Category: Metso

SOLUTION

• Roasting plant for pyrite concentrates

• Gas cleaning & sulfuric acid plants

• Calcine leaching & solvent extraction plants

• AG Mill, Thickeners, Filters & Courier online analyzers for Phosphate Beneficiation Plant

Rising Up to the Occasion

The same feed that they process in Mazidagi was utilised by another company in Turkey, which led to the site becoming aware of the remaining precious metals. Unfortunately for the other company, it proved to be too much of a challenge to recover. However, with a first-of-its-kind innovation, Metso Outotec believed in creating the right solution for them.

The customer wanted to recover metals like Co, Zn, Cu from pyrite, whilst also wanting to produce fertilizer by utilizing the phosphate resources. The first challenge they faced was that there was a phosphate reserve in an abandoned area, where human resources is challenging no matter what operational plans there are. On the other hand, there is the pyrite resource that is far away from phosphate and also carries other valuable metals. The main questions Metso Outotec supported the customer with was: How can we bring these together, what can we recover from this combination, and what technologies are applicable?

The idea was that by roasting the sulfur, it can be converted into sulfuric acid, which then goes into the direction of fertilizer production. We realized there are other valuable metallic elements which can be leached, and by utilising certain technologies, the site would be able to recover base metals such as cobalt, zinc and copper as well as precious metals.

An Established History Together

The customer relationship that Metso Outotec has with Cengiz Holding is not a new one – the companies have been consistently working together for over 50 years. Historically, Metso Outotec has had an installed base in the Eti Bakir concentrator and smelter sites since 1970.

The latest investments of Cengiz Holding is almost a showcase of Metso Outotec technologies. In every major site that belongs to them, there is a complete delivery of a greenfield concentrator or a metals refining site.

With regards to the Eti Bakır Mazıdağı site, Metso Outotec has delivered multiple items already, such as a phosphate beneficiation plant, roasting plant, off gas cleaning , sulfuric acid plant, and also a Leaching, SX and EW plant for the recovery of Co, Zn, Cu. Considering the complete size of the complex, Metso Outotec deliveries comprise of roughly 60% of the whole operation and is thus the heart of the main process sites.

It was this pre-established trust built between the two that presented Metso Outotec with the task to recover the precious metals. Osman Akay – Solution Sales Director for Metals BA, highlights the importance of our successful history working together that led to this opportunity.

“Our metal solution technologies, references and successful track record come from the previous installations at their other sites,” says Osman. “The unique solution was our ability to combine different technologies to work in harmony for such a complex site.”

An innovative design and collaborative installation allowed Metso Outotec to construct first-of-its-kind extraction technologies that set the standard of delivery success in Turkey.

The Eti Bakır Mazıdağı site is located in Mazıdağı, Turkey, and belongs to Cengiz Holding. The Cengiz group has been investing in infrastructure projects dating back to the late 1970’s. Their investments in the energy and mining industries, along with other corporate activities in the area, have enabled Cengiz Holding to grow into a family of 35 companies and affiliates, with an annual revenue exceeding 5 billion USD. Due to their involvement in various construction projects, they are the only Cobalt producer in Turkey, and globally, one of the largest Cobalt producers.

The site became aware that there were economically viable precious and base metals remaining inside the calcine of the roasting in Mazıdağı, but were struggling to recover them. This is when Metso Outotec stepped in to support the customer, from concept planning to realization. The collaboration between the local personnel, the business line and the product line colleagues allowed Metso Outotec to offer the optimal solution for the customer’s needs. Due to this innovation, the site was able to recover the promised amount of metals. Eventually, the process became an orchestra of plants seamlessly working together to concur their shared goal.

CHALLENGES

• Recovery of precious metals & minerals from pyrite concentrate

• Optimum technology selection for effective Leaching & extraction

• Beneficiation process selection for limited & complex phosphate deposit in the project site

Focus on what

really matters

The Metso LCS partnership complements your in-house resources, providing

additional capacity to handle tasks and issues while allowing you to free capacity

to focus more on the core essentials of your operations, risk mitigation and driving

growth.

Service expertise

We’re here to support you with a world class team of experts and decades of

experience gathered from mining projects around the world. We have a proven

track record of helping our customers to succeed, and whatever your specific

needs, we will use our deep understanding of mining processes, product design

and technology to help you achieve and exceed your targets as well.

The key components of LCS payment models

• Parts supply agreements

Having Metso owned inventory (MOI) allows you toreduce your working capital

while maintaining high parts availability. With the added visibility to parts consumption

planning and lead time reporting of the Enhanced Supply Agreement (ESA), you will

enjoy guaranteed parts lead time ensuring your maintenance schedule without

budget surprises.

• Monthly billing

We mutually predetermine your payment schedules to allow better predictability.

Once we’ve defined the scope of your LCS, we’ll schedule monthly invoicing.

• Upgrades and CAPEX deferred payments

Depending on the LCS scope, we offer optional deferred payment plans for new capital

equipment and/or spare parts. This gives you financial flexibility to quickly acquire

the solution you need.

• Performance/KPI based billing

Payments can be adjusted based on KPI targets to ensure Metso is incentivized to

deliver performance or is penalized if the targets are not achieved. Multiple KPI´s

can be considered, typically being equipment availability, component lifetimes,

end product quality, and safety indicators.

• Cost per ton billing

Cost per ton payment plans eliminate cost spikes and charge you based on what is

produced in a given month.

This allows you to better predict costs and cash flows and ensures that interests are

perfectly aligned to maximize production.

Mining services delivering performance and sustainability outcomes

To maintain and increase their productivity, mines need to ensure high equipment reliability

and availability. Metso Life Cycle Services (LCS) offer long-term solutions that can help them

achieve these goals, while maintaining or improving their total cost of ownership (TCO).

Typical challenges in mine operations

In the mining industry, our customers face challenges like managing inventory and

executing shutdowns efficiently, as well as dealing with unplanned maintenance

stops. In addition, customers may require support to improve the productivity,

metallurgical performance, safety and sustainability of their operations.

At times, they can face difficulties finding the right expertise.

Think further – choose Life Cycle Services

Metso LCS can help you overcome such challenges. With LCS, the full range

of Metso aftermarket offering including parts and services amplified by digital

solutions, are made available in outcome-driven partnership contracts scaling from

simple parts consignment stocks to operating your equipment, depending on the

scale of your needs. The LCS partnerships can even encompass equipment through

deferrals.

The partnership durations range from 12 months to multi-year periods, the length

typically being around three years.

Increased safety, performance and availability

Upgrading results in reduced maintenance and guaranteed spare part availability with

additional features such as digital tools for enhanced diagnostics and easier fault

tracking. The user-friendly operator interface with enhanced connectivity to other systems

provides an easier way to maximize process performance.

The latest software assures better usability, improved remote support and enhanced

network security. Service agreements can be included to ensure peace of mind knowing

that the analyzer will operate with maximum availability and accuracy.

Benefits

• Rapid results from up to 24 sample streams

• Real-time recovery calculation

• Improvements in recovery and minimization of precious metal losses

• Guaranteed spare part availability

• Remote support with condition monitoring

Upgrade your system to the latest Courier on-stream analyzer for

peak performance.

Upgrade features

• Automation and Analyzer Services

• Courier® Legacy

• Upgrade

• Automation

For process management, monitoring and control of mineral processing

plants, Courier analyzer systems offer unrivalled sensitivity and the shortest

cycle times available.

Courier legacy upgrade is a low-risk pathforward to the latest industry-leading

analyzer technology. Courier analyzer systems offer unrivaled sensitivity and

the shortest cycle times for process management, monitoring, and control of all

types of mineral processing plants.

The new generation XRF Courier analyzersare based on the same industry-leading

Wavelength Dispersive X-ray Fluorescence (WDXRF) measurement principles as

their predecessors but enable higher analysis accuracy with reduced cycle

times. In addition to the WD measurement channels, the new Courier analyzers can

also be equipped with Energy Dispersive X-ray Fluorescence (EDXRF) measurement

channels to measure additional elements.