Tag Archives: FLSmidth

FLSmidth to boost plant efficiency with SmartCyclone system

Automation, Comminution of minerals, Equipment maintenance, Mineral processing, Mining equipment, Mining maintenance, Mining services, , , ,

With process plant optimisation techniques becoming a necessity for mines looking to maximise their operating performance by keeping costs low, throughput high and downtime to a minimum, FLSmidth has devised an automated monitoring and control solution for reducing cyclone-related process deviations.

The SmartCyclone™ system delivers in all three areas for cyclone circuits, according to the company, improving cyclone overflow particle size distribution, predicting and controling cyclone maintenance schedules, and optimising closed-circuit grinding processes.

FLSmidth said: “This equates to monitoring the performance of individual cyclones within a circuit in real time, preventing unplanned breakdowns from occurring and monitoring wear rates while ensuring the cyclones are operating optimally at all times. This translates into higher efficiencies in the plant and ultimately, higher profitability.”

The SmartCyclone closed circuit grinding optimisation system combines a variety of FLSmidth patented technologies, including the FLSmidth Krebs SmartCyclone wear detection sensor technology and the Krebs’ patented roping sensor technology (with patent-pending wireless controller system). This technology immediately identifies if a cyclone is malfunctioning, the company said.

The closed circuit grinding optimisation system also incorporates FLSmidth’s ECS/ProcessExpert® process control software with a new patent-pending SmartWear™ cyclone maintenance algorithm.

One of the largest benefits associated with this software is the ability to develop a uniform operation strategy that outlines the best way to run the plant, according to FLSmidth. “Once this strategy has been established, the necessity to train new operators is reduced.”

Reducing or eliminating manual operation, which decreases the potential for human error, is also one of the overarching benefits of SmartCyclone, the company says.

FLSmidth has more recently enhanced its Krebs SmartCyclone system with wireless technology that
enhances installation by eliminating the need for individual nodes and the interconnecting cables between the sensors and nodes and associated controllers.

It uses a central wireless controller that can handle up to 16 sensors per unit; providing real-time wireless detection and communication of roping and/or wear data. The new wireless controller unit is a handheld device that can be removed from its docking/charging station to sync the individual sensors. Once removed, it goes into battery-power mode and the user can walk to a desired sensor, activate it with a magnet, trigger and set the necessary operating parameters.

FLSmidth FerroCer wear panels increase uptime at Hindustan Zinc operation

Base metals, Comminution of minerals, Equipment maintenance, Mine operation news, Mineral processing, Mining consumables, Mining services, , , , , , , ,

FLSmidth’s FerroCer® Impact wear panels have proven their worth in the mineral processing circuit at Hindustan Zinc’s Rampura Agucha operations in Rajasthan, India, having significantly outlasted the previous manganese liners the lead-zinc mine was using.

By the end of 2018, the mine couldn’t say exactly just how good FerroCer wear panels were as they were still in place over a year since installation.

However, by March 2019, it was confirmed the FerroCer liners had completed about 480 days (16 months approximately) in operation and had withstood some 2.45 Mt of lead-zinc ore conveyed through the U-13 tripper chute, located after the primary crusher at the mine.

This is a significant improvement on the previous 40 mm-thick manganese steel liners, which had a life span of only 23-25 days, according to FLSmidth.

The constant wear on these liners meant the material handling system needed to be frequently shutdown so the worn-out liners could be replaced with new manganese steel liners, which weighed about 50 kg each.

“Because of the elevated location of several chutes, replacement of the liners required safety preparations (such as scaffolding and other access and handling arrangements), with five to six workers required to get inside the chutes to handle the liners,” FLSmidth said.

FLSmidth visited officials at the Rampura Agucha mines in June 2017 and recommended FerroCer wear panels to address the high wear issues in the material handling chutes.

“Each panel comprises a set of abrasion-resistant ceramic inserts enclosed in a matrix of malleable steel, which ensures only the top surface of the insert is exposed to material impact,” FLSmidth said. “The sides of the inserts are tapered within the matrix, keeping them in place and preventing material particles and fluids from damaging the panels.”

Some in-situ results from the 220-day mark showed the wear on the panels measured only 8-10 mm and had withstood around 1.5 Mt of lead-zinc ore conveyed through the U-13 tripper chute.

“This means FerroCer outlasted the previous panels by over 10 times, meaning a much longer replacement cycle,” FLSmidth said.

Clearly delighted with this outcome, Hindustan Zinc is now looking to use FerroCer impact wear panels across its high-impact wear locations, according to FLSmidth.

Praveen Bhardwaj, Assistant General Manager (Mechanical), HZL – RA Mines, Rajasthan, said: “FerroCer has reduced maintenance time due to the much longer replacement cycle, eliminated possible damage to the mother plate and spillage of material due to the highly abrasive nature of ore, and significantly reduced safety hazards. HZL intends to install FerroCer impact wear panels in all the high impact wear locations.”

The results at the Hindustan Zinc site follow on from results from two mines in Australia. One mine operated for more than a year without replacing its wear liners and the other site is on the same track, approaching its first year without the need for liner replacement.

Meanwhile, in a Peruvian copper mine, 24 smaller and lighter FerroCer panels, each made of steel plates with ceramic inserts, replaced six generic liners. After a total of 12.6 Mt passed, with a feed of 7,500 t/h, wear was no more than 3%, FLSmidth said.

“At that rate, FerroCer lasts at least 10 times longer than the most expensive and recognised wear liner on the market.”

Vista Gold Mt Todd PFS points towards use of ore sorting, fine grinding

Comminution of minerals, Mineral processing, Mineral project development, Mining equipment, Mining techniques, Precious metals, , , , , , , ,

Following extensive metallurgic test work carried out over the past year, Vista Gold looks like it has settled on a flowsheet for its Mt Todd gold project in the Northern Territory of Australia that includes ore sorting and the selection of the FLSmidth VXP mill as the preferred fine-grinding mill.

The company detailed this in an updated prefeasibility study (PFS) for the project, which factored in the results of metallurgical optimisation test work, a redesign of the fine grinding circuit, construction and ramp-up schedule changes and a comprehensive review of all aspects of the project.

The process improvements resulted in improved projected gold recovery and increased estimated gold production at Mt Todd, Vista Gold said.

According to the PFS, a 50,000 t/d operation at Mt Todd could see the operation produce 413,400 oz/y of gold over the 13-year mine life at average all-in sustaining costs of $746/oz.

The estimated initial capital requirement came in at $826 million, with the project offering an after-tax net present value (5% discount) of $823 million at a $1,350/oz gold price and a $0.70=A$1.00 exchange rate.

In the company’s metallurgy, processing and infrastructure section, it detailed the processing side of Mt Todd, saying that recent metallurgic test programs had confirmed the efficiency of ore sorting across a broad range of head grades and the natural concentration of gold in the screen undersize material prior to sorting. The company carried out such test work at TOMRA Sorting Solutions in Germany, where two-stage (X-ray Transmission and laser) sorting tests were completed using production-sized and commercially available equipment.

It also said such test work had confirmed the efficiency of fine grinding and improved gold leach recoveries at an 80% passing grind size of 40 microns, in addition to the selection of the FLSmidth VXP mill as the preferred fine-grinding mill.

The company previously sent samples to Core Metallurgy Pty to obtain fine grinding data simulating grinding in the horizontal IsaMill and to the FLSmidth Minerals Testing and Research Center to obtain data simulating grinding in the vertical VXP Mill.

FLSmidth reflects on KREBS slurry pump dominance in Africa

Equipment maintenance, Mineral processing, Mining equipment, Mining services, Water management, , , , , , ,

KREBS® slurry pumps have become leaders in mill discharge applications in Africa, with the latest Ultimate Mill Discharge (UMD) pump leading the way in these heavy-duty applications, according to FLSmidth.

Andre Hall, FLSmidth Regional Product Line Manager — Pumps, Cyclones and Valves, said: “West African gold mines and the copper operations of Zambia and Democratic Republic of Congo are among the areas where these robust pumps dominate.

“Their popularity,” he says, “is based on their long wear life and high efficiency.”

Ghana is a particular success story for UMD pumps, according to Hall, with nearly all gold mines there using the equipment manufacturer’s pumps to discharge slurry from their mills, he added.

“The KREBS UMD is popular at these mines largely because it lowers the total cost of ownership due to the millMax™ proprietary design that eliminates inefficient recirculation and grinding of slurry within the pump,” FLSmidth said.

“Prior to the millMAX wear ring design, slurry pumps experienced two major problems: mechanical grinding of solids between the suction liner and impeller, and flow recirculating back to the impeller eye on the suction side. Both of these problems decrease pump life and increase power consumption.”

The wear ring stops recirculation by closing the suction-side gap, while still allowing for a large clearance between the impeller and the suction liner, according to FLSmidth. This eliminates the grinding of solids. Adjusting the wear ring while the pump is running, meanwhile, restores performance and provides longer wear life and higher continuous efficiency, in all, lowering the total cost of ownership.

Hall says: “The UMD’s casing symmetry also means less inventory for customers. Mines that have pumps rotating in both left-hand and right-hand orientations must stock different casings, liners and impellers, adding to the operational costs.”

The advantage of the UMD is that it uses the same casing, suction liner, wear ring and back liner, which reduces overall net working capital.

The KREBS gravelMAX™ pumps continue to do well in the Mpumalanga coal sector of South Africa, according to FLSmith, where 14 of these pumps recently replaced competitor units on a single site.

Commonly applied in a cyclone feed application within the dense medium separation (DMS) circuit, the pump’s wider passage allows pumping of larger solids.

“We are also active in iron ore in South Africa with pumps in the DMS circuit,” Hall says. “A Lesotho diamond mine also operates KREBS pumps, which have demonstrated a four-fold increase in wear life compared to a competitor’s previous units.”

In sump pumps, FLSmidth has the vMAX™ range, which features a recessed impeller design allowing the pumps to run dry.

The company explains:“When the sump has been emptied of slurry, the recessed impeller allows the slurry to return safely down the discharge pipe without contacting the impeller, ensuring that it does not vibrate when dry.”

Another recent innovation in the KREBS slurryMAX range of pumps is being introduced to the Africa market after an enthusiastic response in the US and Australia, FLSmidth said. With multiple liner and impeller material options, the slurryMAX split-case pump can handle the majority of applications for any plant across multiple industries.

FLSmidth notes sustainability and digital mining developments in Q2 results

Automation, Bulk handling, Comminution of minerals, Environmental, IoT, Mineral processing, Mining consumables, Mining equipment, Mining finance, Mining services, Mining software, Sustainable mining, Water management, , , , , , ,

FLSmidth’s June quarter saw an improvement in revenue and profitability as the company’s Mining and Cement divisions continued to perform strongly.

The company’s order intake for the June quarter amounted to DKK5 billion ($752 million), down 2% from the same period a year ago. Mining order intake, specifically, declined 7%, mainly due to a lower capital order intake, the company said. This included an order of around DKK375 million from Rio Tinto for its Koodaideri iron ore project.

During the quarter, the company also completed the acquisition of IMP Automation.

FLSmidth’s order backlog stood at DKK16.8 billion by the end of June, up 16% from the same time last year.

Revenue increased 16% year-on-year in the quarter to DKK5.5 billion on high activity level, while earnings before interest taxes and amortisation came in at DKK487 million, up 28% year-on-year.

FLSmidth Group CEO, Thomas Schulz, said: “The second (June) quarter showed a strong performance with improved revenue and profitability, driven by both Mining and Cement. Following a slow start to the year, we have been successful at converting backlog to revenue in the second quarter. In close cooperation with our customers, we have continued to deliver on our vision to provide sustainable productivity enhancement.”

Schulz continued: “Our success with both service and capital orders, demonstrates our customers’ confidence in our ability to enhance their productivity. This is supported by an increased push for sustainable solutions that ties in well with our position, capabilities and track record.”

In the company’s Mining division, Schulz said the company saw increased interest for new technologies such as dry stack tailings, but also a general need to reduce water consumption in the production process. The company said the mining market remained robust.

The company added on the mining market: “Equipment demand continues to evolve around replacement and brownfield projects, with select greenfield opportunities. Miners are attentive of rising global issues and remain cautious on large and high-risk investments. The long-term pipeline for larger projects is encouraging, but most projects are currently not reaching further than the engineering/prefeasibility stage.”

It continued: “Customers across regions and commodities are increasingly demanding digitalised solutions to improve performance, reduce operating costs and maximise safety in operations. Similarly, customers show increased interest in technology to obtain a more sustainable production, not least our effective solutions for tailings management given the latest issues with tailings dams failures and the related environmental impact.”

FLSmidth to help modernise crushing, grinding circuit at Zijin’s Serbia copper op

Base metals, Comminution of minerals, Mine operation news, Mineral processing, Mining equipment, Mining services, , , , , , , , , , ,

Zijin Mining Group has chosen an FLSmidth gyratory crusher, SAG mill and ball mill for the Majdanpek mine, part of the Chinese mining company’s majority owned Zijin Bor copper mine, in Serbia.

The delivery of the equipment to Majdanpek, 180 km from Belgrade, is expected to occur between 12 and 18 months from now, with the project estimated to reach completion by the end of 2020. The order has a combined value of around DKK200 million ($30 million), according to FLSmidth, and has been recognised in the order intake for the September quarter.

The order of the new FLSmidth crushing and grinding circuit for the front end of the concentrator comes as Zijin looks to modernise Majdanpek, which will be the largest of its three Serbian copper concentrators, FLSmidth said.

Acquired as part of the majority acquisition of Bor in late 2018, the Majdanpek mine uses open-pit mining and flotation to produce copper concentrates, with a designed mining and processing scale of 10 Mt/y, according to Zijin. The operation is currently at a scale of 6 Mt/y, it said.

In the next six years, the company says it plans to invest more than $1 billion in the upgrading, expansion, or construction of the four mines and smelter at Bor. After the completion of the first phase of the project, it is estimated output will go to 82,000 t/y of copper in concentrates, with the smelter producing 80,000 t/y of copper cathode. After the completion of phase two, this could go to 120,000 t/y of concentrate and 150,000 t/y of cathode.

Manfred Schaffer, President of Mining and Group Executive Vice President at FLSmidth, said: “This extensive order underlines the strong value proposition of FLSmidth to our customers in the copper industry. Our market leading crushers and mills will provide significant improvements for Zijin Mining in terms of productivity and processing efficiency.”

Namakwa enlists FLSmidth pumps to cut downtime, costs at Kao diamond mine

Comminution of minerals, Diamond mining, Equipment maintenance, Mine operation news, Mineral processing, Mining equipment, Mining maintenance, Mining services, Water management, , , , , , , , , ,

The installation of a FLSmidth KREBS millMAX™ pump at Namawka Diamonds’ Kao mine, in Lesotho, is, according to the mining equipment maker, providing the miner with significant cost savings through increased impeller, casing and back liner wear life.

FLSmidth’s engagement at Kao started when the mine required a pump conversion in the field – an undertaking that can be difficult and time consuming, according to the mining OEM. “It is also a high-stakes operation as a cyclone feed is critical to the overall process and ability to generate returns. A wrong decision can mean a lot of lost revenue,” the company said.

It was the potential for cost efficiency that convinced Kao diamond mine to implement the KREBS millMAX Pump. After initial discussions, the first trial pump – a millMAX 8×6 centrifugal seal (C/S) – was installed in a cyclone feed application (DMS 2 pump 1).

Initial results after seven months showed the millMAX was performing extremely well on the wear side, according to FLSmidth.

“So, once you get the green light, you need to confirm the duty details and measure up the existing installation to ensure that when you begin to install the pump there are no surprises,” the company said.

Brad Moralee, Head of Product Unit Pumps, Cyclones and Valves at FLSmidth, said: “It’s high pressure for us: you are typically given a window of opportunity during a shutdown to complete the change, after which the new pump must run as expected when the plant is re-started.

“You need the combination of a great product but, more importantly, great technical understanding of the duty to be able to propose the correct solution. We understand what is at stake from the customer side.”

The change produced impressive results in comparison with the previous solution from another supplier, according to FLSmidth, with the millMAX increasing the wear life by nine times, across impeller, casing and back liner. “This has seen Kao make significant cost saving on direct replacement costs, reduced downtime and saved labour expenditure,” the company said.

While Kao mine operators were impressed with the benefits from the switch, a slight gland leakage was causing concern, according to FLSmidth. To resolve this, FLSmidth suggested running a one-month trial with the slurryMAX, which had just recently arrived on the South Africa market.

“The slurryMAX trial was based purely on its sealing capabilities as Kao were confident of the hydraulic performance of the pump and had no concern about wear as they were confident the slurryMAX would show predictable and even wear life across all wet-end parts,” the company said.

Kao’s confidence also came from the fact the slurryMAX design is based on the millMAX range, whose wear ring technology has created an efficient and long-lasting slurry pump.

The main difference between the millMAX and the slurryMAX is that the millMAX is an all-metal pump meaning it does not have an outer casing and an inner wear liner (the casing itself is made from the high chrome wear material), while the slurryMAX is a split casing design that has a replaceable inner liner. The purpose of this design is that multiple material liner options are available to fit in the same outer casing.

“The slurryMAX features an improved, more efficient impeller and an optional water drain plug for easier maintenance, allowing water that might have settled at the bottom of the pump to be drained quickly,” the company said.

Leigh Rieder, FLSmidth Sales Engineer, concluded: “Kao is extremely happy with the hydraulics and lack of excessive wear of our pumps, which has meant that their cost of ownership is low. We have recently received an order from the customer for two more slurryMAX pumps and they have expressed interest in our slurryMAX 6×4 and slurryMAX 10×8 pumps.”

FLSmidth to challenge sampling status quo following IMP Automation buy

Automation, Mineral exploration, Mining equipment, Mining services, Mining software, , , , ,

FLSmidth completed the acquisition of IMP Automation earlier this year, creating, the company says, a market-leading portfolio in mineral sampling and laboratory automation.

The finalisation of the acquisition (the deal was first announced in February) means customers can immediately benefit from a complete portfolio of IMP’s laboratory automation solutions in combination with FLSmidth’s global footprint and experience in automated sampling solutions, FLSmidth says.

The Denmark-headquartered company says mine sites, ports and laboratories are increasingly seeing the benefits of automation. “By examining conventional processes, we help you design, construct and implement innovative sampling and laboratory solutions from grassroots exploration to final product,” the company added.

Tina Knudsen, General Manager, Sampling, Preparation and Analysis – Mining at FLSmidth, said integrating the companies’ collective experience in sampling and automation and industry process knowledge, will allow the company to “continue to challenge conventional sample process technologies and deliver innovative and reliable sampling and analytical solutions”.

Knudsen added: “We have united our expertise under the FLSmidth name to create an even stronger portfolio of mineral laboratory automation solutions. Together, we are well positioned to create cutting-edge, competitive solutions for mining applications.”

FLSmidth responds to north Chile mining demand with opening of new service centre

Mineral processing, Mining consumables, Mining equipment, Mining maintenance, Mining services, Sustainable mining, Water management, , , , , , , , ,

FLSmidth says it has launched a new service centre for customers in the north of Chile focused on timely delivery of mining equipment to customers and component maintenance.

The opening event, held last week, was attended by a number of key customers and representatives from local authorities, according to FLSmidth.

The 8,000 m² facility, in Copiapó, is geared towards meeting the high demand for mining service and technical support in the region.

FLSmidth said: “The service centre has a primary emphasis on supplying solutions that extend the asset’s life cycle, such as repairs and rebuilds; equipment and components upgrades; parts and consumables strategic stocking programs; tailored training programs; technical assistance; and customised service packages.”

The facility ensures customers receive the required knowhow to optimise their operations, as well as support when it comes to inspections, process audits and technical issues, the company added.

Andrés Costa, President FLSmidth South America, said: “This is a significant milestone for the company, since Copiapó represents an important part of our operations in Chile. The huge mining industry potential in the area and our large installed base requires an infrastructure like this so we can work closer with our customers, get to know their challenges and deliver sustainable productivity solutions to their operations.”

Carlos Sagredo, Plant Manager North Chile, said: “This new service centre will deliver extra availability and reliability to our customers, improving their productivity and uptime, reducing total cost of ownership and extending their equipment lifespan.”

Copiapó Service Center joins other FLSmidth service facilities in South America region, such as São Paulo (Brazil), Arequipa (Peru), Iquique, Antofagasta and Santiago (Chile).

FLSmidth takes nextSTEP in flotation technology at South Africa platinum mine

Metallurgy, Mineral processing, Mining equipment, Mining techniques, Precious metals, , , , , , , , ,

FLSmidth’s innovative nextSTEP™ rotor and stator flotation technology has proven itself at a large platinum mine in South Africa, the mineral processing company says.

According to Ricus van Reenen, Regional Product Line Manager – Separation at FLSmidth, the nextSTEP rotor and stator combination has been at work for over a year at the mine, achieving positive results.

“The customer has achieved significantly lower power consumption on the full-scale retrofits we installed early in 2018,” van Reenen says. “The more efficient design allows the same or higher slurry circulation at reduced rotor speed, leading to lower power draw.”

The retrofits have been applied to both primary and secondary flotation applications, where energy savings of over 10% have been achieved, according to FLSmidth.

Years of research and development have been invested in the nextSTEP technology, which was originally launched in 2015, the company says. Among the key design elements are the addition of slots to the stator, adjustments in the rotor profile and a parallel distance between the rotor and stator.

“Energy dissipation is now more uniform than in traditional forced-air designs,” van Reenen says. “This means a more even wear pattern across the rotor and stator, and therefore longer intervals between maintenance.”

In the South Africa installations, the wear on the rotors and stators has been minimal after more than a year’s operation, the company says. In one flotation cell, the equipment has been operational for 15 months. The thickness of the rotor has reduced from 65 mm to only 60 mm, and the stator from 75 mm to 70 mm. After 13 months of operation in the second installation, the wear is even less, with the rotor’s thickness having reduced from 65 mm to 63 mm and the stator going from 75 mm to 73 mm.

van Reenen highlighted that there have been other benefits experienced by South Africa users of the new technology. Among these has been 16-18% less blower air usage, with more concentrated bubble formation.

“Better turbulence energy dissipation around the rotor and stator region, with its related finer bubble size distribution, creates more surface area for bubble-particle attachment,” van Reenen says. “This has delivered more froth and a higher mass pull on our local units.”

The success of the nextSTEP technology has led to further retrofits being planned in South Africa, in line with FLSmidth’s drive to promote mines’ productivity and performance. Van Reenen says the intensive R&D process continues apace and is not just in the rotor and stator design but also includes areas such as smart control systems and continued digitalisation of process solutions.