Tag Archives: FLSmidth

FLSmidth and Enter Engineering to work on MOF-4 copper-gold-molybdenum concentrator

Building upon a long-standing relationship, FLSmidth and Enter Engineering have signed a strategic cooperation agreement for the delivery of the core mineral processing equipment for the MOF-4 copper-gold-molybdenum concentrator, which is being constructed in Almalyk, in the Tashkent region of Uzbekistan.

Once completed, the plant is expected to become one of the largest copper concentrators in the world.

The cooperation agreement covers individual equipment and project service delivery orders, including basic engineering. The combined value of these orders could potentially amount to approximately DKK1.5 billion ($217.5 million) over the next several years, FLS says.

A key requirement for Enter Engineering has been to collaborate with a strategic partner that can supply the most efficient process technologies and aftermarket services with the lowest environmental impact across the full mineral processing flowsheet, leading them to the choice of FLSmidth, the OEM says.

Under the agreement, FLSmidth’s expected deliveries include high-pressure grinding rolls, screens, copper and molybdenum flotation, vertical re-grind mills, concentrate and tailing thickeners, concentrate filters, gravity concentrators, samplers as well as pumps, cyclones and valves. The execution of the individual orders will be led by FLSmidth’s Global Product & Technology Centre in Salt Lake City, USA, with the support of localised resources and services.

Mikko Keto, CEO at FLSmidth, said: “Uzbekistan is undergoing a rapid economic development, and its mining industry plays a pivotal role in this. We are very excited to support the country’s continued development through our collaboration with Enter Engineering and Almalyk MMC on the development of this new copper concentrator production line. Being chosen as the key strategic partner is a clear testament to the strength of our full flowsheet offerings and to our proven global execution capabilities.”

The ABB approach to drive positive change across the mining sector

“A green mining industry is not science fiction”, industrial technology giant ABB said earlier this year, pointing to the role it’s been playing in electrifying and automating energy-intensive mining processes for more than a century. Today’s technology presents even more actionable net zero emission pathways, according to ABB Process Industries Division President, Joachim Braun.

Speaking with Mining Beacon Editor, Richard Roberts, ahead of this year’s International Mining and Resources Conference and Expo (IMARC), in Sydney, Australia, Braun says a new ABB mining survey and report highlights a high level of industry planning to achieve significant net-zero transformation over the next five years.

The report will be a focus of an exclusive executive roundtable at IMARC, where industry leaders will converge to discuss strategies for achieving net zero emissions by 2030.

Richard Roberts: Next year is your 30th with ABB? Congratulations on your career so far.

Joachim Braun: Thank you. It’s been an incredible journey with ABB and the rapid pace of change in our industries is especially exciting.

Richard Roberts: It seems like technology has been over the past decade, or is about to be, transformative for engineering, manufacturing and other companies and industries. I read in the latest ABB Review how the company’s eMine simulation tools are enabling advanced mine fleet and power/renewable power integration simulation and modelling. How would you characterise the way in which these tools are changing the way you interact with customers, and how quickly has this happened?

Joachim Braun: Technology has been transformative, particularly in mining, and the eMine Simulation Solution is a great example. It allows customers to simulate renewable energy integration, fleet operations and power systems, optimising efficiency before making investments.

This data-driven approach is a game-changer, enabling customers to model scenarios, mitigate risks and optimise operations. Today, ABB is seen as a strategic partner to the mining industry, providing not only technology but deep expertise to guide customers through their energy transition.

Richard Roberts: In terms of your partnerships with top-tier mining and metals clients, how deeply embedded are these solutions? How central are they to shaping current and future alliances?

Joachim Braun: Our mining systems and solutions are deeply embedded in our partnerships with customers and others in the industry. But it’s not just about technology, it’s about building strong relationships with mining companies, OEMs and technologists. Collaboration is key because it allows us to bring expertise together and ensure the solutions we develop are aligned with real-world challenges. Our partnerships, like those with Perenti and IGO, evolve based on market conditions and shared goals.

Richard Roberts: You have talked in various forums and media about how quickly mining/metals is evolving as a technology adopter, among the process industries you deal with. Off a low base, it must be said. Which technologies do you see as being the most impactful in the sector in the next five years, from a “double materiality” perspective? How impactful will they be?

Joachim Braun: Mining is at a pivotal point and technologies like electrification, automation and digitalisation will have the greatest impact.

For example, our Gearless Mill Drives (GMD) are key for scaling copper production, which is critical for the energy transition. Integrating clean energy and AI-driven optimisation will enable the industry to extract more while reducing environmental impact, focusing on both sustainability and efficiency.

While mining has been slower to adopt certain technologies we’re seeing a shift.

A report which ABB will soon release, based on insights from 412 experts, shows that 53% of mining professionals are planning significant transformation in the next five years.

This is a unique opportunity for mining to leapfrog older stages of digitalisation and implement the most advanced solutions available today. ABB plays a key role in helping companies lay the automation foundation needed for this transition.

Richard Roberts: Mining, generally, is having to build more infrastructure to access remote deposits. It is moving more material to access lower grade, deeper deposits. This is not the way minerals/metals will help reshape the world’s energy, transport and urban landscapes, particularly with demand for primary minerals and metals climbing. Using more information, as others have said, can enable you to use less of other inputs…“More bits and bytes and not more kilos and litres”. How optimistic are you that we get to that world soon enough? Why?

Joachim Braun: As surface deposits deplete and ore grades decline, mining is increasingly moving deeper underground and processing more material for the same yield. This requires smarter solutions. Mine hoists, like those we’ve installed at BHP, are critical for accessing these deeper deposits sustainably. They provide an automated, electrified alternative to truck haulage, which is inefficient at great depths.

For example, at BHP, our hoist increased production from 4.5 Mt to 6.5 Mt annually while lowering emissions. This shows how automation and electrification can optimise operations and reduce environmental impact.

I’m optimistic that we can achieve the energy transition in time, but it requires collective action and the right approach.

This isn’t the first energy transition, but it’s one we must get right. We already have many of the technologies needed, though they are only now reaching the scale and capacity required for the future.

Take electrification. ABB electrified the first mine hoist in the 1890s, but clean energy wasn’t feasible back then. Today we’re seeing the potential of technologies like lithium-ion batteries which, despite their progress, are still in their infancy compared to more established industries.

Success depends on collaboration across the entire supply chain. Miners are leading the way but we need open partnerships, breaking down silos to drive real progress. Only by working together can we achieve our goals and create a sustainable future.

Richard Roberts: You’ve talked a lot about the need for, and power of, collaboration. ABB is working with mining and metals customers, and with mining OEMs/service companies such as FLSmidth, Perenti and Komatsu.

Joachim Braun: Electrification in mining, once thought impossible, is now a reality and a key part of the industry’s push towards sustainability.

Today, no globally-focused mining company can ignore electrification. It’s essential to meet 2030-2050 energy transition targets. ABB’s solutions, like the eMine Trolley System, have helped customers reduce diesel consumption by up to 90%, showing how quickly we can decarbonise operations.

Collaboration with partners like FLSmidth, Perenti and Komatsu has been vital in driving these innovations. While site operators focus on productivity and equipment availability, decarbonisation is becoming a shared goal, enabled by technology.

Richard Roberts: You said, with the recent Komatsu announcement, collaboration across the mining industry had “already been proven to enable real and faster progress and we look forward to driving what happens next”. What are the best examples, in your view, of where “real and faster progress” has occurred where we would not have otherwise seen such progress?

Joachim Braun: Electrification and automation have been game-changers in improving safety and efficiency, especially in remote and harsh mining environments.

A great example is the eMine Robot Automated Connection Device (ACD), developed with Boliden, BHP and Komatsu. This automated, high-power truck charging system eliminates the need for human intervention, maximising machinery uptime and boosting site productivity.
Another example is our automated robotic remote blasting loader, which just won gold at the Euromines Safety Awards 2024. Developed with Boliden, LKAB and explosive suppliers, this technology automates the dangerous process of charging blasting holes, improving safety by removing workers from hazardous environments.

These innovations wouldn’t have progressed as quickly without strong collaboration, proving the power of partnership in driving real progress.

Richard Roberts: What do you hope “happens next” by way of a “difference to the way mining companies operate their sites in the near future”?

Joachim Braun: In the near future I hope to see mining companies fully embrace the opportunities presented by electrification, automation and digitalisation.

Over the past two years working with eMine we’ve gained invaluable insights from collaborating with customers and partners. We now have a clearer understanding of where the mining industry stands in terms of technology adoption and are better equipped to tailor our solutions.

Looking ahead, automation and digitalisation will be crucial for addressing challenges like sustainability and workforce evolution. These technologies will not only optimise operations but also make mining a more attractive and inclusive industry. The focus is now on implementing these changes quickly and effectively.

With the right approach we can drive positive change across the sector.

International Mining is a media sponsor of IMARC, taking place in Sydney, Australia, from October 29-31

FLSmidth to strengthen digital pump, cyclone and valve offering with TIPCO buy

FLSmidth has signed an agreement to acquire TIPCO Tudeshki Industrial Process Control GmbH (Tipco), a technology company based in Aachen, Germany.

Tipco is the developer of cutting-edge sensor technology that can measure the particle size distribution of different mass flows, which offers strong applications across FLSmidth’s Mining portfolio, the OEM says.

The technology will initially be applied to FLSmidth’s hydrocyclones portfolio. The combination of FLSmidth’s KREBS hydrocyclones, offering high-efficiency and cost-effective classification solutions, with Tipco’s sensor technology will further strengthen FLSmidth’s pumps, cyclones and valves (PCV) solutions to mining customers, it says. Over time, FLSmidth will seek to extend the use of the technology to other parts of the mining portfolio, including additional potential applications within the grinding circuit.

Pat Turner, PCV Business Line President at FLSmidth, says: “This acquisition marks an important addition to our PCV offerings and highlights our strategic focus on digital solutions across the mining flowsheet. The optimisation of the grinding circuit plays a crucial part in maximising productivity and operational efficiency of the overall processing plant, and the addition of Tipco’s ground-breaking sensor technology will further strengthen our offerings within this area.”

The terms of the transaction have not been disclosed.

FLS evolving regional strategy to better serve EMEA region

Supporting mining in achieving its energy, water and emissions reduction goals, FLS says it is evolving its regional strategy for even greater impact.

Mining customers are to benefit from the stronger regional capability being developed by FLS, which is making the company even more responsive to customer needs, the OEM says.

This is one of the key outcomes of the company’s strategic evolution underway, according to Bernard Kaninda, newly appointed FLS President Sales and Service for Europe, Middle East and Africa (EMEA). As a leading full flow sheet technology company, FLS occupies a distinctive place in the market, he says, giving it a special relationship with customers.

“Being a partner through all their mineral processing requirements, FLS walks with customers throughout the lifecycle of a comprehensive range of equipment and solutions,” he says. “This engagement gives us greater impact in helping the mining industry achieve its sustainability goals.”

FLS aligns itself with industry imperatives by committing to energy and water reduction targets, and committing to reach zero emissions by 2030. To achieve these goals, Kaninda says, it was imperative to further grow the region’s capability – shifting from the previous regional definition which comprised sub-Saharan Africa, Middle East and Southern Asia to a more cohesive EMEA region.

“We believe the move to an EMEA region will better create the capabilities we are looking for, combining the strengths of Africa and Europe, and our learnings in the Middle East,” Kaninda explains. “We expect to be able to respond more quickly with services, spares and equipment, and are building local resources to achieve these improvements.”

The focus on communication and partnership is being fostered through clusters within the region, which are empowered with adequate resources for quick response times and effective support for end-users.

“As a partner that tailor-makes solutions for our customers, we go further by guaranteeing the performance of that equipment,” Kaninda says. “This means being able to respond effectively as and when the situation demands, so we need to be in close proximity to the customers’ sites – and very familiar with the conditions they experience.”

The clusters in Africa ensure a strong presence in Southern African countries – including South Africa, Zambia and the Democratic Republic of the Congo – as well as West Africa and North Africa. These are areas where FLS already has a significant footprint of equipment in operation.

“The mining sector is dynamic, however, so we are constantly expanding our equipment footprint and will be establishing a presence wherever we have a significant installed base,” Kaninda says. “It has always been a matter of pride for us that FLS customers will receive the same close attention irrespective of where they are around the globe.”

Streamlined logistics are an important aspect of the strategic shift, which will reduce delivery times through better availability of inventory in-country. Teams in the clusters will also facilitate faster access to service and parts.

“We are also committed to the communities in the regions where we operate, and are increasing our local employment as we develop our presence in different countries – especially in Africa,” Kaninda says. “We believe in building local capability and this is visible in our teams, in which 90-100% of staff are already local in the various clusters.”

These teams are supported by specialised training provided by facilities such as the FLS Training Academy at the Chloorkop service centre in South Africa. This well-equipped regional training hub underpins ongoing skills transfer to build the company’s skills base and succession pipeline, he says, ensuring all customers receive the same FLS experience. So successful is Chloorkop’s model of combining technical services with training, that the company plans to replicate such a facility in the Middle East.

“This will allow us to upskill youth and enhance our positive economic and social impact on the community,” he explains. “There is no reason why we shouldn’t even look at another such centre in Africa, as there is growing demand for artisans and other specialised skills.”

Africa remains vital as a provider of mineral resources for the transition to a lower carbon future, concludes Kaninda, highlighting that FLS will continue to partner with customers so that mining itself becomes more responsible to the environment and community.

FLSmidth to launch new NexGen Polyurethane formula for wear products at Electra Mining Africa

FLSmidth is gearing up to showcase how it is supporting customers across Africa in achieving optimal plant performance, with its appearance at Electra Mining Africa, in Johannesburg, South Africa, providing a good platform to launch a new solution for its wear product line.

The company is driving sustainable productivity through its solid and growing support and maintenance infrastructure, it says. According to Alistair McKay, Vice President Mining: Europe, Arabia and Africa at FLS, this includes engaging visitors at the event on the value of the company’s innovative digital solutions.

“In addition to our market leading solutions for mining plants, we will be sharing our extensive foundation of expertise, technical services, spares and consumables to support customers,” McKay says . “The show gives us the opportunity to demonstrate how these resources can lower operating costs and drive profitability.”

Key to FLS’s success in doing this is its understanding of exactly how its solutions are performing in customers’ processing facilities. As the original equipment manufacturer, he argues, the company is best placed to partner with mines to optimise performance and to maintain equipment health at the highest level.

“There is a global shortage of skills to conduct this important work, making it essential that we continue to both replenish and enhance the necessary levels of expertise for our ever-advancing equipment,” he explains. “This is why we invest so heavily in our training facilities and trainers – to upskill not only our own people but those of our customers.”

He highlights that there is “nothing worse” than for customers to invest in high quality, high production equipment, which then underperforms due to insufficient knowledge. The company is also leveraging digital solutions in this endeavour.

“While there is a plethora of digital solutions in the market, we have focused our energies on creating solutions that meets strategic priorities,” McKay says. “This means being able to monitor and analyse the health of the asset, while leveraging this data to optimise the performance of that asset.”

Visitors at the exhibition can also see how FLS’s digital solutions integrate with its control centre, from which it can provide customers with 24/7 support.

In terms of new offerings at the FLS stand, visitors will be witness to the launch of the new NexGen Polyurethane formula for the company’s wear products and can discuss application opportunities with the company’s experts. The NexGen Polyurethane is relevant to screening media and mill trommels – particularly at the front-end of the concentrator where impact and abrasion is high.

“We will also be talking to visitors about our local production facilities that allow products like these to be readily available to our mining customers,” McKay says.

FLS’s slurry pumps will also be showcased for their performance and energy efficiency. With this Electra Mining Africa being the first since the company’s acquisition of Thyssenkrupp’s mining business, McKay said it provided FLS with the opportunity to show visitors its fully integrated portfolio. “This range of products and technologies continues to support optimised and sustainable operations at lower costs,” he added.

FLSmidth wins multi-year contract to service HPGRs at Chile mines

A leading Chile-based iron ore miner has awarded FLSmidth with a multiple year contract to service its five high pressure grinding rolls (HPGRs) across three of its mines in Chile, with the key focus for the customer to enhance productivity and extend the lifetime of its HPGRs.

HPGRs are subject to significant wear and tear. Consequently, keeping them in operation is key to securing a mine’s productivity and throughput as well as reducing customers’ operational costs. To facilitate to this, having a strong service setup around HPGRs is paramount.

The new service order on these five HPGRs, which originally have been installed by another equipment provider, proves that FLSmidth’s HPGR service offerings are among the most attractive in the market, the company says. All assembly works as well as repairs on shafts are included in the contract.

The service contract will be managed and executed by FLSmidth’s Chilean service centre, which is in close proximity to the three mines, thereby reducing logistic costs to customer and providing best in class services, it added. FLSmidth’s service centre is fully equipped to manufacture large HPGR parts and allows all work to be performed in a clean environment and using best in class tools.

Prior to winning this new service contract, FLSmidth has previously delivered HPGR roll tyres to the customer, which have proven to last more than three times as long as the originally installed roll tyres as well as increased operational availability and significantly reduced recirculation, the company says.

Joshua Meyer, Service Business Line President at FLSmidth, says: “For long our HPGR solution has been regarded among the best in the industry. The fact that we can win a large service contract on a non-FLSmidth HPGR platform proves that we have the service concept to back up the technology, securing enhanced productivity and extended lifetime.”

FLSmidth to deliver ball mills, HPGRs to South America copper miner

Following a long-standing relationship with the customer, FLSmidth says it has received an order to supply comminution technologies to a leading copper miner in South America for its new greenfield concentrator.

The order is valued at approximately DKK380 million ($56 million) and was booked in the March quarter of 2024. The equipment is due to be delivered during 2025.

The order includes the delivery of two ball mills and three high pressure grinding rolls (HPGRs). The latter is among the most energy-efficient comminution technologies, as it lowers power consumption, while providing a more stable grinding operation and eliminating the need for grinding media, according to the OEM.

This new order builds on a long-standing relationship with the customer, where FLSmidth has supplied most of the equipment for its original concentrator as well as provided maintenance, spare parts and process support services over the years.

Mikko Keto, CEO at FLSmidth, said: “Receiving new orders from existing customers is always confirmation of a healthy and strong customer relationship. And it is particularly satisfying in this case as the customer is purchasing their first HPGRs and have selected our market leading technology. We look forward to supplying this best-in-class comminution package to positively contribute to both the output and operation of this new copper concentrator.

“This order not only supports our MissionZero ambition, it also clearly underpins FLSmidth’s market leading position within large grinding mills and HPGR.”

FLSmidth to overhaul and update gyratory crushers at South America copper mine

FLSmidth is to deliver three Top Service Design (TSUV) gyratory crushers to a long-standing copper mining customer in South America, the OEM says.

This new order allows FLSmidth to overhaul existing equipment with newer crusher technologies to boost efficiency for the company, it says.

The order is valued at approximately DKK200 million ($28.3 million) and was booked in the September quarter, with the equipment expected to be delivered during 2024.

Under the agreement, FLSmidth will overhaul three existing gyratory crushers, which were originally also supplied by FLSmidth, with three improved and more efficient gyratory crushers with the improved TSUV. By installing these new gyratory crushers, the customer will benefit from increased efficiency as well as safer and simpler maintenance, FLSmidth says.

Two of the crushers will be installed in the existing foundations of the old crushers to minimise construction costs, while also limiting the environmental impact from the replacements.

Chris Reinbold, Products Business Line President at FLSmidth, said: “We really appreciate when existing customers return to us. We see this as a clear vote of confidence in the quality of our technologies and services. Enabling our customers to achieve more efficient copper production is essential to electrification and the green transition.”

In 2020, FLSmidth launched the new “digitally-enabled” TSUV Mark 5 Top Service Gyratory Crusher to deliver the lowest total cost per tonne of material processed, even when crushing the most challenging ore.

FLSmidth out to optimise closed-circuit grinding operations with KREBS SmartCyclone tech

Efficient operation and minimal downtime are crucial for maintaining productivity and profitability in grinding circuits and, to address these challenges, many operations are opting for the KREBS® SmartCyclone™ technology from FLSmidth, according to the OEM.

Abrie Schutte, Senior Applications Engineer at FLSmidth responsible for the KREBS pumps cyclones and valves product business line, says this innovative technology combines advanced monitoring and automation features to optimise closed-circuit grinding operations.

“SmartCyclone integrates various components and software to provide a comprehensive solution for grinding circuit management, and significantly incorporates roping sensor technology, wear detection technology, a wireless controller system and ECS/ProcessExpert® process control software,” Schutte says. “End-users have found that by leveraging these elements, maintenance planning is enhanced, wear reduced and there is an overall improvement in grinding circuit performance.”

The wear detection technology of SmartCyclone employs specialised sensors to monitor the wear status of cyclone components. This real-time information enables operators to proactively plan for part replacements and schedule maintenance activities, minimising unexpected downtime caused by component failures.

Schutte further explains that an automated monitoring system is a key feature of SmartCyclone.

“This is important as it allows operators to detect wear and troubleshoot issues from a centralised control room, eliminating the need for manual equipment inspections with a reduction in associated risks,” he says.

By promptly identifying and addressing potential problems, process disruptions are minimised, ensuring optimal performance of the grinding circuit.

The SmartCyclone system also includes a roping detection feature, which identifies and corrects disturbances known as “roping”. Overloaded cyclones or those experiencing roping can lead to increased bypass of coarse solids to the overflow and greater particle size variation.

“This accumulation of slurry can adversely affect downstream equipment, such as flotation cells,” Schutte says. “By monitoring and detecting roping, operators can confidently operate the plant closer to its limits, thereby increasing production capacity and improving mineral recovery.”

By integrating SmartCyclone with ECS/ProcessExpert software, the grinding circuit’s performance can be further optimised, according to FLSmidth. The system dynamically adjusts variables such as water addition, pump speed and the number of operating cyclones based on real-time data from SmartCyclone sensors. This continuous optimisation enhances particle size distribution, maximises mineral recovery and improves the overall efficiency of the grinding circuit, it says.

SmartCyclone offers a comprehensive solution for closed-circuit grinding operations, FLSmidth says. By leveraging advanced sensor technologies, automated monitoring and process control software, this system empowers operators to enhance maintenance planning, reduce wear and optimise the performance of their grinding circuits.

Schutte concluded: “With its ability to detect early warning signs, troubleshoot potential issues and dynamically adjust variables, SmartCyclone sets a new standard for smart and efficient grinding circuit management.”

FLSmidth to deliver MissionZero comminution equipment to KCGM gold operations

Northern Star Resources Ltd has placed an order for a wide range of FLSmidth mineral processing technologies for its Kalgoorlie Consolidated Gold Mines (KCGM) Operations’ mill expansion project, according to the Denmark-headquartered OEM.

KCGM Operations are east-northeast of Perth in Western Australia, part of one of the richest goldfields in the world, the so-called Golden Mile close to the city of Kalgoorlie-Boulder.

The order is valued at approximately DKK 515 million ($75.1 million) and was booked in the June quarter of 2023. The equipment is due to be delivered during 2024.

Under the agreement, FLSmidth will supply a range of MissionZero products covering most of the flowsheet, including SAG mill, ball mill, primary crusher, pebble crushers, flotation cells and a pre-leach thickener. In addition to these technologies, the order also includes spare and wear parts. Upon installation, these technologies will substantially reduce the mine’s energy consumption.

The 20 MW grinding mills will be the highest power, gear-driven mills in the world and the ball mill will be the first gear driven 28 ft (8.5 m) diameter ball mill, according to FLSmidth.

“This order is yet another important milestone in our ambition to enable zero emission mining by 2030, and we are very pleased with Northern Star Resources’ contribution to fulfilling this ambition,” Mikko Keto, CEO at FLSmidth, said.

This week, Northern Star announced the final investment decision on the KCGM Mill Expansion project, agreeing to invest A$1.5 billion ($1 billion) to boost the mill’s capacity to 27 Mt/y, from 13 Mt/y.

Northern Star Resources’ Managing Director, Stuart Tonkin, said of the FLSmidth order: “Northern Star’s purpose is to generate superior returns for our shareholders, while providing positive benefits for our stakeholders through operational effectiveness, exploration and active portfolio management. Being a responsible producer for the benefit of our shareholders, employees, other stakeholders and the communities in which we operate is key to our sustainable operations. We are pleased to partner with globally leading technology suppliers like FLSmidth in advancing our five-year profitable growth strategy.”