Sizers do matter

Used in a number of industries, ABON® sizers are proving to be a great option for mineral processing applications around the globe.

Low-speed sizing for maximum results
A sizer is a type of crushing equipment that is able to break and reduce rock by means of feeding the rock into rotating cylinders that contain large teeth. As gravity pulls the weight of the rocks into the crushing chamber, the teeth engage the rock and as it moves into the cylinders, the pressures created by the narrow gap between and the force of the teeth coming down on the rock rips it apart. The rock is expelled from the underside in a reduced, more manageable size that can be more easily transported to other areas of the plant for processing.

With the further integration of FLSmidth product companies in 2010, ABON products have been able to enter new markets and enable other FLSmidth solutions to be bundled into cross-complimentary package offerings
— Steve Bond Managing Director FLSmidth

ABON Sizers are driven by means of a proprietary quad reduction gearbox. This means that high levels of output torque can be generated. Due to the low rotation speed of the sizer, the teeth sizing elements and drive train are protected against excessive damage which can be caused by unexpected tramp metal that may be encountered within the feed entering the crushing chamber. Another benefit of the low speed of ABON sizers is that it maximises tooth wear life due to a more positive bite/engagement on the incoming feed. In addition, the sizers incorporate an “all-oil-bath” lubrication which eliminates the need for external auto-lube systems.

‘One Source’ helps conquer new markets
With the further integration of FLSmidth product companies in 2010, ABON products have been able to enter new markets and enable other FLSmidth solutions to be bundled into cross-complimentary package offerings. Successful endeavours between previous legacy companies that now make up today’s stronger and more robust FLSmidth include:

  • FLSmidth Krebs introducing ABON products to the Philippines
  • FLSmidth ABON Sizer packages bundled with rollerscreens and Buffalo feeder breakers for major coal operations client in Indonesia
  • FLSmidth Buffalo expands ABON products on the African continent
  • FLSmidth RAHCO and ABON combining to offer new IPCC (In-Pit Crushing and Conveying) solutions that crush rock in the pit area and then immediately convey the smaller rock rather than using more costly truck haulage operations to move the large extracted rock to crushing stations.



Recently, FLSmidth helped Rio Tinto reach the million tonnes a week milestone for the IPCC overburden project at its Clermont Mine in Queensland, Australia.

At the heart of the Rio Tinto IPCC system is an FLSmidth ABON low speed sizer. Designed to crush ROM lump sizes at rates up to 12,000 tph, the low speed sizer crushes overburden, making it easy to transport the material over conveyor systems.

Since the IPCC system was commissioned in 2010, the ABON sizer has met and exceeded all technical performance parameters. Apart from standard maintenance, no intervention has been required on the ABON unit, proving its rugged structure, smooth operation and added durability.

Improved manufacturing capability
Greater acceptance of and increased demand for ABON Sizers have created the need to upgrade and expand the FLSmidth ABON manufacturing facility in Melbourne. Construction is underway and is being orchestrated to minimise the effect on current production backlogs and deliveries while expanding the facilities to safely handle increased production. The main feature of the upgrade is an additional 1400 square metres of manufacturing floor-space and an additional 100-tonnes of lift capacity. The upgraded areas are expected to be completed during the third quarter of 2011.

Wider application of rollerscreen
FLSmidth also manufactures ABON rollerscreens, originally developed for high tonnage screening in ROM coal applications. With a low profile and low dynamic footprint, as well as high volumetric capacity, the rollerscreen minimises the needed footprint while simplifying standard coal handling circuits.

The product’s unique ability to process high moisture and wet and sticky materials compared with traditional screening mechanisms has seen the product’s application extend to other high tonnage minerals such as bauxite, nickel, mineral tailings and tar sands.

At present, the rollerscreen is undergoing development and testing at Brazil’s Vale mining company in high tonnage/high moisture iron-ore applications.

CONTACT: Steve Bond