Tag Archives: FLSmidth

FLSMIDTH IN HIGH-TECH EXPANSION IN DELMAS TO MANUFACTURE SCREEN MEDIA

FLSmidth has relocated the manufacturing of its core screen media products to the modernised Delmas Supercenter facility, providing a cost-effective base from which to grow its sub-Saharan markets.

“The targeted efficiency improvements for the production lines at the facility will allow us to better serve our extensive installed base of FLSmidth equipment in the sub-Saharan Africa and Middle East region,” says Stephan Kruger, FLSmidth Director for Manufacturing and Warehousing in the region.

This follows the 2017 decision by FLSmidth – a leading supplier of equipment and services to the global mining and cement industries – to proceed with a significant investment at the 120,000m2 premises in Delmas.

In line with this strategy, FLSmidth has opted to focus on the in-house manufacture of three core product lines – polyurethane, wedge wire, and ceramic wear solutions.

FLSmidth concluded the sale of its non-core screen media product lines, including woven wire screens, perforated plate and wire conveyor belts, to Crusher Support Services. During this process, FLSmidth secured a preferential supply agreement to support local industry customers with the continued supply of these products.

The transaction has also preserved 79 jobs in the manufacturing sector, retaining a considerable production capacity within the country. Thirty of the employees have been relocated to the FLSmidth Delmas operation.

“We have invested in state-of-the-art equipment, including full Computer Numerical Control (CNC) machining capability,” says Kruger. “The new facilities include 5-axis and 6-axis machining centres, introducing a high level of technology to support the product lines in our business while optimising production costs.”

The investment in production capacity will allow FLSmidth to manufacture a broader range of components for its spare parts portfolio in-house, and to do this more cost effectively.

Design and construction activities began in 2018 and the infrastructure development is nearing completion. A formal launch is planned for April, when the facility will be fully functional and production will have commenced.

This Supercenter is strategically positioned close to customers and has the capabilities for warehousing, production of FLSmidth equipment and spare parts, refurbishments, rebuilds and retrofits. Current manufacturing activities produce over 150 strategically selected parts for the FLSmidth product range,” says Kruger.

The wedge wire screens to be produced at the facility are commonly used in carbon recovery in carbon-in-pulp (CIP) and carbon-in-leach (CIL) plants in the gold sector. They are also used for dewatering and magnetite recovery in the coal sector and in other applications such as water filtration and sugar production.

The polyurethane products include screen panels and larger spares such as rotors and stators used in the flotation process. Ceramic wear solutions to be produced and distributed from the Delmas facility include the WEAR MAX™ ceramic wear compound and FerroCer® impact wear panels, which combine steel and ceramic parts and are commonly used in feed chutes to address impact and abrasion.

The impressive Delmas operation includes a 10,500m2 workshop with 120-tonne lifting capacity and 11,5m under crane hook. More than 100 staff members are currently employed at the facility. It hosts modern offices, warehouse facilities and a dedicated training centre that can accommodate up to 65 people for technical training purposes.

FLSMIDTH OPTIMISES MILL PERFORMANCE USING ACOUSTICS

The SAGwise™ total process control solution for semi-autogenous (SAG) mills – developed by FLSmidth – promises effective SAG mill optimisation with lower energy consumption and wear part costs.

Winston Mokoena, key account manager at FLSmidth, highlights that the solution reduces critical impacts inside the mill by up to 45%. This adds life to wear liners and grinding balls, helping to prolong liner life between maintenance and giving mills more uptime.

“SAGwise can improve mill production by 6% and substantially reduce process variability,” says Mokoena. “This ensures that the mill provides a constant and optimal feed to the next stage of the process, effectively facilitating better performance of downstream operations.”

Among the challenges that mill optimisation tries to address is too little material in the mill, or too much. Too little leads to critical impacts between the grinding media and the mill liners, damaging both elements without producing value. If the mill is over-filled with mined material, on the other hand, this results in grinding inefficiencies.

The SAGwise system uses four or eight unidirectional or bidirectional audio sensors located in close proximity to the mill, which detect the analogue sounds and convert them into digital signals for analysis by a processing unit. This unit uses the sound patterns and other process variables to determine the necessary adjustment to the mill’s feed, speed and pulp density. So direct are the improvements that can be achieved by this solution that customers can pay back their investment in less than six months, depending on the commodity value and the specific mill environment.

“The parameters that are monitored by SAGwise include the mill’s power consumption, load impacts, mill load and pulp density,” he says. “The system then responds to these parameters by controlling the mill speed, the feed rate and the water to achieve the ‘sweet spot’ where the mill runs at optimum efficiency.”