Innovating for sustainability
Metso serves industries that face challenges such as depletion and degradation of ore grades, water and energy scarcity, dust, high-pressure flow handling and safe and efficient waste processing. Mines, quarries and chemical plants supply raw materials for our daily lives and the world around us. This is where Metso’s technology and expertise comes in.
Our solutions cover rock and minerals processing, metal and waste recycling, and process industry flow control solutions. Helping our customers solve these global challenges gives rise to new business opportunities. By innovation, we make sure our customers can tackle these challenges now and in the future.
The future focus in sustainable innovations is on increasing the competitiveness of the offering through sustainable productivity and digitalization. Digitalization enables new means to improve the sustainability of products and services. For example, remote monitoring increases process efficiency, availability and safety. It also reduces the need for travel.
Innovating for more efficient solutions
The mining industry faces increasing energy costs, declining water resources, stringent environmental legislation, and lower grade ore bodies. Innovating for more energy efficient solutions is one of the key drivers in the mining industry because the comminution process, including crushing and grinding, is the most energy-intensive and energy-inefficient stage of mineral production. Improvements in comminution efficiency can result in significant energy savings and have a large impact on the operating cost of a plant as well as conserve resources and reduce greenhouse gas emissions.
Vertimill® is globally recognized as one of the most energy efficient grinding mills. They have been proven to grind more efficiently than horizontal ball mills, with a typical energy savings of 25-35%, and in some cases even 50%. In addition to grinding efficiency, reduced media consumption, lower installation cost, reduced maintenance, and reduced liner wear make the Metso Vertimill® the lowest total cost of ownership option in many applications.
High-pressure grinding roll technology is a competitive grinding technology that Metso has been developing for years. It lowers specific energy consumption in comparison to conventional fine crushing and AG/SAG mills. HRC™ is a leading solution that offers energy efficiency for crushing hard rock with relatively low moisture content and superior results in the size reduction of a variety of minerals in the comminution process. It can reduce the customer’s energy consumption by 10%.
Our customers who have secondary and tertiary crushing operations, such as producing aggregates for railway ballast, road construction, asphalt and concrete fractions value fuel consumption and efficiency. In 2018, Metso launched Lokotrack LT200HPtm, a new more efficient mobile crushing plant that delivers fuel consumption savings of at least 15% compared to hydraulic-driven cone crushers. Furthermore, it complies with European Stage V emission regulations.
Innovating for a circular economy
Tackling the waste
Aspects of a circular economy are embedded in Metso’s offering in the form of waste and metal recycling equipment as well as asphalt, construction and demolition waste crushing technology. The recycling of metal and waste uses much less energy than producing something for the first time. For example, producing steel from recycled steel scrap saves more than 60% in energy costs. Metso has been providing equipment and services for the recycling industry for over a century.
Metso Metal Recycling offers a wide range of efficient solutions for the fragmentation, compaction and separation of virtually every type of metal scrap. Municipal solid waste contains various valuable materials that can be sorted and sold or made use of, for example in energy production. Different components, like metals, plastics, glass, packaging fiber, organic materials, and paper, are mixed in waste and require processing and sorting before they can be fully utilized. The quicker and more efficient the processing phase is, the more valuable the municipal solid waste is as a raw material. To process municipal waste profitably, the waste treatment equipment must handle many materials of different shapes and sizes.
The recycling of building materials, such as crushed stone and asphalt, also makes a difference in materials use. Construction and demolition waste is an endless source of raw materials for various purposes. Building something new often means that something old is being dismantled. Roads, buildings and bridges do not last forever, and they are under constant repair. Due to continuous renovations, massive amounts of construction and demolition waste are generated around the world; a large part of this waste is not yet utilized efficiently, but instead dumped in landfills. Construction and demolition waste, however, comprises a variety of economically valuable materials – such as concrete, bricks, wood and metals – that can be used in the manufacturing of new products, construction materials, roads, or in energy production.
The depletion of easily available natural sand deposits is a major issue for quarry owners. As the availability of natural sand decreases, regulations relating to its use become stricter and demand starts to shift to manufactured sand. Manufactured sand grain shape is key in the production of concrete, and special equipment is needed to produce high-quality sand. Metso is one of the forerunners in manufactured sand solutions and we have helped design dozens of sand processes for our customers around the world.
The rapid pace of urbanization makes the change to manufactured sand even more significant: According to the United Nations, the number of people living in cities could double to6.5 billion by 2050. To accommodate growing populations, more houses, parks, roads, and subways, among others, are needed – and they all need sand in one form or another as a basic building component.
The use of natural sand is regulated by law in many places and forbidden in some countries, like Japan. Some countries, including Sweden, have called for manufactured sand to be used in place of natural sand whenever possible. In Australia, the constraints relating to obtaining approval are increasing, too
At Metso, we have developed a unique industrial process to reduce the amount of cement needed inconcrete mix. The amount of cement can be decreased by up to 15% when using Metso’s highly advanced manufactured sand solution instead of local natural sand. The production cost of the concrete mix can be significantly decreased when the cement is replaced with high-quality manufactured sand. As a raw material, industrially produced sand is much more inexpensive than cement. The price of manufactured sand can also be lower compared to natural sand, thereby further decreasing the production cost of the concrete.
Improving the customer’s sustainable productivity through digitalization
New predictive maintenance solution for mining
In 2018, Metso launched a new predictive maintenance solution for the mining industry to maximize the uptime and improve the performance of comminution circuits. The Metso Metrics solution provides the maintenance crew and operators at the mine site with new visibility and insight to their machine’s operations, with analytics, condition monitoring and predictive maintenance – all backed by expert support from Metso.
The solution has been designed to help miners with some of their most pressing challenges such as
- Increasing asset uptime and availability in the comminution circuit
- Achieving higher energy efficiency and more stable product quality
- Lowering their overall maintenance cost
- Moving from unplanned towards well planned and safer shutdowns
The new mining solution is the latest addition to Metso's digital services. It covers Metso's primary gyratory crushers, cone crushers and vibrating screens. Eventually, it will also cover other types of minerals processing equipment, such as mills.The first generation of Metso Metrics tools was launched in 2017 to help optimize aggregates production in quarries and at contractor sites. Metso has also developed a similar solution for waste recycling equipment.