Staff Writer

Metso has been working to reshape crushing and screening in the industry for over 100 years. Image: Metso

With decades of industry knowledge and a desire to make its customer’s lives easier, Metso is helping to revolutionise the crushing and screening industry.

A lot can happen in a century.

Industries rise and fall, cities transform, and companies like Metso help to reshape the mining industry as we know it.

During the past century, Metso has been at the forefront of crushing applications. From the primary crusher stage down to fine crushing and pebble applications, the company is renowned for its benchmark crushing solutions – and it has no plans of slowing down.

“Metso takes pride in the deep knowledge of our people and our strong customer service commitment,” Metso crusher technology manager –capital equipment Troy Barry told Australian Mining.

“In Australia for example, we have an impressive footprint of service locations and experts, including our recently opened Karratha Service Centre, Metso’s largest service centre globally.

“We also have a particularly strong team of crushing experts here in Australia, some with over 30 years of crushing expertise – working closely with our expert global design and engineering teams.”

Having been involved in the industry for as long as it has, Metso is no stranger to adapting with the times, especially when it comes to one of the industry’s favourite buzzwords: digitalisation.

“Metso includes a full digital offering for its XM crusher series, comprised of SmartCone, SmartStation and Mineral Crusher Pilot (MCP) automation,” Barry said.

“We deliver intelligence from the simple connection of our IC (integrated control) system at a local level through to the full connection of the operator’s control suite, and all the way to expert global teams remotely monitoring and evaluating the crusher performance.”

The ability to remotely monitor and evaluate a crusher’s performance allows Metso’s teams to be in constant contact with the machine, able to recommend changes to optimise performance in real time.

“This advanced technology extends the time between maintenance intervals and allows for a more continuous operation,” Barry said.

Recognising that each customer has differing crusher requirements, Metso always adapts its approach to suit.

“Our end targets are always based on the customer’s requirements,” Metso senior manager, crusher technical support Neale Baigent told Australian Mining.

“With our chamber optimisation program for instance, each crushing process is unique and feed material properties change over time.

“Based on Metso’s extensive database of over 40,000 crushing installations, plus tools such as our unique simulation software and CrusherMapper scanning, we select optimal alloys, choose or design chamber geometry to maximise wear life and performance.”

The chamber optimisation program is an evolution borne from customer demand, as it’s now also available to non-Metso crushers.

“Based on our results from this program, customers wanted our chamber optimisation also across non-Metso crushers, which is what we now do,” Baigent said.

In terms of evolution, the new poly-cer product, part of Metso’s protective wears portfolio, gives up to four times better wearlife, reducing shutdown frequencies.

“Poly-Cer is a specially designed blend of rubber and high-quality ceramics, reinforced with steel. This ensures both strength and performance,” Baigent said.

“Installation of Poly-Cer is easy and safe, with plug-in, bolt-in installation for most crushers.”

As the company evolves, Metso’s crushing capabilities are always increasing, with the XM series a particular highlight for Barry.

“The entire premise of the XM series is giving the customer the highest performance equipment to achieve optimisation,” he said. “Our up to 25 years warranty protects the customer’s investment and is unheard of in the industry.”

Barry said Metso’s drive to change means it has been able to stay at the forefront of innovation.

“The recently launched XM crusher series combines resilient engineering, unmatched warranties and a new digital package,” he said. “It combines the toughest and most advanced mechanical parts with the latest in digital technologies and automation. And by using the most robust crushers available on the market, the XM series enhanced the Nordberg MP cone crusher and the Superior MKIII primary gyratory with the most extreme duty parts, increasing wear life.”

As Metso looks to the next century, it’s clear this crushing behemoth isn’t slowing down anytime soon.

“As we look to the future, we continue to develop our alloys, product offerings and services,” Baigent said.

“We are always looking to improve and innovate in anticipation of our customers’ needs– after all, the best new developments come from feedback and challenges faced by our customers.”

Staff Writer

ANDRITZ filter presses achieve cost-effective and environmentally friendly filtration. Image: ANDRITZ

ANDRITZ is finding innovative ways to help mining companies be more sustainable in their operations.

As the mining industry explores ways to enable greater operational sustainability, effective tailings management has become a major focal point.

As one of the leading companies in industrial separation technologies, ANDRITZ offers a suite of advanced tailings solutions designed to optimise water recovery, reduce environmental impact, enable dry-stacking solutions, and enhance overall operational efficiency.

ANDRITZ’s tailings offerings encompass a wide range of products designed to cover every aspect of the tailings management process. The company’s solutions extend from sedimentation and dewatering to filtration and water recovery.

“Our broad portfolio for tailings treatment covers the full solid–liquid separation process, including decanter centrifuges, heavy-duty belt presses, hyperbaric and vacuum disc filters, vacuum belt filters, and filter presses,” ANDRITZ regional manager – Australia and New Zealand Paul Stevens said.

These solutions aim to maximise water recovery, reduce storage volumes, and provide safer disposal options for processed tailings.

Among ANDRITZ’s many products, the company highlights its heavy-duty belt press CPF-Q and robust filter presses as key solutions for tailings dewatering.

“Our heavy-duty belt press CPF-Q is a reliable and robust machine that is simple and cost-efficient to operate,” Stevens said. “The CPF-Q is a solution for high throughput tailings dewatering, achieving a low residual moisture with low operating costs.”

Additionally, the excellent water recovery rates of ANDRITZ’s filter presses, a technology known for delivering high filtration rates even in harsh conditions, contribute to reducing water consumption and improving sustainability.

The company’s decanter centrifuges also play a crucial role, especially for operations dealing with slurries that have fine particle size distributions. These machines, with high-speed design capabilities and large diameter-to-length ratios, are particularly effective in handling high volumes while enhancing recovery rates.

Innovation is at the core of ANDRITZ’s strategy in tailings management. The company’s research and development (R&D) efforts in the field of tailings management are focused on three primary objectives: enhanced water recovery, sustainability, and automation and digitalisation.

ANDRITZ is actively developing technologies that maximise water extraction from tailings, which is vital for regions where water scarcity is a significant issue. The company is also exploring ways to reuse processed tailings in applications like construction materials, further promoting sustainable mining practices.

Automation and digitalisation are becoming an increasingly important part of ANDRITZ’s solutions.

“We’re working on advanced monitoring systems and AI-supported process controls that can optimise tailings management in real-time,” ANDRITZ industry director – minerals and mining Mario Gerards said. “This digital shift not only enhances operational efficiency but also improves safety and reduces downtime.”

Mining environments are notoriously tough, and equipment longevity is a major concern. ANDRITZ addresses this by utilising high-quality, wear-resistant materials in its designs and offering comprehensive maintenance programs.

“Our solutions are engineered with robust construction to withstand continuous operation in the harshest conditions,” Gerards said.

ANDRITZ’s commitment to providing comprehensive global service support ensures that equipment remains in peak condition, minimising operational disruptions.

And the company’s focus on reducing energy consumption through optimised designs adds another layer of sustainability to its offerings. By delivering a complete range of solutions from dewatering to water treatment, ANDRITZ enables streamlined operations that maximise efficiency across the entire tailings management process.

One of ANDRITZ’s most notable success stories and one of the best references for dry stacking of tailings comes from the Itaminas iron ore mine in Brazil. By implementing ANDRITZ filter presses with LENSER filter plates as well as an advanced Metris addIQ control system, the mine achieved significant improvements in water recovery and reduced tailings volumes.

This not only minimised Itaminas’ environmental footprint but also lowered operational costs associated with tailings storage, proving the value of ANDRITZ’s technologies in real-world applications.

Looking ahead, ANDRITZ is working on several cutting-edge technologies aimed at revolutionising tailings management.

“One of our current development programs is focused on significant operational enhancements within our filter press technology,” Gerards said.

“Inspired by our vast experience in the Brazilian iron ore industry, we have implemented R&D in improving filter plate handling and filter cloth changing technology.”

Another interesting innovation is the Metris addIQ RheoScan, a system designed to optimise polymer dosage in real-time during the dewatering process.

“This technology automatically adjusts polymer dosing based on the rheological properties of the tailings, ensuring maximum efficiency in flocculation and sedimentation processes,” Gerards said.

The result is reduced polymer consumption, enhanced water recovery, and lower operational costs.

ANDRITZ is currently developing digital twin models that simulate and optimise tailings processes in real-time. These virtual models allow operators to predict and fine-tune performance, leading to improved efficiency and safety in tailings management.

The company is also exploring energy recovery systems that capture and reuse energy generated during the dewatering process, turning waste into a valuable resource stream.

ANDRITZ also plans to roll out a new filter press design over the next 12 to 18 months, alongside other advancements like enhanced digital twin applications and energy-efficient filtration systems.

These innovations are expected to significantly reduce the environmental footprint of tailings management while improving operational efficiency and safety.

This feature appeared in the October 2024 issue of Australian Mining.