Tag Archives: FLSmidth

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.”

Greenland Resources enlists help of FLSmidth for Malmbjerg molybdenum project

Greenland Resources says it has signed a letter of intent (LOI) for supply of metallurgical process equipment, technology, services and technical solutions for the Malmbjerg molybdenum project with FLSmidth.

The Malmbjerg molybdenum project is an open-pit operation with an environmentally friendly mine design focused on reduced water usage, low aquatic disturbance and low footprint due to modularised infrastructure, Greenland Resources says. A 2022 definitive feasibility study on Mambjerg by Tetra Tech outlined proven and probable reserves of 245 Mt at 0.176% MoS2. It also highlighted a 20-year open-pit mine life with average annual production in years 1-10 of 32.8 MIby of contained molybdenum metal at an average grade of 0.23% MoS2 and average annual life of mine production of 24.1 MIb with a cash cost of $6.38/lb Mo.

The company has now added FLSmidth to the list of Denmark-based companies associated with the project. These relationships are expected to facilitate equipment financing from government banks in Denmark, it says.

FLSmidth refocuses equipment portfolio in aim to become the leading METS player

FLSmidth has announced a strategic change to enhance long-term profitability and to accelerate growth in its core Mining business, which could see it offload its portfolio of port systems, stockyard equipment, “standard bucketwheel excavators”, “continuous surface mining equipment”, and mine & overland conveyors.

The decision, which comes seven weeks after closing the acquisition of TK Mining, is the result of a planned strategic review of the combined FLSmidth Mining and former TK Mining technology product portfolio against FLSmidth’s long-term strategic direction and ambitions, FLSmidth said.

“With this change, FLSmidth is creating a new platform for improved profitability, lower risk and strategic focus on the core value creating parts of the Mining business,” it said.

The company clarified that the overall strategic rationale for the acquisition of TK Mining has been reconfirmed and the acquired business is overall in line with its expectations. Furthermore, the cost synergy potential from acquiring TK Mining has been revisited, and further cost synergies have been uncovered, FLSmidth claimed. Additionally, the pace to realise these synergies will be accelerated.

The annual cost synergy target is now expected to be around DKK 560 million ($74 million), instead of the previous DKK360 million, with the annual cost synergy run-rate now expected to be achieved by end of 2023 (previously first two years after closing of the acquisition).

The aforementioned review intended to assess all combined mining activities and products from a strategic, financial and sustainability perspective against FLSmidth’s long-term strategic direction and ambitions, the company said. As a result of the strategic review, it has been decided to split the Mining business into two separate segments for operational and reporting purposes:

  • A continuing Mining segment focused on profitability, growth and sustainability;
  • A new Non-Core Activities segment, where activities will be fully exited either by way of divestment or wind-down of the order backlog.

The new segment split will ensure sharpened strategic focus and stronger execution of the continuing Mining activities that are key to accelerate long-term profitability and growth for FLSmidth, it said. At the same time, dedicated focus and resources will be allocated to the Non-Core Activities to ensure transparency and effective execution of the divestment or wind-down and to minimise losses from these activities.

Group CEO, Mikko Keto, said this split would reduce engineering risk, while setting the company up to become the leading technology and service solutions supplier to the global mining industry

“For years FLSmidth has been focused on engineering and large-scale projects with inherently high risks, challenging execution and volatile profitability,” he said. “We are now taking decisive action to further strengthen the focus on our core business, to ensure stronger execution and to drive value creation. The world must undertake a significant green transition over the coming years and the mining industry plays a crucial part in this. With today’s strategic change, FLSmidth is better positioned than ever before to become the leading technology and service solutions supplier to the global mining industry.”

FLSmidth’s Mining segment is dedicated to provide customers with best-in-class full flowsheet technologies and services solutions to enhance their productivity and sustainability agenda. A key focus for FLSmidth Mining is to enhance profitability through a significant service and aftermarket potential, low execution risks, high technology content and process know-how, and a strong sustainability impact

This could see the company offer single services or products, as well as projects with lower risk consisting of product bundles with related performance guarantees in accordance with FLSmidth’s risk management approach.

The continuing Mining segment encompasses, but is not limited to, FLSmidth’s key products within conveying (former TK Mining’s conveyor systems); milling & grinding (including former TK Mining’s high pressure grinding rolls); crushing & feeding; separation, thickening & filtration; pumps, cyclones & valves; sizers, screens & centrifuges; pyro-processing; sampling, preparation & analysis; and mine shaft systems.

The Non-Core Activities segment comprises specific loss-making mining activities and products that are no longer deemed to be of core strategic importance to FLSmidth, the company said. The selection criteria for these activities and product types have been that either they offer limited or no aftermarket potential, are characterised by high execution risks, are highly engineered and/or lack standardisation, and the company sees no viable commercial model for FLSmidth to turn these around. Furthermore, these products are not aligned with or important for FLSmidth’s sustainability agenda, it said.

Consequently, FLSmidth will either divest or wind-down the following activities and products:

  • All legacy FLSmidth and former TK Mining brands: port systems, stockyard equipment and standard bucketwheel excavators;
  • Legacy FLSmidth Mining brands: continuous surface mining equipment and mine & overland conveyors; and
  • Former TK Mining activities: oil extraction technology and aggregate products.

Existing contracts and ongoing activities in the order backlog will be executed and honoured, if not divested, yet FLSmidth will not take new orders for the Non-Core Activities segment, it said.

A designated organisational structure will be established to oversee the Non-Core Activities segment, with the head of the segment reporting directly to the group CFO. Around 450 employees are expected to be included in the Non-Core Activities segment.

The Non-Core Activities segment comprises of an order backlog of around DKK3.6 billion as of the end of the September quarter of 2022, of which approximately half originates from FLSmidth and half from the former TK Mining. The vast majority of the order backlog relates to capital orders.

The Non-Core Activities order backlog is expected to be divested or wound down within the next three years with an expected total EBITA loss over the period of around DKK1.2 billion, FLSmidth said. The estimate is based on historical performance and costs associated with the wind-down or divestment decision. This estimate is subject to uncertainty due to the nature of winding the business down and may change depending on which of parts of the business are divested, it clarified.

RG Gold looks to quadruple yellow metal output with new processing plant

RG Gold, majority owned Kazakh private equity group Verny Capital, has launched a new processing plant at its operations in Kazakhstan that is expected to enable the company to quadruple its gold output to circa-190,000 oz in 2023.

The new carbon in pulp plant, worth more than $420 million, has an annual processing capacity of around 5 Mt/y.

The new processing plant deploys modern equipment from global industry leaders, including Metso Outotec, thyssenkrupp, FLSmidth, Weir Minerals, Roytec and Kemix, RG Gold said.

RG Gold operates the RayGorodok deposit in northern Kazakhstan, one of the country’s largest mines with 5.9 Moz of JORC Code gold reserves. Its output is set to exceed 50,000 oz this year.

Bulat Utemuratov, the key investor in Verny Capital projects, said: “The launch of the new processing plant is a key milestone for RG Gold. It is underpinned by the highest global industry standards using the latest innovation and technical expertise from Resource Capital Funds, our strategic partner. The new plant allows us not only to quadruple RG Gold’s overall output, but importantly, it also provides the opportunity to boost investment in the region.”

FLSmidth to supply gearless overland conveyor technology to Southeast Asia mine

FLSmidth says it has been chosen to supply an overland conveyor (OLC) for a large, established copper-gold mine in Southeast Asia, which follows a large equipment order from the same customer and site earlier in 2022.

The pit-to-plant conveying system, which is over 5 km in length, has gearless drive technology. The order, including design and supply, was booked in the September quarter of 2022 and is valued at approximately DKK330 million ($44 million).

The conveyor order follows the March quarter 2022 announcement that FLSmidth had been chosen to supply two gearless SAG mills, two gearless ball mills and thickener technology to the same site. This new FLSmidth overland conveyor will deliver the ore from the pit to the new FLSmidth SAG and ball mills at the process plant.

The conveying system, part of the newly acquired tk Mining portfolio, is expected to deliver a significant reduction of operating expenditure due to its gearless drive technology, which uses less energy and results in less maintenance and higher availability during operations.

Mikko Keto, Group CEO at FLSmidth, said: “This overland conveyor system order not only continues our robust relationship with this customer, but it also demonstrates the strength of our portfolio following the acquisition of the tk Mining business. This is evidence that FLSmidth is a global leader in overland conveyors and gearless drive technology. The customer will benefit from our full flowsheet coverage, and we are proud to have provided the majority of the equipment to this mine site expansion.”

The order supports FLSmidth’s MissionZero ambition to enable customers to mine in a more sustainable manner, it said. Overland conveyors significantly reduce the need for diesel-powered truck fleets on mine site and makes material transportation more cost-effective and resource efficient.

FLSmidth to highlight full flowsheet expertise with ShalkiyaZinc project delivery

FLSmidth has signed a contract, valued at around DKK950 million ($130 million), to supply a range of mineral processing equipment to ShalkiyaZinc, the operator of a zinc-lead mine in the Kyzylorda Region of Kazakhstan.

The equipment will transform the plant into a world-class facility that efficiently separates minerals with a minimised environmental impact, the OEM says.

Under the agreement, FLSmidth will supply two underground crushing stations with a materials handling system to the process plant; a full package of comminution and separation equipment, including SAG and ball mills, mill circuit pumps and cyclones; the zinc-lead concentrate flotation and regrinding circuit, including nextSTEP, VXP vertical mills, concentrate thickeners and Pneumapress filters; and reagents preparation and dosing area. Full plant automation is also included, as well as installation and commissioning supervision services.

The new concentrator will be supported from FLSmidth’s new in-country service Supercentre in Karaganda, Kazakhstan.

The equipment delivery is to be completed during 2024, with commissioning to start before the end of that year.

Mikko Keto, Group CEO at FLSmidth, said: “We are excited to receive this first order from ShalkiyaZinc, which highlights our full flowsheet expertise. The wide range of equipment included in the order will help ShalkiyaZinc save on both capital expenditure and operating expenditure; our new nextSTEP flotation technology will improve the quality of the concentrates, the SAG mill will provide more flexibility, while the automation and digital solutions will further enable water and energy savings alongside safer operations.

“We look forward to making this a success on so many levels.”

Assel Rakhimova, Chief Project Director of Tau-Ken Samruk, which owns ShalkiyaZinc, said: “After testing and basic design work executed by FLSmidth, we are pleased to enter this new phase of collaboration with the procurement of critical technologies to improve the productivity and sustainability of our plant. We believe in successful execution and look forward to receiving the ordered equipment according to the schedule for installation and to continue working with FLSmidth on commissioning services and spare parts.”

FLSmidth, Metso Outotec, UHT and Inteco awarded Horizonte Araguaia nickel work

Horizonte Minerals says it has awarded all major and long-lead-time process plant equipment contracts for its flagship Araguaia nickel project in Brazil, with FLSmidth, Metso Outotec, Uvån Hagfors Teknologi AB (UHT) and Inteco Melting and Casting Technologies GMBH named as recipients.

Following completion of the competitive tender processes and detailed negotiations, the company has now secured equipment supply and technical support services for the balance of the Araguaia process flowsheet from these leading suppliers, it said. This is in line with the strategy employed for the award of the furnace contract to Hatch Ltd earlier this year.

“The successful completion of these contract awards is a significant de-risking event for the project,” it said. “Importantly it provides more certainty on costs for a material portion of the overall capital expenditure and builds confidence in the project schedule by gaining commitments for the delivery of key equipment on site in the timeframe required.”

To date, the company has awarded contracts totalling $293 million (including the $135 million of process equipment noted above) on budget and on time, according to CEO Jeremy Martin.

The rotary kiln, rotary dryer and associated dust handling equipment supply contract has been awarded to FLSmidth. FLSmidth, Horizonte says, is a market-leading supplier of engineering, equipment, and service solutions, particularly to the ferronickel industry, notably to Anglo American’s Barro Alto and Vale’s Onca Puma nickel operations in Brazil. FLSmidth has a strong track record of providing equipment and technical support services, with extensive experience in processing ore with characteristics similar to Araguaia, it said.

The ore preparation equipment contract involves the provision of primary, secondary and tertiary crushing, as well as the apron feeder that feeds the dryer. A primary dust control system for the reduction and refinery furnace, in addition to the secondary dust removal system, will also be supplied. This contract has been awarded to Metso Outotec, a leader in end-to-end solutions and services for the minerals processing and metals refining industries. Metso Outotec, Horizonte says, has extensive experience in providing equipment for the mining industry, including for operations worldwide with similar processing plants. It has a substantial presence in Brazil to provide ongoing technical support.

Horizonte has also awarded a contract for the supply of metal granulation equipment to UHT and a contract for the supply of the refinery equipment package to Inteco, which will transform the crude ferronickel produced by the electric arc furnace to high grade ferronickel for sale to customers.

The Araguaia project comprises an open-pit nickel laterite mining operation that delivers ore from a number of pits to a central rotary kiln electric furnace (RKEF) metallurgical processing facility. The metallurgical process comprises a single line RKEF to extract FeNi from the ore. After an initial ramp-up period, the plant will reach a full capacity of approximately 900,000 t/y of dry ore feed to produce 52,000 t of ferronickel, in turn containing 14,500 t/y of nickel. The FeNi product will be transported by road to the port of Vila do Conde in the north of the state for sale to overseas customers.