8/13/2019 Results Minerals Aggregates 3 2012.ENG http://slidepdf.com/reader/full/results-minerals-aggregates-3-2012eng 1/42 The gold rush continues 6 Railway ballast of the highest quality 20 Win an iPad by participating to our reader survey 3 minerals & aggregates METSO’S CUSTOMER MAGAZINE FOR THE MINING AND CONSTRUCTION INDUSTRIES No. / results
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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