SCADA application views and electrical cabinetsfor crushing and screening lines

r

0~ :v

~'4• ' .

~~~~

Com tete o timisationP pPaul Moore visited the operations of Metso France inMacon Worth of Lyon, to find out about the company'sfocus on crusher systems and automation, with the recentcommissioning of a project at Ferrexpo Poltava in Ukraineas a case study

etso France SAS is located in Macon,

M and is the ancestor of the historie

companyAteliers Bergeaud Mâcon

(ABM), whose presence in the quarrying and

mining sector started just alter WWi. The

Company became quite well known in France,

and saw a boom post-1945 W~th the leve! of

construction and rebuilding in the country. A key

date was 1954 With the purchase of a licence for

Symons crushers. The Bergeaud family-owned

business was sold first to Nordberg in the USA,

then Finnish Company Rauma Repola acquired

Nordberg's European assets in 1986 which

included Nordberg in France and the UK.

The real business consolidation of what was

Bergeaud and Nordberg occurred in the 199os.

Nordberg in France was Nordberg Bergeaud and

in Tampere was known as Nordberg Lokomo,

alter its original business of manufacturing

locomotives; with the narre still preserved in

the mobile crushing and screening line of Metso

Lokotrak. The Bergeaud and Lokomo narres

were then dropped so that everything became

Nordberg and in i999~ Rauma Repola and

Valmet merged to become Metso.

The real growth of what we see today started

in zoos with the acquisition by Metso of

Svedala. It was a listed group in Sweden, but

there was some overlap of crushing activites,

and certain assets were sold off to Sandvik.

White Metso had mining assets before, since the

Svedala acquisition, there has been a defined

expansion in mining and mining strategy. Most

recently, on January i, Zoi4, there was a

demerger, making Metso today a Company

encompassing mining and construction,

automation and industrial valves.

The plant and product scopeThe Macon site originally had its own foundry,

but this was dosed in the i97os, due to being

adjacent to the tocan. The factory location

historically was related to river transport and

the position on the rail network, and the factory

still has a rail spur, which is still used to ship

some crushers. Macon is also well placed on the

French road network, being close to the

European Ei5 route section between Dijon and

Lyon and not far from Lyon airport. In rare

instances Metso has Flown equipment to mining

customer sites on request.

Figures for 2oi3 show €289 million net sales

for the Metso in the French location, which

indudes both externat sales to mining

customers but also internat sales within Metso

to other divisions. About 50o people are

employed at the site. Key current and growth

markets for Macon in mining and quarrying

include North Africa, particularly Algeria. In

product terms, the site is a main hub for cone

crusher production —the HP range; but also the

NP series of impact crushers and the range of

vibrating screens and feeders.

The HP cone crusher range represents the

bulk of the factory production, at about 60%,

with NP impact crushers at about 6%, with the

remaining qy% mainly screens and feeders.

Crusher Systems divisionIn sales terms, the Crusher Systems division has

become more important in recent years,

accounting for about €z9 million in zoi3,

followed by customer services, which indudes

service agreements at about €So million plus

other sales at about €79 million. It is very much

the strategy of Metso as a group going forward

to grow in the lifecycle services segment such as

long term service agreements with mining

customers. As would be expected much of this

lifecycle business is located where the mines

are — in Australia, Russia, South America and

elsewhere. The production and engineering site

in Macon is the excellence centre of the Crusher

Systems division with hubs in strategic regions

around the world, where customers were

traditionally quarries, but with mining having

becoming more and more important over the

years. Metso's Crusher Systems division based

in Macon, France holds worldwide

responsibilities and supplies the Metso group as

well as mine operators directly, with both

brownfield and greenfield projects as well as

modular plants.

The scope of projects within Metso's Crusher

Systems division is huge. This group is in charge

of defining and supplying crushing and

screening solutions in both construction and

mining segments to end-users. Crusher Systems

can supply semi-fixed or stationary plants

knowing that the future market demand for

crushing and screening will be flexible and

relocatable solutions. An example is a solution

supplied for a fixed plant used during five

years at a dam construction project in Portugal

which was then dismantled and relocated to

Angola for a new dam project.

Mines and mining contractors are investing in

relocatable plants as they are easy to set up and

easy to moue. These types of projects also

reflect the fact that the mining industry

approach to large projects and cost structures

has changed, with more responsibility given to

those companies like Metso with expertise in

particular areas such as crushing and

automation, with less control in terms of actual

processes in the hands of large engineering

86 International Mining I OCTOBER 2014

houses. Stationary plants are still the

state-of-the-art solutions for crushing

and screening, however, providing

high efficiency and availability along

with easy and safe maintenance.

The Ferrexpo Poltava MiningprojectSince Zoii, Russia, Ukraine and

Kazakhstan have been of increasing

importance to Metso and in particular

to its division Crusher Systems. The

installed base of crushing equipment

in these countries in terms of crushers

and screens is huge. At Ferrexpo

Poltava Mining, the challenge was to

be able to supply a plant that would

have the highest efficiency possible;

and where the crushers would be

choke fed. Metso proposed a

greenfield state-of-the-art design at the outset.

Equipment included a primary screen, one

MP800 cone, and a secondary Multi flo screen

with final magnetic separation as a last step to

separate the tailings from the concentrate.

Then the Metso team visited the existing

plant, which resulted in some significant

changes to that process design. The resultant

project is important as it includes elements of

both brownfield and greenfield work. Initially

Ferrexpo Poltava Mining wanted Metso in the

existing plant to just remove the existing

crushers and put new ones in, running the plant

in the saure way as before. But as a result of

detailed discussions, and comparing operating

costs and efficiency ratios, they then opted to

alter the existing facility as well.

Ferrexpo Poltava Mining wanted to keep the

existing hopper, fed by a gyratory crusher at the

top. So Metso opted to use the saure hopper

and put two new feeders in, with the right surge

capacity between the screens and the cone

crushers; as well as magnetic separation

and tertiary crushers for oversize and fines — all

well designed with easy maintenance. A contract

was signed on this basis in zoiz. Metso told IM:

"If we avant to guarantee a particular

performance, we avant to also be in charge of

the process design, allowing us to make sure

the machines are installed properly, that there is

enough surge capacity, that the drop height

between equipment is correct. All this ensures

that the machines are protected and operated to

O the greatest efficiency."

In the context of Ferrexpo Poltava Mining,

they are a big Company with their own

designers, and also work closely with Design

Institutes and so white Metso did not do all of

the detailed engineering, it was given the

responsibility of the main design plan and

layout. The Design Institutes also ensure that

~h ~~~ tex, ~..

..~

Metso Ferrexpo Poltava Crushing and ScreeningProject executed layout —top view

Me#so and automationIn combining power distribution and control

command inherently linked to the design of

Metso machinery, the Crusher Systems' team

is able to propose the "best-fit" installation in

terms of efficiency, security and reporting. The

automation engineering delivery scope

actually includes basic, eledrical, process,

systems information and automation

engineering.

In summary, the Automation Solutions

provide productivity efficiency through

autpmation by regulating systems based on

machine demands and the working

environment. They also ensure continuous

improvement in productivity through strategic

redundancy. Standard electrical designs are

used to ensure electrical compliance with local

standards and integrate the residual risks of

each machine. In the electrical design stage,

detailed machine drawings assess the risks and

define the cabling category. Selected

components are dassified and adapted to

specific machine requirements (torque, control,

regulation). Standardised electrical architecture

e(iminates the technical risks in inter-dependant

systems. Metso applications also offer

comprehensive data analysis to monitor the

overall energy efficiency; check production

status and identify potential failures in module

equipment by machine and by zone. At the saure

time the systems provide architectural freedom

to mining customers for their hardware

platforms. The user-friendly operator interface

ailows real-time information per process zone,

per machine and equipment for quick and

autonomous intervention. /M

everything meets local industrial and safety

standards, with Metso's basis being EU

standards.

This project concerned the supply of

secondary and tertiary crushing with basic and

detailed engineering as well as programming for

two of the seven crushing and screening lines in

two workshops. Metso signed a contract in May

zosz for eight cone crushers, four new design

ElliptiFlo EF 246i screens combined with four

MF MultiFlo 3o6i screens as well as feeders and

a full conveyor system; along with electrical

panels and a full automation system, which was

the best way of maintaining the plant

performance and efficiency. There were two

feeders in the design redaiming product from

the hopper then the taitings and concentrate

stream. Also important was to locate equipment

to meet Ferrexpo Poltava Mining requirements in

terms of maintenance as well as the conveyors,

which are mining specific and have a bigger

truss; a different range of gearboxes, and some

other elements, all based on around the dod<

mine operations. The two year project,

engineered by Crusher Systems, ran a battery of

real-time FAT (Factory Acceptante Tests) before

shipment to the site location to ensure proper

function before on site installation.

In March 2oi3, ferrexpo Poltava Miningthen

subsequently signed a full engineering contract

for an electrical and automation control system

for the Rotation fine. An interesting part of the

project regarding the flotation fine was that due

to the political situation in Ukraine as of

February zos4, Metso had to act quickly and in

the best interests of the client in terms of solution

start up. Resolving to use new communication

systems, the decision was made to commission

the plant start via phone and video links with

the Ukrainian teams. (a separate article will

appeor on this next month).

OCTOBER 2014 I International Mining 87

~3

*_ _ ~ .w