becoming more and more popular Upon

completion of the tunnel it is likely that

tourist activities will extend to the areanorth of the pass Moreover the tunnel

shortens the distance between the towns

of Manali and Leh by approximately 45 km

thus saving several hours on the small dan-gerous pass road

The Rohtang pass in the Western Himalaya

region of Northern India with its altitude ofalmost four kilometers ranks among thehighest trafficable passes in the world

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The 88-km long horse-shoe-shaped

tunnel provides space for a two-lane8-m-wide carriageway as well as a one-

meter-wide footpath on both sides A

22-m-high and 36-m-wide emergency

tunnel will be integrated in the tun-

nel cross-section Altogether more than

800000 msup3 of rock will be moved Tunneling works started around spring

2010 with excavation driven from both por-

tals As the north portal is inaccessible dur-ing winter closure the excavation focused

on the south After a planned construction

period of 55 years the tunnel is scheduled

to be completed by the end of 2015

Best man for the job

The BRO (Border Road Organization)

wanted to roll out a global tender for theproject due to the challenges that such a

project involves and also considering thatitrsquos the first time in India that a project of

this scale was to be carried out This imme-

diately triggered the need to roll out aglobal tender All major Indian construction

companies bid for it some individually and

some in partnerships

Strabag an Austrian tunnel specialistwas one of the companies who bid for the

project along with AFCONS a Mumbai-

based infrastructure company In Septem-

ber 2009 AFCONS-Strabag was awardedthe contract

Mr Sunil Tyagi Deputy Project Man-ager at AFCONS had this to say about the

unique projectldquoThis project is located in the Himalayas

and as far as we understand the terrain

there is among the toughest We came out

with a new technology and to be honestit is a fairly simple one We would generally

start with the traditional technology of drill-

ing and blasting and then obtain our muck

feed from the inwardbottom of the tunnelrdquo

ldquoThe technology is supplied by Rowa Tunneling Logistics and this is the first

time it is being used in Asia A jaw crusheris placed at a distance of about 40-45

meters behind the face The blasted muckextracted from the face is fed to the crusher

to reduce the lump size and then through

an overhead conveyor transport system

it is then transported out of the tunnelrdquoldquoThis enables free movement of man

and machinery in the lower area or spe-

cifically on the ground area If we were to

conforms to the Indian standard for fines amp

coarse aggregates as prescribed in IS383-1970

The plant was up and running in good

condition and performing to AFCONSrsquos

satisfactionldquoWe have worked with Metso in earlier

projects and are quite impressed by thekind of technology amp services they provide

We have a history together so the trust fac-tor also comes inrdquo explains Dhiman on their

choice of Metso as a partner

Service makes the difference

ldquoMetsorsquos services have made a big dif-ference in the project Without them we

would still be struggling with the machin-

ery and production The service is really

good and the service engineers are knowl-edgeable prompt and quick to act Any

problem can be solved by Metso We donrsquothave to wait until a service engineer turns

up ndash they have the capacity to solve prob-lems over the phone as wellrdquo says Dhiman

ldquoThe Metso plant didnrsquot create any prob-

lems for us We had problems in logistics

the feed was sticky and the weather condi-tions were bad but thankfully we did not

face any problems with production and

efficiency as the Metso plant is performing

very wellrdquo Dhiman concludes

More info

Amol Sinha Tel +91 9811 671 924

amolsinhametsocom

use the old conventional technology this

wouldnrsquot have worked for us in the stipu-lated timerdquo Mr Tyagi adds

When the going gets tough

partner with the toughest

Sensitive projects require the best technol-

ogy After AFCONS-Strabag landed theproject Metso was an obvious choice as a

technology provider not only because of

the long-standing business relationshipbut also for the sheer consistency in prod-

uct quality and service deliverance Metso

strives for

ldquoAfter signing the project we faced alot of road blocks including extreme cold

avalanches roadblocks less oxygen ndash you

name it we faced itrdquo explains Ankit Dhi-

man Plant Manager at AFCONS-Strabag The Rohtang valley is known for its

notorious avalanches and landslides SoAFCONS had to take extra steps and safety

precautions against hazards on the site

ldquoIn this freezing cold not just us humansbut also the machines are at increased risk

of damage I remember when we used

to run the plant during winter the diesel

engines would freeze We had to constantlyheat up the fuel container to get the plant

running And even the sand in the sand

trap would freeze so we had to clean it on

a daily basis to stop the pipes from mal-functioningrdquo Dhiman adds

Plant designed for difficult terrain

Difficult terrain coupled with space con-straints led Metso engineers to put their

minds together to come up with a suitable

plant configuration After studying the

requirements of the project Metso sug-

gested a 150-tons-per-hour three-stagemodular plant using a C106 jaw crusher

a GP11F secondary cone crusher and a

B7150 tertiary vertical shaft impact crusher

In addition considering the unpredict-ability of the feed the plant was about

to reach a point where the amount offines to be handled could be increased

dramatically Metso strongly suggested the TK11-27-3V grizzly scalper and this became

the first-ever TK scalper to be supplied by

Metso to an Indian customer Also in order

to get better products a sand trap SF2360was added to the configuration

The sand trap is important equipment

for this project as it washes the sand thatMr Sunil Tyagi Deputy Project ManagerAFCONS-Strabag

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Smooth transition to new-generation jaw crusher in Germany

Roumlhrig is a German company with a rich heritage The company has been quarrying granite at its plant in Bergstrasse inthe Sonderbach district of Heppenheim for three generations

TEXT amp PHOTOS Ralf Goffin

Roumlhrigrsquos superior product variety is onereason why the companyrsquos proximity to its

customers can be understood in more than

just physical terms The companyrsquos high

level of innovation has allowed it to estab-lish itself as a reliable supplier of materials

both regionally and internationally This

operational and technical expertise always

manages to keep in step with growing

market requirements

In terms of technical processing equip-

ment Roumlhrig has used a Nordberg C160stationary jaw crusher from Metso since

1992 At the start of 2012 it was finally

exchanged for a more up-to-date version

from the same model range

Metsorsquos C Series is specifically designed

to pre-crush hard rock and can cope effort-

lessly with even the hardest of materials

The dimensions of the new stationary jawcrusher are identical to those of the old

one which means that it could simply be

slotted into the housing vacated by the

previous version

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Third-generation Managing DirectorMarco Roumlhrig expects the new machinersquos

service life to be just as long as the previ-

ous model due to the product upgrades

that have been implemented The integral motor base is another plus

point in models made by other manu-

facturers it is located outside the crusher

This element of good fortune ensured that

Roumlhrig could reuse the housing withoutany additional rebuilding

Another advantage lies in the revision

of the guards for the C160rsquos drivetrain andflywheel The sturdier construction method

used for the crusher requires fewer parts

which facilitates easier installation andmaintenance and it makes it simpler to

access the motor

Under the watchful eye of Metsorsquos

Assembly Manager Maik Engelstaumltterthe entire project including removal and

installation was successfully completed

within two weeks

Installation making the most

of the available space

Roumlhrig will likely remember the day the

new crusher was installed for a long time

the pitman and main frame were deliveredseparately prior to installation and assem-

bled on site It took just one hour to replace

the old stationary crusher with the new

model A lorry-mounted crane was used toposition the 85-ton crusher with millimeter

precision in the crushing plant Once the

new crusher had been positioned in theexisting steel structure the next task wasto fix it into place as securely as possible

despite the limited space Special vibration

dampers were installed at a height of two

meters to prevent the crusher from sliding

Norbert Ried (fourth from left) installed thenew C160rsquos predecessor 20 years ago and isdelighted at the durability of the powerfulcrusher that is now making way for a newermodel Also pictured from left to right ManagerVolker Angermann Assembly Manager Maik

Engelstaumltter Technical Manager Stefan

Koob Project Manager Dominic SchoumlnhardtManaging Director Marco Roumlhrig Service

Technician Stefan Kolze and employees ofthe installation company Stafemo

On the hook after theold C160 was liftedout by crane the newcrusher was installedin almost no timeOnly the roof of thehousing had to beremoved

sideways off its mount An initial test run

with materials was carried out around oneweek later after all the electrical cables had

been installed

Simultaneously with the installation

of the C160 which is the first of the latest

generation of crushers to be installed in

Germany a new Nordberg GP100 conecrusher was also being installed in Roumlhrigrsquos

chipping plant Roumlhrig is convinced that

the technical improvements made tothe new Metso crusher can only be an

advantage worldwide

Roumlhrig places great value on consistent

product quality maximum added valueand optimum refinement of its product

range Bearing in mind that Roumlhrig has

enough reserves of raw material to last

for the next 150 years the company canconfidently continue to develop with an

emphasis on quality rather than quantity

More info

Dominic Schoenhardt

Tel +49 (0)621 727 00 610

dominicschoenhardtmetsocom

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Groupe Charier Carriegravere de la Mariais France

Quarrying with certi1047297ed quality The Charier Group with its 1600-strong workforce is a family business thatthis year celebrates 115 years of quarrying The company pursues a long-termdevelopment policy that since 2007 has seen processing installations upgradedat 4 of its 9 extraction sites

TEXT Liliane Boutin (with extracts from Mines amp Carriegraveres and Terrassements amp Carriegraveres magazines)PHOTO Baloon photo

The processing installation is of the horizontal type with a primary station located 56 meters below the site access road to keep it hidden from view

The crushing and screening installation at

Charierrsquos CM La Mariais quarry (at Donges

on the Loire estuary) has been in opera-tion since September 2011 Based on theoperatorrsquos ideas it was designed by Metso

to replace a worn-out installation installed

right on top of the seam being extracted

Since its commissioning it has becomethe second quarry in the company to

receive ISO 14 001 certification

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983122983141983152983151983154983156983145983150983143 983154983141983155

tertiary material of sand and gravel for the

local market to use in concrete surfacingprefabrication etcrdquo

Incorporation of a screening station

The stone extracted from La Mariais is

according to the quarry granitic gneiss

sound and homogeneous with a LosAngeles index of 15 good wear resist-

ance with an MDE of 10 a true density of

265 and a certain abrasiveness (2000 gt)ldquoCharacteristically it has a tendency to form

blocksrdquo Leblin points out

The main criteria in designing the instal-

lation was to provide an output of 600000metric tons from one station (38 hours

week) to produce materials aimed at the

concrete and surfacing markets ldquowhich

involved providing a tertiary station withscreening plantrdquo he adds

With this new unit the operating com-pany expands its product range through

the addition of fine materials obtained

from the tertiary screening station This unitis capable of producing 170 tonshour of

020

Preserving the environment

and optimizing safety

The screens have motorized bogies and

retractable walkways to facilitate access

when the screens are opened for main-tenance Other walkways provide access

to the tunnel input feeders The feederscan be isolated with hydraulic rod gate

bars this hydraulic assistance eliminatesthe need to use a heavy hammer to lodge

these metal bars

All conveyors transporting fines (02

and 04) are covered with a tarpaulin to

avoid flying dust and all the screens arehooded (metal cover with Trellex seal-

ing) The Brunone company has installed

dust-tight containment at the outlet of the

tertiary station crushers (HP300 and HP4)on the belt located under the screens

and under the hoppers located belowthe tertiary screens The crushers are put

under negative pressure and the finesare extracted through sleeve filters (7000

m3 h) with declogging which deposits the

dust back onto the conveyor belt

A high-pressure 100 bar water mist sys-tem has been installed at the primary sta-

tion discharge at the secondary crusherrsquos

discharge chutes (Omnicone) and at the

transfer points on the belt

Designed to last

ldquoThis type of new installation can easily last

thirty yearsrdquo affirms Project Leader Bruno

Peix of Metso ldquoIt quite simply depends on

how well it is maintained Thatrsquos why weprovide maintenance contracts that call for

our technicians to make regular inspection

visits and carry out preventive mainte-nance and any necessary repairsrdquo

In 2011 Metso commissioned about

10 new processing units in France like

the one at La Mariais quarry

More info

Frederic Bazire

Tel +33 (0)681442804

fredericbaziremetsocom

Key figures

DURATION OF WORKS 15 months

DRAWING OFFICE TIME 7800 hours

HEIGHT OF SILOS AND GRINDER BUILDINGS

15 m

TOTAL LENGTH OF CONVEYORS 14 km

WEIGHT OF THE INSTALLATION

1200 metric tons

CONCRETE POURED 1800 cubic meters

PROJECT SITE WORKFORCE 30

INSTALLED POWER 2200 kW(not including pumps 200 kW)

METSO EQUIPMENT

Primary

Vibrating feeder PF561-2V

Primary grizzly VG540-3V

Grizzly feeder TK13-20-3V

Jaw crusher C145 with

hydraulic setting

Secondary

Vibrating screen CVB 2050

refurbished

Cone crusher Omnicocircne 1352 SX

with Metso IC7000 controller Ellivar 16 (16 msup2 3 decks) screen

refurbished by Metso

Tertiary

Cone crusher HP300

Cone crusher HP4

2 Ellivar 20 screens (20 m23 decks) for final products

Expanding the production range

ldquoSince the mid-1990s when we became

owners of La Mariais we had used mobilemachinery with an assembly of beltconveyorsrdquo recalls Daniel Leblin Charierrsquos

Technical Manager for site construction

and maintenance

ldquoIt became clear that we needed ahigher performance tool to achieve the

dual goals of reaching one million metric

tonsrsquo maximum production and producing

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Big Lokotrack LT550GPF boostsquarrying productivity by a thirdMaximizing the productivity of operations is a key issue when striving for cost-effective quarrying Big Lokotracks are oneway to achieve improved operational efficiency The Lokotrack LT550GPF equipped with the high-volume GP550 conecrusher and a large screen is popular in the Nordic countries and in Germany and Australia ndash countries all known for theirhigh quarrying volumes

TEXT amp PHOTOS Eero Haumlmaumllaumlinen

Kone-Kostamorsquos new mobile coneplant has reached an averagecapacity of 300 tons per hour

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983122983141983152983151983154983156983145983150983143 983154983141983155

ldquoWith the same number of employees we

can achieve 30 more productivity with

our new LT550GPF unit The high-capacityFS screen has also eliminated the bottle-neck often seen at fine screeningrdquo says

Aarno Kostamo Managing Director of

Kone-Kostamo Oy one of Finlandrsquos biggest

crushing contractorsAccording to Kostamo the high capacity

of the GP550 gyratory cone crusher easily

handles feed from the C120 and C125 jaw

crushers For the contract with the Talvivaara

nickel mine the LT550GPF is being fed bythe brand new Lokotrack LT120 jaw plant

Average capacity 300 tons per hour

Talvivaara Europersquos largest nickel mine uti-

lizes large quantities of aggregates Kone-Kostamo has contracted several million

tons of different end products for the mineIn August 75000 tons of 0ndash63 mm

road gravel was crushed Smaller amountsof finer 0ndash6 mm 0ndash16 mm and 0ndash32 mm

aggregates are also being produced

The rainy summer increased the need

for road gravel along the muddy roadswhich must endure dump trucks weighing

as much as 260 tons

ldquoThe mobile process consisting of the

LT120 jaw plant and LT550GPF cone plant

is cost-effective while aggregates of vari-ous sizes can be produced in a two-stage

operation and with high capacity The con-trolled stroke and elliptical movement of

the FS screen secure big passing throughcapacitiesrdquo Kostamo explains

Operated in two shifts for a total of 16

hours per day the LT550GPF has logged

more than 600 working hours over a two-month period

Managing Director Aarno Kostamo (left) and foreman Karri Maumlenpaumlauml studying the cavity optionsavailable for the new Lokotrack LT550GPF

Longer perspective than

a single quarter needed

Kone-Kostamo Oy was founded as an

earth-moving company in Kemijaumlrvi

Northern Finland in 1956 The company

expanded its operations to include crush-

ing contracting in 1964 and later on

switched to concentrating fully on crush-ing activities

Kone-Kostamo consistently crushes

and screens around 28 million tons ofaggregates annually and has net sales of

between EUR 8ndash9 million

ldquoWe believe that issues within the crush-

ing industry including the purchasing ofmachinery must be studied with a longer

perspective than a single quarter The

secret to our success has always been our

solid work ethic and professional employ-eesrdquo Kostamo sums up

More info

Esa Berg

Tel + 358 40 837 8692

esabergmetsocom

8132019 Results Minerals Aggregates 3 2012ENG

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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155

Monitoring-based reporting is vital for

assessing the performance of a mobile

crushing plant Metso provides suchreporting tools through its plant-wideautomation system Metso DNA (Dynamic

Network of Applications) with its infor-

mation platform that links all the mobile

crushing and screen units together as oneentity Basically there is a lot of measured

real-time information available in every

crushing plant On-line information is

obtained either from each Metso crusherrsquosmachine automation system IC (Intelligent

Controller) or from separately installed

additional sensors and belt scales

All the collected data is sent to a motorhome using wireless communication

based on WLAN technology The motor

home is a purpose-built environment

inside an on-site container In this environ-ment selected variables can be monitored

for assessing the plantrsquos performance And

to make all this even more flexible the

data can be transmitted to a crushing plant

company office using GPRS3G mobile

data communication technologies Thismakes all the last-minute reports acces-sible to the crushing plant managerial staff

at anytime and basically anywhere within

reach of the cell phone network

Production and fuel economics reports

Essentially monitoring and reporting can

be customized to fit the customerrsquos needs

However there are certain off-the-shelf

reports that provide a lot of useful informa-tion for plant supervision The production

report is one of these Requiring at least one

belt scale for measuring the total produc-tion the production report shows the pro-duction rate (tons per hour) for a selected

reporting period eg a day or a week The

production report constantly keeps track of

the plantrsquos production storing all the datathroughout the plantrsquos life cycle

Performance monitoring and reportingfor a mobile crushing plantTEXT Pasi Airikka PHOTOS Metso

unit during which the unit is running By

storing the availability times between start-ups and shutdowns the crushing plant

operation time (hours per dayshift) can be

recorded analyzed and reported In addi-

tion the availability report can be tailored

to evaluate efficient crushing hours during

which the plant is really working and pro-ducing aggregates Consequently the ratio

(0-100) between efficient crushing time

and total running time can be reported forany selected period of time This boosts

the efficiency of the plantrsquos operations

and results in better productivity

Reports on non-choke

or inadequate feeding

Non-choke feeding to crushers is avoid-

able through smart plant-wide crushingplant controls But estimating its severity in

a systematic manner is not straight-forwardwithout constant monitoring and reporting

The crusher choke feeding report makes

use of the crusher cavity level sensors byanalyzing their level measurements By

calculating average and min-max values

and deviations from the average it can be

shown how often the single crusher suffersfrom non-choke feeding to it

In some cases the bottleneck in the

crushing plantrsquos productivity is the material

feeding to the process In mobile plants thefeeding is human operated and therefore

subject to variations Occasionally the sizeof the human-operated machine simply

does not allow for adequate feeding to thecrushing plant There are specific reports

indicating time periods when the crushing

plant suffers from inadequate feeding

Condition monitoring for

crushers and screens

Machine-specific condition monitoring

focuses on vibrating components in

crushers and screens such as drive shaftbearings safety plate wearings and gears

The low middle and high frequencies ofmonitored components are measured and

supervised in real-time to detect abnor-malities due to slow or fast wear looseness

or imbalance

More info

Pasi Airikka

Tel +358 40 587 2730

pasiairikkametsocom

Condition monitoring provides a view tovibrating crusher and screen components forpredictive equipment maintenance

The daily production report shows the hour-by-hour production trend and distribution chartfor a selected day with min-max average andvariation statistics for comparison

Fuel consumption is always an interest-ing concern The fuel consumption reportgives the fuel consumption of each crush-

ing unit (liters per hour) and their total

consumption (liters per hour) for a selected

reporting period and can track fuel con-

sumption changes over timeCrushing plant availability can be

assessed as well The availability report

calculates time periods for each crushing

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983149983141983156983155983151 983150

for tissue machines The record of 2210

mmin was set on June 1 2012 during a

24-hour production run by the TM 2 tissue

machine at the companyrsquos mill in Yenikoumlynear the city of Izmit in Turkey

ldquoThe cooperation with Metso has been

beyond excellent and both parties did

their utmost to make the project success-ful The results clearly show that the efforts

were worthwhile on both sides This coop-

eration will extend to cover new projects

in the futurerdquo says Luumlt1047297 Aydin Paper GroupDirector Hayat Kimya

ldquoWe are not surprised that Hayat K imya

managed to break the world speed record

We have had great confidence in the capa-bility of the Hayat team since our project

started in 2009 We certainly know our

machine very well its stability production

efficiency and speed capabilityrdquo says Jan

Erikson Vice President Sales Metso

PowerThe worldrsquos first eco-gas fueled

power plant is up and running

Lahti Energy Ltdrsquos new Kymijaumlrvi II gasifica-

tion plant was officially inaugurated on

May 8 2012 It is the first of its kind in the

RecyclingRecycling with Lokotrack LT106

jaw plant in New York

A brand-new Lokotrack LT106 jaw plant is

used in the city area of New York USA to

recycle demolition materials The crushing

site faces the skyscrapers of ManhattanIsland

Paper amp FiberHayat Kimyarsquos Metso-supplied tissue

machine sets world speed record

Thanks to a skilled crew and dedicated

efforts Hayat Kimya AS in Turkey has suc-

ceeded in breaking the world speed record

world This CHP plant runs on clean eco-

gas that is gasified cleaned and cooled

from recycled waste with Metsorsquos innova-tive technology

ldquoItrsquos actually eco-gas that we combust

in the boilerrdquo comments Lahti EnergyrsquosProduction Director Jukka Manskinen

ldquoWe convert unwanted waste material into

energy in an efficient and environmentally

friendly wayrdquoNever before has any plant gasified

waste on such a large scale In the gasifier

recycled waste is turned into combustible

product gas which is cleaned cooled and

combusted in a high-efficiency gas boiler

to produce steam for the steam turbine The plant produces 50 MW of electricity

and 90 MW of district heat for the city of

Lahti and its neighboring areasMetso delivered the circulating fluidized

bed (CFB) gasification process gas cleaning

and cooling steam boiler environmental

protection system and automation systemto the entire plant The production of elec-

tricity and heat is kept even with the Metso

DNA automation system that covers the

whole plant starting from fuel reception

AutomationMetso develops and supplies plant-

wide crushing control solutions for

crushing plants

Metso has recently signed contracts on

delivering plant-wide automation systems

for mobile and portable rock crushing

plants The key objective of these deliveries

is to stabilize and to increase productivityand efficiency of the plants using one sin-

gle automation and information platform

for integrating crusher-specific IC machinecontrols

Furthermore the plant-wide system

with its information management tools not

only increases plant availability and opera-

tional safety it also makes troubleshoot-ing quicker and performance monitoring

easier The control room for plant-wide

operability is located either in an excavator

cabin or a purpose-built container

Metso around the world

The new LT106 jaw plant is suitable for crushing both hard rock and all rock-based demolition materials

The new world speed record for tissue setby Hayat Kimyarsquos Metso-supplied TM 2 is2210 mmin

8132019 Results Minerals Aggregates 3 2012ENG

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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 27: Results Minerals Aggregates 3 2012.ENG

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During the MINExpo exhibition over 1300 people visited the Metso stand

983122983141983152983151983154983156983145983150983143 983154983141983155

Held every four years MIN-Expo consistently grows so

perennial exhibitors like Metso

are challenged with elevating

their presence and drawingin new (and greater numbers

of ) visitors each year ldquoItrsquos not

necessarily a challenge to lsquotoprsquo

our last showingrdquo says Keith

Ference Vice President ofmarketing and communica-

tions North America ldquoThere

are four years between eachMINExpo so we always have

a lot to say and reveal to our

customersrdquo The real challenge

he says is finding an exciting

and dynamic way to deliverthe message ldquoTherersquos so much

to see here so your booth has

to be compelling from the

outside-in and thatrsquos what

we always try to dordquo

Service sets the stage

The Metso booth created buzzin a number of ways and per-

haps the most striking (partly

due to its size) was the live

theater presentation As visitorspassed through the aisles of the show-

room the sights and sounds from Metsorsquos

theater were hard to miss And once guests

entered they were captivated by a short

high-energy video presentation focused

on Metsorsquos service capabilities The message was simple Metso is ldquoyour

local service partner rdquo for all mining and

construction needs The video showed ourservice teams in action all over the world

and the audience came away with an

understanding about Metsorsquos commitment

to service Customers can count on morethan 70 local service centers run by more

than 1700 expert technicians delivering

Metso makes an impact at MINExpo 2012At this yearrsquos MINExpo International nearly 60000 attendees flocked to Las Vegas Nevada the largest turnout in showhistory The visitors ndash mining professionals from all over the globe ndash explored 850000 square feet of showroom spacefeaturing the industry rsquos latest technology equipment products and services They toured the show for three days

seeking the latest and greatest from more than 1800 exhibitorsTEXT Keith Ference PHOTOS Tracey Ford Perry

detailed descriptions andphotos of all of Metsorsquos mining

and construction products and

services The app also provides

digital access to Results and asearchable database of sales

contacts By day three of the

show MetsoMAP had been

downloaded by more than

500 usersIn addition to the app the

booth was equipped with

several LCD screens each con-trolled by Metso experts who

used their iPads to present new

products like the Megalinertrade

and the HRCtrade A featured

presentation on Metsorsquos lineupof energy-efficient comminu-

tion equipment including the

VERTIMILLreg SMD and MP-1250

cone crusher was also avail-

able letting customers seehow Metso technology delivers

some of the worldrsquos most effi-

cient size reduction

Measuring MINExpo success

After a very busy three days

(on top of months of prepara-tion leading up to the show) everyone

involved with MINExpo ndash from the North

American marketing team responsible for

the booth to the product managers and

sales force that worked the floor ndash is view-

ing the show as a success ldquoTherersquos alwaysa sigh of relief after each (MINExpo)rdquo says

Keith ldquoAnd overall the initial feedback

and response has been very positiverdquoWith more than 1300 visitors to the

booth Metso certainly made an impact

ldquoWe learn a lot from each show and with

some time wersquoll have a better understand-ing of the tangible results of our effortsrdquo

Keith adds

reliable service for mining equipment as

well as customized cost-effective life-cycle

services contracts

Technology ndash MetsoMAP

is an industry firstMINExpo provided the industry with its firstglimpse of Metsorsquos revolutionary iPad app

MetsoMAP The app was demoed to the

boothrsquos visitors via ldquothe worldrsquos largest iPadrdquo

a custom-made 80-inch screen that show-cased all of its capabilities most of which are

groundbreaking in the industry MetsoMAPrsquos

simple interface is highly intuitive making

it easy to view process animations videos

The presentation of the new HP cone crusher attracted a large audience

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When yoursquore allowed less than a dozen days per year for breakdowns repair andmaintenance every single hour during a service shutdown counts There simplyisnrsquot any room for surprises Thatrsquos why Boliden counts on MetsoTEXT amp PHOTOS Sofia Williams

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Kurt Kalla Site Managerof Metso Gaumlllivare ServiceCenter is responsible forthe maintenance of Aitik

Metso and Boliden Strivingtogether for 97 uptime

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One of the biggest copper mines in

Europe Bolidenrsquos Aitik is located deep inthe wilderness of Swedish Lapland next to

the small town of Gaumlllivare The mine has

been operating since 1968 and a recent

expansion has increased its annual ore

production to 36 million tons

But the ambitious Swedes are not will-ing to lay back and relax just yet Bolidenrsquos

new aim is to reach a production rate of

45 million tons of ore per year in AitikAfter that Perhaps more than 55 million

tons The ore concentration in Aitik is very

low-grade with a mere 022 copper con-

tent hence the need for high capacityAchieving the ambitious production

goal requires maximum plant availability

This means that everything from the crush-

ers to the filters must be up and runningfor approximately 97 percent of the time

Thatrsquos where Metso comes into play

A cost-per-ton contract in action

The maximum uptime requirement allowsless than a dozen days per year for break-

downs repair and maintenance at Aitik

Every single hour during a service shut-

down counts There simply isnrsquot any roomfor surprises

Executing a successful shutdown under

such conditions requires a reliable service

partner not afraid of challenges and this iswhy Boliden has entrusted Aitikrsquos services

operations to Metso Boliden and Metsohave worked together since the 1960s

and the collaboration took another step

forward in September 2012 when the twocompanies signed a three-year extension

of the services contract for Boliden Aitik

ldquoThe new contract is a cost-per-ton

agreement We get paid based on Aitikrsquos

production Itrsquos a win-win deal for both par-

ties but also a new mindset for usrdquo explainsKurt Kalla Site Manager of Metso Gaumlllivare

Service Center responsible for serving Aitik

From now on the duration of the shut-down is what matters the most According

to Kalla the Metso service organization in

Gaumlllivare is now streamlining its operations

to fit the bill and has already witnessed thestrategy working In August 2012 Metso

carried out a 188-hour service shutdown in

Aitik which turned out to be a success

Zero tolerance for injury

One key factor to the success was theextensive planning of precautionary health

safety and environment procedures under-

taken by Metso prior to the shutdown Thanks to strict measures applied no

injuries or accidents occurred during the

shutdown and the work could easily be

finished on scheduleMats Johansson Health Safety

and Environment Manager for Metso in

Sweden explains how this was achieved

rdquoPlanning of the shutdown included arisk analysis for all new tasks participating

in Bolidenrsquos safety coordination meetingsmeeting with both Metso supervisors and

subcontractor supervisors and finally a

meeting with the entire staff participating

in the shutdown where everyone had to

sign a document stating their commitmentto the information providedrdquo he says

During the actual shutdown plenty of

new barriers signs and awareness cones

were put in place as a result of observa-tions from previous audits and safety plans

and risk analyses were readily available

in the work area Metso and Boliden also

introduced a Mill Inching permit a certifi-cate for completing a mandatory course for

those involved in the process In addition

Metso carried out random safety audits

during the shutdown to make sure thestrict policy was followed

According to Boliden Metsorsquos way of

working is a good example of how health

and safety precautions should be handled

ldquoMetso is a good example of how towork with safety and health plans risk

analysis permits and welding permits

Their table with all binders in the second-

ary mill area was exemplaryrdquo says Kjell-Arne

Johansson a technician from Boliden

The use of the new Metso Megalinertrade

system in the lining of Aitikrsquos Metso AG

mills has also improved the safety of main-tenance staff The Metso Megalinertrade con-

sists of larger-than-average liners bolted

in position from outside the mill Mainte-

nance technicians no longer need to go

inside the mill and stand in the dangerousdrop-zone of the liners gt

Boliden aims to reach a production rate of 45 million tons of ore per yearin the Aitik mine site

ldquoA complete risk analysis was conducted during the planningof the shutdownrdquo comments Mats Johansson Health Safetyand Environment Manager for Metso in Sweden

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Service the Metso way

24 hours a day 365 days a year

In addition to paying close attention to

health and safety issues executing an effi-

cient shutdown requires careful planning

and timing of every step in the mainte-

nance process Wear and spare parts have

to be available on time and a repair shoplarge enough to accommodate equipment

located close by

ldquoTo keep maintenance breaks as short

as possible we aim to replace the pump on

site and bring the old one for repair to our

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

nearby facilities This method gives us the

peace to do a good job and keep the cus-

tomerrsquos operations runningrdquo Kalla describes

the Metso way of handling Aitikrsquos pump

maintenance

Metso is currently expanding its Gaumllli-

vare service center to include a distribu-

tion center for wear and spare parts andalso concentrating its previously scattered

operations under one roof in its Vuoskon-

jaumlrvivaumlgen facility The expansion is due to

be completed by 2014

Metso equipment

delivered to Aitik36

bull 2 AG mills diameter 116 x

137 m gearless 22-MW motor

bull 2 Pebble mills diameter 91 x

113m dual 5-MW pinion drive

bull 3 VPA pressure filters VPA 1540-54

bull 12 sample pumps and pipes

VF50

bull 60 Various slurry pumps up to

MR500 modelbull Appr 5000 m rubber-lined slurry

pipes up to 600 mm diameter

bull Appr 5000 m rubber-lined by

gravity pipes up to 600 mm

diameter

bull Appr 5000 m rubber hoses

up to 600 mm diameter

Not only does the expansion make ser-

vice shutdowns at Aitik run more smoothly

it guarantees a more comprehensive

on-call emergency service response in the

region ndash thanks to the spare and wear parts

inventory available 24 hours a day 365

days a year

More info

Lars Rosenling

Tel +46 70 107 45 90

larsrosenlingmetsocom

Metso grinding equipment dominates the view in the concentrator

Safety on site is made up of small things like

making sure that everyone remembers to secure

the hoses in place

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Pebbles have always been a

challenge for producers of sandsince they cannot be returned

to rivers after extraction For

decades the processing of this

material resulted in a huge

environmental liability with alarge amount of pebbles hav-

ing to be stored away and left

unused

Transforming problems into

business opportunities

Areia amp Cia (areia = sand) has

operated in this market forover 20 years and decided to

enlist the help of Metso to find

a profitable solution for the

processing of pebbles

In July 2011 analyses werebegun to assess the abrasive-

ness and crushability of the

material Four alternatives wereidentified for processing and

transforming pebbles into sand

Initially Areia amp Cia was

interested in acquiring an

impactor for its reason-able price level However the

customer wanted to process

all the pebbles that were col-

lected daily in addition to some of the

material that it had stored In weighing theresults expected by the customer and the

excessive abrasiveness of the material the

HP200 cone crusher was decided on as thebest alternative

Areia amp Cia made the required invest-

ment and after using the HP200 for just

six months the company has already beenreporting outstanding results The HP200

not only transforms pebbles into sand but

also produces sand of excellent quality

with high yield and low maintenanceWith minor adjustments the HP200

also enables the production of sand withspecific particle size distribution for special

applications such as filtering sand blasting

and foundry sand adding value to the prod-

uct and increasing the types of sand offeredldquoMetso is pleased that the HP200 not

only enabled the processing of a product

that had been set aside as unusable but

HP200 cone transforms pebblesinto high-quality sandOver the last few decades Brazilian economic growth has been driving demand for construction aggregates The market

for sand in turn has been experiencing major difficulties in maintaining a consistent supply Presently one of the mainchallenges the industry faces is the large amount of pebbles that are obtained in the process of extracting sand at timesconstituting nearly 50 of the volume of material dredged from riverbeds

TEXT Sheila Ivers PHOTO Areia amp Cia

also that it opened up new

market opportunities for Areiaamp Cia Thatrsquos the standard we

seek to deliver to our custom-

ersrdquo states Luiz Oliveira Techni-

cal Salesperson of Metso Brazil

HP cones entering the

Brazilian sand-making

market

Todayrsquos cones such as theHP200 have high resistance

to impacts and abrasiveness

more efficient crushing cham-

bers low maintenance costsand excellent productivity

Following the acquisition of

the HP200 Areia amp Cia is now

also producing special sands

that command a price that is100 higher than common

sand The entire stockpile of

pebbles accumulated through-out the companyrsquos 20 years of

operations has already been

transformed into sand and the

stock of pebbles held by com-

petitors is also being purchasedfor processing

Cristiane Brizolari the

owner of Areia amp Cia confirms

the transformation that has taken place in

the production and commercial processldquoThe HP200 opened up new niches in

the market enabling the production of dif-

ferent types of sand with added valuerdquo

More info

Luiz Oliveira

Tel +55 011 9971 3603

luizoliveirametsocom

After the pebbles are crushed into sand with the HP200 cone crusherdifferent grades are screened for various end uses

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Where therersquos a will we dig a wayAFCONS-Strabag and Metso embark on tunnel project together

When the joint venture AFCONS-Strabag initiated work on the Rohtang bypass tunnel project at an altitude of 3980 metersabove sea level in Himachal Pradesh India they deliberated each aspect with clockwork precision The project involved anumber of surprises and challenges and required technology and project management skills that were second to none

TEXT amp PHOTOS Monisha Majumdar

Cutting a 10-meter-wide and nearly 9-kilo-

meter-long tunnel through the Himalayas

in one of the toughest terrains and cli-mates in India makes for quite a challengeResults set out to find out how AFCONS-

Strabag and Metso are making their way in

one of their most critical projects to date

The only road connection to the north-Indian border region of the province

Himachal-Pradesh and beyond the Manali-

Leh highway leads across the Rohtang

pass Due to the heavy snowfall and high-

velocity winds in this region the towns

located north of the pass are cut off from

the rest of the country during winter for atleast four often even six months each year

A tunnel with strategic importance

With the construction of the tunnel at

3100 m above sea level the Manali-Lehhighway will become an all-weather road

thereby enabling a significant improve-

ment in the economic development of

northern Himachal-Pradesh and an alter-

nate route to the strategically important

Ladakh region

Manali south of the pass is an alreadywell-developed tourist location that is

becoming more and more popular Upon

completion of the tunnel it is likely that

tourist activities will extend to the areanorth of the pass Moreover the tunnel

shortens the distance between the towns

of Manali and Leh by approximately 45 km

thus saving several hours on the small dan-gerous pass road

The Rohtang pass in the Western Himalaya

region of Northern India with its altitude ofalmost four kilometers ranks among thehighest trafficable passes in the world

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983122983141983152983151983154983156983145983150983143 983154983141983155

The 88-km long horse-shoe-shaped

tunnel provides space for a two-lane8-m-wide carriageway as well as a one-

meter-wide footpath on both sides A

22-m-high and 36-m-wide emergency

tunnel will be integrated in the tun-

nel cross-section Altogether more than

800000 msup3 of rock will be moved Tunneling works started around spring

2010 with excavation driven from both por-

tals As the north portal is inaccessible dur-ing winter closure the excavation focused

on the south After a planned construction

period of 55 years the tunnel is scheduled

to be completed by the end of 2015

Best man for the job

The BRO (Border Road Organization)

wanted to roll out a global tender for theproject due to the challenges that such a

project involves and also considering thatitrsquos the first time in India that a project of

this scale was to be carried out This imme-

diately triggered the need to roll out aglobal tender All major Indian construction

companies bid for it some individually and

some in partnerships

Strabag an Austrian tunnel specialistwas one of the companies who bid for the

project along with AFCONS a Mumbai-

based infrastructure company In Septem-

ber 2009 AFCONS-Strabag was awardedthe contract

Mr Sunil Tyagi Deputy Project Man-ager at AFCONS had this to say about the

unique projectldquoThis project is located in the Himalayas

and as far as we understand the terrain

there is among the toughest We came out

with a new technology and to be honestit is a fairly simple one We would generally

start with the traditional technology of drill-

ing and blasting and then obtain our muck

feed from the inwardbottom of the tunnelrdquo

ldquoThe technology is supplied by Rowa Tunneling Logistics and this is the first

time it is being used in Asia A jaw crusheris placed at a distance of about 40-45

meters behind the face The blasted muckextracted from the face is fed to the crusher

to reduce the lump size and then through

an overhead conveyor transport system

it is then transported out of the tunnelrdquoldquoThis enables free movement of man

and machinery in the lower area or spe-

cifically on the ground area If we were to

conforms to the Indian standard for fines amp

coarse aggregates as prescribed in IS383-1970

The plant was up and running in good

condition and performing to AFCONSrsquos

satisfactionldquoWe have worked with Metso in earlier

projects and are quite impressed by thekind of technology amp services they provide

We have a history together so the trust fac-tor also comes inrdquo explains Dhiman on their

choice of Metso as a partner

Service makes the difference

ldquoMetsorsquos services have made a big dif-ference in the project Without them we

would still be struggling with the machin-

ery and production The service is really

good and the service engineers are knowl-edgeable prompt and quick to act Any

problem can be solved by Metso We donrsquothave to wait until a service engineer turns

up ndash they have the capacity to solve prob-lems over the phone as wellrdquo says Dhiman

ldquoThe Metso plant didnrsquot create any prob-

lems for us We had problems in logistics

the feed was sticky and the weather condi-tions were bad but thankfully we did not

face any problems with production and

efficiency as the Metso plant is performing

very wellrdquo Dhiman concludes

More info

Amol Sinha Tel +91 9811 671 924

amolsinhametsocom

use the old conventional technology this

wouldnrsquot have worked for us in the stipu-lated timerdquo Mr Tyagi adds

When the going gets tough

partner with the toughest

Sensitive projects require the best technol-

ogy After AFCONS-Strabag landed theproject Metso was an obvious choice as a

technology provider not only because of

the long-standing business relationshipbut also for the sheer consistency in prod-

uct quality and service deliverance Metso

strives for

ldquoAfter signing the project we faced alot of road blocks including extreme cold

avalanches roadblocks less oxygen ndash you

name it we faced itrdquo explains Ankit Dhi-

man Plant Manager at AFCONS-Strabag The Rohtang valley is known for its

notorious avalanches and landslides SoAFCONS had to take extra steps and safety

precautions against hazards on the site

ldquoIn this freezing cold not just us humansbut also the machines are at increased risk

of damage I remember when we used

to run the plant during winter the diesel

engines would freeze We had to constantlyheat up the fuel container to get the plant

running And even the sand in the sand

trap would freeze so we had to clean it on

a daily basis to stop the pipes from mal-functioningrdquo Dhiman adds

Plant designed for difficult terrain

Difficult terrain coupled with space con-straints led Metso engineers to put their

minds together to come up with a suitable

plant configuration After studying the

requirements of the project Metso sug-

gested a 150-tons-per-hour three-stagemodular plant using a C106 jaw crusher

a GP11F secondary cone crusher and a

B7150 tertiary vertical shaft impact crusher

In addition considering the unpredict-ability of the feed the plant was about

to reach a point where the amount offines to be handled could be increased

dramatically Metso strongly suggested the TK11-27-3V grizzly scalper and this became

the first-ever TK scalper to be supplied by

Metso to an Indian customer Also in order

to get better products a sand trap SF2360was added to the configuration

The sand trap is important equipment

for this project as it washes the sand thatMr Sunil Tyagi Deputy Project ManagerAFCONS-Strabag

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Smooth transition to new-generation jaw crusher in Germany

Roumlhrig is a German company with a rich heritage The company has been quarrying granite at its plant in Bergstrasse inthe Sonderbach district of Heppenheim for three generations

TEXT amp PHOTOS Ralf Goffin

Roumlhrigrsquos superior product variety is onereason why the companyrsquos proximity to its

customers can be understood in more than

just physical terms The companyrsquos high

level of innovation has allowed it to estab-lish itself as a reliable supplier of materials

both regionally and internationally This

operational and technical expertise always

manages to keep in step with growing

market requirements

In terms of technical processing equip-

ment Roumlhrig has used a Nordberg C160stationary jaw crusher from Metso since

1992 At the start of 2012 it was finally

exchanged for a more up-to-date version

from the same model range

Metsorsquos C Series is specifically designed

to pre-crush hard rock and can cope effort-

lessly with even the hardest of materials

The dimensions of the new stationary jawcrusher are identical to those of the old

one which means that it could simply be

slotted into the housing vacated by the

previous version

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983122983141983152983151983154983156983145983150983143 983154983141983155

Third-generation Managing DirectorMarco Roumlhrig expects the new machinersquos

service life to be just as long as the previ-

ous model due to the product upgrades

that have been implemented The integral motor base is another plus

point in models made by other manu-

facturers it is located outside the crusher

This element of good fortune ensured that

Roumlhrig could reuse the housing withoutany additional rebuilding

Another advantage lies in the revision

of the guards for the C160rsquos drivetrain andflywheel The sturdier construction method

used for the crusher requires fewer parts

which facilitates easier installation andmaintenance and it makes it simpler to

access the motor

Under the watchful eye of Metsorsquos

Assembly Manager Maik Engelstaumltterthe entire project including removal and

installation was successfully completed

within two weeks

Installation making the most

of the available space

Roumlhrig will likely remember the day the

new crusher was installed for a long time

the pitman and main frame were deliveredseparately prior to installation and assem-

bled on site It took just one hour to replace

the old stationary crusher with the new

model A lorry-mounted crane was used toposition the 85-ton crusher with millimeter

precision in the crushing plant Once the

new crusher had been positioned in theexisting steel structure the next task wasto fix it into place as securely as possible

despite the limited space Special vibration

dampers were installed at a height of two

meters to prevent the crusher from sliding

Norbert Ried (fourth from left) installed thenew C160rsquos predecessor 20 years ago and isdelighted at the durability of the powerfulcrusher that is now making way for a newermodel Also pictured from left to right ManagerVolker Angermann Assembly Manager Maik

Engelstaumltter Technical Manager Stefan

Koob Project Manager Dominic SchoumlnhardtManaging Director Marco Roumlhrig Service

Technician Stefan Kolze and employees ofthe installation company Stafemo

On the hook after theold C160 was liftedout by crane the newcrusher was installedin almost no timeOnly the roof of thehousing had to beremoved

sideways off its mount An initial test run

with materials was carried out around oneweek later after all the electrical cables had

been installed

Simultaneously with the installation

of the C160 which is the first of the latest

generation of crushers to be installed in

Germany a new Nordberg GP100 conecrusher was also being installed in Roumlhrigrsquos

chipping plant Roumlhrig is convinced that

the technical improvements made tothe new Metso crusher can only be an

advantage worldwide

Roumlhrig places great value on consistent

product quality maximum added valueand optimum refinement of its product

range Bearing in mind that Roumlhrig has

enough reserves of raw material to last

for the next 150 years the company canconfidently continue to develop with an

emphasis on quality rather than quantity

More info

Dominic Schoenhardt

Tel +49 (0)621 727 00 610

dominicschoenhardtmetsocom

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Groupe Charier Carriegravere de la Mariais France

Quarrying with certi1047297ed quality The Charier Group with its 1600-strong workforce is a family business thatthis year celebrates 115 years of quarrying The company pursues a long-termdevelopment policy that since 2007 has seen processing installations upgradedat 4 of its 9 extraction sites

TEXT Liliane Boutin (with extracts from Mines amp Carriegraveres and Terrassements amp Carriegraveres magazines)PHOTO Baloon photo

The processing installation is of the horizontal type with a primary station located 56 meters below the site access road to keep it hidden from view

The crushing and screening installation at

Charierrsquos CM La Mariais quarry (at Donges

on the Loire estuary) has been in opera-tion since September 2011 Based on theoperatorrsquos ideas it was designed by Metso

to replace a worn-out installation installed

right on top of the seam being extracted

Since its commissioning it has becomethe second quarry in the company to

receive ISO 14 001 certification

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983122983141983152983151983154983156983145983150983143 983154983141983155

tertiary material of sand and gravel for the

local market to use in concrete surfacingprefabrication etcrdquo

Incorporation of a screening station

The stone extracted from La Mariais is

according to the quarry granitic gneiss

sound and homogeneous with a LosAngeles index of 15 good wear resist-

ance with an MDE of 10 a true density of

265 and a certain abrasiveness (2000 gt)ldquoCharacteristically it has a tendency to form

blocksrdquo Leblin points out

The main criteria in designing the instal-

lation was to provide an output of 600000metric tons from one station (38 hours

week) to produce materials aimed at the

concrete and surfacing markets ldquowhich

involved providing a tertiary station withscreening plantrdquo he adds

With this new unit the operating com-pany expands its product range through

the addition of fine materials obtained

from the tertiary screening station This unitis capable of producing 170 tonshour of

020

Preserving the environment

and optimizing safety

The screens have motorized bogies and

retractable walkways to facilitate access

when the screens are opened for main-tenance Other walkways provide access

to the tunnel input feeders The feederscan be isolated with hydraulic rod gate

bars this hydraulic assistance eliminatesthe need to use a heavy hammer to lodge

these metal bars

All conveyors transporting fines (02

and 04) are covered with a tarpaulin to

avoid flying dust and all the screens arehooded (metal cover with Trellex seal-

ing) The Brunone company has installed

dust-tight containment at the outlet of the

tertiary station crushers (HP300 and HP4)on the belt located under the screens

and under the hoppers located belowthe tertiary screens The crushers are put

under negative pressure and the finesare extracted through sleeve filters (7000

m3 h) with declogging which deposits the

dust back onto the conveyor belt

A high-pressure 100 bar water mist sys-tem has been installed at the primary sta-

tion discharge at the secondary crusherrsquos

discharge chutes (Omnicone) and at the

transfer points on the belt

Designed to last

ldquoThis type of new installation can easily last

thirty yearsrdquo affirms Project Leader Bruno

Peix of Metso ldquoIt quite simply depends on

how well it is maintained Thatrsquos why weprovide maintenance contracts that call for

our technicians to make regular inspection

visits and carry out preventive mainte-nance and any necessary repairsrdquo

In 2011 Metso commissioned about

10 new processing units in France like

the one at La Mariais quarry

More info

Frederic Bazire

Tel +33 (0)681442804

fredericbaziremetsocom

Key figures

DURATION OF WORKS 15 months

DRAWING OFFICE TIME 7800 hours

HEIGHT OF SILOS AND GRINDER BUILDINGS

15 m

TOTAL LENGTH OF CONVEYORS 14 km

WEIGHT OF THE INSTALLATION

1200 metric tons

CONCRETE POURED 1800 cubic meters

PROJECT SITE WORKFORCE 30

INSTALLED POWER 2200 kW(not including pumps 200 kW)

METSO EQUIPMENT

Primary

Vibrating feeder PF561-2V

Primary grizzly VG540-3V

Grizzly feeder TK13-20-3V

Jaw crusher C145 with

hydraulic setting

Secondary

Vibrating screen CVB 2050

refurbished

Cone crusher Omnicocircne 1352 SX

with Metso IC7000 controller Ellivar 16 (16 msup2 3 decks) screen

refurbished by Metso

Tertiary

Cone crusher HP300

Cone crusher HP4

2 Ellivar 20 screens (20 m23 decks) for final products

Expanding the production range

ldquoSince the mid-1990s when we became

owners of La Mariais we had used mobilemachinery with an assembly of beltconveyorsrdquo recalls Daniel Leblin Charierrsquos

Technical Manager for site construction

and maintenance

ldquoIt became clear that we needed ahigher performance tool to achieve the

dual goals of reaching one million metric

tonsrsquo maximum production and producing

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Big Lokotrack LT550GPF boostsquarrying productivity by a thirdMaximizing the productivity of operations is a key issue when striving for cost-effective quarrying Big Lokotracks are oneway to achieve improved operational efficiency The Lokotrack LT550GPF equipped with the high-volume GP550 conecrusher and a large screen is popular in the Nordic countries and in Germany and Australia ndash countries all known for theirhigh quarrying volumes

TEXT amp PHOTOS Eero Haumlmaumllaumlinen

Kone-Kostamorsquos new mobile coneplant has reached an averagecapacity of 300 tons per hour

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983122983141983152983151983154983156983145983150983143 983154983141983155

ldquoWith the same number of employees we

can achieve 30 more productivity with

our new LT550GPF unit The high-capacityFS screen has also eliminated the bottle-neck often seen at fine screeningrdquo says

Aarno Kostamo Managing Director of

Kone-Kostamo Oy one of Finlandrsquos biggest

crushing contractorsAccording to Kostamo the high capacity

of the GP550 gyratory cone crusher easily

handles feed from the C120 and C125 jaw

crushers For the contract with the Talvivaara

nickel mine the LT550GPF is being fed bythe brand new Lokotrack LT120 jaw plant

Average capacity 300 tons per hour

Talvivaara Europersquos largest nickel mine uti-

lizes large quantities of aggregates Kone-Kostamo has contracted several million

tons of different end products for the mineIn August 75000 tons of 0ndash63 mm

road gravel was crushed Smaller amountsof finer 0ndash6 mm 0ndash16 mm and 0ndash32 mm

aggregates are also being produced

The rainy summer increased the need

for road gravel along the muddy roadswhich must endure dump trucks weighing

as much as 260 tons

ldquoThe mobile process consisting of the

LT120 jaw plant and LT550GPF cone plant

is cost-effective while aggregates of vari-ous sizes can be produced in a two-stage

operation and with high capacity The con-trolled stroke and elliptical movement of

the FS screen secure big passing throughcapacitiesrdquo Kostamo explains

Operated in two shifts for a total of 16

hours per day the LT550GPF has logged

more than 600 working hours over a two-month period

Managing Director Aarno Kostamo (left) and foreman Karri Maumlenpaumlauml studying the cavity optionsavailable for the new Lokotrack LT550GPF

Longer perspective than

a single quarter needed

Kone-Kostamo Oy was founded as an

earth-moving company in Kemijaumlrvi

Northern Finland in 1956 The company

expanded its operations to include crush-

ing contracting in 1964 and later on

switched to concentrating fully on crush-ing activities

Kone-Kostamo consistently crushes

and screens around 28 million tons ofaggregates annually and has net sales of

between EUR 8ndash9 million

ldquoWe believe that issues within the crush-

ing industry including the purchasing ofmachinery must be studied with a longer

perspective than a single quarter The

secret to our success has always been our

solid work ethic and professional employ-eesrdquo Kostamo sums up

More info

Esa Berg

Tel + 358 40 837 8692

esabergmetsocom

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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155

Monitoring-based reporting is vital for

assessing the performance of a mobile

crushing plant Metso provides suchreporting tools through its plant-wideautomation system Metso DNA (Dynamic

Network of Applications) with its infor-

mation platform that links all the mobile

crushing and screen units together as oneentity Basically there is a lot of measured

real-time information available in every

crushing plant On-line information is

obtained either from each Metso crusherrsquosmachine automation system IC (Intelligent

Controller) or from separately installed

additional sensors and belt scales

All the collected data is sent to a motorhome using wireless communication

based on WLAN technology The motor

home is a purpose-built environment

inside an on-site container In this environ-ment selected variables can be monitored

for assessing the plantrsquos performance And

to make all this even more flexible the

data can be transmitted to a crushing plant

company office using GPRS3G mobile

data communication technologies Thismakes all the last-minute reports acces-sible to the crushing plant managerial staff

at anytime and basically anywhere within

reach of the cell phone network

Production and fuel economics reports

Essentially monitoring and reporting can

be customized to fit the customerrsquos needs

However there are certain off-the-shelf

reports that provide a lot of useful informa-tion for plant supervision The production

report is one of these Requiring at least one

belt scale for measuring the total produc-tion the production report shows the pro-duction rate (tons per hour) for a selected

reporting period eg a day or a week The

production report constantly keeps track of

the plantrsquos production storing all the datathroughout the plantrsquos life cycle

Performance monitoring and reportingfor a mobile crushing plantTEXT Pasi Airikka PHOTOS Metso

unit during which the unit is running By

storing the availability times between start-ups and shutdowns the crushing plant

operation time (hours per dayshift) can be

recorded analyzed and reported In addi-

tion the availability report can be tailored

to evaluate efficient crushing hours during

which the plant is really working and pro-ducing aggregates Consequently the ratio

(0-100) between efficient crushing time

and total running time can be reported forany selected period of time This boosts

the efficiency of the plantrsquos operations

and results in better productivity

Reports on non-choke

or inadequate feeding

Non-choke feeding to crushers is avoid-

able through smart plant-wide crushingplant controls But estimating its severity in

a systematic manner is not straight-forwardwithout constant monitoring and reporting

The crusher choke feeding report makes

use of the crusher cavity level sensors byanalyzing their level measurements By

calculating average and min-max values

and deviations from the average it can be

shown how often the single crusher suffersfrom non-choke feeding to it

In some cases the bottleneck in the

crushing plantrsquos productivity is the material

feeding to the process In mobile plants thefeeding is human operated and therefore

subject to variations Occasionally the sizeof the human-operated machine simply

does not allow for adequate feeding to thecrushing plant There are specific reports

indicating time periods when the crushing

plant suffers from inadequate feeding

Condition monitoring for

crushers and screens

Machine-specific condition monitoring

focuses on vibrating components in

crushers and screens such as drive shaftbearings safety plate wearings and gears

The low middle and high frequencies ofmonitored components are measured and

supervised in real-time to detect abnor-malities due to slow or fast wear looseness

or imbalance

More info

Pasi Airikka

Tel +358 40 587 2730

pasiairikkametsocom

Condition monitoring provides a view tovibrating crusher and screen components forpredictive equipment maintenance

The daily production report shows the hour-by-hour production trend and distribution chartfor a selected day with min-max average andvariation statistics for comparison

Fuel consumption is always an interest-ing concern The fuel consumption reportgives the fuel consumption of each crush-

ing unit (liters per hour) and their total

consumption (liters per hour) for a selected

reporting period and can track fuel con-

sumption changes over timeCrushing plant availability can be

assessed as well The availability report

calculates time periods for each crushing

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983149983141983156983155983151 983150

for tissue machines The record of 2210

mmin was set on June 1 2012 during a

24-hour production run by the TM 2 tissue

machine at the companyrsquos mill in Yenikoumlynear the city of Izmit in Turkey

ldquoThe cooperation with Metso has been

beyond excellent and both parties did

their utmost to make the project success-ful The results clearly show that the efforts

were worthwhile on both sides This coop-

eration will extend to cover new projects

in the futurerdquo says Luumlt1047297 Aydin Paper GroupDirector Hayat Kimya

ldquoWe are not surprised that Hayat K imya

managed to break the world speed record

We have had great confidence in the capa-bility of the Hayat team since our project

started in 2009 We certainly know our

machine very well its stability production

efficiency and speed capabilityrdquo says Jan

Erikson Vice President Sales Metso

PowerThe worldrsquos first eco-gas fueled

power plant is up and running

Lahti Energy Ltdrsquos new Kymijaumlrvi II gasifica-

tion plant was officially inaugurated on

May 8 2012 It is the first of its kind in the

RecyclingRecycling with Lokotrack LT106

jaw plant in New York

A brand-new Lokotrack LT106 jaw plant is

used in the city area of New York USA to

recycle demolition materials The crushing

site faces the skyscrapers of ManhattanIsland

Paper amp FiberHayat Kimyarsquos Metso-supplied tissue

machine sets world speed record

Thanks to a skilled crew and dedicated

efforts Hayat Kimya AS in Turkey has suc-

ceeded in breaking the world speed record

world This CHP plant runs on clean eco-

gas that is gasified cleaned and cooled

from recycled waste with Metsorsquos innova-tive technology

ldquoItrsquos actually eco-gas that we combust

in the boilerrdquo comments Lahti EnergyrsquosProduction Director Jukka Manskinen

ldquoWe convert unwanted waste material into

energy in an efficient and environmentally

friendly wayrdquoNever before has any plant gasified

waste on such a large scale In the gasifier

recycled waste is turned into combustible

product gas which is cleaned cooled and

combusted in a high-efficiency gas boiler

to produce steam for the steam turbine The plant produces 50 MW of electricity

and 90 MW of district heat for the city of

Lahti and its neighboring areasMetso delivered the circulating fluidized

bed (CFB) gasification process gas cleaning

and cooling steam boiler environmental

protection system and automation systemto the entire plant The production of elec-

tricity and heat is kept even with the Metso

DNA automation system that covers the

whole plant starting from fuel reception

AutomationMetso develops and supplies plant-

wide crushing control solutions for

crushing plants

Metso has recently signed contracts on

delivering plant-wide automation systems

for mobile and portable rock crushing

plants The key objective of these deliveries

is to stabilize and to increase productivityand efficiency of the plants using one sin-

gle automation and information platform

for integrating crusher-specific IC machinecontrols

Furthermore the plant-wide system

with its information management tools not

only increases plant availability and opera-

tional safety it also makes troubleshoot-ing quicker and performance monitoring

easier The control room for plant-wide

operability is located either in an excavator

cabin or a purpose-built container

Metso around the world

The new LT106 jaw plant is suitable for crushing both hard rock and all rock-based demolition materials

The new world speed record for tissue setby Hayat Kimyarsquos Metso-supplied TM 2 is2210 mmin

8132019 Results Minerals Aggregates 3 2012ENG

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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 28: Results Minerals Aggregates 3 2012.ENG

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When yoursquore allowed less than a dozen days per year for breakdowns repair andmaintenance every single hour during a service shutdown counts There simplyisnrsquot any room for surprises Thatrsquos why Boliden counts on MetsoTEXT amp PHOTOS Sofia Williams

8983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

Kurt Kalla Site Managerof Metso Gaumlllivare ServiceCenter is responsible forthe maintenance of Aitik

Metso and Boliden Strivingtogether for 97 uptime

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983122983141983152983151983154983156983145983150983143 983154983141983155

One of the biggest copper mines in

Europe Bolidenrsquos Aitik is located deep inthe wilderness of Swedish Lapland next to

the small town of Gaumlllivare The mine has

been operating since 1968 and a recent

expansion has increased its annual ore

production to 36 million tons

But the ambitious Swedes are not will-ing to lay back and relax just yet Bolidenrsquos

new aim is to reach a production rate of

45 million tons of ore per year in AitikAfter that Perhaps more than 55 million

tons The ore concentration in Aitik is very

low-grade with a mere 022 copper con-

tent hence the need for high capacityAchieving the ambitious production

goal requires maximum plant availability

This means that everything from the crush-

ers to the filters must be up and runningfor approximately 97 percent of the time

Thatrsquos where Metso comes into play

A cost-per-ton contract in action

The maximum uptime requirement allowsless than a dozen days per year for break-

downs repair and maintenance at Aitik

Every single hour during a service shut-

down counts There simply isnrsquot any roomfor surprises

Executing a successful shutdown under

such conditions requires a reliable service

partner not afraid of challenges and this iswhy Boliden has entrusted Aitikrsquos services

operations to Metso Boliden and Metsohave worked together since the 1960s

and the collaboration took another step

forward in September 2012 when the twocompanies signed a three-year extension

of the services contract for Boliden Aitik

ldquoThe new contract is a cost-per-ton

agreement We get paid based on Aitikrsquos

production Itrsquos a win-win deal for both par-

ties but also a new mindset for usrdquo explainsKurt Kalla Site Manager of Metso Gaumlllivare

Service Center responsible for serving Aitik

From now on the duration of the shut-down is what matters the most According

to Kalla the Metso service organization in

Gaumlllivare is now streamlining its operations

to fit the bill and has already witnessed thestrategy working In August 2012 Metso

carried out a 188-hour service shutdown in

Aitik which turned out to be a success

Zero tolerance for injury

One key factor to the success was theextensive planning of precautionary health

safety and environment procedures under-

taken by Metso prior to the shutdown Thanks to strict measures applied no

injuries or accidents occurred during the

shutdown and the work could easily be

finished on scheduleMats Johansson Health Safety

and Environment Manager for Metso in

Sweden explains how this was achieved

rdquoPlanning of the shutdown included arisk analysis for all new tasks participating

in Bolidenrsquos safety coordination meetingsmeeting with both Metso supervisors and

subcontractor supervisors and finally a

meeting with the entire staff participating

in the shutdown where everyone had to

sign a document stating their commitmentto the information providedrdquo he says

During the actual shutdown plenty of

new barriers signs and awareness cones

were put in place as a result of observa-tions from previous audits and safety plans

and risk analyses were readily available

in the work area Metso and Boliden also

introduced a Mill Inching permit a certifi-cate for completing a mandatory course for

those involved in the process In addition

Metso carried out random safety audits

during the shutdown to make sure thestrict policy was followed

According to Boliden Metsorsquos way of

working is a good example of how health

and safety precautions should be handled

ldquoMetso is a good example of how towork with safety and health plans risk

analysis permits and welding permits

Their table with all binders in the second-

ary mill area was exemplaryrdquo says Kjell-Arne

Johansson a technician from Boliden

The use of the new Metso Megalinertrade

system in the lining of Aitikrsquos Metso AG

mills has also improved the safety of main-tenance staff The Metso Megalinertrade con-

sists of larger-than-average liners bolted

in position from outside the mill Mainte-

nance technicians no longer need to go

inside the mill and stand in the dangerousdrop-zone of the liners gt

Boliden aims to reach a production rate of 45 million tons of ore per yearin the Aitik mine site

ldquoA complete risk analysis was conducted during the planningof the shutdownrdquo comments Mats Johansson Health Safetyand Environment Manager for Metso in Sweden

8132019 Results Minerals Aggregates 3 2012ENG

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Service the Metso way

24 hours a day 365 days a year

In addition to paying close attention to

health and safety issues executing an effi-

cient shutdown requires careful planning

and timing of every step in the mainte-

nance process Wear and spare parts have

to be available on time and a repair shoplarge enough to accommodate equipment

located close by

ldquoTo keep maintenance breaks as short

as possible we aim to replace the pump on

site and bring the old one for repair to our

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

nearby facilities This method gives us the

peace to do a good job and keep the cus-

tomerrsquos operations runningrdquo Kalla describes

the Metso way of handling Aitikrsquos pump

maintenance

Metso is currently expanding its Gaumllli-

vare service center to include a distribu-

tion center for wear and spare parts andalso concentrating its previously scattered

operations under one roof in its Vuoskon-

jaumlrvivaumlgen facility The expansion is due to

be completed by 2014

Metso equipment

delivered to Aitik36

bull 2 AG mills diameter 116 x

137 m gearless 22-MW motor

bull 2 Pebble mills diameter 91 x

113m dual 5-MW pinion drive

bull 3 VPA pressure filters VPA 1540-54

bull 12 sample pumps and pipes

VF50

bull 60 Various slurry pumps up to

MR500 modelbull Appr 5000 m rubber-lined slurry

pipes up to 600 mm diameter

bull Appr 5000 m rubber-lined by

gravity pipes up to 600 mm

diameter

bull Appr 5000 m rubber hoses

up to 600 mm diameter

Not only does the expansion make ser-

vice shutdowns at Aitik run more smoothly

it guarantees a more comprehensive

on-call emergency service response in the

region ndash thanks to the spare and wear parts

inventory available 24 hours a day 365

days a year

More info

Lars Rosenling

Tel +46 70 107 45 90

larsrosenlingmetsocom

Metso grinding equipment dominates the view in the concentrator

Safety on site is made up of small things like

making sure that everyone remembers to secure

the hoses in place

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Pebbles have always been a

challenge for producers of sandsince they cannot be returned

to rivers after extraction For

decades the processing of this

material resulted in a huge

environmental liability with alarge amount of pebbles hav-

ing to be stored away and left

unused

Transforming problems into

business opportunities

Areia amp Cia (areia = sand) has

operated in this market forover 20 years and decided to

enlist the help of Metso to find

a profitable solution for the

processing of pebbles

In July 2011 analyses werebegun to assess the abrasive-

ness and crushability of the

material Four alternatives wereidentified for processing and

transforming pebbles into sand

Initially Areia amp Cia was

interested in acquiring an

impactor for its reason-able price level However the

customer wanted to process

all the pebbles that were col-

lected daily in addition to some of the

material that it had stored In weighing theresults expected by the customer and the

excessive abrasiveness of the material the

HP200 cone crusher was decided on as thebest alternative

Areia amp Cia made the required invest-

ment and after using the HP200 for just

six months the company has already beenreporting outstanding results The HP200

not only transforms pebbles into sand but

also produces sand of excellent quality

with high yield and low maintenanceWith minor adjustments the HP200

also enables the production of sand withspecific particle size distribution for special

applications such as filtering sand blasting

and foundry sand adding value to the prod-

uct and increasing the types of sand offeredldquoMetso is pleased that the HP200 not

only enabled the processing of a product

that had been set aside as unusable but

HP200 cone transforms pebblesinto high-quality sandOver the last few decades Brazilian economic growth has been driving demand for construction aggregates The market

for sand in turn has been experiencing major difficulties in maintaining a consistent supply Presently one of the mainchallenges the industry faces is the large amount of pebbles that are obtained in the process of extracting sand at timesconstituting nearly 50 of the volume of material dredged from riverbeds

TEXT Sheila Ivers PHOTO Areia amp Cia

also that it opened up new

market opportunities for Areiaamp Cia Thatrsquos the standard we

seek to deliver to our custom-

ersrdquo states Luiz Oliveira Techni-

cal Salesperson of Metso Brazil

HP cones entering the

Brazilian sand-making

market

Todayrsquos cones such as theHP200 have high resistance

to impacts and abrasiveness

more efficient crushing cham-

bers low maintenance costsand excellent productivity

Following the acquisition of

the HP200 Areia amp Cia is now

also producing special sands

that command a price that is100 higher than common

sand The entire stockpile of

pebbles accumulated through-out the companyrsquos 20 years of

operations has already been

transformed into sand and the

stock of pebbles held by com-

petitors is also being purchasedfor processing

Cristiane Brizolari the

owner of Areia amp Cia confirms

the transformation that has taken place in

the production and commercial processldquoThe HP200 opened up new niches in

the market enabling the production of dif-

ferent types of sand with added valuerdquo

More info

Luiz Oliveira

Tel +55 011 9971 3603

luizoliveirametsocom

After the pebbles are crushed into sand with the HP200 cone crusherdifferent grades are screened for various end uses

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Where therersquos a will we dig a wayAFCONS-Strabag and Metso embark on tunnel project together

When the joint venture AFCONS-Strabag initiated work on the Rohtang bypass tunnel project at an altitude of 3980 metersabove sea level in Himachal Pradesh India they deliberated each aspect with clockwork precision The project involved anumber of surprises and challenges and required technology and project management skills that were second to none

TEXT amp PHOTOS Monisha Majumdar

Cutting a 10-meter-wide and nearly 9-kilo-

meter-long tunnel through the Himalayas

in one of the toughest terrains and cli-mates in India makes for quite a challengeResults set out to find out how AFCONS-

Strabag and Metso are making their way in

one of their most critical projects to date

The only road connection to the north-Indian border region of the province

Himachal-Pradesh and beyond the Manali-

Leh highway leads across the Rohtang

pass Due to the heavy snowfall and high-

velocity winds in this region the towns

located north of the pass are cut off from

the rest of the country during winter for atleast four often even six months each year

A tunnel with strategic importance

With the construction of the tunnel at

3100 m above sea level the Manali-Lehhighway will become an all-weather road

thereby enabling a significant improve-

ment in the economic development of

northern Himachal-Pradesh and an alter-

nate route to the strategically important

Ladakh region

Manali south of the pass is an alreadywell-developed tourist location that is

becoming more and more popular Upon

completion of the tunnel it is likely that

tourist activities will extend to the areanorth of the pass Moreover the tunnel

shortens the distance between the towns

of Manali and Leh by approximately 45 km

thus saving several hours on the small dan-gerous pass road

The Rohtang pass in the Western Himalaya

region of Northern India with its altitude ofalmost four kilometers ranks among thehighest trafficable passes in the world

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The 88-km long horse-shoe-shaped

tunnel provides space for a two-lane8-m-wide carriageway as well as a one-

meter-wide footpath on both sides A

22-m-high and 36-m-wide emergency

tunnel will be integrated in the tun-

nel cross-section Altogether more than

800000 msup3 of rock will be moved Tunneling works started around spring

2010 with excavation driven from both por-

tals As the north portal is inaccessible dur-ing winter closure the excavation focused

on the south After a planned construction

period of 55 years the tunnel is scheduled

to be completed by the end of 2015

Best man for the job

The BRO (Border Road Organization)

wanted to roll out a global tender for theproject due to the challenges that such a

project involves and also considering thatitrsquos the first time in India that a project of

this scale was to be carried out This imme-

diately triggered the need to roll out aglobal tender All major Indian construction

companies bid for it some individually and

some in partnerships

Strabag an Austrian tunnel specialistwas one of the companies who bid for the

project along with AFCONS a Mumbai-

based infrastructure company In Septem-

ber 2009 AFCONS-Strabag was awardedthe contract

Mr Sunil Tyagi Deputy Project Man-ager at AFCONS had this to say about the

unique projectldquoThis project is located in the Himalayas

and as far as we understand the terrain

there is among the toughest We came out

with a new technology and to be honestit is a fairly simple one We would generally

start with the traditional technology of drill-

ing and blasting and then obtain our muck

feed from the inwardbottom of the tunnelrdquo

ldquoThe technology is supplied by Rowa Tunneling Logistics and this is the first

time it is being used in Asia A jaw crusheris placed at a distance of about 40-45

meters behind the face The blasted muckextracted from the face is fed to the crusher

to reduce the lump size and then through

an overhead conveyor transport system

it is then transported out of the tunnelrdquoldquoThis enables free movement of man

and machinery in the lower area or spe-

cifically on the ground area If we were to

conforms to the Indian standard for fines amp

coarse aggregates as prescribed in IS383-1970

The plant was up and running in good

condition and performing to AFCONSrsquos

satisfactionldquoWe have worked with Metso in earlier

projects and are quite impressed by thekind of technology amp services they provide

We have a history together so the trust fac-tor also comes inrdquo explains Dhiman on their

choice of Metso as a partner

Service makes the difference

ldquoMetsorsquos services have made a big dif-ference in the project Without them we

would still be struggling with the machin-

ery and production The service is really

good and the service engineers are knowl-edgeable prompt and quick to act Any

problem can be solved by Metso We donrsquothave to wait until a service engineer turns

up ndash they have the capacity to solve prob-lems over the phone as wellrdquo says Dhiman

ldquoThe Metso plant didnrsquot create any prob-

lems for us We had problems in logistics

the feed was sticky and the weather condi-tions were bad but thankfully we did not

face any problems with production and

efficiency as the Metso plant is performing

very wellrdquo Dhiman concludes

More info

Amol Sinha Tel +91 9811 671 924

amolsinhametsocom

use the old conventional technology this

wouldnrsquot have worked for us in the stipu-lated timerdquo Mr Tyagi adds

When the going gets tough

partner with the toughest

Sensitive projects require the best technol-

ogy After AFCONS-Strabag landed theproject Metso was an obvious choice as a

technology provider not only because of

the long-standing business relationshipbut also for the sheer consistency in prod-

uct quality and service deliverance Metso

strives for

ldquoAfter signing the project we faced alot of road blocks including extreme cold

avalanches roadblocks less oxygen ndash you

name it we faced itrdquo explains Ankit Dhi-

man Plant Manager at AFCONS-Strabag The Rohtang valley is known for its

notorious avalanches and landslides SoAFCONS had to take extra steps and safety

precautions against hazards on the site

ldquoIn this freezing cold not just us humansbut also the machines are at increased risk

of damage I remember when we used

to run the plant during winter the diesel

engines would freeze We had to constantlyheat up the fuel container to get the plant

running And even the sand in the sand

trap would freeze so we had to clean it on

a daily basis to stop the pipes from mal-functioningrdquo Dhiman adds

Plant designed for difficult terrain

Difficult terrain coupled with space con-straints led Metso engineers to put their

minds together to come up with a suitable

plant configuration After studying the

requirements of the project Metso sug-

gested a 150-tons-per-hour three-stagemodular plant using a C106 jaw crusher

a GP11F secondary cone crusher and a

B7150 tertiary vertical shaft impact crusher

In addition considering the unpredict-ability of the feed the plant was about

to reach a point where the amount offines to be handled could be increased

dramatically Metso strongly suggested the TK11-27-3V grizzly scalper and this became

the first-ever TK scalper to be supplied by

Metso to an Indian customer Also in order

to get better products a sand trap SF2360was added to the configuration

The sand trap is important equipment

for this project as it washes the sand thatMr Sunil Tyagi Deputy Project ManagerAFCONS-Strabag

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Smooth transition to new-generation jaw crusher in Germany

Roumlhrig is a German company with a rich heritage The company has been quarrying granite at its plant in Bergstrasse inthe Sonderbach district of Heppenheim for three generations

TEXT amp PHOTOS Ralf Goffin

Roumlhrigrsquos superior product variety is onereason why the companyrsquos proximity to its

customers can be understood in more than

just physical terms The companyrsquos high

level of innovation has allowed it to estab-lish itself as a reliable supplier of materials

both regionally and internationally This

operational and technical expertise always

manages to keep in step with growing

market requirements

In terms of technical processing equip-

ment Roumlhrig has used a Nordberg C160stationary jaw crusher from Metso since

1992 At the start of 2012 it was finally

exchanged for a more up-to-date version

from the same model range

Metsorsquos C Series is specifically designed

to pre-crush hard rock and can cope effort-

lessly with even the hardest of materials

The dimensions of the new stationary jawcrusher are identical to those of the old

one which means that it could simply be

slotted into the housing vacated by the

previous version

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983122983141983152983151983154983156983145983150983143 983154983141983155

Third-generation Managing DirectorMarco Roumlhrig expects the new machinersquos

service life to be just as long as the previ-

ous model due to the product upgrades

that have been implemented The integral motor base is another plus

point in models made by other manu-

facturers it is located outside the crusher

This element of good fortune ensured that

Roumlhrig could reuse the housing withoutany additional rebuilding

Another advantage lies in the revision

of the guards for the C160rsquos drivetrain andflywheel The sturdier construction method

used for the crusher requires fewer parts

which facilitates easier installation andmaintenance and it makes it simpler to

access the motor

Under the watchful eye of Metsorsquos

Assembly Manager Maik Engelstaumltterthe entire project including removal and

installation was successfully completed

within two weeks

Installation making the most

of the available space

Roumlhrig will likely remember the day the

new crusher was installed for a long time

the pitman and main frame were deliveredseparately prior to installation and assem-

bled on site It took just one hour to replace

the old stationary crusher with the new

model A lorry-mounted crane was used toposition the 85-ton crusher with millimeter

precision in the crushing plant Once the

new crusher had been positioned in theexisting steel structure the next task wasto fix it into place as securely as possible

despite the limited space Special vibration

dampers were installed at a height of two

meters to prevent the crusher from sliding

Norbert Ried (fourth from left) installed thenew C160rsquos predecessor 20 years ago and isdelighted at the durability of the powerfulcrusher that is now making way for a newermodel Also pictured from left to right ManagerVolker Angermann Assembly Manager Maik

Engelstaumltter Technical Manager Stefan

Koob Project Manager Dominic SchoumlnhardtManaging Director Marco Roumlhrig Service

Technician Stefan Kolze and employees ofthe installation company Stafemo

On the hook after theold C160 was liftedout by crane the newcrusher was installedin almost no timeOnly the roof of thehousing had to beremoved

sideways off its mount An initial test run

with materials was carried out around oneweek later after all the electrical cables had

been installed

Simultaneously with the installation

of the C160 which is the first of the latest

generation of crushers to be installed in

Germany a new Nordberg GP100 conecrusher was also being installed in Roumlhrigrsquos

chipping plant Roumlhrig is convinced that

the technical improvements made tothe new Metso crusher can only be an

advantage worldwide

Roumlhrig places great value on consistent

product quality maximum added valueand optimum refinement of its product

range Bearing in mind that Roumlhrig has

enough reserves of raw material to last

for the next 150 years the company canconfidently continue to develop with an

emphasis on quality rather than quantity

More info

Dominic Schoenhardt

Tel +49 (0)621 727 00 610

dominicschoenhardtmetsocom

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Groupe Charier Carriegravere de la Mariais France

Quarrying with certi1047297ed quality The Charier Group with its 1600-strong workforce is a family business thatthis year celebrates 115 years of quarrying The company pursues a long-termdevelopment policy that since 2007 has seen processing installations upgradedat 4 of its 9 extraction sites

TEXT Liliane Boutin (with extracts from Mines amp Carriegraveres and Terrassements amp Carriegraveres magazines)PHOTO Baloon photo

The processing installation is of the horizontal type with a primary station located 56 meters below the site access road to keep it hidden from view

The crushing and screening installation at

Charierrsquos CM La Mariais quarry (at Donges

on the Loire estuary) has been in opera-tion since September 2011 Based on theoperatorrsquos ideas it was designed by Metso

to replace a worn-out installation installed

right on top of the seam being extracted

Since its commissioning it has becomethe second quarry in the company to

receive ISO 14 001 certification

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983122983141983152983151983154983156983145983150983143 983154983141983155

tertiary material of sand and gravel for the

local market to use in concrete surfacingprefabrication etcrdquo

Incorporation of a screening station

The stone extracted from La Mariais is

according to the quarry granitic gneiss

sound and homogeneous with a LosAngeles index of 15 good wear resist-

ance with an MDE of 10 a true density of

265 and a certain abrasiveness (2000 gt)ldquoCharacteristically it has a tendency to form

blocksrdquo Leblin points out

The main criteria in designing the instal-

lation was to provide an output of 600000metric tons from one station (38 hours

week) to produce materials aimed at the

concrete and surfacing markets ldquowhich

involved providing a tertiary station withscreening plantrdquo he adds

With this new unit the operating com-pany expands its product range through

the addition of fine materials obtained

from the tertiary screening station This unitis capable of producing 170 tonshour of

020

Preserving the environment

and optimizing safety

The screens have motorized bogies and

retractable walkways to facilitate access

when the screens are opened for main-tenance Other walkways provide access

to the tunnel input feeders The feederscan be isolated with hydraulic rod gate

bars this hydraulic assistance eliminatesthe need to use a heavy hammer to lodge

these metal bars

All conveyors transporting fines (02

and 04) are covered with a tarpaulin to

avoid flying dust and all the screens arehooded (metal cover with Trellex seal-

ing) The Brunone company has installed

dust-tight containment at the outlet of the

tertiary station crushers (HP300 and HP4)on the belt located under the screens

and under the hoppers located belowthe tertiary screens The crushers are put

under negative pressure and the finesare extracted through sleeve filters (7000

m3 h) with declogging which deposits the

dust back onto the conveyor belt

A high-pressure 100 bar water mist sys-tem has been installed at the primary sta-

tion discharge at the secondary crusherrsquos

discharge chutes (Omnicone) and at the

transfer points on the belt

Designed to last

ldquoThis type of new installation can easily last

thirty yearsrdquo affirms Project Leader Bruno

Peix of Metso ldquoIt quite simply depends on

how well it is maintained Thatrsquos why weprovide maintenance contracts that call for

our technicians to make regular inspection

visits and carry out preventive mainte-nance and any necessary repairsrdquo

In 2011 Metso commissioned about

10 new processing units in France like

the one at La Mariais quarry

More info

Frederic Bazire

Tel +33 (0)681442804

fredericbaziremetsocom

Key figures

DURATION OF WORKS 15 months

DRAWING OFFICE TIME 7800 hours

HEIGHT OF SILOS AND GRINDER BUILDINGS

15 m

TOTAL LENGTH OF CONVEYORS 14 km

WEIGHT OF THE INSTALLATION

1200 metric tons

CONCRETE POURED 1800 cubic meters

PROJECT SITE WORKFORCE 30

INSTALLED POWER 2200 kW(not including pumps 200 kW)

METSO EQUIPMENT

Primary

Vibrating feeder PF561-2V

Primary grizzly VG540-3V

Grizzly feeder TK13-20-3V

Jaw crusher C145 with

hydraulic setting

Secondary

Vibrating screen CVB 2050

refurbished

Cone crusher Omnicocircne 1352 SX

with Metso IC7000 controller Ellivar 16 (16 msup2 3 decks) screen

refurbished by Metso

Tertiary

Cone crusher HP300

Cone crusher HP4

2 Ellivar 20 screens (20 m23 decks) for final products

Expanding the production range

ldquoSince the mid-1990s when we became

owners of La Mariais we had used mobilemachinery with an assembly of beltconveyorsrdquo recalls Daniel Leblin Charierrsquos

Technical Manager for site construction

and maintenance

ldquoIt became clear that we needed ahigher performance tool to achieve the

dual goals of reaching one million metric

tonsrsquo maximum production and producing

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Big Lokotrack LT550GPF boostsquarrying productivity by a thirdMaximizing the productivity of operations is a key issue when striving for cost-effective quarrying Big Lokotracks are oneway to achieve improved operational efficiency The Lokotrack LT550GPF equipped with the high-volume GP550 conecrusher and a large screen is popular in the Nordic countries and in Germany and Australia ndash countries all known for theirhigh quarrying volumes

TEXT amp PHOTOS Eero Haumlmaumllaumlinen

Kone-Kostamorsquos new mobile coneplant has reached an averagecapacity of 300 tons per hour

8132019 Results Minerals Aggregates 3 2012ENG

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ldquoWith the same number of employees we

can achieve 30 more productivity with

our new LT550GPF unit The high-capacityFS screen has also eliminated the bottle-neck often seen at fine screeningrdquo says

Aarno Kostamo Managing Director of

Kone-Kostamo Oy one of Finlandrsquos biggest

crushing contractorsAccording to Kostamo the high capacity

of the GP550 gyratory cone crusher easily

handles feed from the C120 and C125 jaw

crushers For the contract with the Talvivaara

nickel mine the LT550GPF is being fed bythe brand new Lokotrack LT120 jaw plant

Average capacity 300 tons per hour

Talvivaara Europersquos largest nickel mine uti-

lizes large quantities of aggregates Kone-Kostamo has contracted several million

tons of different end products for the mineIn August 75000 tons of 0ndash63 mm

road gravel was crushed Smaller amountsof finer 0ndash6 mm 0ndash16 mm and 0ndash32 mm

aggregates are also being produced

The rainy summer increased the need

for road gravel along the muddy roadswhich must endure dump trucks weighing

as much as 260 tons

ldquoThe mobile process consisting of the

LT120 jaw plant and LT550GPF cone plant

is cost-effective while aggregates of vari-ous sizes can be produced in a two-stage

operation and with high capacity The con-trolled stroke and elliptical movement of

the FS screen secure big passing throughcapacitiesrdquo Kostamo explains

Operated in two shifts for a total of 16

hours per day the LT550GPF has logged

more than 600 working hours over a two-month period

Managing Director Aarno Kostamo (left) and foreman Karri Maumlenpaumlauml studying the cavity optionsavailable for the new Lokotrack LT550GPF

Longer perspective than

a single quarter needed

Kone-Kostamo Oy was founded as an

earth-moving company in Kemijaumlrvi

Northern Finland in 1956 The company

expanded its operations to include crush-

ing contracting in 1964 and later on

switched to concentrating fully on crush-ing activities

Kone-Kostamo consistently crushes

and screens around 28 million tons ofaggregates annually and has net sales of

between EUR 8ndash9 million

ldquoWe believe that issues within the crush-

ing industry including the purchasing ofmachinery must be studied with a longer

perspective than a single quarter The

secret to our success has always been our

solid work ethic and professional employ-eesrdquo Kostamo sums up

More info

Esa Berg

Tel + 358 40 837 8692

esabergmetsocom

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Monitoring-based reporting is vital for

assessing the performance of a mobile

crushing plant Metso provides suchreporting tools through its plant-wideautomation system Metso DNA (Dynamic

Network of Applications) with its infor-

mation platform that links all the mobile

crushing and screen units together as oneentity Basically there is a lot of measured

real-time information available in every

crushing plant On-line information is

obtained either from each Metso crusherrsquosmachine automation system IC (Intelligent

Controller) or from separately installed

additional sensors and belt scales

All the collected data is sent to a motorhome using wireless communication

based on WLAN technology The motor

home is a purpose-built environment

inside an on-site container In this environ-ment selected variables can be monitored

for assessing the plantrsquos performance And

to make all this even more flexible the

data can be transmitted to a crushing plant

company office using GPRS3G mobile

data communication technologies Thismakes all the last-minute reports acces-sible to the crushing plant managerial staff

at anytime and basically anywhere within

reach of the cell phone network

Production and fuel economics reports

Essentially monitoring and reporting can

be customized to fit the customerrsquos needs

However there are certain off-the-shelf

reports that provide a lot of useful informa-tion for plant supervision The production

report is one of these Requiring at least one

belt scale for measuring the total produc-tion the production report shows the pro-duction rate (tons per hour) for a selected

reporting period eg a day or a week The

production report constantly keeps track of

the plantrsquos production storing all the datathroughout the plantrsquos life cycle

Performance monitoring and reportingfor a mobile crushing plantTEXT Pasi Airikka PHOTOS Metso

unit during which the unit is running By

storing the availability times between start-ups and shutdowns the crushing plant

operation time (hours per dayshift) can be

recorded analyzed and reported In addi-

tion the availability report can be tailored

to evaluate efficient crushing hours during

which the plant is really working and pro-ducing aggregates Consequently the ratio

(0-100) between efficient crushing time

and total running time can be reported forany selected period of time This boosts

the efficiency of the plantrsquos operations

and results in better productivity

Reports on non-choke

or inadequate feeding

Non-choke feeding to crushers is avoid-

able through smart plant-wide crushingplant controls But estimating its severity in

a systematic manner is not straight-forwardwithout constant monitoring and reporting

The crusher choke feeding report makes

use of the crusher cavity level sensors byanalyzing their level measurements By

calculating average and min-max values

and deviations from the average it can be

shown how often the single crusher suffersfrom non-choke feeding to it

In some cases the bottleneck in the

crushing plantrsquos productivity is the material

feeding to the process In mobile plants thefeeding is human operated and therefore

subject to variations Occasionally the sizeof the human-operated machine simply

does not allow for adequate feeding to thecrushing plant There are specific reports

indicating time periods when the crushing

plant suffers from inadequate feeding

Condition monitoring for

crushers and screens

Machine-specific condition monitoring

focuses on vibrating components in

crushers and screens such as drive shaftbearings safety plate wearings and gears

The low middle and high frequencies ofmonitored components are measured and

supervised in real-time to detect abnor-malities due to slow or fast wear looseness

or imbalance

More info

Pasi Airikka

Tel +358 40 587 2730

pasiairikkametsocom

Condition monitoring provides a view tovibrating crusher and screen components forpredictive equipment maintenance

The daily production report shows the hour-by-hour production trend and distribution chartfor a selected day with min-max average andvariation statistics for comparison

Fuel consumption is always an interest-ing concern The fuel consumption reportgives the fuel consumption of each crush-

ing unit (liters per hour) and their total

consumption (liters per hour) for a selected

reporting period and can track fuel con-

sumption changes over timeCrushing plant availability can be

assessed as well The availability report

calculates time periods for each crushing

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983149983141983156983155983151 983150

for tissue machines The record of 2210

mmin was set on June 1 2012 during a

24-hour production run by the TM 2 tissue

machine at the companyrsquos mill in Yenikoumlynear the city of Izmit in Turkey

ldquoThe cooperation with Metso has been

beyond excellent and both parties did

their utmost to make the project success-ful The results clearly show that the efforts

were worthwhile on both sides This coop-

eration will extend to cover new projects

in the futurerdquo says Luumlt1047297 Aydin Paper GroupDirector Hayat Kimya

ldquoWe are not surprised that Hayat K imya

managed to break the world speed record

We have had great confidence in the capa-bility of the Hayat team since our project

started in 2009 We certainly know our

machine very well its stability production

efficiency and speed capabilityrdquo says Jan

Erikson Vice President Sales Metso

PowerThe worldrsquos first eco-gas fueled

power plant is up and running

Lahti Energy Ltdrsquos new Kymijaumlrvi II gasifica-

tion plant was officially inaugurated on

May 8 2012 It is the first of its kind in the

RecyclingRecycling with Lokotrack LT106

jaw plant in New York

A brand-new Lokotrack LT106 jaw plant is

used in the city area of New York USA to

recycle demolition materials The crushing

site faces the skyscrapers of ManhattanIsland

Paper amp FiberHayat Kimyarsquos Metso-supplied tissue

machine sets world speed record

Thanks to a skilled crew and dedicated

efforts Hayat Kimya AS in Turkey has suc-

ceeded in breaking the world speed record

world This CHP plant runs on clean eco-

gas that is gasified cleaned and cooled

from recycled waste with Metsorsquos innova-tive technology

ldquoItrsquos actually eco-gas that we combust

in the boilerrdquo comments Lahti EnergyrsquosProduction Director Jukka Manskinen

ldquoWe convert unwanted waste material into

energy in an efficient and environmentally

friendly wayrdquoNever before has any plant gasified

waste on such a large scale In the gasifier

recycled waste is turned into combustible

product gas which is cleaned cooled and

combusted in a high-efficiency gas boiler

to produce steam for the steam turbine The plant produces 50 MW of electricity

and 90 MW of district heat for the city of

Lahti and its neighboring areasMetso delivered the circulating fluidized

bed (CFB) gasification process gas cleaning

and cooling steam boiler environmental

protection system and automation systemto the entire plant The production of elec-

tricity and heat is kept even with the Metso

DNA automation system that covers the

whole plant starting from fuel reception

AutomationMetso develops and supplies plant-

wide crushing control solutions for

crushing plants

Metso has recently signed contracts on

delivering plant-wide automation systems

for mobile and portable rock crushing

plants The key objective of these deliveries

is to stabilize and to increase productivityand efficiency of the plants using one sin-

gle automation and information platform

for integrating crusher-specific IC machinecontrols

Furthermore the plant-wide system

with its information management tools not

only increases plant availability and opera-

tional safety it also makes troubleshoot-ing quicker and performance monitoring

easier The control room for plant-wide

operability is located either in an excavator

cabin or a purpose-built container

Metso around the world

The new LT106 jaw plant is suitable for crushing both hard rock and all rock-based demolition materials

The new world speed record for tissue setby Hayat Kimyarsquos Metso-supplied TM 2 is2210 mmin

8132019 Results Minerals Aggregates 3 2012ENG

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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 29: Results Minerals Aggregates 3 2012.ENG

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One of the biggest copper mines in

Europe Bolidenrsquos Aitik is located deep inthe wilderness of Swedish Lapland next to

the small town of Gaumlllivare The mine has

been operating since 1968 and a recent

expansion has increased its annual ore

production to 36 million tons

But the ambitious Swedes are not will-ing to lay back and relax just yet Bolidenrsquos

new aim is to reach a production rate of

45 million tons of ore per year in AitikAfter that Perhaps more than 55 million

tons The ore concentration in Aitik is very

low-grade with a mere 022 copper con-

tent hence the need for high capacityAchieving the ambitious production

goal requires maximum plant availability

This means that everything from the crush-

ers to the filters must be up and runningfor approximately 97 percent of the time

Thatrsquos where Metso comes into play

A cost-per-ton contract in action

The maximum uptime requirement allowsless than a dozen days per year for break-

downs repair and maintenance at Aitik

Every single hour during a service shut-

down counts There simply isnrsquot any roomfor surprises

Executing a successful shutdown under

such conditions requires a reliable service

partner not afraid of challenges and this iswhy Boliden has entrusted Aitikrsquos services

operations to Metso Boliden and Metsohave worked together since the 1960s

and the collaboration took another step

forward in September 2012 when the twocompanies signed a three-year extension

of the services contract for Boliden Aitik

ldquoThe new contract is a cost-per-ton

agreement We get paid based on Aitikrsquos

production Itrsquos a win-win deal for both par-

ties but also a new mindset for usrdquo explainsKurt Kalla Site Manager of Metso Gaumlllivare

Service Center responsible for serving Aitik

From now on the duration of the shut-down is what matters the most According

to Kalla the Metso service organization in

Gaumlllivare is now streamlining its operations

to fit the bill and has already witnessed thestrategy working In August 2012 Metso

carried out a 188-hour service shutdown in

Aitik which turned out to be a success

Zero tolerance for injury

One key factor to the success was theextensive planning of precautionary health

safety and environment procedures under-

taken by Metso prior to the shutdown Thanks to strict measures applied no

injuries or accidents occurred during the

shutdown and the work could easily be

finished on scheduleMats Johansson Health Safety

and Environment Manager for Metso in

Sweden explains how this was achieved

rdquoPlanning of the shutdown included arisk analysis for all new tasks participating

in Bolidenrsquos safety coordination meetingsmeeting with both Metso supervisors and

subcontractor supervisors and finally a

meeting with the entire staff participating

in the shutdown where everyone had to

sign a document stating their commitmentto the information providedrdquo he says

During the actual shutdown plenty of

new barriers signs and awareness cones

were put in place as a result of observa-tions from previous audits and safety plans

and risk analyses were readily available

in the work area Metso and Boliden also

introduced a Mill Inching permit a certifi-cate for completing a mandatory course for

those involved in the process In addition

Metso carried out random safety audits

during the shutdown to make sure thestrict policy was followed

According to Boliden Metsorsquos way of

working is a good example of how health

and safety precautions should be handled

ldquoMetso is a good example of how towork with safety and health plans risk

analysis permits and welding permits

Their table with all binders in the second-

ary mill area was exemplaryrdquo says Kjell-Arne

Johansson a technician from Boliden

The use of the new Metso Megalinertrade

system in the lining of Aitikrsquos Metso AG

mills has also improved the safety of main-tenance staff The Metso Megalinertrade con-

sists of larger-than-average liners bolted

in position from outside the mill Mainte-

nance technicians no longer need to go

inside the mill and stand in the dangerousdrop-zone of the liners gt

Boliden aims to reach a production rate of 45 million tons of ore per yearin the Aitik mine site

ldquoA complete risk analysis was conducted during the planningof the shutdownrdquo comments Mats Johansson Health Safetyand Environment Manager for Metso in Sweden

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Service the Metso way

24 hours a day 365 days a year

In addition to paying close attention to

health and safety issues executing an effi-

cient shutdown requires careful planning

and timing of every step in the mainte-

nance process Wear and spare parts have

to be available on time and a repair shoplarge enough to accommodate equipment

located close by

ldquoTo keep maintenance breaks as short

as possible we aim to replace the pump on

site and bring the old one for repair to our

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

nearby facilities This method gives us the

peace to do a good job and keep the cus-

tomerrsquos operations runningrdquo Kalla describes

the Metso way of handling Aitikrsquos pump

maintenance

Metso is currently expanding its Gaumllli-

vare service center to include a distribu-

tion center for wear and spare parts andalso concentrating its previously scattered

operations under one roof in its Vuoskon-

jaumlrvivaumlgen facility The expansion is due to

be completed by 2014

Metso equipment

delivered to Aitik36

bull 2 AG mills diameter 116 x

137 m gearless 22-MW motor

bull 2 Pebble mills diameter 91 x

113m dual 5-MW pinion drive

bull 3 VPA pressure filters VPA 1540-54

bull 12 sample pumps and pipes

VF50

bull 60 Various slurry pumps up to

MR500 modelbull Appr 5000 m rubber-lined slurry

pipes up to 600 mm diameter

bull Appr 5000 m rubber-lined by

gravity pipes up to 600 mm

diameter

bull Appr 5000 m rubber hoses

up to 600 mm diameter

Not only does the expansion make ser-

vice shutdowns at Aitik run more smoothly

it guarantees a more comprehensive

on-call emergency service response in the

region ndash thanks to the spare and wear parts

inventory available 24 hours a day 365

days a year

More info

Lars Rosenling

Tel +46 70 107 45 90

larsrosenlingmetsocom

Metso grinding equipment dominates the view in the concentrator

Safety on site is made up of small things like

making sure that everyone remembers to secure

the hoses in place

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Pebbles have always been a

challenge for producers of sandsince they cannot be returned

to rivers after extraction For

decades the processing of this

material resulted in a huge

environmental liability with alarge amount of pebbles hav-

ing to be stored away and left

unused

Transforming problems into

business opportunities

Areia amp Cia (areia = sand) has

operated in this market forover 20 years and decided to

enlist the help of Metso to find

a profitable solution for the

processing of pebbles

In July 2011 analyses werebegun to assess the abrasive-

ness and crushability of the

material Four alternatives wereidentified for processing and

transforming pebbles into sand

Initially Areia amp Cia was

interested in acquiring an

impactor for its reason-able price level However the

customer wanted to process

all the pebbles that were col-

lected daily in addition to some of the

material that it had stored In weighing theresults expected by the customer and the

excessive abrasiveness of the material the

HP200 cone crusher was decided on as thebest alternative

Areia amp Cia made the required invest-

ment and after using the HP200 for just

six months the company has already beenreporting outstanding results The HP200

not only transforms pebbles into sand but

also produces sand of excellent quality

with high yield and low maintenanceWith minor adjustments the HP200

also enables the production of sand withspecific particle size distribution for special

applications such as filtering sand blasting

and foundry sand adding value to the prod-

uct and increasing the types of sand offeredldquoMetso is pleased that the HP200 not

only enabled the processing of a product

that had been set aside as unusable but

HP200 cone transforms pebblesinto high-quality sandOver the last few decades Brazilian economic growth has been driving demand for construction aggregates The market

for sand in turn has been experiencing major difficulties in maintaining a consistent supply Presently one of the mainchallenges the industry faces is the large amount of pebbles that are obtained in the process of extracting sand at timesconstituting nearly 50 of the volume of material dredged from riverbeds

TEXT Sheila Ivers PHOTO Areia amp Cia

also that it opened up new

market opportunities for Areiaamp Cia Thatrsquos the standard we

seek to deliver to our custom-

ersrdquo states Luiz Oliveira Techni-

cal Salesperson of Metso Brazil

HP cones entering the

Brazilian sand-making

market

Todayrsquos cones such as theHP200 have high resistance

to impacts and abrasiveness

more efficient crushing cham-

bers low maintenance costsand excellent productivity

Following the acquisition of

the HP200 Areia amp Cia is now

also producing special sands

that command a price that is100 higher than common

sand The entire stockpile of

pebbles accumulated through-out the companyrsquos 20 years of

operations has already been

transformed into sand and the

stock of pebbles held by com-

petitors is also being purchasedfor processing

Cristiane Brizolari the

owner of Areia amp Cia confirms

the transformation that has taken place in

the production and commercial processldquoThe HP200 opened up new niches in

the market enabling the production of dif-

ferent types of sand with added valuerdquo

More info

Luiz Oliveira

Tel +55 011 9971 3603

luizoliveirametsocom

After the pebbles are crushed into sand with the HP200 cone crusherdifferent grades are screened for various end uses

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Where therersquos a will we dig a wayAFCONS-Strabag and Metso embark on tunnel project together

When the joint venture AFCONS-Strabag initiated work on the Rohtang bypass tunnel project at an altitude of 3980 metersabove sea level in Himachal Pradesh India they deliberated each aspect with clockwork precision The project involved anumber of surprises and challenges and required technology and project management skills that were second to none

TEXT amp PHOTOS Monisha Majumdar

Cutting a 10-meter-wide and nearly 9-kilo-

meter-long tunnel through the Himalayas

in one of the toughest terrains and cli-mates in India makes for quite a challengeResults set out to find out how AFCONS-

Strabag and Metso are making their way in

one of their most critical projects to date

The only road connection to the north-Indian border region of the province

Himachal-Pradesh and beyond the Manali-

Leh highway leads across the Rohtang

pass Due to the heavy snowfall and high-

velocity winds in this region the towns

located north of the pass are cut off from

the rest of the country during winter for atleast four often even six months each year

A tunnel with strategic importance

With the construction of the tunnel at

3100 m above sea level the Manali-Lehhighway will become an all-weather road

thereby enabling a significant improve-

ment in the economic development of

northern Himachal-Pradesh and an alter-

nate route to the strategically important

Ladakh region

Manali south of the pass is an alreadywell-developed tourist location that is

becoming more and more popular Upon

completion of the tunnel it is likely that

tourist activities will extend to the areanorth of the pass Moreover the tunnel

shortens the distance between the towns

of Manali and Leh by approximately 45 km

thus saving several hours on the small dan-gerous pass road

The Rohtang pass in the Western Himalaya

region of Northern India with its altitude ofalmost four kilometers ranks among thehighest trafficable passes in the world

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The 88-km long horse-shoe-shaped

tunnel provides space for a two-lane8-m-wide carriageway as well as a one-

meter-wide footpath on both sides A

22-m-high and 36-m-wide emergency

tunnel will be integrated in the tun-

nel cross-section Altogether more than

800000 msup3 of rock will be moved Tunneling works started around spring

2010 with excavation driven from both por-

tals As the north portal is inaccessible dur-ing winter closure the excavation focused

on the south After a planned construction

period of 55 years the tunnel is scheduled

to be completed by the end of 2015

Best man for the job

The BRO (Border Road Organization)

wanted to roll out a global tender for theproject due to the challenges that such a

project involves and also considering thatitrsquos the first time in India that a project of

this scale was to be carried out This imme-

diately triggered the need to roll out aglobal tender All major Indian construction

companies bid for it some individually and

some in partnerships

Strabag an Austrian tunnel specialistwas one of the companies who bid for the

project along with AFCONS a Mumbai-

based infrastructure company In Septem-

ber 2009 AFCONS-Strabag was awardedthe contract

Mr Sunil Tyagi Deputy Project Man-ager at AFCONS had this to say about the

unique projectldquoThis project is located in the Himalayas

and as far as we understand the terrain

there is among the toughest We came out

with a new technology and to be honestit is a fairly simple one We would generally

start with the traditional technology of drill-

ing and blasting and then obtain our muck

feed from the inwardbottom of the tunnelrdquo

ldquoThe technology is supplied by Rowa Tunneling Logistics and this is the first

time it is being used in Asia A jaw crusheris placed at a distance of about 40-45

meters behind the face The blasted muckextracted from the face is fed to the crusher

to reduce the lump size and then through

an overhead conveyor transport system

it is then transported out of the tunnelrdquoldquoThis enables free movement of man

and machinery in the lower area or spe-

cifically on the ground area If we were to

conforms to the Indian standard for fines amp

coarse aggregates as prescribed in IS383-1970

The plant was up and running in good

condition and performing to AFCONSrsquos

satisfactionldquoWe have worked with Metso in earlier

projects and are quite impressed by thekind of technology amp services they provide

We have a history together so the trust fac-tor also comes inrdquo explains Dhiman on their

choice of Metso as a partner

Service makes the difference

ldquoMetsorsquos services have made a big dif-ference in the project Without them we

would still be struggling with the machin-

ery and production The service is really

good and the service engineers are knowl-edgeable prompt and quick to act Any

problem can be solved by Metso We donrsquothave to wait until a service engineer turns

up ndash they have the capacity to solve prob-lems over the phone as wellrdquo says Dhiman

ldquoThe Metso plant didnrsquot create any prob-

lems for us We had problems in logistics

the feed was sticky and the weather condi-tions were bad but thankfully we did not

face any problems with production and

efficiency as the Metso plant is performing

very wellrdquo Dhiman concludes

More info

Amol Sinha Tel +91 9811 671 924

amolsinhametsocom

use the old conventional technology this

wouldnrsquot have worked for us in the stipu-lated timerdquo Mr Tyagi adds

When the going gets tough

partner with the toughest

Sensitive projects require the best technol-

ogy After AFCONS-Strabag landed theproject Metso was an obvious choice as a

technology provider not only because of

the long-standing business relationshipbut also for the sheer consistency in prod-

uct quality and service deliverance Metso

strives for

ldquoAfter signing the project we faced alot of road blocks including extreme cold

avalanches roadblocks less oxygen ndash you

name it we faced itrdquo explains Ankit Dhi-

man Plant Manager at AFCONS-Strabag The Rohtang valley is known for its

notorious avalanches and landslides SoAFCONS had to take extra steps and safety

precautions against hazards on the site

ldquoIn this freezing cold not just us humansbut also the machines are at increased risk

of damage I remember when we used

to run the plant during winter the diesel

engines would freeze We had to constantlyheat up the fuel container to get the plant

running And even the sand in the sand

trap would freeze so we had to clean it on

a daily basis to stop the pipes from mal-functioningrdquo Dhiman adds

Plant designed for difficult terrain

Difficult terrain coupled with space con-straints led Metso engineers to put their

minds together to come up with a suitable

plant configuration After studying the

requirements of the project Metso sug-

gested a 150-tons-per-hour three-stagemodular plant using a C106 jaw crusher

a GP11F secondary cone crusher and a

B7150 tertiary vertical shaft impact crusher

In addition considering the unpredict-ability of the feed the plant was about

to reach a point where the amount offines to be handled could be increased

dramatically Metso strongly suggested the TK11-27-3V grizzly scalper and this became

the first-ever TK scalper to be supplied by

Metso to an Indian customer Also in order

to get better products a sand trap SF2360was added to the configuration

The sand trap is important equipment

for this project as it washes the sand thatMr Sunil Tyagi Deputy Project ManagerAFCONS-Strabag

8132019 Results Minerals Aggregates 3 2012ENG

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Smooth transition to new-generation jaw crusher in Germany

Roumlhrig is a German company with a rich heritage The company has been quarrying granite at its plant in Bergstrasse inthe Sonderbach district of Heppenheim for three generations

TEXT amp PHOTOS Ralf Goffin

Roumlhrigrsquos superior product variety is onereason why the companyrsquos proximity to its

customers can be understood in more than

just physical terms The companyrsquos high

level of innovation has allowed it to estab-lish itself as a reliable supplier of materials

both regionally and internationally This

operational and technical expertise always

manages to keep in step with growing

market requirements

In terms of technical processing equip-

ment Roumlhrig has used a Nordberg C160stationary jaw crusher from Metso since

1992 At the start of 2012 it was finally

exchanged for a more up-to-date version

from the same model range

Metsorsquos C Series is specifically designed

to pre-crush hard rock and can cope effort-

lessly with even the hardest of materials

The dimensions of the new stationary jawcrusher are identical to those of the old

one which means that it could simply be

slotted into the housing vacated by the

previous version

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983122983141983152983151983154983156983145983150983143 983154983141983155

Third-generation Managing DirectorMarco Roumlhrig expects the new machinersquos

service life to be just as long as the previ-

ous model due to the product upgrades

that have been implemented The integral motor base is another plus

point in models made by other manu-

facturers it is located outside the crusher

This element of good fortune ensured that

Roumlhrig could reuse the housing withoutany additional rebuilding

Another advantage lies in the revision

of the guards for the C160rsquos drivetrain andflywheel The sturdier construction method

used for the crusher requires fewer parts

which facilitates easier installation andmaintenance and it makes it simpler to

access the motor

Under the watchful eye of Metsorsquos

Assembly Manager Maik Engelstaumltterthe entire project including removal and

installation was successfully completed

within two weeks

Installation making the most

of the available space

Roumlhrig will likely remember the day the

new crusher was installed for a long time

the pitman and main frame were deliveredseparately prior to installation and assem-

bled on site It took just one hour to replace

the old stationary crusher with the new

model A lorry-mounted crane was used toposition the 85-ton crusher with millimeter

precision in the crushing plant Once the

new crusher had been positioned in theexisting steel structure the next task wasto fix it into place as securely as possible

despite the limited space Special vibration

dampers were installed at a height of two

meters to prevent the crusher from sliding

Norbert Ried (fourth from left) installed thenew C160rsquos predecessor 20 years ago and isdelighted at the durability of the powerfulcrusher that is now making way for a newermodel Also pictured from left to right ManagerVolker Angermann Assembly Manager Maik

Engelstaumltter Technical Manager Stefan

Koob Project Manager Dominic SchoumlnhardtManaging Director Marco Roumlhrig Service

Technician Stefan Kolze and employees ofthe installation company Stafemo

On the hook after theold C160 was liftedout by crane the newcrusher was installedin almost no timeOnly the roof of thehousing had to beremoved

sideways off its mount An initial test run

with materials was carried out around oneweek later after all the electrical cables had

been installed

Simultaneously with the installation

of the C160 which is the first of the latest

generation of crushers to be installed in

Germany a new Nordberg GP100 conecrusher was also being installed in Roumlhrigrsquos

chipping plant Roumlhrig is convinced that

the technical improvements made tothe new Metso crusher can only be an

advantage worldwide

Roumlhrig places great value on consistent

product quality maximum added valueand optimum refinement of its product

range Bearing in mind that Roumlhrig has

enough reserves of raw material to last

for the next 150 years the company canconfidently continue to develop with an

emphasis on quality rather than quantity

More info

Dominic Schoenhardt

Tel +49 (0)621 727 00 610

dominicschoenhardtmetsocom

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Groupe Charier Carriegravere de la Mariais France

Quarrying with certi1047297ed quality The Charier Group with its 1600-strong workforce is a family business thatthis year celebrates 115 years of quarrying The company pursues a long-termdevelopment policy that since 2007 has seen processing installations upgradedat 4 of its 9 extraction sites

TEXT Liliane Boutin (with extracts from Mines amp Carriegraveres and Terrassements amp Carriegraveres magazines)PHOTO Baloon photo

The processing installation is of the horizontal type with a primary station located 56 meters below the site access road to keep it hidden from view

The crushing and screening installation at

Charierrsquos CM La Mariais quarry (at Donges

on the Loire estuary) has been in opera-tion since September 2011 Based on theoperatorrsquos ideas it was designed by Metso

to replace a worn-out installation installed

right on top of the seam being extracted

Since its commissioning it has becomethe second quarry in the company to

receive ISO 14 001 certification

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983122983141983152983151983154983156983145983150983143 983154983141983155

tertiary material of sand and gravel for the

local market to use in concrete surfacingprefabrication etcrdquo

Incorporation of a screening station

The stone extracted from La Mariais is

according to the quarry granitic gneiss

sound and homogeneous with a LosAngeles index of 15 good wear resist-

ance with an MDE of 10 a true density of

265 and a certain abrasiveness (2000 gt)ldquoCharacteristically it has a tendency to form

blocksrdquo Leblin points out

The main criteria in designing the instal-

lation was to provide an output of 600000metric tons from one station (38 hours

week) to produce materials aimed at the

concrete and surfacing markets ldquowhich

involved providing a tertiary station withscreening plantrdquo he adds

With this new unit the operating com-pany expands its product range through

the addition of fine materials obtained

from the tertiary screening station This unitis capable of producing 170 tonshour of

020

Preserving the environment

and optimizing safety

The screens have motorized bogies and

retractable walkways to facilitate access

when the screens are opened for main-tenance Other walkways provide access

to the tunnel input feeders The feederscan be isolated with hydraulic rod gate

bars this hydraulic assistance eliminatesthe need to use a heavy hammer to lodge

these metal bars

All conveyors transporting fines (02

and 04) are covered with a tarpaulin to

avoid flying dust and all the screens arehooded (metal cover with Trellex seal-

ing) The Brunone company has installed

dust-tight containment at the outlet of the

tertiary station crushers (HP300 and HP4)on the belt located under the screens

and under the hoppers located belowthe tertiary screens The crushers are put

under negative pressure and the finesare extracted through sleeve filters (7000

m3 h) with declogging which deposits the

dust back onto the conveyor belt

A high-pressure 100 bar water mist sys-tem has been installed at the primary sta-

tion discharge at the secondary crusherrsquos

discharge chutes (Omnicone) and at the

transfer points on the belt

Designed to last

ldquoThis type of new installation can easily last

thirty yearsrdquo affirms Project Leader Bruno

Peix of Metso ldquoIt quite simply depends on

how well it is maintained Thatrsquos why weprovide maintenance contracts that call for

our technicians to make regular inspection

visits and carry out preventive mainte-nance and any necessary repairsrdquo

In 2011 Metso commissioned about

10 new processing units in France like

the one at La Mariais quarry

More info

Frederic Bazire

Tel +33 (0)681442804

fredericbaziremetsocom

Key figures

DURATION OF WORKS 15 months

DRAWING OFFICE TIME 7800 hours

HEIGHT OF SILOS AND GRINDER BUILDINGS

15 m

TOTAL LENGTH OF CONVEYORS 14 km

WEIGHT OF THE INSTALLATION

1200 metric tons

CONCRETE POURED 1800 cubic meters

PROJECT SITE WORKFORCE 30

INSTALLED POWER 2200 kW(not including pumps 200 kW)

METSO EQUIPMENT

Primary

Vibrating feeder PF561-2V

Primary grizzly VG540-3V

Grizzly feeder TK13-20-3V

Jaw crusher C145 with

hydraulic setting

Secondary

Vibrating screen CVB 2050

refurbished

Cone crusher Omnicocircne 1352 SX

with Metso IC7000 controller Ellivar 16 (16 msup2 3 decks) screen

refurbished by Metso

Tertiary

Cone crusher HP300

Cone crusher HP4

2 Ellivar 20 screens (20 m23 decks) for final products

Expanding the production range

ldquoSince the mid-1990s when we became

owners of La Mariais we had used mobilemachinery with an assembly of beltconveyorsrdquo recalls Daniel Leblin Charierrsquos

Technical Manager for site construction

and maintenance

ldquoIt became clear that we needed ahigher performance tool to achieve the

dual goals of reaching one million metric

tonsrsquo maximum production and producing

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Big Lokotrack LT550GPF boostsquarrying productivity by a thirdMaximizing the productivity of operations is a key issue when striving for cost-effective quarrying Big Lokotracks are oneway to achieve improved operational efficiency The Lokotrack LT550GPF equipped with the high-volume GP550 conecrusher and a large screen is popular in the Nordic countries and in Germany and Australia ndash countries all known for theirhigh quarrying volumes

TEXT amp PHOTOS Eero Haumlmaumllaumlinen

Kone-Kostamorsquos new mobile coneplant has reached an averagecapacity of 300 tons per hour

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983122983141983152983151983154983156983145983150983143 983154983141983155

ldquoWith the same number of employees we

can achieve 30 more productivity with

our new LT550GPF unit The high-capacityFS screen has also eliminated the bottle-neck often seen at fine screeningrdquo says

Aarno Kostamo Managing Director of

Kone-Kostamo Oy one of Finlandrsquos biggest

crushing contractorsAccording to Kostamo the high capacity

of the GP550 gyratory cone crusher easily

handles feed from the C120 and C125 jaw

crushers For the contract with the Talvivaara

nickel mine the LT550GPF is being fed bythe brand new Lokotrack LT120 jaw plant

Average capacity 300 tons per hour

Talvivaara Europersquos largest nickel mine uti-

lizes large quantities of aggregates Kone-Kostamo has contracted several million

tons of different end products for the mineIn August 75000 tons of 0ndash63 mm

road gravel was crushed Smaller amountsof finer 0ndash6 mm 0ndash16 mm and 0ndash32 mm

aggregates are also being produced

The rainy summer increased the need

for road gravel along the muddy roadswhich must endure dump trucks weighing

as much as 260 tons

ldquoThe mobile process consisting of the

LT120 jaw plant and LT550GPF cone plant

is cost-effective while aggregates of vari-ous sizes can be produced in a two-stage

operation and with high capacity The con-trolled stroke and elliptical movement of

the FS screen secure big passing throughcapacitiesrdquo Kostamo explains

Operated in two shifts for a total of 16

hours per day the LT550GPF has logged

more than 600 working hours over a two-month period

Managing Director Aarno Kostamo (left) and foreman Karri Maumlenpaumlauml studying the cavity optionsavailable for the new Lokotrack LT550GPF

Longer perspective than

a single quarter needed

Kone-Kostamo Oy was founded as an

earth-moving company in Kemijaumlrvi

Northern Finland in 1956 The company

expanded its operations to include crush-

ing contracting in 1964 and later on

switched to concentrating fully on crush-ing activities

Kone-Kostamo consistently crushes

and screens around 28 million tons ofaggregates annually and has net sales of

between EUR 8ndash9 million

ldquoWe believe that issues within the crush-

ing industry including the purchasing ofmachinery must be studied with a longer

perspective than a single quarter The

secret to our success has always been our

solid work ethic and professional employ-eesrdquo Kostamo sums up

More info

Esa Berg

Tel + 358 40 837 8692

esabergmetsocom

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Monitoring-based reporting is vital for

assessing the performance of a mobile

crushing plant Metso provides suchreporting tools through its plant-wideautomation system Metso DNA (Dynamic

Network of Applications) with its infor-

mation platform that links all the mobile

crushing and screen units together as oneentity Basically there is a lot of measured

real-time information available in every

crushing plant On-line information is

obtained either from each Metso crusherrsquosmachine automation system IC (Intelligent

Controller) or from separately installed

additional sensors and belt scales

All the collected data is sent to a motorhome using wireless communication

based on WLAN technology The motor

home is a purpose-built environment

inside an on-site container In this environ-ment selected variables can be monitored

for assessing the plantrsquos performance And

to make all this even more flexible the

data can be transmitted to a crushing plant

company office using GPRS3G mobile

data communication technologies Thismakes all the last-minute reports acces-sible to the crushing plant managerial staff

at anytime and basically anywhere within

reach of the cell phone network

Production and fuel economics reports

Essentially monitoring and reporting can

be customized to fit the customerrsquos needs

However there are certain off-the-shelf

reports that provide a lot of useful informa-tion for plant supervision The production

report is one of these Requiring at least one

belt scale for measuring the total produc-tion the production report shows the pro-duction rate (tons per hour) for a selected

reporting period eg a day or a week The

production report constantly keeps track of

the plantrsquos production storing all the datathroughout the plantrsquos life cycle

Performance monitoring and reportingfor a mobile crushing plantTEXT Pasi Airikka PHOTOS Metso

unit during which the unit is running By

storing the availability times between start-ups and shutdowns the crushing plant

operation time (hours per dayshift) can be

recorded analyzed and reported In addi-

tion the availability report can be tailored

to evaluate efficient crushing hours during

which the plant is really working and pro-ducing aggregates Consequently the ratio

(0-100) between efficient crushing time

and total running time can be reported forany selected period of time This boosts

the efficiency of the plantrsquos operations

and results in better productivity

Reports on non-choke

or inadequate feeding

Non-choke feeding to crushers is avoid-

able through smart plant-wide crushingplant controls But estimating its severity in

a systematic manner is not straight-forwardwithout constant monitoring and reporting

The crusher choke feeding report makes

use of the crusher cavity level sensors byanalyzing their level measurements By

calculating average and min-max values

and deviations from the average it can be

shown how often the single crusher suffersfrom non-choke feeding to it

In some cases the bottleneck in the

crushing plantrsquos productivity is the material

feeding to the process In mobile plants thefeeding is human operated and therefore

subject to variations Occasionally the sizeof the human-operated machine simply

does not allow for adequate feeding to thecrushing plant There are specific reports

indicating time periods when the crushing

plant suffers from inadequate feeding

Condition monitoring for

crushers and screens

Machine-specific condition monitoring

focuses on vibrating components in

crushers and screens such as drive shaftbearings safety plate wearings and gears

The low middle and high frequencies ofmonitored components are measured and

supervised in real-time to detect abnor-malities due to slow or fast wear looseness

or imbalance

More info

Pasi Airikka

Tel +358 40 587 2730

pasiairikkametsocom

Condition monitoring provides a view tovibrating crusher and screen components forpredictive equipment maintenance

The daily production report shows the hour-by-hour production trend and distribution chartfor a selected day with min-max average andvariation statistics for comparison

Fuel consumption is always an interest-ing concern The fuel consumption reportgives the fuel consumption of each crush-

ing unit (liters per hour) and their total

consumption (liters per hour) for a selected

reporting period and can track fuel con-

sumption changes over timeCrushing plant availability can be

assessed as well The availability report

calculates time periods for each crushing

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983149983141983156983155983151 983150

for tissue machines The record of 2210

mmin was set on June 1 2012 during a

24-hour production run by the TM 2 tissue

machine at the companyrsquos mill in Yenikoumlynear the city of Izmit in Turkey

ldquoThe cooperation with Metso has been

beyond excellent and both parties did

their utmost to make the project success-ful The results clearly show that the efforts

were worthwhile on both sides This coop-

eration will extend to cover new projects

in the futurerdquo says Luumlt1047297 Aydin Paper GroupDirector Hayat Kimya

ldquoWe are not surprised that Hayat K imya

managed to break the world speed record

We have had great confidence in the capa-bility of the Hayat team since our project

started in 2009 We certainly know our

machine very well its stability production

efficiency and speed capabilityrdquo says Jan

Erikson Vice President Sales Metso

PowerThe worldrsquos first eco-gas fueled

power plant is up and running

Lahti Energy Ltdrsquos new Kymijaumlrvi II gasifica-

tion plant was officially inaugurated on

May 8 2012 It is the first of its kind in the

RecyclingRecycling with Lokotrack LT106

jaw plant in New York

A brand-new Lokotrack LT106 jaw plant is

used in the city area of New York USA to

recycle demolition materials The crushing

site faces the skyscrapers of ManhattanIsland

Paper amp FiberHayat Kimyarsquos Metso-supplied tissue

machine sets world speed record

Thanks to a skilled crew and dedicated

efforts Hayat Kimya AS in Turkey has suc-

ceeded in breaking the world speed record

world This CHP plant runs on clean eco-

gas that is gasified cleaned and cooled

from recycled waste with Metsorsquos innova-tive technology

ldquoItrsquos actually eco-gas that we combust

in the boilerrdquo comments Lahti EnergyrsquosProduction Director Jukka Manskinen

ldquoWe convert unwanted waste material into

energy in an efficient and environmentally

friendly wayrdquoNever before has any plant gasified

waste on such a large scale In the gasifier

recycled waste is turned into combustible

product gas which is cleaned cooled and

combusted in a high-efficiency gas boiler

to produce steam for the steam turbine The plant produces 50 MW of electricity

and 90 MW of district heat for the city of

Lahti and its neighboring areasMetso delivered the circulating fluidized

bed (CFB) gasification process gas cleaning

and cooling steam boiler environmental

protection system and automation systemto the entire plant The production of elec-

tricity and heat is kept even with the Metso

DNA automation system that covers the

whole plant starting from fuel reception

AutomationMetso develops and supplies plant-

wide crushing control solutions for

crushing plants

Metso has recently signed contracts on

delivering plant-wide automation systems

for mobile and portable rock crushing

plants The key objective of these deliveries

is to stabilize and to increase productivityand efficiency of the plants using one sin-

gle automation and information platform

for integrating crusher-specific IC machinecontrols

Furthermore the plant-wide system

with its information management tools not

only increases plant availability and opera-

tional safety it also makes troubleshoot-ing quicker and performance monitoring

easier The control room for plant-wide

operability is located either in an excavator

cabin or a purpose-built container

Metso around the world

The new LT106 jaw plant is suitable for crushing both hard rock and all rock-based demolition materials

The new world speed record for tissue setby Hayat Kimyarsquos Metso-supplied TM 2 is2210 mmin

8132019 Results Minerals Aggregates 3 2012ENG

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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 30: Results Minerals Aggregates 3 2012.ENG

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Service the Metso way

24 hours a day 365 days a year

In addition to paying close attention to

health and safety issues executing an effi-

cient shutdown requires careful planning

and timing of every step in the mainte-

nance process Wear and spare parts have

to be available on time and a repair shoplarge enough to accommodate equipment

located close by

ldquoTo keep maintenance breaks as short

as possible we aim to replace the pump on

site and bring the old one for repair to our

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

nearby facilities This method gives us the

peace to do a good job and keep the cus-

tomerrsquos operations runningrdquo Kalla describes

the Metso way of handling Aitikrsquos pump

maintenance

Metso is currently expanding its Gaumllli-

vare service center to include a distribu-

tion center for wear and spare parts andalso concentrating its previously scattered

operations under one roof in its Vuoskon-

jaumlrvivaumlgen facility The expansion is due to

be completed by 2014

Metso equipment

delivered to Aitik36

bull 2 AG mills diameter 116 x

137 m gearless 22-MW motor

bull 2 Pebble mills diameter 91 x

113m dual 5-MW pinion drive

bull 3 VPA pressure filters VPA 1540-54

bull 12 sample pumps and pipes

VF50

bull 60 Various slurry pumps up to

MR500 modelbull Appr 5000 m rubber-lined slurry

pipes up to 600 mm diameter

bull Appr 5000 m rubber-lined by

gravity pipes up to 600 mm

diameter

bull Appr 5000 m rubber hoses

up to 600 mm diameter

Not only does the expansion make ser-

vice shutdowns at Aitik run more smoothly

it guarantees a more comprehensive

on-call emergency service response in the

region ndash thanks to the spare and wear parts

inventory available 24 hours a day 365

days a year

More info

Lars Rosenling

Tel +46 70 107 45 90

larsrosenlingmetsocom

Metso grinding equipment dominates the view in the concentrator

Safety on site is made up of small things like

making sure that everyone remembers to secure

the hoses in place

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983122983141983152983151983154983156983145983150983143 983154983141983155

Pebbles have always been a

challenge for producers of sandsince they cannot be returned

to rivers after extraction For

decades the processing of this

material resulted in a huge

environmental liability with alarge amount of pebbles hav-

ing to be stored away and left

unused

Transforming problems into

business opportunities

Areia amp Cia (areia = sand) has

operated in this market forover 20 years and decided to

enlist the help of Metso to find

a profitable solution for the

processing of pebbles

In July 2011 analyses werebegun to assess the abrasive-

ness and crushability of the

material Four alternatives wereidentified for processing and

transforming pebbles into sand

Initially Areia amp Cia was

interested in acquiring an

impactor for its reason-able price level However the

customer wanted to process

all the pebbles that were col-

lected daily in addition to some of the

material that it had stored In weighing theresults expected by the customer and the

excessive abrasiveness of the material the

HP200 cone crusher was decided on as thebest alternative

Areia amp Cia made the required invest-

ment and after using the HP200 for just

six months the company has already beenreporting outstanding results The HP200

not only transforms pebbles into sand but

also produces sand of excellent quality

with high yield and low maintenanceWith minor adjustments the HP200

also enables the production of sand withspecific particle size distribution for special

applications such as filtering sand blasting

and foundry sand adding value to the prod-

uct and increasing the types of sand offeredldquoMetso is pleased that the HP200 not

only enabled the processing of a product

that had been set aside as unusable but

HP200 cone transforms pebblesinto high-quality sandOver the last few decades Brazilian economic growth has been driving demand for construction aggregates The market

for sand in turn has been experiencing major difficulties in maintaining a consistent supply Presently one of the mainchallenges the industry faces is the large amount of pebbles that are obtained in the process of extracting sand at timesconstituting nearly 50 of the volume of material dredged from riverbeds

TEXT Sheila Ivers PHOTO Areia amp Cia

also that it opened up new

market opportunities for Areiaamp Cia Thatrsquos the standard we

seek to deliver to our custom-

ersrdquo states Luiz Oliveira Techni-

cal Salesperson of Metso Brazil

HP cones entering the

Brazilian sand-making

market

Todayrsquos cones such as theHP200 have high resistance

to impacts and abrasiveness

more efficient crushing cham-

bers low maintenance costsand excellent productivity

Following the acquisition of

the HP200 Areia amp Cia is now

also producing special sands

that command a price that is100 higher than common

sand The entire stockpile of

pebbles accumulated through-out the companyrsquos 20 years of

operations has already been

transformed into sand and the

stock of pebbles held by com-

petitors is also being purchasedfor processing

Cristiane Brizolari the

owner of Areia amp Cia confirms

the transformation that has taken place in

the production and commercial processldquoThe HP200 opened up new niches in

the market enabling the production of dif-

ferent types of sand with added valuerdquo

More info

Luiz Oliveira

Tel +55 011 9971 3603

luizoliveirametsocom

After the pebbles are crushed into sand with the HP200 cone crusherdifferent grades are screened for various end uses

8132019 Results Minerals Aggregates 3 2012ENG

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Where therersquos a will we dig a wayAFCONS-Strabag and Metso embark on tunnel project together

When the joint venture AFCONS-Strabag initiated work on the Rohtang bypass tunnel project at an altitude of 3980 metersabove sea level in Himachal Pradesh India they deliberated each aspect with clockwork precision The project involved anumber of surprises and challenges and required technology and project management skills that were second to none

TEXT amp PHOTOS Monisha Majumdar

Cutting a 10-meter-wide and nearly 9-kilo-

meter-long tunnel through the Himalayas

in one of the toughest terrains and cli-mates in India makes for quite a challengeResults set out to find out how AFCONS-

Strabag and Metso are making their way in

one of their most critical projects to date

The only road connection to the north-Indian border region of the province

Himachal-Pradesh and beyond the Manali-

Leh highway leads across the Rohtang

pass Due to the heavy snowfall and high-

velocity winds in this region the towns

located north of the pass are cut off from

the rest of the country during winter for atleast four often even six months each year

A tunnel with strategic importance

With the construction of the tunnel at

3100 m above sea level the Manali-Lehhighway will become an all-weather road

thereby enabling a significant improve-

ment in the economic development of

northern Himachal-Pradesh and an alter-

nate route to the strategically important

Ladakh region

Manali south of the pass is an alreadywell-developed tourist location that is

becoming more and more popular Upon

completion of the tunnel it is likely that

tourist activities will extend to the areanorth of the pass Moreover the tunnel

shortens the distance between the towns

of Manali and Leh by approximately 45 km

thus saving several hours on the small dan-gerous pass road

The Rohtang pass in the Western Himalaya

region of Northern India with its altitude ofalmost four kilometers ranks among thehighest trafficable passes in the world

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The 88-km long horse-shoe-shaped

tunnel provides space for a two-lane8-m-wide carriageway as well as a one-

meter-wide footpath on both sides A

22-m-high and 36-m-wide emergency

tunnel will be integrated in the tun-

nel cross-section Altogether more than

800000 msup3 of rock will be moved Tunneling works started around spring

2010 with excavation driven from both por-

tals As the north portal is inaccessible dur-ing winter closure the excavation focused

on the south After a planned construction

period of 55 years the tunnel is scheduled

to be completed by the end of 2015

Best man for the job

The BRO (Border Road Organization)

wanted to roll out a global tender for theproject due to the challenges that such a

project involves and also considering thatitrsquos the first time in India that a project of

this scale was to be carried out This imme-

diately triggered the need to roll out aglobal tender All major Indian construction

companies bid for it some individually and

some in partnerships

Strabag an Austrian tunnel specialistwas one of the companies who bid for the

project along with AFCONS a Mumbai-

based infrastructure company In Septem-

ber 2009 AFCONS-Strabag was awardedthe contract

Mr Sunil Tyagi Deputy Project Man-ager at AFCONS had this to say about the

unique projectldquoThis project is located in the Himalayas

and as far as we understand the terrain

there is among the toughest We came out

with a new technology and to be honestit is a fairly simple one We would generally

start with the traditional technology of drill-

ing and blasting and then obtain our muck

feed from the inwardbottom of the tunnelrdquo

ldquoThe technology is supplied by Rowa Tunneling Logistics and this is the first

time it is being used in Asia A jaw crusheris placed at a distance of about 40-45

meters behind the face The blasted muckextracted from the face is fed to the crusher

to reduce the lump size and then through

an overhead conveyor transport system

it is then transported out of the tunnelrdquoldquoThis enables free movement of man

and machinery in the lower area or spe-

cifically on the ground area If we were to

conforms to the Indian standard for fines amp

coarse aggregates as prescribed in IS383-1970

The plant was up and running in good

condition and performing to AFCONSrsquos

satisfactionldquoWe have worked with Metso in earlier

projects and are quite impressed by thekind of technology amp services they provide

We have a history together so the trust fac-tor also comes inrdquo explains Dhiman on their

choice of Metso as a partner

Service makes the difference

ldquoMetsorsquos services have made a big dif-ference in the project Without them we

would still be struggling with the machin-

ery and production The service is really

good and the service engineers are knowl-edgeable prompt and quick to act Any

problem can be solved by Metso We donrsquothave to wait until a service engineer turns

up ndash they have the capacity to solve prob-lems over the phone as wellrdquo says Dhiman

ldquoThe Metso plant didnrsquot create any prob-

lems for us We had problems in logistics

the feed was sticky and the weather condi-tions were bad but thankfully we did not

face any problems with production and

efficiency as the Metso plant is performing

very wellrdquo Dhiman concludes

More info

Amol Sinha Tel +91 9811 671 924

amolsinhametsocom

use the old conventional technology this

wouldnrsquot have worked for us in the stipu-lated timerdquo Mr Tyagi adds

When the going gets tough

partner with the toughest

Sensitive projects require the best technol-

ogy After AFCONS-Strabag landed theproject Metso was an obvious choice as a

technology provider not only because of

the long-standing business relationshipbut also for the sheer consistency in prod-

uct quality and service deliverance Metso

strives for

ldquoAfter signing the project we faced alot of road blocks including extreme cold

avalanches roadblocks less oxygen ndash you

name it we faced itrdquo explains Ankit Dhi-

man Plant Manager at AFCONS-Strabag The Rohtang valley is known for its

notorious avalanches and landslides SoAFCONS had to take extra steps and safety

precautions against hazards on the site

ldquoIn this freezing cold not just us humansbut also the machines are at increased risk

of damage I remember when we used

to run the plant during winter the diesel

engines would freeze We had to constantlyheat up the fuel container to get the plant

running And even the sand in the sand

trap would freeze so we had to clean it on

a daily basis to stop the pipes from mal-functioningrdquo Dhiman adds

Plant designed for difficult terrain

Difficult terrain coupled with space con-straints led Metso engineers to put their

minds together to come up with a suitable

plant configuration After studying the

requirements of the project Metso sug-

gested a 150-tons-per-hour three-stagemodular plant using a C106 jaw crusher

a GP11F secondary cone crusher and a

B7150 tertiary vertical shaft impact crusher

In addition considering the unpredict-ability of the feed the plant was about

to reach a point where the amount offines to be handled could be increased

dramatically Metso strongly suggested the TK11-27-3V grizzly scalper and this became

the first-ever TK scalper to be supplied by

Metso to an Indian customer Also in order

to get better products a sand trap SF2360was added to the configuration

The sand trap is important equipment

for this project as it washes the sand thatMr Sunil Tyagi Deputy Project ManagerAFCONS-Strabag

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Smooth transition to new-generation jaw crusher in Germany

Roumlhrig is a German company with a rich heritage The company has been quarrying granite at its plant in Bergstrasse inthe Sonderbach district of Heppenheim for three generations

TEXT amp PHOTOS Ralf Goffin

Roumlhrigrsquos superior product variety is onereason why the companyrsquos proximity to its

customers can be understood in more than

just physical terms The companyrsquos high

level of innovation has allowed it to estab-lish itself as a reliable supplier of materials

both regionally and internationally This

operational and technical expertise always

manages to keep in step with growing

market requirements

In terms of technical processing equip-

ment Roumlhrig has used a Nordberg C160stationary jaw crusher from Metso since

1992 At the start of 2012 it was finally

exchanged for a more up-to-date version

from the same model range

Metsorsquos C Series is specifically designed

to pre-crush hard rock and can cope effort-

lessly with even the hardest of materials

The dimensions of the new stationary jawcrusher are identical to those of the old

one which means that it could simply be

slotted into the housing vacated by the

previous version

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983122983141983152983151983154983156983145983150983143 983154983141983155

Third-generation Managing DirectorMarco Roumlhrig expects the new machinersquos

service life to be just as long as the previ-

ous model due to the product upgrades

that have been implemented The integral motor base is another plus

point in models made by other manu-

facturers it is located outside the crusher

This element of good fortune ensured that

Roumlhrig could reuse the housing withoutany additional rebuilding

Another advantage lies in the revision

of the guards for the C160rsquos drivetrain andflywheel The sturdier construction method

used for the crusher requires fewer parts

which facilitates easier installation andmaintenance and it makes it simpler to

access the motor

Under the watchful eye of Metsorsquos

Assembly Manager Maik Engelstaumltterthe entire project including removal and

installation was successfully completed

within two weeks

Installation making the most

of the available space

Roumlhrig will likely remember the day the

new crusher was installed for a long time

the pitman and main frame were deliveredseparately prior to installation and assem-

bled on site It took just one hour to replace

the old stationary crusher with the new

model A lorry-mounted crane was used toposition the 85-ton crusher with millimeter

precision in the crushing plant Once the

new crusher had been positioned in theexisting steel structure the next task wasto fix it into place as securely as possible

despite the limited space Special vibration

dampers were installed at a height of two

meters to prevent the crusher from sliding

Norbert Ried (fourth from left) installed thenew C160rsquos predecessor 20 years ago and isdelighted at the durability of the powerfulcrusher that is now making way for a newermodel Also pictured from left to right ManagerVolker Angermann Assembly Manager Maik

Engelstaumltter Technical Manager Stefan

Koob Project Manager Dominic SchoumlnhardtManaging Director Marco Roumlhrig Service

Technician Stefan Kolze and employees ofthe installation company Stafemo

On the hook after theold C160 was liftedout by crane the newcrusher was installedin almost no timeOnly the roof of thehousing had to beremoved

sideways off its mount An initial test run

with materials was carried out around oneweek later after all the electrical cables had

been installed

Simultaneously with the installation

of the C160 which is the first of the latest

generation of crushers to be installed in

Germany a new Nordberg GP100 conecrusher was also being installed in Roumlhrigrsquos

chipping plant Roumlhrig is convinced that

the technical improvements made tothe new Metso crusher can only be an

advantage worldwide

Roumlhrig places great value on consistent

product quality maximum added valueand optimum refinement of its product

range Bearing in mind that Roumlhrig has

enough reserves of raw material to last

for the next 150 years the company canconfidently continue to develop with an

emphasis on quality rather than quantity

More info

Dominic Schoenhardt

Tel +49 (0)621 727 00 610

dominicschoenhardtmetsocom

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Groupe Charier Carriegravere de la Mariais France

Quarrying with certi1047297ed quality The Charier Group with its 1600-strong workforce is a family business thatthis year celebrates 115 years of quarrying The company pursues a long-termdevelopment policy that since 2007 has seen processing installations upgradedat 4 of its 9 extraction sites

TEXT Liliane Boutin (with extracts from Mines amp Carriegraveres and Terrassements amp Carriegraveres magazines)PHOTO Baloon photo

The processing installation is of the horizontal type with a primary station located 56 meters below the site access road to keep it hidden from view

The crushing and screening installation at

Charierrsquos CM La Mariais quarry (at Donges

on the Loire estuary) has been in opera-tion since September 2011 Based on theoperatorrsquos ideas it was designed by Metso

to replace a worn-out installation installed

right on top of the seam being extracted

Since its commissioning it has becomethe second quarry in the company to

receive ISO 14 001 certification

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983122983141983152983151983154983156983145983150983143 983154983141983155

tertiary material of sand and gravel for the

local market to use in concrete surfacingprefabrication etcrdquo

Incorporation of a screening station

The stone extracted from La Mariais is

according to the quarry granitic gneiss

sound and homogeneous with a LosAngeles index of 15 good wear resist-

ance with an MDE of 10 a true density of

265 and a certain abrasiveness (2000 gt)ldquoCharacteristically it has a tendency to form

blocksrdquo Leblin points out

The main criteria in designing the instal-

lation was to provide an output of 600000metric tons from one station (38 hours

week) to produce materials aimed at the

concrete and surfacing markets ldquowhich

involved providing a tertiary station withscreening plantrdquo he adds

With this new unit the operating com-pany expands its product range through

the addition of fine materials obtained

from the tertiary screening station This unitis capable of producing 170 tonshour of

020

Preserving the environment

and optimizing safety

The screens have motorized bogies and

retractable walkways to facilitate access

when the screens are opened for main-tenance Other walkways provide access

to the tunnel input feeders The feederscan be isolated with hydraulic rod gate

bars this hydraulic assistance eliminatesthe need to use a heavy hammer to lodge

these metal bars

All conveyors transporting fines (02

and 04) are covered with a tarpaulin to

avoid flying dust and all the screens arehooded (metal cover with Trellex seal-

ing) The Brunone company has installed

dust-tight containment at the outlet of the

tertiary station crushers (HP300 and HP4)on the belt located under the screens

and under the hoppers located belowthe tertiary screens The crushers are put

under negative pressure and the finesare extracted through sleeve filters (7000

m3 h) with declogging which deposits the

dust back onto the conveyor belt

A high-pressure 100 bar water mist sys-tem has been installed at the primary sta-

tion discharge at the secondary crusherrsquos

discharge chutes (Omnicone) and at the

transfer points on the belt

Designed to last

ldquoThis type of new installation can easily last

thirty yearsrdquo affirms Project Leader Bruno

Peix of Metso ldquoIt quite simply depends on

how well it is maintained Thatrsquos why weprovide maintenance contracts that call for

our technicians to make regular inspection

visits and carry out preventive mainte-nance and any necessary repairsrdquo

In 2011 Metso commissioned about

10 new processing units in France like

the one at La Mariais quarry

More info

Frederic Bazire

Tel +33 (0)681442804

fredericbaziremetsocom

Key figures

DURATION OF WORKS 15 months

DRAWING OFFICE TIME 7800 hours

HEIGHT OF SILOS AND GRINDER BUILDINGS

15 m

TOTAL LENGTH OF CONVEYORS 14 km

WEIGHT OF THE INSTALLATION

1200 metric tons

CONCRETE POURED 1800 cubic meters

PROJECT SITE WORKFORCE 30

INSTALLED POWER 2200 kW(not including pumps 200 kW)

METSO EQUIPMENT

Primary

Vibrating feeder PF561-2V

Primary grizzly VG540-3V

Grizzly feeder TK13-20-3V

Jaw crusher C145 with

hydraulic setting

Secondary

Vibrating screen CVB 2050

refurbished

Cone crusher Omnicocircne 1352 SX

with Metso IC7000 controller Ellivar 16 (16 msup2 3 decks) screen

refurbished by Metso

Tertiary

Cone crusher HP300

Cone crusher HP4

2 Ellivar 20 screens (20 m23 decks) for final products

Expanding the production range

ldquoSince the mid-1990s when we became

owners of La Mariais we had used mobilemachinery with an assembly of beltconveyorsrdquo recalls Daniel Leblin Charierrsquos

Technical Manager for site construction

and maintenance

ldquoIt became clear that we needed ahigher performance tool to achieve the

dual goals of reaching one million metric

tonsrsquo maximum production and producing

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Big Lokotrack LT550GPF boostsquarrying productivity by a thirdMaximizing the productivity of operations is a key issue when striving for cost-effective quarrying Big Lokotracks are oneway to achieve improved operational efficiency The Lokotrack LT550GPF equipped with the high-volume GP550 conecrusher and a large screen is popular in the Nordic countries and in Germany and Australia ndash countries all known for theirhigh quarrying volumes

TEXT amp PHOTOS Eero Haumlmaumllaumlinen

Kone-Kostamorsquos new mobile coneplant has reached an averagecapacity of 300 tons per hour

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983122983141983152983151983154983156983145983150983143 983154983141983155

ldquoWith the same number of employees we

can achieve 30 more productivity with

our new LT550GPF unit The high-capacityFS screen has also eliminated the bottle-neck often seen at fine screeningrdquo says

Aarno Kostamo Managing Director of

Kone-Kostamo Oy one of Finlandrsquos biggest

crushing contractorsAccording to Kostamo the high capacity

of the GP550 gyratory cone crusher easily

handles feed from the C120 and C125 jaw

crushers For the contract with the Talvivaara

nickel mine the LT550GPF is being fed bythe brand new Lokotrack LT120 jaw plant

Average capacity 300 tons per hour

Talvivaara Europersquos largest nickel mine uti-

lizes large quantities of aggregates Kone-Kostamo has contracted several million

tons of different end products for the mineIn August 75000 tons of 0ndash63 mm

road gravel was crushed Smaller amountsof finer 0ndash6 mm 0ndash16 mm and 0ndash32 mm

aggregates are also being produced

The rainy summer increased the need

for road gravel along the muddy roadswhich must endure dump trucks weighing

as much as 260 tons

ldquoThe mobile process consisting of the

LT120 jaw plant and LT550GPF cone plant

is cost-effective while aggregates of vari-ous sizes can be produced in a two-stage

operation and with high capacity The con-trolled stroke and elliptical movement of

the FS screen secure big passing throughcapacitiesrdquo Kostamo explains

Operated in two shifts for a total of 16

hours per day the LT550GPF has logged

more than 600 working hours over a two-month period

Managing Director Aarno Kostamo (left) and foreman Karri Maumlenpaumlauml studying the cavity optionsavailable for the new Lokotrack LT550GPF

Longer perspective than

a single quarter needed

Kone-Kostamo Oy was founded as an

earth-moving company in Kemijaumlrvi

Northern Finland in 1956 The company

expanded its operations to include crush-

ing contracting in 1964 and later on

switched to concentrating fully on crush-ing activities

Kone-Kostamo consistently crushes

and screens around 28 million tons ofaggregates annually and has net sales of

between EUR 8ndash9 million

ldquoWe believe that issues within the crush-

ing industry including the purchasing ofmachinery must be studied with a longer

perspective than a single quarter The

secret to our success has always been our

solid work ethic and professional employ-eesrdquo Kostamo sums up

More info

Esa Berg

Tel + 358 40 837 8692

esabergmetsocom

8132019 Results Minerals Aggregates 3 2012ENG

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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155

Monitoring-based reporting is vital for

assessing the performance of a mobile

crushing plant Metso provides suchreporting tools through its plant-wideautomation system Metso DNA (Dynamic

Network of Applications) with its infor-

mation platform that links all the mobile

crushing and screen units together as oneentity Basically there is a lot of measured

real-time information available in every

crushing plant On-line information is

obtained either from each Metso crusherrsquosmachine automation system IC (Intelligent

Controller) or from separately installed

additional sensors and belt scales

All the collected data is sent to a motorhome using wireless communication

based on WLAN technology The motor

home is a purpose-built environment

inside an on-site container In this environ-ment selected variables can be monitored

for assessing the plantrsquos performance And

to make all this even more flexible the

data can be transmitted to a crushing plant

company office using GPRS3G mobile

data communication technologies Thismakes all the last-minute reports acces-sible to the crushing plant managerial staff

at anytime and basically anywhere within

reach of the cell phone network

Production and fuel economics reports

Essentially monitoring and reporting can

be customized to fit the customerrsquos needs

However there are certain off-the-shelf

reports that provide a lot of useful informa-tion for plant supervision The production

report is one of these Requiring at least one

belt scale for measuring the total produc-tion the production report shows the pro-duction rate (tons per hour) for a selected

reporting period eg a day or a week The

production report constantly keeps track of

the plantrsquos production storing all the datathroughout the plantrsquos life cycle

Performance monitoring and reportingfor a mobile crushing plantTEXT Pasi Airikka PHOTOS Metso

unit during which the unit is running By

storing the availability times between start-ups and shutdowns the crushing plant

operation time (hours per dayshift) can be

recorded analyzed and reported In addi-

tion the availability report can be tailored

to evaluate efficient crushing hours during

which the plant is really working and pro-ducing aggregates Consequently the ratio

(0-100) between efficient crushing time

and total running time can be reported forany selected period of time This boosts

the efficiency of the plantrsquos operations

and results in better productivity

Reports on non-choke

or inadequate feeding

Non-choke feeding to crushers is avoid-

able through smart plant-wide crushingplant controls But estimating its severity in

a systematic manner is not straight-forwardwithout constant monitoring and reporting

The crusher choke feeding report makes

use of the crusher cavity level sensors byanalyzing their level measurements By

calculating average and min-max values

and deviations from the average it can be

shown how often the single crusher suffersfrom non-choke feeding to it

In some cases the bottleneck in the

crushing plantrsquos productivity is the material

feeding to the process In mobile plants thefeeding is human operated and therefore

subject to variations Occasionally the sizeof the human-operated machine simply

does not allow for adequate feeding to thecrushing plant There are specific reports

indicating time periods when the crushing

plant suffers from inadequate feeding

Condition monitoring for

crushers and screens

Machine-specific condition monitoring

focuses on vibrating components in

crushers and screens such as drive shaftbearings safety plate wearings and gears

The low middle and high frequencies ofmonitored components are measured and

supervised in real-time to detect abnor-malities due to slow or fast wear looseness

or imbalance

More info

Pasi Airikka

Tel +358 40 587 2730

pasiairikkametsocom

Condition monitoring provides a view tovibrating crusher and screen components forpredictive equipment maintenance

The daily production report shows the hour-by-hour production trend and distribution chartfor a selected day with min-max average andvariation statistics for comparison

Fuel consumption is always an interest-ing concern The fuel consumption reportgives the fuel consumption of each crush-

ing unit (liters per hour) and their total

consumption (liters per hour) for a selected

reporting period and can track fuel con-

sumption changes over timeCrushing plant availability can be

assessed as well The availability report

calculates time periods for each crushing

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983149983141983156983155983151 983150

for tissue machines The record of 2210

mmin was set on June 1 2012 during a

24-hour production run by the TM 2 tissue

machine at the companyrsquos mill in Yenikoumlynear the city of Izmit in Turkey

ldquoThe cooperation with Metso has been

beyond excellent and both parties did

their utmost to make the project success-ful The results clearly show that the efforts

were worthwhile on both sides This coop-

eration will extend to cover new projects

in the futurerdquo says Luumlt1047297 Aydin Paper GroupDirector Hayat Kimya

ldquoWe are not surprised that Hayat K imya

managed to break the world speed record

We have had great confidence in the capa-bility of the Hayat team since our project

started in 2009 We certainly know our

machine very well its stability production

efficiency and speed capabilityrdquo says Jan

Erikson Vice President Sales Metso

PowerThe worldrsquos first eco-gas fueled

power plant is up and running

Lahti Energy Ltdrsquos new Kymijaumlrvi II gasifica-

tion plant was officially inaugurated on

May 8 2012 It is the first of its kind in the

RecyclingRecycling with Lokotrack LT106

jaw plant in New York

A brand-new Lokotrack LT106 jaw plant is

used in the city area of New York USA to

recycle demolition materials The crushing

site faces the skyscrapers of ManhattanIsland

Paper amp FiberHayat Kimyarsquos Metso-supplied tissue

machine sets world speed record

Thanks to a skilled crew and dedicated

efforts Hayat Kimya AS in Turkey has suc-

ceeded in breaking the world speed record

world This CHP plant runs on clean eco-

gas that is gasified cleaned and cooled

from recycled waste with Metsorsquos innova-tive technology

ldquoItrsquos actually eco-gas that we combust

in the boilerrdquo comments Lahti EnergyrsquosProduction Director Jukka Manskinen

ldquoWe convert unwanted waste material into

energy in an efficient and environmentally

friendly wayrdquoNever before has any plant gasified

waste on such a large scale In the gasifier

recycled waste is turned into combustible

product gas which is cleaned cooled and

combusted in a high-efficiency gas boiler

to produce steam for the steam turbine The plant produces 50 MW of electricity

and 90 MW of district heat for the city of

Lahti and its neighboring areasMetso delivered the circulating fluidized

bed (CFB) gasification process gas cleaning

and cooling steam boiler environmental

protection system and automation systemto the entire plant The production of elec-

tricity and heat is kept even with the Metso

DNA automation system that covers the

whole plant starting from fuel reception

AutomationMetso develops and supplies plant-

wide crushing control solutions for

crushing plants

Metso has recently signed contracts on

delivering plant-wide automation systems

for mobile and portable rock crushing

plants The key objective of these deliveries

is to stabilize and to increase productivityand efficiency of the plants using one sin-

gle automation and information platform

for integrating crusher-specific IC machinecontrols

Furthermore the plant-wide system

with its information management tools not

only increases plant availability and opera-

tional safety it also makes troubleshoot-ing quicker and performance monitoring

easier The control room for plant-wide

operability is located either in an excavator

cabin or a purpose-built container

Metso around the world

The new LT106 jaw plant is suitable for crushing both hard rock and all rock-based demolition materials

The new world speed record for tissue setby Hayat Kimyarsquos Metso-supplied TM 2 is2210 mmin

8132019 Results Minerals Aggregates 3 2012ENG

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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 31: Results Minerals Aggregates 3 2012.ENG

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Pebbles have always been a

challenge for producers of sandsince they cannot be returned

to rivers after extraction For

decades the processing of this

material resulted in a huge

environmental liability with alarge amount of pebbles hav-

ing to be stored away and left

unused

Transforming problems into

business opportunities

Areia amp Cia (areia = sand) has

operated in this market forover 20 years and decided to

enlist the help of Metso to find

a profitable solution for the

processing of pebbles

In July 2011 analyses werebegun to assess the abrasive-

ness and crushability of the

material Four alternatives wereidentified for processing and

transforming pebbles into sand

Initially Areia amp Cia was

interested in acquiring an

impactor for its reason-able price level However the

customer wanted to process

all the pebbles that were col-

lected daily in addition to some of the

material that it had stored In weighing theresults expected by the customer and the

excessive abrasiveness of the material the

HP200 cone crusher was decided on as thebest alternative

Areia amp Cia made the required invest-

ment and after using the HP200 for just

six months the company has already beenreporting outstanding results The HP200

not only transforms pebbles into sand but

also produces sand of excellent quality

with high yield and low maintenanceWith minor adjustments the HP200

also enables the production of sand withspecific particle size distribution for special

applications such as filtering sand blasting

and foundry sand adding value to the prod-

uct and increasing the types of sand offeredldquoMetso is pleased that the HP200 not

only enabled the processing of a product

that had been set aside as unusable but

HP200 cone transforms pebblesinto high-quality sandOver the last few decades Brazilian economic growth has been driving demand for construction aggregates The market

for sand in turn has been experiencing major difficulties in maintaining a consistent supply Presently one of the mainchallenges the industry faces is the large amount of pebbles that are obtained in the process of extracting sand at timesconstituting nearly 50 of the volume of material dredged from riverbeds

TEXT Sheila Ivers PHOTO Areia amp Cia

also that it opened up new

market opportunities for Areiaamp Cia Thatrsquos the standard we

seek to deliver to our custom-

ersrdquo states Luiz Oliveira Techni-

cal Salesperson of Metso Brazil

HP cones entering the

Brazilian sand-making

market

Todayrsquos cones such as theHP200 have high resistance

to impacts and abrasiveness

more efficient crushing cham-

bers low maintenance costsand excellent productivity

Following the acquisition of

the HP200 Areia amp Cia is now

also producing special sands

that command a price that is100 higher than common

sand The entire stockpile of

pebbles accumulated through-out the companyrsquos 20 years of

operations has already been

transformed into sand and the

stock of pebbles held by com-

petitors is also being purchasedfor processing

Cristiane Brizolari the

owner of Areia amp Cia confirms

the transformation that has taken place in

the production and commercial processldquoThe HP200 opened up new niches in

the market enabling the production of dif-

ferent types of sand with added valuerdquo

More info

Luiz Oliveira

Tel +55 011 9971 3603

luizoliveirametsocom

After the pebbles are crushed into sand with the HP200 cone crusherdifferent grades are screened for various end uses

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Where therersquos a will we dig a wayAFCONS-Strabag and Metso embark on tunnel project together

When the joint venture AFCONS-Strabag initiated work on the Rohtang bypass tunnel project at an altitude of 3980 metersabove sea level in Himachal Pradesh India they deliberated each aspect with clockwork precision The project involved anumber of surprises and challenges and required technology and project management skills that were second to none

TEXT amp PHOTOS Monisha Majumdar

Cutting a 10-meter-wide and nearly 9-kilo-

meter-long tunnel through the Himalayas

in one of the toughest terrains and cli-mates in India makes for quite a challengeResults set out to find out how AFCONS-

Strabag and Metso are making their way in

one of their most critical projects to date

The only road connection to the north-Indian border region of the province

Himachal-Pradesh and beyond the Manali-

Leh highway leads across the Rohtang

pass Due to the heavy snowfall and high-

velocity winds in this region the towns

located north of the pass are cut off from

the rest of the country during winter for atleast four often even six months each year

A tunnel with strategic importance

With the construction of the tunnel at

3100 m above sea level the Manali-Lehhighway will become an all-weather road

thereby enabling a significant improve-

ment in the economic development of

northern Himachal-Pradesh and an alter-

nate route to the strategically important

Ladakh region

Manali south of the pass is an alreadywell-developed tourist location that is

becoming more and more popular Upon

completion of the tunnel it is likely that

tourist activities will extend to the areanorth of the pass Moreover the tunnel

shortens the distance between the towns

of Manali and Leh by approximately 45 km

thus saving several hours on the small dan-gerous pass road

The Rohtang pass in the Western Himalaya

region of Northern India with its altitude ofalmost four kilometers ranks among thehighest trafficable passes in the world

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The 88-km long horse-shoe-shaped

tunnel provides space for a two-lane8-m-wide carriageway as well as a one-

meter-wide footpath on both sides A

22-m-high and 36-m-wide emergency

tunnel will be integrated in the tun-

nel cross-section Altogether more than

800000 msup3 of rock will be moved Tunneling works started around spring

2010 with excavation driven from both por-

tals As the north portal is inaccessible dur-ing winter closure the excavation focused

on the south After a planned construction

period of 55 years the tunnel is scheduled

to be completed by the end of 2015

Best man for the job

The BRO (Border Road Organization)

wanted to roll out a global tender for theproject due to the challenges that such a

project involves and also considering thatitrsquos the first time in India that a project of

this scale was to be carried out This imme-

diately triggered the need to roll out aglobal tender All major Indian construction

companies bid for it some individually and

some in partnerships

Strabag an Austrian tunnel specialistwas one of the companies who bid for the

project along with AFCONS a Mumbai-

based infrastructure company In Septem-

ber 2009 AFCONS-Strabag was awardedthe contract

Mr Sunil Tyagi Deputy Project Man-ager at AFCONS had this to say about the

unique projectldquoThis project is located in the Himalayas

and as far as we understand the terrain

there is among the toughest We came out

with a new technology and to be honestit is a fairly simple one We would generally

start with the traditional technology of drill-

ing and blasting and then obtain our muck

feed from the inwardbottom of the tunnelrdquo

ldquoThe technology is supplied by Rowa Tunneling Logistics and this is the first

time it is being used in Asia A jaw crusheris placed at a distance of about 40-45

meters behind the face The blasted muckextracted from the face is fed to the crusher

to reduce the lump size and then through

an overhead conveyor transport system

it is then transported out of the tunnelrdquoldquoThis enables free movement of man

and machinery in the lower area or spe-

cifically on the ground area If we were to

conforms to the Indian standard for fines amp

coarse aggregates as prescribed in IS383-1970

The plant was up and running in good

condition and performing to AFCONSrsquos

satisfactionldquoWe have worked with Metso in earlier

projects and are quite impressed by thekind of technology amp services they provide

We have a history together so the trust fac-tor also comes inrdquo explains Dhiman on their

choice of Metso as a partner

Service makes the difference

ldquoMetsorsquos services have made a big dif-ference in the project Without them we

would still be struggling with the machin-

ery and production The service is really

good and the service engineers are knowl-edgeable prompt and quick to act Any

problem can be solved by Metso We donrsquothave to wait until a service engineer turns

up ndash they have the capacity to solve prob-lems over the phone as wellrdquo says Dhiman

ldquoThe Metso plant didnrsquot create any prob-

lems for us We had problems in logistics

the feed was sticky and the weather condi-tions were bad but thankfully we did not

face any problems with production and

efficiency as the Metso plant is performing

very wellrdquo Dhiman concludes

More info

Amol Sinha Tel +91 9811 671 924

amolsinhametsocom

use the old conventional technology this

wouldnrsquot have worked for us in the stipu-lated timerdquo Mr Tyagi adds

When the going gets tough

partner with the toughest

Sensitive projects require the best technol-

ogy After AFCONS-Strabag landed theproject Metso was an obvious choice as a

technology provider not only because of

the long-standing business relationshipbut also for the sheer consistency in prod-

uct quality and service deliverance Metso

strives for

ldquoAfter signing the project we faced alot of road blocks including extreme cold

avalanches roadblocks less oxygen ndash you

name it we faced itrdquo explains Ankit Dhi-

man Plant Manager at AFCONS-Strabag The Rohtang valley is known for its

notorious avalanches and landslides SoAFCONS had to take extra steps and safety

precautions against hazards on the site

ldquoIn this freezing cold not just us humansbut also the machines are at increased risk

of damage I remember when we used

to run the plant during winter the diesel

engines would freeze We had to constantlyheat up the fuel container to get the plant

running And even the sand in the sand

trap would freeze so we had to clean it on

a daily basis to stop the pipes from mal-functioningrdquo Dhiman adds

Plant designed for difficult terrain

Difficult terrain coupled with space con-straints led Metso engineers to put their

minds together to come up with a suitable

plant configuration After studying the

requirements of the project Metso sug-

gested a 150-tons-per-hour three-stagemodular plant using a C106 jaw crusher

a GP11F secondary cone crusher and a

B7150 tertiary vertical shaft impact crusher

In addition considering the unpredict-ability of the feed the plant was about

to reach a point where the amount offines to be handled could be increased

dramatically Metso strongly suggested the TK11-27-3V grizzly scalper and this became

the first-ever TK scalper to be supplied by

Metso to an Indian customer Also in order

to get better products a sand trap SF2360was added to the configuration

The sand trap is important equipment

for this project as it washes the sand thatMr Sunil Tyagi Deputy Project ManagerAFCONS-Strabag

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Smooth transition to new-generation jaw crusher in Germany

Roumlhrig is a German company with a rich heritage The company has been quarrying granite at its plant in Bergstrasse inthe Sonderbach district of Heppenheim for three generations

TEXT amp PHOTOS Ralf Goffin

Roumlhrigrsquos superior product variety is onereason why the companyrsquos proximity to its

customers can be understood in more than

just physical terms The companyrsquos high

level of innovation has allowed it to estab-lish itself as a reliable supplier of materials

both regionally and internationally This

operational and technical expertise always

manages to keep in step with growing

market requirements

In terms of technical processing equip-

ment Roumlhrig has used a Nordberg C160stationary jaw crusher from Metso since

1992 At the start of 2012 it was finally

exchanged for a more up-to-date version

from the same model range

Metsorsquos C Series is specifically designed

to pre-crush hard rock and can cope effort-

lessly with even the hardest of materials

The dimensions of the new stationary jawcrusher are identical to those of the old

one which means that it could simply be

slotted into the housing vacated by the

previous version

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983122983141983152983151983154983156983145983150983143 983154983141983155

Third-generation Managing DirectorMarco Roumlhrig expects the new machinersquos

service life to be just as long as the previ-

ous model due to the product upgrades

that have been implemented The integral motor base is another plus

point in models made by other manu-

facturers it is located outside the crusher

This element of good fortune ensured that

Roumlhrig could reuse the housing withoutany additional rebuilding

Another advantage lies in the revision

of the guards for the C160rsquos drivetrain andflywheel The sturdier construction method

used for the crusher requires fewer parts

which facilitates easier installation andmaintenance and it makes it simpler to

access the motor

Under the watchful eye of Metsorsquos

Assembly Manager Maik Engelstaumltterthe entire project including removal and

installation was successfully completed

within two weeks

Installation making the most

of the available space

Roumlhrig will likely remember the day the

new crusher was installed for a long time

the pitman and main frame were deliveredseparately prior to installation and assem-

bled on site It took just one hour to replace

the old stationary crusher with the new

model A lorry-mounted crane was used toposition the 85-ton crusher with millimeter

precision in the crushing plant Once the

new crusher had been positioned in theexisting steel structure the next task wasto fix it into place as securely as possible

despite the limited space Special vibration

dampers were installed at a height of two

meters to prevent the crusher from sliding

Norbert Ried (fourth from left) installed thenew C160rsquos predecessor 20 years ago and isdelighted at the durability of the powerfulcrusher that is now making way for a newermodel Also pictured from left to right ManagerVolker Angermann Assembly Manager Maik

Engelstaumltter Technical Manager Stefan

Koob Project Manager Dominic SchoumlnhardtManaging Director Marco Roumlhrig Service

Technician Stefan Kolze and employees ofthe installation company Stafemo

On the hook after theold C160 was liftedout by crane the newcrusher was installedin almost no timeOnly the roof of thehousing had to beremoved

sideways off its mount An initial test run

with materials was carried out around oneweek later after all the electrical cables had

been installed

Simultaneously with the installation

of the C160 which is the first of the latest

generation of crushers to be installed in

Germany a new Nordberg GP100 conecrusher was also being installed in Roumlhrigrsquos

chipping plant Roumlhrig is convinced that

the technical improvements made tothe new Metso crusher can only be an

advantage worldwide

Roumlhrig places great value on consistent

product quality maximum added valueand optimum refinement of its product

range Bearing in mind that Roumlhrig has

enough reserves of raw material to last

for the next 150 years the company canconfidently continue to develop with an

emphasis on quality rather than quantity

More info

Dominic Schoenhardt

Tel +49 (0)621 727 00 610

dominicschoenhardtmetsocom

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Groupe Charier Carriegravere de la Mariais France

Quarrying with certi1047297ed quality The Charier Group with its 1600-strong workforce is a family business thatthis year celebrates 115 years of quarrying The company pursues a long-termdevelopment policy that since 2007 has seen processing installations upgradedat 4 of its 9 extraction sites

TEXT Liliane Boutin (with extracts from Mines amp Carriegraveres and Terrassements amp Carriegraveres magazines)PHOTO Baloon photo

The processing installation is of the horizontal type with a primary station located 56 meters below the site access road to keep it hidden from view

The crushing and screening installation at

Charierrsquos CM La Mariais quarry (at Donges

on the Loire estuary) has been in opera-tion since September 2011 Based on theoperatorrsquos ideas it was designed by Metso

to replace a worn-out installation installed

right on top of the seam being extracted

Since its commissioning it has becomethe second quarry in the company to

receive ISO 14 001 certification

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983122983141983152983151983154983156983145983150983143 983154983141983155

tertiary material of sand and gravel for the

local market to use in concrete surfacingprefabrication etcrdquo

Incorporation of a screening station

The stone extracted from La Mariais is

according to the quarry granitic gneiss

sound and homogeneous with a LosAngeles index of 15 good wear resist-

ance with an MDE of 10 a true density of

265 and a certain abrasiveness (2000 gt)ldquoCharacteristically it has a tendency to form

blocksrdquo Leblin points out

The main criteria in designing the instal-

lation was to provide an output of 600000metric tons from one station (38 hours

week) to produce materials aimed at the

concrete and surfacing markets ldquowhich

involved providing a tertiary station withscreening plantrdquo he adds

With this new unit the operating com-pany expands its product range through

the addition of fine materials obtained

from the tertiary screening station This unitis capable of producing 170 tonshour of

020

Preserving the environment

and optimizing safety

The screens have motorized bogies and

retractable walkways to facilitate access

when the screens are opened for main-tenance Other walkways provide access

to the tunnel input feeders The feederscan be isolated with hydraulic rod gate

bars this hydraulic assistance eliminatesthe need to use a heavy hammer to lodge

these metal bars

All conveyors transporting fines (02

and 04) are covered with a tarpaulin to

avoid flying dust and all the screens arehooded (metal cover with Trellex seal-

ing) The Brunone company has installed

dust-tight containment at the outlet of the

tertiary station crushers (HP300 and HP4)on the belt located under the screens

and under the hoppers located belowthe tertiary screens The crushers are put

under negative pressure and the finesare extracted through sleeve filters (7000

m3 h) with declogging which deposits the

dust back onto the conveyor belt

A high-pressure 100 bar water mist sys-tem has been installed at the primary sta-

tion discharge at the secondary crusherrsquos

discharge chutes (Omnicone) and at the

transfer points on the belt

Designed to last

ldquoThis type of new installation can easily last

thirty yearsrdquo affirms Project Leader Bruno

Peix of Metso ldquoIt quite simply depends on

how well it is maintained Thatrsquos why weprovide maintenance contracts that call for

our technicians to make regular inspection

visits and carry out preventive mainte-nance and any necessary repairsrdquo

In 2011 Metso commissioned about

10 new processing units in France like

the one at La Mariais quarry

More info

Frederic Bazire

Tel +33 (0)681442804

fredericbaziremetsocom

Key figures

DURATION OF WORKS 15 months

DRAWING OFFICE TIME 7800 hours

HEIGHT OF SILOS AND GRINDER BUILDINGS

15 m

TOTAL LENGTH OF CONVEYORS 14 km

WEIGHT OF THE INSTALLATION

1200 metric tons

CONCRETE POURED 1800 cubic meters

PROJECT SITE WORKFORCE 30

INSTALLED POWER 2200 kW(not including pumps 200 kW)

METSO EQUIPMENT

Primary

Vibrating feeder PF561-2V

Primary grizzly VG540-3V

Grizzly feeder TK13-20-3V

Jaw crusher C145 with

hydraulic setting

Secondary

Vibrating screen CVB 2050

refurbished

Cone crusher Omnicocircne 1352 SX

with Metso IC7000 controller Ellivar 16 (16 msup2 3 decks) screen

refurbished by Metso

Tertiary

Cone crusher HP300

Cone crusher HP4

2 Ellivar 20 screens (20 m23 decks) for final products

Expanding the production range

ldquoSince the mid-1990s when we became

owners of La Mariais we had used mobilemachinery with an assembly of beltconveyorsrdquo recalls Daniel Leblin Charierrsquos

Technical Manager for site construction

and maintenance

ldquoIt became clear that we needed ahigher performance tool to achieve the

dual goals of reaching one million metric

tonsrsquo maximum production and producing

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Big Lokotrack LT550GPF boostsquarrying productivity by a thirdMaximizing the productivity of operations is a key issue when striving for cost-effective quarrying Big Lokotracks are oneway to achieve improved operational efficiency The Lokotrack LT550GPF equipped with the high-volume GP550 conecrusher and a large screen is popular in the Nordic countries and in Germany and Australia ndash countries all known for theirhigh quarrying volumes

TEXT amp PHOTOS Eero Haumlmaumllaumlinen

Kone-Kostamorsquos new mobile coneplant has reached an averagecapacity of 300 tons per hour

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983122983141983152983151983154983156983145983150983143 983154983141983155

ldquoWith the same number of employees we

can achieve 30 more productivity with

our new LT550GPF unit The high-capacityFS screen has also eliminated the bottle-neck often seen at fine screeningrdquo says

Aarno Kostamo Managing Director of

Kone-Kostamo Oy one of Finlandrsquos biggest

crushing contractorsAccording to Kostamo the high capacity

of the GP550 gyratory cone crusher easily

handles feed from the C120 and C125 jaw

crushers For the contract with the Talvivaara

nickel mine the LT550GPF is being fed bythe brand new Lokotrack LT120 jaw plant

Average capacity 300 tons per hour

Talvivaara Europersquos largest nickel mine uti-

lizes large quantities of aggregates Kone-Kostamo has contracted several million

tons of different end products for the mineIn August 75000 tons of 0ndash63 mm

road gravel was crushed Smaller amountsof finer 0ndash6 mm 0ndash16 mm and 0ndash32 mm

aggregates are also being produced

The rainy summer increased the need

for road gravel along the muddy roadswhich must endure dump trucks weighing

as much as 260 tons

ldquoThe mobile process consisting of the

LT120 jaw plant and LT550GPF cone plant

is cost-effective while aggregates of vari-ous sizes can be produced in a two-stage

operation and with high capacity The con-trolled stroke and elliptical movement of

the FS screen secure big passing throughcapacitiesrdquo Kostamo explains

Operated in two shifts for a total of 16

hours per day the LT550GPF has logged

more than 600 working hours over a two-month period

Managing Director Aarno Kostamo (left) and foreman Karri Maumlenpaumlauml studying the cavity optionsavailable for the new Lokotrack LT550GPF

Longer perspective than

a single quarter needed

Kone-Kostamo Oy was founded as an

earth-moving company in Kemijaumlrvi

Northern Finland in 1956 The company

expanded its operations to include crush-

ing contracting in 1964 and later on

switched to concentrating fully on crush-ing activities

Kone-Kostamo consistently crushes

and screens around 28 million tons ofaggregates annually and has net sales of

between EUR 8ndash9 million

ldquoWe believe that issues within the crush-

ing industry including the purchasing ofmachinery must be studied with a longer

perspective than a single quarter The

secret to our success has always been our

solid work ethic and professional employ-eesrdquo Kostamo sums up

More info

Esa Berg

Tel + 358 40 837 8692

esabergmetsocom

8132019 Results Minerals Aggregates 3 2012ENG

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Monitoring-based reporting is vital for

assessing the performance of a mobile

crushing plant Metso provides suchreporting tools through its plant-wideautomation system Metso DNA (Dynamic

Network of Applications) with its infor-

mation platform that links all the mobile

crushing and screen units together as oneentity Basically there is a lot of measured

real-time information available in every

crushing plant On-line information is

obtained either from each Metso crusherrsquosmachine automation system IC (Intelligent

Controller) or from separately installed

additional sensors and belt scales

All the collected data is sent to a motorhome using wireless communication

based on WLAN technology The motor

home is a purpose-built environment

inside an on-site container In this environ-ment selected variables can be monitored

for assessing the plantrsquos performance And

to make all this even more flexible the

data can be transmitted to a crushing plant

company office using GPRS3G mobile

data communication technologies Thismakes all the last-minute reports acces-sible to the crushing plant managerial staff

at anytime and basically anywhere within

reach of the cell phone network

Production and fuel economics reports

Essentially monitoring and reporting can

be customized to fit the customerrsquos needs

However there are certain off-the-shelf

reports that provide a lot of useful informa-tion for plant supervision The production

report is one of these Requiring at least one

belt scale for measuring the total produc-tion the production report shows the pro-duction rate (tons per hour) for a selected

reporting period eg a day or a week The

production report constantly keeps track of

the plantrsquos production storing all the datathroughout the plantrsquos life cycle

Performance monitoring and reportingfor a mobile crushing plantTEXT Pasi Airikka PHOTOS Metso

unit during which the unit is running By

storing the availability times between start-ups and shutdowns the crushing plant

operation time (hours per dayshift) can be

recorded analyzed and reported In addi-

tion the availability report can be tailored

to evaluate efficient crushing hours during

which the plant is really working and pro-ducing aggregates Consequently the ratio

(0-100) between efficient crushing time

and total running time can be reported forany selected period of time This boosts

the efficiency of the plantrsquos operations

and results in better productivity

Reports on non-choke

or inadequate feeding

Non-choke feeding to crushers is avoid-

able through smart plant-wide crushingplant controls But estimating its severity in

a systematic manner is not straight-forwardwithout constant monitoring and reporting

The crusher choke feeding report makes

use of the crusher cavity level sensors byanalyzing their level measurements By

calculating average and min-max values

and deviations from the average it can be

shown how often the single crusher suffersfrom non-choke feeding to it

In some cases the bottleneck in the

crushing plantrsquos productivity is the material

feeding to the process In mobile plants thefeeding is human operated and therefore

subject to variations Occasionally the sizeof the human-operated machine simply

does not allow for adequate feeding to thecrushing plant There are specific reports

indicating time periods when the crushing

plant suffers from inadequate feeding

Condition monitoring for

crushers and screens

Machine-specific condition monitoring

focuses on vibrating components in

crushers and screens such as drive shaftbearings safety plate wearings and gears

The low middle and high frequencies ofmonitored components are measured and

supervised in real-time to detect abnor-malities due to slow or fast wear looseness

or imbalance

More info

Pasi Airikka

Tel +358 40 587 2730

pasiairikkametsocom

Condition monitoring provides a view tovibrating crusher and screen components forpredictive equipment maintenance

The daily production report shows the hour-by-hour production trend and distribution chartfor a selected day with min-max average andvariation statistics for comparison

Fuel consumption is always an interest-ing concern The fuel consumption reportgives the fuel consumption of each crush-

ing unit (liters per hour) and their total

consumption (liters per hour) for a selected

reporting period and can track fuel con-

sumption changes over timeCrushing plant availability can be

assessed as well The availability report

calculates time periods for each crushing

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983149983141983156983155983151 983150

for tissue machines The record of 2210

mmin was set on June 1 2012 during a

24-hour production run by the TM 2 tissue

machine at the companyrsquos mill in Yenikoumlynear the city of Izmit in Turkey

ldquoThe cooperation with Metso has been

beyond excellent and both parties did

their utmost to make the project success-ful The results clearly show that the efforts

were worthwhile on both sides This coop-

eration will extend to cover new projects

in the futurerdquo says Luumlt1047297 Aydin Paper GroupDirector Hayat Kimya

ldquoWe are not surprised that Hayat K imya

managed to break the world speed record

We have had great confidence in the capa-bility of the Hayat team since our project

started in 2009 We certainly know our

machine very well its stability production

efficiency and speed capabilityrdquo says Jan

Erikson Vice President Sales Metso

PowerThe worldrsquos first eco-gas fueled

power plant is up and running

Lahti Energy Ltdrsquos new Kymijaumlrvi II gasifica-

tion plant was officially inaugurated on

May 8 2012 It is the first of its kind in the

RecyclingRecycling with Lokotrack LT106

jaw plant in New York

A brand-new Lokotrack LT106 jaw plant is

used in the city area of New York USA to

recycle demolition materials The crushing

site faces the skyscrapers of ManhattanIsland

Paper amp FiberHayat Kimyarsquos Metso-supplied tissue

machine sets world speed record

Thanks to a skilled crew and dedicated

efforts Hayat Kimya AS in Turkey has suc-

ceeded in breaking the world speed record

world This CHP plant runs on clean eco-

gas that is gasified cleaned and cooled

from recycled waste with Metsorsquos innova-tive technology

ldquoItrsquos actually eco-gas that we combust

in the boilerrdquo comments Lahti EnergyrsquosProduction Director Jukka Manskinen

ldquoWe convert unwanted waste material into

energy in an efficient and environmentally

friendly wayrdquoNever before has any plant gasified

waste on such a large scale In the gasifier

recycled waste is turned into combustible

product gas which is cleaned cooled and

combusted in a high-efficiency gas boiler

to produce steam for the steam turbine The plant produces 50 MW of electricity

and 90 MW of district heat for the city of

Lahti and its neighboring areasMetso delivered the circulating fluidized

bed (CFB) gasification process gas cleaning

and cooling steam boiler environmental

protection system and automation systemto the entire plant The production of elec-

tricity and heat is kept even with the Metso

DNA automation system that covers the

whole plant starting from fuel reception

AutomationMetso develops and supplies plant-

wide crushing control solutions for

crushing plants

Metso has recently signed contracts on

delivering plant-wide automation systems

for mobile and portable rock crushing

plants The key objective of these deliveries

is to stabilize and to increase productivityand efficiency of the plants using one sin-

gle automation and information platform

for integrating crusher-specific IC machinecontrols

Furthermore the plant-wide system

with its information management tools not

only increases plant availability and opera-

tional safety it also makes troubleshoot-ing quicker and performance monitoring

easier The control room for plant-wide

operability is located either in an excavator

cabin or a purpose-built container

Metso around the world

The new LT106 jaw plant is suitable for crushing both hard rock and all rock-based demolition materials

The new world speed record for tissue setby Hayat Kimyarsquos Metso-supplied TM 2 is2210 mmin

8132019 Results Minerals Aggregates 3 2012ENG

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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 32: Results Minerals Aggregates 3 2012.ENG

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Where therersquos a will we dig a wayAFCONS-Strabag and Metso embark on tunnel project together

When the joint venture AFCONS-Strabag initiated work on the Rohtang bypass tunnel project at an altitude of 3980 metersabove sea level in Himachal Pradesh India they deliberated each aspect with clockwork precision The project involved anumber of surprises and challenges and required technology and project management skills that were second to none

TEXT amp PHOTOS Monisha Majumdar

Cutting a 10-meter-wide and nearly 9-kilo-

meter-long tunnel through the Himalayas

in one of the toughest terrains and cli-mates in India makes for quite a challengeResults set out to find out how AFCONS-

Strabag and Metso are making their way in

one of their most critical projects to date

The only road connection to the north-Indian border region of the province

Himachal-Pradesh and beyond the Manali-

Leh highway leads across the Rohtang

pass Due to the heavy snowfall and high-

velocity winds in this region the towns

located north of the pass are cut off from

the rest of the country during winter for atleast four often even six months each year

A tunnel with strategic importance

With the construction of the tunnel at

3100 m above sea level the Manali-Lehhighway will become an all-weather road

thereby enabling a significant improve-

ment in the economic development of

northern Himachal-Pradesh and an alter-

nate route to the strategically important

Ladakh region

Manali south of the pass is an alreadywell-developed tourist location that is

becoming more and more popular Upon

completion of the tunnel it is likely that

tourist activities will extend to the areanorth of the pass Moreover the tunnel

shortens the distance between the towns

of Manali and Leh by approximately 45 km

thus saving several hours on the small dan-gerous pass road

The Rohtang pass in the Western Himalaya

region of Northern India with its altitude ofalmost four kilometers ranks among thehighest trafficable passes in the world

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The 88-km long horse-shoe-shaped

tunnel provides space for a two-lane8-m-wide carriageway as well as a one-

meter-wide footpath on both sides A

22-m-high and 36-m-wide emergency

tunnel will be integrated in the tun-

nel cross-section Altogether more than

800000 msup3 of rock will be moved Tunneling works started around spring

2010 with excavation driven from both por-

tals As the north portal is inaccessible dur-ing winter closure the excavation focused

on the south After a planned construction

period of 55 years the tunnel is scheduled

to be completed by the end of 2015

Best man for the job

The BRO (Border Road Organization)

wanted to roll out a global tender for theproject due to the challenges that such a

project involves and also considering thatitrsquos the first time in India that a project of

this scale was to be carried out This imme-

diately triggered the need to roll out aglobal tender All major Indian construction

companies bid for it some individually and

some in partnerships

Strabag an Austrian tunnel specialistwas one of the companies who bid for the

project along with AFCONS a Mumbai-

based infrastructure company In Septem-

ber 2009 AFCONS-Strabag was awardedthe contract

Mr Sunil Tyagi Deputy Project Man-ager at AFCONS had this to say about the

unique projectldquoThis project is located in the Himalayas

and as far as we understand the terrain

there is among the toughest We came out

with a new technology and to be honestit is a fairly simple one We would generally

start with the traditional technology of drill-

ing and blasting and then obtain our muck

feed from the inwardbottom of the tunnelrdquo

ldquoThe technology is supplied by Rowa Tunneling Logistics and this is the first

time it is being used in Asia A jaw crusheris placed at a distance of about 40-45

meters behind the face The blasted muckextracted from the face is fed to the crusher

to reduce the lump size and then through

an overhead conveyor transport system

it is then transported out of the tunnelrdquoldquoThis enables free movement of man

and machinery in the lower area or spe-

cifically on the ground area If we were to

conforms to the Indian standard for fines amp

coarse aggregates as prescribed in IS383-1970

The plant was up and running in good

condition and performing to AFCONSrsquos

satisfactionldquoWe have worked with Metso in earlier

projects and are quite impressed by thekind of technology amp services they provide

We have a history together so the trust fac-tor also comes inrdquo explains Dhiman on their

choice of Metso as a partner

Service makes the difference

ldquoMetsorsquos services have made a big dif-ference in the project Without them we

would still be struggling with the machin-

ery and production The service is really

good and the service engineers are knowl-edgeable prompt and quick to act Any

problem can be solved by Metso We donrsquothave to wait until a service engineer turns

up ndash they have the capacity to solve prob-lems over the phone as wellrdquo says Dhiman

ldquoThe Metso plant didnrsquot create any prob-

lems for us We had problems in logistics

the feed was sticky and the weather condi-tions were bad but thankfully we did not

face any problems with production and

efficiency as the Metso plant is performing

very wellrdquo Dhiman concludes

More info

Amol Sinha Tel +91 9811 671 924

amolsinhametsocom

use the old conventional technology this

wouldnrsquot have worked for us in the stipu-lated timerdquo Mr Tyagi adds

When the going gets tough

partner with the toughest

Sensitive projects require the best technol-

ogy After AFCONS-Strabag landed theproject Metso was an obvious choice as a

technology provider not only because of

the long-standing business relationshipbut also for the sheer consistency in prod-

uct quality and service deliverance Metso

strives for

ldquoAfter signing the project we faced alot of road blocks including extreme cold

avalanches roadblocks less oxygen ndash you

name it we faced itrdquo explains Ankit Dhi-

man Plant Manager at AFCONS-Strabag The Rohtang valley is known for its

notorious avalanches and landslides SoAFCONS had to take extra steps and safety

precautions against hazards on the site

ldquoIn this freezing cold not just us humansbut also the machines are at increased risk

of damage I remember when we used

to run the plant during winter the diesel

engines would freeze We had to constantlyheat up the fuel container to get the plant

running And even the sand in the sand

trap would freeze so we had to clean it on

a daily basis to stop the pipes from mal-functioningrdquo Dhiman adds

Plant designed for difficult terrain

Difficult terrain coupled with space con-straints led Metso engineers to put their

minds together to come up with a suitable

plant configuration After studying the

requirements of the project Metso sug-

gested a 150-tons-per-hour three-stagemodular plant using a C106 jaw crusher

a GP11F secondary cone crusher and a

B7150 tertiary vertical shaft impact crusher

In addition considering the unpredict-ability of the feed the plant was about

to reach a point where the amount offines to be handled could be increased

dramatically Metso strongly suggested the TK11-27-3V grizzly scalper and this became

the first-ever TK scalper to be supplied by

Metso to an Indian customer Also in order

to get better products a sand trap SF2360was added to the configuration

The sand trap is important equipment

for this project as it washes the sand thatMr Sunil Tyagi Deputy Project ManagerAFCONS-Strabag

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Smooth transition to new-generation jaw crusher in Germany

Roumlhrig is a German company with a rich heritage The company has been quarrying granite at its plant in Bergstrasse inthe Sonderbach district of Heppenheim for three generations

TEXT amp PHOTOS Ralf Goffin

Roumlhrigrsquos superior product variety is onereason why the companyrsquos proximity to its

customers can be understood in more than

just physical terms The companyrsquos high

level of innovation has allowed it to estab-lish itself as a reliable supplier of materials

both regionally and internationally This

operational and technical expertise always

manages to keep in step with growing

market requirements

In terms of technical processing equip-

ment Roumlhrig has used a Nordberg C160stationary jaw crusher from Metso since

1992 At the start of 2012 it was finally

exchanged for a more up-to-date version

from the same model range

Metsorsquos C Series is specifically designed

to pre-crush hard rock and can cope effort-

lessly with even the hardest of materials

The dimensions of the new stationary jawcrusher are identical to those of the old

one which means that it could simply be

slotted into the housing vacated by the

previous version

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983122983141983152983151983154983156983145983150983143 983154983141983155

Third-generation Managing DirectorMarco Roumlhrig expects the new machinersquos

service life to be just as long as the previ-

ous model due to the product upgrades

that have been implemented The integral motor base is another plus

point in models made by other manu-

facturers it is located outside the crusher

This element of good fortune ensured that

Roumlhrig could reuse the housing withoutany additional rebuilding

Another advantage lies in the revision

of the guards for the C160rsquos drivetrain andflywheel The sturdier construction method

used for the crusher requires fewer parts

which facilitates easier installation andmaintenance and it makes it simpler to

access the motor

Under the watchful eye of Metsorsquos

Assembly Manager Maik Engelstaumltterthe entire project including removal and

installation was successfully completed

within two weeks

Installation making the most

of the available space

Roumlhrig will likely remember the day the

new crusher was installed for a long time

the pitman and main frame were deliveredseparately prior to installation and assem-

bled on site It took just one hour to replace

the old stationary crusher with the new

model A lorry-mounted crane was used toposition the 85-ton crusher with millimeter

precision in the crushing plant Once the

new crusher had been positioned in theexisting steel structure the next task wasto fix it into place as securely as possible

despite the limited space Special vibration

dampers were installed at a height of two

meters to prevent the crusher from sliding

Norbert Ried (fourth from left) installed thenew C160rsquos predecessor 20 years ago and isdelighted at the durability of the powerfulcrusher that is now making way for a newermodel Also pictured from left to right ManagerVolker Angermann Assembly Manager Maik

Engelstaumltter Technical Manager Stefan

Koob Project Manager Dominic SchoumlnhardtManaging Director Marco Roumlhrig Service

Technician Stefan Kolze and employees ofthe installation company Stafemo

On the hook after theold C160 was liftedout by crane the newcrusher was installedin almost no timeOnly the roof of thehousing had to beremoved

sideways off its mount An initial test run

with materials was carried out around oneweek later after all the electrical cables had

been installed

Simultaneously with the installation

of the C160 which is the first of the latest

generation of crushers to be installed in

Germany a new Nordberg GP100 conecrusher was also being installed in Roumlhrigrsquos

chipping plant Roumlhrig is convinced that

the technical improvements made tothe new Metso crusher can only be an

advantage worldwide

Roumlhrig places great value on consistent

product quality maximum added valueand optimum refinement of its product

range Bearing in mind that Roumlhrig has

enough reserves of raw material to last

for the next 150 years the company canconfidently continue to develop with an

emphasis on quality rather than quantity

More info

Dominic Schoenhardt

Tel +49 (0)621 727 00 610

dominicschoenhardtmetsocom

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Groupe Charier Carriegravere de la Mariais France

Quarrying with certi1047297ed quality The Charier Group with its 1600-strong workforce is a family business thatthis year celebrates 115 years of quarrying The company pursues a long-termdevelopment policy that since 2007 has seen processing installations upgradedat 4 of its 9 extraction sites

TEXT Liliane Boutin (with extracts from Mines amp Carriegraveres and Terrassements amp Carriegraveres magazines)PHOTO Baloon photo

The processing installation is of the horizontal type with a primary station located 56 meters below the site access road to keep it hidden from view

The crushing and screening installation at

Charierrsquos CM La Mariais quarry (at Donges

on the Loire estuary) has been in opera-tion since September 2011 Based on theoperatorrsquos ideas it was designed by Metso

to replace a worn-out installation installed

right on top of the seam being extracted

Since its commissioning it has becomethe second quarry in the company to

receive ISO 14 001 certification

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983122983141983152983151983154983156983145983150983143 983154983141983155

tertiary material of sand and gravel for the

local market to use in concrete surfacingprefabrication etcrdquo

Incorporation of a screening station

The stone extracted from La Mariais is

according to the quarry granitic gneiss

sound and homogeneous with a LosAngeles index of 15 good wear resist-

ance with an MDE of 10 a true density of

265 and a certain abrasiveness (2000 gt)ldquoCharacteristically it has a tendency to form

blocksrdquo Leblin points out

The main criteria in designing the instal-

lation was to provide an output of 600000metric tons from one station (38 hours

week) to produce materials aimed at the

concrete and surfacing markets ldquowhich

involved providing a tertiary station withscreening plantrdquo he adds

With this new unit the operating com-pany expands its product range through

the addition of fine materials obtained

from the tertiary screening station This unitis capable of producing 170 tonshour of

020

Preserving the environment

and optimizing safety

The screens have motorized bogies and

retractable walkways to facilitate access

when the screens are opened for main-tenance Other walkways provide access

to the tunnel input feeders The feederscan be isolated with hydraulic rod gate

bars this hydraulic assistance eliminatesthe need to use a heavy hammer to lodge

these metal bars

All conveyors transporting fines (02

and 04) are covered with a tarpaulin to

avoid flying dust and all the screens arehooded (metal cover with Trellex seal-

ing) The Brunone company has installed

dust-tight containment at the outlet of the

tertiary station crushers (HP300 and HP4)on the belt located under the screens

and under the hoppers located belowthe tertiary screens The crushers are put

under negative pressure and the finesare extracted through sleeve filters (7000

m3 h) with declogging which deposits the

dust back onto the conveyor belt

A high-pressure 100 bar water mist sys-tem has been installed at the primary sta-

tion discharge at the secondary crusherrsquos

discharge chutes (Omnicone) and at the

transfer points on the belt

Designed to last

ldquoThis type of new installation can easily last

thirty yearsrdquo affirms Project Leader Bruno

Peix of Metso ldquoIt quite simply depends on

how well it is maintained Thatrsquos why weprovide maintenance contracts that call for

our technicians to make regular inspection

visits and carry out preventive mainte-nance and any necessary repairsrdquo

In 2011 Metso commissioned about

10 new processing units in France like

the one at La Mariais quarry

More info

Frederic Bazire

Tel +33 (0)681442804

fredericbaziremetsocom

Key figures

DURATION OF WORKS 15 months

DRAWING OFFICE TIME 7800 hours

HEIGHT OF SILOS AND GRINDER BUILDINGS

15 m

TOTAL LENGTH OF CONVEYORS 14 km

WEIGHT OF THE INSTALLATION

1200 metric tons

CONCRETE POURED 1800 cubic meters

PROJECT SITE WORKFORCE 30

INSTALLED POWER 2200 kW(not including pumps 200 kW)

METSO EQUIPMENT

Primary

Vibrating feeder PF561-2V

Primary grizzly VG540-3V

Grizzly feeder TK13-20-3V

Jaw crusher C145 with

hydraulic setting

Secondary

Vibrating screen CVB 2050

refurbished

Cone crusher Omnicocircne 1352 SX

with Metso IC7000 controller Ellivar 16 (16 msup2 3 decks) screen

refurbished by Metso

Tertiary

Cone crusher HP300

Cone crusher HP4

2 Ellivar 20 screens (20 m23 decks) for final products

Expanding the production range

ldquoSince the mid-1990s when we became

owners of La Mariais we had used mobilemachinery with an assembly of beltconveyorsrdquo recalls Daniel Leblin Charierrsquos

Technical Manager for site construction

and maintenance

ldquoIt became clear that we needed ahigher performance tool to achieve the

dual goals of reaching one million metric

tonsrsquo maximum production and producing

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Big Lokotrack LT550GPF boostsquarrying productivity by a thirdMaximizing the productivity of operations is a key issue when striving for cost-effective quarrying Big Lokotracks are oneway to achieve improved operational efficiency The Lokotrack LT550GPF equipped with the high-volume GP550 conecrusher and a large screen is popular in the Nordic countries and in Germany and Australia ndash countries all known for theirhigh quarrying volumes

TEXT amp PHOTOS Eero Haumlmaumllaumlinen

Kone-Kostamorsquos new mobile coneplant has reached an averagecapacity of 300 tons per hour

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983122983141983152983151983154983156983145983150983143 983154983141983155

ldquoWith the same number of employees we

can achieve 30 more productivity with

our new LT550GPF unit The high-capacityFS screen has also eliminated the bottle-neck often seen at fine screeningrdquo says

Aarno Kostamo Managing Director of

Kone-Kostamo Oy one of Finlandrsquos biggest

crushing contractorsAccording to Kostamo the high capacity

of the GP550 gyratory cone crusher easily

handles feed from the C120 and C125 jaw

crushers For the contract with the Talvivaara

nickel mine the LT550GPF is being fed bythe brand new Lokotrack LT120 jaw plant

Average capacity 300 tons per hour

Talvivaara Europersquos largest nickel mine uti-

lizes large quantities of aggregates Kone-Kostamo has contracted several million

tons of different end products for the mineIn August 75000 tons of 0ndash63 mm

road gravel was crushed Smaller amountsof finer 0ndash6 mm 0ndash16 mm and 0ndash32 mm

aggregates are also being produced

The rainy summer increased the need

for road gravel along the muddy roadswhich must endure dump trucks weighing

as much as 260 tons

ldquoThe mobile process consisting of the

LT120 jaw plant and LT550GPF cone plant

is cost-effective while aggregates of vari-ous sizes can be produced in a two-stage

operation and with high capacity The con-trolled stroke and elliptical movement of

the FS screen secure big passing throughcapacitiesrdquo Kostamo explains

Operated in two shifts for a total of 16

hours per day the LT550GPF has logged

more than 600 working hours over a two-month period

Managing Director Aarno Kostamo (left) and foreman Karri Maumlenpaumlauml studying the cavity optionsavailable for the new Lokotrack LT550GPF

Longer perspective than

a single quarter needed

Kone-Kostamo Oy was founded as an

earth-moving company in Kemijaumlrvi

Northern Finland in 1956 The company

expanded its operations to include crush-

ing contracting in 1964 and later on

switched to concentrating fully on crush-ing activities

Kone-Kostamo consistently crushes

and screens around 28 million tons ofaggregates annually and has net sales of

between EUR 8ndash9 million

ldquoWe believe that issues within the crush-

ing industry including the purchasing ofmachinery must be studied with a longer

perspective than a single quarter The

secret to our success has always been our

solid work ethic and professional employ-eesrdquo Kostamo sums up

More info

Esa Berg

Tel + 358 40 837 8692

esabergmetsocom

8132019 Results Minerals Aggregates 3 2012ENG

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983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155

Monitoring-based reporting is vital for

assessing the performance of a mobile

crushing plant Metso provides suchreporting tools through its plant-wideautomation system Metso DNA (Dynamic

Network of Applications) with its infor-

mation platform that links all the mobile

crushing and screen units together as oneentity Basically there is a lot of measured

real-time information available in every

crushing plant On-line information is

obtained either from each Metso crusherrsquosmachine automation system IC (Intelligent

Controller) or from separately installed

additional sensors and belt scales

All the collected data is sent to a motorhome using wireless communication

based on WLAN technology The motor

home is a purpose-built environment

inside an on-site container In this environ-ment selected variables can be monitored

for assessing the plantrsquos performance And

to make all this even more flexible the

data can be transmitted to a crushing plant

company office using GPRS3G mobile

data communication technologies Thismakes all the last-minute reports acces-sible to the crushing plant managerial staff

at anytime and basically anywhere within

reach of the cell phone network

Production and fuel economics reports

Essentially monitoring and reporting can

be customized to fit the customerrsquos needs

However there are certain off-the-shelf

reports that provide a lot of useful informa-tion for plant supervision The production

report is one of these Requiring at least one

belt scale for measuring the total produc-tion the production report shows the pro-duction rate (tons per hour) for a selected

reporting period eg a day or a week The

production report constantly keeps track of

the plantrsquos production storing all the datathroughout the plantrsquos life cycle

Performance monitoring and reportingfor a mobile crushing plantTEXT Pasi Airikka PHOTOS Metso

unit during which the unit is running By

storing the availability times between start-ups and shutdowns the crushing plant

operation time (hours per dayshift) can be

recorded analyzed and reported In addi-

tion the availability report can be tailored

to evaluate efficient crushing hours during

which the plant is really working and pro-ducing aggregates Consequently the ratio

(0-100) between efficient crushing time

and total running time can be reported forany selected period of time This boosts

the efficiency of the plantrsquos operations

and results in better productivity

Reports on non-choke

or inadequate feeding

Non-choke feeding to crushers is avoid-

able through smart plant-wide crushingplant controls But estimating its severity in

a systematic manner is not straight-forwardwithout constant monitoring and reporting

The crusher choke feeding report makes

use of the crusher cavity level sensors byanalyzing their level measurements By

calculating average and min-max values

and deviations from the average it can be

shown how often the single crusher suffersfrom non-choke feeding to it

In some cases the bottleneck in the

crushing plantrsquos productivity is the material

feeding to the process In mobile plants thefeeding is human operated and therefore

subject to variations Occasionally the sizeof the human-operated machine simply

does not allow for adequate feeding to thecrushing plant There are specific reports

indicating time periods when the crushing

plant suffers from inadequate feeding

Condition monitoring for

crushers and screens

Machine-specific condition monitoring

focuses on vibrating components in

crushers and screens such as drive shaftbearings safety plate wearings and gears

The low middle and high frequencies ofmonitored components are measured and

supervised in real-time to detect abnor-malities due to slow or fast wear looseness

or imbalance

More info

Pasi Airikka

Tel +358 40 587 2730

pasiairikkametsocom

Condition monitoring provides a view tovibrating crusher and screen components forpredictive equipment maintenance

The daily production report shows the hour-by-hour production trend and distribution chartfor a selected day with min-max average andvariation statistics for comparison

Fuel consumption is always an interest-ing concern The fuel consumption reportgives the fuel consumption of each crush-

ing unit (liters per hour) and their total

consumption (liters per hour) for a selected

reporting period and can track fuel con-

sumption changes over timeCrushing plant availability can be

assessed as well The availability report

calculates time periods for each crushing

8132019 Results Minerals Aggregates 3 2012ENG

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983149983141983156983155983151 983150

for tissue machines The record of 2210

mmin was set on June 1 2012 during a

24-hour production run by the TM 2 tissue

machine at the companyrsquos mill in Yenikoumlynear the city of Izmit in Turkey

ldquoThe cooperation with Metso has been

beyond excellent and both parties did

their utmost to make the project success-ful The results clearly show that the efforts

were worthwhile on both sides This coop-

eration will extend to cover new projects

in the futurerdquo says Luumlt1047297 Aydin Paper GroupDirector Hayat Kimya

ldquoWe are not surprised that Hayat K imya

managed to break the world speed record

We have had great confidence in the capa-bility of the Hayat team since our project

started in 2009 We certainly know our

machine very well its stability production

efficiency and speed capabilityrdquo says Jan

Erikson Vice President Sales Metso

PowerThe worldrsquos first eco-gas fueled

power plant is up and running

Lahti Energy Ltdrsquos new Kymijaumlrvi II gasifica-

tion plant was officially inaugurated on

May 8 2012 It is the first of its kind in the

RecyclingRecycling with Lokotrack LT106

jaw plant in New York

A brand-new Lokotrack LT106 jaw plant is

used in the city area of New York USA to

recycle demolition materials The crushing

site faces the skyscrapers of ManhattanIsland

Paper amp FiberHayat Kimyarsquos Metso-supplied tissue

machine sets world speed record

Thanks to a skilled crew and dedicated

efforts Hayat Kimya AS in Turkey has suc-

ceeded in breaking the world speed record

world This CHP plant runs on clean eco-

gas that is gasified cleaned and cooled

from recycled waste with Metsorsquos innova-tive technology

ldquoItrsquos actually eco-gas that we combust

in the boilerrdquo comments Lahti EnergyrsquosProduction Director Jukka Manskinen

ldquoWe convert unwanted waste material into

energy in an efficient and environmentally

friendly wayrdquoNever before has any plant gasified

waste on such a large scale In the gasifier

recycled waste is turned into combustible

product gas which is cleaned cooled and

combusted in a high-efficiency gas boiler

to produce steam for the steam turbine The plant produces 50 MW of electricity

and 90 MW of district heat for the city of

Lahti and its neighboring areasMetso delivered the circulating fluidized

bed (CFB) gasification process gas cleaning

and cooling steam boiler environmental

protection system and automation systemto the entire plant The production of elec-

tricity and heat is kept even with the Metso

DNA automation system that covers the

whole plant starting from fuel reception

AutomationMetso develops and supplies plant-

wide crushing control solutions for

crushing plants

Metso has recently signed contracts on

delivering plant-wide automation systems

for mobile and portable rock crushing

plants The key objective of these deliveries

is to stabilize and to increase productivityand efficiency of the plants using one sin-

gle automation and information platform

for integrating crusher-specific IC machinecontrols

Furthermore the plant-wide system

with its information management tools not

only increases plant availability and opera-

tional safety it also makes troubleshoot-ing quicker and performance monitoring

easier The control room for plant-wide

operability is located either in an excavator

cabin or a purpose-built container

Metso around the world

The new LT106 jaw plant is suitable for crushing both hard rock and all rock-based demolition materials

The new world speed record for tissue setby Hayat Kimyarsquos Metso-supplied TM 2 is2210 mmin

8132019 Results Minerals Aggregates 3 2012ENG

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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 33: Results Minerals Aggregates 3 2012.ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155

The 88-km long horse-shoe-shaped

tunnel provides space for a two-lane8-m-wide carriageway as well as a one-

meter-wide footpath on both sides A

22-m-high and 36-m-wide emergency

tunnel will be integrated in the tun-

nel cross-section Altogether more than

800000 msup3 of rock will be moved Tunneling works started around spring

2010 with excavation driven from both por-

tals As the north portal is inaccessible dur-ing winter closure the excavation focused

on the south After a planned construction

period of 55 years the tunnel is scheduled

to be completed by the end of 2015

Best man for the job

The BRO (Border Road Organization)

wanted to roll out a global tender for theproject due to the challenges that such a

project involves and also considering thatitrsquos the first time in India that a project of

this scale was to be carried out This imme-

diately triggered the need to roll out aglobal tender All major Indian construction

companies bid for it some individually and

some in partnerships

Strabag an Austrian tunnel specialistwas one of the companies who bid for the

project along with AFCONS a Mumbai-

based infrastructure company In Septem-

ber 2009 AFCONS-Strabag was awardedthe contract

Mr Sunil Tyagi Deputy Project Man-ager at AFCONS had this to say about the

unique projectldquoThis project is located in the Himalayas

and as far as we understand the terrain

there is among the toughest We came out

with a new technology and to be honestit is a fairly simple one We would generally

start with the traditional technology of drill-

ing and blasting and then obtain our muck

feed from the inwardbottom of the tunnelrdquo

ldquoThe technology is supplied by Rowa Tunneling Logistics and this is the first

time it is being used in Asia A jaw crusheris placed at a distance of about 40-45

meters behind the face The blasted muckextracted from the face is fed to the crusher

to reduce the lump size and then through

an overhead conveyor transport system

it is then transported out of the tunnelrdquoldquoThis enables free movement of man

and machinery in the lower area or spe-

cifically on the ground area If we were to

conforms to the Indian standard for fines amp

coarse aggregates as prescribed in IS383-1970

The plant was up and running in good

condition and performing to AFCONSrsquos

satisfactionldquoWe have worked with Metso in earlier

projects and are quite impressed by thekind of technology amp services they provide

We have a history together so the trust fac-tor also comes inrdquo explains Dhiman on their

choice of Metso as a partner

Service makes the difference

ldquoMetsorsquos services have made a big dif-ference in the project Without them we

would still be struggling with the machin-

ery and production The service is really

good and the service engineers are knowl-edgeable prompt and quick to act Any

problem can be solved by Metso We donrsquothave to wait until a service engineer turns

up ndash they have the capacity to solve prob-lems over the phone as wellrdquo says Dhiman

ldquoThe Metso plant didnrsquot create any prob-

lems for us We had problems in logistics

the feed was sticky and the weather condi-tions were bad but thankfully we did not

face any problems with production and

efficiency as the Metso plant is performing

very wellrdquo Dhiman concludes

More info

Amol Sinha Tel +91 9811 671 924

amolsinhametsocom

use the old conventional technology this

wouldnrsquot have worked for us in the stipu-lated timerdquo Mr Tyagi adds

When the going gets tough

partner with the toughest

Sensitive projects require the best technol-

ogy After AFCONS-Strabag landed theproject Metso was an obvious choice as a

technology provider not only because of

the long-standing business relationshipbut also for the sheer consistency in prod-

uct quality and service deliverance Metso

strives for

ldquoAfter signing the project we faced alot of road blocks including extreme cold

avalanches roadblocks less oxygen ndash you

name it we faced itrdquo explains Ankit Dhi-

man Plant Manager at AFCONS-Strabag The Rohtang valley is known for its

notorious avalanches and landslides SoAFCONS had to take extra steps and safety

precautions against hazards on the site

ldquoIn this freezing cold not just us humansbut also the machines are at increased risk

of damage I remember when we used

to run the plant during winter the diesel

engines would freeze We had to constantlyheat up the fuel container to get the plant

running And even the sand in the sand

trap would freeze so we had to clean it on

a daily basis to stop the pipes from mal-functioningrdquo Dhiman adds

Plant designed for difficult terrain

Difficult terrain coupled with space con-straints led Metso engineers to put their

minds together to come up with a suitable

plant configuration After studying the

requirements of the project Metso sug-

gested a 150-tons-per-hour three-stagemodular plant using a C106 jaw crusher

a GP11F secondary cone crusher and a

B7150 tertiary vertical shaft impact crusher

In addition considering the unpredict-ability of the feed the plant was about

to reach a point where the amount offines to be handled could be increased

dramatically Metso strongly suggested the TK11-27-3V grizzly scalper and this became

the first-ever TK scalper to be supplied by

Metso to an Indian customer Also in order

to get better products a sand trap SF2360was added to the configuration

The sand trap is important equipment

for this project as it washes the sand thatMr Sunil Tyagi Deputy Project ManagerAFCONS-Strabag

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Smooth transition to new-generation jaw crusher in Germany

Roumlhrig is a German company with a rich heritage The company has been quarrying granite at its plant in Bergstrasse inthe Sonderbach district of Heppenheim for three generations

TEXT amp PHOTOS Ralf Goffin

Roumlhrigrsquos superior product variety is onereason why the companyrsquos proximity to its

customers can be understood in more than

just physical terms The companyrsquos high

level of innovation has allowed it to estab-lish itself as a reliable supplier of materials

both regionally and internationally This

operational and technical expertise always

manages to keep in step with growing

market requirements

In terms of technical processing equip-

ment Roumlhrig has used a Nordberg C160stationary jaw crusher from Metso since

1992 At the start of 2012 it was finally

exchanged for a more up-to-date version

from the same model range

Metsorsquos C Series is specifically designed

to pre-crush hard rock and can cope effort-

lessly with even the hardest of materials

The dimensions of the new stationary jawcrusher are identical to those of the old

one which means that it could simply be

slotted into the housing vacated by the

previous version

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983122983141983152983151983154983156983145983150983143 983154983141983155

Third-generation Managing DirectorMarco Roumlhrig expects the new machinersquos

service life to be just as long as the previ-

ous model due to the product upgrades

that have been implemented The integral motor base is another plus

point in models made by other manu-

facturers it is located outside the crusher

This element of good fortune ensured that

Roumlhrig could reuse the housing withoutany additional rebuilding

Another advantage lies in the revision

of the guards for the C160rsquos drivetrain andflywheel The sturdier construction method

used for the crusher requires fewer parts

which facilitates easier installation andmaintenance and it makes it simpler to

access the motor

Under the watchful eye of Metsorsquos

Assembly Manager Maik Engelstaumltterthe entire project including removal and

installation was successfully completed

within two weeks

Installation making the most

of the available space

Roumlhrig will likely remember the day the

new crusher was installed for a long time

the pitman and main frame were deliveredseparately prior to installation and assem-

bled on site It took just one hour to replace

the old stationary crusher with the new

model A lorry-mounted crane was used toposition the 85-ton crusher with millimeter

precision in the crushing plant Once the

new crusher had been positioned in theexisting steel structure the next task wasto fix it into place as securely as possible

despite the limited space Special vibration

dampers were installed at a height of two

meters to prevent the crusher from sliding

Norbert Ried (fourth from left) installed thenew C160rsquos predecessor 20 years ago and isdelighted at the durability of the powerfulcrusher that is now making way for a newermodel Also pictured from left to right ManagerVolker Angermann Assembly Manager Maik

Engelstaumltter Technical Manager Stefan

Koob Project Manager Dominic SchoumlnhardtManaging Director Marco Roumlhrig Service

Technician Stefan Kolze and employees ofthe installation company Stafemo

On the hook after theold C160 was liftedout by crane the newcrusher was installedin almost no timeOnly the roof of thehousing had to beremoved

sideways off its mount An initial test run

with materials was carried out around oneweek later after all the electrical cables had

been installed

Simultaneously with the installation

of the C160 which is the first of the latest

generation of crushers to be installed in

Germany a new Nordberg GP100 conecrusher was also being installed in Roumlhrigrsquos

chipping plant Roumlhrig is convinced that

the technical improvements made tothe new Metso crusher can only be an

advantage worldwide

Roumlhrig places great value on consistent

product quality maximum added valueand optimum refinement of its product

range Bearing in mind that Roumlhrig has

enough reserves of raw material to last

for the next 150 years the company canconfidently continue to develop with an

emphasis on quality rather than quantity

More info

Dominic Schoenhardt

Tel +49 (0)621 727 00 610

dominicschoenhardtmetsocom

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Groupe Charier Carriegravere de la Mariais France

Quarrying with certi1047297ed quality The Charier Group with its 1600-strong workforce is a family business thatthis year celebrates 115 years of quarrying The company pursues a long-termdevelopment policy that since 2007 has seen processing installations upgradedat 4 of its 9 extraction sites

TEXT Liliane Boutin (with extracts from Mines amp Carriegraveres and Terrassements amp Carriegraveres magazines)PHOTO Baloon photo

The processing installation is of the horizontal type with a primary station located 56 meters below the site access road to keep it hidden from view

The crushing and screening installation at

Charierrsquos CM La Mariais quarry (at Donges

on the Loire estuary) has been in opera-tion since September 2011 Based on theoperatorrsquos ideas it was designed by Metso

to replace a worn-out installation installed

right on top of the seam being extracted

Since its commissioning it has becomethe second quarry in the company to

receive ISO 14 001 certification

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983122983141983152983151983154983156983145983150983143 983154983141983155

tertiary material of sand and gravel for the

local market to use in concrete surfacingprefabrication etcrdquo

Incorporation of a screening station

The stone extracted from La Mariais is

according to the quarry granitic gneiss

sound and homogeneous with a LosAngeles index of 15 good wear resist-

ance with an MDE of 10 a true density of

265 and a certain abrasiveness (2000 gt)ldquoCharacteristically it has a tendency to form

blocksrdquo Leblin points out

The main criteria in designing the instal-

lation was to provide an output of 600000metric tons from one station (38 hours

week) to produce materials aimed at the

concrete and surfacing markets ldquowhich

involved providing a tertiary station withscreening plantrdquo he adds

With this new unit the operating com-pany expands its product range through

the addition of fine materials obtained

from the tertiary screening station This unitis capable of producing 170 tonshour of

020

Preserving the environment

and optimizing safety

The screens have motorized bogies and

retractable walkways to facilitate access

when the screens are opened for main-tenance Other walkways provide access

to the tunnel input feeders The feederscan be isolated with hydraulic rod gate

bars this hydraulic assistance eliminatesthe need to use a heavy hammer to lodge

these metal bars

All conveyors transporting fines (02

and 04) are covered with a tarpaulin to

avoid flying dust and all the screens arehooded (metal cover with Trellex seal-

ing) The Brunone company has installed

dust-tight containment at the outlet of the

tertiary station crushers (HP300 and HP4)on the belt located under the screens

and under the hoppers located belowthe tertiary screens The crushers are put

under negative pressure and the finesare extracted through sleeve filters (7000

m3 h) with declogging which deposits the

dust back onto the conveyor belt

A high-pressure 100 bar water mist sys-tem has been installed at the primary sta-

tion discharge at the secondary crusherrsquos

discharge chutes (Omnicone) and at the

transfer points on the belt

Designed to last

ldquoThis type of new installation can easily last

thirty yearsrdquo affirms Project Leader Bruno

Peix of Metso ldquoIt quite simply depends on

how well it is maintained Thatrsquos why weprovide maintenance contracts that call for

our technicians to make regular inspection

visits and carry out preventive mainte-nance and any necessary repairsrdquo

In 2011 Metso commissioned about

10 new processing units in France like

the one at La Mariais quarry

More info

Frederic Bazire

Tel +33 (0)681442804

fredericbaziremetsocom

Key figures

DURATION OF WORKS 15 months

DRAWING OFFICE TIME 7800 hours

HEIGHT OF SILOS AND GRINDER BUILDINGS

15 m

TOTAL LENGTH OF CONVEYORS 14 km

WEIGHT OF THE INSTALLATION

1200 metric tons

CONCRETE POURED 1800 cubic meters

PROJECT SITE WORKFORCE 30

INSTALLED POWER 2200 kW(not including pumps 200 kW)

METSO EQUIPMENT

Primary

Vibrating feeder PF561-2V

Primary grizzly VG540-3V

Grizzly feeder TK13-20-3V

Jaw crusher C145 with

hydraulic setting

Secondary

Vibrating screen CVB 2050

refurbished

Cone crusher Omnicocircne 1352 SX

with Metso IC7000 controller Ellivar 16 (16 msup2 3 decks) screen

refurbished by Metso

Tertiary

Cone crusher HP300

Cone crusher HP4

2 Ellivar 20 screens (20 m23 decks) for final products

Expanding the production range

ldquoSince the mid-1990s when we became

owners of La Mariais we had used mobilemachinery with an assembly of beltconveyorsrdquo recalls Daniel Leblin Charierrsquos

Technical Manager for site construction

and maintenance

ldquoIt became clear that we needed ahigher performance tool to achieve the

dual goals of reaching one million metric

tonsrsquo maximum production and producing

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Big Lokotrack LT550GPF boostsquarrying productivity by a thirdMaximizing the productivity of operations is a key issue when striving for cost-effective quarrying Big Lokotracks are oneway to achieve improved operational efficiency The Lokotrack LT550GPF equipped with the high-volume GP550 conecrusher and a large screen is popular in the Nordic countries and in Germany and Australia ndash countries all known for theirhigh quarrying volumes

TEXT amp PHOTOS Eero Haumlmaumllaumlinen

Kone-Kostamorsquos new mobile coneplant has reached an averagecapacity of 300 tons per hour

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983122983141983152983151983154983156983145983150983143 983154983141983155

ldquoWith the same number of employees we

can achieve 30 more productivity with

our new LT550GPF unit The high-capacityFS screen has also eliminated the bottle-neck often seen at fine screeningrdquo says

Aarno Kostamo Managing Director of

Kone-Kostamo Oy one of Finlandrsquos biggest

crushing contractorsAccording to Kostamo the high capacity

of the GP550 gyratory cone crusher easily

handles feed from the C120 and C125 jaw

crushers For the contract with the Talvivaara

nickel mine the LT550GPF is being fed bythe brand new Lokotrack LT120 jaw plant

Average capacity 300 tons per hour

Talvivaara Europersquos largest nickel mine uti-

lizes large quantities of aggregates Kone-Kostamo has contracted several million

tons of different end products for the mineIn August 75000 tons of 0ndash63 mm

road gravel was crushed Smaller amountsof finer 0ndash6 mm 0ndash16 mm and 0ndash32 mm

aggregates are also being produced

The rainy summer increased the need

for road gravel along the muddy roadswhich must endure dump trucks weighing

as much as 260 tons

ldquoThe mobile process consisting of the

LT120 jaw plant and LT550GPF cone plant

is cost-effective while aggregates of vari-ous sizes can be produced in a two-stage

operation and with high capacity The con-trolled stroke and elliptical movement of

the FS screen secure big passing throughcapacitiesrdquo Kostamo explains

Operated in two shifts for a total of 16

hours per day the LT550GPF has logged

more than 600 working hours over a two-month period

Managing Director Aarno Kostamo (left) and foreman Karri Maumlenpaumlauml studying the cavity optionsavailable for the new Lokotrack LT550GPF

Longer perspective than

a single quarter needed

Kone-Kostamo Oy was founded as an

earth-moving company in Kemijaumlrvi

Northern Finland in 1956 The company

expanded its operations to include crush-

ing contracting in 1964 and later on

switched to concentrating fully on crush-ing activities

Kone-Kostamo consistently crushes

and screens around 28 million tons ofaggregates annually and has net sales of

between EUR 8ndash9 million

ldquoWe believe that issues within the crush-

ing industry including the purchasing ofmachinery must be studied with a longer

perspective than a single quarter The

secret to our success has always been our

solid work ethic and professional employ-eesrdquo Kostamo sums up

More info

Esa Berg

Tel + 358 40 837 8692

esabergmetsocom

8132019 Results Minerals Aggregates 3 2012ENG

httpslidepdfcomreaderfullresults-minerals-aggregates-3-2012eng 40420983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155

Monitoring-based reporting is vital for

assessing the performance of a mobile

crushing plant Metso provides suchreporting tools through its plant-wideautomation system Metso DNA (Dynamic

Network of Applications) with its infor-

mation platform that links all the mobile

crushing and screen units together as oneentity Basically there is a lot of measured

real-time information available in every

crushing plant On-line information is

obtained either from each Metso crusherrsquosmachine automation system IC (Intelligent

Controller) or from separately installed

additional sensors and belt scales

All the collected data is sent to a motorhome using wireless communication

based on WLAN technology The motor

home is a purpose-built environment

inside an on-site container In this environ-ment selected variables can be monitored

for assessing the plantrsquos performance And

to make all this even more flexible the

data can be transmitted to a crushing plant

company office using GPRS3G mobile

data communication technologies Thismakes all the last-minute reports acces-sible to the crushing plant managerial staff

at anytime and basically anywhere within

reach of the cell phone network

Production and fuel economics reports

Essentially monitoring and reporting can

be customized to fit the customerrsquos needs

However there are certain off-the-shelf

reports that provide a lot of useful informa-tion for plant supervision The production

report is one of these Requiring at least one

belt scale for measuring the total produc-tion the production report shows the pro-duction rate (tons per hour) for a selected

reporting period eg a day or a week The

production report constantly keeps track of

the plantrsquos production storing all the datathroughout the plantrsquos life cycle

Performance monitoring and reportingfor a mobile crushing plantTEXT Pasi Airikka PHOTOS Metso

unit during which the unit is running By

storing the availability times between start-ups and shutdowns the crushing plant

operation time (hours per dayshift) can be

recorded analyzed and reported In addi-

tion the availability report can be tailored

to evaluate efficient crushing hours during

which the plant is really working and pro-ducing aggregates Consequently the ratio

(0-100) between efficient crushing time

and total running time can be reported forany selected period of time This boosts

the efficiency of the plantrsquos operations

and results in better productivity

Reports on non-choke

or inadequate feeding

Non-choke feeding to crushers is avoid-

able through smart plant-wide crushingplant controls But estimating its severity in

a systematic manner is not straight-forwardwithout constant monitoring and reporting

The crusher choke feeding report makes

use of the crusher cavity level sensors byanalyzing their level measurements By

calculating average and min-max values

and deviations from the average it can be

shown how often the single crusher suffersfrom non-choke feeding to it

In some cases the bottleneck in the

crushing plantrsquos productivity is the material

feeding to the process In mobile plants thefeeding is human operated and therefore

subject to variations Occasionally the sizeof the human-operated machine simply

does not allow for adequate feeding to thecrushing plant There are specific reports

indicating time periods when the crushing

plant suffers from inadequate feeding

Condition monitoring for

crushers and screens

Machine-specific condition monitoring

focuses on vibrating components in

crushers and screens such as drive shaftbearings safety plate wearings and gears

The low middle and high frequencies ofmonitored components are measured and

supervised in real-time to detect abnor-malities due to slow or fast wear looseness

or imbalance

More info

Pasi Airikka

Tel +358 40 587 2730

pasiairikkametsocom

Condition monitoring provides a view tovibrating crusher and screen components forpredictive equipment maintenance

The daily production report shows the hour-by-hour production trend and distribution chartfor a selected day with min-max average andvariation statistics for comparison

Fuel consumption is always an interest-ing concern The fuel consumption reportgives the fuel consumption of each crush-

ing unit (liters per hour) and their total

consumption (liters per hour) for a selected

reporting period and can track fuel con-

sumption changes over timeCrushing plant availability can be

assessed as well The availability report

calculates time periods for each crushing

8132019 Results Minerals Aggregates 3 2012ENG

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983149983141983156983155983151 983150

for tissue machines The record of 2210

mmin was set on June 1 2012 during a

24-hour production run by the TM 2 tissue

machine at the companyrsquos mill in Yenikoumlynear the city of Izmit in Turkey

ldquoThe cooperation with Metso has been

beyond excellent and both parties did

their utmost to make the project success-ful The results clearly show that the efforts

were worthwhile on both sides This coop-

eration will extend to cover new projects

in the futurerdquo says Luumlt1047297 Aydin Paper GroupDirector Hayat Kimya

ldquoWe are not surprised that Hayat K imya

managed to break the world speed record

We have had great confidence in the capa-bility of the Hayat team since our project

started in 2009 We certainly know our

machine very well its stability production

efficiency and speed capabilityrdquo says Jan

Erikson Vice President Sales Metso

PowerThe worldrsquos first eco-gas fueled

power plant is up and running

Lahti Energy Ltdrsquos new Kymijaumlrvi II gasifica-

tion plant was officially inaugurated on

May 8 2012 It is the first of its kind in the

RecyclingRecycling with Lokotrack LT106

jaw plant in New York

A brand-new Lokotrack LT106 jaw plant is

used in the city area of New York USA to

recycle demolition materials The crushing

site faces the skyscrapers of ManhattanIsland

Paper amp FiberHayat Kimyarsquos Metso-supplied tissue

machine sets world speed record

Thanks to a skilled crew and dedicated

efforts Hayat Kimya AS in Turkey has suc-

ceeded in breaking the world speed record

world This CHP plant runs on clean eco-

gas that is gasified cleaned and cooled

from recycled waste with Metsorsquos innova-tive technology

ldquoItrsquos actually eco-gas that we combust

in the boilerrdquo comments Lahti EnergyrsquosProduction Director Jukka Manskinen

ldquoWe convert unwanted waste material into

energy in an efficient and environmentally

friendly wayrdquoNever before has any plant gasified

waste on such a large scale In the gasifier

recycled waste is turned into combustible

product gas which is cleaned cooled and

combusted in a high-efficiency gas boiler

to produce steam for the steam turbine The plant produces 50 MW of electricity

and 90 MW of district heat for the city of

Lahti and its neighboring areasMetso delivered the circulating fluidized

bed (CFB) gasification process gas cleaning

and cooling steam boiler environmental

protection system and automation systemto the entire plant The production of elec-

tricity and heat is kept even with the Metso

DNA automation system that covers the

whole plant starting from fuel reception

AutomationMetso develops and supplies plant-

wide crushing control solutions for

crushing plants

Metso has recently signed contracts on

delivering plant-wide automation systems

for mobile and portable rock crushing

plants The key objective of these deliveries

is to stabilize and to increase productivityand efficiency of the plants using one sin-

gle automation and information platform

for integrating crusher-specific IC machinecontrols

Furthermore the plant-wide system

with its information management tools not

only increases plant availability and opera-

tional safety it also makes troubleshoot-ing quicker and performance monitoring

easier The control room for plant-wide

operability is located either in an excavator

cabin or a purpose-built container

Metso around the world

The new LT106 jaw plant is suitable for crushing both hard rock and all rock-based demolition materials

The new world speed record for tissue setby Hayat Kimyarsquos Metso-supplied TM 2 is2210 mmin

8132019 Results Minerals Aggregates 3 2012ENG

httpslidepdfcomreaderfullresults-minerals-aggregates-3-2012eng 4242

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: Results Minerals Aggregates 3 2012.ENG

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Smooth transition to new-generation jaw crusher in Germany

Roumlhrig is a German company with a rich heritage The company has been quarrying granite at its plant in Bergstrasse inthe Sonderbach district of Heppenheim for three generations

TEXT amp PHOTOS Ralf Goffin

Roumlhrigrsquos superior product variety is onereason why the companyrsquos proximity to its

customers can be understood in more than

just physical terms The companyrsquos high

level of innovation has allowed it to estab-lish itself as a reliable supplier of materials

both regionally and internationally This

operational and technical expertise always

manages to keep in step with growing

market requirements

In terms of technical processing equip-

ment Roumlhrig has used a Nordberg C160stationary jaw crusher from Metso since

1992 At the start of 2012 it was finally

exchanged for a more up-to-date version

from the same model range

Metsorsquos C Series is specifically designed

to pre-crush hard rock and can cope effort-

lessly with even the hardest of materials

The dimensions of the new stationary jawcrusher are identical to those of the old

one which means that it could simply be

slotted into the housing vacated by the

previous version

8132019 Results Minerals Aggregates 3 2012ENG

httpslidepdfcomreaderfullresults-minerals-aggregates-3-2012eng 3542983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088

983122983141983152983151983154983156983145983150983143 983154983141983155

Third-generation Managing DirectorMarco Roumlhrig expects the new machinersquos

service life to be just as long as the previ-

ous model due to the product upgrades

that have been implemented The integral motor base is another plus

point in models made by other manu-

facturers it is located outside the crusher

This element of good fortune ensured that

Roumlhrig could reuse the housing withoutany additional rebuilding

Another advantage lies in the revision

of the guards for the C160rsquos drivetrain andflywheel The sturdier construction method

used for the crusher requires fewer parts

which facilitates easier installation andmaintenance and it makes it simpler to

access the motor

Under the watchful eye of Metsorsquos

Assembly Manager Maik Engelstaumltterthe entire project including removal and

installation was successfully completed

within two weeks

Installation making the most

of the available space

Roumlhrig will likely remember the day the

new crusher was installed for a long time

the pitman and main frame were deliveredseparately prior to installation and assem-

bled on site It took just one hour to replace

the old stationary crusher with the new

model A lorry-mounted crane was used toposition the 85-ton crusher with millimeter

precision in the crushing plant Once the

new crusher had been positioned in theexisting steel structure the next task wasto fix it into place as securely as possible

despite the limited space Special vibration

dampers were installed at a height of two

meters to prevent the crusher from sliding

Norbert Ried (fourth from left) installed thenew C160rsquos predecessor 20 years ago and isdelighted at the durability of the powerfulcrusher that is now making way for a newermodel Also pictured from left to right ManagerVolker Angermann Assembly Manager Maik

Engelstaumltter Technical Manager Stefan

Koob Project Manager Dominic SchoumlnhardtManaging Director Marco Roumlhrig Service

Technician Stefan Kolze and employees ofthe installation company Stafemo

On the hook after theold C160 was liftedout by crane the newcrusher was installedin almost no timeOnly the roof of thehousing had to beremoved

sideways off its mount An initial test run

with materials was carried out around oneweek later after all the electrical cables had

been installed

Simultaneously with the installation

of the C160 which is the first of the latest

generation of crushers to be installed in

Germany a new Nordberg GP100 conecrusher was also being installed in Roumlhrigrsquos

chipping plant Roumlhrig is convinced that

the technical improvements made tothe new Metso crusher can only be an

advantage worldwide

Roumlhrig places great value on consistent

product quality maximum added valueand optimum refinement of its product

range Bearing in mind that Roumlhrig has

enough reserves of raw material to last

for the next 150 years the company canconfidently continue to develop with an

emphasis on quality rather than quantity

More info

Dominic Schoenhardt

Tel +49 (0)621 727 00 610

dominicschoenhardtmetsocom

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Groupe Charier Carriegravere de la Mariais France

Quarrying with certi1047297ed quality The Charier Group with its 1600-strong workforce is a family business thatthis year celebrates 115 years of quarrying The company pursues a long-termdevelopment policy that since 2007 has seen processing installations upgradedat 4 of its 9 extraction sites

TEXT Liliane Boutin (with extracts from Mines amp Carriegraveres and Terrassements amp Carriegraveres magazines)PHOTO Baloon photo

The processing installation is of the horizontal type with a primary station located 56 meters below the site access road to keep it hidden from view

The crushing and screening installation at

Charierrsquos CM La Mariais quarry (at Donges

on the Loire estuary) has been in opera-tion since September 2011 Based on theoperatorrsquos ideas it was designed by Metso

to replace a worn-out installation installed

right on top of the seam being extracted

Since its commissioning it has becomethe second quarry in the company to

receive ISO 14 001 certification

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155

tertiary material of sand and gravel for the

local market to use in concrete surfacingprefabrication etcrdquo

Incorporation of a screening station

The stone extracted from La Mariais is

according to the quarry granitic gneiss

sound and homogeneous with a LosAngeles index of 15 good wear resist-

ance with an MDE of 10 a true density of

265 and a certain abrasiveness (2000 gt)ldquoCharacteristically it has a tendency to form

blocksrdquo Leblin points out

The main criteria in designing the instal-

lation was to provide an output of 600000metric tons from one station (38 hours

week) to produce materials aimed at the

concrete and surfacing markets ldquowhich

involved providing a tertiary station withscreening plantrdquo he adds

With this new unit the operating com-pany expands its product range through

the addition of fine materials obtained

from the tertiary screening station This unitis capable of producing 170 tonshour of

020

Preserving the environment

and optimizing safety

The screens have motorized bogies and

retractable walkways to facilitate access

when the screens are opened for main-tenance Other walkways provide access

to the tunnel input feeders The feederscan be isolated with hydraulic rod gate

bars this hydraulic assistance eliminatesthe need to use a heavy hammer to lodge

these metal bars

All conveyors transporting fines (02

and 04) are covered with a tarpaulin to

avoid flying dust and all the screens arehooded (metal cover with Trellex seal-

ing) The Brunone company has installed

dust-tight containment at the outlet of the

tertiary station crushers (HP300 and HP4)on the belt located under the screens

and under the hoppers located belowthe tertiary screens The crushers are put

under negative pressure and the finesare extracted through sleeve filters (7000

m3 h) with declogging which deposits the

dust back onto the conveyor belt

A high-pressure 100 bar water mist sys-tem has been installed at the primary sta-

tion discharge at the secondary crusherrsquos

discharge chutes (Omnicone) and at the

transfer points on the belt

Designed to last

ldquoThis type of new installation can easily last

thirty yearsrdquo affirms Project Leader Bruno

Peix of Metso ldquoIt quite simply depends on

how well it is maintained Thatrsquos why weprovide maintenance contracts that call for

our technicians to make regular inspection

visits and carry out preventive mainte-nance and any necessary repairsrdquo

In 2011 Metso commissioned about

10 new processing units in France like

the one at La Mariais quarry

More info

Frederic Bazire

Tel +33 (0)681442804

fredericbaziremetsocom

Key figures

DURATION OF WORKS 15 months

DRAWING OFFICE TIME 7800 hours

HEIGHT OF SILOS AND GRINDER BUILDINGS

15 m

TOTAL LENGTH OF CONVEYORS 14 km

WEIGHT OF THE INSTALLATION

1200 metric tons

CONCRETE POURED 1800 cubic meters

PROJECT SITE WORKFORCE 30

INSTALLED POWER 2200 kW(not including pumps 200 kW)

METSO EQUIPMENT

Primary

Vibrating feeder PF561-2V

Primary grizzly VG540-3V

Grizzly feeder TK13-20-3V

Jaw crusher C145 with

hydraulic setting

Secondary

Vibrating screen CVB 2050

refurbished

Cone crusher Omnicocircne 1352 SX

with Metso IC7000 controller Ellivar 16 (16 msup2 3 decks) screen

refurbished by Metso

Tertiary

Cone crusher HP300

Cone crusher HP4

2 Ellivar 20 screens (20 m23 decks) for final products

Expanding the production range

ldquoSince the mid-1990s when we became

owners of La Mariais we had used mobilemachinery with an assembly of beltconveyorsrdquo recalls Daniel Leblin Charierrsquos

Technical Manager for site construction

and maintenance

ldquoIt became clear that we needed ahigher performance tool to achieve the

dual goals of reaching one million metric

tonsrsquo maximum production and producing

8132019 Results Minerals Aggregates 3 2012ENG

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983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Big Lokotrack LT550GPF boostsquarrying productivity by a thirdMaximizing the productivity of operations is a key issue when striving for cost-effective quarrying Big Lokotracks are oneway to achieve improved operational efficiency The Lokotrack LT550GPF equipped with the high-volume GP550 conecrusher and a large screen is popular in the Nordic countries and in Germany and Australia ndash countries all known for theirhigh quarrying volumes

TEXT amp PHOTOS Eero Haumlmaumllaumlinen

Kone-Kostamorsquos new mobile coneplant has reached an averagecapacity of 300 tons per hour

8132019 Results Minerals Aggregates 3 2012ENG

httpslidepdfcomreaderfullresults-minerals-aggregates-3-2012eng 3942983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088

983122983141983152983151983154983156983145983150983143 983154983141983155

ldquoWith the same number of employees we

can achieve 30 more productivity with

our new LT550GPF unit The high-capacityFS screen has also eliminated the bottle-neck often seen at fine screeningrdquo says

Aarno Kostamo Managing Director of

Kone-Kostamo Oy one of Finlandrsquos biggest

crushing contractorsAccording to Kostamo the high capacity

of the GP550 gyratory cone crusher easily

handles feed from the C120 and C125 jaw

crushers For the contract with the Talvivaara

nickel mine the LT550GPF is being fed bythe brand new Lokotrack LT120 jaw plant

Average capacity 300 tons per hour

Talvivaara Europersquos largest nickel mine uti-

lizes large quantities of aggregates Kone-Kostamo has contracted several million

tons of different end products for the mineIn August 75000 tons of 0ndash63 mm

road gravel was crushed Smaller amountsof finer 0ndash6 mm 0ndash16 mm and 0ndash32 mm

aggregates are also being produced

The rainy summer increased the need

for road gravel along the muddy roadswhich must endure dump trucks weighing

as much as 260 tons

ldquoThe mobile process consisting of the

LT120 jaw plant and LT550GPF cone plant

is cost-effective while aggregates of vari-ous sizes can be produced in a two-stage

operation and with high capacity The con-trolled stroke and elliptical movement of

the FS screen secure big passing throughcapacitiesrdquo Kostamo explains

Operated in two shifts for a total of 16

hours per day the LT550GPF has logged

more than 600 working hours over a two-month period

Managing Director Aarno Kostamo (left) and foreman Karri Maumlenpaumlauml studying the cavity optionsavailable for the new Lokotrack LT550GPF

Longer perspective than

a single quarter needed

Kone-Kostamo Oy was founded as an

earth-moving company in Kemijaumlrvi

Northern Finland in 1956 The company

expanded its operations to include crush-

ing contracting in 1964 and later on

switched to concentrating fully on crush-ing activities

Kone-Kostamo consistently crushes

and screens around 28 million tons ofaggregates annually and has net sales of

between EUR 8ndash9 million

ldquoWe believe that issues within the crush-

ing industry including the purchasing ofmachinery must be studied with a longer

perspective than a single quarter The

secret to our success has always been our

solid work ethic and professional employ-eesrdquo Kostamo sums up

More info

Esa Berg

Tel + 358 40 837 8692

esabergmetsocom

8132019 Results Minerals Aggregates 3 2012ENG

httpslidepdfcomreaderfullresults-minerals-aggregates-3-2012eng 40420983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155

Monitoring-based reporting is vital for

assessing the performance of a mobile

crushing plant Metso provides suchreporting tools through its plant-wideautomation system Metso DNA (Dynamic

Network of Applications) with its infor-

mation platform that links all the mobile

crushing and screen units together as oneentity Basically there is a lot of measured

real-time information available in every

crushing plant On-line information is

obtained either from each Metso crusherrsquosmachine automation system IC (Intelligent

Controller) or from separately installed

additional sensors and belt scales

All the collected data is sent to a motorhome using wireless communication

based on WLAN technology The motor

home is a purpose-built environment

inside an on-site container In this environ-ment selected variables can be monitored

for assessing the plantrsquos performance And

to make all this even more flexible the

data can be transmitted to a crushing plant

company office using GPRS3G mobile

data communication technologies Thismakes all the last-minute reports acces-sible to the crushing plant managerial staff

at anytime and basically anywhere within

reach of the cell phone network

Production and fuel economics reports

Essentially monitoring and reporting can

be customized to fit the customerrsquos needs

However there are certain off-the-shelf

reports that provide a lot of useful informa-tion for plant supervision The production

report is one of these Requiring at least one

belt scale for measuring the total produc-tion the production report shows the pro-duction rate (tons per hour) for a selected

reporting period eg a day or a week The

production report constantly keeps track of

the plantrsquos production storing all the datathroughout the plantrsquos life cycle

Performance monitoring and reportingfor a mobile crushing plantTEXT Pasi Airikka PHOTOS Metso

unit during which the unit is running By

storing the availability times between start-ups and shutdowns the crushing plant

operation time (hours per dayshift) can be

recorded analyzed and reported In addi-

tion the availability report can be tailored

to evaluate efficient crushing hours during

which the plant is really working and pro-ducing aggregates Consequently the ratio

(0-100) between efficient crushing time

and total running time can be reported forany selected period of time This boosts

the efficiency of the plantrsquos operations

and results in better productivity

Reports on non-choke

or inadequate feeding

Non-choke feeding to crushers is avoid-

able through smart plant-wide crushingplant controls But estimating its severity in

a systematic manner is not straight-forwardwithout constant monitoring and reporting

The crusher choke feeding report makes

use of the crusher cavity level sensors byanalyzing their level measurements By

calculating average and min-max values

and deviations from the average it can be

shown how often the single crusher suffersfrom non-choke feeding to it

In some cases the bottleneck in the

crushing plantrsquos productivity is the material

feeding to the process In mobile plants thefeeding is human operated and therefore

subject to variations Occasionally the sizeof the human-operated machine simply

does not allow for adequate feeding to thecrushing plant There are specific reports

indicating time periods when the crushing

plant suffers from inadequate feeding

Condition monitoring for

crushers and screens

Machine-specific condition monitoring

focuses on vibrating components in

crushers and screens such as drive shaftbearings safety plate wearings and gears

The low middle and high frequencies ofmonitored components are measured and

supervised in real-time to detect abnor-malities due to slow or fast wear looseness

or imbalance

More info

Pasi Airikka

Tel +358 40 587 2730

pasiairikkametsocom

Condition monitoring provides a view tovibrating crusher and screen components forpredictive equipment maintenance

The daily production report shows the hour-by-hour production trend and distribution chartfor a selected day with min-max average andvariation statistics for comparison

Fuel consumption is always an interest-ing concern The fuel consumption reportgives the fuel consumption of each crush-

ing unit (liters per hour) and their total

consumption (liters per hour) for a selected

reporting period and can track fuel con-

sumption changes over timeCrushing plant availability can be

assessed as well The availability report

calculates time periods for each crushing

8132019 Results Minerals Aggregates 3 2012ENG

httpslidepdfcomreaderfullresults-minerals-aggregates-3-2012eng 4142983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088

983149983141983156983155983151 983150

for tissue machines The record of 2210

mmin was set on June 1 2012 during a

24-hour production run by the TM 2 tissue

machine at the companyrsquos mill in Yenikoumlynear the city of Izmit in Turkey

ldquoThe cooperation with Metso has been

beyond excellent and both parties did

their utmost to make the project success-ful The results clearly show that the efforts

were worthwhile on both sides This coop-

eration will extend to cover new projects

in the futurerdquo says Luumlt1047297 Aydin Paper GroupDirector Hayat Kimya

ldquoWe are not surprised that Hayat K imya

managed to break the world speed record

We have had great confidence in the capa-bility of the Hayat team since our project

started in 2009 We certainly know our

machine very well its stability production

efficiency and speed capabilityrdquo says Jan

Erikson Vice President Sales Metso

PowerThe worldrsquos first eco-gas fueled

power plant is up and running

Lahti Energy Ltdrsquos new Kymijaumlrvi II gasifica-

tion plant was officially inaugurated on

May 8 2012 It is the first of its kind in the

RecyclingRecycling with Lokotrack LT106

jaw plant in New York

A brand-new Lokotrack LT106 jaw plant is

used in the city area of New York USA to

recycle demolition materials The crushing

site faces the skyscrapers of ManhattanIsland

Paper amp FiberHayat Kimyarsquos Metso-supplied tissue

machine sets world speed record

Thanks to a skilled crew and dedicated

efforts Hayat Kimya AS in Turkey has suc-

ceeded in breaking the world speed record

world This CHP plant runs on clean eco-

gas that is gasified cleaned and cooled

from recycled waste with Metsorsquos innova-tive technology

ldquoItrsquos actually eco-gas that we combust

in the boilerrdquo comments Lahti EnergyrsquosProduction Director Jukka Manskinen

ldquoWe convert unwanted waste material into

energy in an efficient and environmentally

friendly wayrdquoNever before has any plant gasified

waste on such a large scale In the gasifier

recycled waste is turned into combustible

product gas which is cleaned cooled and

combusted in a high-efficiency gas boiler

to produce steam for the steam turbine The plant produces 50 MW of electricity

and 90 MW of district heat for the city of

Lahti and its neighboring areasMetso delivered the circulating fluidized

bed (CFB) gasification process gas cleaning

and cooling steam boiler environmental

protection system and automation systemto the entire plant The production of elec-

tricity and heat is kept even with the Metso

DNA automation system that covers the

whole plant starting from fuel reception

AutomationMetso develops and supplies plant-

wide crushing control solutions for

crushing plants

Metso has recently signed contracts on

delivering plant-wide automation systems

for mobile and portable rock crushing

plants The key objective of these deliveries

is to stabilize and to increase productivityand efficiency of the plants using one sin-

gle automation and information platform

for integrating crusher-specific IC machinecontrols

Furthermore the plant-wide system

with its information management tools not

only increases plant availability and opera-

tional safety it also makes troubleshoot-ing quicker and performance monitoring

easier The control room for plant-wide

operability is located either in an excavator

cabin or a purpose-built container

Metso around the world

The new LT106 jaw plant is suitable for crushing both hard rock and all rock-based demolition materials

The new world speed record for tissue setby Hayat Kimyarsquos Metso-supplied TM 2 is2210 mmin

8132019 Results Minerals Aggregates 3 2012ENG

httpslidepdfcomreaderfullresults-minerals-aggregates-3-2012eng 4242

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: Results Minerals Aggregates 3 2012.ENG

8132019 Results Minerals Aggregates 3 2012ENG

httpslidepdfcomreaderfullresults-minerals-aggregates-3-2012eng 3542983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088

983122983141983152983151983154983156983145983150983143 983154983141983155

Third-generation Managing DirectorMarco Roumlhrig expects the new machinersquos

service life to be just as long as the previ-

ous model due to the product upgrades

that have been implemented The integral motor base is another plus

point in models made by other manu-

facturers it is located outside the crusher

This element of good fortune ensured that

Roumlhrig could reuse the housing withoutany additional rebuilding

Another advantage lies in the revision

of the guards for the C160rsquos drivetrain andflywheel The sturdier construction method

used for the crusher requires fewer parts

which facilitates easier installation andmaintenance and it makes it simpler to

access the motor

Under the watchful eye of Metsorsquos

Assembly Manager Maik Engelstaumltterthe entire project including removal and

installation was successfully completed

within two weeks

Installation making the most

of the available space

Roumlhrig will likely remember the day the

new crusher was installed for a long time

the pitman and main frame were deliveredseparately prior to installation and assem-

bled on site It took just one hour to replace

the old stationary crusher with the new

model A lorry-mounted crane was used toposition the 85-ton crusher with millimeter

precision in the crushing plant Once the

new crusher had been positioned in theexisting steel structure the next task wasto fix it into place as securely as possible

despite the limited space Special vibration

dampers were installed at a height of two

meters to prevent the crusher from sliding

Norbert Ried (fourth from left) installed thenew C160rsquos predecessor 20 years ago and isdelighted at the durability of the powerfulcrusher that is now making way for a newermodel Also pictured from left to right ManagerVolker Angermann Assembly Manager Maik

Engelstaumltter Technical Manager Stefan

Koob Project Manager Dominic SchoumlnhardtManaging Director Marco Roumlhrig Service

Technician Stefan Kolze and employees ofthe installation company Stafemo

On the hook after theold C160 was liftedout by crane the newcrusher was installedin almost no timeOnly the roof of thehousing had to beremoved

sideways off its mount An initial test run

with materials was carried out around oneweek later after all the electrical cables had

been installed

Simultaneously with the installation

of the C160 which is the first of the latest

generation of crushers to be installed in

Germany a new Nordberg GP100 conecrusher was also being installed in Roumlhrigrsquos

chipping plant Roumlhrig is convinced that

the technical improvements made tothe new Metso crusher can only be an

advantage worldwide

Roumlhrig places great value on consistent

product quality maximum added valueand optimum refinement of its product

range Bearing in mind that Roumlhrig has

enough reserves of raw material to last

for the next 150 years the company canconfidently continue to develop with an

emphasis on quality rather than quantity

More info

Dominic Schoenhardt

Tel +49 (0)621 727 00 610

dominicschoenhardtmetsocom

8132019 Results Minerals Aggregates 3 2012ENG

httpslidepdfcomreaderfullresults-minerals-aggregates-3-2012eng 36426983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Groupe Charier Carriegravere de la Mariais France

Quarrying with certi1047297ed quality The Charier Group with its 1600-strong workforce is a family business thatthis year celebrates 115 years of quarrying The company pursues a long-termdevelopment policy that since 2007 has seen processing installations upgradedat 4 of its 9 extraction sites

TEXT Liliane Boutin (with extracts from Mines amp Carriegraveres and Terrassements amp Carriegraveres magazines)PHOTO Baloon photo

The processing installation is of the horizontal type with a primary station located 56 meters below the site access road to keep it hidden from view

The crushing and screening installation at

Charierrsquos CM La Mariais quarry (at Donges

on the Loire estuary) has been in opera-tion since September 2011 Based on theoperatorrsquos ideas it was designed by Metso

to replace a worn-out installation installed

right on top of the seam being extracted

Since its commissioning it has becomethe second quarry in the company to

receive ISO 14 001 certification

8132019 Results Minerals Aggregates 3 2012ENG

httpslidepdfcomreaderfullresults-minerals-aggregates-3-2012eng 3742983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088

983122983141983152983151983154983156983145983150983143 983154983141983155

tertiary material of sand and gravel for the

local market to use in concrete surfacingprefabrication etcrdquo

Incorporation of a screening station

The stone extracted from La Mariais is

according to the quarry granitic gneiss

sound and homogeneous with a LosAngeles index of 15 good wear resist-

ance with an MDE of 10 a true density of

265 and a certain abrasiveness (2000 gt)ldquoCharacteristically it has a tendency to form

blocksrdquo Leblin points out

The main criteria in designing the instal-

lation was to provide an output of 600000metric tons from one station (38 hours

week) to produce materials aimed at the

concrete and surfacing markets ldquowhich

involved providing a tertiary station withscreening plantrdquo he adds

With this new unit the operating com-pany expands its product range through

the addition of fine materials obtained

from the tertiary screening station This unitis capable of producing 170 tonshour of

020

Preserving the environment

and optimizing safety

The screens have motorized bogies and

retractable walkways to facilitate access

when the screens are opened for main-tenance Other walkways provide access

to the tunnel input feeders The feederscan be isolated with hydraulic rod gate

bars this hydraulic assistance eliminatesthe need to use a heavy hammer to lodge

these metal bars

All conveyors transporting fines (02

and 04) are covered with a tarpaulin to

avoid flying dust and all the screens arehooded (metal cover with Trellex seal-

ing) The Brunone company has installed

dust-tight containment at the outlet of the

tertiary station crushers (HP300 and HP4)on the belt located under the screens

and under the hoppers located belowthe tertiary screens The crushers are put

under negative pressure and the finesare extracted through sleeve filters (7000

m3 h) with declogging which deposits the

dust back onto the conveyor belt

A high-pressure 100 bar water mist sys-tem has been installed at the primary sta-

tion discharge at the secondary crusherrsquos

discharge chutes (Omnicone) and at the

transfer points on the belt

Designed to last

ldquoThis type of new installation can easily last

thirty yearsrdquo affirms Project Leader Bruno

Peix of Metso ldquoIt quite simply depends on

how well it is maintained Thatrsquos why weprovide maintenance contracts that call for

our technicians to make regular inspection

visits and carry out preventive mainte-nance and any necessary repairsrdquo

In 2011 Metso commissioned about

10 new processing units in France like

the one at La Mariais quarry

More info

Frederic Bazire

Tel +33 (0)681442804

fredericbaziremetsocom

Key figures

DURATION OF WORKS 15 months

DRAWING OFFICE TIME 7800 hours

HEIGHT OF SILOS AND GRINDER BUILDINGS

15 m

TOTAL LENGTH OF CONVEYORS 14 km

WEIGHT OF THE INSTALLATION

1200 metric tons

CONCRETE POURED 1800 cubic meters

PROJECT SITE WORKFORCE 30

INSTALLED POWER 2200 kW(not including pumps 200 kW)

METSO EQUIPMENT

Primary

Vibrating feeder PF561-2V

Primary grizzly VG540-3V

Grizzly feeder TK13-20-3V

Jaw crusher C145 with

hydraulic setting

Secondary

Vibrating screen CVB 2050

refurbished

Cone crusher Omnicocircne 1352 SX

with Metso IC7000 controller Ellivar 16 (16 msup2 3 decks) screen

refurbished by Metso

Tertiary

Cone crusher HP300

Cone crusher HP4

2 Ellivar 20 screens (20 m23 decks) for final products

Expanding the production range

ldquoSince the mid-1990s when we became

owners of La Mariais we had used mobilemachinery with an assembly of beltconveyorsrdquo recalls Daniel Leblin Charierrsquos

Technical Manager for site construction

and maintenance

ldquoIt became clear that we needed ahigher performance tool to achieve the

dual goals of reaching one million metric

tonsrsquo maximum production and producing

8132019 Results Minerals Aggregates 3 2012ENG

httpslidepdfcomreaderfullresults-minerals-aggregates-3-2012eng 38428983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Big Lokotrack LT550GPF boostsquarrying productivity by a thirdMaximizing the productivity of operations is a key issue when striving for cost-effective quarrying Big Lokotracks are oneway to achieve improved operational efficiency The Lokotrack LT550GPF equipped with the high-volume GP550 conecrusher and a large screen is popular in the Nordic countries and in Germany and Australia ndash countries all known for theirhigh quarrying volumes

TEXT amp PHOTOS Eero Haumlmaumllaumlinen

Kone-Kostamorsquos new mobile coneplant has reached an averagecapacity of 300 tons per hour

8132019 Results Minerals Aggregates 3 2012ENG

httpslidepdfcomreaderfullresults-minerals-aggregates-3-2012eng 3942983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088

983122983141983152983151983154983156983145983150983143 983154983141983155

ldquoWith the same number of employees we

can achieve 30 more productivity with

our new LT550GPF unit The high-capacityFS screen has also eliminated the bottle-neck often seen at fine screeningrdquo says

Aarno Kostamo Managing Director of

Kone-Kostamo Oy one of Finlandrsquos biggest

crushing contractorsAccording to Kostamo the high capacity

of the GP550 gyratory cone crusher easily

handles feed from the C120 and C125 jaw

crushers For the contract with the Talvivaara

nickel mine the LT550GPF is being fed bythe brand new Lokotrack LT120 jaw plant

Average capacity 300 tons per hour

Talvivaara Europersquos largest nickel mine uti-

lizes large quantities of aggregates Kone-Kostamo has contracted several million

tons of different end products for the mineIn August 75000 tons of 0ndash63 mm

road gravel was crushed Smaller amountsof finer 0ndash6 mm 0ndash16 mm and 0ndash32 mm

aggregates are also being produced

The rainy summer increased the need

for road gravel along the muddy roadswhich must endure dump trucks weighing

as much as 260 tons

ldquoThe mobile process consisting of the

LT120 jaw plant and LT550GPF cone plant

is cost-effective while aggregates of vari-ous sizes can be produced in a two-stage

operation and with high capacity The con-trolled stroke and elliptical movement of

the FS screen secure big passing throughcapacitiesrdquo Kostamo explains

Operated in two shifts for a total of 16

hours per day the LT550GPF has logged

more than 600 working hours over a two-month period

Managing Director Aarno Kostamo (left) and foreman Karri Maumlenpaumlauml studying the cavity optionsavailable for the new Lokotrack LT550GPF

Longer perspective than

a single quarter needed

Kone-Kostamo Oy was founded as an

earth-moving company in Kemijaumlrvi

Northern Finland in 1956 The company

expanded its operations to include crush-

ing contracting in 1964 and later on

switched to concentrating fully on crush-ing activities

Kone-Kostamo consistently crushes

and screens around 28 million tons ofaggregates annually and has net sales of

between EUR 8ndash9 million

ldquoWe believe that issues within the crush-

ing industry including the purchasing ofmachinery must be studied with a longer

perspective than a single quarter The

secret to our success has always been our

solid work ethic and professional employ-eesrdquo Kostamo sums up

More info

Esa Berg

Tel + 358 40 837 8692

esabergmetsocom

8132019 Results Minerals Aggregates 3 2012ENG

httpslidepdfcomreaderfullresults-minerals-aggregates-3-2012eng 40420983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155

Monitoring-based reporting is vital for

assessing the performance of a mobile

crushing plant Metso provides suchreporting tools through its plant-wideautomation system Metso DNA (Dynamic

Network of Applications) with its infor-

mation platform that links all the mobile

crushing and screen units together as oneentity Basically there is a lot of measured

real-time information available in every

crushing plant On-line information is

obtained either from each Metso crusherrsquosmachine automation system IC (Intelligent

Controller) or from separately installed

additional sensors and belt scales

All the collected data is sent to a motorhome using wireless communication

based on WLAN technology The motor

home is a purpose-built environment

inside an on-site container In this environ-ment selected variables can be monitored

for assessing the plantrsquos performance And

to make all this even more flexible the

data can be transmitted to a crushing plant

company office using GPRS3G mobile

data communication technologies Thismakes all the last-minute reports acces-sible to the crushing plant managerial staff

at anytime and basically anywhere within

reach of the cell phone network

Production and fuel economics reports

Essentially monitoring and reporting can

be customized to fit the customerrsquos needs

However there are certain off-the-shelf

reports that provide a lot of useful informa-tion for plant supervision The production

report is one of these Requiring at least one

belt scale for measuring the total produc-tion the production report shows the pro-duction rate (tons per hour) for a selected

reporting period eg a day or a week The

production report constantly keeps track of

the plantrsquos production storing all the datathroughout the plantrsquos life cycle

Performance monitoring and reportingfor a mobile crushing plantTEXT Pasi Airikka PHOTOS Metso

unit during which the unit is running By

storing the availability times between start-ups and shutdowns the crushing plant

operation time (hours per dayshift) can be

recorded analyzed and reported In addi-

tion the availability report can be tailored

to evaluate efficient crushing hours during

which the plant is really working and pro-ducing aggregates Consequently the ratio

(0-100) between efficient crushing time

and total running time can be reported forany selected period of time This boosts

the efficiency of the plantrsquos operations

and results in better productivity

Reports on non-choke

or inadequate feeding

Non-choke feeding to crushers is avoid-

able through smart plant-wide crushingplant controls But estimating its severity in

a systematic manner is not straight-forwardwithout constant monitoring and reporting

The crusher choke feeding report makes

use of the crusher cavity level sensors byanalyzing their level measurements By

calculating average and min-max values

and deviations from the average it can be

shown how often the single crusher suffersfrom non-choke feeding to it

In some cases the bottleneck in the

crushing plantrsquos productivity is the material

feeding to the process In mobile plants thefeeding is human operated and therefore

subject to variations Occasionally the sizeof the human-operated machine simply

does not allow for adequate feeding to thecrushing plant There are specific reports

indicating time periods when the crushing

plant suffers from inadequate feeding

Condition monitoring for

crushers and screens

Machine-specific condition monitoring

focuses on vibrating components in

crushers and screens such as drive shaftbearings safety plate wearings and gears

The low middle and high frequencies ofmonitored components are measured and

supervised in real-time to detect abnor-malities due to slow or fast wear looseness

or imbalance

More info

Pasi Airikka

Tel +358 40 587 2730

pasiairikkametsocom

Condition monitoring provides a view tovibrating crusher and screen components forpredictive equipment maintenance

The daily production report shows the hour-by-hour production trend and distribution chartfor a selected day with min-max average andvariation statistics for comparison

Fuel consumption is always an interest-ing concern The fuel consumption reportgives the fuel consumption of each crush-

ing unit (liters per hour) and their total

consumption (liters per hour) for a selected

reporting period and can track fuel con-

sumption changes over timeCrushing plant availability can be

assessed as well The availability report

calculates time periods for each crushing

8132019 Results Minerals Aggregates 3 2012ENG

httpslidepdfcomreaderfullresults-minerals-aggregates-3-2012eng 4142983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088

983149983141983156983155983151 983150

for tissue machines The record of 2210

mmin was set on June 1 2012 during a

24-hour production run by the TM 2 tissue

machine at the companyrsquos mill in Yenikoumlynear the city of Izmit in Turkey

ldquoThe cooperation with Metso has been

beyond excellent and both parties did

their utmost to make the project success-ful The results clearly show that the efforts

were worthwhile on both sides This coop-

eration will extend to cover new projects

in the futurerdquo says Luumlt1047297 Aydin Paper GroupDirector Hayat Kimya

ldquoWe are not surprised that Hayat K imya

managed to break the world speed record

We have had great confidence in the capa-bility of the Hayat team since our project

started in 2009 We certainly know our

machine very well its stability production

efficiency and speed capabilityrdquo says Jan

Erikson Vice President Sales Metso

PowerThe worldrsquos first eco-gas fueled

power plant is up and running

Lahti Energy Ltdrsquos new Kymijaumlrvi II gasifica-

tion plant was officially inaugurated on

May 8 2012 It is the first of its kind in the

RecyclingRecycling with Lokotrack LT106

jaw plant in New York

A brand-new Lokotrack LT106 jaw plant is

used in the city area of New York USA to

recycle demolition materials The crushing

site faces the skyscrapers of ManhattanIsland

Paper amp FiberHayat Kimyarsquos Metso-supplied tissue

machine sets world speed record

Thanks to a skilled crew and dedicated

efforts Hayat Kimya AS in Turkey has suc-

ceeded in breaking the world speed record

world This CHP plant runs on clean eco-

gas that is gasified cleaned and cooled

from recycled waste with Metsorsquos innova-tive technology

ldquoItrsquos actually eco-gas that we combust

in the boilerrdquo comments Lahti EnergyrsquosProduction Director Jukka Manskinen

ldquoWe convert unwanted waste material into

energy in an efficient and environmentally

friendly wayrdquoNever before has any plant gasified

waste on such a large scale In the gasifier

recycled waste is turned into combustible

product gas which is cleaned cooled and

combusted in a high-efficiency gas boiler

to produce steam for the steam turbine The plant produces 50 MW of electricity

and 90 MW of district heat for the city of

Lahti and its neighboring areasMetso delivered the circulating fluidized

bed (CFB) gasification process gas cleaning

and cooling steam boiler environmental

protection system and automation systemto the entire plant The production of elec-

tricity and heat is kept even with the Metso

DNA automation system that covers the

whole plant starting from fuel reception

AutomationMetso develops and supplies plant-

wide crushing control solutions for

crushing plants

Metso has recently signed contracts on

delivering plant-wide automation systems

for mobile and portable rock crushing

plants The key objective of these deliveries

is to stabilize and to increase productivityand efficiency of the plants using one sin-

gle automation and information platform

for integrating crusher-specific IC machinecontrols

Furthermore the plant-wide system

with its information management tools not

only increases plant availability and opera-

tional safety it also makes troubleshoot-ing quicker and performance monitoring

easier The control room for plant-wide

operability is located either in an excavator

cabin or a purpose-built container

Metso around the world

The new LT106 jaw plant is suitable for crushing both hard rock and all rock-based demolition materials

The new world speed record for tissue setby Hayat Kimyarsquos Metso-supplied TM 2 is2210 mmin

8132019 Results Minerals Aggregates 3 2012ENG

httpslidepdfcomreaderfullresults-minerals-aggregates-3-2012eng 4242

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: Results Minerals Aggregates 3 2012.ENG

8132019 Results Minerals Aggregates 3 2012ENG

httpslidepdfcomreaderfullresults-minerals-aggregates-3-2012eng 36426983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Groupe Charier Carriegravere de la Mariais France

Quarrying with certi1047297ed quality The Charier Group with its 1600-strong workforce is a family business thatthis year celebrates 115 years of quarrying The company pursues a long-termdevelopment policy that since 2007 has seen processing installations upgradedat 4 of its 9 extraction sites

TEXT Liliane Boutin (with extracts from Mines amp Carriegraveres and Terrassements amp Carriegraveres magazines)PHOTO Baloon photo

The processing installation is of the horizontal type with a primary station located 56 meters below the site access road to keep it hidden from view

The crushing and screening installation at

Charierrsquos CM La Mariais quarry (at Donges

on the Loire estuary) has been in opera-tion since September 2011 Based on theoperatorrsquos ideas it was designed by Metso

to replace a worn-out installation installed

right on top of the seam being extracted

Since its commissioning it has becomethe second quarry in the company to

receive ISO 14 001 certification

8132019 Results Minerals Aggregates 3 2012ENG

httpslidepdfcomreaderfullresults-minerals-aggregates-3-2012eng 3742983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088

983122983141983152983151983154983156983145983150983143 983154983141983155

tertiary material of sand and gravel for the

local market to use in concrete surfacingprefabrication etcrdquo

Incorporation of a screening station

The stone extracted from La Mariais is

according to the quarry granitic gneiss

sound and homogeneous with a LosAngeles index of 15 good wear resist-

ance with an MDE of 10 a true density of

265 and a certain abrasiveness (2000 gt)ldquoCharacteristically it has a tendency to form

blocksrdquo Leblin points out

The main criteria in designing the instal-

lation was to provide an output of 600000metric tons from one station (38 hours

week) to produce materials aimed at the

concrete and surfacing markets ldquowhich

involved providing a tertiary station withscreening plantrdquo he adds

With this new unit the operating com-pany expands its product range through

the addition of fine materials obtained

from the tertiary screening station This unitis capable of producing 170 tonshour of

020

Preserving the environment

and optimizing safety

The screens have motorized bogies and

retractable walkways to facilitate access

when the screens are opened for main-tenance Other walkways provide access

to the tunnel input feeders The feederscan be isolated with hydraulic rod gate

bars this hydraulic assistance eliminatesthe need to use a heavy hammer to lodge

these metal bars

All conveyors transporting fines (02

and 04) are covered with a tarpaulin to

avoid flying dust and all the screens arehooded (metal cover with Trellex seal-

ing) The Brunone company has installed

dust-tight containment at the outlet of the

tertiary station crushers (HP300 and HP4)on the belt located under the screens

and under the hoppers located belowthe tertiary screens The crushers are put

under negative pressure and the finesare extracted through sleeve filters (7000

m3 h) with declogging which deposits the

dust back onto the conveyor belt

A high-pressure 100 bar water mist sys-tem has been installed at the primary sta-

tion discharge at the secondary crusherrsquos

discharge chutes (Omnicone) and at the

transfer points on the belt

Designed to last

ldquoThis type of new installation can easily last

thirty yearsrdquo affirms Project Leader Bruno

Peix of Metso ldquoIt quite simply depends on

how well it is maintained Thatrsquos why weprovide maintenance contracts that call for

our technicians to make regular inspection

visits and carry out preventive mainte-nance and any necessary repairsrdquo

In 2011 Metso commissioned about

10 new processing units in France like

the one at La Mariais quarry

More info

Frederic Bazire

Tel +33 (0)681442804

fredericbaziremetsocom

Key figures

DURATION OF WORKS 15 months

DRAWING OFFICE TIME 7800 hours

HEIGHT OF SILOS AND GRINDER BUILDINGS

15 m

TOTAL LENGTH OF CONVEYORS 14 km

WEIGHT OF THE INSTALLATION

1200 metric tons

CONCRETE POURED 1800 cubic meters

PROJECT SITE WORKFORCE 30

INSTALLED POWER 2200 kW(not including pumps 200 kW)

METSO EQUIPMENT

Primary

Vibrating feeder PF561-2V

Primary grizzly VG540-3V

Grizzly feeder TK13-20-3V

Jaw crusher C145 with

hydraulic setting

Secondary

Vibrating screen CVB 2050

refurbished

Cone crusher Omnicocircne 1352 SX

with Metso IC7000 controller Ellivar 16 (16 msup2 3 decks) screen

refurbished by Metso

Tertiary

Cone crusher HP300

Cone crusher HP4

2 Ellivar 20 screens (20 m23 decks) for final products

Expanding the production range

ldquoSince the mid-1990s when we became

owners of La Mariais we had used mobilemachinery with an assembly of beltconveyorsrdquo recalls Daniel Leblin Charierrsquos

Technical Manager for site construction

and maintenance

ldquoIt became clear that we needed ahigher performance tool to achieve the

dual goals of reaching one million metric

tonsrsquo maximum production and producing

8132019 Results Minerals Aggregates 3 2012ENG

httpslidepdfcomreaderfullresults-minerals-aggregates-3-2012eng 38428983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Big Lokotrack LT550GPF boostsquarrying productivity by a thirdMaximizing the productivity of operations is a key issue when striving for cost-effective quarrying Big Lokotracks are oneway to achieve improved operational efficiency The Lokotrack LT550GPF equipped with the high-volume GP550 conecrusher and a large screen is popular in the Nordic countries and in Germany and Australia ndash countries all known for theirhigh quarrying volumes

TEXT amp PHOTOS Eero Haumlmaumllaumlinen

Kone-Kostamorsquos new mobile coneplant has reached an averagecapacity of 300 tons per hour

8132019 Results Minerals Aggregates 3 2012ENG

httpslidepdfcomreaderfullresults-minerals-aggregates-3-2012eng 3942983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088

983122983141983152983151983154983156983145983150983143 983154983141983155

ldquoWith the same number of employees we

can achieve 30 more productivity with

our new LT550GPF unit The high-capacityFS screen has also eliminated the bottle-neck often seen at fine screeningrdquo says

Aarno Kostamo Managing Director of

Kone-Kostamo Oy one of Finlandrsquos biggest

crushing contractorsAccording to Kostamo the high capacity

of the GP550 gyratory cone crusher easily

handles feed from the C120 and C125 jaw

crushers For the contract with the Talvivaara

nickel mine the LT550GPF is being fed bythe brand new Lokotrack LT120 jaw plant

Average capacity 300 tons per hour

Talvivaara Europersquos largest nickel mine uti-

lizes large quantities of aggregates Kone-Kostamo has contracted several million

tons of different end products for the mineIn August 75000 tons of 0ndash63 mm

road gravel was crushed Smaller amountsof finer 0ndash6 mm 0ndash16 mm and 0ndash32 mm

aggregates are also being produced

The rainy summer increased the need

for road gravel along the muddy roadswhich must endure dump trucks weighing

as much as 260 tons

ldquoThe mobile process consisting of the

LT120 jaw plant and LT550GPF cone plant

is cost-effective while aggregates of vari-ous sizes can be produced in a two-stage

operation and with high capacity The con-trolled stroke and elliptical movement of

the FS screen secure big passing throughcapacitiesrdquo Kostamo explains

Operated in two shifts for a total of 16

hours per day the LT550GPF has logged

more than 600 working hours over a two-month period

Managing Director Aarno Kostamo (left) and foreman Karri Maumlenpaumlauml studying the cavity optionsavailable for the new Lokotrack LT550GPF

Longer perspective than

a single quarter needed

Kone-Kostamo Oy was founded as an

earth-moving company in Kemijaumlrvi

Northern Finland in 1956 The company

expanded its operations to include crush-

ing contracting in 1964 and later on

switched to concentrating fully on crush-ing activities

Kone-Kostamo consistently crushes

and screens around 28 million tons ofaggregates annually and has net sales of

between EUR 8ndash9 million

ldquoWe believe that issues within the crush-

ing industry including the purchasing ofmachinery must be studied with a longer

perspective than a single quarter The

secret to our success has always been our

solid work ethic and professional employ-eesrdquo Kostamo sums up

More info

Esa Berg

Tel + 358 40 837 8692

esabergmetsocom

8132019 Results Minerals Aggregates 3 2012ENG

httpslidepdfcomreaderfullresults-minerals-aggregates-3-2012eng 40420983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155

Monitoring-based reporting is vital for

assessing the performance of a mobile

crushing plant Metso provides suchreporting tools through its plant-wideautomation system Metso DNA (Dynamic

Network of Applications) with its infor-

mation platform that links all the mobile

crushing and screen units together as oneentity Basically there is a lot of measured

real-time information available in every

crushing plant On-line information is

obtained either from each Metso crusherrsquosmachine automation system IC (Intelligent

Controller) or from separately installed

additional sensors and belt scales

All the collected data is sent to a motorhome using wireless communication

based on WLAN technology The motor

home is a purpose-built environment

inside an on-site container In this environ-ment selected variables can be monitored

for assessing the plantrsquos performance And

to make all this even more flexible the

data can be transmitted to a crushing plant

company office using GPRS3G mobile

data communication technologies Thismakes all the last-minute reports acces-sible to the crushing plant managerial staff

at anytime and basically anywhere within

reach of the cell phone network

Production and fuel economics reports

Essentially monitoring and reporting can

be customized to fit the customerrsquos needs

However there are certain off-the-shelf

reports that provide a lot of useful informa-tion for plant supervision The production

report is one of these Requiring at least one

belt scale for measuring the total produc-tion the production report shows the pro-duction rate (tons per hour) for a selected

reporting period eg a day or a week The

production report constantly keeps track of

the plantrsquos production storing all the datathroughout the plantrsquos life cycle

Performance monitoring and reportingfor a mobile crushing plantTEXT Pasi Airikka PHOTOS Metso

unit during which the unit is running By

storing the availability times between start-ups and shutdowns the crushing plant

operation time (hours per dayshift) can be

recorded analyzed and reported In addi-

tion the availability report can be tailored

to evaluate efficient crushing hours during

which the plant is really working and pro-ducing aggregates Consequently the ratio

(0-100) between efficient crushing time

and total running time can be reported forany selected period of time This boosts

the efficiency of the plantrsquos operations

and results in better productivity

Reports on non-choke

or inadequate feeding

Non-choke feeding to crushers is avoid-

able through smart plant-wide crushingplant controls But estimating its severity in

a systematic manner is not straight-forwardwithout constant monitoring and reporting

The crusher choke feeding report makes

use of the crusher cavity level sensors byanalyzing their level measurements By

calculating average and min-max values

and deviations from the average it can be

shown how often the single crusher suffersfrom non-choke feeding to it

In some cases the bottleneck in the

crushing plantrsquos productivity is the material

feeding to the process In mobile plants thefeeding is human operated and therefore

subject to variations Occasionally the sizeof the human-operated machine simply

does not allow for adequate feeding to thecrushing plant There are specific reports

indicating time periods when the crushing

plant suffers from inadequate feeding

Condition monitoring for

crushers and screens

Machine-specific condition monitoring

focuses on vibrating components in

crushers and screens such as drive shaftbearings safety plate wearings and gears

The low middle and high frequencies ofmonitored components are measured and

supervised in real-time to detect abnor-malities due to slow or fast wear looseness

or imbalance

More info

Pasi Airikka

Tel +358 40 587 2730

pasiairikkametsocom

Condition monitoring provides a view tovibrating crusher and screen components forpredictive equipment maintenance

The daily production report shows the hour-by-hour production trend and distribution chartfor a selected day with min-max average andvariation statistics for comparison

Fuel consumption is always an interest-ing concern The fuel consumption reportgives the fuel consumption of each crush-

ing unit (liters per hour) and their total

consumption (liters per hour) for a selected

reporting period and can track fuel con-

sumption changes over timeCrushing plant availability can be

assessed as well The availability report

calculates time periods for each crushing

8132019 Results Minerals Aggregates 3 2012ENG

httpslidepdfcomreaderfullresults-minerals-aggregates-3-2012eng 4142983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088

983149983141983156983155983151 983150

for tissue machines The record of 2210

mmin was set on June 1 2012 during a

24-hour production run by the TM 2 tissue

machine at the companyrsquos mill in Yenikoumlynear the city of Izmit in Turkey

ldquoThe cooperation with Metso has been

beyond excellent and both parties did

their utmost to make the project success-ful The results clearly show that the efforts

were worthwhile on both sides This coop-

eration will extend to cover new projects

in the futurerdquo says Luumlt1047297 Aydin Paper GroupDirector Hayat Kimya

ldquoWe are not surprised that Hayat K imya

managed to break the world speed record

We have had great confidence in the capa-bility of the Hayat team since our project

started in 2009 We certainly know our

machine very well its stability production

efficiency and speed capabilityrdquo says Jan

Erikson Vice President Sales Metso

PowerThe worldrsquos first eco-gas fueled

power plant is up and running

Lahti Energy Ltdrsquos new Kymijaumlrvi II gasifica-

tion plant was officially inaugurated on

May 8 2012 It is the first of its kind in the

RecyclingRecycling with Lokotrack LT106

jaw plant in New York

A brand-new Lokotrack LT106 jaw plant is

used in the city area of New York USA to

recycle demolition materials The crushing

site faces the skyscrapers of ManhattanIsland

Paper amp FiberHayat Kimyarsquos Metso-supplied tissue

machine sets world speed record

Thanks to a skilled crew and dedicated

efforts Hayat Kimya AS in Turkey has suc-

ceeded in breaking the world speed record

world This CHP plant runs on clean eco-

gas that is gasified cleaned and cooled

from recycled waste with Metsorsquos innova-tive technology

ldquoItrsquos actually eco-gas that we combust

in the boilerrdquo comments Lahti EnergyrsquosProduction Director Jukka Manskinen

ldquoWe convert unwanted waste material into

energy in an efficient and environmentally

friendly wayrdquoNever before has any plant gasified

waste on such a large scale In the gasifier

recycled waste is turned into combustible

product gas which is cleaned cooled and

combusted in a high-efficiency gas boiler

to produce steam for the steam turbine The plant produces 50 MW of electricity

and 90 MW of district heat for the city of

Lahti and its neighboring areasMetso delivered the circulating fluidized

bed (CFB) gasification process gas cleaning

and cooling steam boiler environmental

protection system and automation systemto the entire plant The production of elec-

tricity and heat is kept even with the Metso

DNA automation system that covers the

whole plant starting from fuel reception

AutomationMetso develops and supplies plant-

wide crushing control solutions for

crushing plants

Metso has recently signed contracts on

delivering plant-wide automation systems

for mobile and portable rock crushing

plants The key objective of these deliveries

is to stabilize and to increase productivityand efficiency of the plants using one sin-

gle automation and information platform

for integrating crusher-specific IC machinecontrols

Furthermore the plant-wide system

with its information management tools not

only increases plant availability and opera-

tional safety it also makes troubleshoot-ing quicker and performance monitoring

easier The control room for plant-wide

operability is located either in an excavator

cabin or a purpose-built container

Metso around the world

The new LT106 jaw plant is suitable for crushing both hard rock and all rock-based demolition materials

The new world speed record for tissue setby Hayat Kimyarsquos Metso-supplied TM 2 is2210 mmin

8132019 Results Minerals Aggregates 3 2012ENG

httpslidepdfcomreaderfullresults-minerals-aggregates-3-2012eng 4242

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 37: Results Minerals Aggregates 3 2012.ENG

8132019 Results Minerals Aggregates 3 2012ENG

httpslidepdfcomreaderfullresults-minerals-aggregates-3-2012eng 3742983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088

983122983141983152983151983154983156983145983150983143 983154983141983155

tertiary material of sand and gravel for the

local market to use in concrete surfacingprefabrication etcrdquo

Incorporation of a screening station

The stone extracted from La Mariais is

according to the quarry granitic gneiss

sound and homogeneous with a LosAngeles index of 15 good wear resist-

ance with an MDE of 10 a true density of

265 and a certain abrasiveness (2000 gt)ldquoCharacteristically it has a tendency to form

blocksrdquo Leblin points out

The main criteria in designing the instal-

lation was to provide an output of 600000metric tons from one station (38 hours

week) to produce materials aimed at the

concrete and surfacing markets ldquowhich

involved providing a tertiary station withscreening plantrdquo he adds

With this new unit the operating com-pany expands its product range through

the addition of fine materials obtained

from the tertiary screening station This unitis capable of producing 170 tonshour of

020

Preserving the environment

and optimizing safety

The screens have motorized bogies and

retractable walkways to facilitate access

when the screens are opened for main-tenance Other walkways provide access

to the tunnel input feeders The feederscan be isolated with hydraulic rod gate

bars this hydraulic assistance eliminatesthe need to use a heavy hammer to lodge

these metal bars

All conveyors transporting fines (02

and 04) are covered with a tarpaulin to

avoid flying dust and all the screens arehooded (metal cover with Trellex seal-

ing) The Brunone company has installed

dust-tight containment at the outlet of the

tertiary station crushers (HP300 and HP4)on the belt located under the screens

and under the hoppers located belowthe tertiary screens The crushers are put

under negative pressure and the finesare extracted through sleeve filters (7000

m3 h) with declogging which deposits the

dust back onto the conveyor belt

A high-pressure 100 bar water mist sys-tem has been installed at the primary sta-

tion discharge at the secondary crusherrsquos

discharge chutes (Omnicone) and at the

transfer points on the belt

Designed to last

ldquoThis type of new installation can easily last

thirty yearsrdquo affirms Project Leader Bruno

Peix of Metso ldquoIt quite simply depends on

how well it is maintained Thatrsquos why weprovide maintenance contracts that call for

our technicians to make regular inspection

visits and carry out preventive mainte-nance and any necessary repairsrdquo

In 2011 Metso commissioned about

10 new processing units in France like

the one at La Mariais quarry

More info

Frederic Bazire

Tel +33 (0)681442804

fredericbaziremetsocom

Key figures

DURATION OF WORKS 15 months

DRAWING OFFICE TIME 7800 hours

HEIGHT OF SILOS AND GRINDER BUILDINGS

15 m

TOTAL LENGTH OF CONVEYORS 14 km

WEIGHT OF THE INSTALLATION

1200 metric tons

CONCRETE POURED 1800 cubic meters

PROJECT SITE WORKFORCE 30

INSTALLED POWER 2200 kW(not including pumps 200 kW)

METSO EQUIPMENT

Primary

Vibrating feeder PF561-2V

Primary grizzly VG540-3V

Grizzly feeder TK13-20-3V

Jaw crusher C145 with

hydraulic setting

Secondary

Vibrating screen CVB 2050

refurbished

Cone crusher Omnicocircne 1352 SX

with Metso IC7000 controller Ellivar 16 (16 msup2 3 decks) screen

refurbished by Metso

Tertiary

Cone crusher HP300

Cone crusher HP4

2 Ellivar 20 screens (20 m23 decks) for final products

Expanding the production range

ldquoSince the mid-1990s when we became

owners of La Mariais we had used mobilemachinery with an assembly of beltconveyorsrdquo recalls Daniel Leblin Charierrsquos

Technical Manager for site construction

and maintenance

ldquoIt became clear that we needed ahigher performance tool to achieve the

dual goals of reaching one million metric

tonsrsquo maximum production and producing

8132019 Results Minerals Aggregates 3 2012ENG

httpslidepdfcomreaderfullresults-minerals-aggregates-3-2012eng 38428983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Big Lokotrack LT550GPF boostsquarrying productivity by a thirdMaximizing the productivity of operations is a key issue when striving for cost-effective quarrying Big Lokotracks are oneway to achieve improved operational efficiency The Lokotrack LT550GPF equipped with the high-volume GP550 conecrusher and a large screen is popular in the Nordic countries and in Germany and Australia ndash countries all known for theirhigh quarrying volumes

TEXT amp PHOTOS Eero Haumlmaumllaumlinen

Kone-Kostamorsquos new mobile coneplant has reached an averagecapacity of 300 tons per hour

8132019 Results Minerals Aggregates 3 2012ENG

httpslidepdfcomreaderfullresults-minerals-aggregates-3-2012eng 3942983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088

983122983141983152983151983154983156983145983150983143 983154983141983155

ldquoWith the same number of employees we

can achieve 30 more productivity with

our new LT550GPF unit The high-capacityFS screen has also eliminated the bottle-neck often seen at fine screeningrdquo says

Aarno Kostamo Managing Director of

Kone-Kostamo Oy one of Finlandrsquos biggest

crushing contractorsAccording to Kostamo the high capacity

of the GP550 gyratory cone crusher easily

handles feed from the C120 and C125 jaw

crushers For the contract with the Talvivaara

nickel mine the LT550GPF is being fed bythe brand new Lokotrack LT120 jaw plant

Average capacity 300 tons per hour

Talvivaara Europersquos largest nickel mine uti-

lizes large quantities of aggregates Kone-Kostamo has contracted several million

tons of different end products for the mineIn August 75000 tons of 0ndash63 mm

road gravel was crushed Smaller amountsof finer 0ndash6 mm 0ndash16 mm and 0ndash32 mm

aggregates are also being produced

The rainy summer increased the need

for road gravel along the muddy roadswhich must endure dump trucks weighing

as much as 260 tons

ldquoThe mobile process consisting of the

LT120 jaw plant and LT550GPF cone plant

is cost-effective while aggregates of vari-ous sizes can be produced in a two-stage

operation and with high capacity The con-trolled stroke and elliptical movement of

the FS screen secure big passing throughcapacitiesrdquo Kostamo explains

Operated in two shifts for a total of 16

hours per day the LT550GPF has logged

more than 600 working hours over a two-month period

Managing Director Aarno Kostamo (left) and foreman Karri Maumlenpaumlauml studying the cavity optionsavailable for the new Lokotrack LT550GPF

Longer perspective than

a single quarter needed

Kone-Kostamo Oy was founded as an

earth-moving company in Kemijaumlrvi

Northern Finland in 1956 The company

expanded its operations to include crush-

ing contracting in 1964 and later on

switched to concentrating fully on crush-ing activities

Kone-Kostamo consistently crushes

and screens around 28 million tons ofaggregates annually and has net sales of

between EUR 8ndash9 million

ldquoWe believe that issues within the crush-

ing industry including the purchasing ofmachinery must be studied with a longer

perspective than a single quarter The

secret to our success has always been our

solid work ethic and professional employ-eesrdquo Kostamo sums up

More info

Esa Berg

Tel + 358 40 837 8692

esabergmetsocom

8132019 Results Minerals Aggregates 3 2012ENG

httpslidepdfcomreaderfullresults-minerals-aggregates-3-2012eng 40420983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155

Monitoring-based reporting is vital for

assessing the performance of a mobile

crushing plant Metso provides suchreporting tools through its plant-wideautomation system Metso DNA (Dynamic

Network of Applications) with its infor-

mation platform that links all the mobile

crushing and screen units together as oneentity Basically there is a lot of measured

real-time information available in every

crushing plant On-line information is

obtained either from each Metso crusherrsquosmachine automation system IC (Intelligent

Controller) or from separately installed

additional sensors and belt scales

All the collected data is sent to a motorhome using wireless communication

based on WLAN technology The motor

home is a purpose-built environment

inside an on-site container In this environ-ment selected variables can be monitored

for assessing the plantrsquos performance And

to make all this even more flexible the

data can be transmitted to a crushing plant

company office using GPRS3G mobile

data communication technologies Thismakes all the last-minute reports acces-sible to the crushing plant managerial staff

at anytime and basically anywhere within

reach of the cell phone network

Production and fuel economics reports

Essentially monitoring and reporting can

be customized to fit the customerrsquos needs

However there are certain off-the-shelf

reports that provide a lot of useful informa-tion for plant supervision The production

report is one of these Requiring at least one

belt scale for measuring the total produc-tion the production report shows the pro-duction rate (tons per hour) for a selected

reporting period eg a day or a week The

production report constantly keeps track of

the plantrsquos production storing all the datathroughout the plantrsquos life cycle

Performance monitoring and reportingfor a mobile crushing plantTEXT Pasi Airikka PHOTOS Metso

unit during which the unit is running By

storing the availability times between start-ups and shutdowns the crushing plant

operation time (hours per dayshift) can be

recorded analyzed and reported In addi-

tion the availability report can be tailored

to evaluate efficient crushing hours during

which the plant is really working and pro-ducing aggregates Consequently the ratio

(0-100) between efficient crushing time

and total running time can be reported forany selected period of time This boosts

the efficiency of the plantrsquos operations

and results in better productivity

Reports on non-choke

or inadequate feeding

Non-choke feeding to crushers is avoid-

able through smart plant-wide crushingplant controls But estimating its severity in

a systematic manner is not straight-forwardwithout constant monitoring and reporting

The crusher choke feeding report makes

use of the crusher cavity level sensors byanalyzing their level measurements By

calculating average and min-max values

and deviations from the average it can be

shown how often the single crusher suffersfrom non-choke feeding to it

In some cases the bottleneck in the

crushing plantrsquos productivity is the material

feeding to the process In mobile plants thefeeding is human operated and therefore

subject to variations Occasionally the sizeof the human-operated machine simply

does not allow for adequate feeding to thecrushing plant There are specific reports

indicating time periods when the crushing

plant suffers from inadequate feeding

Condition monitoring for

crushers and screens

Machine-specific condition monitoring

focuses on vibrating components in

crushers and screens such as drive shaftbearings safety plate wearings and gears

The low middle and high frequencies ofmonitored components are measured and

supervised in real-time to detect abnor-malities due to slow or fast wear looseness

or imbalance

More info

Pasi Airikka

Tel +358 40 587 2730

pasiairikkametsocom

Condition monitoring provides a view tovibrating crusher and screen components forpredictive equipment maintenance

The daily production report shows the hour-by-hour production trend and distribution chartfor a selected day with min-max average andvariation statistics for comparison

Fuel consumption is always an interest-ing concern The fuel consumption reportgives the fuel consumption of each crush-

ing unit (liters per hour) and their total

consumption (liters per hour) for a selected

reporting period and can track fuel con-

sumption changes over timeCrushing plant availability can be

assessed as well The availability report

calculates time periods for each crushing

8132019 Results Minerals Aggregates 3 2012ENG

httpslidepdfcomreaderfullresults-minerals-aggregates-3-2012eng 4142983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088

983149983141983156983155983151 983150

for tissue machines The record of 2210

mmin was set on June 1 2012 during a

24-hour production run by the TM 2 tissue

machine at the companyrsquos mill in Yenikoumlynear the city of Izmit in Turkey

ldquoThe cooperation with Metso has been

beyond excellent and both parties did

their utmost to make the project success-ful The results clearly show that the efforts

were worthwhile on both sides This coop-

eration will extend to cover new projects

in the futurerdquo says Luumlt1047297 Aydin Paper GroupDirector Hayat Kimya

ldquoWe are not surprised that Hayat K imya

managed to break the world speed record

We have had great confidence in the capa-bility of the Hayat team since our project

started in 2009 We certainly know our

machine very well its stability production

efficiency and speed capabilityrdquo says Jan

Erikson Vice President Sales Metso

PowerThe worldrsquos first eco-gas fueled

power plant is up and running

Lahti Energy Ltdrsquos new Kymijaumlrvi II gasifica-

tion plant was officially inaugurated on

May 8 2012 It is the first of its kind in the

RecyclingRecycling with Lokotrack LT106

jaw plant in New York

A brand-new Lokotrack LT106 jaw plant is

used in the city area of New York USA to

recycle demolition materials The crushing

site faces the skyscrapers of ManhattanIsland

Paper amp FiberHayat Kimyarsquos Metso-supplied tissue

machine sets world speed record

Thanks to a skilled crew and dedicated

efforts Hayat Kimya AS in Turkey has suc-

ceeded in breaking the world speed record

world This CHP plant runs on clean eco-

gas that is gasified cleaned and cooled

from recycled waste with Metsorsquos innova-tive technology

ldquoItrsquos actually eco-gas that we combust

in the boilerrdquo comments Lahti EnergyrsquosProduction Director Jukka Manskinen

ldquoWe convert unwanted waste material into

energy in an efficient and environmentally

friendly wayrdquoNever before has any plant gasified

waste on such a large scale In the gasifier

recycled waste is turned into combustible

product gas which is cleaned cooled and

combusted in a high-efficiency gas boiler

to produce steam for the steam turbine The plant produces 50 MW of electricity

and 90 MW of district heat for the city of

Lahti and its neighboring areasMetso delivered the circulating fluidized

bed (CFB) gasification process gas cleaning

and cooling steam boiler environmental

protection system and automation systemto the entire plant The production of elec-

tricity and heat is kept even with the Metso

DNA automation system that covers the

whole plant starting from fuel reception

AutomationMetso develops and supplies plant-

wide crushing control solutions for

crushing plants

Metso has recently signed contracts on

delivering plant-wide automation systems

for mobile and portable rock crushing

plants The key objective of these deliveries

is to stabilize and to increase productivityand efficiency of the plants using one sin-

gle automation and information platform

for integrating crusher-specific IC machinecontrols

Furthermore the plant-wide system

with its information management tools not

only increases plant availability and opera-

tional safety it also makes troubleshoot-ing quicker and performance monitoring

easier The control room for plant-wide

operability is located either in an excavator

cabin or a purpose-built container

Metso around the world

The new LT106 jaw plant is suitable for crushing both hard rock and all rock-based demolition materials

The new world speed record for tissue setby Hayat Kimyarsquos Metso-supplied TM 2 is2210 mmin

8132019 Results Minerals Aggregates 3 2012ENG

httpslidepdfcomreaderfullresults-minerals-aggregates-3-2012eng 4242

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 38: Results Minerals Aggregates 3 2012.ENG

8132019 Results Minerals Aggregates 3 2012ENG

httpslidepdfcomreaderfullresults-minerals-aggregates-3-2012eng 38428983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

983122983141983152983151983154983156983145983150983143 983154983141983155983157983148983156983155

Big Lokotrack LT550GPF boostsquarrying productivity by a thirdMaximizing the productivity of operations is a key issue when striving for cost-effective quarrying Big Lokotracks are oneway to achieve improved operational efficiency The Lokotrack LT550GPF equipped with the high-volume GP550 conecrusher and a large screen is popular in the Nordic countries and in Germany and Australia ndash countries all known for theirhigh quarrying volumes

TEXT amp PHOTOS Eero Haumlmaumllaumlinen

Kone-Kostamorsquos new mobile coneplant has reached an averagecapacity of 300 tons per hour

8132019 Results Minerals Aggregates 3 2012ENG

httpslidepdfcomreaderfullresults-minerals-aggregates-3-2012eng 3942983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088

983122983141983152983151983154983156983145983150983143 983154983141983155

ldquoWith the same number of employees we

can achieve 30 more productivity with

our new LT550GPF unit The high-capacityFS screen has also eliminated the bottle-neck often seen at fine screeningrdquo says

Aarno Kostamo Managing Director of

Kone-Kostamo Oy one of Finlandrsquos biggest

crushing contractorsAccording to Kostamo the high capacity

of the GP550 gyratory cone crusher easily

handles feed from the C120 and C125 jaw

crushers For the contract with the Talvivaara

nickel mine the LT550GPF is being fed bythe brand new Lokotrack LT120 jaw plant

Average capacity 300 tons per hour

Talvivaara Europersquos largest nickel mine uti-

lizes large quantities of aggregates Kone-Kostamo has contracted several million

tons of different end products for the mineIn August 75000 tons of 0ndash63 mm

road gravel was crushed Smaller amountsof finer 0ndash6 mm 0ndash16 mm and 0ndash32 mm

aggregates are also being produced

The rainy summer increased the need

for road gravel along the muddy roadswhich must endure dump trucks weighing

as much as 260 tons

ldquoThe mobile process consisting of the

LT120 jaw plant and LT550GPF cone plant

is cost-effective while aggregates of vari-ous sizes can be produced in a two-stage

operation and with high capacity The con-trolled stroke and elliptical movement of

the FS screen secure big passing throughcapacitiesrdquo Kostamo explains

Operated in two shifts for a total of 16

hours per day the LT550GPF has logged

more than 600 working hours over a two-month period

Managing Director Aarno Kostamo (left) and foreman Karri Maumlenpaumlauml studying the cavity optionsavailable for the new Lokotrack LT550GPF

Longer perspective than

a single quarter needed

Kone-Kostamo Oy was founded as an

earth-moving company in Kemijaumlrvi

Northern Finland in 1956 The company

expanded its operations to include crush-

ing contracting in 1964 and later on

switched to concentrating fully on crush-ing activities

Kone-Kostamo consistently crushes

and screens around 28 million tons ofaggregates annually and has net sales of

between EUR 8ndash9 million

ldquoWe believe that issues within the crush-

ing industry including the purchasing ofmachinery must be studied with a longer

perspective than a single quarter The

secret to our success has always been our

solid work ethic and professional employ-eesrdquo Kostamo sums up

More info

Esa Berg

Tel + 358 40 837 8692

esabergmetsocom

8132019 Results Minerals Aggregates 3 2012ENG

httpslidepdfcomreaderfullresults-minerals-aggregates-3-2012eng 40420983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155

Monitoring-based reporting is vital for

assessing the performance of a mobile

crushing plant Metso provides suchreporting tools through its plant-wideautomation system Metso DNA (Dynamic

Network of Applications) with its infor-

mation platform that links all the mobile

crushing and screen units together as oneentity Basically there is a lot of measured

real-time information available in every

crushing plant On-line information is

obtained either from each Metso crusherrsquosmachine automation system IC (Intelligent

Controller) or from separately installed

additional sensors and belt scales

All the collected data is sent to a motorhome using wireless communication

based on WLAN technology The motor

home is a purpose-built environment

inside an on-site container In this environ-ment selected variables can be monitored

for assessing the plantrsquos performance And

to make all this even more flexible the

data can be transmitted to a crushing plant

company office using GPRS3G mobile

data communication technologies Thismakes all the last-minute reports acces-sible to the crushing plant managerial staff

at anytime and basically anywhere within

reach of the cell phone network

Production and fuel economics reports

Essentially monitoring and reporting can

be customized to fit the customerrsquos needs

However there are certain off-the-shelf

reports that provide a lot of useful informa-tion for plant supervision The production

report is one of these Requiring at least one

belt scale for measuring the total produc-tion the production report shows the pro-duction rate (tons per hour) for a selected

reporting period eg a day or a week The

production report constantly keeps track of

the plantrsquos production storing all the datathroughout the plantrsquos life cycle

Performance monitoring and reportingfor a mobile crushing plantTEXT Pasi Airikka PHOTOS Metso

unit during which the unit is running By

storing the availability times between start-ups and shutdowns the crushing plant

operation time (hours per dayshift) can be

recorded analyzed and reported In addi-

tion the availability report can be tailored

to evaluate efficient crushing hours during

which the plant is really working and pro-ducing aggregates Consequently the ratio

(0-100) between efficient crushing time

and total running time can be reported forany selected period of time This boosts

the efficiency of the plantrsquos operations

and results in better productivity

Reports on non-choke

or inadequate feeding

Non-choke feeding to crushers is avoid-

able through smart plant-wide crushingplant controls But estimating its severity in

a systematic manner is not straight-forwardwithout constant monitoring and reporting

The crusher choke feeding report makes

use of the crusher cavity level sensors byanalyzing their level measurements By

calculating average and min-max values

and deviations from the average it can be

shown how often the single crusher suffersfrom non-choke feeding to it

In some cases the bottleneck in the

crushing plantrsquos productivity is the material

feeding to the process In mobile plants thefeeding is human operated and therefore

subject to variations Occasionally the sizeof the human-operated machine simply

does not allow for adequate feeding to thecrushing plant There are specific reports

indicating time periods when the crushing

plant suffers from inadequate feeding

Condition monitoring for

crushers and screens

Machine-specific condition monitoring

focuses on vibrating components in

crushers and screens such as drive shaftbearings safety plate wearings and gears

The low middle and high frequencies ofmonitored components are measured and

supervised in real-time to detect abnor-malities due to slow or fast wear looseness

or imbalance

More info

Pasi Airikka

Tel +358 40 587 2730

pasiairikkametsocom

Condition monitoring provides a view tovibrating crusher and screen components forpredictive equipment maintenance

The daily production report shows the hour-by-hour production trend and distribution chartfor a selected day with min-max average andvariation statistics for comparison

Fuel consumption is always an interest-ing concern The fuel consumption reportgives the fuel consumption of each crush-

ing unit (liters per hour) and their total

consumption (liters per hour) for a selected

reporting period and can track fuel con-

sumption changes over timeCrushing plant availability can be

assessed as well The availability report

calculates time periods for each crushing

8132019 Results Minerals Aggregates 3 2012ENG

httpslidepdfcomreaderfullresults-minerals-aggregates-3-2012eng 4142983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088

983149983141983156983155983151 983150

for tissue machines The record of 2210

mmin was set on June 1 2012 during a

24-hour production run by the TM 2 tissue

machine at the companyrsquos mill in Yenikoumlynear the city of Izmit in Turkey

ldquoThe cooperation with Metso has been

beyond excellent and both parties did

their utmost to make the project success-ful The results clearly show that the efforts

were worthwhile on both sides This coop-

eration will extend to cover new projects

in the futurerdquo says Luumlt1047297 Aydin Paper GroupDirector Hayat Kimya

ldquoWe are not surprised that Hayat K imya

managed to break the world speed record

We have had great confidence in the capa-bility of the Hayat team since our project

started in 2009 We certainly know our

machine very well its stability production

efficiency and speed capabilityrdquo says Jan

Erikson Vice President Sales Metso

PowerThe worldrsquos first eco-gas fueled

power plant is up and running

Lahti Energy Ltdrsquos new Kymijaumlrvi II gasifica-

tion plant was officially inaugurated on

May 8 2012 It is the first of its kind in the

RecyclingRecycling with Lokotrack LT106

jaw plant in New York

A brand-new Lokotrack LT106 jaw plant is

used in the city area of New York USA to

recycle demolition materials The crushing

site faces the skyscrapers of ManhattanIsland

Paper amp FiberHayat Kimyarsquos Metso-supplied tissue

machine sets world speed record

Thanks to a skilled crew and dedicated

efforts Hayat Kimya AS in Turkey has suc-

ceeded in breaking the world speed record

world This CHP plant runs on clean eco-

gas that is gasified cleaned and cooled

from recycled waste with Metsorsquos innova-tive technology

ldquoItrsquos actually eco-gas that we combust

in the boilerrdquo comments Lahti EnergyrsquosProduction Director Jukka Manskinen

ldquoWe convert unwanted waste material into

energy in an efficient and environmentally

friendly wayrdquoNever before has any plant gasified

waste on such a large scale In the gasifier

recycled waste is turned into combustible

product gas which is cleaned cooled and

combusted in a high-efficiency gas boiler

to produce steam for the steam turbine The plant produces 50 MW of electricity

and 90 MW of district heat for the city of

Lahti and its neighboring areasMetso delivered the circulating fluidized

bed (CFB) gasification process gas cleaning

and cooling steam boiler environmental

protection system and automation systemto the entire plant The production of elec-

tricity and heat is kept even with the Metso

DNA automation system that covers the

whole plant starting from fuel reception

AutomationMetso develops and supplies plant-

wide crushing control solutions for

crushing plants

Metso has recently signed contracts on

delivering plant-wide automation systems

for mobile and portable rock crushing

plants The key objective of these deliveries

is to stabilize and to increase productivityand efficiency of the plants using one sin-

gle automation and information platform

for integrating crusher-specific IC machinecontrols

Furthermore the plant-wide system

with its information management tools not

only increases plant availability and opera-

tional safety it also makes troubleshoot-ing quicker and performance monitoring

easier The control room for plant-wide

operability is located either in an excavator

cabin or a purpose-built container

Metso around the world

The new LT106 jaw plant is suitable for crushing both hard rock and all rock-based demolition materials

The new world speed record for tissue setby Hayat Kimyarsquos Metso-supplied TM 2 is2210 mmin

8132019 Results Minerals Aggregates 3 2012ENG

httpslidepdfcomreaderfullresults-minerals-aggregates-3-2012eng 4242

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 39: Results Minerals Aggregates 3 2012.ENG

8132019 Results Minerals Aggregates 3 2012ENG

httpslidepdfcomreaderfullresults-minerals-aggregates-3-2012eng 3942983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088

983122983141983152983151983154983156983145983150983143 983154983141983155

ldquoWith the same number of employees we

can achieve 30 more productivity with

our new LT550GPF unit The high-capacityFS screen has also eliminated the bottle-neck often seen at fine screeningrdquo says

Aarno Kostamo Managing Director of

Kone-Kostamo Oy one of Finlandrsquos biggest

crushing contractorsAccording to Kostamo the high capacity

of the GP550 gyratory cone crusher easily

handles feed from the C120 and C125 jaw

crushers For the contract with the Talvivaara

nickel mine the LT550GPF is being fed bythe brand new Lokotrack LT120 jaw plant

Average capacity 300 tons per hour

Talvivaara Europersquos largest nickel mine uti-

lizes large quantities of aggregates Kone-Kostamo has contracted several million

tons of different end products for the mineIn August 75000 tons of 0ndash63 mm

road gravel was crushed Smaller amountsof finer 0ndash6 mm 0ndash16 mm and 0ndash32 mm

aggregates are also being produced

The rainy summer increased the need

for road gravel along the muddy roadswhich must endure dump trucks weighing

as much as 260 tons

ldquoThe mobile process consisting of the

LT120 jaw plant and LT550GPF cone plant

is cost-effective while aggregates of vari-ous sizes can be produced in a two-stage

operation and with high capacity The con-trolled stroke and elliptical movement of

the FS screen secure big passing throughcapacitiesrdquo Kostamo explains

Operated in two shifts for a total of 16

hours per day the LT550GPF has logged

more than 600 working hours over a two-month period

Managing Director Aarno Kostamo (left) and foreman Karri Maumlenpaumlauml studying the cavity optionsavailable for the new Lokotrack LT550GPF

Longer perspective than

a single quarter needed

Kone-Kostamo Oy was founded as an

earth-moving company in Kemijaumlrvi

Northern Finland in 1956 The company

expanded its operations to include crush-

ing contracting in 1964 and later on

switched to concentrating fully on crush-ing activities

Kone-Kostamo consistently crushes

and screens around 28 million tons ofaggregates annually and has net sales of

between EUR 8ndash9 million

ldquoWe believe that issues within the crush-

ing industry including the purchasing ofmachinery must be studied with a longer

perspective than a single quarter The

secret to our success has always been our

solid work ethic and professional employ-eesrdquo Kostamo sums up

More info

Esa Berg

Tel + 358 40 837 8692

esabergmetsocom

8132019 Results Minerals Aggregates 3 2012ENG

httpslidepdfcomreaderfullresults-minerals-aggregates-3-2012eng 40420983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155

Monitoring-based reporting is vital for

assessing the performance of a mobile

crushing plant Metso provides suchreporting tools through its plant-wideautomation system Metso DNA (Dynamic

Network of Applications) with its infor-

mation platform that links all the mobile

crushing and screen units together as oneentity Basically there is a lot of measured

real-time information available in every

crushing plant On-line information is

obtained either from each Metso crusherrsquosmachine automation system IC (Intelligent

Controller) or from separately installed

additional sensors and belt scales

All the collected data is sent to a motorhome using wireless communication

based on WLAN technology The motor

home is a purpose-built environment

inside an on-site container In this environ-ment selected variables can be monitored

for assessing the plantrsquos performance And

to make all this even more flexible the

data can be transmitted to a crushing plant

company office using GPRS3G mobile

data communication technologies Thismakes all the last-minute reports acces-sible to the crushing plant managerial staff

at anytime and basically anywhere within

reach of the cell phone network

Production and fuel economics reports

Essentially monitoring and reporting can

be customized to fit the customerrsquos needs

However there are certain off-the-shelf

reports that provide a lot of useful informa-tion for plant supervision The production

report is one of these Requiring at least one

belt scale for measuring the total produc-tion the production report shows the pro-duction rate (tons per hour) for a selected

reporting period eg a day or a week The

production report constantly keeps track of

the plantrsquos production storing all the datathroughout the plantrsquos life cycle

Performance monitoring and reportingfor a mobile crushing plantTEXT Pasi Airikka PHOTOS Metso

unit during which the unit is running By

storing the availability times between start-ups and shutdowns the crushing plant

operation time (hours per dayshift) can be

recorded analyzed and reported In addi-

tion the availability report can be tailored

to evaluate efficient crushing hours during

which the plant is really working and pro-ducing aggregates Consequently the ratio

(0-100) between efficient crushing time

and total running time can be reported forany selected period of time This boosts

the efficiency of the plantrsquos operations

and results in better productivity

Reports on non-choke

or inadequate feeding

Non-choke feeding to crushers is avoid-

able through smart plant-wide crushingplant controls But estimating its severity in

a systematic manner is not straight-forwardwithout constant monitoring and reporting

The crusher choke feeding report makes

use of the crusher cavity level sensors byanalyzing their level measurements By

calculating average and min-max values

and deviations from the average it can be

shown how often the single crusher suffersfrom non-choke feeding to it

In some cases the bottleneck in the

crushing plantrsquos productivity is the material

feeding to the process In mobile plants thefeeding is human operated and therefore

subject to variations Occasionally the sizeof the human-operated machine simply

does not allow for adequate feeding to thecrushing plant There are specific reports

indicating time periods when the crushing

plant suffers from inadequate feeding

Condition monitoring for

crushers and screens

Machine-specific condition monitoring

focuses on vibrating components in

crushers and screens such as drive shaftbearings safety plate wearings and gears

The low middle and high frequencies ofmonitored components are measured and

supervised in real-time to detect abnor-malities due to slow or fast wear looseness

or imbalance

More info

Pasi Airikka

Tel +358 40 587 2730

pasiairikkametsocom

Condition monitoring provides a view tovibrating crusher and screen components forpredictive equipment maintenance

The daily production report shows the hour-by-hour production trend and distribution chartfor a selected day with min-max average andvariation statistics for comparison

Fuel consumption is always an interest-ing concern The fuel consumption reportgives the fuel consumption of each crush-

ing unit (liters per hour) and their total

consumption (liters per hour) for a selected

reporting period and can track fuel con-

sumption changes over timeCrushing plant availability can be

assessed as well The availability report

calculates time periods for each crushing

8132019 Results Minerals Aggregates 3 2012ENG

httpslidepdfcomreaderfullresults-minerals-aggregates-3-2012eng 4142983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088

983149983141983156983155983151 983150

for tissue machines The record of 2210

mmin was set on June 1 2012 during a

24-hour production run by the TM 2 tissue

machine at the companyrsquos mill in Yenikoumlynear the city of Izmit in Turkey

ldquoThe cooperation with Metso has been

beyond excellent and both parties did

their utmost to make the project success-ful The results clearly show that the efforts

were worthwhile on both sides This coop-

eration will extend to cover new projects

in the futurerdquo says Luumlt1047297 Aydin Paper GroupDirector Hayat Kimya

ldquoWe are not surprised that Hayat K imya

managed to break the world speed record

We have had great confidence in the capa-bility of the Hayat team since our project

started in 2009 We certainly know our

machine very well its stability production

efficiency and speed capabilityrdquo says Jan

Erikson Vice President Sales Metso

PowerThe worldrsquos first eco-gas fueled

power plant is up and running

Lahti Energy Ltdrsquos new Kymijaumlrvi II gasifica-

tion plant was officially inaugurated on

May 8 2012 It is the first of its kind in the

RecyclingRecycling with Lokotrack LT106

jaw plant in New York

A brand-new Lokotrack LT106 jaw plant is

used in the city area of New York USA to

recycle demolition materials The crushing

site faces the skyscrapers of ManhattanIsland

Paper amp FiberHayat Kimyarsquos Metso-supplied tissue

machine sets world speed record

Thanks to a skilled crew and dedicated

efforts Hayat Kimya AS in Turkey has suc-

ceeded in breaking the world speed record

world This CHP plant runs on clean eco-

gas that is gasified cleaned and cooled

from recycled waste with Metsorsquos innova-tive technology

ldquoItrsquos actually eco-gas that we combust

in the boilerrdquo comments Lahti EnergyrsquosProduction Director Jukka Manskinen

ldquoWe convert unwanted waste material into

energy in an efficient and environmentally

friendly wayrdquoNever before has any plant gasified

waste on such a large scale In the gasifier

recycled waste is turned into combustible

product gas which is cleaned cooled and

combusted in a high-efficiency gas boiler

to produce steam for the steam turbine The plant produces 50 MW of electricity

and 90 MW of district heat for the city of

Lahti and its neighboring areasMetso delivered the circulating fluidized

bed (CFB) gasification process gas cleaning

and cooling steam boiler environmental

protection system and automation systemto the entire plant The production of elec-

tricity and heat is kept even with the Metso

DNA automation system that covers the

whole plant starting from fuel reception

AutomationMetso develops and supplies plant-

wide crushing control solutions for

crushing plants

Metso has recently signed contracts on

delivering plant-wide automation systems

for mobile and portable rock crushing

plants The key objective of these deliveries

is to stabilize and to increase productivityand efficiency of the plants using one sin-

gle automation and information platform

for integrating crusher-specific IC machinecontrols

Furthermore the plant-wide system

with its information management tools not

only increases plant availability and opera-

tional safety it also makes troubleshoot-ing quicker and performance monitoring

easier The control room for plant-wide

operability is located either in an excavator

cabin or a purpose-built container

Metso around the world

The new LT106 jaw plant is suitable for crushing both hard rock and all rock-based demolition materials

The new world speed record for tissue setby Hayat Kimyarsquos Metso-supplied TM 2 is2210 mmin

8132019 Results Minerals Aggregates 3 2012ENG

httpslidepdfcomreaderfullresults-minerals-aggregates-3-2012eng 4242

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 40: Results Minerals Aggregates 3 2012.ENG

8132019 Results Minerals Aggregates 3 2012ENG

httpslidepdfcomreaderfullresults-minerals-aggregates-3-2012eng 40420983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088983089983090

983120983154983151983140983157983139983156983155 983137983150983140 983155983151983148983157983156983145983151983150983155

Monitoring-based reporting is vital for

assessing the performance of a mobile

crushing plant Metso provides suchreporting tools through its plant-wideautomation system Metso DNA (Dynamic

Network of Applications) with its infor-

mation platform that links all the mobile

crushing and screen units together as oneentity Basically there is a lot of measured

real-time information available in every

crushing plant On-line information is

obtained either from each Metso crusherrsquosmachine automation system IC (Intelligent

Controller) or from separately installed

additional sensors and belt scales

All the collected data is sent to a motorhome using wireless communication

based on WLAN technology The motor

home is a purpose-built environment

inside an on-site container In this environ-ment selected variables can be monitored

for assessing the plantrsquos performance And

to make all this even more flexible the

data can be transmitted to a crushing plant

company office using GPRS3G mobile

data communication technologies Thismakes all the last-minute reports acces-sible to the crushing plant managerial staff

at anytime and basically anywhere within

reach of the cell phone network

Production and fuel economics reports

Essentially monitoring and reporting can

be customized to fit the customerrsquos needs

However there are certain off-the-shelf

reports that provide a lot of useful informa-tion for plant supervision The production

report is one of these Requiring at least one

belt scale for measuring the total produc-tion the production report shows the pro-duction rate (tons per hour) for a selected

reporting period eg a day or a week The

production report constantly keeps track of

the plantrsquos production storing all the datathroughout the plantrsquos life cycle

Performance monitoring and reportingfor a mobile crushing plantTEXT Pasi Airikka PHOTOS Metso

unit during which the unit is running By

storing the availability times between start-ups and shutdowns the crushing plant

operation time (hours per dayshift) can be

recorded analyzed and reported In addi-

tion the availability report can be tailored

to evaluate efficient crushing hours during

which the plant is really working and pro-ducing aggregates Consequently the ratio

(0-100) between efficient crushing time

and total running time can be reported forany selected period of time This boosts

the efficiency of the plantrsquos operations

and results in better productivity

Reports on non-choke

or inadequate feeding

Non-choke feeding to crushers is avoid-

able through smart plant-wide crushingplant controls But estimating its severity in

a systematic manner is not straight-forwardwithout constant monitoring and reporting

The crusher choke feeding report makes

use of the crusher cavity level sensors byanalyzing their level measurements By

calculating average and min-max values

and deviations from the average it can be

shown how often the single crusher suffersfrom non-choke feeding to it

In some cases the bottleneck in the

crushing plantrsquos productivity is the material

feeding to the process In mobile plants thefeeding is human operated and therefore

subject to variations Occasionally the sizeof the human-operated machine simply

does not allow for adequate feeding to thecrushing plant There are specific reports

indicating time periods when the crushing

plant suffers from inadequate feeding

Condition monitoring for

crushers and screens

Machine-specific condition monitoring

focuses on vibrating components in

crushers and screens such as drive shaftbearings safety plate wearings and gears

The low middle and high frequencies ofmonitored components are measured and

supervised in real-time to detect abnor-malities due to slow or fast wear looseness

or imbalance

More info

Pasi Airikka

Tel +358 40 587 2730

pasiairikkametsocom

Condition monitoring provides a view tovibrating crusher and screen components forpredictive equipment maintenance

The daily production report shows the hour-by-hour production trend and distribution chartfor a selected day with min-max average andvariation statistics for comparison

Fuel consumption is always an interest-ing concern The fuel consumption reportgives the fuel consumption of each crush-

ing unit (liters per hour) and their total

consumption (liters per hour) for a selected

reporting period and can track fuel con-

sumption changes over timeCrushing plant availability can be

assessed as well The availability report

calculates time periods for each crushing

8132019 Results Minerals Aggregates 3 2012ENG

httpslidepdfcomreaderfullresults-minerals-aggregates-3-2012eng 4142983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088

983149983141983156983155983151 983150

for tissue machines The record of 2210

mmin was set on June 1 2012 during a

24-hour production run by the TM 2 tissue

machine at the companyrsquos mill in Yenikoumlynear the city of Izmit in Turkey

ldquoThe cooperation with Metso has been

beyond excellent and both parties did

their utmost to make the project success-ful The results clearly show that the efforts

were worthwhile on both sides This coop-

eration will extend to cover new projects

in the futurerdquo says Luumlt1047297 Aydin Paper GroupDirector Hayat Kimya

ldquoWe are not surprised that Hayat K imya

managed to break the world speed record

We have had great confidence in the capa-bility of the Hayat team since our project

started in 2009 We certainly know our

machine very well its stability production

efficiency and speed capabilityrdquo says Jan

Erikson Vice President Sales Metso

PowerThe worldrsquos first eco-gas fueled

power plant is up and running

Lahti Energy Ltdrsquos new Kymijaumlrvi II gasifica-

tion plant was officially inaugurated on

May 8 2012 It is the first of its kind in the

RecyclingRecycling with Lokotrack LT106

jaw plant in New York

A brand-new Lokotrack LT106 jaw plant is

used in the city area of New York USA to

recycle demolition materials The crushing

site faces the skyscrapers of ManhattanIsland

Paper amp FiberHayat Kimyarsquos Metso-supplied tissue

machine sets world speed record

Thanks to a skilled crew and dedicated

efforts Hayat Kimya AS in Turkey has suc-

ceeded in breaking the world speed record

world This CHP plant runs on clean eco-

gas that is gasified cleaned and cooled

from recycled waste with Metsorsquos innova-tive technology

ldquoItrsquos actually eco-gas that we combust

in the boilerrdquo comments Lahti EnergyrsquosProduction Director Jukka Manskinen

ldquoWe convert unwanted waste material into

energy in an efficient and environmentally

friendly wayrdquoNever before has any plant gasified

waste on such a large scale In the gasifier

recycled waste is turned into combustible

product gas which is cleaned cooled and

combusted in a high-efficiency gas boiler

to produce steam for the steam turbine The plant produces 50 MW of electricity

and 90 MW of district heat for the city of

Lahti and its neighboring areasMetso delivered the circulating fluidized

bed (CFB) gasification process gas cleaning

and cooling steam boiler environmental

protection system and automation systemto the entire plant The production of elec-

tricity and heat is kept even with the Metso

DNA automation system that covers the

whole plant starting from fuel reception

AutomationMetso develops and supplies plant-

wide crushing control solutions for

crushing plants

Metso has recently signed contracts on

delivering plant-wide automation systems

for mobile and portable rock crushing

plants The key objective of these deliveries

is to stabilize and to increase productivityand efficiency of the plants using one sin-

gle automation and information platform

for integrating crusher-specific IC machinecontrols

Furthermore the plant-wide system

with its information management tools not

only increases plant availability and opera-

tional safety it also makes troubleshoot-ing quicker and performance monitoring

easier The control room for plant-wide

operability is located either in an excavator

cabin or a purpose-built container

Metso around the world

The new LT106 jaw plant is suitable for crushing both hard rock and all rock-based demolition materials

The new world speed record for tissue setby Hayat Kimyarsquos Metso-supplied TM 2 is2210 mmin

8132019 Results Minerals Aggregates 3 2012ENG

httpslidepdfcomreaderfullresults-minerals-aggregates-3-2012eng 4242

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 41: Results Minerals Aggregates 3 2012.ENG

8132019 Results Minerals Aggregates 3 2012ENG

httpslidepdfcomreaderfullresults-minerals-aggregates-3-2012eng 4142983122983109983123983125983116983124983123 983149983145983150983141983154983137983148983155 983078 983137983143983143983154983141983143983137983156983141983155 983091983090983088

983149983141983156983155983151 983150

for tissue machines The record of 2210

mmin was set on June 1 2012 during a

24-hour production run by the TM 2 tissue

machine at the companyrsquos mill in Yenikoumlynear the city of Izmit in Turkey

ldquoThe cooperation with Metso has been

beyond excellent and both parties did

their utmost to make the project success-ful The results clearly show that the efforts

were worthwhile on both sides This coop-

eration will extend to cover new projects

in the futurerdquo says Luumlt1047297 Aydin Paper GroupDirector Hayat Kimya

ldquoWe are not surprised that Hayat K imya

managed to break the world speed record

We have had great confidence in the capa-bility of the Hayat team since our project

started in 2009 We certainly know our

machine very well its stability production

efficiency and speed capabilityrdquo says Jan

Erikson Vice President Sales Metso

PowerThe worldrsquos first eco-gas fueled

power plant is up and running

Lahti Energy Ltdrsquos new Kymijaumlrvi II gasifica-

tion plant was officially inaugurated on

May 8 2012 It is the first of its kind in the

RecyclingRecycling with Lokotrack LT106

jaw plant in New York

A brand-new Lokotrack LT106 jaw plant is

used in the city area of New York USA to

recycle demolition materials The crushing

site faces the skyscrapers of ManhattanIsland

Paper amp FiberHayat Kimyarsquos Metso-supplied tissue

machine sets world speed record

Thanks to a skilled crew and dedicated

efforts Hayat Kimya AS in Turkey has suc-

ceeded in breaking the world speed record

world This CHP plant runs on clean eco-

gas that is gasified cleaned and cooled

from recycled waste with Metsorsquos innova-tive technology

ldquoItrsquos actually eco-gas that we combust

in the boilerrdquo comments Lahti EnergyrsquosProduction Director Jukka Manskinen

ldquoWe convert unwanted waste material into

energy in an efficient and environmentally

friendly wayrdquoNever before has any plant gasified

waste on such a large scale In the gasifier

recycled waste is turned into combustible

product gas which is cleaned cooled and

combusted in a high-efficiency gas boiler

to produce steam for the steam turbine The plant produces 50 MW of electricity

and 90 MW of district heat for the city of

Lahti and its neighboring areasMetso delivered the circulating fluidized

bed (CFB) gasification process gas cleaning

and cooling steam boiler environmental

protection system and automation systemto the entire plant The production of elec-

tricity and heat is kept even with the Metso

DNA automation system that covers the

whole plant starting from fuel reception

AutomationMetso develops and supplies plant-

wide crushing control solutions for

crushing plants

Metso has recently signed contracts on

delivering plant-wide automation systems

for mobile and portable rock crushing

plants The key objective of these deliveries

is to stabilize and to increase productivityand efficiency of the plants using one sin-

gle automation and information platform

for integrating crusher-specific IC machinecontrols

Furthermore the plant-wide system

with its information management tools not

only increases plant availability and opera-

tional safety it also makes troubleshoot-ing quicker and performance monitoring

easier The control room for plant-wide

operability is located either in an excavator

cabin or a purpose-built container

Metso around the world

The new LT106 jaw plant is suitable for crushing both hard rock and all rock-based demolition materials

The new world speed record for tissue setby Hayat Kimyarsquos Metso-supplied TM 2 is2210 mmin

8132019 Results Minerals Aggregates 3 2012ENG

httpslidepdfcomreaderfullresults-minerals-aggregates-3-2012eng 4242

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 42: Results Minerals Aggregates 3 2012.ENG

8132019 Results Minerals Aggregates 3 2012ENG

httpslidepdfcomreaderfullresults-minerals-aggregates-3-2012eng 4242

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