IN-PIT CRUSHING & CONVEYING
One of three large Metso FIT TM stations at S11D, which optimise the operation of the fifth crushing plant
manufacturing, and delivery – was completed in nine months, versus the 14 months typically required by traditional approaches.
“ The concept of modularisation is something we seek within Vale. It reduces people’ s exposure to risks, reduces implementation time and brings more quality and efficiency to the operation,” adds Gomes.
According to Luiz Otávio Arantes, Vale’ s Engineering Manager, three factors were decisive: the fact that it was project ready, which facilitated planning; modularisation, which drastically reduced the assembly time; and security, with a solution validated by Metso.
“ Metso’ s FIT TM station is a new technology, with a system of keys and skids, all modularised and implemented in an extremely short time,” reinforces Roberto Nascimento, Master Engineer of Capital projects at Vale.
The configuration included GP500 crushers, screens and conveyor belts, totalling 1,200 t. Two stations were installed overlapping, taking advantage of the plant’ s restricted space. The assembly used skid bases, eliminating traditional civil foundations and allowing the 94- day deadline to be met, including the commissioning and start-up stages.
With the activation of the FIT TM station, Vale achieved the goal: reducing the top size from 450 mm to 150 mm, ensuring greater reliability in the posterior circuit and flexibility for blends.
“ The crusher has delivered a good performance. Today it is visible that the material has a much smaller particle size,” says Luis Otavio Arantes, Vale’ s Operations Engineer.
One of the great challenges was to show that the 100 % Metso solution, in line with national and international standards, fully meets Vale’ s demands.“ Convincing Vale of the FIT TM station model was a challenge, but the modularity and foundation concept allowed delivery in record time and met the assembly window,” says Gabriel Oliveira,
Project Manager at Metso. The Metso FIT TM station is a modular solution developed by Metso to accelerate crushing projects safely, efficiently and with less environmental impact. By using skid bases and standardised components, it reduces the need for civil works, reduces soil movements and generates less waste, aligning with sustainability practices.
In addition, modularisation contributes to less exposure of people to risks, fewer displacements and greater predictability in execution.
And the compact crushing project...
Iron ore mining in Brazil is moving to processing harder and more compact itabirite ores. Vale also ordered from Metso all the major comminution equipment for its Compactos iron ore greenfield project, located in Itatiaiuçu, Minas Gerais, Brazil.
The aim with the new plant is to produce 4.5 Mt / y of high-grade premium pellet feed, in two phases. The more energy-efficient comminution circuit of the first phase will process compact itabirite iron ore and will consist of a Nordberg ® C160 TM jaw crusher, followed by a Nordberg ® MP800 cone crusher, an HRCe TM HPGR and a 3.9 MW Select™ ball mill for primary grinding. The regrinding will be carried out with two VTM4500 Vertimill ® mills. The order for the Vertimill ® mills was registered in the third
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