In issue 2/2014, we take a close look at an in-pit crushing solution in Australia, visit a Lehigh Hanson quarry in Indianapolis where Metso helped achieve significant electricity savings, and much more.
Read it online here
The latest issue of Results customer magazine is out now
In issue 1/2014 we introduce the world’s largest mobile track-mounted jaw crushing plant, witness a successful truckless crushing system in action, and take a look at how MetsoDNA plant automation helps German aggregate producer secure a smooth workflow.
Maarakennus Jalonen crushes with Finland’s cleanest Lokotrack
Emissions regulations set for construction machinery, including crushers, are being constantly tightened, with the targeted final level being the Tier 4 Final standards. The Finnish construction company Maarakennus Jalonen crushes rock using a unit with the lowest emissions in Finland: Metso’s Lokotrack LT120 mobile jaw crusher. Read more
Optimized crushing chamber helps Norsk Stein’s Jelsa quarry save 500 MWh per year An optimized crushing chamber in a primary gyratory crusher can have a significant positive effect on energy costs and on higher capacity. Metso’s crushing chamber optimization project helped the major Norwegian quarry of Norsk Stein to save electricity in the region of 500 MWh per year while still delivering the expected results.
Metso Oil And Gas Crushing Plant
Refining-In-depth process understanding and flow control solution knowledge in refining applications
Valves for naphtha crackers, MEG plants and everything in between – that’s the extent of Metso’s deliveries to the petrochemical industry
The fact that more than 60% of the world’s LNG flows through Neles and Mapag valves provides living proof that our customers
Replacing fossil fuels with renewable fuels is an important step in curbing greenhouse gas concentration. Metso has supplied substantial quantities of valves, actuators and intelligent controllers to bioethanol and biodiesel plants across the world
Lokotrack Mobile Crushing Plants
For contracting, quarrying and inpit crushing applications, Metso’s Mining and Construction Technology offers a wide range of proven products. With the Lokotrack mobile crushing plants, you can build a fully mobile and independent mobile process for your needs.
The proven Lokotrack series features an extensive range of track-mounted crushing plants designed for contracting, quarrying and in-pit crushing applications. The plants are built around robust, high capacity crushers, feeders and screens, enabling them to process practically any rock or ore.
Replacing the conventional dump truck fleet with a Lokotrack LT series primary crushing plant followed by a belt conveying system, or with a complete mobile in-pit crushing plant, brings significant savings in production costs. It also significantly reduces the load on the environment.
The LT Series crushing plants can operate close to the face, so the excavator or wheel loader operator can control the complete crushing operation. This reduces both costs and the workload.
For aggregate production, the LT Series can comprise two or three stage crushing plants. For in-pit and mining applications, the Lokotrack LT range is complemented by Nordberg LL Series conveyors and MAF mobile apron feeder products.
Recognized as the world leader, Metso’s Mining and Construction Technology offers the complete range of primary gyratory crushers to meet every application requirement.
Metso applies computer aided design to our extensive process knowledge resources so that crushing chambers on Nordberg SUPERIOR® gyratory crushers provide the greatest possible throughput with less stress on related components. That means higher capacities, lower power requirements, and more evenly distributed wear patterns on all crusher wear parts for lower operating cost per ton.
SUPERIOR® primary gyratory crushers are suitable for:
The most demanding crushing applications
Stationary and semi-mobile applications
The hardest rock and ores
Surface and underground operations
Main customer benefits of the SUPERIOR® primary gyratory crushers:
Dual counter balance arrangement minimizes the dynamic forces transmitted to your supporting structure
Large-diameter main shaft upper journal with threaded, replaceable alloy steel sleeve
Hydraulically operated and controlled positioning system for quick and effective adjustment of the main shaft/mantle to compensate for liner wear
Main shaft position indicating system is included
Main features of the SUPERIOR® primary gyratory crusher:
Exceptionally high capacity and maximum liner life
Long life and reliable operation provided by an extra heavy-duty frame
Optimized production provided by a computer-designed crushing chamber
Easy maintenance and service
Nordberg NW Series Portable Plants
Putting crushing and screening process on wheels really boosts process efficiency. The Nordberg NW Series portable plant concept can be adapted for all mobile crushing applications, opening up new business opportunities.
Nordberg NW Series portable plants are ideal for:
crushing and screening applications requiring high mobility
stand alone use or as a part of multi stage processes
low cost per tonne operations
Main customer benefits of the Nordberg NW Series portable plants are:
everything on board: feeders, crusher, screen, and power installation
quick road transportation thanks to the king pin arrangement
simple and robust construction for high availability
Main features of the Nordberg NW Series portable plants are:
The NW Series offers maximum set-up flexibility, from coarse to fine crushing, and is cost efficient. It improves working safety, reduces the need for quarry road maintenance, and gives better access to material resources. A further benefit is that waste material can be separated on-site.
The NW Series portable plant can be arranged as a two-stage crushing and screening system, as a three stage coarse, secondary and tertiary crushing and screening system, or as three independent units.
Nordberg C Series Jaw Crushers
The proven Nordberg C Series jaw crushers are designed to crush efficiently all, even hardest rock and recycle materials.
C Series jaw crushers are suitable for:
any demanding crushing application
both stationary and mobile processes
hardest rock and recycle materials
Main customer benefits of the C Series jaw crushers:
high reliability and durability
top continuous crushing performance
excellent total crushing economy
Main features of of the C Series jaw crushers:
The C Series crushers are based on a revolutionary modular, non-welded frame construction, offering owners the highest possible fatigue strength, excellent reliability and numerous mounting possibilities. Thanks to the accurately balanced structure, the C Series jaws are easy and economical to install. Combined with special high-quality cast steel components and durable wear parts, means exceptionally high crusher availability, cost-efficient crushing and low cost per ton.
Nordberg NP Series Impact Crushers
Nordberg NP Series impact crushers feature a unique combination of heavy-duty rotor, wear material and crushing chamber design. This combination has proved revolutionary in improving capacity, product quality and in reducing operating and wear costs.
Why Nordberg NP Impact Crushers?
To get process benefits
To get crusher working benefits
To get maintenance benefits
Very high reduction ratio
Very good cubical shape to meet asphalt and concrete product specifications for flakiness and elongation
Less sensitive to sticky material than other machines
Versatile machine – suitable for quarrying and gravel pit industries, cement industry, concrete and asphalt recycling, and slag recycling
Quick and easy installation
Very simple design with high mechanical reliability
Simple to use
Fixed or mobile applications
Easy blow bars locking device
Wide choice of blow bars and liners
Friendly design to easy maintenance
Many options to improve crusher efficiency
Safe environment working conditions
Nordberg NP Series impact crushers are built on our 50 years’ successful experience with BP and HS impact crushers. The field proven NP series combines the best of these crushers’ technologies and benefits from the latest developments in wear material quality. All helps to achieve the highest levels of profitability.
Nordberg GP Series Cone Crushers
Nordberg GP Series cone crushers have been developed to crush feed materials and create the required end products accurately, efficiently and reliably.
GP Series cones are ideal for:
aggregates production and mines
secondary, tertiary and fine crushing stages
stationary and mobile applications
Main customer benefits of the GP Series cones:
full process adaptability
advanced automation as standard
large feed opening for secondary applications
Main features of the GP Series cones:
The compact size and low weight contributes to a high crushing performance, making the Nordberg GP Series crushers highly popular world wide. Several thousands of GP Series gyratory cone crushers are working around the globe today, a testimony to their first-class reliability and versatility.
The whole range of the GP cones enjoy a global Metso pre and after sales product support including process simulation and planning services, and a comprehensive range of OEM wear parts.
Nordberg HP Series Cone Crushers
Nordberg HP High Performance Series cone crushers are the best available choice for the aggregate and mining market. HP Series features a unique combination of crusher speed, throw and cavity design.
HP Series cones are ideal for:
Main customer benefits of the HP Series cone crushers:
High capacity and yield
High equipment quality
Easy and cost-effective maintenance
Easy to operate
Durable O.E.M. wear parts
With these benefits, the Nordberg HP Series provides unbeatable performance in secondary, tertiary and quaternary applications.
Nordberg MP Series Cone Crushers
Well known throughout the world, Nordberg MP Series cone crushers out-perform the competition, with rugged components and superior crushing ability designed into every machine.
With field proven technology in demanding mining operations, the Nordberg MP Series cone crushers process more ore than any competitive unit at the same reduction ratio or product size.
The MP Series cone crushers deliver up to twice the capacity per crushing station compared to competing crushers.
MP Seriescone crushers are ideal for:
Secondary and tertiary crushing for feeding grinding mills and leach pads
Critical-size material crushing to achieve optimum autogenous or semi-autogenous mill productivity
Special secondary crushing for high reduction ratio applications
Autogenous or Semi-Autogenous pre-crushing
Main customer benefits of the MPSeries cone crushers:
Unobstructed feed opening with a high pivot point for improved performance
Fully automated hydraulic tramp release protects crusher
Pressure sensing lubrication system for longer bearing life
Modular components for easy replacement
Durable O.E.M. wear parts for less downtime
Barmac B Series VSI
The Barmac VSI is an ideal third or fourth stage crusher designed to crush the complete range of ores, rocks and minerals. The Barmac rock-on-rock crushing principle has revolutionised material reduction by providing a crusher that produces excellent reduction at a low operating cost.
Barmac VSIs combine high velocity impact crushing with attrition crushing to produce cubical product & quality sand. Barmac VSIs are unique amongst all vertical shaft impactors due to the pure rock-on-rock principle. Impeller shoes or impact anvils are not needed to achieve reduction.
With over 4000 units operating in aggregate and mineral processing installations around the world, the Barmac VSI has an established track record of cost savings, durability and unmatched performance in a variety of applications. The Barmac VSI is the only thoroughly field proven, successful rock-on-rock vertical shaft impactor.
The Barmac VSI gives you:
Superior cubically shaped product
The lowest possible cost per tonne
Improved energy efficiency
Lower wear costs
Improved crushing performance and control
Versatility to operate in many demanding and diverse applications
Cost effective serviceability
The User Friendly VSI
The Barmac VSI is designed with ease of installation in mind. It arrives on site either as a number of bolt together components or partially assembled.
Assembly, installation and commissioning can be achieved by two people in 2-3 days. Foundation requirements are minimal due to the light weight of the machine and the minimal dynamic forces when in operation. Existing support work can be used or a support frame, legs and skid can be supplied.
Barmac IC3000 Automation System
Barmac Operational Control System IC3.
Barmac Roof Lifter
Barmac Automatic Lubrication System
The overall crushing action in a Barmac VSI is more complex than many other crushers because several different crushing mechanisms are involved.
The Barmac VSI makes product of superior cubical shape.
Size reduction is achieved by several fracture mechanisms which occur when particles collide with each other and with the rock beds within the rotor and crushing chamber. These mechanisms are:
Impact or Shatter
The type of fracture mechanism prevailing depends entirely on the nature of the collision (direct or glancing) and the speed at which it occurs. The high energy interparticle and particle-to-rock-bed collisions produce a particle breakage chiefly along planes of weakness, such as mineral boundaries, jointing and micro fractures, freeing the natural grains without over grinding. The resultant product is freer of weak zones, cubically shaped and often has the valuable mineral exposed or liberated.
Several design features such as rotor size, cascade ratio, rotor speed and crushing chamber liner profile, can be adjusted to enable a wide range of control over the final product grading.
This is the unique Barmac VSI crushing process. It combines several fracture mechanisms to reduce and shape rock particles with high energy efficiency, low wear costs and great application versatility.
Barmac VSI Services
The skills and knowledge acquired from 35 years of manufacturing, applying and servicing the Barmac VSI allow the best solutions to be given to the customer to help maximise the potential of their operation.
To ensure the best service to Barmac VSI customers, Metso provides a comprehensive product support team of dedicated professionals, based at the factory and in the field. We provide full after market support for the Barmac rock-on-rock VSI.
Options for the Customer
Metso offers a range of options which allow the customer to maximise the use of their Barmac VSI, both now and in the future:
Rotor Lease Programmes
Ongoing Product Development
Technical Service Specialists
Specialist Application Knowledge
Support Literature available in a wide variety of languages
The idea for the machine was created by a pressing quarry problem. High quality stone was abundant but the crushing plant could not produce the fines or shape required.
Other plants in the area were using rod mills and hammer mills to overcome the difficulty, but the high costs involved in both capital and operation were impractical. From this initial problem Jim MacDonald and Bryan Bartley developed the Barmac Vertical Shaft Impactor.
In the late 1970 s Tidco, an engineering business based in Matamata, New Zealand, was offered the opportunity of manufacturing and marketing the Barmac VSI.
During the mid-1980’s, joint venture distribution and marketing companies were established in Canada, the USA, Chile and, later, Hungary. By 1987 Tidco had successfully introduced the Barmac VSI to the North American market. This success helped open up other markets around the world.
In 1990, Tidco was acquired by Svedala Indusri AB, a global leader in the production of equipment and systems for the construction, mining, aggregate, mineral processing and bulk materials handling sectors.
Tidco gave Svedala access to the fast growing VSI crusher market, thus complementing their existing range of compression crushers.
In 2001, Svedala merged with Metso to create a world leader in rock and mineral processing technology.
Barmac VSI Produced Sand
Barmac VSIs have consistently produced the best sand for concrete. Ever since the first Barmac VSI rolled off the assembly line concrete plants throughout the world have been making full use of its superior product performance.
The rock on rock crushing action of a Barmac VSI provides perfectly shaped and textured aggregates, ready for use in high strength concrete mixtures. The full gradation of the product allows direct application, giving higher strength concrete and a reduction in cement content.
To further enhance the quality of Barmac VSI produced sand, take advantage of the air classification solutions Metso has to offer.
Introduction To Aggregates
The Barmac VSI can manufacture sand and aggregate to meet the highest specifications for all concrete, asphalt road and other construction purposes. The Barmac VSI’s unique rock on rock crushing action transforms low grade material into premium aggregate products, all the while ensuring low wear and operating costs.
The Barmac VSI crushes a wide range of materials and will process hard, highly abrasive rocks as a matter of course.
The high velocity impact crushing achieved in a Barmac VSI improves the soundness and shape of the stone, reducing product moisture and easing the screening task while producing superior products at a minimum cost.
In a tough market place, the best stone wins contracts. By improving product shape across the range, the Barmac VSI turns otherwise unsaleable material into premium aggregate sizes.
Metso, the manufacturer of the Barmac VSI, is the leader in the field of manufacturing crushing equipment that produces the high specification aggregates used in race track surfaces and many other types of roading.
A Concrete foundation Concrete is the most widely used construction material in the world.
It is cheap and easy to produce and suitable for all levels of technology. Manufacturers wishing to produce premium quality aggregate and sand for all types of concrete make the Barmac VSI their shaper of choice.
The Barmac VSI, with its high capacity and ability to produce finely graded products such as mill feed, sinter feed or material for heap leach operations, is an ideal machine to replace high cost, inefficient crushing and milling equipment.
The addition of a Barmac VSI to an existing crushing circuit can save considerable capital funds when increased production is required from an existing milling circuit.
Critical Size Control
The Barmac VSIs unique autogenous crushing and grinding action has been successful in reducing critical size pebbles from the mill, either as the critical size crusher itself or by relieving the existing critical size crusher.
Advantages of using the Barmac VSI include gaining increases in capacity, low cost modifications, ease of maintenance, reduced power consumption, peak load control and maximised operational efficiency.
Critical size control in SAG & AG milling circuits
A problem associated with autogenous and semi-autogenous grinding is the production of critical size material. These are the particles that are too small to efficiently grind other particles, but too large to be ground themselves.
Critical size particles tend to accumulate in the mill, which reduces capacity and increases the required specific power draw causing mill capacity increases in the order of 12% to 25%. They have to be removed and crushed separately by traditional crushing equipment.
The critical size particles for each milling circuit are different, depending on the viscosity of the pulp, configuration of the plant, seasonal variations and a whole host of raw feed and plant considerations.
The best method of determining the critical size particles is to pilot scale laboratory tests or testing in an existing mill. The means of identifying critical sized particles is to compare particle size fraction/s that shows least change in the amount of material before and after test.
For best mill performance, this material should be taken out of the circulating load and processed by communition means. For optimal performance, however, the crushed recirculating critical sized material should be crushed as finely as possible. This results in even less mill work required and finer mill product.
Barmac VSI as a means of treating critical sized material
The Barmac VSI rock-on-rock crushing action uses attrition and abrasion crushing mechanisms as well as cleavage and impact to crush material. The attrition and abrasion crushing mechanisms of the crushing action produce micro fines and fines in the crusher product.
The unique crushing action of the Barmac VSI makes it ideally suited to the role of pregrinding or oversize reduction in any mill circuit.
Depending on the present system, mill capacity can be increased by up to 25% and specific power savings of around 15% can readily be achieved, often without the need to replace any other equipment.
The Barmac VSI utilises a high energy rock-on-rock crushing action that produces a crushed product high in fines and protects the machine from rock-on-metal wear.
Designed to achieve low operating costs and high availability, the Barmac VSI will readily fit into any processing environment.
Replacement Of Fine Crushing Equipment
The Barmac VSI is a crushing machine which combines impact crushing, high intensity grinding, and inter-particle pulverising. It is best suited in the last crushing stage or as the first stage of the milling process.
Over the last few years there has been an increasing trend towards reducing the number of downstream communition machines. The traditional technology utilised in mining has not changed much in the past 25 years or so. To improve mining circuits new practices and machines must be adopted.
Since the development and use of rock-on-rock crushers in mining circuits, the one area where it has outperformed traditional crushing equipment is in fine crushing duties.
There are various crushers in the industry which perform fine crushing duties, however in many of these applications operators experience difficulties due to the crushing technique employed.
Problems associated with other types of crushers and mills do not occur with the Barmac VSI. Problems with wet and sticky feeds, high wear costs, generation of too little fine and ultra fine material, capacity problems, ‘caking’ and the shape of crusher product can all be mitigated by installing a Barmac VSI.
Some ore bodies will not withstand the cost of milling down to micron sizes, or the ore may be disseminated in such a way that its unnecessary to reduce it to very fine sizes for satisfactory recovery.
To obtain optimum results from the leaching process the ore must be carefully reduced to a particle size that ensures the maximum liberation of target mineral/s. An example of this technique is leaching.
Reduction of the grain size allows more rapid dissolution of the target minera ls. Cost aspects of fine crushing and/or grinding must be weighed up against the extra recovery that may be expected. Also, consumption of the reagent due to finer gangue particles is higher.
The two most important cost factors associated with crushing practice are wear cost of components and power required to run equipment.
In crushing abrasive to extremely abrasive materials these considerations should be taken very seriously when looking at purchasing equipment, particularly for processing industrial minerals.
Barmac VSIs are currently employed in the fine crushing of such materials as bauxite, fused alumina, quartzite, cement clinker, abrasive limestone and many more difficult and abrasive materials as required in the quarrying and mineral processing industries.
Benefits Of Barmac VSI Product
After adding a Barmac VSI to a crushing circuit in an industrial minerals application, the resulting product will be superior to that coming from any other crusher.
The unique rock-on-rock crushing action provides a mechanism for obtaining the best final product results. Variables such as feed gradation, cascade percentage, crushing chamber configuration and rotor tip speed can be altered to maximise the production of required size fractions. This leads to improved returns for the operator.
Barmac VSI product allows for improved wear rates and improved screening efficiencies. This results in lower operating costs and greatly improved final product.
The reduced wear costs of operating a Barmac VSI lessens the metallic wear per tonne of product produced.
This is extremely important in the industrial minerals market where metallic contaminants must be kept to a minimum.
In most industrial mineral applications, high metallic content from wear on crusher parts results in a sub-standard final product. This requires further, costly, processing to have metallic constituents removed. If they aren’t removed a lower sale value of the processed mineral will result.
When dealing with fine profit margins, operators are constantly looking for ways of reducing this aspect of their costs.
Barmac VSIs are currently employed in the fine crushing of such materials as bauxite, fused alumina, quartzite, cement clinker, abrasive limestone and many more difficult and abrasive materials as required in the mineral processing and quarrying industries.
In a Barmac VSI, the high energies required for crushing fine particles are not required to the extent of conventional compression crushing equipment.
t should be noted that grinding is the single largest user of energy within the raw material and cement clinker process circuit.
In the cement manufacturing industry, limestone or dolomite raw materials require grinding twice before the final cement product can be packaged and sold.
Initially, the process is a typical crushing and screening application. Rock is blasted from the quarry face, crushed and screened down to a 40mm to 20mm product before being placed through a mill. The milled raw material is then heated in a kiln to produce cement clinker which in turn requires grinding to produce a saleable cement product.
As the communition process decreases the particle size, subsequent costs and energy requirements of producing fine material go up. With a Barmac VSI installed the cost of producing high amounts of fine material can be done at a minimal cost.
The rock-on-rock crushing action of both the rotor and the crushing chamber promotes the generation of substantial fine material and lower wear costs per hour than conventional compression crushers for a similar throughput and lower power consumption per tonne of product.
The Barmac VSIs rock-on-rock crushing action uses attrition and abrasion crushing mechanisms as well as cleavage and shatter to crush material. The attrition and the abrasion crushing mechanisms of the crushing action produce micro fines and fines in the crusher product. The ability of the Barmac VSI to produce a product with a high proportion of fine material improves milling circuit performance by reducing energy requirement.
This is achieved with the mill doing less work by adding additional fines in the feed and a smaller feed top size. This leads to an increase plant capacity. Furthermore, the improved shape of the mill feed can produce increased grinding media and wear plate life.
Considerable work has been carried out (and is on-going) in the use of Barmac VSIs as pregrinding machines for the production of raw mill feed and also in the pregrinding of cement clinker. Utilising the Barmac VSI principle, it is possible to increase the output of tube mills while at the same time reducing the specific power requirement when related to kWh/t of production.
The increase in production and savings in energy are directly related to the specific surface area of the cement produced. As might be expected, the coarser or lower the specific surface area the higher the savings.
In actual production, trial increases of output in the order of 25%, with specific power savings of around 20%, have been achieved when cements in the 2800/3000 cm/g (Blaine) have been ground.
As the specific surface area increases, these gains decrease when only the performance of the tube mill alone is considered.
It is important to note that adjustments to the existing grinding circuit, such as resizing of grinding media and changing of mill liners, must be made to gain maximum benefits.
Materials which have the required properties are processed to make bricks for the refractory industry. This involves the reduction of material to a suitable size so high resistant bricks can be made for an industry where extremely high heats are achieved or for abrasive environments.
Bricks are required to be as dense as possible to ensure longevity while in service. The product used to make these bricks must have excellent particle shape so high densities can be achieved. Abrasiveness of materials used in refractory products will cause excessive wear on metallic wear parts.
Traditional crushing systems, such as compression crushers and rock-on-metal impactors, have high wear costs and produce considerable product contamination from metallic wear.
Composed of pure carbon, the diamond has an isometric crystal structure, the most common form being octahedral. The diamond representing the top of Moh’s hardness scale is the hardest known natural substance.
The Barmac VSI is utilised as a preferential crusher, where it is used to free diamonds from the matrix of placer deposits. The crushing action of the Barmac VSI doesn’t reduce the diamond in any way, therefore maintaining stone integr
Geographically, diamonds are very limited in their distribution. They are only found in kimberlites and lamprolites or as placer deposits. Not all kimberlites produce diamonds, and of the ones that do the minimum economically workable grade is roughly 0.2 to 0.25 carats per ton. At the surface kimberlite deposits are readily weathered due to their unstable mineral assemblages. Weathered materials are eroded and in this way deposits of alluvial diamond accumulate on river banks, in the mouth of rivers and along coastal areas. These sediments are dredged and recovery is by gravity separation.
The use of diamonds is dependant on their quality. Top quality diamonds are used as gem stones where they fetch the highest price. Lesser quality diamonds are used in industrial applications (referred to as bort) for drilling, cutting, reaming, lapping and wire drawing, where the superior hardness and longevity outweighs cost considerations.
Even though diamonds are very abrasive, they are brittle and will quite readily fracture along octahedral cleavage planes.
The use and application of clay denotes the meaning. To the soil scientist and the geologist the word clay generally means a particle less than 0.002mm and/or a group minerals known as clay minerals.
The Barmac VSI excels in processing this type of mineral in partly weathered granites. As the granites weather, kaolin clays are formed.
When utilising the Barmac VSI as a preferential crusher the clay, feldspar and quartz components of weathered granite can be separated. This is due to the different rates of weathering of each of the components. Quartz, being a durable mineral, takes longer to weather than feldspar and the quick weathering minerals that form kaolin.
The Barmac VSI can be placed as a pregrinder of the calcined clay before entering the ball mill. This reduces the mill feed and the subsequent energy consumption of the mill
Where clay is formed from the weathering of silica rich rocks such as granite and gneiss, it occurs with feldspar and quartz. The clay is separated from the other constituents by washing with water cannons and the slurry is then centrifuged to remove 75% of the minus 0.002mm fraction. Clay is also processed to remove any contaminating materials such as iron, aluminium quartz and feldspar. It is dried and fired to produce molochite and then fed into a ball mill. Various product gradations can be produced.
The uses of clay are varied, depending on the type and markets available. The paper industry relies on clay as both as a coating and as a filler. The traditional home of clay is in ceramics where china clay has become synonymous with high quality pottery. The use today has expanded to include ceramics ranging from sanitary ware to bone china, floor and wall tiles to electrical porcelain.
To a lesser extent, clay is used in refractories, in fiberglass and in portland cement Once the clay is heated to over 500 C it becomes calcinated, forming calcined kaolin. This product has a distinctive crystal structure providing enhanced brightness and opacity.
Waste & Recycling
As the costs of producing aggregates from natural supplies becomes more distant from markets due to residential and industrial zoning, plant operators are looking at recycling as a viable option for providing aggregates and industrial minerals to their markets.
Recycled materials not only take the form of mineral aggregates for the construction industry, but also glass, slags and any other waste product that can be reduced and sold.
These materials are usually fairly cheap to secure and, if treated properly, will provide performance equal to any naturally sourced material.
The Barmac VSI provides the perfect means of treating these materials. The versatility of the Barmac VSI allows it to be used to great effect in many applications.
By applying the unique crushing action of the Barmac VSI, existing heaps of waste crusher fines can be processed into premium manufactured sand by a mobile Barmac VSI crushing plant, thus converting a liability into an asset and improving the bottom line of your operation.
The Barmac VSI has proved an effective tool for handling steel slag and other abrasive metal slags such as that from tin, copper and aluminium.
Rock on rock reduction allows these unsaleable by-products to be crushed and shaped into premium grade aggregates for roading, concrete and drainage uses.
The use of recycled material is an ever increasing market area. Asphalt recycling is also becoming a more active industry as the potential of this particular waste product is recognised.
In a world with a developing social conscience, where recycling a material to increase its useful life and reduce pressure on the environment is vital, the recycling of concrete to produce second generation aggregates is increasingly gaining acceptance. At present, approximately 5% of the aggregates used in the construction industry contains recycled concrete.
Recycling glass is environmentally responsible and makes economic sense. The experience and knowledge gained from participating in the glass recycling industry put the Barmac VSI in a position of strength when it comes to attacking glass recycling applications.
From time to time the Barmac VSI has been applied in situations not categorised by the other four areas. Included here are a couple of sample applications.
The end stability of the dam, whether it be a concrete arch gravity dam or a rockfill dam, depends on the quality of materials used in construction. Better shape leads to better packing of the particles. This results in less voids and a structurally sound in-situ fill materials.
Material required for this type of application must be of a high quality. Not only must the materials be clean of deleterious particles, they must be of excellent shape and consist of tough clean particles.
The Barmac VSI offers both a shaping and a cleaning mechanism to the production of these types of coarse and fine aggregates. The action of the crusher breaks down soft material at a faster rate than the harder tougher particles. This results in a product that is free of softer materials that would perform poorly when subjected to the loads and conditions involved.
If the aggregate used in construction is susceptible to chemical attack, then over the working life of the dam the aggregate quality may decrease. The improved shape of the Barmac VSI product makes a sounder aggregate that is more resistant to the chemical conditions that may exist within the structure.
Over the years we have found that people interested in the Barmac VSI frequently ask the same questions. Below we have provided a list of questions we are frequently asked and provided the answers. Should you have questions that are not answered here or elsewhere on the website we encourage you to contact us or your local representative. We are happy to answer your questions and discuss your application.
1. Is the Barmac VSI dusty in operation?
Under normal conditions the crusher will only emit dust when running empty, this is at startup and stop. In extremely dry conditions or fine crushing duties the crusher may emit dust whilst in operation. This is seldom a great quantity and can be readily controlled by a spray system or dust collection system.
2. Is a high moisture content a problem?
The Barmac VSI crusher is very tolerant of moist feeds. Moisture contents up to 8% are acceptable. Material with greater moisture can be accepted, but may require some minor modification to limit excessive build-up within the crusher.
3. Can the Barmac VSI be operated with a slurry feed?
Metso does not recommend slurry feeds to the machine (except in specialist applications). A slurry feed will result in poor or non existent build-up within the crusher, higher wear and reduced reduction. The Barmac VSI can be modified for slurry operation but is generally limited to a scrubbing duty.
4. Will sticky feed cause a problem?
This is generally related to moisture content, see above questions. Sticky feeds can cause excessive build-up in the rotor, crushing chamber and base. Excessive build-up is not desirable as this can result in increased rotor wear and reduced throughput. Where sticky feed is a problem the introduction of a water spray onto the bottom of the rotor can act to slump out the excess build-up and maintain the normal operation of the crusher. The Barmac VSI is a third or fourth stage crusher – if the feed material does not give problems in crushers or screens before the Barmac VSI, it will not give problems in the Barmac.
5. Is the Barmac VSI noisy in operation?
The Barmac VSI is not a noisy crusher. Sound levels are about 68 to 71 dB one metre from the machine when it is in operation. The rock lining within the crushing chamber is a very effective sound insulator. The electric motor and neighbouring screens are frequently noisier.
6. Does the Barmac VSI vibrate when in operation?
In normal operation there is a slight low amplitude vibration. To restrict any vibration the rotor should always be statically balanced prior to installation in the crusher.
7. Will the rotor go out of balance in normal operation?
No. Wear on the rotor is even and does not affect the balance of the rotor.
Spare Parts Services
Crafted to the same strict specifications and exacting standards as our equipment, Metso replacement parts provide reliable performance for years to come. Whatever your equipment, we have the right OEM certified spares for your rock-crushing needs.
Whatever your crusher, we have the right spare parts.
Vertical shaft impact crushers
Horizontal impact crushers
Track mounted crushers
Wheel mounted crushers
Benefits of using Metso quality spare parts.
Reliable equipment performance
Improved equipment availability
Backed by Metso expertise
Main features of Metso OEM spare parts:
As the original equipment manufacturer, Metso is here for you and your spare part needs. Correct tolerances and dimensions ensure the best results for your stone crushing process. Combined with functionality and endurance, our spares preserve the longevity of your machine.
We also provide OEM spare parts to our numerous heritage brands:
Crusher Wear Parts Services
Our wear parts are designed along with the machine to ensure compatibility for best possible crushing performance. Accurate dimensions and solid casting protect your crusher from overload danger.
Whatever your crusher, we have the right wear parts
Gyratory crusher parts
Jaw crusher parts
Cone crusher parts
Impact crusher parts
Close process control is essential to production, starting with the selection of pure raw materials. Every step of the manufacturing process, including chemical analyses, melting and heat treatment, is recorded to make sure the mechanical properties of the crusher wear parts are top quality.
The final step in the manufacturing process is machining to ensure a precise fit. Certified Metso crusher wear parts consistently provide the highest possible quality and capacity while maintaining maximum trade-in value of your equipment.
Download your Wear Parts Application Guide here!
English PDF 2 MB
Chinese PDF 4 MB
German PDF 2.5 MB
Russian PDF 1.2 Mb
More effective production
Improved working environment
Backed by Metso expertise
We provide wear parts to our numerous heritage brands:
Crusher Chamber Optimization Services
Chamber optimization is especially beneficial for high-volume crushing purposes, where tailoring enables increased production.
Crushing chamber optimization is suitable for:
Main customer benefits of Metso crushing chamber optimization:
Increased production volume
More economical use of energy and wear parts
Less waste and low value product in total production
Main features of Metso crushing chamber optimization.
In data collection phase, our local specialists conduct plant audits to verify such factors as feed gradation, material samples, power draw, foam castings of wear patterns and crusher settings.
The next step is analyzing, where our competence center network focuses on crushing process simulation, material characteristics, improvement potential and global benchmarking.
In re-engineering, we utilize Metso’s global know-how in wear materials metallurgy, state-of-the-art computer simulations and cavity design experience.
Manufacturing takes place in Metso’s own global foundries, whereby we have full control of the supply chain. This ensures consistent quality, perfect fit and high availability.
In the delivery and installation phase, we are able to offer efficient logistics with local know-how and service – boosted by our sales, manufacturing and service facilities in over 100 countries.
Inspections by Metso’s local specialists supported by remote monitoring facilities ensure an efficient follow-up – meaning more uptime, increased capacity, longer wear life and lower cost per ton for our customers.
Supervision And Maintenance Services
Regular inspection and maintenance of equipment installed in your plant is essential to achieving production goals. Metso’s professional service team is armed with the latest product developments, technical specifications and detailed work procedures. Put Metso’s experience to work for you.
Supervision and maintenance are suitable for:
Grinding mills and associated equipment
Pyro processing equipment and associated equipment
Bulk materials handling equipment
Main features of Metso supervision and maintenance.
Experience has shown that regular inspections aid the achievement of production goals in terms of quality, quantity and time. Regular inspections help prevent the mechanical and electrical failures that have a direct affect on equipment availability and productivity.
Our service network is available to provide regular and corrective maintenance services. Our repair facility network offers an extensive range of services stretching from bearing replacement to complete equipment reconditioning. Our repair facilities have highly skilled personnel and the latest technology for equipment repairs.
Main customer benefits of Metso supervision and maintenance.
Parts Replacement Services
Our skilled technicians can ensure safe and efficient parts replacement, provide valuable feedback on equipment condition, and propose appropriate maintenance solutions. Put Metso’s experience to work for you.
Pyro processing equipment
Main features of Metso parts replacement:
The parts replacement service offers delivery and replacement of parts as well as equipment inspection. Our professional crews replace wear and spare parts safely and efficiently and – in addition – evaluate equipment condition and wear.
Main customer benefits of Metso parts replacement:
Repairs, Refurbishments Services
Metso’s repair centers combine skilled personnel, global industry experience and the latest technology. Our extensive range of services include equipment modification and repair; equipment rebuilds and upgrades; and in-depth failure analysis and trouble-shooting. From bearing replacement to complete machine refurbishment, Metso’s repair centers are committed to keeping your equipment in peak operating condition.
Repairs, refurbishments and retrofits are suitable for.
Horizontal shaft impactors
Vertical shaft impactors
High pressure grinding rolls
Bulk material handling equipment
Main features of Metso repairs, refurbishments and retrofits.
Metso offers extensive repair and rebuilding services as a cost-effective alternative to purchasing new or replacement equipment. These services are available through our experienced aftermarket engineering staff and customer service representatives, at our manufacturing facilities worldwide.
Backed by years of experience, we can repair broken or damaged equipment to “like-new” condition and restore worn or irreplaceable equipment to perfect operating condition.
Main customer benefits of Metso repairs, refurbishments and retrofits.
Circuit Design And Optimization Services
A change in comminution circuit design or operational philosophy can often result in a reduction in power usage or an increase in circuit throughput. Metso PTI, Process Technology and Innovation, has vast experience in crushing, screening and grinding modelling and simulation techniques.
This simulation expertise, coupled with extensive industrial and consulting experience, is used to assess comminution circuit configuration and the key design variables of the system. Alternative operating strategies and conditions can be simulated and the outcomes compared to each other and the current situation to evaluate various strategies with minimal disruption to production. Different equipment options can be compared and evaluated; including fine and ultrafine grinding as well as equipment from within and outside the Metso portfolio.
The operation of a comminution circuit is often strongly constrained by the feed size distribution it receives and the product size it is required to deliver to prevent losses in downstream processes such as flotation. PTI conducts comminution optimization with a fundamental understanding of these upstream constraints and downstream effects.
Equipment Protection Plan Services
Protect your business against unexpected component failures. Metso Equipment Protection Plan provides extended insurance cover for key components of construction crushing equipment against their unexpected failure for a period of 5 years or 10,000 hours of operation.
Metso Equipment Protection Plan is suitable for:
Main customer benefits of Metso Equipment Protection Plan.
Less unexpected maintenance costs
Main features of Metso Equipment Protection Plan:
Equipment Protection Plan is a reliability assurance program that covers key components of your Metso equipment, representing up to 75% of the complete crushing equipment value. Standard freight and service supervisory work are also included in the program coverage.
Regular equipment inspection visits from a Metso certified inspector are part of the reliability assurance program. Certified inspectors help optimize your equipment’s life-cycle productivity, aiming for the lowest sustainable cost of production. Profit from our expertise, available through the Metso worldwide service network. Get service from the leading specialists in the industry.
Maintenance And Operation Training Services
Metso customer training seminars focus on OEM recommended operation and maintenance procedures knowing that skilled equipment operators and maintenance crews keep plants operating profitably. Training seminars are organized in a wide variety of languages and locations worldwide.
Certified training is available for.
Main features of Metso certified training.
At Metso, we believe that a knowledgeable and well-trained workforce is vital to the success of any organization. Whatever your objectives, Metso is committed to sharing our expertise with your operators and other plant personnel. As a result, Metso has developed important training that will help you reach your goals. We offer both classroom seminars and training at customer’s plant location.
Screening Equipment Services
Lokotrack Mobile Screens Services
The proven Lokotrack mobile screens are designed for high screening performance combined with good mobility. Their excellent capacity and easy adaptability to different crushing and screening processes guarantee suitability for a wide range of quarrying and contracting applications.
Lokotrack mobile screens are ideal for.
accurate classification of gravel, sand, aggregates and recycle materials
multi stage crushing and screening operations with other Lokotracks
Main customer benefits of the Lokotrack series mobile screens are.
excellent screening capacity
operator friendliness thanks to intelligent process steering
easy to move from site to site
world wide spares & screen media back up
Main features of the Lokotrack range mobile screens are.
The ST Series track-mounted mobile screens have heavy duty frames and proven components to give long service life in most demanding screening jobs. With the ST Series, you can choose flexibly and accurately the end product fractions to be screened.
Vibrating Equipment Services
Metso’s Mining and Construction Technology offers numerous vibrating equipment brands that the industry has grown to respect and trust – Hewitt Robins, Tyler, Seco, Nordberg and Svedala.
Equipped with over 400 years of combined vibrating equipment experience, the North American Vibrating Equipment Group is continuously developing new and improved products to keep up with the ever-changing demands of both the aggregate and mining industries.
In addition to being a provider of crushing and complete rock and mineral processing solutions, Metso has also gained a worldwide reputation as a specialist in vibrating equipment.
This is demonstrated by thousands of installations worldwide where our screens, feeders and scalpers operate in the most demanding applications, from complete multi-stage plants to highly mobile installations.
All of these installations benefit from Metso’s superior know-how and years of field experience.
A history of quality
In 2001, Metso became an even stronger player in the manufacture of vibrating equipment through the merger of Nordberg and Svedala. Metso now offers more than 300 years of collective experience in vibrating equipment.
Whatever your process requirements, Metso has the right solution – from sturdy feeders and scalpers to efficient inclined or horizontal classifying screens. Just name your application, and Metso’s professionals will find the most productive and cost-effective vibrating equipment for you.
Metso Mining Screen Range Services
Metso has leveraged its vast product knowledge, unequalled industry experience and exceptional design expertise to create a breakthrough product range of vibrating screens for the mining industry.
Combining mining industry standards such as Nordberg, Svedala, Allis Chalmers and Hewitt Robbins into a unified global new product range, the Metso mining screen range.
Our range includes following models:
MF Multi Flo Linear Motion Curved Decks
RF Ripl Flo Circular Motion, Curved Decks
LH Low Head Linear Motion, Horizontal Decks
Product is ideal for
Our new mining screen range is specifically designed and manufactured for the mining industry.
Can be designed with Metso Trellex screen media for full process guarantees
All components are standardised as global parts allowing supply chain and manufacturing, spares and support benefits
Global product support and application expertise with local dedicated experts
Can be supplied with Metso Trellex dust enclosures
Compatible with all Metso’s minerals processing equipment as well as other brands, Metso mining screens come with a unique process quarantee. Other features include.
New linear Motion Gearboxes and new Circular Motion exciters both with quickly adjustable flywheels for stroke adjustment
Ability to be driven with vee belt, jack shaft and variable speed drives to optimize the speed needed
Ability to be utilized with remote monitoring of a customer’s site
On-line screen performance monitoring availablity
New 24hr performance and condition monitoring system
Roller Screens Services
Metso s roller screens are used to separate on size particles from the oversize and undersize fractions.
Gentle handling by the roller screen maintains the integrity of fragile materials.
Rotary Railcar Dumpers Services
Metso’s railcar dumpers have set industry standards worldwide since 1905. We offer various systems and features custom-designed to service random and unit trains of any length or style, and with varying car sizes.
Single, tandem and triple dumpers are engineered to provide long life and low maintenance service in dumping coal, ores, sulphur, phosphates, wood chips and other bulk materials.
Our rotary railcar dumpers can be furnished with a patented integrated dust containment system.
The metso’s railcar positioners are designed to move individual cuts of 1-10 cars to entire unit trains in excess of 200 railcars. When combined with our dumper, the complete railcar dumper/positioner system provides fast dependable train turnaround requiring only one operator.
These systems are computer monitored and SCR controlled to meet exacting dumping requirements from 5 cars per hour to more than 90 cars per hour.
Upgrades & Retrofits Services
Metso employs a dedicated staff of multi discipline engineers with the sole purpose of fixing and solving problems. Our group provides.
Design modifications to improve reliability, maintainability, and safety
Controls upgrading to use readily available parts, improve operations or to automate machine operations
Rebuilds and retrofits for restoration to original condition or adaptation to new technology
Application engineering to determine the “why” behind problems and develop innovative solutions for materials handling efficiency, dust containment, e
Stacking & Reclaiming Services
Our complete stockpiling and reclaiming systems include interconnecting conveyors, transfer points and ancillary equipment such as scales, feeders and dust collection suppression.
We have been serving customers since 1889 in many diverse industries. Our respected brand and trademarked names include:
Stephens Adamson McNally Pittsburg Lakeside A.C. Hoyle Breco FACO McDowell Wellman Meade Morrison MKT Corporation Mukand McNally Wellman PECO Nolan HCM McNally Wellman Cable Belt NICO Strachan & Henshaw – Strata-Tro
Bulk Handling Services
Engineered Parts Services
Metso supports equipment previously sold under a variety of trade names. Based on original specifications and incorporating the most recent innovations, our custom-engineered solutions fit seamlessly with your existing equipment and processes.
Engineered-to-order parts are suitable for:
Main features of Metso engineered-to-order parts:
Parts are critical to the successful operation of any processing plant. Metso owns and maintains the drawings, specifications, manuals and design calculations for equipment previously sold under a variety of trade names. In addition to our heritage brands, we can also provide engineered to order parts for selected third party equipment.
As a result, Metso can provide repair parts built to the original tolerances and specifications while also incorporating the latest design improvements. Our engineered-to-order replacement parts will keep your equipment productive for years to come.
Main customer benefits of Metso engineered-to-order parts:
Trellex Conveyor Accessories Services
Our motto is Reliability in Conveying It means we develop manufacture and market conveyor components and accessories that increase the reliability of our customers conveying operations.
Trellex products increase up time improve the environment and reduce the need for maintenance. They feature smart simple design that makes them efficient rugged and maintenance friendly.
Metso Minerals offers a wide and deep knowledge of conveying materials. With experience built-up since the 60’s we provide expertise
to solve problems and improve the efficiency of existing installation.
Collected here, you find a few samples of common problems and samples of how to solve them.
Lining Solutions Services
Metso’s concept of providing the right product for the right application has resulted in the most complete and flexible range of lining products available to the market today.
Lining solutions are suitable for.
Main customer benefits of Metso lining solutions.
Improved wear life
Reduced cost for service and maintenance
Main features of Metso lining solutions.
We develop and produce linings for most types of applications in the aggregate, mining, cement, pulp and paper industry. Trellex lining solutions are designed to maximize productivity by keeping material flow up and maintenance down.
We offer unique lining systems:
Rubber with built in high quality hardness ceramics, with excellent resistance to abrasive wear even in high material flow and speed
Rubber plates with excellent wear resistance in applications with both impact and sliding wear
Lining system where we bring together different materials to maximize flexibility and wear life
Engineered Retrofits Services
Our engineered to order solutions can help either to restore your equipment to its original condition by replacing damaged parts or to adapt it to new technology by implementing design modifications and installing modern components.
Engineered to order upgrades and retrofits are suitable for.
Main features of Metso engineered to order upgrades and retrofits.
When compared to the acquisition of brand new equipment, implementing modifications dramatically shortens lead times – and is much more cost effective. Depending on what the job entails, it can be done within your own facility or at the nearest Metso repair center.
By incorporating our engineered to order solutions, you get the best results from your equipment, regardless if it is a current or previous model. In addition to our heritage brands, we can also provide engineered to order upgrades and retrofits for selected third party equipment.
Since alkylation occurs in the presence of highly acidic catalysts hydrofluoric acid or sulfuric acid, special attention is required when selecting valves and their material. Metso’s and for control and isolation ensure optimum control performance, friction free tight valves in a wide selection of materials for optimum reactor performance and column efficiency that ensure top-quality alkylate compound for gasoline blending.
Catalytic Reforming Services
Until recently, the only answer to regenerating the coke-coated catalyst was to shut down the system and do it manually, meaning costly downtime. But the UOP CCR Continuous Catalyst Regeneration Platforming process technology permits the addition and removal of the catalyst from the reactor while the system is still running, negating the need to shut down the system.
You know what’s interesting? UOP has stated that it used Neles valve designs and their respective Cv and flow coefficient values to establish the flow parameters for the CCR Platforming process. No wonder most of the valves installed in these systems are Neles valves. Needless to say, we offer multiple solutions for handling a range of isolation and control challenges in key segments of the CCR Platforming system: Proven performance, coupled with our extensive experience in this field, makes Neles valves the clear choice among UOP field technicians.
Delayed Coking Services
Neles Delayed Coker 2-way ball valves provide tight, bi directional shut off. Unlike competitive valves that are tight in only one direction, Neles valves operate reliably under normal or severe pressure or flow conditions a key requirement in the overhead vapor area, where higher pressure occurs on the valve closest to the fractionator return line.
The Neles Delayed Coker valve’s live loaded stem packing and steam purge connection prevents residuum from leaking into the gland packing area. The stem purge design is critical to the life expectancy of the valves. Because the valves are oriented horizontally in the pipelines, residuum tends to flow into the lower confines of the ball body cavity. Neles supplies two body purge ports on every 2 way valve one in the lower part of the cavity and one in the upper part – to flood the cavity with steam and minimize the flow of residuum to this area. The results? Neles Delayed Coker ball valves have a proven record of trouble-free operation for periods exceeding 6 to 7 years without maintenance.
Crude Distillation Services
In crude and vacuum unit heater feed control and isolation the Neles MBV Series X full- bore ball valve provides maximum flow capacity and tight shutoff at low pressure. Do you want control and isolation of the fuel gas to the heater? Then you want the Neles R-Series V-port segment valve with Quadra-Powr® actuator combined with the Q-Trim® attenuation device for an equal percentage flow characteristic along with Cv and control rangeability. Our customers report remarkable savings in maintenance costs after installing our control valves in CDU heater coils. Sticky oil leaking through the gland packing has been avoided with Neles Finetrol and Top Entry valves, thanks to their rotary stem. This obviously improves heater performance and reduces leakage to the environment.
The Neles Finetrol® control valve is ideal for efficient column performance producing top quality distillates. Neles metal-seated ESD (emergency shutdown) ball valves and the Neles ValvGuard partial stroke testing system are designed to increase the availability of safety instrumented systems. Neles ESD valves also ensure the safe flow of heavy bottom as it progresses to the vacuum distillation column. In vacuum breaker service, Neles L6 Series double-flanged Neldisc triple eccentric disc valves can be equipped with the Neles ValvGuard ESD safety system to protect the distillation column in the event of a process upset.
Gas Treatment Amine Plant Services
Major operating considerations for amine units are maintaining the condition of the amine solution, minimizing losses and preventing hydrocarbon carryover to the sulfur plant. The amine circulation rate according to the acid gas loading is one of the two typical process variables to be optimized. With Neles Finetrol and Neles RotaryGlobe, high loop performance gives the potential to operate the absorber closer to the edge of the operating envelope. The savings are realized in reduced amine consumption. Long lasting metal-seat tightness minimizes amine losses and the gland packing structure reduces emissions to the environment. Process reliability can be improved by the Neles ND9000 intelligent valve controller’s on-line diagnostics that provide full transparency of valve performance. Wide rangeability with rotary valves ensures that the lean amine circulation rate can be changed as the need arises during the run period. For severe applications, such as rich amine letdown, we recommend Finetrol flow to close or T-series top-entry rotary valves for high-pressure applications with optional hard coatings and Q-Trims for flashing conditions or outgassing applications to ensure optimum plant performance.
Efficient operation of the amine plant stripper is a balance between the amine separation from acid gases and reboiler energy consumption. Neles Finetrol valve is ideal for these tasks, due to its stable control behavior that keeps process variability to a minimum. Savings are realized in effective amine separation from acid gases and reduced energy consumption in the reboiler. Rotary design low emission valves with reliable stem packing provide a simple and cost-effective way to avoid fugitive emission for acid gas service.
Fluid Catalytic Cracking Services
The Neles product line, known for its reliable valve sealing technology, has been developing demanding application valves for more than 50 years. Some of the most demanding applications reside in the FCC unit, due to the abrasive nature of the catalyst fines. That’s why Neles gives special attention to material selection and hard coating of the trim. Another strength is the proven and unique solids-resistant seat design in ball valves – just one more reason why so many Neles valves are found in these systems. Whether it is oil slurry isolation, oil slurry flow control, or hot air regenerator systems, Metso has the solution. Proven performance coupled with extensive experience in the field are why our valves are the clear favorites among FCC technicians.
The objective of hydrocracking is to convert heavy hydrocarbons into high-quality lighter products. The most important part of the cracking process is the catalyst system and reactor temperature control in order to avoid catalyst fouling and safety risks. This control is achieved by injecting cold hydrogen quench into the reactor.
With the Neles RotaryGlobe valve and the Neles ND9000 intelligent valve controller the hydrogen quench to the reactor can be controlled safely and accurately. This gives potential to improve the process economics by optimized hydrogen consumption and the use of more efficient catalysts. Therefore the unit production can be increased. Wide rangeability with rotary valves ensures that hydrogen flow can be increased as the need arises during the run period due to catalyst activity loss; reserve capacity for emergency quench is available with a single valve solution.
Neles control valves provide proven reliability and accuracy to heater fuel gas control with \ single valve solution that eliminates the use of split range control. Reliable fuel gas control is important in order to avoid system failures and to protect the reactor from excessive temperatures.
Sulfur Recovery Tail Gas Treatment Services
Increasing environmental demands require correct performance of these units, which are critical to the operation of the entire refinery. Correct valve selection for control and isolation of the sulfur recovery and tail gas treatment units is therefore a critical factor in overall performance.
Neles valves have been installed in these plants for a number of control, on off and ESD installations worldwide for over 30 years. Because sulfur compounds are very hostile to metals, particularly at the high pressures and temperatures encountered in refining, the quality of control valves takes on prime importance. Stable and accurate control behavior obtained by Neles Finetrol and Segment valves is extremely important for efficient burner operation. Rotary design low-emission valves with reliable stem packing provide a simple and cost effective way to reduce overall fugitive emission.
With Neles high-integrity certified ESD valves and the SIL 3 Neles ValvGuard™ partial stroking system, sulfur recovery unit safety and reliability targets can be met. Neldisc butterfly valve’s long lasting bi-directional metal-seat tightness and fire-safe construction ensure long-term performance and tight shut-off with full steam jacket and optional bearing protection that prevent sulfur build-up and provide a compact and economical valve solution for the handling of liquid elemental sulfur.
Neles Finetrol and Top Entry control valves are ideal in demanding visbreaker applications from heater coil flow control to column bottom residue control. Due to the rotary stem, oil leaking through gland packing can be avoided, and the unique Q-trim design reduces the risk of coke particle build up inside the valve. Neles valves provide reliable fuel gas control with a single valve solution and reduced variability that improves heater efficiency and visbreaker heater outlet temperature control, which is important for optimum cracking temperature.
Pulp And Paper Solutions Services
Plant Automation Solution Services
The Stora Enso Imatra Mills produce over a million tons of board and paper per year. The energy production of the mills relies on two recovery boilers, the KK2 bark boiler and the K12 gas boiler. In order to secure availability, Metso updated the automation systems of the KK2 bark boiler and the K12 gas boiler, and improved the process with steam network management, combustion control and turbine controls and protection.
Caliper Control Improves Services
The first of a new generation of Metso’s IQ Induction profiler has been operating in Metsä Board’s Kyro mill in Finland since May 2013. As well as improved CD caliper profiles, new CD controls also help machine crews to reduce breaks.
Valves Iincrease Process Services
Admittedly, valves are not the most exciting components in the pulp and papermaking processes. Yet their role can be crucial in maximizing process availability and increasing efficiency the much sought after goals in today’s tough economic times. In the past 60 years, Metso’s flow control solutions have contributed to numerous success stories around the world.
Energy Efficiency Services
Having had problems with fouling on conventional steamboxes, Metsä Tissue Mänttä Mill in Finland was doubtful about Metso IQ Steam Profiler performance on its PM 10. Well, the doubts have been removed. In addition to better cleanliness, the results include lower Yankee hood gas consumption and improved moisture CD profiles.
Brightness And ERIC Measurements Services
The past few years have been marked by trends of increasing raw material costs and energy costs, leading to higher operating costs. At the same time, increasing competition and higher quality demands at lower prices have created the need to optimize operating costs while enhancing product quality.
Productive Machine Operation Services
Metso’s comprehensive but scalable automation solution is geared towards optimum productivity, energy efficiency and product quality. This comprehensive automation concept is now complemented with newly updated products for furnish analysis and control, machinery condition and process stability monitoring and diagnosis and high-speed web break analysis capabilities. This paper and presentation describes Metso’s tissue automation concept with particular emphasis the newly updated products.
Fugitive Emissions Efficiency Services
Mikko Vuolanto, Metso Automation, Finland, discusses how safety standards can enhance both safety and efficiency simultaneously.
Uniform Efficiency Services
In order to increase the share of renewable energy in production and to considerably reduce coal consumption, Vaskiluodon Voima invested in a new gasification plant at its Vaasa power plant site. The gasifier feeds the old pulverized coal boiler with product gas, which is combusted in the boiler in combination with the main fuel. Automation solution was designed to ensure the plant efficiency in operation with biofuels, the moisture content and heat value of which typically vary a lot. Read more
Waste & Energy Services
Anyang City is a medium-sized city in the Republic of Korea with approximately 630,000 inhabitants. The city, located in Gyeonggi do about 55 kilometers south of Seoul, has a vast amount of experience in solving the problem of handling municipal waste in an eco-friendly way. For more than 20 years, Anyang City disposed of its problem by using the waste in combined heat and power production
Control Loop Services
Control loop performance is more than just about tuning. There are huge opportunities. About 20 % of control loops are in manual. This is an incredible waste of investment. The cost of a loop is about the same as the cost of a car if you consider the entire design and installation cost. Having the loop in manual is like having a car parked in the driveway
Pharmaceutical Industries Services
Automation solutions for production and product control.
Food Industry Services
Automation systems, measurement sensors and valves for modern food production plants.
Customized solutions and services for metal and waste recycling.
Numerous automation installations for ships starting in the early
Power Generation Services
Reliable, capable and agile partner in power automation.
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