Solutions for more sustainable, productive mines
Discover FLS solutions to help you reduce energy and water use, cut CO2 emissions and downtime, increase recovery and production.
IPCC
Sustainable In-Pit Crushing and Conveying Solutions Reducing CO₂ Emissions
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Technology
Strategic mine solutions ensure sustainable mining operations and a low environmental footprint
- Decrease GHG emissions by more than 100,000 ton of CO2e per year
- Up to 75% reduction of operating expenses per ton compared to using trucks
- Reduce OPEX significantly with less manpower, minimized maintenance and lower fuel costs
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Spare Parts and Maintenance
Improve productivity while minimizing operating costs
- Improve productivity with parts designed for long component life
- Increase safety with planned maintenance and parts replacement
- Reduce downtime through optimal inventory levels
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Digital
Improve productivity and safety with our digital twin belt conveyor.
- Increase service life of components by condition monitoring
- Improve safety with less service team involvement at site
- Identify and reduce potential bottlenecks
Significantly reduce CO2 emissions and OPEX by optimised limiting the need for haul trucks at mines with our sustainable in-pit crushing and conveying solutions. Combining condition-based maintenance, an optimal parts inventory, and opreational related maintenance scheduling reduces downtimes, improves plant availability, lowers OPEX and enhances safety. Finally, by using digital twin technology to model the conveyor system, we can identify and reduce bottlenecks to improve productivity at the mine site.
Our customer stories and performance cases
Performance study
How semi-mobile crushing cuts costs and emissions at a copper mine
Performance study
How IPCC supports greener mining at Vale’s S11D Eliezer Batista complex
Discover
IPCCs vs BEVs:
the key differences between IPCCs and battery-powered haul trucks
Services
Mine planning services
Crushing & screening
Crushing & screening solutions to meet your productivity targets
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Technology
High performance and ease of operations.
- Highest capacity in the market with throughput rates up to 15.000 mtph
- Reduce maintenance time up to 50% with our rotatable shells
- Lowest cost per ton of product processed
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Upgrades and Rebuilds
Cost-effective and environmentally responsible equipment services.
- Improve energy efficiency and reduce emissions
- Increase profitability, enhancing the life cycle of your equipment
- Reduce bottlenecks and increase productivity
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Spares and Wears
Improve equipment availability, increase performance and reduce waste.
- Improve wear resilience with durable high-performing parts
- Increase performance and lower wear with patented design
- Maximise uptime with our liner optimisation solutions
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Digital
Increase safety and consistency in day-to-day operations.
- Reduce downtime and improve productivity with accurate real-time data
- Extend equipment component wear life with optimization programs
- Increase reliability with condition monitoring systems
Our productivity-enhancing crushing and screening equipment can deliver the lowest cost per processed ton and the highest processing capacity on the market (15,000 mtph). If you want to be more sustainable by getting more from existing equipment our rebuild and upgrade services can improve equipment productivity, energy efficiency and safety. Reduce downtime through our long-life crusher liners and screening media, condition-based maintenance and our rotatable shells that cut maintenance time by 50%. Extend equipment and crusher liner life through our optimisation services to deliver better availability and productivity.
Our customer stories and performance cases
Performance study
The new ERC® crusher improves throughput, product fineness and energy consumption
Customer story
Crusher liner optimisation improves wear life and reduces downtime
Customer story
Primary crusher liner cuts wear maintenance and increases throughput
Customer story
Concave liner carousel safely reduces maintenance time
Customer story
Screen aperture switch increases mine’s capacity and efficiency
HPGR
Sustainable and energy-efficient HPGR grinding technology
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Technology
The next level of efficiency and sustainability.
- Higher grinding efficiency compared to horizontal grinding mills
- Reduce the need in consumption of grinding media from the comminution circuit
- Stabilize grinding operations when faced with high ore variability
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HPGR Pro
Upgrade to the latest comminution technology to increase productivity.
- Up to 20% improved throughput compared to conventional HPGRs
- Up to 15% reduction energy consumption
- Up to 30% extended roller life
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Spares and wears
Solutions to improve equipment availability and reliability.
- Reduce maintenance cost, using the right parts and maintenance programme
- Improve safety with fewer, shorter and safer maintenance stops
- Increase availability and reliability with long lasting wears & spares
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Digital
Expertise to keep operating at maximum productivity.
- Decrease downtime with our unique laser stud detection system
- Maximize availability via our AMPS (advanced machine protection system)
- Increase plant productivity – energy, feed and product quality
Take grinding to the next level of energy efficiency and sustainability with our market-leading HPGR. Compared to traditional horizontal grinding mills, our latest HPGR offers higher grinding efficiency, reduces grinding media consumption and stabilises grinding operations when there is high ore variability.
For existing HPGR owners, we offer Pro upgrades that can increase production, extend roller life and reduce energy consumption. To improve process availability we offer advanced detection and protection systems that minimise unplanned downtime and with the right parts and maintenance regime, offered by our extensive service centre network, maximise the time between planned shutdowns. If you want the highest reductions in energy consumption and the greatest improvement in productivity we provide digital-based optimisation solutions so you can meet your targets.
Our customer stories and performance cases
Customer story
FLSmidth's HPGR improves productivity for South American copper mine
Technology
HPGR Pro High Pressure Grinding Roll
Customer story
The new F-Series HPGR is a successful prospect for Ivrindi Gold
Milling
AG/SAG Milling Solutions For Mining
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Technology
Maximize productivity and profitability
- High throughput to enhance productivity and profitability
- Lower maintenance costs and improved energy efficiency
- Compact layouts, long-lasting wear parts and easy access for maintenance
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Upgrades and rebuilds
Sustainable use of resources by refurbishing rather than replacing or buying new.
- Reduce bottlenecks and increase productivity
- Minimize downtime by upgrading to more durable liners with longer wear life
- Improve energy efficiency, reduce emissions and save water
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Spares and wears
Improve equipment reliability, availability and wear life.
- Extend uptime, optimize mill power and increase ROI
- Reduce liner weight by 50%, with 50% fewer parts with composite mill liners
- Increase grinding capacity and throughput potential
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Digital
Increase comminution efficiency and reliability with smart solutions.
- Optimize mill loading with LoadIQ® smart sensor technology
- Increase throughput by up to 6%
- Reduce power consumption and increase operational stability
Our latest AG/SAG mill equipment solutions deliver high throughput and improved energy efficiency all in a compact footprint so you can make more effective use of plant space. For older horizontal mills, we offer rebuilds and upgrades that remove bottlenecks and allow you to upgrade to more durable, longer-lasting liners, improving productivity and being more sustainable. By upgrading your mill, you can also use composite mill liners which weigh less, increasing grinding capacity and improving the mill's energy efficiency. Finally, by adding LoadIQ sensor technology you can optimise your grinding mill loading to increase throughput with a further improvement in energy efficiency as well as increased operational stability.
Our customer stories and performance cases
Performance study
How a copper mine increased revenues with LoadIQ®
Customer story
Our ring gear innovation to improve a mining operation in Chile
Customer story
Customised liner solution boosts SAG mill throughput and mine profits
Customer story
How an issue with SAG mill dischargers become a 9+ years of collaboration
Customer story
Superior mill liners, service and support combine to improve mine’s success
Slurry pumping
Mining Slurry Pump Solutions
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Technology
Designed to improve your productivity and energy efficiency.
- 5 to 10% energy savings with our wear ring technology
- Reduce capital cost and carbon footprint with longer wear life for wet-end parts
- Improve productivity by reducing number of grinding circuit shutdowns
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Upgrades and wears
Upgrade your pumps by selecting one of many material options
- Reduce downtime by up to 50% with our patented Quick Release™ system
- Increase productivity with correct slurry pump and material selection
- Improve safety with offsite maintenance and rebuilds
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Spares and wears
Dedicated to ensure the right replacement parts at the right time
- Minimize downtime due to parts availability
- Reduce impeller wear with patented Supertanker technology
- Optimise equipment uptime with multiple wear part material options
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Digital
Smart decisions always start with good information
- Maximise process efficiencies with real-time condition monitoring
- Reduce manual involvement with automatic alerts and notifications
- Improve equipment performance and preventative maintenance capabilities
Improve your productivity and energy efficiency with our heavy duty, long-lasting horizontal and vertical slurry pumps! Our patented Wear Ring technology not only reduces energy consumption but also prolongs the life of crucial components. Meanwhile, our Quick Release system helps cut downtime in half when performing maintenance. And with component design that prioritizes extending wear life, such as our Supertanker impeller technology, you can further reduce downtime by reducing the amount of maintenance necessary for that pump. Lastly, with multiple real-time condition monitoring options available, pump performance and maintenance can be optimized so components are reaching their full potential.
Our customer stories and performance cases
Customer story
The lowest cost per ton pumped at a gold mine in Indonesia
Customer story
Simple adaptation to impact on the entire value chain
Customer story
Pumping up productivity
Customer story
The Quick Release™ system, a change in the maintenance of slurry pumps
Customer story
FLS knocks-out competition with KREBS® UMD™ pumps
Hydrocyclones
Hydrocyclones That Increase Recovery Rates
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Technology
High-efficient and cost-effective classification.
- Increase wear life with our gMAX® technology
- Reduce loss of valuable minerals in tails
- Finer separation at higher densities
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Upgrades and rebuilds
Cyclone rebuild programme provides lower costs solutions.
- Improve separation by retrofitting cyclones into existing installations
- Optimise wear life with multiple material options
- Minimise downtime with our cyclone rebuild program
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Spares and wears
Reduce downtime with spares and rebuild programs.
- Minimize stock of spare parts with increased wear life
- Liner optimization which leads to even wear and predictable maintenance
- Increase availability with our multiple liner material options
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Digital
Smart decisions always start with good information
- Maximise efficiencies with real time process and condition monitoring
- Increase mineral recovery and production capacity
- Predictable maintenance
Increase productivity and sustainability with our highly efficient hydrocylones! Our gMAX cyclones reduce the loss of valuable minerals to tails, raising recovery in your circuits. These cyclones also create finer separations at higher densities, allowing for reduced footprint. Along with that, built-in flexibility in our manifold and cyclone design means we can retrofit existing, dated systems, with our newer, more efficient technologies! Lastly, our cyclone rebuild program, which allows for quick change-out of end-of-life units, improves productivity by ensuring the best cyclone is always installed.
Our customer stories and performance cases
Solutions
Efficient condition monitoring of hydrocyclone processes
DISCOVER
SmartCyclone™ delivers new opportunities for process optimisation
Solutions
SmartCyclone™ - Optimisation and condition monitoring solutions
Flotation
Energy Efficient Flotation With Better Recovery Rates
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Technology
Maximise metallurgical performance and productivity.
- Improve recovery up to 5% utilising conventional and fast flotation equipment
- Maximise metallurgical performance using less energy
- Increase throughput by enhanced separation efficiency
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Upgrades and rebuilds
Delivering high efficiency and value by improving existing flotation equipment.
- Lower risk with the latest technology to speed up ROI
- Improve metallurgical performance with advanced froth control upgrade
- Increase life of your wear parts with nextSTEP™ and WEMCO® II mechanisms
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Spares and wears
Genuine wear parts deliver flotation efficiency and availability.
- Optimise performance with 24/7 expert support
- Minimise operating costs using durable wear parts
- Improve your equipment availability using high-quality OEM parts
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Digital
Smart flotation for higher recovery and greater efficiency.
- Reduce maintenance costs and extend equipment life up to 50%
- Optimise recovery when treating complex ores
- Improve mass pull distribution over the entire flotation circuit
Increase recovery rates and energy efficiency by raising the separation efficiency with our latest innovative flotation solutions. If you have older FLSmidth flotation systems, our advanced froth control upgrade can improve metallurgical performance and our nextSTEP™ and WEMCO® II upgrades can increase the life of your wear parts. Our digital solutions can improve mass pull distribution over the entire flotation circuit and optimise recovery rates when treating complex ores. 24/7 expert support and long-lasting quality parts mean that you can maximise your flotation plant’s availability.
Our customer stories and performance cases
Performance study
Single REFLUX™ Flotation Cell could replace up to 10 conventional flotation cells
Technology
REFLUX™ Flotation Cell (RFC)
Technology
Froth Recovery Upgrade Package
Technology
Flotation System: achieve more
Dewatering
Reduce Water Usage with Sustainable Dewatering Solutions
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Technology - Thickening
Improved water stewardship for sustainable mining.
- Improve underflow density and recover more valuable process water
- Minimize water lost to tailings with improved underflow density
- Lower cost and improve underflow densities with high-density thickeners
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Digital
Thickener real-time advanced process control improves water sustainability.
- Reduce value of water lost to tailings
- Increase underflow density, reduce flocculant consumption and improve water quality
- Minimise costs associated with energy consumption
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Upgrades and rebuilds
Boost thickener performance.
- Increase underflow densities up 5%
- Decrease water lost to tailings up to 15%
- Minimise flocculant use with the right solution
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Filtration Technology
The sustainable approach to high-volume dewatering.
- Minimize operating costs - lowest cost per tonne
- Maximize recovery of process water - up to 95% with AFP technology
- Optimise efficiency with fast filtration rates and short mechanical times
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Upgrades and rebuilds
Cut costs while improving filtration productivity.
- Increase flexibility with AFP2500 tailings filter – “membrane-ready” solution
- Improve cloth maintenance – cloth failure detection with Intelliplate™ technology
- Optimise filtration parameters – adaptive control with the automated moisture analyser
Our thickening and filtration solutions enable you to recover more water, which means drier tailings and more water being fed back into your process – by up to 95% with our advanced filter press technology. High-density thickeners and high filtration rate filters mean you can process high feed volumes and achieve the lowest possible cost per tonne.
Our upgrades allow existing thickeners to minimise flocculant use, decrease tailings water and increase underflow densities, improving productivity and efficiency. For filter systems, upgrading to our Intelliplate™ technology allows you to detect cloth failure and optimise maintenance activities.
Adding our Advanced Process Control digital solution to thickeners makes it possible to reduce water usage further, reduce flocculant consumption, improve productivity and minimise energy consumption. For filters, our adaptive control with an automated moisture analyser allows you to optimise filtration parameters to maximise productivity.
Our customer stories and performance cases
Performance study
Debottlenecked throughput and increased gold recovery
Performance study
Increased tailings dam stability and water recovery at a copper mine
Performance study
Achieving over 5 million m³ reduction in water to tailings at a copper-moly mine
Customer story
Thickener rake upgrade at a copper mine reduced water losses to tailings
Performance study
How a thickener rake upgrade at a Chilean copper mine reduced water losses to tailings