Vale optimizes crushing at S11D with Metso’s modular technology

The challenge

At Brazil’s largest mining complex, S11D, Vale faced a critical bottleneck in the fifth crushing stage—a key step feeding subsequent processing phases. The operation, composed of three primary crushing fronts, suffered from unplanned conveyor belt stoppages across more than 12 km of belts.

The issue was particle size: the top size needed to be reduced from 450 mm to 150 mm. This adjustment would prevent belt damage and allow greater flexibility for iron ore blending. Additionally, the solution had to fit within a restricted layout and be implemented during the annual shutdown, with a maximum activation window of 90 days.

The solution

To meet these requirements, Vale selected Metso’s FIT™ station technology—a modular, ready-to-install solution that reduces risk, shortens implementation time, and ensures quality.

Three new modular crushing stations were designed and delivered, creating an intermediate stage between existing primary and secondary crushing. The entire process—design, procurement, manufacturing, and delivery—was completed in nine months, compared to the usual 14 months for traditional approaches.

“Modularization is something we strive for at Vale. It reduces people’s exposure to risk, shortens implementation time, and brings more quality and efficiency to operations,” says Anderson Gomes, General Manager of Implementation at Vale.

According to Luiz Otávio Arantes, Vale's Engineering Manager, three factors were decisive:

1. Pre-engineered design, simplifying planning.
2. Modularization, drastically reducing assembly time.
3. Safety, with a solution validated by Metso.

“The FIT station is a new technology with a key-and-skid system, fully modularized and implemented in an extremely short timeframe,” says Roberto Nascimento, Master Project Engineer at Vale.

The configuration included GP500 crushers, screens, and conveyors, totaling 1,200 tons. Two stations were installed in a stacked arrangement to maximize limited space. Skid-mounted bases eliminated traditional civil foundations, enabling completion within 94 days, including commissioning and start-up.

The results

With the FIT stations activated, Vale achieved its goal: reducing top size from 450 mm to 150 mm, ensuring greater reliability in downstream circuits and flexibility for blending.

“The crusher has delivered strong performance. Today, it’s clear that the material size is much smaller,” says Arantes.

One major challenge was proving that a 100% Metso solution, aligned with national and international standards, could fully meet Vale’s demands.

“Convincing Vale of the FIT station model was a challenge, but modularity and the foundation concept enabled delivery within a record timeframe and met the installation window,” says Gabriel Oliveira, Project Manager at Metso.

FIT station and the future of mining

FIT station is a modular solution developed by Metso to accelerate crushing projects with safety, efficiency, and lower environmental impact. By using skid-mounted bases and standardized components, it reduces civil works, minimizes soil movement, and generates less waste—aligned with sustainability practices.

Modularization also reduces personnel exposure to risk, limits travel, and improves predictability, reinforcing the commitment to the mining of the future—focused on innovation, safety, and environmental responsibility.