Increasing capacity and reducing costs at Sedibeng iron ore mine

Metso will deliver a stationary crushing and screening solution to Sedibeng Iron Ore (Pty) Ltd’s, a subsidiary of Tata Steel Ltd, Sedibeng iron ore mine in the Northern Cape, South Africa.

Metso and Sedibeng Iron Ore have agreed on a combined order consisting of a stationary crushing and screening plant, including primary and secondary crushers, as well as a five-year Life Cycle Services contract. The cold commissioning is scheduled for late 2016 and the plant should be operating at the beginning of 2017.

It is expected that the five-year Life Cycle Services contract, which will bring Sedibeng increased production capacity and reliability while reducing production costs.

"This complete solution covers services and equipment and thus ensures planned maintenance and better production reliability for the customer. For Metso, the order represents a new way of operating in southern Africa. It increases our installed base in the area and will surely open up new opportunities in the growing market," said Charles Ntsele, Metso's General Manager for Mining Sales in Southern Africa.

The Sedibeng iron ore mine had previously been using a Metso mobile crushing & screening solution operated by a subcontractor. Due to a planned increase in capacity, Tata Steel, the principal shareholder, wanted to investigate the possibility for a stationary plant.

"The key target for Sedibeng was to both guarantee plant availability and lower their production costs. We worked with the customer in analysing their needs, such as operating costs and plant availability. For example, the design of the plant was carefully considered and the process design criteria reviewed. Based on the analysis, we came up with a high-end technical solution, which will increase plant availability from 65 – 70% to 90% and increase plant capacity to 600 tph. Partnering up with the end user allows Metso to build on our understanding of our customers' business drivers and offer tailored solutions," Ntsele explained.

The complete solution consists of a Vibrating Feeder 561 - 2V, a C130 Jaw, a CVB 603 screen, an HP 500 cone crusher, conveyors, electrics and automation together with the other auxiliary equipment required for a crushing and screening plant. The Life Cycle Services contract covers the supervision of the plant maintenance, including maintenance planning, training customer personnel, as well as spares and wears management.