Metso’s history of innovation gives it a unique perspective on mining processes and how every component in a circuit fits together.
Metso’s expertise is grounded in a history of innovation that spans more than a century.
From the steam-age inventions of Bruno Nordberg through to artificial intelligence (AI)-driven technologies such as RockSense 3D, the company draws on a lineage of mining innovation with few peers in the industry.
These breakthroughs have made Metso a name synonymous with core mining processes, including feeding, screening and crushing.
Alongside its extensive product portfolio, Metso prides itself on supporting customers throughout the design, establishment and operation of a project. For Metso, the whole is always greater than the sum of its parts.
“One of the most valuable things Metso provides is process design,” Pardawala told Australian Mining.
“We look at the entire flowsheet and simulate the whole circuit rather than treating equipment as standalone.
“Our simulation tools and expertise spans across crushing, screening and feeding, which allows us to ensure that the entire circuit performs as intended. One of the most crucial parts of this is getting the process input information as accurate as possible.”
It also gives Metso the opportunity to educate customers, test options through simulation and apply lessons from its large installed base.
Metso technology manager – screening Asia Pacific – Peter Lundberg said inefficiency in one area quickly compounds across the system.
“Variability in crusher feed, whether due to fluctuating ore fragmentation, inconsistent particle size distribution, or poor choke feeding, can lead to non-uniform product shape,” Lundberg said.
“Irregular shape and size distribution compromise downstream comminution efficiency, particularly in milling circuits, where predictable grindability and throughput depend on consistent feed characteristics.”
“If we’re not getting the separation we designed for, too much undersize goes to the crusher,” he said.
“Excessive fines in the crushing chamber can cause packing, force spikes and high power draw. Fines don’t need crushing, but they still wear the chamber and decrease efficiency.”
Perrella said poor feeding can also create a force imbalance in the crusher.
“If we’re not maintaining a proper material level in the crushing chamber, slabby and long particles get through and then affect the screen, and so on,” he said.
“We’re not just a crushing, screening or feeding company; we cover the entire mineral processing flowsheet,” he said.
“Our team has shared expertise across all technologies.”
The scale of Metso’s installed base is another major advantage.
“We’ve got well over 100 years of experience designing circuits with these machines, and a huge global installed base,” Perrella said.
“That real-world data feeds into our modelling tools – including Bruno – and into our knowledge bank. It allows us to deliver advanced consultation and accurate, refined circuits very early in a project’s life.”
“With tools like RockSense – using 2D or 3D particle-size analysis on the belt – operators can constantly track what’s coming into and out of each part of the plant ,” he said.
“That enables on-the-fly adjustments to balance the circuit.”
While technologies like RockSense seem far removed from the steam-age innovations of Bruno Nordberg, they share a lineage that has made Metso a trusted name for more than a century.