SME MINEXCHANGE 2027

Theme: Automation/Robotics/AI

Topic: Upgrade in Crushing Plant Operation Through Advanced Instrumentation, Digitalization and AI-Based Control

Authors: R. Bernardes, T. Batalha and D. Nagano; Metso, Sorocaba, SP, Brazil

Details: A 700 t/h iron ore crushing plant in central Brazil faced frequent variations in feed moisture and particle size distribution, resulting in unstable operation and a strong dependence on operator decisions to define the feeder setpoint. This paper presents a case study in which online moisture analyzers, belt scales and granulometry sensors were integrated into a real-time machine learning model. Based on the measured ore characteristics, the model continuously calculates the optimum feeder speed and automatically adjusts the process through the plant control system. The solution combines advanced instrumentation, digitalization, remote monitoring and AI-based process control within the Metso Smart Crushing Plant platform. Results showed an increase in annual production capacity from 3.5 to 4.7 million tons per year, improved operational stability, reduced operator intervention, increased availability from 86% to 89%, corresponding to approximately 263 additional operating hours per year, and 22% of reduction in operational workforce. The case demonstrates the potential of data-driven control strategies to improve productivity and operational efficiency in crushing circuits.

Date: Monday, March 1, 2027

Time: 4:05 pm

Room: 605

Theme: MPD: Flotation: Fine Particle Flotation

Topic: Concorde Cell Technology validation at Kevitsa Cu-Ni-PGM Concentrator

Authors: T. Mattsson², R. Dube¹, H. Kela³, B. Musuku³, M. Kasala³, J. Sovechles², B. Tunc² and A. Yanez²; ¹Metso USA, York, PA; ²Metso Finland, Espoo, Finland and ³Boliden, Sodankylä, Finland

Details: A Concorde Cell™ equipped with a DN500 Concorde BlastTube™ was commissioned and brought into operation at the Boliden Kevitsa Cu-Ni-PGM concentrator in January 2025. The implementation of this high-intensity pneumatic flotation cell into the Ni cleaner flotation circuit was followed by a test campaign in which the metallurgical and gas dispersion performance of the unit were evaluated. In addition to assessing metallurgical performance, the scalability of the technology was investigated by operating a Concorde Cell™ pilot unit in parallel with the industrial-scale unit. This paper reviews the measured metallurgical performance of the industrial unit and the observed relationships between cell operating parameters and metallurgical performance. The gas dispersion performance of the unit is presented across a range of superficial gas velocities, and the scale-up of the technology is discussed based on metallurgical performance measured at both pilot and industrial scales.

Date: Tuesday, March 2, 2027

Time: 3:05 pm

Room: 708

Theme: MPD: Flotation: Coarse & Fine Particle Flotation

Topic: Synergies Between the Concorde Cell™ and the HIGmill™ Compared to Conventional Technologies on a Copper Ore

Authors: N. Kupka, H. Heiskari, E. Lkhagvadorj, F. Wang, A. Yáñez and R. Dube; Metso, Espoo, Finland

Details: As ore grades continue to decline, achieving economic mineral recovery increasingly requires finer grinding to liberate valuable minerals, resulting in a growing proportion of fine and ultrafine particles entering flotation circuits. Metso has two technologies that can handle this very challenge, the HIGmill™, an energy-efficient ultra-fine grinding/liberation solution and the Concorde Cell™, a high-shear fine-bubbles pneumatic flotation cell. In this study, their synergies are explored on the rougher concentrate of a copper plant and compared to conventional technologies, e.g. a ball mill and mechanical cells. A summary of the metallurgical performance size-by-size on the copper ore will be presented.

Date: Wednesday, March 3, 2027

Time: 3:05 pm

Room: 704

Theme: MPD: Flotation: Coarse & Fine Particle Flotation

Topic: Performance of Metso’s Sampo™ Cell in the Recovery of Coarse Particles from Copper Rougher Tailings at Industrial Scale

Authors: C. Emer, M. Durán, M. Carvalho, N. Kupka, R. Dube and A. Rinne; Metso, Espoo, Finland

Details: The Sampo cell is Metso’s coarse particle flotation technology where the slurry is fed on top of a deep froth, in which the particles are segregated. Ore containing particles remain in the froth and go into the overflow as concentrate. Gangue particles fall through the froth as tailings. This technology was launched in 2026, after almost a year of testing at industrial scale on the rougher tailings of a copper concentrator in Chile, presented in this paper. Across a wide range of feed grades, throughputs, and operating conditions, the Sampo cell consistently achieved copper stage recoveries above 60%, with recoveries exceeding 80% under favorable conditions at relatively low mass pulls. Concentrate grades obtained were higher than the main concentrator feed and suitable for reprocessing through regrinding and conventional flotation. The results demonstrate that the Sampo cell is an effective scavenging technology for recovering coarse and partially liberated copper particles from the flotation circuit, providing a viable approach to improving overall plant recovery while mitigating the energy demand associated with fine grinding.

Date: Wednesday, March 3, 2027

Time: 2:25 pm

Room: 704