Enhancing reliability and process performance at Terrafame mine

Terrafame, one of Europe’s largest producers of battery chemicals and multi-metals, operates an extensive integrated production chain in Sotkamo, Finland. Production spans from mining to metals recovery and further to battery chemicals, including several sequential chemical processes. Sustainability is a core element: the carbon footprint of Terrafame’s nickel sulfate is among the lowest in the industry.

Acidic solutions, abrasive slurries, and high utilization rates set exceptional requirements for flow control. “Flow control is a key factor in solution-based processes. It enables significant savings in chemical costs while improving the quality of the final product,” says Arto Kiviluoto, Work planner, Electricity and Automation Services at Terrafame.

The cooperation between Valmet and Terrafame dates back to the original construction phase of the mine. The first Neles™ and Flowrox™ valves, along with Flowrox™ peristaltic hose pumps, were installed during the Talvivaara project startup in 2008.

Since then, the installed base has been gradually expanded to form the backbone of Terrafame’s production, complemented by Valmet’s Jamesbury™ valves and Stonel™ limit switches as part of the overall flow control and automation solution.

Terrafame’s entire production chain operates as one physical and operational entity within a single plant area. Mining, bioleaching, metals recovery and the battery chemicals plant are tightly interconnected, and flow control directly affects process stability and the quality of end products. High availability is a key factor in both metals recovery and battery chemicals production.

“When processes run smoothly, disturbances are not limited to a single piece of equipment but are reflected across the entire production chain. That is why anticipating disturbances is more important to us than reacting quickly to them,” says Paakkari.

Thousands of valves are in operation across Terrafame’s site, controlling flows throughout multiple sequential process stages. At this scale, valve selection has a direct impact on overall production performance and the predictability of maintenance activities.

While valves, pumps and field devices form the physical foundation of Terrafame’s process, their performance is realized through the automation system. Control, monitoring and reporting across the entire plant are implemented using the Valmet DNA system. A unified automation system enables the use of consistent control strategies across different process areas and supports continuous development of production.

“One of the biggest advantages of having the same automation supplier across the entire plant is that proven solutions can be easily replicated in other departments. It has significantly advanced our operations,” says Mikko Jauhonen, Automation Maintenance Engineer at Terrafame.

A browser-based user interface and role-based access control support safe operation in a 24/7 environment and reduce the risk of human error.

Condition monitoring of field devices is centralized in the Field Device Manager system, where diagnostic data is utilized on a daily basis. Alarm limits can be defined individually for each device, and deviations are transferred directly to the automation system for further action.

“Thanks to FDM, we can detect early-stage equipment faults and target maintenance to planned shutdowns. We avoid unnecessary maintenance and focus only on areas where actions truly add value,” Jauhonen explains.

In addition, monthly analysis of control loops helps identify potential equipment or sizing issues, allowing fine-tuning before they lead to production interruptions. When automation and valve solutions operate as an integrated whole, they create added value in process reliability and predictability.

Resident Engineer as part of daily operations

Valmet’s comprehensive service offering plays a key role in Terrafame’s maintenance. The service agreement supports maintenance in many ways. Valmet’s local Resident Engineer, Pertti Puurunen, is familiar with Terrafame’s processes, critical assets and equipment history, supporting proactive and systematic maintenance.

“Cooperation runs smoothly. Pertti knows the site and processes extremely well. Things move forward quickly without the need for additional onboarding,” says Kalle Niskanen, Work Planner at Terrafame.

Resident Engineer Pertti Puurunen takes care of the valves and has worked at the Terrafame mine for over five years.

Managing shutdowns proactively and efficiently

Shutdowns, spare parts and maintenance activities are jointly reviewed in advance to ensure workloads, schedules and risks are managed in a controlled manner. Post-shutdown review sessions support continuous improvement and help identify areas where process availability and equipment lifecycle can be further enhanced.

“Shutdown schedules, spare parts and workflows are reviewed in advance. After each shutdown, we hold a debrief session to assess performance and identify areas for future improvement,” adds Kiviluoto.

Terrafame’s flow control is based on complementary valve solutions selected for different process stages. Properly sized and process-optimized valves reduce unexpected disturbances, support maintenance planning and enable production development without unnecessary downtime.

“The material flows are highly abrasive and the solutions are often acidic. When they thicken in pipelines, mechanical stress increases further. That is why selecting the right valves for the right applications is critically important for us,” Paakkari states.

Together, Neles and Flowrox solutions form a comprehensive flow control portfolio that supports high availability, predictive maintenance and reliable operation across the entire integrated production chain.

Neles valves in critical control and shut-off applications

Neles valves play a key role in critical control and shut-off applications requiring precise, stable and controlled performance in varying conditions. Terrafame has more than 2,000 Neles valves in use, particularly in applications with continuous control where process stability directly impacts product quality and chemical consumption.

“With valves, we are not looking for the lowest cost solution, but one that can withstand our process and operate reliably over the long term,” says Kalle Niskanen.

One concrete and economically significant application area is chemical dosing, where precise and repeatable control directly impacts chemical consumption and reduces waste. In these applications, Terrafame uses Neles RE series segment valves.

Valve performance is supported by the Neles ND9000 intelligent valve controller, which is also widely used at Terrafame with control valves from other manufacturers. Accurate control, reliable valve performance data and broad compatibility support predictive process control and maintenance. Advanced diagnostics enable condition monitoring and support predictive maintenance via the Field Device Manager system.

“The reliability of Neles and Flowrox equipment is exceptionally high,” Kiviluoto concludes.

Olli Hinkkainen, Kalle Niskanen and Pertti Puurunen checking Neles valves together.

Flowrox valves in demanding slurry and solution applications

In demanding slurry and solution applications, flow control is supported by Flowrox pinch valves, of which Terrafame has more than 900 units, particularly in the metals recovery plant. These valves are used in precipitation, thickening and filtration, as well as in other applications where process flow contain solids and concentrations vary. Flowrox valves are also used in battery chemicals processing, lime plants, water treatment and uranium recovery.

The full-bore design, tight shut-off, simple operating principle and high reliability ensure controlled flow and disturbance-free operation even in challenging conditions.

Valmet experts Olli Hinkkainen and Pertti Puurunen checking Flowrox pinch valves at Terrafame.

Flowrox hose pumps in demanding processes for nearly 20 years

Flowrox hose pumps have long been a key part of Terrafame’s material handling in metals recovery and battery chemicals production. They are particularly used in demanding process stages involving abrasive media and harsh operating conditions.

Hose pumps are used at the battery chemicals plant in crystallization and extraction stages, as well as in metals recovery in wash water circulation lines for belt filters. The technology enables the transfer of abrasive media with up to 80% solids without mechanical seals, reducing wear parts and supporting high availability in continuous operation.

Olli Hinkkainen inspecting one of the Flowrox hose pumps installed nearly 20 years ago. Its distinctive red color originates from that era.

“When Talvivaara was established in 2008, the first Flowrox products were delivered to the project, and when Terrafame was founded in 2015, those same pumps are still in operation,” Paakkari notes. Some pumps have been in service for nearly two decades and are now being systematically renewed as part of long-term development.

Terrafame continues to develop its operations towards more efficient and sustainable production. The aim is to utilize mined ore more precisely and recover new products from it. Reliable flow control, predictive maintenance and long-term cooperation with Valmet form the foundation for this development.

Long-standing cooperation with Valmet has enabled both technology choices and service models to evolve alongside production, rather than being tied to individual projects. Long lifecycle solutions, predictive maintenance and process control also support environmental and energy efficiency targets. Terrafame’s development is guided by long-term goals, including carbon neutrality by 2039.

“Over this long history, both companies have changed names several times, but the collaboration has remained seamless — and will continue into the future,” Jauhonen concludes. “It is difficult to find anything to improve,” Niskanen adds.