Why sustainability in mining isn’t only about new technology

The definition of asset value in mining is changing

Asset value is not only measured by the cost of repair, the cost of replacement or the immediate impact of downtime. These factors matter, especially when cost per ton and availability are critical. However, mines are increasingly considering these factors alongside resource efficiency, lead times and long-term asset value.

A new component may provide predictability and long-term performance, while a qualified repair may help restore availability faster and preserve value already embedded in the asset. The important question is which option will deliver reliable performance and the greatest lifecycle value in that operating context.

This broader view is changing how mines approach repair. Rather than being considered mainly after failure, repairs can be evaluated earlier as part of lifecycle planning. Condition assessments, inspections and reliability-based maintenance practices can help identify repair opportunities earlier. This gives maintenance teams more time to assess options, compare trade-offs and choose the path that best supports their targets. The value of repair comes from knowing where useful life remains.

And that means that repair will not always be the right option. Each case needs to be assessed individually to find the best outcome. A new component or equipment is recommended when repair is no longer technically feasible, economically justified or able to meet the required safety and performance standards. The goal is to identify the right lifecycle decision for the asset and the operation, whether that means repair or replacement.

Why repair and replacement decisions require a lifecycle view

Repair and replacement decisions require a lifecycle view because the best option rarely depends on one factor alone. For operators, the right decision depends on component condition, operating environment, business need and expected performance over time. A timely planned component replacement optimizes component life and inventory holding costs.

Repair can support lifecycle value when they help:

• Maintain equipment availability
• Reduce the impact of long replacement lead times
• Extend the useful life of critical assets
• Reduce demand for newly manufactured components
• Improve resource efficiency
• Support planned maintenance and inventory strategies

Repair is often worth evaluating when a component can be inspected before failure, when replacement lead times are long, when downtime has a high production impact or when the asset still has recoverable value. These situations give operators more options and can help avoid decisions made under time pressure.

Location can also influence the decision. In remote regions, or in situations where replacement parts are difficult to source quickly, a qualified repair close to the customer can become a practical advantage. In these cases, speed and reliability may carry as much weight as the direct cost comparison between repair and replacement.

Lifecycle thinking helps teams evaluate cost, lead time, reliability, material use and sustainability impact together. As these decisions become more data-driven, they increasingly involve not only maintenance teams, but also operations, procurement and sustainability stakeholders.

Looking beyond operational emissions: what embedded carbon reveals about asset value

When emissions are discussed in mining, attention often focuses on the energy and fuel consumed during operation, as well as overall process efficiency. They remain critical areas for improvement. At the same time, every new component carries embedded CO₂e* which may contribute to a company's Scope 3 emissions through purchased goods and services. This makes it an increasingly important consideration in emissions reporting and reduction efforts.

*Embedded CO₂e refers to emissions generated before a component enters operation, including emissions from raw material extraction and production. For many organizations, these emissions may be reported as part of Scope 3 emissions under the Greenhouse Gas Protocol's "Purchased goods and services" category. 

Embedded carbon adds another dimension to asset value. It encourages operators to consider the resources already invested in a component, as well as the environmental impact of manufacturing a new replacement. Metso’s embedded CO₂e calculations can make this comparison more tangible by showing the difference between refurbishing a component and manufacturing a new one. The results depend on the component, repair scope and calculation boundaries, but they provide useful insight for repair-versus-replacement discussions.

For example, of an instead of purchasing a new replacement can result in*:

• Up to 75% lower embedded CO₂e emissions compared with purchasing a new bearing unit
• Approximately 1,257 kg of CO₂e emissions avoided per unit
• Up to 600 kg of steel saved per unit

*The example is based on an OK-38 cell bearing unit. The embedded CO₂e of a new bearing unit is 1,656 kg CO₂e, compared with 399 kg CO₂e for a refurbished unit, resulting in approximately 75% lower embedded CO₂e emissions. The calculation includes emissions from raw material extraction and production phases only and excludes all subsequent lifecycle phases. CO₂e calculations are based on secondary data and emission factors sourced from the Ecoinvent database.

For operators, this type of calculation can support more informed internal discussions between maintenance, procurement and sustainability teams. It helps show how a technical service decision can also contribute to material efficiency and embedded emissions reduction. Embedded CO₂e and material use provide additional context for assessing long-term value.

From insight to action: making lifecycle decisions easier

The value of lifecycle thinking depends on the quality of the decision behind it. Operators need to understand whether a component is repairable, what performance can be expected after repair, how quickly the work can be completed and how the option compares with replacement in terms of cost, risk, availability and sustainability impact. For operators, the opportunity is to move from reactive decisions to planned lifecycle management. By assessing equipment condition earlier and considering repair before replacement, companies can make better use of existing assets while supporting long-term performance and sustainability goals.

This is where Metso’s OEM expertise and experienced service partners can make a practical difference. OEM knowledge helps determine how equipment condition and operating demands affect repairability. This supports reliable decision making on whether repair or replacement will provide better long-term value.

To make repair easier to include in planning, customers also need clear and actionable information. This includes defined repair scopes, reliable turnaround expectations, faster quotations, standardized offerings and practical data that supports comparison with replacement.

Metso applies OEM knowledge and repair experience to help customers evaluate the available options with confidence. Where applicable, Metso also uses embedded CO₂e calculations to compare the environmental impact of repairing a component with purchasing a new replacement. These calculations can make material use and embedded emissions more visible, giving customers another data point alongside cost, lead time, reliability and availability.

With the right expertise, data and service process, repair-versus-replacement decisions become clearer and more connected to the realities of each operation. This helps operators choose the option that delivers long-term value while supporting both site performance and environmental goals.

Sustainability through smarter lifecycle decisions

Repairs are becoming an important part of lifecycle decision-making as mining operators seek to manage costs without compromising reliability. When applied in the right circumstances, they can help extend equipment life, reduce material consumption, lower emissions and support reliable production.

For operators, this means looking beyond the next maintenance event. Each repair-or-replace decision becomes an opportunity to improve asset performance, use resources more efficiently and support long-term value across the equipment lifecycle.