CRUSHING, SCREENING AND MILLING
Flsmidth builds most complete comminution range
With the acquisition of thyssenkrupp’s Mining business (TK Min-
ing), FLSmidth now boasts arguably the most complete comminu-
tion portfolio in the world.
T
he TK Mining offering consisted primarily of
crushing, conveying, grinding and process-
ing – areas that are broadly complementary to
FLSmidth’s line-up, according to Craig Brickhill,
FLSmidth’s Regional Product Line Manager – Milling
and HPGR. In grinding, for instance, TK Mining had Craig Brickhill, FLSmidth’s Demitri Kokoroyanis, Regional
a strong position with HPGRs, while FLSmidth is a Regional Product Line Manager – Product Line Manager – Crushing
Milling and HPGR. and Screening for FLSmidth.
leading provider in other grinding solutions such
as semi-autogenous grinding (SAG), ball and stirred mines deal with large feed rocks and higher through-
mills. put demands, while minimising energy costs.
“Under the FLSmidth name, FLSmidth is now “The large top feed size capability and high
able to bring the very best solutions, equipment and throughput capacities make the Top Service Gyratory
“The large top feed expertise from across the flowsheet to our custom- Crusher models a popular option for many custom-
size capability and ers,” says Brickhill. ers,” Kokoroyanis says.
high throughput According to Demitri Kokoroyanis, Regional Another differentiator for FLSmidth is its Jaw
Product Line Manager - Crushing and Screening for Gyratory Crusher Pro. He explains that this technol-
capacities make the
FLSmidth, among the enhancements in FLSmidth’s ogy was designed for block cave mining and above
Top Service Gyratory pit-to-plant range of technology and equipment surface crushing applications and is also capable of
Crusher models a are market-leading High Pressure Grinding Rolls
popular option for (HPGRs) and Eccentric Roll Crushers (ERC®s).
“Our combined technologies on the crushing
many customers,”
side now put us well ahead of competitors,” says
Kokoroyanis says. Kokoroyanis. “Our Top Service Gyratory Crushers
have been a significant step forward in ultra heavy-
duty design, where leading lean design within the
industry was leveraged resulting in balancing instal-
lation height, weight, erection and maintainability.”
With FLSmidth’s range of Top Service Gyratory
Crusher models, 95% of the servicing – including
the bevel gear and hydraulic servicing – can be
conducted from the top, without having to venture
underneath the crusher. This makes maintenance
easier and safer; and reduces operational down-
time. The larger openings and high crushing power
of these machines play an important role in helping
Among the enhancements in Another development has been the introduction of the larger Jaw Crusher
FLSmidth’s pit-to-plant range of Pro models with improved nip angles and stroke.
technology and equipment are
market-leading High Pressure
Grinding Rolls (HPGRs).
feature
The FLSmidth Eccentric Roll Crusher ERC® can accept large rocks and
produce a suitable size for conveying and secondary, or directly to
tertiary, crushing if applicable.
24MODERN MININGMay 2023
Its wide range of offerings allows FLSmidth to integrate its equipment into an entire semi-
mobile in-pit crushing plant for customers.
the discharge conveyor, and the plant comes complete with auxil-
iary equipment ensuring smooth operation.”
A key asset in the newly combined offering within FLSmidth
has been the HPGR range, explains Brickhill. “This,” he says, “was
a particularly exciting aspect of the acquisition given TK Mining’s
decades of experience in the technology. The FLSmidth popula-
tion of HPGR units in the field now rises to almost 160.
“It is a highly energy efficient alternative to traditional milling,
as it transfers energy directly into the rock. It is also a dry process,
so is useful for water-scarce locations or where mines are trying to
A large top feed size capability and high throughput capacities make the FLSmidth Top reduce water consumption.”
Service Gyratory Crusher models a popular option for many customers.
The other important benefit of HPGR technology is that it pro-
handling larger feed sizes than standard gyratory crushers on the motes micro-cracking within rock. This essentially weakens the
market. integrity of crushed material, opening pores that expose it better to
Yet another development has been the introduction of the metallurgical processes.
new larger Jaw Crusher Pro models with improved nip angles and “The high pressures in the equipment are able to reduce the
stroke. These crushers can crush harder material and are capable rock to a permeable cake,” Brickhill says. “Canals are created to
of increased capacities. The base of the machine can be installed the precious metals inside the rock, allowing better recoveries from
in a matter of two to three hours and is designed with an optimised processes like heap leaching.”
concept, reducing service time by up to 20%. The HPGR Pro is the latest addition to the range, and further
“Our Eccentric Roll Crusher ERC® – released in 2019 – is also improvements have been incorporated, including a rotating side
an exciting development and here we also have no competitor,” plate (RSP) that rotates with the rolls – rather than being stationary.
Kokoroyanis says. “Fitting into our range between jaw crushers and This has allowed the crushing to take place efficiently across the
large gyratory crushers, these can accept large rocks and produce full width of the roll. “The rotating side plates mean that there is
a suitable size for conveying and secondary crushing or directly to less recirculating load of oversized material, and so it has higher
tertiary crushing, if applicable.” throughput,” Brickhill notes.
The ERC has a built-in static grizzly screen situated before the FLSmidth remains a leader in autogenous grinding (AG), SAG
crushing zone to allow removal of the fine material. Large rocks and rod-and-ball and stirred mills, with an installed base of over
are fractured at the opening of the jaw to increase throughput and 3 000 mills worldwide. The trunnion-supported range has now
reduce power consumption. been augmented with the shell-supported products from TK
“This is what makes the equipment special. It allows a great Mining’s legacy.
deal of power to be put into the material and can handle very hard The acquisition has also brought a state-of-the-art 1 700 m2
material up to 350 MPa, and even higher,” he says. “We are plan- engineering facility for the refurbishment of HPGRs, into FLSmidth.
ning an installation in Angola in the coming months, which will be a Located in Chloorkop near Midrand, it is another addition to the
good reference for southern Africa.” company’s service capability. The facility will also service the com-
Its wide range of offerings allows FLSmidth to integrate its pany’s DRS sizers and Buffalo machines, which are used mainly in
equipment into an entire semi-mobile in-pit crushing plant for cus- coal and softer materials, such as bauxite. The facility includes a
feature
tomers. So successful have these complete plants been that there test centre where material can be tested for suitability for process-
are today over 285 installations worldwide. ing by HPGR and for sizing of full-scale units.
“These plants can encompass direct feed with mainly gyratory The expertise base of FLSmidth has, of course, been consider-
crushers, and indirect feed with an apron feeder before a gyra- ably broadened by the acquisition, further expanding the footprint
tory, ERC, jaw crusher, double roll crusher or double roll sizer,” says of expert services to assist customers with equipment, critical oper-
Kokoroyanis. “We can take care of everything from the truck tip to ational and maintenance support.
May 2023MODERN MINING25
