Metso showcases their HP350e crusher

The HP350e is a new innovation from Metso. Image: Metso

Metso has pushed ahead with a new evolution of its HP range, introducing the HP350e and other models for crushing operators.

How do you evolve a recognised brand to become even better?

That question challenged Metso as it sought to develop the Nordberg HP, which was reviewing the classic workhorse from the “ground up.” The result is the Nordberg HPe.

The Nordberg HPe series aims to provide improved performance, uptime, application coverage, and serviceability more sustainably than its predecessor.

“Nordberg HP cone crushers are globally accepted as the go-to crusher for aggregates and mining,” Metso’s cone crusher product range Ilkka Somero said.

“The range continues to evolve and align with customer and industry needs and demands. Today there are drivers pushing for ever higher efficiency in productivity. In terms of overall production but also in terms of production of most valuable product fractions.

“In HPe development, this is achieved with higher overall performance, higher uptime with ease of service and maintenance as well as with enhanced application flexibility.”

When Metso examined the key mining and aggregates industries it serves worldwide, it noticed efficiency is the central focus of many operations. Quarry and mining businesses are looking to achieve maximum performance in throughput, reduction, or higher yield of certain aggregate fractions.

The new Nordberg HPe series needed to meet all of these requirements while also addressing the sustainability challenges that many businesses face every day.

Metso has further developed the kinematical crushing action and crusher chamber. The improvements balance kinematics, chambers, release force, and power rating. The redesign enables the HPe series to deliver more head motion, higher power, and new chambers. The upgrades of the kinetics enable the Nordberg HPe series to cover more applications than previous models.

Operators will have alternative kinetics along with improved chamber designs and application-specific options to select from. Metso’s team can assist customers in creating the optimal chamber for their needs.

According to Metso’s data, the new HP350e crusher delivers ten per cent performance compared to the traditional HP300 crusher in secondary or tertiary applications.

“Our development engineers and manufacturing facilities have provided a full range of eRange cones from 200 to 900kW, following a full redesign of a classic workhorse. We are excited to bring these products to the market to increase our customer’s bottom line,” Metso’s business development manager for aggregates, John O’Reilly, said.

“The evolution enables us to meet industry needs where you want more production and, more importantly, more efficiency when producing the needed product yields.”

One of the major upgrades in the HPe series involves the crusher liners. Metso’s latest update allows for the installation of these liners without backing material. While this may seem minor, the update significantly simplifies liner changes, making them easier and safer for operators.

Metso will feature the HPe range at international trade shows throughout 2025. Image: Metso

This reduces the need for quarries to source, store and transport backing compounds. Operators will also not need to handle, mix and pour the backing material, making operations safer and line change-outs faster. Metso can also tailor the liners to suit particular applications, including manufactured sand or specific aggregate fractions with its NF liner.

The anti-spin brake and ring bounce monitoring feature help extend the lifespan of the liners while also safeguarding the machine.

These upgrades will help operators increase machine uptime and productivity in the quarry. Metso has designed the HPe range, including the HP350e, to fit within the HP300 footprint while delivering more power.

“It is an evolution, but it is not just that we’ve put more power onto the machine and redesigned the cavity kinematics; there are more safety features, which is very important and simpler maintenance,” O’Reilly said.

“It has the same footprint as its predecessors. For example, the HP450e replaces the existing HP400 but is the same size on the outside. Because it is the same size envelope, there is no extra structural work to replace it. You can switch one in and one out.”

The HPe series is set to be unveiled progressively throughout the year by Metso at the world’s biggest quarrying trade shows.

The original equipment manufacturer is set to launch the HP450e at AGG-1 in St Louis. Attendees to bauma 2025 in Munich, Germany, can witness the debut of the HP600e. Other launches with the Nordberg HPe range will include the 600e later in 2025.

Metso’s Australian team and service and support network will fully support the introduction of the HPe series into Australia. With extensive industry experience, the team can help optimise a Nordberg HPe series crusher to suit the customer’s application.

“Metso is strongly focused on supporting the Australian quarry industry with world-class aggregate-producing solutions. The Nordberg HPe range is the evolution we believe our customers have been asking for,” O’Reilly said. •

Sandvik showcases innovative rock processing technology at bauma 2025

by Guy Woodford

The Sandvik CH830i cone crusher with ACS-c is on show at bauma 2025. Image/Sandvik

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Sandvik is showcasing its latest lineup of eco-efficient rock processing solutions at bauma 2025, designed to address the increasing demand for safe, efficient, reliable and cost-effective operations.

According to Richard Harris, President of Sandvik Rock Processing Solutions, digitalisation is a cornerstone of innovation, significantly enhancing the efficiency and sustainability of crushing and screening operations.

“Not only is our latest equipment easier to operate, manage, maintain, and service, but it also contributes to our industry’s desire to reduce its environmental impact,” Harris said. “Through our close partnerships with customers and unwavering focus on innovation, we are shaping a future where rock processing is both eco-efficient, productive and profitable.”

Sandvik vibrating screens and feeders are now available with ACS-s, Sandvik’s next-generation condition monitoring system. Image/Sandvik

The Sandvik 800i cone crusher series reflects the company’s commitment to continuous evolution in design, materials and technology. Integrated with the ACS-c 5 automation system, these models combine robust mechanical design with powerful, user-friendly automation, supporting diverse operational needs. ACS-c 5 provides valuable operational insights, enabling smoother operations and improved target achievement.

On display at bauma 2025 is the Sandvik CH830i, one of its most technologically advanced, high-capacity cone crushers. Designed for secondary and tertiary crushing in mining and large quarry applications, it boasts a robust unibody design with few moving parts, ensuring durability and reliability. The top serviceability feature simplifies access, making maintenance both easier and safer. The transition from welded to bolted parts enhances durability, while the new plastic backing-free liners eliminate the need for epoxy resin, significantly reducing waste. Additionally, the direct drive system provides high power with less energy loss, thereby enhancing overall efficiency.

The broad range of Sandvik vibrating screens and feeders are now available with ACS-s – Sandvik’s next generation condition monitoring system, which provides real-time data for informed maintenance decisions, improving operational efficiency and maximising uptime.

The Sandvik stand features a fully operational vibrating screen fitted with ACS-s, allowing visitors to experience the system’s hardware and software in action. In addition, Sandvik will present its groundbreaking digital applications, DeckMapp and WearApp, designed to revolutionise screen deck maintenance, uptime and efficiency.

Both ACS-c 5 and ACS-s are seamlessly integrated with SAM by Sandvik, the cloud-based digital assistant designed to support operational excellence in crushing and screening plants. SAM captures data from all connected Sandvik equipment, offering a comprehensive overview of the entire operation. Operators can monitor equipment status, communicate across teams, receive alerts and notifications, and proactively order spare parts from a centralised platform.

DeckMapp is Sandvik’s revolutionary digital tool and your single source of information for the management of screening media Image/Sandvik

Sandvik’s latest innovations are designed to cut energy use, reduce waste and enhance operational efficiency in its customers’ operations. At the company’s eco-efficient foundry in Svedala, Sweden, it produces high-quality parts using over 92 percent recycled steel, where in vast majority all powered by renewable energy. By repurposing worn-out wear parts, Sandvik prevented the emission of 16,000 tons of CO2 yearly by avoiding the use of virgin materials. Additionally, Sandvik pioneered the industry’s first Environmental Product Declaration (EPD) for manganese crusher wear parts, demonstrating a lower environmental impact and further validating its commitment to sustainability.

Learn more about Sandvik Rock Processing Solution’s offering at rockprocessing.sandvik or visit Sandvik in hall C2, stand 149 this week at bauma 2025.

Greensteel Australia places $1.6 billion order for fabrication of steel mill

Jack Lloyd

Image: GreenSteel Australia

Sydney-based Greensteel Australia has announced it had placed an order with leading global steelmaking infrastructure group Danieli Group to purchase stages two and three of its proposed ultra-low-carbon steel mill.

The order, valued in excess of $1.6 billion, comprises a direct reduced iron (DRI) plant, two electric arc furnaces, a structural steel rolling mill with high-speed rail capability, and a second rolling mill for reinforced steel (rebar).

The order follows Greensteel’s placement of an initial order with Italy-based Danieli for fabrication of a single reinforced steel (rebar) rolling mill in October last year.

Delivery of the three mills, two arc furnaces and DRI plant is expected by late 2026 or early 2027 and will mark a crucial milestone in Greensteel’s plans to establish Australia’s first ultra-low-carbon steelmaking operation, bolstering the country’s sovereign steelmaking capability.

Speaking at a contract-signing event in Adelaide, Greensteel president and executive director, Mena Ibrahim, emphasised the company’s commitment to establishing Australia’s most advanced steelmaking hub while contributing to heavy-industry decarbonisation.

“Danieli is the world’s leading provider of advanced, high-technology steelmaking infrastructure. Bringing their expertise to Australia will immediately position this country among the ranks of the most advanced steel suppliers globally,” Ibrahim said.

“We have agreed on an expedited delivery timetable with Danieli that will allow us to bring our steelmaking capability onstream within two years. This will bring our steelmaking capability onstream within two years, creating over 1,500 permanent jobs and 2,500 jobs during construction. These are critical steps forward, especially given the uncertainty caused by the collapse of the existing steel works in Whyalla and the gap it leaves in Australia’s sovereign steel capability.

“We’re excited to be partnering with Greensteel on their plans to bring ultra-low-carbon steelmaking to Australia. From the very beginning we have been impressed with the boldness of Greensteel’s vision and their commitment to the industrial decarbonization agenda. We look forward to delivering on this commitment and bringing world-leading steelmaking capability to Australia.”

Among the new facility’s capabilities is the capacity to produce ultra-long sections required for high-speed rail, currently not manufactured in Australia. Although significantly expanding Australia’s steelmaking output (to four times that of the existing Whyalla plant), the modern configuration requires just 70 hectares, in contrast to Whyalla’s 1,000-hectare footprint.

The DRI plant can operate on hydrogen rather than coking coal to refine magnetite into iron pellets, enabling a cleaner steelmaking process.

While Greensteel continues to assess potential sites for the mill, the preferred location remains Whyalla, adjacent to the existing steel works.

“Whyalla offers everything we need – an experienced workforce, a high-quality magnetite resource, port facilities and reliable renewable energy,” Ibrahim said.

“Greensteel’s proposed mill provides a clear way forward for the region. With the existing steelworks in Administration, we believe our mill can be built in parallel, enabling a smooth transition for the workforce at the conclusion of that process. This is vital for the people of Whyalla and the local community.”,” he said.

Greensteel’s sister company Reosteel, based in Sydney, is a well-established manufacturer of finished steel products for the construction industry.

Astec and Mineral Processing Solutions go national

by Kelsie Tibben

Astec and MPS are positioning themselves to play a pivotal role in the development of Australia’s infrastructure. Image: Astec Australia

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A national partnership between Astec and Mineral Processing Solutions is the latest step in an ongoing collaboration that is based on a commitment to quality equipment.

Astec Australia has strengthened its partnership with Mineral Processing Solutions (MPS), a subsidiary of OPS Group, in a strategic move that extends the distribution of its fixed and modular plant equipment across all states and territories. This expansion follows a mid-2024 agreement that saw MPS take on distribution rights for Astec’s aggregate and mining sector equipment in New South Wales.

MPS now holds the rights to supply and support all Astec fixed and modular crushing, screening and washing equipment, as well as material handling and breaker technology products, right across Australia.

“Over the years, Astec and MPS customers have seen the benefits forged from our strong partnership,” Astec material solutions business line manager Adam Gordon told Mining.

The Astec BTI Rockbreaker being loaded out of the OPS group Bibra Lake facility. Image: Astec Australia

“The MPS team’s extensive local market knowledge and experience in mineral processing, supported by Astec’s innovative technologies and manufacturing capability, has made MPS the perfect partner to deliver outstanding products and service.”

The original plan to extend MPS’s distribution footprint was scheduled for a later date, but the success of the initial expansion into NSW prompted an accelerated timeline.

“Those plans have been brought forward as a testament to the success of the relationship between Astec and MPS,” Gordon said. “This new network will enable us to deliver parts more efficiently, reducing downtime and enhancing the operational efficiency of Australian businesses.”

MPS’s well-established and expanding infrastructure in eastern Australia played a key role in facilitating the expansion. With depots in Goodna, Queensland, Rutherford, NSW, and Laverton, Victoria, MPS has a strong presence in major mining and construction hubs.

These facilities, alongside additional branches in Darwin, Perth and Adelaide, help to ensure customers receive timely access to equipment, spare parts and technical support.

“The ability to reduce downtime through fast and efficient parts delivery is a critical advantage for businesses operating in these industries,” Gordon said.

The move is also expected to drive operational efficiencies by consolidating supply lines and reducing lead times for customers.

Astec’s extensive range of products, combined with MPS’s experienced sales and service teams, provides a competitive advantage in the Australian market.

“MPS’s reputation for exceptional after-sales support and technical expertise further strengthens the value proposition for businesses relying on high-performance fixed plant solutions,” Gordon said.

“For customers, the expansion means not only greater convenience and accessibility to Astec’s globally recognised equipment; it will also provide access to knowledgeable team members who can assist with installation, maintenance and ongoing operational support.

“Whether in the construction materials sector or large-scale mining operations, operators will benefit from a seamless procurement process and enhanced support services.”

Astec and MPS customers have seen the benefits forged from a strong partnership. Image: Astec Australia

By deepening their collaboration, Astec and MPS are positioning themselves to play a pivotal role in the development of Australia’s infrastructure.

The increased availability of robust crushing, screening, and material handling solutions supports the efficiency and productivity of businesses that form the backbone of the country’s resources and construction industries.

This strategic expansion highlights both companies’ strong commitment to innovation and customer service, ensuring that Australian businesses continue to benefit from world-class equipment and expert support.

“As demand for high-quality processing solutions continues to grow, the strengthened partnership between Astec and MPS represents a proactive approach to meeting industry needs,” Gordon said.

“By leveraging our combined expertise and resources, both companies are well-positioned to support Australia’s mining and construction sectors into the future.

“This agreement not only enhances service delivery but also reinforces the long-term stability and reliability of supply chains for critical equipment in the industry.”

This feature also appears in the Autumn issue of Mining.

Metso launches new Nordberg HPe series

Alexandra Eastwood

Image: Metso

Metso has introduced three next-generation cone crushers to its Nordberg HPe series.

The new HP600e, HP800e and HP900e units maintain the trusted Metso HPe features that customers have come to rely on while extending the series to larger crushing capacities for both aggregates production and high-demand mining applications.

“The evolution of Metso’s cone crusher technology brings multiple benefits and presents a true step change in terms of performance, uptime, serviceability and application coverage,” Metso product manager of HP cones Ilkka Somero said.

“We are excited to expand the Nordberg HPe series and bring to market a wider offering of these high-performance crushers fit for different production purposes.”

The HP600e and HP900e are an evolution to the existing range and have been built and based on class-leading proven technology.

HP800e features as a new addition to the series with a crushing size option of 600 kilowatts/800 horsepower. All three units come with two modern automation platform options: IC70C and MCP.

“Efficiency is the key to meeting the industry’s needs,” Metso director of gyratory and large cone crushers Nicolas Gallay said. “With the robust new HPe units, we can offer performance, longer lifetime and higher cost efficiency to our customers.”

Metso also provides the installation and commissioning, inspections, refurbishment and shutdown support for its products, executing all upgrades and services to its high standards.

The company’s distribution network offers an additional layer of support and services by providing localised expertise, rapid response times and tailored service solutions.

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Metso’s Australian crushing and screening training praised

by Adam Daunt

Metso’s Glenn Oldfield led the training course. Image: Metso

Metso has successfully conducted crushing and screening training courses with plans to expand the offering in 2026.

Starting at the fundamental level for all competencies, Metso expert Glenn Oldfield is conducting a one-day course on crushing and screening nationwide.

Metso’s focus was to provide non-partisan training for any quarry industry professionals, aiming to allow better understanding and hopefully optimisation of their plants, whatever the equipment brand. With more than 30 years with Metso and 17 years before that in the industry on the customer side of the fence, Oldfield’s contribution to the industry is invaluable.

“Our goal is to grow industry knowledge of the aggregate processing field for the benefit of all. Quarrying is a field we all want to grow and retain staff, by sharing our experience Metso hope to assist in this endeavour,” Metso senior application and project manager for Asia Glenn Oldfield said.

“So far, we have had a fantastic take up of this opportunity with Boral, Heidelberg, Holcim, Adbri, and many other industry players.”

In February, a group of industry leaders from Queensland, including 20 personnel from Boral, participated in Metso’s Crushing and Screening Fundamentals Course. The Boral team comprised quarry managers, supervisors, leading hands, and fixed plant operators. The primary goal of the training sessions was to refresh skills and reinforce fundamental knowledge on this crucial topic.

Several Boral employees attended the training. Image: Metso

Boral asset manager for SEQ Quarries Michael Long shared his feedback with John O’Reilly and Glenn Oldfield after the training.

“The feedback after the session was overwhelmingly positive. The course was well-paced, and the content was delivered excellently by a respected industry expert. Glenn’s style of delivery was unbiased, balanced, and well-informed, providing valuable insights on a range of equipment and processes,” Long said.

“The objective of the sessions was to refresh the skills of our key personnel, whose roles include management, supervision, operations, asset care, and quality assurance.

“I highly recommend this program to anyone in our industry who is looking for foundational training and an understanding of the basic theory behind crushing and screening technology. It’s a valuable investment for both businesses and individuals.”

Metso’s focus was to provide non-partisan training for any quarry industry professionals. Image: Metso

Institute of Quarrying Australia president Michael Close welcomed the initiative which helps all industry professionals.

“I found the course very informative and flowed well for the day. Glenn did say it would be fairly basic content, but with 20-plus years of crushing and screening experience, I still got a lot out of it and takeaways to discuss back with our operations,” he said.

“I think it is a great training initiative that Metso is providing for the industry “free of charge”, and I fully encourage operations managers, process improvement, quarry managers, site supervisors and plant operators to attend.

“The content will help provide a skills gap with the aging quarrying workforce. With the mix of people attending the course, further learning and insights are gained as we share our own experiences and issues, making big ones into little ones.”

Courses will continue around Australia throughout 2025 and expand in 2026 and beyond.

Major steel player to scope out Whyalla steelworks

Olivia Thomson

The Whyalla steelworks in South Australia. Image: Alexander/stock.adobe.com

Bluescope has been appointed as a steelmaking advisor to KordaMentha, the administrators of the Whyalla steelworks business in South Australia.

Known as Australia’s largest steel manufacturer, BlueScope will provide technical and operational support in an advisory capacity to the administrators as they try to secure ongoing operations at the Whyalla steelworks.

“BlueScope has a long-standing history with the Whyalla steelworks, and we know its people and assets well,” BlueScope managing director and chief executive officer Mark Vassella said.

“We recognise the ongoing importance of Whyalla to the Australian economy and sovereign capability. This is a difficult time for the steel industry in the Asia Pacific region, but we are in a position to help.

“Accordingly, we will provide a team of experts from Port Kembla Steelworks to assist the administrators work through their process.”

BlueScope has not provided investment or corporate support to the administration process, nor has it decided to participate in any potential sale at this stage.

However, Vassella said BlueScope becoming an advisor to Whyalla steelworks’ administrators may help inform potential participation.

BlueScope’s appointment comes as the $2.4 billion support package from the SA and Federal Governments is progressing to plan, with funds flowing to the local Whyalla community.

The support package was announced in late February to support local jobs and stimulate growth in SA’s steel sector following the Whyalla steelworks’ owner, OneSteel Manufacturing, being placed under administration amid various operational challenges at the site.

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FLS to significantly expand global service network

Dylan Brown

Image: FLSmidth

Leading mining technology and service supplier FLS will open or expand seven service centres in strategic locations across the globe in 2025.

These facilities are in direct support of FLS’ CORE’26 mining strategy that includes targeting service growth, and adds to the company’s already comprehensive global network of service centres that can enhance mining customers’ productivity.

New facilities will open in Accra, Ghana; Surabaja, Indonesia; and Dammam, Saudi Arabia, while FLS’ operations in Mackay, Australia will relocate to a larger facility.

Expansions are planned in Parauapebas, Brazil; Karaganda, Kazakhstan; and Ulaanbaatar, Mongolia.

Operations in each of these new locations will begin within the coming months with official opening details to be announced at a later date.

In addition, an expansion of the service centre in Chloorkop, South Africa is ongoing and will be completed in 2026.

“Our service centres serve primarily as workshops for improving or repairing customer equipment and can also have warehousing capabilities for distribution,” FLS head of professional services Christian Fabry said.

“With these new openings and expansions, we further strengthen our service capabilities and best-in-class service offerings to customers.”

“We can do that by shortening the operational down time for customers thanks to the service centres’ strategic proximity to mine sites and greater availability of spare and wear parts to local customers.”

FLS offers a comprehensive range of service offerings that allow mining companies to maximise productivity.

The company has developed the strategic global presence and advanced service-based solutions required to provide responsive support wherever customers are located.

This includes:

Strong inventory of OEM spare parts and consumables in service centres around the world
Regional and global field engineers, plus remote asset health and performance optimisation services
Mineral laboratory services for fast, accurate mineralogical and metallurgical testing
Upgrades, rebuilds and exchange services to help you get more from your equipment.

FLSmidth work on the ground, and know that in a 24/7 process every hour of downtime adds up to very high costs in lost productivity.

That’s why its mining service centres are strategically located to offer local support to its customers operations – wherever they are in the world.

The company has service centres in East (Pinkenba, Beresfield, Mackay, Rockhampton) and the West (Henderson & Welshpool).

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Minprovise further expands wear parts and liners supply

Staff Writer

Image: Minprovise

Minprovise, a leading supplier in the mining and quarrying industries, has recently expanded its product range to include a variety of wear parts and liners.

This new offering includes high-quality manganese crusher liners, apron feeder pans and jaw crusher wear parts. The new range of high-performance crusher liners can also be supplied with tungsten inserts (TIC) offering unmatched toughness and extended service life, increasing plant availability and reducing costly downtime.

By offering a comprehensive range of wear parts and liners, Minprovise aims to provide reliable and high-quality alternatives to expensive original equipment manufacturer (OEM) parts, helping clients reduce costs and improve operational performance.

Further to that, Minprovise has recently introduced bi-metal wear plates and composite white iron wear bars (chocky blocks) into their suite of wear products.

To assist clients with reliable supply and the shortest possible lead time, Minprovise hold considerable stock of various sized chocky blocks to suit the majority of more common wear applications.

From a quality standpoint, Minprovise’s commitment is evident in its rigorous selection, auditing and qualification process for all suppliers. Independent metallurgical test reports from both Australian and international laboratories are available on request for the Minprovise range of wear products.

This dedication to excellence has made Minprovise a forward thinking and trusted partner for many mining and quarrying operations, with well established relationships with organisations such as Rio Tinto, BHP, FMG, AngloGold and Roy Hill to mention just a few.

Product range support

Minprovise boasts a dedicated technical team with decades of experience in both Australian and international mining and quarrying industries.

Where required, Minprovise technical experts work alongside client teams to analyse areas of high wear with the goal of developing and implementing custom wear solutions. These can generally be implemented quickly, drawing from the extensive stock on hand and utilising rapid turnaround fabrication via the Welshpool-based workshop facility.

With this expansion, the company’s focus on innovation and safety first ensures that clients receive the best possible solutions for their needs. For more information about Minprovise’s new product range, including wear parts, liners, and chocky blocks, visit the Minprovise website.

Steelworks forced into administration to ‘save’ future

The Whyalla Steelworks has been placed into administration after the South Australian government rushed legislation through parliament and pledged “one of the most comprehensive industry support packages that this nation has ever seen”.

The move gives the government authority to act on debts owed by GFG Alliance and secure the future of the mid-north operations.