Why use advanced process control?

Advanced process control from FLSmidth ensures that minerals plants perform better, resulting in less downtime and higher profitability.

  • ECS ProcessExpert®
  • For equipment to operate reliably and...

When a minerals company wants to get the most out of its processing plant, Expert Control and Supervision (ECS) is the key. FLSmidth’s ECS/ProcessExpert provides advanced process control and optimisation for minerals plants, so they can achieve maximum efficiency and higher profitability.

ECS/ProcessExpert stabilises the plant, balances equipment loads, manages and corrects process disruptions and minimises wear on the plant’s equipment – all to ensure optimum plant performance. By improving circuit availability and utilisation, the system helps reduce operational and maintenance costs.

Using a sophisticated toolbox and specialised application modules, ECS/ProcessExpert continuously performs complex analyses of a plant’s process conditions. This enables it to make adjustments to the process more frequently and reliably than a human operator can.

Installed on a standard PC, the system has an easy-to-interpret graphical interface and advanced alarm and trend capabilities that are easy to use and manage. The system can control any grinding circuit that uses AG, SAG, ball, pebble or rod mills – and it’s compatible with most other plant control systems.

FLSmidth – the process knowledge experts

FLSmidth’s international team of grinding experts designs solutions specifically for minerals applications. With more than 40 years of plant automation experience, FLSmidth has installed over 700 control systems and 450 laboratory systems – and so understands the needs of today’s minerals plants.

FLSmidth is a world leader in building and maintaining minerals plants, and that first-hand experience plays an important role when developing innovative automation solutions that enhance the production capabilities of customers’ plants.

FLSmidth’s 8 step implementation model provides the professional support necessary to ensure the system meets all requirements and expectations.


The moment FLSmidth begins an advanced process control project, a dedicated project manager is assigned to coordinate all activities over the lifetime of the plant. As the main contact for the plant, the project manager is involved in the implementation process right from the start, providing the plant with a clear and detailed project plan that contains all the phases, key deadlines, project meetings and more.

Working with the FLSmidth 8 step model, the project manager will ensure the process control system delivers reliable performance as quickly and as smoothly as possible. The model also ensures that the system is maintained correctly after implementation – so it continues to generate top performance for years to come.


Long-term support for long-term success

To ensure the lasting performance of the ECS/ProcessExpert control system, FLSmidth offers to continue to evaluate the system and its processes after commissioning is complete.

ECS/ProcessExpert continually gathers plant data and sends it to the processing centre at FLSmidth’s headquarters. A detailed KPI monitoring report is then generated, and if this indicates that the plant is not performing as efficiently as possible, in collaboration with the plant management FLSmidth can make adjustments remotely or onsite. However, if the plant prefers to do the data analysis in-house, FLSmidth will send all the necessary data directly to the plant.

FLSmidth’s 8 step implementation process

  1. Project planning: An FLSmidth project manager prepares a comprehensive, start-to-finish strategy
  2. Client process interviews: FLSmidth technicians visit the site to determine the plant’s control needs
  3. Application design and process strategy review: FLSmidth designs the right solution based on the site visit and interviews
  4. Primary system commissioning: Commissioning is completed and the system is implemented and monitored onsite
  5. Operator and super-user training: FLSmidth representatives train operators in the new system
  6. Remote monitoring and fine-tuning: As the final part of the commissioning phase, FLSmidth makes small adjustments to the system either remotely or onsite
  7. Follow-up visit: After commissioning is complete, FLSmidth visits the site and transitions to the service phase of the agreement
  8. Establishing long-term support: FLSmidth continues to monitor the system and analyse KPI data, and the dedicated project manager remains in contact with the plant.

As part of the long-term support agreement, FLSmidth generates periodic KPI reports that help support the system and ensure the plant runs as efficiently as possible.


ECS/ProcessExpert - Minerals
Download:English Spanish Portuguese Russian


Nkomati Case Story


Article - ECS/ProcessExpert for minerals grinding circuits