METSO INDIA CUSTOMER MAGAZINE FOR THE MINING AND CONSTRUCTION INDUSTRIES · PDF...

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resultsminerals & aggregates

METSO INDIA CUSTOMER MAGAZINE FOR THE MINING AND CONSTRUCTION INDUSTRIES Vol. 18 4 2011

India races on….Jaypee Group and Metso create history together 4

For more information: www.metso.com/performancesolutions

Long term reliabilityMetso Perfomance Solutions consists of Metso global team of professionals possessing experience, technological know-how and pro-active attitude to extend the life cycle of your industrial processes.

We build solid long term relationships with our customers through mutual learning. Understanding of your value chain enables us to steer innovations based on your daily challenges.

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2716666www.metso.com/in

2 RESULTS MINERALS & AGGREGATES 4/2011 RESULTS MINERALS & AGGREGATES 4/2011 3

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 EDITORIAL Amol Sinha, Amit Mishra, Arup Raha,

Ashutosh Agarwal, Niraj Srivastava,

Peeyush Bajpai, Sudhir Kamath.

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

In this issue

4 India races on….

Jaypee Group and Metso create

history together

10 Metso Process Technology and

Innovation, Metso’s SmartTag™

Ore tracking, the next generation

and beyond

14 Metso C120 Jaw Crusher

The new face of reliability

Dear Customer,

Looking at 2011 in retrospect draws a lot of learning when we see it from the perspective of what we all have achieved together. It is

always good to take stock and learn from the experience as it gives us a better understanding of how we should plan for the future.

We expanded our flagship manufacturing unit in India, Metso Park, by acquiring additional land of around 30 acres in Alwar, Rajasthan.

With this Metso Park has now become Metso’s second biggest manufacturing base spanning around 80 acres. Amongst the first of

factories opened in this facility, Slurry pumps and Rubber factories have already gathered steam this year and we reached the landmark of

producing and selling 1000 Pumps in one single year. Metso Park is accredited with some of the best integrated management practices

and certifications such as ISO 9001, ISO 14001 and OSHAS18001, making it a truly global facility. This year will see further expansion at

Metso Park and we are now ready to rollout our Track Plants and open the Vibrating Equipments factory from this facility. Our strategy of

being closer to the markets is clearly in action now.

Our mining customers rediscovered their interest for HGMS. The technology has the unique efficiency to scavenge tailings, thereby greatly

improving the recovery by ensuring almost zero loss of precious iron ore minerals. Due to its unique features the demand outstrips supply

and we are working hard to improve deliveries.

We continued to work towards making our offering more competitive by investing in enhancing our local skills in engineering, procure-

ment and project management. We have also further strengthened our Service capability with increased investment in distribution and

warehousing with the objective of serving our customers more efficiently. Year 2011 started with optimism but has ended with skepticism

about future rate of growth. Industry is looking for clear policy signals to spur the growth momentum. We sincerely hope that this

skepticism gives way to growth soon. We are committed to support you with renewed vigor and are looking forward to working with our

customers in supporting their needs for new investment or optimizing the existing one.

We thank you for your patronage and wish you a happy and successful year ahead !

Kamal PahujaVice President – IndiaMining & Construction Technology

16 Ellipti Flo Screen

For high capacity, high moisture

screening

20 News in brief

Global experts introduce Metso’s

Comprehensive mining solutions

to Tata Steel Limited

22 Slag crushing technology from

Metso

26 Metso Vertimills® in Iron Ore

The most efficient Grinding solution

to Iron ore processing

30 Facilities for the Sochi Winter

Olympics constructed

with high-quality aggregates

(2) (3)


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 EDITORIAL Amol Sinha, Amit Mishra, Arup Raha,

Ashutosh Agarwal, Niraj Srivastava,

Peeyush Bajpai, Sudhir Kamath.

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

In this issue

4 India races on….

Jaypee Group and Metso create

history together

10 Metso Process Technology and

Innovation, Metso’s SmartTag™

Ore tracking, the next generation

and beyond

14 Metso C120 Jaw Crusher

The new face of reliability

Dear Customer,

Looking at 2011 in retrospect draws a lot of learning when we see it from the perspective of what we all have achieved together. It is

always good to take stock and learn from the experience as it gives us a better understanding of how we should plan for the future.

We expanded our flagship manufacturing unit in India, Metso Park, by acquiring additional land of around 30 acres in Alwar, Rajasthan.

With this Metso Park has now become Metso’s second biggest manufacturing base spanning around 80 acres. Amongst the first of

factories opened in this facility, Slurry pumps and Rubber factories have already gathered steam this year and we reached the landmark of

producing and selling 1000 Pumps in one single year. Metso Park is accredited with some of the best integrated management practices

and certifications such as ISO 9001, ISO 14001 and OSHAS18001, making it a truly global facility. This year will see further expansion at

Metso Park and we are now ready to rollout our Track Plants and open the Vibrating Equipments factory from this facility. Our strategy of

being closer to the markets is clearly in action now.

Our mining customers rediscovered their interest for HGMS. The technology has the unique efficiency to scavenge tailings, thereby greatly

improving the recovery by ensuring almost zero loss of precious iron ore minerals. Due to its unique features the demand outstrips supply

and we are working hard to improve deliveries.

We continued to work towards making our offering more competitive by investing in enhancing our local skills in engineering, procure-

ment and project management. We have also further strengthened our Service capability with increased investment in distribution and

warehousing with the objective of serving our customers more efficiently. Year 2011 started with optimism but has ended with skepticism

about future rate of growth. Industry is looking for clear policy signals to spur the growth momentum. We sincerely hope that this

skepticism gives way to growth soon. We are committed to support you with renewed vigor and are looking forward to working with our

customers in supporting their needs for new investment or optimizing the existing one.

We thank you for your patronage and wish you a happy and successful year ahead !

Kamal PahujaVice President – IndiaMining & Construction Technology

16 Ellipti Flo Screen

For high capacity, high moisture

screening

20 News in brief

Global experts introduce Metso’s

Comprehensive mining solutions

to Tata Steel Limited

22 Slag crushing technology from

Metso

26 Metso Vertimills® in Iron Ore

The most efficient Grinding solution

to Iron ore processing

30 Facilities for the Sochi Winter

Olympics constructed

with high-quality aggregates

(2) (3)

mailto:[email protected]


http://www.metso.com/in


(4) (5)

India races on….

C O V E R S T O R Y

Jaypee Group and Metso create history together

Buddha International Circuit (BIC), undoubtedly, is the finest example of sports infrastructure in India. Not something that we acknowledge easily since we may be biased but the international audience and media minced no words in praising this big leap that India took in October 2011. The 5.1km race track has beaten the best of quality and timelines at the global stage. Jaypee group made India proud this Diwali and gifted the country a sport that is fast growing in popularity. Both the sport and project are symbolic of India’s amazing speed and quality to build world class infrastructure. BIC broke all myths and created benchmarks with the most stringent deadlines and specifications to build the track. With the highest of stakes involved in the USD 400 million project, Jaypee Group believed only Metso could deliver as per time and quality specifications. For Metso it was a dream project that turned out to be the most challenging and satisfying till date.

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These asphalt tracks have to take a lot of

beating far exceeding that of a

carriageway of highway and hence have

to be designed to deliver higher

strength. To achieve higher strength,

aggregate quality and specification also

has to be superior. The project was

subcontracted to Oriental Structural

Engineering and 4 out of 6 crushing &

screening plants being used at Yamuna

Expressway were handed over for laying

of F1 track to M/s Oriental Structural

Engineering Pvt. Ltd. They have vast

experience in the development of

various major highways, were confident

to deliver the superior quality of track

and they not only met but exceeded the

expectations by using Metso Plants.

Says Mr. Anjan Meher, DGM (Plant & Machinery), Oriental Structural Engineering Pvt Ltd. ” In the F1 tracks we

had followed the British Standard

specifications so maintaining the quality of

works was more challenging. Timelines

were very strict too. Metso machines were

quite efficient and hence 80% of the raw

materials came from Metso machines. “

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

Opening doors to F1

The Formula 1 Grand Prix started in 1950

and achieved instant commercial success

and publicity. Held in 68 countries today

F1 championship came to India in its

62nd season. When the opportunity of

hosting the prestigious event started

making headlines in India, quite a few

potential venues popped up to host the

coveted event. Kolkata, Chennai,

Coimbatore, Bengaluru, Hyderabad,

Mumbai, Delhi, Gurgaon & Lucknow were

all deliberated by the various state

administrations & industrialists. National

Capital Region with its established image

and infrastructure became the obvious

choice in the end. Greater Noida that

already is seen as world class city by living

standards and by the quality of

infrastructure, became the first choice

and Jaypee Group won the project hands

down for its impeccable legacy of

executing the best of projects in the

country, that gave birth to the biggest

sporting dream of India - The “Buddha

International Circuit”.

The 5.14 km long Buddha International

Circuit (BIC) has been designed by

renowned German architect and race

track designer, Herman Tilke, who has

designed world –class race circuits in

Malaysia, Bahrain, China, Turkey,

Indonesia, the UAE, South Africa, South

Korea and the US. Tilke’s signature is

unmistakably inscribed across BIC. Two

expansive straights, blend into an

interesting mix of 16 curves and corners,

making for an exciting challenge. These

combinations of high speed straights and

elevations are is what makes this sport

exciting. And to talk about the top speed,

F1 cars on BIC can zoom as high as

325km/hr which is the fastest in the

world.

Yamuna Expressway to F1 Track

JP and Metso’s partnership goes a long

way back with the first delivery of

crushers almost a decade back for the

Tehri Dam project. Several hydro projects

executed since then by JP group from

Tehri to Vishnuprayag to Baglihar Power

Plant found repeat orders to Metso. A

decade long experience of Metso

technology with several C Jaw crushers,

GP cones and HP cones performing day

and night at several projects created a

unique partnership and understanding

between the two companies.

With time, confidence in technology kept

rising and Metso’s expertise created a

niche for itself in many projects so much

so that today over 50 crushers with JP

have an established track record. The

confidence for the critical F1 project also

emanated out of the results from the

prestigious Yamuna Expressway project

that was awarded to JP in 2003. A 165 km

build – operate – transfer (BOT) model

expressway that connects Noida with

Agra had supplies of 6 units of 300 MTPH

plant with the HP300 and B9100SE to

construct the 8 lane expressway. The

results particularly from the HP crusher

were appreciated. All in all the success at

the Yamuna Expressway was the apt

precedent to select Metso for the most

ambitious and critical project – Buddha

International Circuit.

Says Mr. Baldev V Raisinghani, President (Purchase), Jaypee Group, “F-1 is probably

the most prestigious of all events to ever

come to India. Without a shadow of

doubt, the Buddha International Circuit

Greater Noida, which has brought F-1 to

subcontinent for the first time has

created history, whosoever got the

opportunity to participate/witness have

seen history being created. This achieve-

ment is expected to be talked about for

some time to come.”

Special mix for better grip

The F1 race track had international

standards to be adhered to and high

efficiency levels to be delivered. To

achieve a course with a sufficient degree

of undulation, some 12 million cubic

meter of soil was to be excavated. Within

the first three months itself, an elevation

of 14 meters was created, dotted with

features inspired by the best around the

world. Determined to get it right, JPSI

sought inputs from the racing teams

themselves, so that after a series of

factory simulations and modifications, a

fast course that facilitates overtaking was

developed to add to the excitement of

India’s first motorsports event of this

magnitude.

These steep accelerations, high speed

sharp bends and screeching brakings

transfer all the brute force of roaring

engines of F1 cars onto the asphalt tracks.

Specifications for the aggregate and type of standards that were needed for the F1 tracks.

M/s Oriental managed to achieve 3 to 4% better than what the norms required for each case.

Parameter

Medium polishedstone value

Los Angelesabrasion

%m < 20 < 20 < 30 ASTM 131-81Size: 10-15 mm

Water absorption %m < 1.0 < 2 < 2 BS 812

Dust content(< 0.075mm)

%Adhesivity tobituminous binder

Aggregate shape(flakiness index)

Amount of light coloured aggregates in mix

%m

%m

%m

< 0.5

< 20< 16

> 35 no requirement no requirement

< 25 BS 812

> 95 > 90 > 80 ASTMD 1664with ultrasonic

bath

< 1 < 1

> 56 no requirement no requirement British StandardBS 812

Dim. Binder Course Asphalt BaseCourse

Test MethodWearing Course


























Opening doors to F1











































world.































































magnitude.





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C O V E R S T O R Y

Niraj SrivastavaVice President, Technical support,

CSR, Metso India

[email protected]

Expertise delivered

The plants supplied to JP were 300 MTPH

3 stage plants with the configuration of

Metso secondary Cone Crusher HP300

and Metso Barmac VSI B9100 SE. These

plants were instrumental in achieving the

desired quality & quantity and to achieve

it was no easy feat; reliability &

productivity which each & every plant of

Metso exuberate were key to delivering

this promise of Metso. Backed by the

technical knowhow and service

commitment from Metso, M/s Oriental

were able to finish the job well within the

stipulated time.

Says Mr. Raisinghani, “The critical

parameters to select the technical

partners were based on past experience

and reputation. We needed a partner

who could not only produce aggregates

as per the specifications but also do it in

the strict timelines given. Metso was the

preferred supplier for us for the

construction of the course aggregates.”

Below are the details of the plants Metso supplied to JP for this project:

Capacity – 300 MTPH, 3 stage, Fixed plant

Grizzly feeder – VMO T 46/12

Primary screen – CVB 2060 – 2D

Cone crusher – HP300

Barmac VSI – B9100 SE (Double Drive,

2x220 kW)

Product screen – CVB 2060 – 3D

Product fraction – (-40)mm

Metso’s expertise delivered aggregates as

per the shape, size and timelines.

Experts in application from Metso studied

the special requirements of aggregate

gradation was as per British standard

which not only exceed the Indian

Standard but also require deep

understanding of qualitative properties of

aggregates. The experts utilised their

knowhow and came out with right

suggestions to M/s Oriental to achieve

the qualitative requirements.

To make the output suitable for this

project, a few modifications were done to

the existing plant to make it suitable for

producing aggregates for F1.

After analysis it was concluded that the

existing aggregate plant would need

additional conveyor belt for stacking of

4th product. So, wire meshes depending

on the product gradation required

should be procured and installed in the

screens.

Says Mr. Raisinghani, “The project

execution despite various problems

met race schedule delivery line and all

participant suppliers played a critical role

in demonstrating highest standard of

sales and support during the execution

of the project. “

Says Mr. Niraj Srivastava, Vice President,

Technical support, CSR, "We are proud that

Metso plants have contributed to the F1

race tracks. Having proven technology with

Fixed Shaft Cone Crusher, Rock on Rock VSI

Technology and High Efficiency Screens &

Feeders, Metso machines produced

aggregates meeting tough international

specifications laid down by the authorities

for preparation of world class F1 Track in

India.

Our Application, Service and After Market

Support facilitated this plant to operate at

optimum level so that the project could be

completed in the tight scheduled time. This

project placed India firmly in world sporting

map and has built a lot of confidence in

Metso technology being able to build

world class sporting infrastructure."

REQUIREMENT OF AGGREGATES FOR BITUMENOUS WORKS AT F-1 RACE TRACK PROJECTActivity Wearing Course DGBM 25 DGBM 40

cum MT/cum MT cum MT/cum MT cum MT/cum MTQuantity 28623 2.4021 68755.3 21764 2.39 52016.0 53641 2.4 128738.4 AddWastage 3% 70818.0 53576.4 132600.6Agg Size(in mm) Total Rqmt QTY ( MT) % QTY( MT) % QTY (MT)

37.5 to 26.5 29172.121 0 0 0 22 29172.12

26.5 to 19 9107.9946 0 17 9107.995 0

26.5 to 13.2 19227.08 14.5 19227.08

19 to 13.2 11550.3 10&2.5* 3513.8 15 8036.466

13.2 to 9.5 11833.7 11&19.5* 11833.7 0 0 0

13.2 to 4.75 34991.9 22 11786.82 17.5 23205.1

9.5 to 4.75 19175.0 17&32* 19175.0

4.75 to 0 121936.8 62&46* 36295.4 46 24645.16 46 60996.25Total 256995.0

Grading of Nominal aggregate size (-) 19 mm IS Sieve Cum % by WT of total aggregate passing

mm Lower Limit of wearing course Upper Limit of wearing course 26.5 100 100 19 79 100

13.2 59 79 9.5 52 72

4.75 35 55 2.36 28 46 1.18 20 34 0.6 15 27 0.3 10 20

0.15 5 13 0.075 2 8

Requirement of aggregates for the F1 race track as required by JP shown below:

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P R O D U C T S A N D S O L U T I O N S

Innovation at its best

Metso’s Process Technology and

Innovation group is a world leader in

mineral processing consulting. A

significant amount of this consulting

work involves Process Integration and

Optimisation (PIO) studies, which

includes investigating the effects of drill

and blast design and implementation on

downstream processing. Critical to these

studies is the ability to track specific ore

into and through the plant.

To increase the accuracy of this ore

tracking, Metso Process Technology and

Innovation (PTI) developed a system to

track ores using RFID transponders called

SmartTag™. Since its commercialisation

in 2007 SmartTag™ has been used in the

majority of PTI’s consulting projects and

several permanent systems have been

installed world wide.

The benefits of using SmartTag™

include: linking spatial mine data to time

based processing data; increased

confidence in ore blending; proactive

process changes for known ore types;

and accurate measurement of residence

times in stock piles and bins.

Since 2007 there have been significant

advancements with RFID technology that

has allowed PTI to extend the reach of

SmartTag™ beyond secondary crushing

to tertiary crushing and beyond. This has

been achieved by drastically reducing the

size of the SmartTags from a diameter of

60 mm to 20 mm. The new smaller RFID

tags have been successfully used in

several studies.

The SmartTag™ System

A SmartTag™ RFID tag travels through a

mine and mineral processing plant in a

series of simple steps. Initially, the tag and

insertion location is logged using a hand

held computer or PDA, then it is inserted

into the ore (e.g. into a blast hole). The

tag travels with the ore through digging,

transport and processing, before being

detected at detection locations (on

conveyor belts), when the time and

specific tag is recorded. The RFID tag data

is then loaded into a database and

analysed as required.

To achieve this, the SmartTag™ system

requires five main components. The first

component in the SmartTag™ system is a

PDA, which allows the initial RFID tag

insertion process to become more

efficient and accurate. Each RFID tag is

added to the database using one of three

options; it is associated with a GPS

coordinate; it is associated with a

predefined point (such as a blast hole); or

it is associated with a new point, which

can be accurately located later.

At present the system does not allow for

high precision GPS but it can locate the

nearest point in a series of predefined

points, such as blast holes, and allow the

user to associate RFID tags with these

points.

The next component in the system, the

antenna, is located at the conveyor belts.

The antenna both induces a charge on

the tag and also receives a transmitted

signal back from the tag. The design of

the antenna is decided by two param-

eters, which are its size and its robustness.

The size of the antenna dictates the size

and the strength of the field it radiates.

For this application the area of field

strong enough to charge the tag should

be as large as possible; therefore, the

antenna used for the SmartTag™ system

is the largest available for this frequency

of RFID system.

An RFID reader then decodes the signal

from the antenna and determines the ID

of the RFID tag passing the antenna. Later

versions of the readers also have

auto-tuning capabilities which ensure

that the maximum possible read distance

is achieved at all time. In the SmartTag™

system the reader then transmits the ID

using serial communications.

A data logging or buffer stage improves

the reliability of the systems and also

makes movable systems possible. The

data logger receives data directly from

the RFID reader, stores the IDs with the

time they were detected and monitors

vital system parameters, such as the

tuning state of the antenna. The data

logging stage also makes SmartTag™ less

reliant on communication links (such as

wireless) as the data is stored at the

detection point until a link is established

to the software applications. The critical

communications links, like the one

between the antenna and the reader, are

all wired and very reliable.

The core of the SmartTag™ software is an

SQL (Structured Query Language)

database. The database, located on a

dedicated server, stores all the informa-

tion about the detection points, detected

RFID tags and original locations. There are

several SmartTag™ software applications

which either input data into the database

or use the data to output information.

These include the SmartTagServer, which

reads data from the data loggers, the

SmartTagPDA, which exchanges data

with the PDAs and translates site blast

hole layout diagrams, and the Smart-

TagRes, which calculates the residence

time between two detection points.

Adding mini RFID tags

To expand the applications of SmartTag™

through and beyond secondary crushing

a mini RFID tag was required. To incorpo-

rate the mini RFID tags into the

SmartTag™ system, PTI faced two

significant challenges; firstly, the reduced

read distance, and secondly, making the

mini tags robust.

By reducing the size of the RFID tag, the

size of the antenna in the tag is also

reduced. The size of the antenna in the

tag is directly proportional to the amount

of charge that is induced, for a given field

strength. Therefore, the read range of a

tag will be reduced as the size of the tag

is reduced.

Through investigation, the 20 mm tags

were found to have an insufficient read

range for the standard SmartTag™

installation. PTI trialed two methods for

fixing this issue; one method was to use

two antennas while the second method

was to place the antenna closer to the

RFID tags.

Both systems were tested at an iron ore

mine. Both approaches, dual antennas or

closer antenna distance, were found to

have similar detection capability.

However, based purely on the ease of

installation, a single antenna located

under the belt, was chosen as the new

standard installation method.

The second challenge faced when

incorporating the mini RFID tags into the

SmartTag™ system was how to protect

them sufficiently to survive a blast. A

method previously used by PTI to achieve

this was to encase the tags in a two part

epoxy. The method works well for

protecting the tags, and although it is

time consuming and expensive it is

currently the preferred method for

protecting the tags. Different encasing

materials, such as reinforced nylon, are

still being investigated.

After encasing in epoxy, the mini-tags

have a diameter of 20 mm and are

shown, with a standard SmartTag™ as

reference, in Figure 1. The size of the mini

RFID tags allows them to pass easily

through screens with apertures down to

25 mm.

Conclusions

Metso PTI has successfully incorporated a

smaller, or mini, RFID tag into their

SmartTag™ system. The changes to the

system installation are minor and increase

the reliability of the system as a whole. In

several examples the mini RFID tags have

proven to be, on average, more robust

than normal sized RFID tags.

The PTI team envisage that with the

successful incorporation of the mini RFID

tags into the SmartTag™ system it will

allow applications for the system to be

expanded. These new applications could

include a wider use in the iron ore

industry where size is the critical material

quality. PTI is now working on proving

the reliability of the next size of RFID tags,

the even smaller micro RFID tag, which

can pass through a 10 mm mesh screen.

With the decreasing size of RFID tags and

the development of SmartTag™ into a

truly distributed system, it can be

extended past the mine to cover the

whole minerals supply chain. Detection

points can now be located in the plant,

the port and even at the location of the

customer, such as a blast furnace.

Case Studies

The two case studies presented here

demonstrate applications where it is

advantageous to use the mini RFID tags

rather than the normal size RFID tags.

Case Study 1 - Secondary Crushing

Circuit

As part of a wider PIO study a secondary

crushing circuit was surveyed while

being fed with a particular ore type. To

determine the origin of the ore at any

particular time and, most importantly,

during the surveys, SmartTag™ detection

points were set up at three locations

around the circuit. The three locations

were primary crusher product, secondary

crusher feed and secondary crusher

product.

A total of 384 mini RFID tags were placed

on eight polygons (a polygon is defined

as different ore zones within the mine

block model) after the blast, the ROM pad

and trucks as they tipped ore into the

primary crusher.

Of the 384 tags placed onto either the

muck pile or on the ROM pad 45 per cent

were detected. However, if this is

compared with the percentage of each

polygon that had been excavated by the

end of the trial it is a fair conclusion that

many of the RFID tags that weren’t

detected were also not excavated during

the trial.

To determine the survival rate of the tags

during secondary crushing the number

of tags detected before and after the

secondary crusher were compared. Of

the 128 tags detected before the

secondary crusher, 97 were also detected

after secondary crushing.

However, as there were 52 tags that were

detected after the secondary crusher but

weren’t detected before the secondary

crusher, the real survival rate is difficult to

determine. By just comparing RFID tags

detected at both detection points, it can


SmartTag™ Metso Process Technology and InnovationOre tracking, the next generation and beyond

SmartTag™ is an RFID (Radio Frequency Identification) based technology designed to allow tracking of ore

from its source through blasting, run of mine (ROM) pads, crushers, intermediate stockpiles and finally into

the concentrator. Here we look at current developments and the future direction of the SmartTag™ ore

tracking system.

be concluded that at least 76 per cent of

the mini tags survived secondary

crushing, although this number is likely to

be much higher.

The screen immediately following the

secondary crusher uses panels with 55

mm apertures and, as expected, none of

the tags were recycled back through the

secondary crusher.

The primary application for SmartTag™

was to determine the origin of the ore

being processed during the plant

surveys. In this application, where the

plant feed included ore from ROM mixing

and stock piles, SmartTag™ was essential

for determining which materials were

processed in the plant at the time of the

surveys. Mini tags were required to

enable the ore source to be tracked all

the way through secondary crushing, and

proved to be robust enough to survive

both blasting and secondary crushing.

Case Study 2 - HPGR Circuit

PTI was contracted to assess the

performance of a circuit at a mine located

in South America. The SmartTag™ system

was used in this application to allow the

PTI engineers to know exactly when a

surveyed blast was being processed. For

this reason, detection points were

located on conveyor belts carrying the

product of the primary crusher, the

output of the stock pile and the HPGR

(High Pressure Grinding Roll) feed.

As the blast was being audited RFID tags

were deposited into 68 blast holes, using

an even split of 34 normal tags and 34

mini tags. A further 50 tags were later

added into the trays of 25 trucks at the

primary crusher, using one of each of the

two different types of tags in each truck.

A total of 68 tags were identified at the

primary crusher product detection point,

23 at the stockpile output detection

point and 41 at the HPGR feed detection

point.

The blast occurred on the 22nd of

January and the excavation of the muck

pile took place between the 15th and

17th of March (two months later). The

SmartTag™ system monitored the

material passing through the process

over a period of 30 hours. During this

period, a total of 67 different tags were

detected; 33 were of normal size and 34

were mini tags.

For the stock pile and HPGR feed

detection points, the recovery was

calculated with reference to the 64

distinct RFID tags detected at the primary

crusher. Of the normal tags detected at

the primary crusher detection point, 42.4

per cent were then detected at the HPGR

feed detection point; whereas for the

mini tags 67.6 per cent of tags detected

at the primary crusher were also detected

at the HPGR feed. This shows that the

survival of the mini tags in the circuit is

higher than the normal tags. In a

hypothetical situation, where the

secondary screening mesh is smaller than

50 x 50 mm, normal tags certainly would

not reach the HPGR.

The detection of tags at the primary

crusher was also affected by the removal

of the SmartTag™ system before the

entire blast was processed (for logistical

reasons).

The tags were used to track the material

during an optimization campaign at the

plant. During the plant survey the

material that fed the plant originated

from the central portion of the blast.

An unexpected result was that three of

the mini tags were twice detected at the

HPGR feed detection point. An explana-

tion for this is that they survived the

HPGRs and returned with the circulating

ore (screened to +5 mm).

Says Mr. Peeyush Bajpai, Vice

President, Strategic development,

Mining & Construction Technology,

Metso India, “The Smart TagTM system

offers a reliable way to track the ore from

the mine to input in the processing

circuit and thereby allows for tracking of

characteristics of the ore entering the

process line. It also helps the user to

decide operation parameters and

methodology to be planned for. Having

proven its utility in various mines around

the world, Metso offers the cumulative

experience of varied applications with in

the Smart TagTM, which is a winning

proposition for operations planning and

ore tracking.”






































several studies.
































points.















of RFID system.


















































mini tags robust.








is reduced.




Peeyush Bajpai

Vice President, Strategic development,


Metso India

[email protected]

(12) (13)





RFID tags.




























25 mm.

Conclusions




























Case Studies






Circuit











product.






primary crusher.









the trial.


















be much higher.





secondary crusher.





































point.










were mini tags.

















not reach the HPGR.





reasons).




























ore tracking.”

P R O D U C T S A N D S O L U T I O N SP R O D U C T S A N D S O L U T I O N S






































several studies.
































points.















of RFID system.


















































mini tags robust.








is reduced.




Peeyush Bajpai

Vice President, Strategic development,


Metso India

[email protected]

(12) (13)





RFID tags.




























25 mm.

Conclusions




























Case Studies






Circuit











product.






primary crusher.









the trial.


















be much higher.





secondary crusher.





































point.










were mini tags.

















not reach the HPGR.





reasons).




























ore tracking.”



(14) (15)

A new titan on the rise

The C120 is a heavy duty Jaw crusher that

perfectly fits into demanding stationary

application but also meets requirements

set by mobile and portable applications.

Even at the first glance it is clear from the

C120 that Metso has paid special

attention to its new, durable and

user-friendly design, which begins with

the casting, the design of which is based

on thorough FEA and casting simulations.

Every detail of the C120 is engineered for

reliable operation and long life, resulting

in high, constant crushing capacity and

uptime.

The new C120 has been designed after

closely listening to the customer and

collected field data from a number of

sites. Based on that, Metso decided to

design the crusher cavity and kinematics

first. As a result, Metso can now offer

aggregate producers, large-scale

contracts and mining companies a new

crusher that meets all the standards set

for any demanding application.

C120 key features:

1. Outstanding productivity through

long stroke and fixed jaw die –

The outstanding productivity of the C120

is guaranteed, thanks to several new

design elements. The crusher novelty

features a long and aggressively directed

stroke, and a fixed jaw die longer than

previously seen in this crusher size class.

The C120 has a large feed opening of

1200 X 870 mm (34X47”) and an

aggressive cavity cross section, securing a

high performance and reduction ratio.

In terms of cavity volume and crusher

weight, the C120 is positioned between

the existing Metso C116 Jaw crusher and

C125 Jaw crusher models.

2. Easy to install –

The C120 is easy to install, thanks to its

compact design, and includes for

example an optional integrated motor

bed and guards. Being well-balanced, the

C120 is quick, easy and cost-efficient to

install through rubber mounted pads

underneath the crusher mounting

brackets. No separate horizontal supports

are needed. The crusher can be mounted

in multiple ways to ensure an easy fit

onto an existing or a new steel structure.

For a quick, easy and safe setting

adjustment, it is possible to select either a

mechanical or hydraulic setting

adjustment system. For Jaw dies, several

cavity options are available depending

on the customer’s performance, it is

possible to use either single – or two –

piece Jaw dies.

3. Safety is the highest priority –

The C120 features optional robust

composite flywheel guards that allow

quick and safe access to all service points.

The standard delivery includes lifting

tools for Jaw dies, cheek plates and

toggle plate, contributing to operational

safety when changing wear parts.

The Metso C120’s nominal power is

160kW (200 HP), operating speed 230

rpm, closed side setting between 70-200

mm (2 3/4” – 8”). The operational weight

is 26,000 kg (57,200 lbs), excluding

options.

Other features

1. Application flexibility –

There is an option for multiple different

level cavity options. It comes with

movable and fixed 1 piece and 2 piece

configurations. It also has 3 & 4 fixed jaw

die options. A setting adjustment system

with either mechanical or hydraulic

wedges. As a result, the setting

adjustment system is safe, easy and quick.

Three partly overlapping setting ranges

for ultimate application flexibility.

Possible to utilize all managense without

special installation or removal.

2. Strong focus on user friendliness –

Metso has made sure that with the C120,

the operation and service are safe and

easy. The durable composite guards are

used for easy and safe handling.

C120 advantages

1. Reliability –

Owing to its structural excellence it

guarantees reliability to the aggregate

producer. The material and component

selection for the C120 is designed around

the needs of the customer from a Jaw

crusher.

2. Productivity –

The C120 has been engineered on

kinematics, crusher and cavity design that

has been proven in field tests.

3. Safety –

Safety is one of the major reasons to try

the new Metso C120 Jaw crusher. Lifting

tools are delivered with the crusher as a

standard offering. With limited number of

service points, Composite guards make it

easy to open the crusher for maintenance

and services.

All in all the C120 is a Jaw crusher that

provides the user with lowest achievable

cost/ton that is safe and easy to operate.

With this kind of configuration it is hard

to go wrong. The C120 being designed

on customers’ needs, Metso’s in-house

foundry expertise and only

improvements were done without any

compromises. The C120 is a safe

investment to providing with greater

reliability and performance. The C120 is a

crusher that is safe to own and operate.

For further details contact :

[email protected]

Metso C120 Jaw Crusher The new face of reliability

Like all other innovations by Metso, the C120 has been designed around customer needs. Engineered

around crusher cavity and kinematics, it ensures reliable operations and a long life, for constant crushing

capacity and uptime. Read on to know more.


N E W A T M E T S O

Ellipti Flo screen For high capacity, high moisture screeningRising environmental restrictions and high capacity screening requirements prompted Metso to come up

with a new screening technology that adheres to all standards and fulfill the customers need for dry screen-

ing. Metso introduces the new ELLIPTI FLO screen that allows complete dynamic process control and

ensures high capacity and high moisture dry screening.

(16) (17)


Demand and supply

There is an emerging demand for high

capacity dry screening with finer

separation and with high moisture

content up to 12% (a laboratory test is

required to ensure the capacity). It has

been seen that in many customer sites,

such feed material is traditionally

processed in wet process due to difficulty

in screening in rainy season.

However dry screening process means a

lower operational cost, lower capital

equipment investment for Greenfield

projects due to lack of water processing

equipment and also a shorter time to get

environmental license for new projects,

so customers always prefer dry screening.

An R&D challenge

Metso rose up to the challenge and

started R&D on finding the right kind of

solution and hence tried to understand

the moisture, acceleration, type of media

and special anti agglomeration devices

that influence the screening process.

After the results of the laboratory tests, a

prototype screen was built with self

synchronism elliptical motion with a

special feature of attack angle controlled

by encoders. The unique design of the

mechanisms with self synchronism at 45°

allows independence of encoder devices

that means no screen stoppage due to

electronic failure.

The Ellipti Flo screen is able to work with

any screening media, but due to its

combination of high acceleration and

elliptical motion, the screen is able to

perform with rigid high % open area

media without clogging, increasing the

screening capacity. Common linear

motion screens needs to operate with a

flexible media to prevent clogging.

N E W A T M E T S O

(18) (19)


As EF screen has an elliptical “anti-clogging” motion, the Metso

special % open area media, called Hiper Flow, is the right

combination to optimize the screening performance. Higher % of

open area is possible when using rigid polyurethane media, as the

membrane doesn’t need to support secondary vibration.

After a large number of tests during the rainy season, the prototype

screen process tests completed. One of the customers from South

America confirmed that the EF screen surpassed the performance

of the Banana linear motion screen, conventional circular screen

and also roller screens.

Hence the new unique high acceleration, stroke control, elliptical

motion screen was baptized as ELLIPTIFLO screen.

Arup Raha

Deputy General Manager -

Product Support -

Vibrating Screens, Metso India

[email protected]

Amit Mishra

Manager Sales-

Vibrating Screens

Metso India

[email protected]

Design concept

The introduction of Ellipti Flo Screen has

not only widened the gamut of the

product line but also has performed in a

much more satisfactory way in a number

of ways as compared to conventional

screens. The concept behind the design

of the ELLIPTI FLO is as follows:

• The Roller bearings are a limitation for

large screen design (larger than 3m wide)

with exciters assembled in the side plate.

• The successful bronze bushing

technology of cone crusher was

borrowed to build a powerful bronze

bushing exciter.

• The elliptical motion together with a

high acceleration (5G) assured a blinding

and clogging free media operation, even

for rigid wire media.

Features of the ELLIPTI FLO screen

1. Upto 30% more capacity compared to

conventional screens.

2. Process control: 30 to 60° stroke angle

and 4 to 5 G acceleration

3. Elliptical motion to provide low

clogging and blinding tendency

4. Lifetime bronze bushing exciter for

large screens

5. Designed to work with wide range of

Metso Trellex media ( Polyurethane,

rubber or wire mesh)

The EF screen advantage

I. Motion Control

Smart Speed System

• Electronic control by encoders

• Changing the attack angle it is

possible to control time of material over

the deck

• Natural synchronization at 45°. No risk

to stop the screen due to encoder failure.

II. Stroke control use for high moisture

ore

Non agglomerated ore

• Easy screening

• Working angle of 40 to 35°

• Optimized capacity

Agglomerated ore

• Difficulty screening


• Optimized efficiency (more screening

time)

A notch higher at lesser cost

Metso believes in surpassing its own

benchmarks. Metso’s Banana screen is

one such benchmark product for

screening fines. Now Metso has

surpassed that and has come up with the

EF screen for fine screening.

Comparison of Total weights of MF

and EF screen

MF 2461 -2 (8’ x 20’ DD) – 18385 kg

EF 2461 -2 (8’ x 20’ DD) – 15812 kg

The Ellipto Flo Screens can also

replace the Banana Screens for

product screening for dry application

where the capacity requirement is very

high , moisture is high and finer

separation is required .

A very large Banana can be replaced

with a moderate size Ellipto Flo Screen

and thus saving the structural and

engineering cost besides performing

better in the high moisture.

N E W A T M E T S O N E W A T M E T S O

40°35°

50°60°

Conclusion

• Elliptical motion is the best one for rigid wire media.

• It combines the high capacity, high efficiency (no clogging tendency) and allows working in any deck angle

Trellex LS

HiPer Flow

1176 holes (FR8)

resulting in an

effective open

area of 41,1%

Trellex LS (Standard)

880 holes (FR8) resulting in an effective open area of 30.8%

(18) (19)


As EF screen has an elliptical “anti-clogging” motion, the Metso

special % open area media, called Hiper Flow, is the right

combination to optimize the screening performance. Higher % of

open area is possible when using rigid polyurethane media, as the

membrane doesn’t need to support secondary vibration.

After a large number of tests during the rainy season, the prototype

screen process tests completed. One of the customers from South

America confirmed that the EF screen surpassed the performance

of the Banana linear motion screen, conventional circular screen

and also roller screens.

Hence the new unique high acceleration, stroke control, elliptical

motion screen was baptized as ELLIPTIFLO screen.

Arup Raha

Deputy General Manager -

Product Support -

Vibrating Screens, Metso India

[email protected]

Amit Mishra

Manager Sales-

Vibrating Screens

Metso India

[email protected]

Design concept

The introduction of Ellipti Flo Screen has

not only widened the gamut of the

product line but also has performed in a

much more satisfactory way in a number

of ways as compared to conventional

screens. The concept behind the design

of the ELLIPTI FLO is as follows:

• The Roller bearings are a limitation for

large screen design (larger than 3m wide)

with exciters assembled in the side plate.

• The successful bronze bushing

technology of cone crusher was

borrowed to build a powerful bronze

bushing exciter.

• The elliptical motion together with a

high acceleration (5G) assured a blinding

and clogging free media operation, even

for rigid wire media.

Features of the ELLIPTI FLO screen

1. Upto 30% more capacity compared to

conventional screens.

2. Process control: 30 to 60° stroke angle

and 4 to 5 G acceleration

3. Elliptical motion to provide low

clogging and blinding tendency

4. Lifetime bronze bushing exciter for

large screens

5. Designed to work with wide range of

Metso Trellex media ( Polyurethane,

rubber or wire mesh)

The EF screen advantage

I. Motion Control

Smart Speed System

• Electronic control by encoders

• Changing the attack angle it is

possible to control time of material over

the deck

• Natural synchronization at 45°. No risk

to stop the screen due to encoder failure.

II. Stroke control use for high moisture

ore

Non agglomerated ore

• Easy screening


• Optimized capacity

Agglomerated ore

• Difficulty screening


• Optimized efficiency (more screening

time)

A notch higher at lesser cost

Metso believes in surpassing its own

benchmarks. Metso’s Banana screen is

one such benchmark product for

screening fines. Now Metso has

surpassed that and has come up with the

EF screen for fine screening.

Comparison of Total weights of MF

and EF screen

MF 2461 -2 (8’ x 20’ DD) – 18385 kg

EF 2461 -2 (8’ x 20’ DD) – 15812 kg

The Ellipto Flo Screens can also

replace the Banana Screens for

product screening for dry application

where the capacity requirement is very

high , moisture is high and finer

separation is required .

A very large Banana can be replaced

with a moderate size Ellipto Flo Screen

and thus saving the structural and

engineering cost besides performing

better in the high moisture.

N E W A T M E T S O N E W A T M E T S O

40°35°

50°60°

Conclusion

• Elliptical motion is the best one for rigid wire media.

• It combines the high capacity, high efficiency (no clogging tendency) and allows working in any deck angle

Trellex LS

HiPer Flow

1176 holes (FR8)

resulting in an

effective open

area of 41,1%

Trellex LS (Standard)

880 holes (FR8) resulting in an effective open area of 30.8%



(20) (21)


upon Tata Steel’s current requirement of

ore transportation from one of their

deposits into the plant. The topic was

well received with questions on

anticipated transportation issues and the

technology on offer.

Dusty Jacobson ( Applications Manager ,

large mining crushers, Metso York ) and

Subhas Hazra (Senior Product Manager ,

Grinding Mills , Metso York) spoke on

‘Optimized solutions on crushing and

milling tehcnologies’ . Dusty shared his

experience in optimized solutions in

mining crushers and Subhas spoke on

optimized solutions in grinding.

In the end, Peeyush Bajpai enlightened

the audience on Metso’s service offerings

and and our ‘hands on’ experience with

proprietary equipment and their

applications at the clients‘ sites.

Our speakers cited examples from across

the globe, which best highlighted our

customer’s positive experiences with our

machines. The interest of the customers

was substantiated by the response and

queries which we generated after the

session.

Our guests were also invited to a light

entertainment program and dinner

during which they had an opportunity to

interact with our global experts in person

for their queries and requirements.

In all, we were successful in achieving our

objective of bringing our ‘comprehensive

mining’ solutions portfolio to a key

account like Tata Steel and the client

could also benefit from the ‘One Metso’

outlook that we had on display.

Sudhir KamathDeputy General Manager,

Mining Sales, Equipment & Systems,

Metso India

[email protected]

Global experts introduce Metso’s comprehensive mining solutions to Tata Steel Limited A conclave was organized on 13th December, 2011, in Jamshedpur; where Metso showcased its comprehensive

mining solutions to Tata Steel. Around 60 people from Tata Steel attended the conclave, during which

global experts interacted with the customer and explained our world class mining solutions.

The conclave was opened by Kamal

Pahuja (Vice President, Mining and

Construction Technology, India) who

gave a brief introduction of the speakers,

followed by Sudhir Srivastava (Senior Vice

President , Mining and Construction

Technology , Asia Pacific) who presented

an overview of Metso Corporation and its

presence across the globe. Sudhir’s

speech was followed by Heikki

Hartikainen (Manager Product Training ,

beneficiation systems, Metso Sala ,

Sweden ) who presented Metso’s

involvement in ore beneficiation.

Considering the three beneficiation

plants envisaged at Tata Steel during

2012, it was a subject which generated

interest and was appropriate for the forum.

This was followed by a presentation from

Graham Gilliam ( Sales and Service

Manager , Cable belt conveyors, BMH ,

Metso UK ) who spoke on Cable belt

conveyors, wherein emphasis was laid

N E W S I N B R I E F

Slag is a vitreous mass left as a residue by the smelting of metallic ore. Due to presence of un-crushable

metallic residue, slag cannot be crushed by regular crushers. It requires modifications in the regular crusher

to crush the slag. New technology known as the Active Setting Control from Metso has eased the mecha-

nism of such tedious crushing and can be adjusted with the Metso Jaw crusher to give effective results.

Read on to know more.

Slag crushing technology from Metso

(22) (23)

Alok Jha

General Manager, CSR,

Operations, Metso India

[email protected]

determined by local market needs. The

metallics can be returned to the mill or

brokered for sale. The slag products are

marketed for various construction

purposes depending on its nature.

Modern slag uses

Depending upon nature of Slag i.e. its

mineral composition, mineral

composition, physical strength it can be

used for suitable purposes. For example

some Blast Furnace slag have

cementitious property, hence it can be

grounded and granulated and used in

concrete in combination with Portland

cement as part of a blended cement.

Ground granulated slag reacts with water

to produce cementitious properties.

Concrete containing ground granulated

slag develops strength over a longer

period, leading to reduced permeability

and better durability. Since the unit

volume of Portland cement is reduced,

this concrete is less vulnerable to

alkali-silica and attack.

The slag can also be used to create fibers

which can be used as an insulation

material named slag wool.

If the slag posseses good strength and is

inert in nature it can be used as

aggregate in road building activity. It can

also be used in base layer or mixed with

other cementitious material like asphalt

or cement and can be used in various

Macadam layers used in laying a road.

While some other kind of slag may

contain solid pieces of metal which

sometimes are left behind in process of

smelting. Slag also needs to re processed

to extract more of these metallics.

Metso solution for slag crushing

The metallics in the slag pose the biggest

challenge for the crushing of slag as

these can be of very high strength and

are uncrushable in nature. It is

recommended that as much as of these

metallics should be removed before

being fed into any crusher. Multiple

magnetic separators like magnetic pulley,

overhead band magnet etc should be

placed before each and every crusher

even in a multi stage crushing, so that

maximum metallics are recovered and

also amount of uncrushable particles

entering any crusher is minimized.


What is Slag?

In nature, the ores of metals such as iron,

copper, lead, aluminium and other metals

are found in impure states, often oxidized

and mixed in with silicates of other metals.

During smelting, when the ore is exposed

to high temperatures, these impurities are

separated from the molten metal and can

be removed. The collection of compounds

that is removed is the slag. Slag is a partially

vitreous by-product of smelting ore to

separate the metal fraction from the

unwanted fraction. It can usually be

considered to be a mixture of metal oxides

and silicon dioxide. However, slag can

contain metal compounds and even metal

in the metallic form. While slag generally

comes out as a waste in metal smelting

process, it can also serve other purposes as

it contains valuable metal compounds &

metals itself. Slag can also be used as

aggregate in construction industry or they

can be processed again to recover more of

metal or useful minerals from it.

Once the slag has cooled sufficiently, it is

processed through a slag plant to remove

recoverable metallics and to size the slag

into various products, which are

C Jaw with ASC forms the primary

crusher in any slag crushing plant and

will reduce boulders to predominantly

-80mm lumps. If process demands that

these lumps be further crushed down to

still smaller particles Metso offers

Nordberg HP Cone Crusher technology

which are well suited for crushing lumps

with some amount of uncrushable

“tramp” steel pieces.

Boulders of slag when crushed in a C Jaw

Crusher with ASC will break down and

metallic pieces will be liberated from

them hence it will again be advised to

put in place multiple magnetic separators

before HP Cone crusher.

The Tramp release system of HP Cone

crusher are the best available technology

to handle the metallics present in Slag

feed.

HP Cone crusher will further reduce the

lumps to predominantly -30mm lumps

which can be screened to specific sizes

so that the waste Slag is converted into

useful aggregate etc. This stage of

crushing will further liberate more

metallics which can be extracted. In case

process requires that it is further ground

into still finer particles Metso brings in

another of its technology suitable to

further crush these very abrasive Slag

with maximum ease, viz Barmac VSI.

Barmac VSI acts like an Autogenous Mill.

The conventional Barmac VSI rotor can be

dressed with highly abrasion resistant

parts like:

- Tungsten Distributor Plate

- Tungsten Trail Plate

- Laminated Tip Sets

- Lipped upper & lower wear plates

These offer maximum rotor protection

against hard and abrasive Slag particles.

Features and benefits

1. Release function –

• In an overload situation the pressure

relief valves lets the oil escape from the

hydraulic cylinders to the tank

releasing the setting.

• No down time because of toggle plate

bending

• Ability to go extreme applications

concerning steel.

2. Recovery function –

• Returns the setting back to normal

after release

• Optional in stationary applications and

standard in an LT

• Ensures constant end product

recovery function in a stationary

application

• The recovery function is handled

through the IC1000 automation

control system

• In an overload situation the oil escapes

to a tank and the IC 1000 returns it to

the cylinders until the setting has

returned to the target level

• The setting is adjusted by means of an

ultrasonic sensor connected to the

IC 1000

• In C-Jaw applications with the IC1000

the opening pressure is 300 bar (4350

PSI) which means that the whole

setting range can be utilised

recovery function in a LT


through the IC controls


to a tank and the IC returns it to the

target level.

Active Setting Control (ASC)Operating principle

3 integrated cylinders

Overload returns to tank

Overload to accumulator

Recovery to cylinders

To tank

To accumulator

To tank

No wedges, cylinders adjust the setting!

Yet it is never possible to ensure 100%

removal of large or small solid metallic

pieces which are uncrushable and pose

serious danger to the health of crusher

and if they report to cavity of crusher will

lead to lengthy & costly breakdown.

To take care of this tough application

Metso has taken up this challenge and

has designed crushers specifically meant

for our customer who are involved in

business of Slag crushing and processing.

The most significant product in this niche

range is C jaws with “Active setting

Control” technology.

Active Setting Control

The Active Setting Control is a new

system that acts as a setting adjustment

system and releases the crusher cavity to

open in the event of hitting

non-crushable, oversized material.

The Active Control System is based on

three hydraulic cylinders and an

ultrasonic sensor attached to the rear of

the crusher. In cases where

non-crushable material like a piece of

iron enters the crushing cavity and

generates a high pressure, the relief valve

is opened and releases the hydraulic oil

from the cylinders.

Active Setting Control adjustment is used

basically in the same way as the hydraulic

wedge setting adjustment. The system is

powered with an independent hydraulic

unit, or it can be connected to a large

hydraulic system, as in the Lokotrack.

When the setting of the jaw is adjusted

the hydraulic oil flow moves the pistons

in the ASC cylinders in and out, which

increases and decreases the crusher

setting respectively. Pressure relief valves

hold the oil in the cylinders when the

setting is not adjusted which in turn hold

the setting of the jaw constant.

The Active Setting Control also functions

as a safety device. If there are any

uncrushable objects in the jaw cavity, the

pressure in the cylinders rises. When the

pressure rises over a pre-set value, the

pressure relief valves open and let the

piston move in. The crusher setting opens

and the uncrushable material can exit the

jaw cavity.

The active setting control works as a

safety device only throughout the

adjustment range of the cylinders. If the

uncrushable object is larger than the

maximum physical setting, the toggle

plate gives up through elastic buckling.

Main Components & Operating

Principle

Setting is adjusted by increasing or

decreasing the oil volume in the

cylinders. There is no adjustment wedges.

Instead of wedges there are three

hydraulic cylinders.

In an overload situation (when the

pressure exceeds the limit value) the

pressure relief valves lets the oil escape

from the hydraulic cylinders to the oil

tank releasing the setting. This decreases

down time caused by toggle plate

bending and increases ability to go to

extreme applications concerning steel.


ultrasonic sensor connected to the IC.

• In LT applications the opening

pressure is 300 bar (4350 PSI) which

means that the whole setting range

can be utilised.

3. Operating principle –

(i) Stationary application –

• Release function as standard

• Recovery function as an option

optional recovery function taken care

of by IC1000

(ii) LT application –


• Recovery function as standard

Recovery function handled through

the IC controls (Ultrasonic sensor)

• Opening pressure > 300 bar

• The whole setting range can be

utilized

Applications

• Recycling applications

• Slag

• Applications with relatively big

uncrushable particles (up to the size of

the largest allowed c.s.s. of the crusher)

Availability

• C96/LT96

• C106/LT106

• Possible other models in the future viz

C120, etc.



Slag is a vitreous mass left as a residue by the smelting of metallic ore. Due to presence of un-crushable

metallic residue, slag cannot be crushed by regular crushers. It requires modifications in the regular crusher

to crush the slag. New technology known as the Active Setting Control from Metso has eased the mecha-

nism of such tedious crushing and can be adjusted with the Metso Jaw crusher to give effective results.

Read on to know more.

Slag crushing technology from Metso

(22) (23)

Alok Jha

General Manager, CSR,

Operations, Metso India

[email protected]






Modern slag uses


















































What is Slag?















































feed.
















parts like:














bending


concerning steel.



after release


standard in an LT



application



control system







IC 1000










target level.

Active Setting Control (ASC)Operating principle

3 integrated cylinders

Overload returns to tank

Overload to accumulator

Recovery to cylinders

To tank

To accumulator

To tank

No wedges, cylinders adjust the setting!





























from the cylinders.























jaw cavity.








Principle



















can be utilised.






of by IC1000








utilized

Applications


• Slag




Availability

• C96/LT96

• C106/LT106


C120, etc.







Modern slag uses

















































What is Slag?




























(24) (25)

Amol Sinha

Manager - Applications,

CSR, Metso India

[email protected]




















feed.
















parts like:














bending


concerning steel.



after release


standard in an LT



application



control system







IC 1000










target level.






























from the cylinders.























jaw cavity.








Principle



















can be utilised.






of by IC1000








utilized

Applications


• Slag




Availability

• C96/LT96

• C106/LT106


C120, etc.


(26) (27)


Metso Vertimills® in Iron Ore The most efficient Grinding solution to Iron ore processing

Significantly reduced energy consumption, media consumption, lower installation cost, highest availability,

greater operational ease, better product and minimal liner wear is what defines the concept of the Metso

Vertimill®. Globally recognized as energy efficient machines, these grinding equipment from Metso can

guarantee lowest total cost of ownership in almost all applications, hence substantially improving the

profitability of the grinding plant. And Iron Ore grinding is no exception to this fact. Read on to know more

about the Metso Vertimill® and how they make a positive impact on Iron Ore processing.

ABSTRACT

In the past twenty years more than 60

Vertimills® have been sold for Iron Ore

applications, with more than 20 of those

in the last two years alone. The Metso

Vertimill® had become the standard in

regrind applications, but quickly the

industry realized its potential in coarser

applications as well.

The mill has been proven to grind more

efficiently than ball mills even with feeds

as coarse as 6 mm. While there are still

cost advantages with multiple Vertimills

compared to a single ball mill, the newly

developed 3000 HP (2240 kW) Vertimill®

lowers the total cost of ownership even

further. By replacing ball mills in power

intensive grinding applications such as

grinding SAG mill and HPGR products,

the savings that have been experienced

in regrind applications can be multiplied

further. Typically, the total cost of

ownership of the Vertimill® compared

with traditional ball mills is 35% less.

Potentially every MW of ball mill power

saved in a primary or secondary

application means a NPV cost savings of

US$ 10 million and 80,000 tonnes of

carbon saved over a ten year mine life.

With increasing energy costs and

environmental consciousness, it is an

economic inevitability that Vertimills® will

become the standard in secondary

grinding, further lowering the processing

costs of Iron ore.

Introduction

Vertimills® are primarily selected because

of the operational cost savings they have

over other grinding mills. The total cost of

ownership for a Vertimill® is almost always

significantly less than a traditional

horizontal ball mill solution.

The Vertimill® advantages include:

• Reduced energy consumption

• Reduced media consumption

• Reduced Maintenance due to machine

simplicity

• Lower Installation Cost

• Less floor space

• High Availability

• Long Wear Life

• Quiet operation (less than 85 db

possible)

• Greater operational safety

Now the big question is: Is it possible to

replace the ball mill completely by the

use of stirred mills and would there be

process and energy consumption

benefits?

The answer is a Yes, however the below

case studies would form a quite reliable

basis for this answer.

There are many such analysis on operating benefits of Vertimills as compared to Ball mill which can be provided on request.

(28) (29)

Case Study – 1: Hibbing Taconite Application (Iron Ore Pelletization plant)

An interesting example is Hibbing

Taconite Application. Hibbing installed

Vertimills as they were facing the below

issues with their existing installations

PROBLEMS• Silica Levels were increasing

• Ore weight recovery was declining

• It was getting difficult to meet

Pelletizing Specifications for grind

SOLUTION?2 Nos. Vertimills VTM-1250-WB installed at

Hibbing Taconite

Circuit Flowsheet for Hibbing Taconite Company

The original flow sheet at Hibbing

Taconite consisted of single stage

crushing followed by single stage

grinding, closed circuited with

hydrocyclones and two steps of

magnetic separation. Fine screens were

added in 1988 to maintain productivity

while handling lower grade ores and

targeting a lower silica content in the

fired pellet. Here, the fine screen oversize

was routed back to the primary mill for

additional grinding. Cobbing and

crushing of the trommel oversize pebbles

was added in 1995 to increase

productivity, on four mill lines. Secondary

cyclones were added to those same four

mill lines in 1997 to improve silica, grind

and Blaine control. The fine screen

oversize grinding circuit, called FSOG, was

added in 1999.

The new circuit removes and grinds, fine

screen oversize material, outside of the

primary autogenous mill circuit.

Apart from the operational

improvements, the Vertimills proved to

significantly lower maintenance budget

by reducing the wear parts consumption.

While the shell liners (Metso Orebed ®

liners) are kind of permanent liners and

are fitted for life, the screw liners also

delivered an impressive service life.

Report on wear life of the Vertimills for Hibbing Taconite Application

Screw Wear

Findings on Screw Liner wear• 5066 Operating Hours, 37 % weight

loss, 0.45 lbs./hr

• Liners can be used until greater than

70% weight loss

• Average Digging Shoe life of 18 months

• The shoe on the right is new, compared

to the shoe on the left which was

removed after 5066 operating hours and

showed 37 percent weight loss, about

0.45 of a pound per operating hour, or

about 0.003 of a pound per ton of mill

feed.


Hibbing Taconite w

p

c

m

a

o

a

T

s

p

A

i

s

b

W

l

a

dResults

Mine and Concentrator Savings

• 1,500,000 tons in the 2000 mine plan

originally classified as waste was

re-classified as ore and successfully

processed in the plant

• A reduction in loading units - 7 shovels

to 6, 2 loaders to 1

• Increased Concentrate Production by

442,000 tons

• Improved Silica Control (see below

table)

MEAN 3 SIGMA COMPLIANCE

1997 4.17 0.41 83%

1998 4.15 0.48 80%

1999 4.13 0.47 86%

2000 4.10 0.29 98%

Case Study – 2 : Las Encinas (Two (2) VTM-1500-WB )

Application : Secondary grinding of Magnetite

Equipment : 2 nos. VTM-1500-WB replaced 2 nos.

operating ball mills of 2000 hp each

Selection : sizing was done based on plant data

• F80 = 240 microns

• P80 =50 microns

Vertimills at Les Encinas

Achievements• 47% Less Media Consumption

• 25-35% Less energy

• 18% Increase in Throughput

Proven Technology

The Vertimill® is a proven technology that

offers considerable savings in media and

energy operating costs that will lower the

cost of production significantly. Also, the

environmental impact of an iron or for

that matter any concentrator is signifi-

cantly decreased.

In India where the cost of energy is

significant, availability of power is a

challenge, Grinding media is quite costly

and environmental norms are becoming

tougher by the passing day, it is prudent

that a technology is adopted which

lowers the burden of Power, Media and

Maintenance cost, provides a safer

working environment in addition to

reduced impact on environment.

In the future, it is extremely likely that

more sites will adopt this technology for

more of their grinding needs to improve

their profitability.

Ashutosh AgarwalManager - Mining sales,

Mining & Construction Technology

[email protected]

T E C H T A L K

HIBBING TACONITE COMPANY

“In the initial stages of preparation for the

technical requirements of the equipment,

we had planned to purchase a mobile

washing plant, but Metso’s engineers

convinced us of the advantages of

stationary washing and screening

equipment. Today, with the complex

working 24/7 at full capacity, it is easy to

see that we made the right choice,” says

Maykop Nerud’s Deputy General Director,

Alexey Poddubny.

From sand-gravel mix to quality

aggregates

As raw material Maykop Nerud uses

metamorphic alluvial sediments of hard

rock, deposited in the valley of the Belaya

River millions of years ago. The

sand-gravel mix in the company’s quarry

features some properties of granite with

excellent hardness, making it a good feed

for the production of quality aggregates.

Straightforward quarrying technology is

utilized: excavators dig up the

sand-gravel mix and move it to

stockpiles. From the stockpiles the

sand-gravel mix is reclaimed to Metso’s

three-stage crushing and screening

process, consisting of tracked jaw and

cone crushing plants and a mobile

screen.

Crushed to the size of 0–20 mm, the

material is transported by conveyors to a

washing complex consisting of a feed

hopper, conveyors, a 4-deck washing

screen, a spiral classifier and an

automated control system.

In order to facilitate the operations of its

customers, Metso has established a stock

of spares and consumables on Maykop

Nerud’s territory; Maykop Nerud can use

the stock for its own purposes and parts

can also be delivered to other Metso

customers as required. The reliability of

the equipment and its operational

effectiveness mainly depend on the

availability and prompt replacement of

spares and consumables – a prerequisite

ensured by the mutual efforts of Metso

personnel and Maykop Nerud staff.

Powerful crushing complex in

combination with washing plant

Having taken into account the growing

demand for high-quality end products,

Maykop Nerud and Metso agreed to

extend their cooperation and create an

even more powerful stationary crushing

and screening complex, including a

primary jaw crusher and two stationary

cone crushers for operation in combina-

tion with a stationary washing complex.

“Beginning in the second quarter of 2012,

we will use the new stationary crushing

and screening complex along with the

mobile equipment, thus allowing us to

increase our capacity to 130,000 –

140,000 tons per month in order to meet

the constantly growing demand,” says

Stanislav Steblyansky, Deputy General

Director of Maykop Nerud.

The company’s sand-gravel-mix resources

are expected to last upwards of 20 years.

Upon the completion of mining and

once the territory has been rehabilitated,

the quarry will be transformed into an

artificial lake for recreation and fishing for

the residents of the City of Maykop.

More info:

Alexey Shevyakhov

Tel. +7 495 915 29 30

[email protected]

FACT FILE

Maykop quarry, owned by the Maykop

Nerud Company

Location: City of Maykop, Republic of

Adygea, Southern Russia

Raw material: hard rock sand-gravel mix,

hardness 40 kN

Capacity: 250 t/h, with increase up to 550

t/h in 2012

Resources: over 10 million cubic meters

On-site Меtsо equipment:

1 Lokotrack LT106 jaw plant

1 Lokotrack LT200HP cone plant

1 Lokotrack ST3.5 mobile screen

1 Nordberg CVB 2060-4 inclined screen;

1 Nordberg SF2870 sand trap

Equipment being installed with

commissioning in 2nd quarter of 2012:

1 Nordberg C80 jaw crusher

2 Nordberg HP4 cone crushers

2 Nordberg CVB2060-4 inclined screens



End products:

Washed building sand 0–5 mm and

crushed aggregates 5–10 mm, 10–20

mm, 5–20 mm, 20–40 mm.

Picture captions:

Sochi_1: Metso’s stationary washing plant

was delivered to Maykop Nerud and so

far has processed over 500,000 tons of

high-quality aggregates and sand for the

construction of Olympic facilities in Sochi.

Sochi _2: The sand & gravel mix is

crushed and screened into 0–20 mm

fractions using jaw and cone crushing

plants combined with a mobile screen.

Sochi _3: Positive estimate of the end

product quality. General Director of

Maykop Nerud Company Alexander

Kozhanov (in the middle), with his

deputies Alexey Poddubny and Stanislav

Steblyansky.

Sochi _4: Metso’s sand trap is a critical

component of the washing complex.

Sochi _5: The Maykop Nerud Company

has supplied more than 150,000 tons of

0–5 mm washed sand and aggregates

fractions of 5–10 mm, 10–20 mm and

5–20 mm for shotcreting and for the

concrete lining of the constructed

tunnels.

Construction projects at a total

budget of EUR 5.34 billion

The construction budget of EUR 5.34

billion for projects in Sochi includes three

major sites: the Olympic Park along the

shore of Black Sea, the Olympic Village

containing residences for the athletes,

and the ski resort Krasnaya Polyana in the

Caucasus Mountains.

These three sites will be interconnected

by numerous new highways, roads,

bridges and tunnels. Essentially, the entire

infrastructure within and around the

110-km-long Sochi will be renewed.

More than 155,000 workers are involved

in the construction projects. In total,

more than 300,000 cubic meters of

concrete will be used for shotcreting and

for the solid cladding of the tunnels. A

considerable proportion of that concrete

will be prepared using the aggregates

and sand of Maykop Nerud.

The company Severstroy is producing

concrete elements for lining 23 kilome-

ters of various tunnels. All of the washed

aggregates and sand for those projects is

also being supplied by Maykop Nerud.

Picture:

Sochi_6: In August 2011, construction of

the new ice stadium in Olympic Park was

at full speed.

(30) (31)


The City of Sochi, despite its subtropical

climate, is preparing to host the Winter

Olympic Games in 2014. In connection

with this event, major sports and

infrastructure facilities are being built.

Because the Olympic site is classified as a

12-magnitude seismic zone, the State

Corporation “Olympstroy” and Russian

construction regulations only allow the

use of high-quality washed aggregates in

concrete when constructing critical

objects in Sochi.

The above-mentioned requirements are

being met in full by the company

Maykop Nerud Company, which

produces crushed stone of various

fractions and sand using Metso’s mobile

crushing and screening plant and a

stationary washing complex, processing

ancient metamorphic alluvial formations

into high-quality construction materials.

To date, Maykop Nerud has shipped to

Sochi more than a million tons of inert

materials/aggregates produced in its

in-house production and in adjacent

quarries. Inert materials are delivered to

Sochi exclusively by rail, due to difficult

mountain conditions. The company

dispatches 1 to 2 trains containing 3,000

– 6,000 tons of crushed stone and

building sand to the Olympic city daily.

Aggregates from Maykop Nerud are

being used in many Olympic projects,

including a major ice rink, and in tunnel

complex No. 1, consisting of 2.5 kilome-

ters of road, railway and service tunnels,

which will be used to transport guests at

the Sochi 2014 Olympic Games between

the Olympic Village and a ski complex in

Krasnaya Polyana.

Maykop Nerud’s washed sand is also

being used by manufacturers of tubing

for five tunnels under construction.

“Мetso is more than just a partner”

Maykop Nerud was established just four

years ago and was supplying the inert

materials of other producers using an

in-house railroad warehouse. Later, the

company entered into contracts with

major construction companies running

operations in Sochi and purchased its

own equipment for crushing and

screening.

“While looking for an equipment supplier,

we were approached by leading

manufacturers of crushing and screening

equipment. After their proposals were

subsequently cross-checked, Metso was

deservedly appreciated as a supplier of

high-quality equipment by all other

bidders,” says Alexander Kozhanov,

General Director of Maykop Nerud.

“Since choosing Metso as our equipment

supplier and during the course of our

cooperation we have come to the

realization that Metso is a true partner for

us. In close cooperation with Metso we

develop and implement processes

unavailable to competitors, work

together as a united team and share

valuable experience,” Kozhanov adds.

A good example is Metso’s washing

complex, operated at Maykop Nerud’s

quarry. It is the first complex of its kind in

Russia.

Facilities for the Sochi Winter Olympics constructed with high-quality aggregatesTEXT & PHOTOS Eero Hämäläinen

G L O B E T R O T T I N G

“In the initial stages of preparation for the

technical requirements of the equipment,

we had planned to purchase a mobile

washing plant, but Metso’s engineers

convinced us of the advantages of

stationary washing and screening

equipment. Today, with the complex

working 24/7 at full capacity, it is easy to

see that we made the right choice,” says

Maykop Nerud’s Deputy General Director,

Alexey Poddubny.

From sand-gravel mix to quality

aggregates

As raw material Maykop Nerud uses

metamorphic alluvial sediments of hard

rock, deposited in the valley of the Belaya

River millions of years ago. The

sand-gravel mix in the company’s quarry

features some properties of granite with

excellent hardness, making it a good feed

for the production of quality aggregates.

Straightforward quarrying technology is

utilized: excavators dig up the

sand-gravel mix and move it to

stockpiles. From the stockpiles the

sand-gravel mix is reclaimed to Metso’s

three-stage crushing and screening

process, consisting of tracked jaw and

cone crushing plants and a mobile

screen.

Crushed to the size of 0–20 mm, the

material is transported by conveyors to a

washing complex consisting of a feed

hopper, conveyors, a 4-deck washing

screen, a spiral classifier and an

automated control system.

In order to facilitate the operations of its

customers, Metso has established a stock

of spares and consumables on Maykop

Nerud’s territory; Maykop Nerud can use

the stock for its own purposes and parts

can also be delivered to other Metso

customers as required. The reliability of

the equipment and its operational

effectiveness mainly depend on the

availability and prompt replacement of

spares and consumables – a prerequisite

ensured by the mutual efforts of Metso

personnel and Maykop Nerud staff.

Powerful crushing complex in

combination with washing plant

Having taken into account the growing

demand for high-quality end products,

Maykop Nerud and Metso agreed to

extend their cooperation and create an

even more powerful stationary crushing

and screening complex, including a

primary jaw crusher and two stationary

cone crushers for operation in combina-

tion with a stationary washing complex.

“Beginning in the second quarter of 2012,

we will use the new stationary crushing

and screening complex along with the

mobile equipment, thus allowing us to

increase our capacity to 130,000 –

140,000 tons per month in order to meet

the constantly growing demand,” says

Stanislav Steblyansky, Deputy General

Director of Maykop Nerud.

The company’s sand-gravel-mix resources

are expected to last upwards of 20 years.

Upon the completion of mining and

once the territory has been rehabilitated,

the quarry will be transformed into an

artificial lake for recreation and fishing for

the residents of the City of Maykop.

More info:

Alexey Shevyakhov

Tel. +7 495 915 29 30

[email protected]

FACT FILE

Maykop quarry, owned by the Maykop

Nerud Company

Location: City of Maykop, Republic of

Adygea, Southern Russia

Raw material: hard rock sand-gravel mix,

hardness 40 kN

Capacity: 250 t/h, with increase up to 550

t/h in 2012

Resources: over 10 million cubic meters

On-site Меtsо equipment:

1 Lokotrack LT106 jaw plant

1 Lokotrack LT200HP cone plant

1 Lokotrack ST3.5 mobile screen

1 Nordberg CVB 2060-4 inclined screen;


Equipment being installed with

commissioning in 2nd quarter of 2012:

1 Nordberg C80 jaw crusher

2 Nordberg HP4 cone crushers

2 Nordberg CVB2060-4 inclined screens



End products:

Washed building sand 0–5 mm and

crushed aggregates 5–10 mm, 10–20

mm, 5–20 mm, 20–40 mm.

Picture captions:

Sochi_1: Metso’s stationary washing plant

was delivered to Maykop Nerud and so

far has processed over 500,000 tons of

high-quality aggregates and sand for the

construction of Olympic facilities in Sochi.

Sochi _2: The sand & gravel mix is

crushed and screened into 0–20 mm

fractions using jaw and cone crushing

plants combined with a mobile screen.

Sochi _3: Positive estimate of the end

product quality. General Director of

Maykop Nerud Company Alexander

Kozhanov (in the middle), with his

deputies Alexey Poddubny and Stanislav

Steblyansky.

Sochi _4: Metso’s sand trap is a critical

component of the washing complex.

Sochi _5: The Maykop Nerud Company

has supplied more than 150,000 tons of

0–5 mm washed sand and aggregates

fractions of 5–10 mm, 10–20 mm and

5–20 mm for shotcreting and for the

concrete lining of the constructed

tunnels.

Construction projects at a total

budget of EUR 5.34 billion

The construction budget of EUR 5.34

billion for projects in Sochi includes three

major sites: the Olympic Park along the

shore of Black Sea, the Olympic Village

containing residences for the athletes,

and the ski resort Krasnaya Polyana in the

Caucasus Mountains.

These three sites will be interconnected

by numerous new highways, roads,

bridges and tunnels. Essentially, the entire

infrastructure within and around the

110-km-long Sochi will be renewed.

More than 155,000 workers are involved

in the construction projects. In total,

more than 300,000 cubic meters of

concrete will be used for shotcreting and

for the solid cladding of the tunnels. A

considerable proportion of that concrete

will be prepared using the aggregates

and sand of Maykop Nerud.

The company Severstroy is producing

concrete elements for lining 23 kilome-

ters of various tunnels. All of the washed

aggregates and sand for those projects is

also being supplied by Maykop Nerud.

Picture:

Sochi_6: In August 2011, construction of

the new ice stadium in Olympic Park was

at full speed.

(30) (31)


The City of Sochi, despite its subtropical

climate, is preparing to host the Winter

Olympic Games in 2014. In connection

with this event, major sports and

infrastructure facilities are being built.

Because the Olympic site is classified as a

12-magnitude seismic zone, the State

Corporation “Olympstroy” and Russian

construction regulations only allow the

use of high-quality washed aggregates in

concrete when constructing critical

objects in Sochi.

The above-mentioned requirements are

being met in full by the company

Maykop Nerud Company, which

produces crushed stone of various

fractions and sand using Metso’s mobile

crushing and screening plant and a

stationary washing complex, processing

ancient metamorphic alluvial formations

into high-quality construction materials.

To date, Maykop Nerud has shipped to

Sochi more than a million tons of inert

materials/aggregates produced in its

in-house production and in adjacent

quarries. Inert materials are delivered to

Sochi exclusively by rail, due to difficult

mountain conditions. The company

dispatches 1 to 2 trains containing 3,000

– 6,000 tons of crushed stone and

building sand to the Olympic city daily.

Aggregates from Maykop Nerud are

being used in many Olympic projects,

including a major ice rink, and in tunnel

complex No. 1, consisting of 2.5 kilome-

ters of road, railway and service tunnels,

which will be used to transport guests at

the Sochi 2014 Olympic Games between

the Olympic Village and a ski complex in

Krasnaya Polyana.

Maykop Nerud’s washed sand is also

being used by manufacturers of tubing

for five tunnels under construction.

“Мetso is more than just a partner”

Maykop Nerud was established just four

years ago and was supplying the inert

materials of other producers using an

in-house railroad warehouse. Later, the

company entered into contracts with

major construction companies running

operations in Sochi and purchased its

own equipment for crushing and

screening.

“While looking for an equipment supplier,

we were approached by leading

manufacturers of crushing and screening

equipment. After their proposals were

subsequently cross-checked, Metso was

deservedly appreciated as a supplier of

high-quality equipment by all other

bidders,” says Alexander Kozhanov,

General Director of Maykop Nerud.

“Since choosing Metso as our equipment

supplier and during the course of our

cooperation we have come to the

realization that Metso is a true partner for

us. In close cooperation with Metso we

develop and implement processes

unavailable to competitors, work

together as a united team and share

valuable experience,” Kozhanov adds.

A good example is Metso’s washing

complex, operated at Maykop Nerud’s

quarry. It is the first complex of its kind in

Russia.

Facilities for the Sochi Winter Olympics constructed with high-quality aggregatesTEXT & PHOTOS Eero Hämäläinen

G L O B E T R O T T I N G


(34) (1)

resultsminerals & aggregates

METSO INDIA CUSTOMER MAGAZINE FOR THE MINING AND CONSTRUCTION INDUSTRIES Vol. 18 4 2011

India races on….Jaypee Group and Metso create history together 4

For more information: www.metso.com/performancesolutions

Long term reliabilityMetso Perfomance Solutions consists of Metso global team of professionals possessing experience, technological know-how and pro-active attitude to extend the life cycle of your industrial processes.

We build solid long term relationships with our customers through mutual learning. Understanding of your value chain enables us to steer innovations based on your daily challenges.

QR code for smartphones

2716666www.metso.com/in

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