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resultsminerals & aggregates

METSO INDIA CUSTOMER MAGAZINE FOR THE MINING AND CONSTRUCTION INDUSTRIES Vol. 16 2 2011

Pouring resultsMetso India foundry adjudgedone of the best in global quality standards 42716666

www.metso.com/in

service support is becoming inevitable

for any customer. “In present circum-

stances only those companies will

survive who can provide full life cycle

support to its customers. Metso is a

comprehensive solutions provider with

flexible service packages based on

customer requirements.” Backbone

Enterprises Ltd., has been using Metso’s

genuine ware and spare parts and their

trust has only strengthened over the

years.

“I prefer genuine Metso parts as they

come with warranty, timely delivered

and are of excellent quality”, said

Mr. Viramgama.

He also added, “The Metso service

experts are thoroughly trained which

helps operators to understand machines

in order to fetch higher efficiency. All key

components and other parts are

properly designed, verified and tested

for its perfection in performance. In case

parts are worn out, positive response

from service dealers with readily

available spares are immediately within

our reach on request.”

Expanding boundaries

Looking at the prospects and the

potential that the alternate energy and

power sector present, Backbone

Enterprises Ltd. envisions their future

into these sectors.

“Metso machines have excellent

crushing abilities and low cost per ton.

We will strongly recommend to have

Metso crushing units on field of our

future projects and hopefully a very

strong business relationship as we grow

forward to contribute to our mission of

service to the Nation”, concluded

Mr. Kishor Viramgama.

Pouring results

With over a decade of operations Metso foundry in India has built a DNA of high quality and efficient solutions for construction and mining customers. Over 150 committed employees work day after day towards a common goal of bringing the best in material science to our vast installed base across India. A legacy that is built on stringent quality norms and advanced testing facilities has led this facility today ranking amongst the best foundries in Metso group companies. Recent expansions gave more substance to our claim that nothing can beat the original!

RESULTS MINERALS & AGGREGATES 2/2011 5

An invincible journey

Started operations in 2001, Metso’s

captive foundry, an asset added through

acquision of an existing foundry, has

paved way for our OEM Wear parts

business in India. A journey that was

significant in many ways and today has

made the India foundry rank amongst

the high performing units in our global

family of foundries.

Coming a long way since inception the

foundry has scaled several firsts in

process improvements and capacity

utilization. Growing demands from

customers have ensured that the

expansion matches the pace. Located in

Odhav industrial area in Ahmedabad,

Metso foundry conforms to the best in

industry quality and environmental

norms. Armed with ISO certifications,

Metso foundry, testifies to our stringent

global audits besides undergoing the ISO

audits regularly.

Foundry operations snapshot

Three fold growth in production level

from 2000 MT to 6000 MT

• Product mix : 350 wears

• Mining segment : 40%

• Construction segment : 60%

Maximum single piece cast weight

4000 kg

Casting simulation and software CAD

facility

Investment in improved process

efficiency in production processes

Ex stock delivery of standard crusher

Mn wears and Pump wears

Customer support process as nodal

interface with product support

12% export of wears to Asia and Brazil

in 2010

Says, Pranav Srivastava, Foundry Head,

“Coming a long way since inception the

foundry has scaled through significant

upgrades in Processes & obtained High

Capacity utilization.

Growing demands from customers have

ensured that our expansion strategy is in

sync with this pace.” Armed with ISO:

9001 and ISO:14001 Certifications , Metso

foundry, testifies to our stringent Annual

Process audits conducted by Global

Foundry Technology Team besides

undergoing the ISO audits as per system

requirement.

Technology transfer to back flawless

engineering

Metso foundry works at 90% current

capacity utilization, with an average of

525 -570 tons per month. Recent

expansions in terms of processes,

technology transfer and Quality

Assurance system have added

substantially to our production

capabilities. Recent advancements

include:

- Parts for the mining crushers - HP500

and Symons Cone crushers,

- Development of in-house machining

capabilities, with investments in highly

productive machines

- Introduction of a flow coating process

for improved finish on castings

- Improved heat treatment facility, with

mechanized agitation system and

125,000 litres quench tank

Mr Edson Pessoa , Vice President – Cast

wear supply operations and Global Head

of Metso Group Foundries , says “Metso

Ahmedabad Foundry ranks amongst the

top 3 foundries of Metso Group globally

in terms of Quality , Efficiency and

Delivery Performance”.

Reiterates Pranav Srivastava, Foundry

Head , “We’ve kept pace with the market

and have subsequently improved

deliveries and cast quality level.

Feedbacks from customer sites through

Service & Product Support Team have

been one of the key drivers for product

optimization to suit customer needs. This

is just the beginning, our goal is to

double the current capacity of Cast

Wears Supply foot print by 2015. As we

see the future business potential of Cast

wears for Metso equipment in India and

Asia Pacific & Europe , our capacities in

few years time are likely to be split in the

ratio of 2/3rd for local market and about

1/3rd for exports.”

Metso foundry in India is set to become a

benchmark in production in our sector;

and this is most definitely in sync with

the management’s vision for Metso

Foundry. The foundry occupies a key

position in strengthening Metso’s wear

and castings business globally. A case in

point is the pumps casting production.

Current production of Pump wears to

support 1000 pumps , is pegged to grow

almost 3 times by year 2015 as India is

projected to be Global sourcing hub for

Pump Product Line .

A feather in the cap

The Rock Test Lab at Metso foundry

has certainly added a lot of advantage for

our customers. Rock testing is an

important facet as the life of the wear

parts and crusher performance has direct

relation with how good or bad the stone

is for crushing and what quantity of steel

would be consumed while crushing by

steel wear parts (jaws, cones).

Rock testing is often conducted on two

basic parameters – Crushability and

Abrasiveness.

The relationship between rocks

crushability and abrasiveness can be

estimated in relation to our machines Mn

steel wear parts life time during the

service and cost per tonne.

The rock test lab at Metso foundry has

successfully completed over 150 rock

tests untill recently. With a captive Rock

Test lab, Metso has established itself far

ahead from its competition. Expert

knowledge and understanding of the

“Rock Mechanics” is the Metso advantage

for customers. For example, a few

developments due to a captive Rock test

lab include developments such as special

recipe, smart design correction in jaws,

increase in cheek plate life and reduction

in cost per tonne.

Says Mr. Peeyush Bajpai, Vice President,

ETO, Conveyors, LCS, PTI & Repairs, Mining

& Construction Technology, Metso,

“Having a dedicated laboratory, ensures

that our customers can rely on us to

support them with analysis, which can

optimise their processes. Our endeavor is

to constantly upgrade technology and

invest in R&D to ensure the lowest cost

per ton for our customers and offer

solutions to our customers, which

increase their productivity and efficiency.

Our Foundry operations are at the core of

our endeavour towards customer

services and is strategic arm of our

operations in India."

Says Mr. Rakesh Vohra, Director Anant

Stones, “Metso foundry has recently

developed a C Jaw liner for our plant.

We consider Metso wear parts to be

genuine. The liners result in greater

uptime and loss of production time is

minimal. The innovations at the Metso

foundry transform into something

tangible for us – higher profits off

course!”

The rock test lab enjoys favorable

endorsements not just from our

customers, but equally from our global

auditors, “Metso Rock Test lab at

Ahmedabad is doing some of the most

accurate and advance tests for crushing

in Construction and Mining. It’s great to

see everyday results that our customers

are able to enjoy due to these facilities in

their local markets”, says Keijo Viilo,

Research Director, Metso Minerals Inc.

Customer connect

The essence of any equipment support is

that all required services associated with

the equipment are aligned to provide

faster response and priority solutions. In

the case of the foundry, all wear parts are

ensured to have

a) Machining - Machined wear surfaces

and matched tolerances. This ensures

that fitment is correct and there is no

damage to the seating areas of the

equipment. Wrong dimensions of the

wear liners causes excessive stress on the

Pitman bearings and also the main shaft

assemblies of the cone crushers, thus

reducing life of the equipment and

causing collateral damage.

b) Chamber geometry – Metso designs

and develops geometry suitable for a

variety of applications. This not only helps

in ideal reduction ratio in the crusher

cavity, but provides correct power draw

on the equipment. Metso also develops

special Chamber to optimize life of the

liners on a customized basis.

c) Dimensional accuracy - Chemistry

and Recipe – with continuous variances

in the quarry and mines, the feed to the

crusher can cause reduction in life of the

liners. This causes changes in scheduled

maintenance and burden to the cost per

ton. Metso foundry is now having a range

of chemistry, which can be suited to

support the problems faced by the

customer.

d) Green conciousness - All liners being

made at the foundry are in line with the

Green norms being globally practiced by

Metso. In line with the same, the

pollution and emission norm of the state

are subscribed to and it can be

confidently mentioned that the

ingredients being used in the

manufacture are rigorously in line with

ISO 14001 practices. Thus the users can

always be assured of being in line with

their Green endeavour.

Field support

Process improvements in the foundry boil

down to better support for our

customer’s processes. Regular visits to

customer sites and gathering live

feedback from them enables foundry to

come up with best in class solutions and

to channelize learning’s from other key

markets. “Customer is at the centre of all

2 RESULTS MINERALS & AGGREGATES 2/2011 RESULTS MINERALS & AGGREGATES 2/2011 3

4 RESULTS MINERALS & AGGREGATES 2/2011

PUBLISHED BY Metso Minerals India Pvt. Ltd.,

DLF Building No. 10,

Tower A, 1st Floor,

DLF Cybercity, DLF Phase II,

Gurgaon - 122002,

Tel: +91 124 2716666,

Fax: +91 124 2351601

EDITORDinesh Sharda

ASSOCIATE EDITORIALAmol Sinha, Anand Sinha,

Ashutosh Agarwal, Deepika Sharma,

Monisha Majumdar, Praful Rawal,

Pranav Srivastava, Vishwesh Rai

RESULTSMetso India customer magazine is a

quarterly magazine and is for

circulation in India. To receive your

copy, please write to

[email protected]

Metso is the leading global supplier of

technology and services for the mining

and construction industries. Our

customers work in quarrying,

aggregates production, construction,

civil engineering, mining and minerals

processing.

FOR MORE INFORMATIONPlease write to the editor

at [email protected] or

visit us at www.metso.com/in

Retract:

Correction in Results No. 01 /2011,

AMC details in the cover story

"Unlocking value" - 350 TPH Modular

Plant in Dhanodara, Gujarat,

installed in Sep' 2010 has crushed

446,522.26 tonnes in 1,594.83 hours.

Regret the error.

In this issue

4 Pouring results Metso India foundry adjudged

one of the best in global quality

standards

8 Consistent performance. Consistent results Backbone Enterprises found several

answers in Metso

12 Keeping you ahead Metso’s new HP4 and HP5 Cone

Crushers for the mining & aggregates

industry

Praful Rawal -

Regional Product & Support

Manager, Materials

Development, Ahmedabad

[email protected]

Pranav Srivastava -

Foundry Head, Metso India

[email protected]

Vishwesh Rai - Manager,

Construction Sales,

Mining & Construction

Technology

[email protected]

Total area 26000 sq mt

Covered area 13000 sq mtEmployee base 150 +Product mix Crusher manganese wears for C series jaw crushers, GP series Cone Crushers, Symons crushers, Hi-Chrome slurry pumps wears

Quality parameter 2nd best

Delivery 2nd best with 75%

on-time delivery

Manufacturing 2nd bestcycle time

Efficiency 3rd best (Man hour efficiency)

A strategic entry

“There is a sea change in how infrastruc-

ture projects are executed in the country

– quality, safety and timely completion

being at the top of priority list. Once you

have established yourself on the above

parameters, there’s no looking back”;

says Mr. Kishor Viramgama, Chairman

and Managing Director of Backbone

Enterprises Ltd.

Backbone Enterprises Ltd., is a pioneer in

construction of superior quality roads,

bridges, buildings (residential and

commercial), cable laying etc. and has

carved a niche for itself in the infrastruc-

ture market in different states of India.

Founded in 1991 and based in Gujarat,

their mission is “Service to the Nation” by

being an integral part of superior

infrastructural development in this

country, something that has not

changed over the years.

“Business and economic situation in our

country has taken a giant leap in the

post liberalization era. A lot of focus has

been put on infrastructure development

as a key prerogative for the nation’s

growth. Huge mechanization is the key

of development in this sector and

commitment to quality and respect to

time is the biggest achievement” says

Business partners today also have a

challenge. They have to keep pace with

their customers changing requirements.

Understanding of the customer’s

business strategy makes all the

difference. Tough demands will be

placed on business partners, and that’s

when Backbone Enterprises Ltd., found a

trustworthy and quality conscious

partner in Metso.

Over 6 years of cooperation with

In 2005 when Backbone Enterprises Ltd.

was looking to expand its operations,

Mr. Kishor Viramgama, had one thing

very clear in his mind - top of the world

technology for aggregate production to

replace the local made crushing

technology that Backbone Enterprises

Ltd. has been using. “While buying a

new plant, technological advancement

was at the centre of our decision making

criterion. Backbone Enterprises Ltd., was

sure to buy world class technology that

Consistent performance. Consistent results Making a mark in the fast growing infrastructure development space in the country , Backbone Enterprises found several answers in Metso. Quest for quality and high reliability was critical to grow and Metso delivered solutions with proven results. Backbone Enterprises is one of the companies who relied on Metso’s technology & services to acknowledge that at the end of it all its just the performance that matters in the business today. Results finds more

could fully support our operations. Since

the number of infrastructure projects

was increasing and pressure for quality

products was paramount, upgrading to

better technology that has full life cycle

service support was important. “, said

Mr. Viramgama.

Mr. Viramgama first saw a Metso plant in

action at a site in Gwalior. The quality of

aggregate produced and the low dust

and noise levels at the site caught his

attention and Mr. Kishor Viramgama

quickly ordered for 250 TPH 3 stage NW

Portable Plant with the configuration

C116, GP11M and B7150DD.

Says Mr. Kishor Viramgama, “We have

seen the quality and production of Metso

crushers at many renowned infrastruc-

ture giants in the country for National

Highway and road projects – outstanding

performance with very low downtime is

what Metso crushers stand for.”

Beyond the end product

Quality, safety, timely completion of

projects and environmental conscious-

ness is in the corporate DNA of

Backbone Enterprises Ltd. With their

stake in many infrastructural projects,

Backbone Enterprises Ltd., has chosen

Metso not only because of the technol-

ogy but also because of the versatility,

efficacy, prudence and reliability in

production. Says Mr. Viramgama, “There

are clearly defined parameters such as

elongation and flakiness on which the

strength and quality of work depends

and it is arduous to produce such type

of aggregate from an ordinary crusher.

Metso has a concise unit which gives

the desired result.” What really impressed

Mr. Viramgama, was the versatility and

robustness of the NW Series Wheel

mounted portable plant.

“The versatility of the Metso plant

impressed me greatly. Also, I can rely on

the plant for giving consistent produc-

tion throughout the year. This is a great

comforting factor – when you know

there is a strong technology backing

that won’t fail, especially during peak

production time. Coupled with Metso’s

decades of experience in design and

manufacture of various types of crushers

and strong service network, Metso does

stand out as a complete solution

provider. We have witnessed economies

– cost effective operations and ease of

maintenance, beyond the end product”,

said Mr. Viramgama,. Round the clock

Process for rock testing

The rock test lab at Metso Foundry, AhmedabadSand mixing process at Metso Foundry, Ahmedabad

For Nagpur Ring

Road project, Umri

near Nagpur

For Jetpur -

Somnath Four Lane

NH project

For Jetpur -

Somnath Four Lane

NH project

250 TPH 3 stageNW Wheel mountedportable plant

250 TPH 3 stage NW Wheel mountedportable plant

Running

commissioned

by July 2011

commissioned

by July 2011

S.No. Location Specifications Product fractions Year Status

0-5mm, 5-10mm, 10-

20mm, 20-40mm

0-5mm, 5-10mm, 10-

20mm, 20-40mm

0-5mm, 5-10mm, 10-

20mm, 20-40mm

4 For Jetpur -

Somnath Four Lane

NH project

2011 To be

commissioned

by July 2011

0-5mm, 5-10mm, 10-

20mm, 20-40mm

Mr. Kishor Viramgama

Chairman and Managing Director, Backbone Enterprises Ltd

C O V E R S T O R Y C O V E R S T O R Y

R E P O R T I N G R E S U L T S

C O V E R S T O R Y

Dear customer,

In this dynamic and highly competitive environment, our customers are always looking for innovative solutions that could improve

profitability either by optimizing cost of operation or by increasing productivity – to ensure that they stay ahead of their competition.

Business environment and customer segments have matured to the extent that decisions are now driven by the lowest life cycle costs

rather than lowest initial investment. CAPEX and OPEX are now equally integral to any buying decision and are not delinked, as in the past.

Metso has always been at the forefront in offering solutions which help our customers in optimizing the “Total Cost” over the life of the

investment.

Our recent offerings such as the VertiMills, Lokotracks and Air Classifiers are a step in that direction.

Metso VertiMills use attrition to grind as compared to attrition and impact used in horizontal Ball Mills. This helps in considerable savings

on energy costs as compared to horizontal Ball Mills apart from reduction in cost of consumables. The product of VertiMill is sharper and

closer to the desired curve. Our experience in rest of the world, where these mills have been installed, have shown that higher initial cost

of these mills can be recovered quickly through savings in energy and consumable cost and better product quality. Considering that

energy cost in our country is relatively higher compared to many countries, the paybacks here would be faster.

Our latest offerings of Lokotracks, use Metso’s time tested and proven crushers, that have been re-engineered specially for the Indian

market – not only keeping in mind tough operating conditions but also to ensure simplicity in operations and economies due to fuel

savings. These “Engineered for India” track solutions are to ensure that our customers are leaps and bounds ahead of competition in

productivity and profitability.

Sensitivity to the environment is on the rise, specifically in our industry. Air Classifiers for sand classification is not only an environmental

friendly technology but also helps our customers to produce high quality concrete. Our customers can move up the value chain by

experiencing economies through lower operating costs.

Constant innovation is at the core of our operations - to enable our customer to become more competitive and profitable in their

operations. We look forward to your patronage for these new offerings and many more to come in the future.

Warm Regards

Kamal PahujaVice President – IndiaMining & Construction Technology

Sample detailsrecording

Sample arrivalfrom site

Sample primarycrushing for big tomedium to small rocks

Primary sievingfor size-10mm to-4mm

The retained-3.15mm and-2.5mm collected to 250 grams each

Final sieving done to retain the -2.0, 1.6,0.125 and pan

Secondary crushing by RollCrusher and (or) Barmac Labcrusher

Secondary sieving forsize- -3.15mm to- 2.5mm

Such 250 gms eachtogether 500 gms crushedtogether in crushabilitymeter

our initiatives. To make customer

initiatives more robust, regular meets

with service engineers from across the

country are organized and are preceded

by the Technical services group from

Foundry. Customer support process has

always been an integral part of the

foundry and from beginning of year

2011, a nodal interface with Metso

product support and service team has

been initiated. The essential purpose is to

improve resolution time of issues raised

on customer feedbacks ”, added Pranav

Srivastava.

Based on customer interactions, new

variants of equipments are developed on

an ongoing basis to meet customer

requirements at the site.

Reiterates Mrs. Asha Prasanna Kumar,

Managing Director, Apkon Infrastructure,

“The sales team is often accompanied by

representatives from the Foundry. Based

on our operations and the requirements,

a new set of liners were tried on the

machine. The parts have given 70%

more wear life. This is truly

overwhelming. Metso is undoubtedly a

strategic business partner for us”.

To give impetus to the customer connect

initiatives, a few internal programs have

also been started. Efficiency

improvements are at the core of

employee driven programs. A case in

point to measure the success of such

programs is savings of 2% by reduction of

rejections and manufacturing cycle time.

Kaizen 5 S

Total Quality Quality Circles Management

Certified for success

Metso foundry caters to the entire

demand of wear parts for Metso’s

installed base in India. Top quality

production needs best in class

management practices. Metso

Ahmedabad foundry enjoys the following

certifications & associations:

1. ISO 9001 - Quality Management

System

2. ISO 14001 - Management System

3. Membership to the American

Foundry Society

With a process driven culture and best in

class management practices, foundry has

experienced considerable reduction in

percentage of new product development

cycle to 10-12 weeks as compared to 16

weeks earlier. Further improvisations in

the pattern development process to

further bring down the cycle to 8-10

weeks.

Safety & environment go hand in hand

Metso foundry sets a benchmark for

conducting manufacturing in an

environmentally sound way, whilst

fulfilling Metso’s HSE responsibilities. Says

Pranav Srivastava, “Health, Safety and

Environment issues are key concerns for

Metso . These are addressed with the

same sense of seriousness as quality,

productivity and cost efficiency. HSE

initiatives are a part of our existence, and

each one of our employees contributes

to this issue with passion.” Metso foundry

is surrounded by a thick lush green belt

maintained by the foundry that covers

35% of the area in the vicinity. Some of

the regular initiatives to spread

environmental consciousness include

observing Annual Environment Day with

active tree plantations, using solar power

streets lights within the foundry campus

and use of clean fuel - PNG as against LPG

and LDO for process equipments.

Metso foundry is committed to a strong

growth path and continuous

development in a sustainable and a safe

way. Regular health camps are organized

to ensure good health for the workers

and their family members. Protective

safety measure – such as wearing safety

gears at all times while on the shop floor

are mandatory. “Awareness programs and

regular Safety Alerts ensure that

employees take safety with equal

seriousness. We bring down global

experts from other Metso manufacturing

units and experts from National Safety

Council to conduct regular safety

trainings. We are proud to say that due to

the raise in awareness, foundry had LTIF

(Lost Time Incident Frequency ) as 4 per

One million man hours only in year 2010

due to regular observance of Safety

Practices at work place as against Plan of

10 per million man hours per annum

globally . Our aim to achieve Zero

Accident year in 2011 and so far we have

been in Zero Accident zone in this year ”,

adds Pranav.

“We have been using Metso wear parts

for the last four years. The quality of

these wear parts are consistent and

associated service has made Metso a

reliable partner in our projects enabling

timely completion of projects with

optimized costs”, says Mr. Devendra

Jain, Director, Dilip Buildcon Ltd.

Says Mr. N.K. Palai, Deputy General

Manager (Mines), Gujarat Cluster, Larsen

& Toubro Limited, ECC Division, “We

have a business relationship with Metso

for more than a decade. This

relationship has steadily grown due to

their strong & committed customer

focus in many areas. They have

established a world class foundry & a

modern R&D, metallurgical laboratory in

Ahmedabad to support the customers.

As a part of a knowledge sharing

program, a group of 30 plant engineers

from our company had visited the

foundry and enriched the knowledge

out of this visit. We hope Metso

contributes more towards environment

friendly technology in the future.”

16 Metso Vertimill® Your Savings Account

22 News in brief25 Re-engineering repairs Metso India’s first ever

Centrifuge repair

27 Globe trotting Fassa makes sustainable

quarrying a reality

COVER PHOTO : Metal pouring process at the Metso Foundry, Ahmedabad

Metso India foundry adjudged one of the best in global quality standards

(2) (3)

(4) (5)

(6) (7)

(8) (9)

(10) (11)

years.

Mr. Viramgama.

into these sectors.

Pouring results

audits regularly.

4000 kg

facility

in 2010

requirement.

engineering

include:

productive machines

Pump Product Line .

Abrasiveness.

in cost per tonne.

course!”

Customer connect

ensured to have

customer.

Field support

Tower A, 1st Floor,

Gurgaon - 122002,

Tel: +91 124 2716666,

Fax: +91 124 2351601

EDITORDinesh Sharda

[email protected]

processing.

Retract:

446,522.26 tonnes in 1,594.83 hours.

Regret the error.

In this issue

standards

answers in Metso

industry

Praful Rawal -

Manager, Materials

[email protected]

Pranav Srivastava -

[email protected]

Construction Sales,

Technology

[email protected]

on-time delivery

A strategic entry

Enterprises Ltd.

partner in Metso.

Mr. Viramgama.

For Nagpur Ring

Road project, Umri

near Nagpur

For Jetpur -

Somnath Four Lane

NH project

For Jetpur -

Somnath Four Lane

NH project

Running

commissioned

by July 2011

commissioned

by July 2011

0-5mm, 5-10mm, 10-

20mm, 20-40mm

0-5mm, 5-10mm, 10-

20mm, 20-40mm

0-5mm, 5-10mm, 10-

20mm, 20-40mm

4 For Jetpur -

Somnath Four Lane

NH project

2011 To be

commissioned

by July 2011

0-5mm, 5-10mm, 10-

20mm, 20-40mm

C O V E R S T O R Y

Dear customer,

investment.

Warm Regards

Srivastava.

Kaizen 5 S

System

Foundry Society

weeks.

adds Pranav.

Centrifuge repair

quarrying a reality

(2) (3)

(4) (5)

(6) (7)

(8) (9)

(10) (11)

years.

Mr. Viramgama.

into these sectors.

Pouring results

audits regularly.

4000 kg

facility

in 2010

requirement.

engineering

include:

productive machines

Pump Product Line .

Abrasiveness.

in cost per tonne.

course!”

Customer connect

ensured to have

customer.

Field support

Tower A, 1st Floor,

Gurgaon - 122002,

Tel: +91 124 2716666,

Fax: +91 124 2351601

EDITORDinesh Sharda

[email protected]

processing.

Retract:

446,522.26 tonnes in 1,594.83 hours.

Regret the error.

In this issue

standards

answers in Metso

industry

Praful Rawal -

Manager, Materials

[email protected]

Pranav Srivastava -

[email protected]

Construction Sales,

Technology

[email protected]

on-time delivery

A strategic entry

Enterprises Ltd.

partner in Metso.

Mr. Viramgama.

For Nagpur Ring

Road project, Umri

near Nagpur

For Jetpur -

Somnath Four Lane

NH project

For Jetpur -

Somnath Four Lane

NH project

Running

commissioned

by July 2011

commissioned

by July 2011

0-5mm, 5-10mm, 10-

20mm, 20-40mm

0-5mm, 5-10mm, 10-

20mm, 20-40mm

0-5mm, 5-10mm, 10-

20mm, 20-40mm

4 For Jetpur -

Somnath Four Lane

NH project

2011 To be

commissioned

by July 2011

0-5mm, 5-10mm, 10-

20mm, 20-40mm

C O V E R S T O R Y

Dear customer,

investment.

Warm Regards

Srivastava.

Kaizen 5 S

System

Foundry Society

weeks.

adds Pranav.

Centrifuge repair

quarrying a reality

(2) (3)

(4) (5)

(6) (7)

(8) (9)

(10) (11)

years.

Mr. Viramgama.

into these sectors.

Pouring results

audits regularly.

4000 kg

facility

in 2010

requirement.

engineering

include:

productive machines

Pump Product Line .

Abrasiveness.

in cost per tonne.

course!”

Customer connect

ensured to have

customer.

Field support

Tower A, 1st Floor,

Gurgaon - 122002,

Tel: +91 124 2716666,

Fax: +91 124 2351601

EDITORDinesh Sharda

[email protected]

processing.

Retract:

446,522.26 tonnes in 1,594.83 hours.

Regret the error.

In this issue

standards

answers in Metso

industry

Praful Rawal -

Manager, Materials

[email protected]

Pranav Srivastava -

[email protected]

Construction Sales,

Technology

[email protected]

on-time delivery

A strategic entry

Enterprises Ltd.

partner in Metso.

Mr. Viramgama.

For Nagpur Ring

Road project, Umri

near Nagpur

For Jetpur -

Somnath Four Lane

NH project

For Jetpur -

Somnath Four Lane

NH project

Running

commissioned

by July 2011

commissioned

by July 2011

0-5mm, 5-10mm, 10-

20mm, 20-40mm

0-5mm, 5-10mm, 10-

20mm, 20-40mm

0-5mm, 5-10mm, 10-

20mm, 20-40mm

4 For Jetpur -

Somnath Four Lane

NH project

2011 To be

commissioned

by July 2011

0-5mm, 5-10mm, 10-

20mm, 20-40mm

C O V E R S T O R Y

Dear customer,

investment.

Warm Regards

Srivastava.

Kaizen 5 S

System

Foundry Society

weeks.

adds Pranav.

Centrifuge repair

quarrying a reality

(2) (3)

(4) (5)

(6) (7)

(8) (9)

(10) (11)

years.

Mr. Viramgama.

into these sectors.

Pouring results

audits regularly.

4000 kg

facility

in 2010

requirement.

engineering

include:

productive machines

Pump Product Line .

Abrasiveness.

in cost per tonne.

course!”

Customer connect

ensured to have

customer.

Field support

Tower A, 1st Floor,

Gurgaon - 122002,

Tel: +91 124 2716666,

Fax: +91 124 2351601

EDITORDinesh Sharda

[email protected]

processing.

Retract:

446,522.26 tonnes in 1,594.83 hours.

Regret the error.

In this issue

standards

answers in Metso

industry

Praful Rawal -

Manager, Materials

[email protected]

Pranav Srivastava -

[email protected]

Construction Sales,

Technology

[email protected]

on-time delivery

A strategic entry

Enterprises Ltd.

partner in Metso.

Mr. Viramgama.

For Nagpur Ring

Road project, Umri

near Nagpur

For Jetpur -

Somnath Four Lane

NH project

For Jetpur -

Somnath Four Lane

NH project

Running

commissioned

by July 2011

commissioned

by July 2011

0-5mm, 5-10mm, 10-

20mm, 20-40mm

0-5mm, 5-10mm, 10-

20mm, 20-40mm

0-5mm, 5-10mm, 10-

20mm, 20-40mm

4 For Jetpur -

Somnath Four Lane

NH project

2011 To be

commissioned

by July 2011

0-5mm, 5-10mm, 10-

20mm, 20-40mm

C O V E R S T O R Y

Dear customer,

investment.

Warm Regards

Srivastava.

Kaizen 5 S

System

Foundry Society

weeks.

adds Pranav.

Centrifuge repair

quarrying a reality

(2) (3)

(4) (5)

(6) (7)

(8) (9)

(10) (11)

years.

Mr. Viramgama.

into these sectors.

Pouring results

audits regularly.

4000 kg

facility

in 2010

requirement.

engineering

include:

productive machines

Pump Product Line .

Abrasiveness.

in cost per tonne.

course!”

Customer connect

ensured to have

customer.

Field support

Tower A, 1st Floor,

Gurgaon - 122002,

Tel: +91 124 2716666,

Fax: +91 124 2351601

EDITORDinesh Sharda

[email protected]

processing.

Retract:

446,522.26 tonnes in 1,594.83 hours.

Regret the error.

In this issue

standards

answers in Metso

industry

Praful Rawal -

Manager, Materials

[email protected]

Pranav Srivastava -

[email protected]

Construction Sales,

Technology

[email protected]

on-time delivery

A strategic entry

Enterprises Ltd.

partner in Metso.

Mr. Viramgama.

For Nagpur Ring

Road project, Umri

near Nagpur

For Jetpur -

Somnath Four Lane

NH project

For Jetpur -

Somnath Four Lane

NH project

Running

commissioned

by July 2011

commissioned

by July 2011

0-5mm, 5-10mm, 10-

20mm, 20-40mm

0-5mm, 5-10mm, 10-

20mm, 20-40mm

0-5mm, 5-10mm, 10-

20mm, 20-40mm

4 For Jetpur -

Somnath Four Lane

NH project

2011 To be

commissioned

by July 2011

0-5mm, 5-10mm, 10-

20mm, 20-40mm

C O V E R S T O R Y

Dear customer,

investment.

Warm Regards

Srivastava.

Kaizen 5 S

System

Foundry Society

weeks.

adds Pranav.

Centrifuge repair

quarrying a reality

(2) (3)

(4) (5)

(6) (7)

(8) (9)

(10) (11)

years.

Mr. Viramgama.

into these sectors.

Pouring results

audits regularly.

4000 kg

facility

in 2010

requirement.

engineering

include:

productive machines

Pump Product Line .

Abrasiveness.

in cost per tonne.

course!”

Customer connect

ensured to have

customer.

Field support

Tower A, 1st Floor,

Gurgaon - 122002,

Tel: +91 124 2716666,

Fax: +91 124 2351601

EDITORDinesh Sharda

[email protected]

processing.

Retract:

446,522.26 tonnes in 1,594.83 hours.

Regret the error.

In this issue

standards

answers in Metso

industry

Praful Rawal -

Manager, Materials

[email protected]

Pranav Srivastava -

[email protected]

Construction Sales,

Technology

[email protected]

on-time delivery

A strategic entry

Enterprises Ltd.

partner in Metso.

Mr. Viramgama.

For Nagpur Ring

Road project, Umri

near Nagpur

For Jetpur -

Somnath Four Lane

NH project

For Jetpur -

Somnath Four Lane

NH project

Running

commissioned

by July 2011

commissioned

by July 2011

0-5mm, 5-10mm, 10-

20mm, 20-40mm

0-5mm, 5-10mm, 10-

20mm, 20-40mm

0-5mm, 5-10mm, 10-

20mm, 20-40mm

4 For Jetpur -

Somnath Four Lane

NH project

2011 To be

commissioned

by July 2011

0-5mm, 5-10mm, 10-

20mm, 20-40mm

C O V E R S T O R Y

Dear customer,

investment.

Warm Regards

Srivastava.

Kaizen 5 S

System

Foundry Society

weeks.

adds Pranav.

Centrifuge repair

quarrying a reality

(2) (3)

(4) (5)

(6) (7)

(8) (9)

(10) (11)

years.

Mr. Viramgama.

into these sectors.

Pouring results

audits regularly.

4000 kg

facility

in 2010

requirement.

engineering

include:

productive machines

Pump Product Line .

Abrasiveness.

in cost per tonne.

course!”

Customer connect

ensured to have

customer.

Field support

Tower A, 1st Floor,

Gurgaon - 122002,

Tel: +91 124 2716666,

Fax: +91 124 2351601

EDITORDinesh Sharda

[email protected]

processing.

Retract:

446,522.26 tonnes in 1,594.83 hours.

Regret the error.

In this issue

standards

answers in Metso

industry

Praful Rawal -

Manager, Materials

[email protected]

Pranav Srivastava -

[email protected]

Construction Sales,

Technology

[email protected]

on-time delivery

A strategic entry

Enterprises Ltd.

partner in Metso.

Mr. Viramgama.

For Nagpur Ring

Road project, Umri

near Nagpur

For Jetpur -

Somnath Four Lane

NH project

For Jetpur -

Somnath Four Lane

NH project

Running

commissioned

by July 2011

commissioned

by July 2011

0-5mm, 5-10mm, 10-

20mm, 20-40mm

0-5mm, 5-10mm, 10-

20mm, 20-40mm

0-5mm, 5-10mm, 10-

20mm, 20-40mm

4 For Jetpur -

Somnath Four Lane

NH project

2011 To be

commissioned

by July 2011

0-5mm, 5-10mm, 10-

20mm, 20-40mm

C O V E R S T O R Y

Dear customer,

investment.

Warm Regards

Srivastava.

Kaizen 5 S

System

Foundry Society

weeks.

adds Pranav.

Centrifuge repair

quarrying a reality

(2) (3)

(4) (5)

(6) (7)

(8) (9)

(10) (11)

years.

Mr. Viramgama.

into these sectors.

Pouring results

audits regularly.

4000 kg

facility

in 2010

requirement.

engineering

include:

productive machines

Pump Product Line .

Abrasiveness.

in cost per tonne.

course!”

Customer connect

ensured to have

customer.

Field support

Tower A, 1st Floor,

Gurgaon - 122002,

Tel: +91 124 2716666,

Fax: +91 124 2351601

EDITORDinesh Sharda

[email protected]

processing.

Retract:

446,522.26 tonnes in 1,594.83 hours.

Regret the error.

In this issue

standards

answers in Metso

industry

Praful Rawal -

Manager, Materials

[email protected]

Pranav Srivastava -

[email protected]

Construction Sales,

Technology

[email protected]

on-time delivery

A strategic entry

Enterprises Ltd.

partner in Metso.

Mr. Viramgama.

For Nagpur Ring

Road project, Umri

near Nagpur

For Jetpur -

Somnath Four Lane

NH project

For Jetpur -

Somnath Four Lane

NH project

Running

commissioned

by July 2011

commissioned

by July 2011

0-5mm, 5-10mm, 10-

20mm, 20-40mm

0-5mm, 5-10mm, 10-

20mm, 20-40mm

0-5mm, 5-10mm, 10-

20mm, 20-40mm

4 For Jetpur -

Somnath Four Lane

NH project

2011 To be

commissioned

by July 2011

0-5mm, 5-10mm, 10-

20mm, 20-40mm

C O V E R S T O R Y

Dear customer,

investment.

Warm Regards

Srivastava.

Kaizen 5 S

System

Foundry Society

weeks.

adds Pranav.

Centrifuge repair

quarrying a reality

(2) (3)

(4) (5)

(6) (7)

(8) (9)

(10) (11)

years.

Mr. Viramgama.

into these sectors.

Pouring results

audits regularly.

4000 kg

facility

in 2010

requirement.

engineering

include:

productive machines

Pump Product Line .

Abrasiveness.

in cost per tonne.

course!”

Customer connect

ensured to have

customer.

Field support

Tower A, 1st Floor,

Gurgaon - 122002,

Tel: +91 124 2716666,

Fax: +91 124 2351601

EDITORDinesh Sharda

[email protected]

processing.

Retract:

446,522.26 tonnes in 1,594.83 hours.

Regret the error.

In this issue

standards

answers in Metso

industry

Praful Rawal -

Manager, Materials

[email protected]

Pranav Srivastava -

[email protected]

Construction Sales,

Technology

[email protected]

on-time delivery

A strategic entry

Enterprises Ltd.

partner in Metso.

Mr. Viramgama.

For Nagpur Ring

Road project, Umri

near Nagpur

For Jetpur -

Somnath Four Lane

NH project

For Jetpur -

Somnath Four Lane

NH project

Running

commissioned

by July 2011

commissioned

by July 2011

0-5mm, 5-10mm, 10-

20mm, 20-40mm

0-5mm, 5-10mm, 10-

20mm, 20-40mm

0-5mm, 5-10mm, 10-

20mm, 20-40mm

4 For Jetpur -

Somnath Four Lane

NH project

2011 To be

commissioned

by July 2011

0-5mm, 5-10mm, 10-

20mm, 20-40mm

C O V E R S T O R Y

Dear customer,

investment.

Warm Regards

Srivastava.

Kaizen 5 S

System

Foundry Society

weeks.

adds Pranav.

Centrifuge repair

quarrying a reality

(2) (3)

(4) (5)

(6) (7)

(8) (9)

(10) (11)

• Access door for maintenance and

screw removal

• Low intensity = Low wear

• Media Size Matched with

grind 38 – 5 mm

Large scale installations of multiple

Vertimill® are possible and are becoming

more and more popular. One project is

currently installing sixteen (16)

VTM-1500-WBs in a secondary grinding

application. It is projected that the

energy and media consumptions savings

alone will be in excess of $100 million US

Dollars over the life of the mine

compared with traditional ball mills.

The VERTIMILL® has proven to be a

versatile tool that exhibits many

advantages over traditional ball

milling. Metso VERTIMILL® offers

lowest total cost of ownership.

Typically, the total cost of ownership

of the Vertimill® compared with

traditional ball mills can be 35% less.

Vertimill - Efficient and effective

The improved grinding energy efficiency

of the Vertimill® is due largely to the

effect of the vertical arrangement.

A horizontal Ball mill relies on the

tumbling action of the slurry and media

for both impact breakage and attrition

grinding. However, impact energy is

generally not as efficient as attrition

grinding since much of the impact

energy is wasted if the grinding balls

impact the liners or other steel balls.

The most efficient grinding zone inside of

a ball mill is known as the “kidney”

because of its shape and it is efficient

because the grinding media and particles

are constantly in contact with one

another and grind by attrition. Figure 2

shows the flow of the grinding media

inside of a Vertimill®.

The screw rotates slowly enough that

media is not fluidized but settles by

gravity. The screw pulls media up the

center of the mill, which eventually

cascades over the edge of the screw

creating a general downward flow at the

mill perimeter.

As you can see in the figure, the velocities

of the particles are quite low because the

media stay in contact with one another,

while in a ball mill media can be in free

fall through open space. The entire

grinding action inside of the Vertimill®

closely mimics the attrition grinding in

the “kidney” of a ball mill.

The vertical arrangement, also,

contributes to minor internal

classification of particles, reducing over

grinding, thus, increasing efficiency.

As the feed material enters the top of the

grinding chamber, the downward travel

of the material into the grinding media is

influenced by the uprising velocity

created by the recycle flow. This uprising

velocity removes or “washes” out fine

product size material before entering the

grinding media and exits the mill to the

external classification step where it is

removed from the system with very little

energy applied.

The second reason for the improved

grinding efficiency is that the Vertimill®

effectively uses finer media. Since a ball

mill relies partially on impact breakage, a

certain size grinding ball is required

generate enough kinetic energy while

tumbling. In a Vertimill® the larger ball

sizes isn’t required because impact isn’t

the grinding mechanism. Therefore, the

mill can be charged with a smaller media

top size creating an overall smaller size

distribution.

Table 1 shows how a small change in

media size can have a big impact on the

total grinding surface area. In general, a

Vertimill® size distribution has greater

than three times the surface areas of an

equivalent ball mill grinding charge.

Why Vertical Stirred Mills?

With any technology consideration, you

want a solution that has the lowest total

cost of ownership while meeting the

product requirements. Vertically stirred

mills have many advantages that make

them the lowest total cost of ownership.

These advantages include:

• Higher energy efficiency – typically

30-35%; In many cases greater than 50%

energy savings have been reported

• Lower operating cost

– Lower media consumption

– Typically coincides with energy savings

(as low as 50%)

– Requires little maintenance – saves

time and labor

– Long Wear Life – lower wear parts costs

and labor associated with replacement

• High Availability -greater than 98% is

common

• Lower installation cost –shorter duration

and simpler foundations (savings of time

and money in foundation construction

and mill installation, as low as 50%)

• Requires less floor space

• Less noise -usually below 85db

• Greater operating safety

VERTIMILL® : Higher Energy Efficiency

delivered

Several operating plants have established

much better energy savings in

VERTIMILL® operation as compared to

conventional ball mill. The following

mines have reported more than 30%

power savings as compared to

conventional ball mills with the

installation of Metso VERTIMILL®

• Secondary grinding

- Mexican copper mine: 34.2%

- SW USA copper mine: 29 – 39%

• Tertiary grinding

- Chino mines: 35%

- Cadia: 35%

• Regrinding

- Red Dog: 40%

• In 1987, it was the first large scale

metallic operation for the VERTIMILL®

- Las Encinas: 35%

- La Candelaria: 44%

* Reference papers for all data shown is

available upon request

• VERTIMILL® : Lower installation cost

ensured

• Typical large ball mill takes 12 + weeks

to install

• Typical VTM takes 2 weeks to install

• VTM-1500-WB has been installed in

5 days

• Smaller foundations

• Less floor space required

• VERTIMILL® : Higher Availability and

Lower Maintenance

• Fewer parts

• Less maintenance

• Long wear life

• Long screw liner life ranging from 9

months to 2 years, depending on

application

• “Permanent” shell liners

• Over 98% availability

Metso can offer availability guarantees

with Life Cycle Service contracts

Metso’s First VTM 3000-WB installation

at Newcrest Mining Ltd. Cadia Valley

Operations

• The VTM 3000-WB mill has the following

Grinding Design

• F80 – 150 μm

• P80 – 90μm

• Capacity - 780 mtph

• The Mills operation has Successfully

Exceeded efficiency predictions

• Flotation plant has achieved much

higher recovery than anticipated on

account of

• Sharper particle size distribution

• Finer feed to flotation

• Tertiary circuit stabilizes feed to rougher

flotation circuit

• No installation complications

• No mechanical complications

• No process complications

• Within 3 days of the start of

commissioning, the mill became an

active part of plant operations

• Improving recovery

• Increasing capacity

• Project and Installation executed with

efficiency, quality, and functionality of a

typical smaller VTM project

• Original set of liners still in use (8

months so far)

Metso has supplied more than 345

Vertimill® worldwide which are running

successfully with performance level

higher than expected. Metso strongly

recommends installation of Vertimill® in

your Primary grinding, Secondary

grinding, Regrind, Fine grinding and Lime

Slaking applications.

We offer a complete spectrum of

engineering services, including testing,

process design, installation,

commissioning, start-up, and continuous

lifetime product support services.

Our experienced personnel understand

the challenges mineral processing can

present. Metso has the people,

technology, expertise, and product

support services to help you maximize

the efficiency of your grinding circuit.

Metso's process engineers welcome the

opportunity to assist our esteemed

clients with circuit and circuit control

design as well as start-up, operation, and

optimization of the milling plant.

Let us put our knowledge to work for

Keeping you aheadHP4 and HP5 Cone Crushers

Metso’s new HP4 and HP5 Cone Crushers are a boon for the aggregates and mining

market, as there’s no better choice when it comes to high productivity, low service cost

and long service life. Read on more to explore the new crushing giant offered by Metso.

Designed for your needs

In todays dynamic crushing and

screening environment, you adapt and

innovate or you fall behind. That’s why

Metso listens to its customers, to find out

what they need to succeed. The demand

seems to be for a machine with:

• A small profile

• Tight settings

• Minimize operating costs and

• Versatility for re-crushing

Metso’s research & development team

met that challenge with the Metso HP4

& HP5 Cone Crushers. Designed for

maximum versatility and hardest

applications, it provides maximized

productivity while minimizing operating

costs.

Metso HP series Cone Crusher feature a

unique combination of crusher speed,

throw and cavity design. This

combination is renowned for providing

higher capacity and superior product

quality, and having a wider range of

application suitability:

• Limestone to taconite

• Road ballast to manufactured sand

• Compact portable plant to the largest

stationary.

The HP4 Cone Crusher – Stepping

stone to the future

The HP4 is a crusher with a heavy duty

design for the hardest

applications. Its

unique features for

highest reduction

ratios, maximum

versatility and lowest

maintenance

requirements

guarantees highest

levels of productivity

and minimized

operating costs.

With a combination of

optimized speed and

large throw, HP4

provides the highest reduction ratio of

any current Cone Crusher. Due to its

highly efficient crushing action, the HP4

has the best power utilization per cone

diameter.

Specifications:

Power: 315kW

Weight: 19.8 to 23.6 tons: Extra heavy

Performance: upto 140 TPH of 0/10 mm

High tramp release force: 236 tonnes,

Setting range: depending on the cavity:

8mm – 45mm

Metso Vertimill®

Metso provides end-to-end solutions in communition to the

customer (refer to our article on Grinding mills in the previous

issue). The Vertimill is a unique product offered exclusively by

Metso that has a long history in the metallic mining industry. The

Vertimill is just more than a grinding mill. Its “intelligent” grinding

concept not only saves energy but also controls the process of

reduction. Read on to know more about the Vertimill from Metso.

Crusher for the next generation

Metso HP5 Cone Crusher

The HP5 follows the successful HP4 as the

second model of the all new range of

high performance Cone Crushers, which

benefits from the very latest in Metso

crushing technology.

It achieves new heights with the unique

features that produce the highest

reduction ratios, easy to operate and has

low maintenance requirements.

Specifications:

Power: 450kW

Weight: 30 – 44 tons: Extra heavy duty

Performance: upto 210 TPH of 0/10mm

Max feed: 330 mm

High tramp release force = 316 tons,

i.e. equivalent to 7’ HD Symons Crusher

Setting range: Depending on cavity:

8 to 50mm

Advantages of the HP4 and HP5 Cone

Crusher

1. Highest performance

The HP4 & HP5 crushers enable you to

produce much finer products with fewer

crushing stages, thereby lowering your

investment and saving energy. That is

possible for the combination of optimized

speed and large throw, that these

crushers can provide the highest

reduction ratios of any current Cone

Crusher. Due to their super efficient

crushing action, the HP4 & HP5 have the

best power utilization per cone diameter.

So you can save twice with lower

recirculation load. Higher cavity density

improves inter-particular crushing action

for end products with more consistent

gradation and superior shape (cubicity).

Its various features also allow them to

reduce wear costs and make sure that the

crusher setting is instantaneously

maintained even after passing a piece of

tramp iron.

2. Less downtime

Another way the HP4 & HP5 crushers

deliver is less downtime and increased

operator confidence. Dual – acting

hydraulic tramp release cylinders let the

HP4 and HP5 pass tramp iron that would

stall, or damage many other crushers. If

the crusher does not stop under load, the

dual-acting cylinders provide a large

clearing stroke, independent of liner

wear, to quickly clear the crushing cavity.

If you pull the head you will find a new

fixed counterweight guard that protects

the counterweight and seals out dust.

3. Easy to maintain

Bronze bushing throughout provide

superior load capability in the dusty, high

shock crushing environment. In

combination with forced lubrication

system they provide better efficiency yet

they cost less than rolling element

bearings and are easy to replace in the

field with normal tools. The HP4 & HP5

are easy to disassemble. All components

are accessible from the top or side. The

bowl and head are easily removed; no

interference fit to contend with.

4. Versatility

Due to the strength, speed range and

ease of converting from coarse to extra

fine applications, the HP4 & HP5 provide

application flexibility that was unheard of

till now.

• Saving stockpile space by recrushing

excess or slowmoving products without

intermediate crushing stage.

• Converting from coarse to extra fine

application and back again just by

changing liners and rpm

• Liner and rpm combinations go from

secondary applications to sand

manufacturing

5. Asset protection

The new tramp release design also

protects the main frame from

uncrushables by smoothing out the

impact forces and returns the bowl to its

original position after passing tramp iron.

Inside, a new fixed guard protects

counterweight and seals out dust. An

optional cover around the crusher

adjustment and tramp release

mechanisms. It also helps protect the

workplace with reduced dust emissions.

6. No backing compound

The environment benefits too from the

advanced fastening system for mantle

and bowl liner that do not require

backing material.

Overview

In this issue we shall talk about the Stirred

milling technology that Metso provides

as a solution in communition to the

customer.

The stirred milling technologies currently

available can be divided into two

sub-categories:

1. Gravity induced

2. Fluidized

Gravity-induced

Gravity-induced Stirred Mills initiate a ball

charge motion via rotational movement

of a screw to provide a size reduction

mechanism. In contrast, Fluidized Stirred

Mills use a rotational movement to

fluidize a media-slurry mixture, resulting

in a size reduction mechanism. The type

of mill and the circuit configuration are

intrinsic to maximizing the grade and

recovery profile of an ore.

Metso has both stirred milling

technologies in the Vertimill® and the

Stirred Media Detritor (SMD®), allowing

Metso to offer the optimum equipment

solution for the circuit.

The Vertimill®

The Vertimill® is a unique product offered

exclusively by Metso that has a long

history in the metallic mining industry.

The technology was originally developed

in the 1950’s for industrial applications.

Metso successfully developed and

implemented the technology in the first

large scale metallic operations in 1980. In

the thirty years since, the Metso Vertimill®

has built the largest installed base of any

stirred milling technology.

Applications of VERTIMILL® are highly

diverse with unit sizes from as low as

15HP to as high as 3000 HP.

They can take any feed size of less

than 6 mm and can produce product

sizes as low as 15 μm.

Metso draws from more than 100 years of

mill design and manufacturing expertise,

and more than three decades of

successful VERTIMILL® applications.

Till now, more than 345 units have been

successfully commissioned worldwide

with results much better than expected.

The VERTIMILL® is suitable for:

• Primary grinding

• Regrind applications

• Fine grinding

• Lime slaking

Main features of VERTIMILL® are:

• Premium efficiency high

Torque Motor

• Three stage reducer

• Automatically greased bearings

• Solid steel grinding screw with bolt

on replaceable liners

• Orebed® magnetic shell liners

• Modular mill body

Amol Sinha - Manager,

Technical Support, CSR,

Technology

[email protected]

Ashutosh Agarwal -

Manager, Mining Sales,

Technology

[email protected]

• The most mature stirred milling

technologies

• The largest installed base in terms of

quantity of units and installed power

• Continuous development program

Lime (slaking)

Lime Powder

Limestone

Magnesium Oxide

Magnetite Concentrate

Manganese Dioxide

Manganese Ore

Marble

Molybdenite

Molybdenum Concentrate

Oil Sludge

Petroleum Coke

Phosphate Rock

Pottery Stone

Pyrite

Red Phosphorous

Rock Salt

Sand Iron

Sericite

Silica

Silica Sand

Strontium Ferrite

Sulphur

Uranium

Zinc Concentrate

Zinc Lead Ore

Materials successfully ground in the Metso VERTIMILL® include the following:

Aluminum Oxide

Aragonite

Barite

Blast Furnace Slag

Calcined Bauxite

Calcite

Calcium Carbonate

Coal – Oil

Coal – water

Coal Tar Sludge

Coke – Oil

Copper Molybdenum

Copper Concentrate

Copper Ore

Copper Slag

Copper-Lead-Zinc Ore

Decanter Tar Sludge

Ferrite

Ferro Alloy

Ferro Manganese

Gold Ore

Gold Tailings

Graphite

Hydrated Alumina

Iron Oxide

Iron Sand

Kaoline

Lead Concentrate

Lead Zinc Ore

Typical Ball Mill Foundation

VTM 3000-WB installation at Newcrest Mining Ltd. Cadia Valley Operations

N E W A T M E T S O

T E C H T A L K T E C H T A L K

T E C H T A L K

Similar capacity VERTIMILL® can be

accommodated in this size of foundation

Your Savings Account

“We were running the Symons

crusher before and the results were

satisfactory. Based on our new

requirement, Metso suggested the

new HP4 crusher. HP4 provides

economical operations alongwith

ease of maintenance and

process improvement. Metso HP4

Cone Crusher has a thumbs up

from me!”

Says Mr. B.D.

Mohanty, Chief

(Processing &

Logistics) OMQ,

Tata Steel Ltd.,

Ball Size(mm)

Surface AreaM2/mton

Number of Balls/mton

Number of BallsNormalized

Table 1: Media Surface Area

157190

530516

4144132

19648758

66314560

Translational Velocity, m/sec

(12) (13)

(14) (15)

(16) (17)

(18) (19)

(20) (21)

screw removal

grind 38 – 5 mm

mill perimeter.

energy applied.

distribution.

(as low as 50%)

time and labor

common

delivered

- Chino mines: 35%

- Cadia: 35%

• Regrinding

- Red Dog: 40%

- Las Encinas: 35%

ensured

to install

5 days

Lower Maintenance

• Fewer parts

• Long wear life

application

Operations

Grinding Design

• F80 – 150 μm

• P80 – 90μm

account of

flotation circuit

months so far)

• A small profile

• Tight settings

costs.

stationary.

stone to the future

applications. Its

unique features for

highest reduction

ratios, maximum

maintenance

requirements

guarantees highest

and minimized

operating costs.

optimized speed and

large throw, HP4

diameter.

Specifications:

Power: 315kW

8mm – 45mm

Metso Vertimill®

Specifications:

Power: 450kW

Max feed: 330 mm

8 to 50mm

Crusher

tramp iron.

2. Less downtime

3. Easy to maintain

4. Versatility

till now.

manufacturing

5. Asset protection

backing material.

Overview

customer.

sub-categories:

1. Gravity induced

2. Fluidized

Gravity-induced

The Vertimill®

• Fine grinding

• Lime slaking

Torque Motor

Technology

[email protected]

Ashutosh Agarwal -

Technology

[email protected]

technologies

Lime (slaking)

Lime Powder

Limestone

Magnesium Oxide

Manganese Dioxide

Manganese Ore

Marble

Molybdenite

Oil Sludge

Petroleum Coke

Phosphate Rock

Pottery Stone

Pyrite

Red Phosphorous

Rock Salt

Sand Iron

Sericite

Silica

Silica Sand

Strontium Ferrite

Sulphur

Uranium

Zinc Concentrate

Zinc Lead Ore

Aluminum Oxide

Aragonite

Barite

Blast Furnace Slag

Calcined Bauxite

Calcite

Calcium Carbonate

Coal – Oil

Coal – water

Coal Tar Sludge

Coke – Oil

Copper Molybdenum

Copper Concentrate

Copper Ore

Copper Slag

Decanter Tar Sludge

Ferrite

Ferro Alloy

Ferro Manganese

Gold Ore

Gold Tailings

Graphite

Hydrated Alumina

Iron Oxide

Iron Sand

Kaoline

Lead Concentrate

Lead Zinc Ore

N E W A T M E T S O

T E C H T A L K

from me!”

Says Mr. B.D.

Mohanty, Chief

(Processing &

Logistics) OMQ,

Tata Steel Ltd.,

Ball Size(mm)

Surface AreaM2/mton

157190

530516

4144132

19648758

66314560

(12) (13)

(14) (15)

(16) (17)

(18) (19)

(20) (21)

screw removal

grind 38 – 5 mm

mill perimeter.

energy applied.

distribution.

(as low as 50%)

time and labor

common

delivered

- Chino mines: 35%

- Cadia: 35%

• Regrinding

- Red Dog: 40%

- Las Encinas: 35%

ensured

to install

5 days

Lower Maintenance

• Fewer parts

• Long wear life

application

Operations

Grinding Design

• F80 – 150 μm

• P80 – 90μm

account of

flotation circuit

months so far)

• A small profile

• Tight settings

costs.

stationary.

stone to the future

applications. Its

unique features for

highest reduction

ratios, maximum

maintenance

requirements

guarantees highest

and minimized

operating costs.

optimized speed and

large throw, HP4

diameter.

Specifications:

Power: 315kW

8mm – 45mm

Metso Vertimill®

Specifications:

Power: 450kW

Max feed: 330 mm

8 to 50mm

Crusher

tramp iron.

2. Less downtime

3. Easy to maintain

4. Versatility

till now.

manufacturing

5. Asset protection

backing material.

Overview

customer.

sub-categories:

1. Gravity induced

2. Fluidized

Gravity-induced

The Vertimill®

• Fine grinding

• Lime slaking

Torque Motor

Technology

[email protected]

Ashutosh Agarwal -

Technology

[email protected]

technologies

Lime (slaking)

Lime Powder

Limestone

Magnesium Oxide

Manganese Dioxide

Manganese Ore

Marble

Molybdenite

Oil Sludge

Petroleum Coke

Phosphate Rock

Pottery Stone

Pyrite

Red Phosphorous

Rock Salt

Sand Iron

Sericite

Silica

Silica Sand

Strontium Ferrite

Sulphur

Uranium

Zinc Concentrate

Zinc Lead Ore

Aluminum Oxide

Aragonite

Barite

Blast Furnace Slag

Calcined Bauxite

Calcite

Calcium Carbonate

Coal – Oil

Coal – water

Coal Tar Sludge

Coke – Oil

Copper Molybdenum

Copper Concentrate

Copper Ore

Copper Slag

Decanter Tar Sludge

Ferrite

Ferro Alloy

Ferro Manganese

Gold Ore

Gold Tailings

Graphite

Hydrated Alumina

Iron Oxide

Iron Sand

Kaoline

Lead Concentrate

Lead Zinc Ore

N E W A T M E T S O

T E C H T A L K

from me!”

Says Mr. B.D.

Mohanty, Chief

(Processing &

Logistics) OMQ,

Tata Steel Ltd.,

Ball Size(mm)

Surface AreaM2/mton

157190

530516

4144132

19648758

66314560

(12) (13)

(14) (15)

(16) (17)

(18) (19)

(20) (21)

screw removal

grind 38 – 5 mm

mill perimeter.

energy applied.

distribution.

(as low as 50%)

time and labor

common

delivered

- Chino mines: 35%

- Cadia: 35%

• Regrinding

- Red Dog: 40%

- Las Encinas: 35%

ensured

to install

5 days

Lower Maintenance

• Fewer parts

• Long wear life

application

Operations

Grinding Design

• F80 – 150 μm

• P80 – 90μm

account of

flotation circuit

months so far)

• A small profile

• Tight settings

costs.

stationary.

stone to the future

applications. Its

unique features for

highest reduction

ratios, maximum

maintenance

requirements

guarantees highest

and minimized

operating costs.

optimized speed and

large throw, HP4

diameter.

Specifications:

Power: 315kW

8mm – 45mm

Metso Vertimill®

Specifications:

Power: 450kW

Max feed: 330 mm

8 to 50mm

Crusher

tramp iron.

2. Less downtime

3. Easy to maintain

4. Versatility

till now.

manufacturing

5. Asset protection

backing material.

Overview

customer.

sub-categories:

1. Gravity induced

2. Fluidized

Gravity-induced

The Vertimill®

• Fine grinding

• Lime slaking

Torque Motor

Technology

[email protected]

Ashutosh Agarwal -

Technology

[email protected]

technologies

Lime (slaking)

Lime Powder

Limestone

Magnesium Oxide

Manganese Dioxide

Manganese Ore

Marble

Molybdenite

Oil Sludge

Petroleum Coke

Phosphate Rock

Pottery Stone

Pyrite

Red Phosphorous

Rock Salt

Sand Iron

Sericite

Silica

Silica Sand

Strontium Ferrite

Sulphur

Uranium

Zinc Concentrate

Zinc Lead Ore

Aluminum Oxide

Aragonite

Barite

Blast Furnace Slag

Calcined Bauxite

Calcite

Calcium Carbonate

Coal – Oil

Coal – water

Coal Tar Sludge

Coke – Oil

Copper Molybdenum

Copper Concentrate

Copper Ore

Copper Slag

Decanter Tar Sludge

Ferrite

Ferro Alloy

Ferro Manganese

Gold Ore

Gold Tailings

Graphite

Hydrated Alumina

Iron Oxide

Iron Sand

Kaoline

Lead Concentrate

Lead Zinc Ore

N E W A T M E T S O

T E C H T A L K

from me!”

Says Mr. B.D.

Mohanty, Chief

(Processing &

Logistics) OMQ,

Tata Steel Ltd.,

Ball Size(mm)

Surface AreaM2/mton

157190

530516

4144132

19648758

66314560

(12) (13)

(14) (15)

(16) (17)

(18) (19)

(20) (21)

screw removal

grind 38 – 5 mm

mill perimeter.

energy applied.

distribution.

(as low as 50%)

time and labor

common

delivered

- Chino mines: 35%

- Cadia: 35%

• Regrinding

- Red Dog: 40%

- Las Encinas: 35%

ensured

to install

5 days

Lower Maintenance

• Fewer parts

• Long wear life

application

Operations

Grinding Design

• F80 – 150 μm

• P80 – 90μm

account of

flotation circuit

months so far)

• A small profile

• Tight settings

costs.

stationary.

stone to the future

applications. Its

unique features for

highest reduction

ratios, maximum

maintenance

requirements

guarantees highest

and minimized

operating costs.

optimized speed and

large throw, HP4

diameter.

Specifications:

Power: 315kW

8mm – 45mm

Metso Vertimill®

Specifications:

Power: 450kW

Max feed: 330 mm

8 to 50mm

Crusher

tramp iron.

2. Less downtime

3. Easy to maintain

4. Versatility

till now.

manufacturing

5. Asset protection

backing material.

Overview

customer.

sub-categories:

1. Gravity induced

2. Fluidized

Gravity-induced

The Vertimill®

• Fine grinding

• Lime slaking

Torque Motor

Technology

[email protected]

Ashutosh Agarwal -

Technology

[email protected]

technologies

Lime (slaking)

Lime Powder

Limestone

Magnesium Oxide

Manganese Dioxide

Manganese Ore

Marble

Molybdenite

Oil Sludge

Petroleum Coke

Phosphate Rock

Pottery Stone

Pyrite

Red Phosphorous

Rock Salt

Sand Iron

Sericite

Silica

Silica Sand

Strontium Ferrite

Sulphur

Uranium

Zinc Concentrate

Zinc Lead Ore

Aluminum Oxide

Aragonite

Barite

Blast Furnace Slag

Calcined Bauxite

Calcite

Calcium Carbonate

Coal – Oil

Coal – water

Coal Tar Sludge

Coke – Oil

Copper Molybdenum

Copper Concentrate

Copper Ore

Copper Slag

Decanter Tar Sludge

Ferrite

Ferro Alloy

Ferro Manganese

Gold Ore

Gold Tailings

Graphite

Hydrated Alumina

Iron Oxide

Iron Sand

Kaoline

Lead Concentrate

Lead Zinc Ore

N E W A T M E T S O

T E C H T A L K

from me!”

Says Mr. B.D.

Mohanty, Chief

(Processing &

Logistics) OMQ,

Tata Steel Ltd.,

Ball Size(mm)

Surface AreaM2/mton

157190

530516

4144132

19648758

66314560

(12) (13)

(14) (15)

(16) (17)

(18) (19)

(20) (21)

screw removal

grind 38 – 5 mm

mill perimeter.

energy applied.

distribution.

(as low as 50%)

time and labor

common

delivered

- Chino mines: 35%

- Cadia: 35%

• Regrinding

- Red Dog: 40%

- Las Encinas: 35%

ensured

to install

5 days

Lower Maintenance

• Fewer parts

• Long wear life

application

Operations

Grinding Design

• F80 – 150 μm

• P80 – 90μm

account of

flotation circuit

months so far)

• A small profile

• Tight settings

costs.

stationary.

stone to the future

applications. Its

unique features for

highest reduction

ratios, maximum

maintenance

requirements

guarantees highest

and minimized

operating costs.

optimized speed and

large throw, HP4

diameter.

Specifications:

Power: 315kW

8mm – 45mm

Metso Vertimill®

Specifications:

Power: 450kW

Max feed: 330 mm

8 to 50mm

Crusher

tramp iron.

2. Less downtime

3. Easy to maintain

4. Versatility

till now.

manufacturing

5. Asset protection

backing material.

Overview

customer.

sub-categories:

1. Gravity induced

2. Fluidized

Gravity-induced

The Vertimill®

• Fine grinding

• Lime slaking

Torque Motor

Technology

[email protected]

Ashutosh Agarwal -

Technology

[email protected]

technologies

Lime (slaking)

Lime Powder

Limestone

Magnesium Oxide

Manganese Dioxide

Manganese Ore

Marble

Molybdenite

Oil Sludge

Petroleum Coke

Phosphate Rock

Pottery Stone

Pyrite

Red Phosphorous

Rock Salt

Sand Iron

Sericite

Silica

Silica Sand

Strontium Ferrite

Sulphur

Uranium

Zinc Concentrate

Zinc Lead Ore

Aluminum Oxide

Aragonite

Barite

Blast Furnace Slag

Calcined Bauxite

Calcite

Calcium Carbonate

Coal – Oil

Coal – water

Coal Tar Sludge

Coke – Oil

Copper Molybdenum

Copper Concentrate

Copper Ore

Copper Slag

Decanter Tar Sludge

Ferrite

Ferro Alloy

Ferro Manganese

Gold Ore

Gold Tailings

Graphite

Hydrated Alumina

Iron Oxide

Iron Sand

Kaoline

Lead Concentrate

Lead Zinc Ore

N E W A T M E T S O

T E C H T A L K

from me!”

Says Mr. B.D.

Mohanty, Chief

(Processing &

Logistics) OMQ,

Tata Steel Ltd.,

Ball Size(mm)

Surface AreaM2/mton

157190

530516

4144132

19648758

66314560

(12) (13)

(14) (15)

(16) (17)

(18) (19)

(20) (21)

screw removal

grind 38 – 5 mm

mill perimeter.

energy applied.

distribution.

(as low as 50%)

time and labor

common

delivered

- Chino mines: 35%

- Cadia: 35%

• Regrinding

- Red Dog: 40%

- Las Encinas: 35%

ensured

to install

5 days

Lower Maintenance

• Fewer parts

• Long wear life

application

Operations

Grinding Design

• F80 – 150 μm

• P80 – 90μm

account of

flotation circuit

months so far)

• A small profile

• Tight settings

costs.

stationary.

stone to the future

applications. Its

unique features for

highest reduction

ratios, maximum

maintenance

requirements

guarantees highest

and minimized

operating costs.

optimized speed and

large throw, HP4

diameter.

Specifications:

Power: 315kW

8mm – 45mm

Metso Vertimill®

Specifications:

Power: 450kW

Max feed: 330 mm

8 to 50mm

Crusher

tramp iron.

2. Less downtime

3. Easy to maintain

4. Versatility

till now.

manufacturing

5. Asset protection

backing material.

Overview

customer.

sub-categories:

1. Gravity induced

2. Fluidized

Gravity-induced

The Vertimill®

• Fine grinding

• Lime slaking

Torque Motor

Technology

[email protected]

Ashutosh Agarwal -

Technology

[email protected]

technologies

Lime (slaking)

Lime Powder

Limestone

Magnesium Oxide

Manganese Dioxide

Manganese Ore

Marble

Molybdenite

Oil Sludge

Petroleum Coke

Phosphate Rock

Pottery Stone

Pyrite

Red Phosphorous

Rock Salt

Sand Iron

Sericite

Silica

Silica Sand

Strontium Ferrite

Sulphur

Uranium

Zinc Concentrate

Zinc Lead Ore

Aluminum Oxide

Aragonite

Barite

Blast Furnace Slag

Calcined Bauxite

Calcite

Calcium Carbonate

Coal – Oil

Coal – water

Coal Tar Sludge

Coke – Oil

Copper Molybdenum

Copper Concentrate

Copper Ore

Copper Slag

Decanter Tar Sludge

Ferrite

Ferro Alloy

Ferro Manganese

Gold Ore

Gold Tailings

Graphite

Hydrated Alumina

Iron Oxide

Iron Sand

Kaoline

Lead Concentrate

Lead Zinc Ore

N E W A T M E T S O

T E C H T A L K

from me!”

Says Mr. B.D.

Mohanty, Chief

(Processing &

Logistics) OMQ,

Tata Steel Ltd.,

Ball Size(mm)

Surface AreaM2/mton

157190

530516

4144132

19648758

66314560

(12) (13)

(14) (15)

(16) (17)

(18) (19)

(20) (21)

screw removal

grind 38 – 5 mm

mill perimeter.

energy applied.

distribution.

(as low as 50%)

time and labor

common

delivered

- Chino mines: 35%

- Cadia: 35%

• Regrinding

- Red Dog: 40%

- Las Encinas: 35%

ensured

to install

5 days

Lower Maintenance

• Fewer parts

• Long wear life

application

Operations

Grinding Design

• F80 – 150 μm

• P80 – 90μm

account of

flotation circuit

months so far)

• A small profile

• Tight settings

costs.

stationary.

stone to the future

applications. Its

unique features for

highest reduction

ratios, maximum

maintenance

requirements

guarantees highest

and minimized

operating costs.

optimized speed and

large throw, HP4

diameter.

Specifications:

Power: 315kW

8mm – 45mm

Metso Vertimill®

Specifications:

Power: 450kW

Max feed: 330 mm

8 to 50mm

Crusher

tramp iron.

2. Less downtime

3. Easy to maintain

4. Versatility

till now.

manufacturing

5. Asset protection

backing material.

Overview

customer.

sub-categories:

1. Gravity induced

2. Fluidized

Gravity-induced

The Vertimill®

• Fine grinding

• Lime slaking

Torque Motor

Technology

[email protected]

Ashutosh Agarwal -

Technology

[email protected]

technologies

Lime (slaking)

Lime Powder

Limestone

Magnesium Oxide

Manganese Dioxide

Manganese Ore

Marble

Molybdenite

Oil Sludge

Petroleum Coke

Phosphate Rock

Pottery Stone

Pyrite

Red Phosphorous

Rock Salt

Sand Iron

Sericite

Silica

Silica Sand

Strontium Ferrite

Sulphur

Uranium

Zinc Concentrate

Zinc Lead Ore

Aluminum Oxide

Aragonite

Barite

Blast Furnace Slag

Calcined Bauxite

Calcite

Calcium Carbonate

Coal – Oil

Coal – water

Coal Tar Sludge

Coke – Oil

Copper Molybdenum

Copper Concentrate

Copper Ore

Copper Slag

Decanter Tar Sludge

Ferrite

Ferro Alloy

Ferro Manganese

Gold Ore

Gold Tailings

Graphite

Hydrated Alumina

Iron Oxide

Iron Sand

Kaoline

Lead Concentrate

Lead Zinc Ore

N E W A T M E T S O

T E C H T A L K

from me!”

Says Mr. B.D.

Mohanty, Chief

(Processing &

Logistics) OMQ,

Tata Steel Ltd.,

Ball Size(mm)

Surface AreaM2/mton

157190

530516

4144132

19648758

66314560

(12) (13)

(14) (15)

(16) (17)

(18) (19)

(20) (21)

screw removal

grind 38 – 5 mm

mill perimeter.

energy applied.

distribution.

(as low as 50%)

time and labor

common

delivered

- Chino mines: 35%

- Cadia: 35%

• Regrinding

- Red Dog: 40%

- Las Encinas: 35%

ensured

to install

5 days

Lower Maintenance

• Fewer parts

• Long wear life

application

Operations

Grinding Design

• F80 – 150 μm

• P80 – 90μm

account of

flotation circuit

months so far)

• A small profile

• Tight settings

costs.

stationary.

stone to the future

applications. Its

unique features for

highest reduction

ratios, maximum

maintenance

requirements

guarantees highest

and minimized

operating costs.

optimized speed and

large throw, HP4

diameter.

Specifications:

Power: 315kW

8mm – 45mm

Metso Vertimill®

Specifications:

Power: 450kW

Max feed: 330 mm

8 to 50mm

Crusher

tramp iron.

2. Less downtime

3. Easy to maintain

4. Versatility

till now.

manufacturing

5. Asset protection

backing material.

Overview

customer.

sub-categories:

1. Gravity induced

2. Fluidized

Gravity-induced

The Vertimill®

• Fine grinding

• Lime slaking

Torque Motor

Technology

[email protected]

Ashutosh Agarwal -

Technology

[email protected]

technologies

Lime (slaking)

Lime Powder

Limestone

Magnesium Oxide

Manganese Dioxide

Manganese Ore

Marble

Molybdenite

Oil Sludge

Petroleum Coke

Phosphate Rock

Pottery Stone

Pyrite

Red Phosphorous

Rock Salt

Sand Iron

Sericite

Silica

Silica Sand

Strontium Ferrite

Sulphur

Uranium

Zinc Concentrate

Zinc Lead Ore

Aluminum Oxide

Aragonite

Barite

Blast Furnace Slag

Calcined Bauxite

Calcite

Calcium Carbonate

Coal – Oil

Coal – water

Coal Tar Sludge

Coke – Oil

Copper Molybdenum

Copper Concentrate

Copper Ore

Copper Slag

Decanter Tar Sludge

Ferrite

Ferro Alloy

Ferro Manganese

Gold Ore

Gold Tailings

Graphite

Hydrated Alumina

Iron Oxide

Iron Sand

Kaoline

Lead Concentrate

Lead Zinc Ore

N E W A T M E T S O

T E C H T A L K

from me!”

Says Mr. B.D.

Mohanty, Chief

(Processing &

Logistics) OMQ,

Tata Steel Ltd.,

Ball Size(mm)

Surface AreaM2/mton

157190

530516

4144132

19648758

66314560

(12) (13)

(14) (15)

(16) (17)

(18) (19)

(20) (21)

screw removal

grind 38 – 5 mm

mill perimeter.

energy applied.

distribution.

(as low as 50%)

time and labor

common

delivered

- Chino mines: 35%

- Cadia: 35%

• Regrinding

- Red Dog: 40%

- Las Encinas: 35%

ensured

to install

5 days

Lower Maintenance

• Fewer parts

• Long wear life

application

Operations

Grinding Design

• F80 – 150 μm

• P80 – 90μm

account of

flotation circuit

months so far)

• A small profile

• Tight settings

costs.

stationary.

stone to the future

applications. Its

unique features for

highest reduction

ratios, maximum

maintenance

requirements

guarantees highest

and minimized

operating costs.

optimized speed and

large throw, HP4

diameter.

Specifications:

Power: 315kW

8mm – 45mm

Metso Vertimill®

Specifications:

Power: 450kW

Max feed: 330 mm

8 to 50mm

Crusher

tramp iron.

2. Less downtime

3. Easy to maintain

4. Versatility

till now.

manufacturing

5. Asset protection

backing material.

Overview

customer.

sub-categories:

1. Gravity induced

2. Fluidized

Gravity-induced

The Vertimill®

• Fine grinding

• Lime slaking

Torque Motor

Technology

[email protected]

Ashutosh Agarwal -

Technology

[email protected]

technologies

Lime (slaking)

Lime Powder

Limestone

Magnesium Oxide

Manganese Dioxide

Manganese Ore

Marble

Molybdenite

Oil Sludge

Petroleum Coke

Phosphate Rock

Pottery Stone

Pyrite

Red Phosphorous

Rock Salt

Sand Iron

Sericite

Silica

Silica Sand

Strontium Ferrite

Sulphur

Uranium

Zinc Concentrate

Zinc Lead Ore

Aluminum Oxide

Aragonite

Barite

Blast Furnace Slag

Calcined Bauxite

Calcite

Calcium Carbonate

Coal – Oil

Coal – water

Coal Tar Sludge

Coke – Oil

Copper Molybdenum

Copper Concentrate

Copper Ore

Copper Slag

Decanter Tar Sludge

Ferrite

Ferro Alloy

Ferro Manganese

Gold Ore

Gold Tailings

Graphite

Hydrated Alumina

Iron Oxide

Iron Sand

Kaoline

Lead Concentrate

Lead Zinc Ore

N E W A T M E T S O

T E C H T A L K

from me!”

Says Mr. B.D.

Mohanty, Chief

(Processing &

Logistics) OMQ,

Tata Steel Ltd.,

Ball Size(mm)

Surface AreaM2/mton

157190

530516

4144132

19648758

66314560

(12) (13)

(14) (15)

(16) (17)

(18) (19)

(20) (21)

The project group during the contract

signing: front, from right, Karl-Axel

Waplan from Northland Resources and

Andy Benko from Metso. Behind, from

right, Taina Tirkkonen, Alf Rydberg, Peter

Pernlöf, Shane Williams, Johan Karlström

and Erik Degerstedt.

MCT and the Swedish based mining

company Northland Resources AB signed

in February a contract that marks the

starting point of one of Metso’s most

significant mining contracts so far. The

delivery consists of minerals processing

equipment and basic engineering for the

two process lines at Northland’s new

Kaunisvaara iron ore project in Sweden.

Managing this project, which is expected

to last more than four years, requires a

strong project team and cooperation

between five Metso units worldwide.

At the new iron ore project, the Tapuli

and Sahavaara iron ore deposits will be

exploited targeting an annual production

of 12 million tons of dry iron ore. Our

delivery will include for each line a

primary gyratory crusher, an autogenous

grinding mill, three vertical grinding mills

for Tapuli and four for Sahavaara, mining

screens, and all works related to the

process plant system for the Kaunisvaara

project.

Time-wise, the project sales team leader,

Alf Rydberg, Commercial Manager, MCT,

is busy with the challenging job of

finalizing all outstanding issues in relation

to the contracts. Time runs, and the first

machinery deliveries are scheduled for

the second quarter of 2012 and will

continue until mid-2014.

Kaunisvaara is located in Northern

Sweden, approximately 100 km north of

the Arctic Circle. The location presents

another challenge due to the arctic

climate conditions.

Three vertical grinding mills – Vertimills®

– are included in the first Northland

Resources long lead Item contract, to be

followed by another four at a later date.

“We have process experience and a

good product match”

Alf believes Metso’s extensive iron ore

processing expertise and good product

match are the main reasons it was

selected as the main supplier for the

project.

“Metso was able to present Northland

with a good deal of working references in

the region. Our communication with the

customer and their consultants has been

good. In addition, we have good service

capacity in the region with well-educated

and skilled personnel.”

According to Alf, a good and complete

equipment package could be offered,

with more than 70% of the requested

equipment being Metso-owned

proprietary.

“We have a clear technical advantage

with our Vertimills® . In addition, the

customer’s concentrate filter specification

matched well with Metso’s VPA filters. We

also had the capacity to meet the

requested delivery times for long lead

items, and could offer a plant perfor-

mance guarantee.”

Five MCT units involved

Metso Minerals Sweden and the Major

projects group headed by Dan Malmgren

are responsible for the Northland

Resources project execution and are

currently setting up a team of experi-

enced and dedicated people to handle

the project. The project organization is

based on previous experience working

on similar projects.

One of Metso’s most significant mining

contracts was signed by Karl-Axel Waplan

(right) from Northland Resources and

Andy Benko from Metso.

In addition to the above, other Metso

units involved in the supply are Sala (VPA

filters, magnetic separators, flotation cells

slurry pumps and classifiers), York

(AG/SAG mills and VTM’s), Waukesha

(primary crushers) and SSO Germany

(screens). SSO Sweden is responsible for

aftermarket and services.

SSO Sweden will be responsible for

aftermarket and LCS services, an area

where we have the opportunity to enter

into agreements, offering advanced

service to Northland.

Metso has been involved in the project

for three years now and one example of

our capacity in Major projects is that

Metso Minerals in Sala did the scooping

study for the project.

Key issues for successful completion

Alf lists the key issues for successful

completion of the project as follows:

“We have to meet the high demands of

the experienced mining crew that

Northland Resources has among their

staff, maintain the right level of commu-

nication, and optimize design to match

process and to meet the time schedule.”

The equipment for the Tapuli process line

will be delivered between May and

September 2012, targeting a production

start-up in early 2013. The Sahavaara line

follows with completion scheduled for

May 2014, and with full production in the

latter part of 2014.

N E W S I N B R I E F

A global project team secures the

prompt delivery of a significant

mining contract to Sweden

Quick decisions for faster results

Mc Nally Wellman Vibrating Screen type

Centrifuge model A150 was supplied to

Aryan Coal for the Sasti Plant in the year

2003. It was brought for refurbishment in

the year 2010 after running for long.

Although this was our mining equipment

for repair, Our services team took up on

themselves the challenge to repair the

Vibrating screen locally at our repairs

facility in Faridabad, near Delhi. The

project being the first ever mining repair

that was been handled by the team,

brought excitement and nervousness at

the same time. The parts for repair were

procured from Bawal and then moved to

the ARF facility at Faridabad for assembly.

The centrifuge repaired will be used at

Himgiri for an upcoming Aryan Coal

Washery project.

Experts at work

The centrifuge to be repaired was

supplied to Aryan in 2003. The equip-

ment was used in full swing from 2003 to

2007. After almost 5 years of usage, the

need for refurbishment arose.

The team, lead by Anand Sinha, Services

sales Manager Metso, undertook the task

to repair the centrifuge locally, aiming to

considerably save on customer’s time and

bringing cost efficiencies to the entire

process.

Says Anand Sinha , “It was a challenge to

accept the order for the refurbishment as

the machine was not in working

condition since 2007. All machine parts –

such as pulleys, basket, shaft threads and

body had rusted, centrifuge was choked

and conked out fully. I was confident of

our technical teams ability to pull it off –

one of the most important factor for me

to accept the order for repair.”

The machine was completely out of

order, and massive refurbishments had to

be undertaken. It was quite a task to

dismantle the basket as all the locknuts

and threads of the shaft were rusted.

Repair and beyond

“The scope of work was comprehensive.

With our extensive experience in product

maintenance and refurbishment, we

decided to perform this task locally.

Centrifuge basket, basket shaft, pulleys, V

belt, seals, hydraulic fittings, lubrication

system etc. were replaced, for us, it was

almost like making a new machine”, adds

Anand Sinha.

Metso’s technical team at Metso factory,

Bawal and ARF facility worked closely on

this project. The parts were procured at

Bawal (Haryana, India) factory and

assembly was done at the ARF facility at

Faridabad (Haryana, India). The procure-

ment of new parts was equally critical as

it had to be done through local vendors.

Post the overhauling; a final test run was

conducted under the supervision of

Metso services team at ARF facility at

Faridabad. The repaired centrifuge was

inspected by Aryan Coal at our

warehouse with 100% satisfaction.

” Like any refurbishment project,

unexpected delays did creep in but with

a dedicated team, a positive attitude and

a lot of hard work, we achieved this

milestone. This is the first mining

equipment ever repaired locally and was

our first step into a world of opportunities

for Metso India”, says Anand Sinha.

The major parts replaced were:

• Centrifuge basket

• Basket Shaft

• Pulleys

• V Belt

• Seals

• Hydraulic fitting

• Lubrication system to name a few

A revolutionary product

Typical applications include the drying of

coal fines, refuge fines, coal slurry and

middling.

If you are drying coal fines, or any

number of other coal, mineral and mine

products and want a sturdy performer in

your drying circuits, a Mc Nally Wellman

Re-engineering repairs

In its journey to become a Lifecycle services provider, Metso is adding new

benchmarks in services each day. Handling complete repairs and refurbish-

ments of a McNally Wellman centrifuge at Metso India warehouse in

Faridabad speaks volume about our service capabilities. A “first” for Metso

India, this has certainly opened the way for many more repairs that can be

handled locally.

Pioneering dry classification

Production of high quality manufactured

sand requires specialist knowledge in fine

crushing and separation technology to

achieve a quality end product. Metso’s Air

Classifier Technology lends itself perfectly

to dry classification solutions to produce

top quality manufactured sand. The Air

Classifier range provides versatile,

economic technology that can be

combined with a range of different

crushing and screening equipment to

produce a tailored plant. It allows for the

production of dry products so there are

no dewatering or drying costs. Process

water is not required, which significantly

reduces the quarries’ water demand and

therefore eliminates the need for settling

ponds. This dry process makes even arid

regions viable whilst still producing top

quality manufactured sand.

Metso offers producers two classifier

options. The Gravitational Inertial (GI)

Classifier is typically fed 0/4mm or less

and makes separations between 300

microns (50#) and 63 microns (230#).

These units are ideal for use in the

manufacturing of sands for concrete and

asphalt that typically require a reduction

in the amount of 150 microns (100#)

present. This unit is designed with an

internal recirculating function that allows

the efficiency of the separation to be

adjusted dependant on the desired

grading curve. When finer separations are

required, the Centrifugal (C) Classifier can

make separations of between 100

This makes these units suitable for the

production of very fine products such as

fly ash, lime and industrial minerals.

Global experts unveil AC Series

Classifiers

A two day Conclave was organized on

10-11 March, 2011, in Mumbai, Western

India. The first day of product launch was

followed with a site visit to the Larsen &

Tubro aggregate production site at Uran,

near Mumbai. Larsen & Tubro is using a

Metso GI Air Classifier for the production

of high grade concrete sand.

Customers exchanged healthy dialogue

with the experts. David Morrow, Global

Business Development for Metso Air

Classifiers was the lead presenter. He was

supported by Niraj Srivastava, GM,

Crushing and Screening Applications for

Metso India. He presented new

developments in portable and modular

plants from Metso.

Added Mukunda Venkatesh, Vice

President-Construction Sales, Metso

India, ”Initial responses to this technology

is positive and encouraging for us.

Metso’s Air Classifier Technology provides

versatile, economic technology that can

be combined with a range of different

crushing and screening equipment.

Process water is not required, which

significantly reduces the quarries water

demands and settling pond

requirements.”

“Seeing the Air Classifier live in action

gave us a better perspective of what they

can do for our operations. We could

inspect the quality of the manufactured

sand and could see the proof in the

product”, said one of our customers from

Kerala.

Creating sand successMetso launches AC Series Air Classifiers

in IndiaOver the last few years, the demand for high quality sand in India has grown

exponentially. Classification is an integral part of manufacturing high strength

concrete sand. Dry sand classification is increasingly gaining prominence in this

roll. Specifications vary from region to region and successful implementation of

manufactured sand differs from operator to operator. Metso recently unveiled its

dry sand classification technology in Mumbai to over 50 customers

from across the country.

More info:

Federico Bata

Tel. +39 335 1093511

[email protected]

“Metso is a preferred partner for

Fassa”

Fassa placed an order with Metso for the

new primary plant in 2008, and the

crushing started in July 2010. The primary

section includes, in addition to the

primary jaw crusher, a push feeder,

primary scalper, the related conveyors,

and a large silo to load the crushed

limestone onto the trucks. Metso Italy

also took care of the overall process

planning.

“It wasn’t just the proven machines, but

also the low unit maintenance costs and

excellent process knowledge that were

the main reasons behind our choice of

Metso. Today we can say with confidence

that Metso is our preferred partner,” says

Alberto Marzano, Quarry Manager

responsible for the Monte Budellone and

Paitone operations.

“I believe that Metso has the best

expertise in crushing and screening in

the world. After Monte Budellone, we are

cooperating on two process modification

projects in our other quarries. One of

Metso’s strengths is the ability to

intervene also in competitors’ systems, to

make changes that better suit our

process,” adds Alberto Dutto, Director

responsible for Fassa’s 10 quarries in Italy.

Environmental issues crucial

In Italy, as in most countries, being

granted licenses to start or expand any

quarrying activities is always a challenge.

“For our Monte Budellone project, it took

six years to get an operational license

from the officials. In our case, locating the

primary section underground was

therefore the only possibility,” Marzano

stresses.

“We had planned with Metso an

800-meter-long conveyor to connect the

new primary section to the existing

Paitone secondary plant. Because one of

the three communities owning the land

rejected our plan, we have to use trucks,”

says Alberto Dutto.

Today, Fassa has permission to exploit

3,7million cubic meters at the Monte

Budellone quarry. The company’s plan is

to extract the valuable limestone down

level by level so that during the 2020s,

the mountain face will be lowered to the

same level as the primary plant.

Fact file

Fassa Monte Budellone quarry

Situated: in Gavardo, near Garda Lake,

Feed material: exclusive limestone to

produce lime and plast

Glory hole mine shaft: diameter 3.68 m,

length 85 m, angle 70

Crushing gallery size: 13 m high, 9 meter

wide, 45 meter long

Discharge tunnel 6 m high, 5 m wide, 100

m long

Metso equipment on site

1 Nordberg HRBM6015 push feeder

1 Nordberg VG6453 primary scalper

1 Nordberg C140 jaw crusher

Feed material size 0–800 mm

Closed side setting 200–250 mm

Average capacity: 500 mtph

136 meters of conveyors

Discharge silo of 480 m³

Over 300 years of quarrying activity

Fassa S.p.A. is arguably one of world’s

oldest quarrying companies, having

started operations over 300 years ago in

1710. Headed today by Mr Paolo Fassa,

the company employs 900 people and is

clearly the domestic market leader, with

activities also in Portugal, Switzerland,

France and Croatia.

Today, two Fassa quarries feed the

Paitone secondary plant. The company

believes demand for lime products will

grow in the near future. For that reason,

Fassa’s lime factory capacity in Brescia has

recently been doubled.

The Garda Lake area is classified as

“medium” in terms of seismic activity,

placing special requirements on all

project planning. The last earthquake in

the area was observed in 2004.

Picture caption: Over_300_years: Aerial

view of the Paitone secondary plant,

situated close to Lake Garda.

Fassa makes sustainable

quarrying a realityOperating a full-scale quarry in the middle of Italy’s famous tourist area along Lake

Garda seems like mission impossible. Fassa, the leading Italian producer of lime and

plaster, has made sustainable quarrying a reality. With the help of Metso, the

company’s entire new primary stage has been excavated underground.

As a result, Fassa’s Monte Budellone quarry is highly eco-efficient and totally dust and

noise-free to the environment. The noise caused by the primary crushing is kept in

the excavated underground gallery and dust is efficiently filtered from the outgoing

air. The feeding of the primary plant is also quite extraordinary. The excavated

limestone feed is dropped to the jaw via an 85-meter-long glory hole mine shaft.

Metso’s push feeder ensures steady feeding of the jaw crusher.

Vibrating Screen type Centrifuge is the

best solution.

Bringing your process closer to

perfection

In these centrifuges, the material to be

dewatered passes down an inlet chute.

Feed material is then distributed onto the

inner surface of the screen basket.

The rotating screen basket is kept in axial

vibratory motion by a vibratory unit.

These axial vibrations move the material

towards the large diameter of the basket.

In addition, vibrating action keeps the

basket opening clean. Meanwhile the

feed material is continuously loosened

up, which improves dewatering even in a

high through-put of the solids. The

dewatered material which is thrown out

at the diameter end of the basket then

falls freely downward while the water,

which is centrifuged out is ejected at the

"Metso undertook to deliver on the

repair and refurbishment of centrifuge

locally at their facility has brought

significant economies to us - both in

N E W S I N B R I E F P R O D U C T S & S O L U T I O N S

P R O D U C T S & S O L U T I O N S G L O B E T R O T T I N G

RefurbishedCentrifuge at

Metso warehousein Faridabad

Representatives of Aryan Coal Ltd. with Metso experts

at the Metso ARF facility in Faridabad

Anand Sinha - Manager,

Services Sales, Metso India

[email protected]

Says Mr. Ramesh Khanna, Vice PresidentAryan Coal, "Metso undertook to deliver on the repair and refurbishment of centrifuge locally at their facility that has brought significant economies to us - both in terms of time and cost. Repair was although delayed from its stipulated schedule was completed , with constant monitoring of Metso experts and were updated on a continual basis. The capability to handle such repairs and refurbishments locally is a step up in Metso's journey to become a life cycle services provider and is an advantage to the customers as this adds value proposition for them too"..

Metso India’s first ever Centrifuge repair

project.

climate conditions.

project.

proprietary.

mance guarantee.”

Washery project.

Experts at work

process.

Repair and beyond

Anand Sinha.

• Basket Shaft

• Pulleys

• V Belt

• Seals

middling.

handled locally.

Classifiers

plants from Metso.

requirements.”

Kerala.

More info:

Federico Bata

Tel. +39 335 1093511

[email protected]

Fassa”

planning.

Paitone operations.

stresses.

says Alberto Dutto.

Fact file

wide, 45 meter long

m long

France and Croatia.

best solution.

perfection

[email protected]

project.

climate conditions.

project.

proprietary.

mance guarantee.”

Washery project.

Experts at work

process.

Repair and beyond

Anand Sinha.

• Basket Shaft

• Pulleys

• V Belt

• Seals

middling.

handled locally.

Classifiers

plants from Metso.

requirements.”

Kerala.

More info:

Federico Bata

Tel. +39 335 1093511

[email protected]

Fassa”

planning.

Paitone operations.

stresses.

says Alberto Dutto.

Fact file

wide, 45 meter long

m long

France and Croatia.

best solution.

perfection

[email protected]

project.

climate conditions.

project.

proprietary.

mance guarantee.”

Washery project.

Experts at work

process.

Repair and beyond

Anand Sinha.

• Basket Shaft

• Pulleys

• V Belt

• Seals

middling.

handled locally.

Classifiers

plants from Metso.

requirements.”

Kerala.

More info:

Federico Bata

Tel. +39 335 1093511

[email protected]

Fassa”

planning.

Paitone operations.

stresses.

says Alberto Dutto.

Fact file

wide, 45 meter long

m long

France and Croatia.

best solution.

perfection

[email protected]

project.

climate conditions.

project.

proprietary.

mance guarantee.”

Washery project.

Experts at work

process.

Repair and beyond

Anand Sinha.

• Basket Shaft

• Pulleys

• V Belt

• Seals

middling.

handled locally.

Classifiers

plants from Metso.

requirements.”

Kerala.

More info:

Federico Bata

Tel. +39 335 1093511

[email protected]

Fassa”

planning.

Paitone operations.

stresses.

says Alberto Dutto.

Fact file

wide, 45 meter long

m long

France and Croatia.

best solution.

perfection

[email protected]

project.

climate conditions.

project.

proprietary.

mance guarantee.”

Washery project.

Experts at work

process.

Repair and beyond

Anand Sinha.

• Basket Shaft

• Pulleys

• V Belt

• Seals

middling.

handled locally.

Classifiers

plants from Metso.

requirements.”

Kerala.

More info:

Federico Bata

Tel. +39 335 1093511

[email protected]

Fassa”

planning.

Paitone operations.

stresses.

says Alberto Dutto.

Fact file

wide, 45 meter long

m long

France and Croatia.

best solution.

perfection

[email protected]

resultsminerals & aggregates

METSO INDIA CUSTOMER MAGAZINE FOR THE MINING AND CONSTRUCTION INDUSTRIES Vol. 16 2 2011

Pouring resultsMetso India foundry adjudgedone of the best in global quality standards 42716666

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