Onsite service for screen media

FLSmidth began a screen media service contract on December 1, 2013, with a full-time crew on site to perform daily maintenance duties on all screen media, as well as cyclone inspections at the Khumani Iron Ore Mine in South Africa.

The implementation of FLSmidth’s screen media service contract has brought many improvements to the plant operations, including:

  • Reduction in production delays due to panel failures
  • Reduction in call-outs
  • Improved screening efficiencies, resulting in an improvement in overall plant efficiency and reduced cost per tonne
  • Day-to-day interface with mine management and the team on the plant proper
  • Formal monthly meetings involving reports on performance, replacement of screen media and reasons for replacements
  • Optimal usage of screening media whereby wear and metallurgical parameters dictate replacement and not distortion and mechanical failure (e.g. dishing of screen media)
  • Continuous product development
  • Ongoing solving of existing

In 2012, FLSmidth acquired the internationally recognised Meshcape brand to offer screen media products, including woven wire screens, wedge wire, wire conveyor belts, perforated material and polyurethane screens.

During the past 14 years, FLSmidth’s screen media team has been actively involved with the Assmang Group regarding screen media development and supplies for the Khumani Iron Ore Mine (formerly known as the Bruce, King and Mokaning (“BKM”) Project, which is situated approximately 30 km south of the town of Kathu in the Northern Cape Province of South Africa and approximately 65 km north of the Beeshoek Mine.)

Over this period, FLSmidth has added value by introducing innovative screening media and imparting knowledge to improve throughput and up-time, and to reduce cost per tonne.

Based on positive results after years of extensive on-site testing in various applications against competitors, Assmang has standardized on the MESHCAPE™ range of screen media at Khumani, Beeshoek and Black Rock (Manganese) process plants, and FLSmidth has become the largest supplier of all screen media for these plants. In addition to this, the Bolted Pin System (BPS), which is a modular panel system with polyurethane screening surface, has proven the most successful and efficient fixing system for modular screen media in the iron ore and manganese industries.

In 2013, driven by Etienne Mulder, Assmang Khumani – Superintendent Production Process, envisaged an opportunity to increase revenue and reduce plant operational costs through proper maintenance of screening media.

FLSmidth was invited to take part in the tender process for a screen media and cyclone maintenance service at the beginning of September 2013, and on September 23, 2013, the adjudication of the service enquiry voted in favor of FLSmidth.

The screen media service contract was implemented by Peter Janse van Rensburg and commenced on December 1, 2013, with a full-time crew on site to perform daily maintenance duties on all screen media and to conduct cyclone inspections.

The on-site crew consists of seven panel installers who are supervised and managed by Wynand van Wyk, who is also responsible for monthly meetings and daily feedback to relevant mine personnel with regard to operations, changes and suggestions to improve process performance.

FLSmidth’s screen media solutions and service have proven once again to be the ideal solution for screening media. FLSmidth experts on hand in cooperation with on-site operations help to maintain this standard of excellence and carry it on into the future. Service contracts like this are available not only to the South African market but also around all parts of the world.

CONTACT: David Sibley