Talvivaara's primary crushing capacity boosted by crusher cavity optimization

Talvivaara mine, located in Northern Finland, is today the biggest sulfide nickel ore mine in Europe. In close cooperation with Metso, and with crusher cavity optimization, Talvivaara recently boosted its primary crushing capacity annually by up to 3.5 million tons.
An open pit nickel deposit with 0.22% average content, Talvivaara is a mine of many superlatives. Today, about 22 million tons of nickel ore is excavated at the mine annually. Using bioheapleaching, the mine currently produces 30,000 tons of metallic nickel per year.
After huge, up to 300,000-ton blasts, the feed material is dumped into the primary gyratory crusher and then transported along a more than two kilometer long conveyor to the secondary and tertiary crushing stages. After activating the ore, bioheapleaching of the ≤8-mm ore takes place in four piles, each 400 x 1200 meters in size. The natural bacteria are used to extract the nickel out of the ore.
A challenge caused by slippery ore
The nickel ore in Talvivaara is hidden inside black schist, which is extremely slippery material to crush. Already the first crushing test indicated that normal capacities would not be easily achievable.
After installing the huge 60 x 89 inch primary gyratory crusher, it immediately became apparent that the capacity would fall far behind the planned capacities. For the total mine economy, this presented a real challenge.
"Our main problem was caused by the profile of the original crusher wear mantle. Its cavity was not the right one for processing slippery ore, and it caused the feed material to jump up from the cavity, thus decreasing the capacity," explains Erkki Kärkkäinen, Manager of Materials Handling at Talvivaara mine.

“Throughout the entire development process, our cooperation has been very open and honest.”
Jyrki Lahenius, Department Engineer, ore processing at Talvivaara

Cavity optimized through cooperation with Metso
In order to quickly find a solution to the primary crusher cavity issue, Talvivaara contacted Metso's crusher wear parts specialists at the Tampere office in Finland. The task presented was to find a cavity that can better process the slippery ore and guarantee the capacities required for the mine economy.
"Actually, we studied all of our crushing-related parameters with Metso in order to find the right solution. Throughout the entire development process, our cooperation has been very open and honest," recalls Jyrki Lahenius, Department Engineer, ore processing, at Talvivaara.
After several meetings, using Metso's crusher cavity optimization process know-how, including 3D mantle design tools, the right angle for the mantle cavity was found, and the suitable manganese type selected. Metso's Tampere foundry casted the huge, two-piece wear mantles in the spring of 2010.
A 15% capacity increase can make a difference

Bioheapleaching extracts the nickel ore from the ore, resulting in a bright green liquid, several million liters of which is pumped daily during the leaching process.

In May of 2010, the Metso mantles and outer wear parts were installed into the primary gyratory. After crushing for 8 months, the results are quite positive. The primary crushing capacity has increased by an average of 15%.
Given as a percentage, the increase sounds quite modest. However, when calculating the annual capacity increase, Erkki Kärkkäinen ends up with a figure of 3.5 million tons of extra capacity.
In terms of hourly capacities, the primary gyratory’s original capacity during test drive was under 3,000 tons, and, after installing the Metso wear parts, it is about 3,500 tons per hour.
"I believe that with more efficient feeding, we can achieve a continuous production that exceeds 3,000 tons per hour. We currently feed the crusher using big Hitachi dump trucks, dumping 150 tons of ore into the crusher every 2.5 minutes," says Kärkkäinen.

Gold ore crushing plant in South Africa

Rand aurideposit are famous for it is the largest gold producing area of the world. In South Africa, the gold are the top tree mineral for export and it do bring great much interests to South Africa economy. In South Africa, gold ore do attract a number of businessmen. No matter the scale is big or small, gold ore crushers are widely built in South Africa.

Though these years, the gold ore production cost increase a lot, and the gold market is not so bright with the decline of iron ore price. Many investors are still confident of the South Africa gold industry.

South Africa Gold Ore Crushers

Because many largest gold ore deposits are controlled, most investors’ gold ore crushing plant are small scale. The popular gold ore crushers are small jaw crusher, hammer crusher, ball mill and matched sand washing machines and vibrating screens.

Hammer crusher in South Africa

Double produces many hammer crusher models to satisfy different customers’ requirements. Our hammer traditional hammer crushers are produced according to some customers’ special requirements. Following are the advantages:
1.Simple structure and easy for maintenance
2.Small capacity and wide wide application: some customers may new in the crushing industry and just want to start one small capacity crushing plant, the hammer crusher fit for the customers very well.
3.Adjustable discharge opening size: the hammer crusher has its own grate at the bottom, it is easy for changing. Also, the final products size range is quite wide.
4.Good production sharp. Aggregates crushed by the hammer crusher are almost square, it is good for varies industries.

Double updated hammer crushers for new demand

But there are still some problems in satisfy many customers’ demands. So we update the hammer crusher at the beginning of 2011. Our new style hammer crushers make up shortage of the traditional ones.
1.The new style hammer crusher has big capacity and high crushing ratio. Sometimes, customers may need to produce very fine particles and big capacity,such as many customers may want to crush coal, glass, NPK Granules and some others to fine particles. The new style hammer crusher is competent to this task very well.
2. The rear frame can be opened for convenient maintenance
3. Separate bottom gate is convenient for adjust the discharge opening size

Ball mill for South Africa gold ore

These hammer crushers well satisfy small scale South Africa gold ore producers. Meanwhile, ball mill are very popular, too. It can easily ground the gold ore to small particles. At the bottom of ball mill, one wire mesh is installed, so it separates the qualified ones directly before discharging them from the machine. Actually, ball mills are widely used in sorts of South Africa mining ore beneficiation plants. Such as tin ore beneficiation plants, iron ore dressing plants, manganese ore processing plants, etc. It is really a high performance and price ratio mining processing equipments.
If you are one investor and plan to invest in South Africa gold ore industry, just be free to contact us; if you any problems about the South Africa gold ore crusher, just be free to contact us. You can chat with our engineer on-line, the answer will be shown you immediately; you could also leave your email address with us, we will get in touch with you within 24 hours.

200TPH chrome ore crushing plant in South Africa

South Africa mineral resources are very rich, it take 50% mineral resources of Africa countries in amount and the mineral resources is the fifth one of the world. Especially, the platinum metals, the chrome, gold, andalusite, vanadiumore resources are the first one of the world. South Africa is Chrome oxide and there is only one compary (the MMC) have electrolysis Chrome production line. So a large amount of Chrome ore is mainly used for export. While, the quality of South Africa Chrome ore is very good, the Chrome content by weight is about 50%. Great many South Africa Chrome ore crusher are installed here for its advantages.

Chrome Ore Crusher for Sale in South Africa

At the beginning of 2011, one customer from America made one inquiry and would like to invest in building one 200TPH Chrome ore crushing plant in South Africa. Communicated with him and his partner, we have a general idea of their demands and we shared our opinion with them according to their budget.

Finally we got an agreement of one design and they placed an order after visiting Double Company and Double factory. In this Chrome ore crushing plant, one unit vibrating feeder, one unit jaw crusher and two units cone crushers and two units vibrating screen are used.

Chrome ore processing equipment

The whole crushing process begins from dumping the raw ore to steel hopper above the vibrating feeder, which ensure steady feeding process. Double vibrating feeder structure is very simple and we strengthen the wear parts, increasing the service life greatly. To the jaw crusher, we adopt heavy movable jaw and optimized connect methods, in this way, the hard mining ores can be crushed easily.

Obviously, jaw crushers are just primary crushers, they can crush big lumps to small lumps, but the products output size is still bigger than customers’ requirements. So when material discharged from the bottom of the jaw crusher, they are transported to one transfer station by belt conveyors. Under the transfer station, there are two units electric vibrating feeders, they feed the crushed lumps to belt conveyor steadily.

Then the lumps will be fed to the cone crusher. Double has two series cone crusher for sale in South Africa, one is HP series hydraulic cone crusher and another one is S series cone crusher. Here considering the budget, we suggest customer using two set S series cone crushers. By using this type cone crusher, customers can crusher mining ore aggregates to small particles easily.

For example, mining ore lumps can be crushed to 0~5mm, 5~10mm, 10~20mm or 0~1/8”, 1/8”~1/4”, 1/4”~1/2”, 1/2”~3/4” and 3/4”~1”. These size ranges well satisfy the world’s customers’ commonly requirements. Particles outputted from cone crushers are mixed with each other, to separate the different sizes particles, Double vibrating screens are necessary. The wire meshes are changeable, so producers just need to change the wire mesh if they need produce different size products. Finally, the qualified ones are conveyed to the store pile sites and oversize ones are transported to the cone crushers for crushing again.

chrome ore crushing plant

Simple illustration is just like this, now all the equipments have been shipped to South Africa already and it may started to run in the next year. This chrome ore crushing plant in South Africa will help more and more customers know Double products.

If you are interested in mining ore crushing plant, if you want to utilize mining ore crusher well, just be free to contact us. You can chat with our engineer on-line, this way, you will get answer immediately; you can also leave your email address, we will answer you within 24 hour

Beneficiation process of magnetite ore

Iron ore being the essential raw-material for iron & steel industry, its mining arguably is the cynosure of all mining activities undertaken by any country.

About 87% magnetite ore deposits occur in Southern Sector, especially in Karnataka. Of these, hematite is considered to be superior because of its high grade. Indian deposits of hematite belong to the Precambrian Iron Ore Series and the ore is within banded iron ore formations occurring as massive, laminated, friable and also in powdery form.

Magnetite ore beneficiation process

Iron ore beneficiation processes and other mineral processing operations with magnetite in the ore require accurate mass flow measurements to properly balance the grinding and separation circuits as well as to determine the true throughput impact of circuit changes. Determination of the mass flow requires an accurate measurement of the volumetric flow rate and the specific gravity of the slurry.

Magnetic separation and flotation

Magnetic separation and flotation are the most widely accepted technologies for upgrading fine iron ore particles, but both processes result in iron concentrates with high amounts of very fine and/or interlocked silica particles. Gravity separation is a common process used in iron industry, but the separation efficiency becomes unacceptable with finely disseminated materials (<45 microns).

Batch flotation studies were carried out to select either direct or reverse flotation technique to optimize reagent combination and to establish the number of stages of operations. Denver D-12 sub-aeration flotation machine was used for the batch flotation studies.

Crusher plant production and maintenance

The production line of crusher plant mainly consists of Vibrating Feeder, Jaw Crusher, Impact Crusher, Vibrating Screen, Belt Conveyor, Electric Control Box, etc. Double equipment design different production lines ranging 50 t/h to 500 t/h by combining different models of equipments also matching Cone Crusher, Bag Dust Catcher, etc. to satisfy different customers’ technological requirements.

Crusher plant maintenance

Convenient maintenance is so important in the quarrying crusher plant industry. Maintenance can be defined as working on something to keep it in a functioning and safe state and preserving it from failure or decline. Maintenance activities at quarries range from the maintenance of machines, equipment and vehicles to the keeping of roadways on site in good order, attending to such matters as providing edge protection and securing excavations.

It’s important to keep structural costs down, to design for ease of maintenance and operation, and to combine best practices with advances in fabrication and erection.

Best installation for crusher plant

In mining operations, the layout of crushing plants and ancillary equipment and structures is a crucial factor in meeting production requirements while keeping capital and operational costs to a minimum.Since the crushing plant’s structure and enclosure can represent the largest single cost element in a primary crushing plant, it is imperative to optimize these structural and construction costs to suit the life of the operation.

The fundamental goal for the design of a crushing plant is an installation that meets the required production requirements, operates at competitive cost, complies with today’s tough environmental regulations, and can be built at a reasonable price despite the rising costs of equipment, energy and construction labor.