Metso Delivers Modular Crushing Stations to Vale's S11D Mine

Metso Oyj has delivered three modular crushing stations to Vale's S11D mine in Pará, Brazil, aimed at optimizing the fifth stage of iron ore crushing. The project was completed and delivered within a nine-month timeframe, significantly faster than traditional methods.

The S11D mine, Brazil's largest mining complex, previously faced bottlenecks due to unplanned conveyor belt stoppages. These issues stemmed from oversized particles, with top sizes reaching 450 mm. The new Metso stations reduce this top size to 150 mm, preventing belt damage and allowing for greater flexibility in ore blending. The solution also needed to fit within a restricted layout and be implemented during a 90-day annual shutdown window.

Vale selected Metso's FIT™ station technology, a modular and ready-to-install solution designed to reduce risk and implementation time. The three new stations were designed and manufactured efficiently. Anderson Gomes, Vale's General Manager of Implementation, stated the project was safer, faster, and more efficient, with approximately 1,200 tons of structures assembled in just 94 days.

The installation process benefited from a pre-engineered design and modularization, which drastically cut assembly time and enhanced safety. Two stations were installed in a stacked configuration to maximize limited space, and skid-mounted bases eliminated the need for traditional civil foundations. Luiz Otávio Arantes, Vale's Engineering Manager, confirmed the crushers have performed strongly, achieving the desired reduction in material size.

Metso highlights that the FIT station is a modular solution that accelerates crushing projects by focusing on safety, efficiency, and reduced environmental impact. It minimizes civil works and waste generation, aligning with sustainability practices, and improves personnel safety and operational predictability.