Many mineral processing operations still rely on manual sampling and laboratory analysis to monitor particle size. These methods are labour intensive, prone to human error, and deliver delayed results. Designed for continuous, real-time particle size distribution measurement directly within the process stream, the recently introduced FLSmidth KREBS® OSA provides immediate visibility into grinding circuit performance and changing process conditions.
The analyser uses a pulse-based, intrusive measurement principle to determine particle size distribution directly within the process stream. As material flows through the measurement zone, particles interact with a highly sensitive oscillator positioned in the mass flow. Each particle impact generates a measurable vibration response.
Following initial calibration, these vibration signals are continuously recorded and processed in real time. Advanced algorithms interpret the vibration patterns and convert them into an accurate particle size distribution profile. This enables continuous, live process visibility without the delays associated with manual sampling or laboratory analysis.
The analyser continuously measures full particle size distribution with customisable size ranges up to 4 mm, helping support more responsive process control and improved circuit stability. The solution also supports OPC UA and Modbus TCP integration capabilities, enabling live process trending and historical performance monitoring directly from the operation.
FLS: “Real-time data enables immediate grinding circuit adjustments, while optimal particle size distribution improves flotation and leaching performance. Continuous monitoring also helps prevent surges in coarse or fine particles, reducing overgrinding and associated energy waste.”
Intrusive measurement from inside the process flow removes the need for manual intervention while helping eliminate human error from particle size monitoring. It also improves operator safety by reducing sampling exposure and delivers continuous results instead of hours after conditions have changed.
The standalone, plug-and-play system requires no IT or cloud connection and is hard-wired to the control room for secure, stable data transmission. It integrates into existing control systems with minimal set-up, while the subscription model removes the upfront CAPEX barrier with full installation and support included.
FLS says the KREBS® OSA is available on a subscription basis, removing the need for upfront capital investment. All plans include full installation and calibration, software licence, maintenance with spare parts, and field service and technical support. Predictable, fixed pricing includes a complete lifecycle service to ensure sustained performance, operational efficiency, and long-term reliability. Flexible service plans are available on a monthly basis or through prepaid multi-year intervals to align with customer budgeting needs.