Safe, sustainable, and efficient – Terrafame and Metso’s process technology powering the battery future

Aiming to expand its global presence in the battery market, Terrafame identified operational safety and sustainable production as key enablers for successful integration into the value chain. Metso was selected as an end-to-end supplier for the project, offering comprehensive support from process piloting to production optimization, and aligning with Terrafame’s values for project success. With the help of Metso’s unique solutions, Terrafame was able to enhance both the value and purity of its nickel and cobalt production. Metso’s OKTOP® autoclave and VSF® X solvent extraction mixer-settlers played a key role in the project.

2018 – Planning begins

In 2018, planning for the battery chemicals processing plant officially commenced. Metso delivered an extensive scope of work for the pressure leaching plant and the complete SX process chain, including laboratory test work, flowsheet development, and basic engineering design. During the implementation phase, Metso supplied proprietary equipment for all key process areas, including the OKTOP® autoclave and reactors, Larox® filters, a High Rate Thickener, and VSF® X solvent extraction equipment. The scope also included comprehensive commissioning support and operator training, ensuring that quality and safety were prioritized throughout the project lifecycle. 

2020 – Installation phase

Installation of the battery chemicals plant began in 2020. Metso’s proprietary equipment was delivered to the site as pre-assembled as possible from the workshop, where quality control and installation readiness were thoroughly verified. During the installation phase, Metso provided continuous on-site advisory support, ensuring an efficient and safe installation process at Terrafame’s site. Mechanical completion was achieved on schedule—less than two years after the project contract was signed. 

Terrafame was extremely satisfied with the battery chemicals plant project. Metso’s equipment delivery and installation were completed on time and within budget. 

The mechanical installation of three Metso’s VSF® X solvent extraction circuits were completed in just two months. This phase involved lifting the pre-assembled equipment modules into position, securing them to the foundations, and performing the necessary FRP site laminations to connect the modules. A total of 101 modules were installed efficiently, thanks to the modular design and well-coordinated site operations, enabling rapid progress without compromising quality. 

The autoclave vessel was delivered fully welded from the workshop and transported to its foundation in just two days. Metso’s OKTOP® autoclave agitators were also delivered pre-assembled, and the installation of five heavy-duty agitators took less than 80 man-hours, including final assembly, lifting, and phased torquing.

• Zero accidents were reported during the installation and commissioning phases. 

• A comprehensive training program was implemented, starting before commissioning and continuing with updated training sessions three years after the plant became operational.

• On-time and on-budget delivery and installation.

• Less than two years from the start of engineering and design to full plant commissioning.

• End-to-end process support—from test work and commissioning to ongoing process optimization.

2021 – Plant commissioning

Commissioning of the battery chemicals plant officially began in 2021. Metso continued to provide on-site expertise and commissioning management services throughout both the cold and hot commissioning phases. 

To ensure the safety of all personnel, Terrafame conducted a comprehensive safety training program for operators and contractors. No accidents were reported in the process areas during commissioning, highlighting the effectiveness of the project’s safety-focused design and planning. 

This was particularly evident in the Solvent Extraction process hall, where regular manual sampling and operator presence are required. The covered and enclosed design of Metso’s VSF® X modules, with special attention to accessibility, significantly contributes to operator safety during manual tasks. 

2022 – Production ramp up and maintenance support

After the successful commissioning of the plant, some challenges emerged during the ramp-up phase—a common occurrence in industrial plants of this scale. Metso continued to provide both ramp-up support and shutdown services, contributing to Terrafame’s long-term maintenance strategy. 

• Ramp-Up Support 

• • POX scaling management workshops, jointly conducted by Terrafame and Metso, offered targeted solutions to manage scale formation in the autoclave through case-specific process control measures. 

• • Process control workshops led by Metso experts supported Terrafame in the continuous training and development of plant operators. 

• Shutdown Services 

• • Metso’s field service professionals supported Terrafame’s predictive maintenance program by inspecting equipment and recommending future maintenance actions. 

• • When required, Metso’s field services team performed on-site maintenance, ensuring equipment reliability and operational continuity. 

The collaboration between Terrafame and Metso stands as a model of effective partnership in the industry. From initial planning to full-scale production and ongoing maintenance, the project showcases how shared values, advanced technology, and close cooperation can drive long-term success. Together, the teams have built a safe, efficient, and environmentally responsible operation that supports the growing demand for battery materials.