High-Capacity Cone Crushers for Copper Concentrator Expansion

Metso outlines the role of advanced cone crusher technology in increasing throughput at Grupo Mexico’s La Caridad copper concentrator in Sonora, Mexico.  www.metsagroup.com Large copper concentrators depend on high-capacity, energy-efficient crushing systems to sustain throughput as ore volumes increase. In this context, Metso is supplying high-capacity cone crushers to support a capacity increase at Grupo Mexico’s La Caridad copper mine concentrator plant. Integration of high-capacity cone crushing into the concentrator flowsheet The delivered equipment consists of several Nordberg® MP800 cone crushers, which will be installed at the La Caridad concentrator in Nacozari, Sonora. The crushers are intended to increase overall plant capacity by handling higher throughput while maintaining consistent particle size reduction, a key requirement for downstream grinding and flotation processes in copper concentrators. The order, valued at more than EUR 20 million, was recorded in Metso’s Minerals segment order intake for the third quarter of 2025, reflecting the scale of the expansion project. Crushing force and chamber geometry as throughput drivers The Nordberg® MP800 is positioned as a high-capacity cone crusher designed for demanding mining environments. According to Metso, the model provides up to 15% higher capacity compared with earlier cone crusher generations, supported by increased crushing force and an optimized chamber design. These design changes enable higher feed acceptance and sustained reduction ratios while maintaining stable operating conditions, which is critical in large copper operations where upstream variability can propagate through the comminution circuit. Managing bottlenecks between crushing and grinding stages In concentrator operations, constraints in the secondary or tertiary crushing stages directly affect mill feed stability. The MP800’s higher throughput capacity is intended to reduce congestion at the crushing–grinding interface, improving consistency in particle size distribution delivered to the milling circuit. Automation readiness and maintenance-oriented design features support continuous operation, helping to limit unplanned downtime that can otherwise cascade through the concentrator. Energy efficiency under high-duty comminution conditions Size reduction is one of the most energy-intensive steps in mineral processing. Metso’s crushing portfolio is engineered to achieve target product sizes with optimized energy input per ton, using chamber design and crushing force to maximize effective breakage. At La Caridad, higher throughput per installed crusher allows capacity gains without a proportional increase in installed power or equipment count, supporting energy efficiency and operating cost control in large-scale copper processing. Equipment supply aligned with long-term concentrator operation Grupo Mexico, the largest copper producer in Mexico, has an established supply relationship with Metso, which has provided equipment to multiple mining operations operated by the group in recent years. The La Caridad delivery continues this cooperation in an operating environment where equipment availability and service support are central to sustained concentrator output. The delivery combines crusher supply with Metso’s service capability, supporting installation, commissioning, and long-term performance in high-duty copper applications. Impact on concentrator throughput and operating stability Increasing concentrator capacity requires comminution equipment that can absorb higher feed rates without compromising mechanical reliability or downstream process stability. The integration of Nordberg® MP800 cone crushers at La Caridad reflects an approach focused on increasing throughput while maintaining control over energy use, maintenance intervals, and overall plant availability. www.metso.com Powered by Induportals Media Publishing