Tag Archives: FLSmidth

Client Focus

SERVICE, SUSTAINABILITY UNDERPIN FLS QUALITY PORTFOLIO

Supporting customers in achieving optimal plant performance is today more vital than ever, in the face of inflationary cost increases and volatile commodity markets. 

These concerns are behind FLS’s service focus at Electra Mining Africa this year, where the company is driving sustainable productivity through its solid and growing support and maintenance infrastructure. 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,” says McKay. “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,” says McKay. “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,” he says.

FLS’s leading slurry pumps will also be showcased for their performance and energy efficiency. McKay concludes that this year’s Electra Mining Africa will be the first since the company’s acquisition of Thyssenkrupp’s mining business.

“We can therefore show visitors our fully integrated FLS portfolio which has leveraged the best-in-class offerings of both companies,” he says. “This range of products and technologies continues to support optimised and sustainable operations at lower costs.”

Visit FLS in Hall 6 Stand D16. 

Client Focus

FLSMIDTH BUILDS SOLID SKILLS BASE FOR LOCAL, GLOBAL SUCCESSION

To support its full flowsheet technology capabilities, FLSmidth is continuously developing vital skills at its well-resourced Training Academy at the company’s Chloorkop Service Centre in Gauteng.

According to the FLSmidth Training Academy Head Steve Parkinson, the training underpins the ground-up succession strategy of ensuring long term competence within the business – with the depth to embrace evolving technologies that continuously improve its offerings. 

“Our considerable investment in skills development nurtures local talent to provide us with a strong pipeline of relevant and quality expertise,” says Parkinson. “This knowledge base is shared within FLSmidth not only across the continent but globally. At the same time, we invariably train more people than we can absorb, so we provide a rich resource of trained individuals for other players in the local mining and engineering sectors – including our customers and competitors.”

Through a rigorous selection process countrywide that targets unemployed youth under 26 years old, 10 apprentices are enrolled every year at the academy. They spend three years in formalised training towards their qualification and future role as an artisan. FLSmidth employs as many as it can accommodate within its resource planning and budgeting; the company also goes the extra mile in trying to find placements for the others, either among its customers or the broader industry.  

“In this way, we develop our own specialised in-house expertise while creating a skills pipeline that supports the local economy and builds a stronger base for the manufacturing, mining and other sectors,” he explains. “This is part of our commitment to the growth of mining and industry in Africa.”

Such training is only possible because of FLSmidth’s depth of skill already at work in its advanced Chloorkop Service Centre on the same site. Here, the company conducts turnkey refurbishment and repair services, supported by infrastructure that includes a large fabrication shop, an assessment and assembly area, and a heavy machining section with both conventional and CNC equipment.

“The rules of supervising and mentoring apprenticeships require that there is at least one artisan for every three apprentices,” explains Parkinson. “We therefore leverage our existing skills base to nurture the artisans of tomorrow – ensuring that each apprentice is closely supervised and well managed to enhance the practical learning process.”

FLSmidth also hosts a two-year Engineering Graduate Internship programme, where it develops graduates in disciplines such as mechanical, chemical and metallurgical engineering. Each intern is supervised by an FLSmidth engineer working in the relevant field. 

A further training programme being offered is a unique learnership that FLSmidth conducts in collaboration with the German Chamber of Commerce. The Commercial Apprenticeship Training scheme (CATS) involves a two-year learning programme, earning the successful participant an Institute of Certified Bookkeepers (ICB) qualification at Level 5 in South Africa, as well as a German qualification – the Diploma in Industrial Management Assistant.

An information technology (IT) learnership is also offered for 20 local people with disabilities; with its focus on computer-based system development skills, the field is less inhibiting for people with disabilities, he points out. This initiative aligns well with the company’s social responsibility strategy and its sustainability goals.

“The track record of the Training Academy in South Africa has been so successful that we now have valuable experience to share with FLSmidth operations globally,” he says. “Colleagues abroad are able to draw on our model to achieve similar results in their regions. A number of our trainees have, in fact, already been placed in operations abroad, proving the world class quality of our outputs.”

Within the FLSmidth Service Centre itself, the quality of the learners from the Training Academy is already well proven. For example, the current foreman of the machining shop was an apprentice in this facility just 14 years ago. There have also been general workers admitted to the apprenticeship programme, qualifying successfully to become qualified machine operators.

The Training Centre also provides staff and customers with product training, says Parkinson. This generally covers three levels: the first level is general knowledge about products, the second level is basic operations and preventative maintenance, and the third level focuses on specialised maintenance.

Client Focus

OPTMISING COMMUNITION PROCESSES WITH FLSMIDTH’S ECCENTRIC ROLL CRUSHER

The energy-intensive nature of comminution processes has led to FLSmidth’s efforts to develop more energy efficient equipment. One such technology is the patented Eccentric Roll Crusher (ERC®) which, through its innovative design, not only reduces energy consumption in the primary crushing of hard rock, but also offers increased throughput and reduced wear.  

Comminution by its nature is an energy intensive process, and its efficiency not only impacts the overall energy consumption of processing plants but also improves the sustainability of mining and quarrying activities. Ideally suited for use in both underground and surface operations, the ERC® offers significantly higher efficiency and flexibility than any conventional crushers in the processing of hard rock, says Demitri Kokoroyanis, Regional Product Line Manager – Crushing & Screening, Sub-Saharan Africa, Middle East & South Asia Region (SSAMESA) at FLSmidth. 

“A particularly effective kinematic of the oscillating roll with constant stroke in the entire crusher cavity allows for a higher reduction ratio and more effective use of crushing energy,” he says. “The reduction ratio of 1:10 potentially allows for elimination of secondary crushing stages, depending on the material characteristics.”

In addition, the high moment of inertia of the roll and flywheels contributes to accumulated crushing energy, reducing the power requirements and effectively compensating load peaks in the comminution process. 

Key design features of the ERC® are compactness and robustness. Due to its low profile, the crusher offers a construction height up to 50% lower than other hard rock primary crushers. This compact design and the reduced number of components simplifies transportation, installation and maintenance, and also lessens CAPEX costs by up to 10%. 

The integrated pre-screen allows for efficient bypassing of fines, boosting crusher capacity as well as reducing energy consumption by up to 40% and increasing liner life in the process. Bypassing fines also reduces the risk of compacting and overloading of the crushing chamber.

“Mine operators and quarry owners can also benefit from the higher service life of wear elements on the roll,” says Kokoroyanis. “The back-turning of the roll occurring during the crushing process distributes the loads over the entire circumference. This prevents local wear zones and results in uniform wear.”

With impact resistance and wear in mind, the large chunks of feed material in the crushing chamber do not fall directly onto the mounted working element, but hit the hood, which is significantly more resistant to such loads than other components. That is a key advantage over many conventional primary crushers. 

“As more and more mine operators become aware of the benefits of this innovative technology, we are seeing a great deal of interest in the ERC® range. We have already sold several units over the past four years, with some being installed in Laos, Asia, and, we hope, soon in Angola,” concludes Kokoroyanis. 

Client Focus

FLSMIDTH LEVERAGES GLOBAL TECHNOLOGY FOR LOCAL IMPACT

Driving its leading technology through a pure play mining strategy, FLSmidth has been optimising its footprint to be closer to customers with local solutions and expertise.

Alistair McKay, FLSmidth’s Head of Site and Service Sales Sub Saharan Africa, Middle East & South Asia (SSAMESA), highlights the CORE’26 mission at the centre of this strategy. CORE’26, explains McKay, is based on the principles of sustainability, technology, service and performance. 

“We go to the market through our five regional structures around the world, which deliver sales, service and order execution,” he says. “The regions are in turn supported by our global organisation and its leading product lines. The global resources are strategically located in countries such as the US, Denmark, Germany, India and South Africa, where we have a concentration of expertise to support our offerings.”

As part of the footprint optimisation, resources have been deployed and infrastructure investments made in key areas, with Johannesburg remaining as the mining hub for the SSAMESA region. World class facilities in the region include the Stormill service centre – for KREBS® pumps, valves and cyclones – and the Delmas manufacturing facility for vibrating screens and other equipment. There is also the fully integrated engineering facility and a service centre at Chloorkop, focused as a centre of excellence on refurbishing high pressure grinding rolls. 

McKay highlights that the manufacturing, assembly and refurbishment capacity of these centres cater for product lines not just for this region but for FLSmidth globally.

The regional footprint includes local sales and services offices in Ghana, Saudi Arabia and India. “Our strategy allows us to get closer to customers around Sub-Saharan Africa, South Asia and the Middle East, while building the local manufacturing base as part of our global supply chain,” says McKay. 

He also emphasises the importance of technical knowledge in successfully building the SSAMESA footprint. “Relevant expertise and know-how remain important enablers to our customers for projects and broader development in Africa especially,” he says. 

The company’s focus on local manufacture in countries like South Africa also means that the domestic economy is supported while local skills are employed and developed. With a focus on skills development, FLSmidth contributes to the training of customers’ staff, while pursuing talent development through learnerships, apprenticeships and scholarships. 

“As a technology provider of world class sustainable offerings across the full flowsheet, the expertise in our regional footprint is key,” he says. “We also prioritise research and development that supports our sustainability ambitions and our customers’ green journey.”

Client Focus

MAXIMISING GRINDING EFFICIENCY AND REDUCING WEAR WITH KREBS® SMARTCYCLONE™

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

Abrie Schutte, senior applications engineer, product business line KREBS® pumps, cyclones and valves at FLSmidth.
Abrie Schutte, senior applications engineer, product business line KREBS® pumps, cyclones and valves at FLSmidth.

According to Abrie Schutte, Senior Applications Engineer at FLSmidth responsible for the KREBS® pumps cyclones and valves product business line, 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.

KREBS® hydrocyclones are engineered for reliable operation in the recovery of minerals.
KREBS® hydrocyclones are engineered for reliable operation in the recovery of minerals.
The KREBS® SmartCyclone™ Wireless System is a gamechanger for process plants.
The KREBS® SmartCyclone™ Wireless System is a gamechanger for process plants.
Installation of a KREBS® gMAX15 cyclone.
Installation of a KREBS® gMAX15 cyclone.

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.”

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. By monitoring and detecting roping, operators can confidently operate the plant closer to its limits, thereby increasing production capacity and improving mineral recovery,” he says.

By integrating SmartCyclone™ with ECS/ProcessExpert software, the grinding circuit’s performance can be further optimised. 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.

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

“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,” Schutte concludes.

Client Focus

KREBS® PUMPS SUPPORT MINES’ EFFICIENCY DRIVE

In the mining industry’s drive to conserve energy, a focus on pumps is essential, especially given the sheer scale of pumping equipment required on the average mine and mineral processing plant. 

On this score, global minerals process specialist FLSmidth has allowed mines to achieve new levels of efficiency with the initially patented wear ring technology on its KREBS pumps, according to Stephan Kruger, FLSmidth’s Vice President Pumps, Cyclones and Valves for Sub-Saharan Africa, Middle East and South Asia. Mines have seen significant efficiency gains by using KREBS pumps, explains Kruger, resulting in considerable bottom line impacts when multiplied by the dozens or even hundreds of pumps often employed on a single mine site. 

A KREBS® slurryMAX™ high pressure tailings pump on a mobile skid.
A KREBS® slurryMAX™ high pressure tailings pump on a mobile skid.

“It is not only the rising cost of electricity that drives mines’ energy strategies, but also their commitment to a low carbon future,” he says. “FLSmidth’s KREBS pumps directly support these efforts by our mining customers, thanks in great part to our innovative wear ring technology.”

He highlights that two key aspects that reduce efficiency in slurry pumps tend to be suction side recirculation and mechanical grinding between the casing and the impeller. The wear ring significantly reduces both of these factors, leading to lower power draw and longer pump life. 

“Through our case studies, we have seen power draw being cut by 5 to 10% for the same flow and head with the application of KREBS pumps,” he points out. “Similarly, we have measured the impact on pump life, and have shown that the life of wet end parts can be lengthened by one and a half to two times.”

Final adjustments on a KREBS® gravelMAX™ pump.
Final adjustments on a KREBS® gravelMAX™ pump.

According to Derek Lane, General Manager Operations, conventional products in the market solve only one of these factors through impeller and liner adjustment which may reduce recirculation but simultaneously exacerbates the grinding. “This leaves the pump user having to compromise on efficiency, which we do not expect our customers to do,” Lane explains.

He says adjusting the wear ring allows the speed of the pump to be maintained as a constant, rather than users having to speed up the pump in response to the impact of grinding and wear. The wear ring in KREBS pumps can be easily adjusted so that it continues drawing the same power for the required pressure, holding energy consumption to a minimum.

The regular adjustment of KREBS pumps can also be done without shutting down the pump and disrupting operations, says Morne Potgieter, FLSmidth Sales Manager Pumps, Cyclones and Valves for Central and Southern Africa. This is important as it contributes to the general continuity – and hence efficiency – of the whole operation. 

KREBS® UMD™ Ultimate Mill Discharge slurry pumps being assembled at FLSmidth South Africa facility.
KREBS® UMD™ Ultimate Mill Discharge slurry pumps being assembled at FLSmidth South Africa facility.
Pump, cyclone and valve stockholding in FLSmidth South Africa facility.
Pump, cyclone and valve stockholding in FLSmidth South Africa facility.
An extensive stockholding supports customers across the region.
An extensive stockholding supports customers across the region.

“The wear ring can be simply adjusted by hand while the pump is running, and without the use of any special tools,” he notes. “This allows the gaps to be kept as small as possible to avoid recirculation inside the pump, while maintaining speed and pressure.”

FLSmidth makes the most of this technological innovation through its skilled field service teams and training offerings, which ensure that customers understand and apply the wear ring adjustment to best effect. Potgieter says the training leaves on-mine operators more comfortable with the task of adjustment, even if many of them may be hesitant about working on rotating machinery.

“We also do extensive technical training with customers on aspects such as pump assemblies, and make sure that we are available when they need us,” he says.

The life of KREBS pumps is further enhanced by the range of materials of construction available to suit the application, says Kruger. “The choice of material is based on the application requirements and in particular minimising wear. There are a number of factors considered which determine the material of construction such as pump size, impeller size and tip speed as well as slurry hardness.”. 

Materials used in the construction of slurry pumps are classified into two main types: metals and elastomers. For metal pumps high-chrome alloys, hypereutectic alloys, hypoeutectic alloys and stainless steels are commonly used. Elastomers options vary between natural rubber, polyurethane and synthetics such as neoprene.

He emphasises that the application of these materials makes their own contribution to the mining sector’s sustainability agenda, by reducing the level of scrap produced due to equipment replacement. 

Client Focus

FLSMIDTH’S COMMINUTION LINE-UP NOW LEADS THE PACK

Leading technology and products have been added to the FLSmidth stable with the TK Mining acquisition, arguably making FLSmidth the world leader with its comminution portfolio.

Craig Brickhill, FLSmidth’s Regional Product Line Manager – Milling and HPGR, highlights that the FLSmidth brand now encompasses the best solutions, equipment and expertise from across the flowsheet.

“On the grinding side, for instance, FLSmidth is a leader in solutions such as semi-autogenous grinding (SAG) mills, while TK Mining held decades of positive experience with High Pressure Grinding Rolls (HPGR),” says Brickhill.

FLSmidth Regional Product Line Manager – Crushing and Screening Demitri Kokoroyanis says the same applies to crushing. The company’s combined crushing technologies now put it well ahead of competitors, argues Kokoroyanis.

“Our Top Service Gyratory Crushers are advanced in both their ultra heavy-duty design and the way they facilitate safe and efficient servicing,” he says. He also points to company’s Eccentric Roll Crusher ERC®, which fits between the jaw and gyratory crushers in the range and this differentiates FLSmidth from the competition. The ERC® has a built-in static grizzly screen before the crushing zone to allow removal of the fine material. Large rocks are fractured at the opening of the jaw to increase throughput and reduce the power consumption.

With FLSmidth’s top service range of gyratory crusher models, 95% of the servicing can be conducted from the top.
With FLSmidth’s top service range of gyratory crusher models, 95% of the servicing can be conducted from the top.

A key addition to FLSmidth’s current offering is the HPGR range, says Brickhill, with an installed population of about 160 units. The technology is an energy efficient alternative to traditional milling, as it transfers energy directly into the rock. As a dry process, it is also likely to see growing uptake as mines pursue sustainability targets that minimise water use.

The wide range of crushing offerings feeds into FLSmidth’s role as a provider of semi-mobile in-pit crushing plants – of which there are over 285 installations worldwide.

“Our plants can be designed for direct feed – usually from gyratory crushers – and also for indirect feed, which can be accomplished with an apron feeder before a gyratory, ERC®, jaw crusher, double roll crusher or double roll sizer,” says Kokoroyanis. “We can take care of everything from the truck tip to the discharge conveyor, and the plant comes complete with auxiliary equipment for a smooth operation. The plants can be relocated to a new position in the pit with the use of transport crawlers with minimum disassembly required as mining progresses.

Brickhill notes that the acquisition also means that FLSmidth’s engineering infrastructure now includes a world class engineering facility at Chloorkop, Gauteng, focused on refurbishing HPGRs. The facility also includes a test centre where material can be tested for suitability for processing by HPGR and for sizing of full-scale units.

Among the enhancements in FLSmidth’s pit-to-plant range of technology and equipment are market leading High Pressure Grinding Rolls (HPGRs).
Among the enhancements in FLSmidth’s pit-to-plant range of technology and equipment are market leading High Pressure Grinding Rolls (HPGRs).
Client Focus

FLSMIDTH SHARPENS FOCUS TO SERVE ‘MINES OF TOMORROW’

The future of FLSmidth has been redefined as a pure play mining company, which will renew its focus on sustainability, service and technology. 

Speaking during the recent Investing in African Mining Indaba 2023 in Cape Town, FLSmidth Vice President for Mining Site and Service Sales Sub-Saharan Africa, Middle East and South Asia, Alistair McKay explains that this strategy will enable the business to better service existing and new mining customers.

“We are now very much a mining-focused company,” says McKay. “Moving forward, we are fundamentally more focused on our core technologies – moving away from the engineering project realm and really looking to our innovative products to drive value for our customers.”

He highlights that FLSmidth’s CORE’26 mining strategy prioritises sustainability, service, technology and performance. This provides the platform to pursue its purpose of ‘mining for a sustainable world’ with a mission of ‘delivering solutions for tomorrow’s mine’.

“This direction creates more clarity on where we will direct our resources – and that will be towards moving our best-in-class products forward through our extensive research and development capability,” he says. “As before, this also relies on our close working relationship with our customers, through our technical feedback loop.”

He emphasises the vital role that mining will play in the global energy transition. This, he says will rely on the efforts by mines and their technology partners to evolve sustainable strategies for mining to continue to deliver responsibly. 

The HPGR Pro will take grinding to the next level of efficiency.
The HPGR Pro will take grinding to the next level of efficiency.

“Mining will be an essential industry for many years, and we are ensuring that we play our part in the industry’s future – to the 2030 sustainability goals and well beyond,” he says. 

This focus on product evolution enhances the value of FLSmidth’s range of offerings within customers’ integrated projects. Venkatesan Punniyamurthy, FLSmidth’s Vice President for Capital Sales in Mining, Sub-Saharan Africa, Middle East and South Asia, notes that the repositioning will see the company’s competence and resources fully focused on their products and their performance. 

“As we move toward a more service-centric model, we will continue to work with customers over the full lifecycle of the asset,” says Punniyamurthy. “Even after the equipment is sold and installed, our R&D insights can provide continuous optimisation through digital and other enhancements to our technology.”

Mines can therefore expect an ongoing contribution by FLSmidth to productivity and profitability, with products that also support the achievement of sustainability targets. 

Applying innovative technology to the energy-intensive crushing circuit, for instance, can reduce power costs and assist the decarbonisation process. Water saving technologies like filter presses and high pressure grinding rolls (HPGRs) will also play an increasingly important role in conserving water – especially in areas that become drier due to climate change. 

McKay says the scope for evolving mining technologies was significant as the world looked to Africa for many of the minerals demanded by a low-carbon future. The Mining Indaba Africa 2023 showed once again that stakeholders in the mining sector – from company shareholders to governments and communities – are expecting steadily more attention to be placed on how responsibly mining in conducted. 

“Through our CORE’26 strategy, we are strengthening our role as a global partner for equipment life-cycle performance and sustainability,” he says. “Our strategic acquisitions over the years – including the recent acquisition of thyssenkrupp’s mining business – have created a powerful portfolio of solutions across the flowsheet. Fine-tuning our strategy will allow customers to fully leverage both our decades of experience and our leading technology offering.”

Client Focus

FLSMIDTH DRIVES MISSIONZERO BY LEVERAGING DIGITAL TECHNOLOGY

Mining customers at FLSmidth’s stand at Electra Mining Africa this year showed growing interest in digital solutions which drive sustainability while lifting productivity.

“Our customers recognise the value of reducing carbon emissions in plant operations, but are looking beyond a ‘big bang’ event to achieve MissionZero,” says Alistair McKay, FLSmidth Vice President for Mining in Sub-Saharan Africa, Middle East and South Asia. “Rather, they are looking for a longer term collaboration with technology partners like FLSmidth to steadily achieve sustainability goals.”

McKay highlighted that progress was not necessarily based on just new capital innovations, but on the ongoing optimisation of existing equipment throughout the process flowsheet. The performance of conventional equipment such as pumps can be optimised through smart monitoring and optimisation, he emphasises.

“An important question we are helping customers to answer is: How do we put the ‘building blocks’ of success together to support the MissionZero strategy?” he says. “This approach looks beyond quick wins to be etched up in an ESG rating, and considers a longer term and sustainable process.”

Digitalisation is already paving the path to greater efficiency and lower energy consumption, he explains. This includes making operational information on all equipment available to operators and decision makers in a usable format – on whichever device they are using. By pulling through all the relevant data and analysing it in real time, the performance of various equipment can be monitored and assessed for continuous improvement.

Mining customers at FLSmidth’s stand at Electra Mining Africa this year showed growing interest in digital solutions which drive lower emissions while lifting productivity.
Mining customers at FLSmidth’s stand at Electra Mining Africa this year showed growing interest in digital solutions which drive lower emissions while lifting productivity.

“Our LoadIQ™ smart sensor, which is used to optimise mill loads, is a perfect example of this,” he says. “By measuring volumetric filling and ore trajectory in real-time, LoadIQ™ allows mill operating parameters to be automatically adjusted as grinding conditions change.”

Its application on a mill at a large copper mine in South America led to throughput improvements of 10% – translating to additional revenues of some $150 million per year.

Deon de Kock, FLSmidth President for Sub-Saharan Africa, Middle East and South Asia, supports this assessment, pointing to customers’ concern to ‘achieve more with less’. They are looking for more production from the same plant, with less energy and less water, says de Kock. 

“Plant operators are looking to us to help them get more from their existing plants,” he says. “This means reducing their carbon footprint and water consumption while optimising production.”

The expertise to apply the necessary technology to do this is readily available in FLSmidth’s operations around this region, he says. Further specialist knowledge can be drawn in from the company’s global network, providing the necessary insights and experience. 

Electra Mining Africa also provided a great platform for FLSmidth to confirm the exciting news of its acquisition of thyssenkrupp’s Mining business. De Kock highlighted that the organisational integration was underway for the two companies to be operating as one by year-end. 

“This acquisition boosts FLSmidth’s position as a global leader in mineral process solutions, particularly with the newly acquired high pressure grinding roll (HPGR) technology, eccentric roll crushers and bulk materials handling equipment,” he says. “This expands our pit-to-plant range of sustainable solutions and supports our central ambition of bringing sustainable technology to mines, increasing productivity and reducing the environmental footprint.”

Client Focus

LEVEL 1 B-BBEE IS BIG STEP IN FLSMIDTH’S TRANSFORMATION JOURNEY

The recent earning of Level 1 Broad-Based Black Economic Empowerment (B-BBEE) status was not an end-goal but a step in FLSmidth’s transformation journey in South Africa.

Deon de Kock, FLSmidth President for Sub-Saharan Africa, Middle East and South Asia, emphasises that diversity, inclusion and engagement are imperatives for good business.

Deon de Kock, FLSmidth President for Sub-Saharan Africa, Middle East and South Asia.
Deon de Kock, FLSmidth President for Sub-Saharan Africa, Middle East and South Asia.

“As we drive success through productivity enhancement, we draw on the best available human and technological resources,” says De Kock. “This includes not just our staff but all stakeholders in our supply chain.”

Investing in its talent pipeline was particularly important in promoting diversity, he says. This has included skills development through apprenticeships, learnerships, scholarships and graduate programmes. The success of these candidates has ensured solid progress in employment equity, as one B-BBEE element within its integrated approach.

“B-BBEE is not a once-a-year event for FLSmidth, but rather a long-term business strategy,” says Estelle Steytler, head of People and Organisational Development and Transformation at FLSmidth. Steytler highlighted the important role of dedicated champions within the business to implement B-BBEE policy. 

“Each of these champions focuses on a particular aspect of B-BBEE,” she says. “These include management control, skills development, ownership, socio-economic development, and enterprise and supplier development.”

FLSmidth draws on the best available human and technological resources to optimise productivity enhancement.
FLSmidth draws on the best available human and technological resources to optimise productivity enhancement.
FLSmidth invests in its talent pipeline through skills development.
FLSmidth invests in its talent pipeline through skills development.
Nondzondelelo Sibanda, Business Support and Facility Management at FLSmidth.
Nondzondelelo Sibanda, Business Support and Facility Management at FLSmidth.
Boitumelo Phoolo, Proposal Administrator, Mining Site and Field Sales at FLSmidth.
Boitumelo Phoolo, Proposal Administrator, Mining Site and Field Sales at FLSmidth.
Nothando Ngomane, Business Admin Learner, Manufacturing & Warehousing at FLSmidth.
Nothando Ngomane, Business Admin Learner, Manufacturing & Warehousing at FLSmidth.

Structures have also been set up to support the FLSmidth board, keeping transformation as a top priority on the agenda. A social and ethics committee reports to the board. This committee in turn receives input from an employment equity and skills development committee, an enterprise and supplier development committee, and a corporate social responsibility committee. 

“It has always been our aim to deliver transformation through a focus on shared value, with clear aims and intent,” she says. 

She also emphasises the success in building the talent pipeline. Many university students supported by FLSmidth bursaries are now employed in roles such as mechanical engineers, technology specialists and HR experts. De Kock points out the vital importance of taking young graduates and trainees into the business. 

“It is one thing to support students, apprentices and learners in their studies, but it is also necessary to have uptake capacity,” he says. “We pick the cream of the crop to start their careers with us, and to grow with the company.”

The same applies to FLSmidth’s supplier development programme. He emphasises that small businesses are not only given capacity-building support, but they are also contracted to supply goods and services to the company. 

The direct benefit to FLSmidth’s Level 1 status is that customers receive 135% recognition for their expenditure with the business – higher than many competitors. This helps customers meet their preferential procurement targets. 

“This also makes us an employer of choice, as people want to be associated with an organisation that takes transformation seriously,” he says.

Steytler concludes that FLSmidth’s empowerment of stakeholders – and the resulting Level 1 status – is its license to operate. 

“While increasing our opportunities in bidding for and winning tenders, we are also proud to be contributing towards empowering the overall market,” she says. “This impacts the wider economy in a positive manner while strengthening our brand.”