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Digitalization Solution
Flsmidth enablr – digital solutions to power your productivity recently, the mining and cement industries have seen a change in what shapes growth. The spotlight has shifted from increasing capacity to enhancing productivity. Digitalisation has considerable advantages to make this shift possible. To support our customers, we are building a growing portfolio of digital solutions that connect, monitor and optimise performance, in response to the demands of this changing business landscape. We call it flsmidth enablr. Because it enables you to simplify your operations and improve productivity.
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risk assessment service
audits
Optimising processes with comprehensive and specialised audits Perhaps you are facing decreased production, insufficient product quality or rising maintenance costs – there are many inefficiencies that you might want to remedy. A comprehensive audit, or an audit focused on one particular area, identifies opportunities to improve processes that deliver sustainable plant benefits.
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Operating Procedure Audits
Operating procedure audits: Unlock your operations potential. There are a lot of factors that influence mine performance. Operational audits from FLSmidth are designed to give you a detailed look at those factors, and to give you the information you need to optimise your operations for increased profitability and efficiency. Reaching full potential Are you getting the most out of your operation? Answering that question is sometimes more difficult than it should be. It demands an in-depth understanding of a variety of interconnected factors, and it requires specific equipment and industry expertise to evaluate. But once you’ve developed a clear picture of your operation and how to improve you, the potential benefits are undeniable — more throughput, reduced costs, improved health and sustainability, less downtime and better product quality, to name only a few. Our operating procedure audits help you develop that picture, and then advise you on how best to act on it. Audits are performed by our experienced industry experts. These auditors take all of the important factors into account and work with you to ensure that your site achieves maximum, sustainable performance. And whether you want to get expert assistance for the entire site, or you are looking to add extra efficiency to a particular part of your operation, we have a solution that is right for you. We’ll identify any problem areas, give you a clear, detailed picture of current performance, and work with you to find possible opportunities going forward.
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Electrical and Automation Audits
Electrical and automation audits: Unlock your site’s potential. Our electrical and automation audit services are carried out by experienced professionals, and are designed to put your site’s vital systems under a microscope. The end result? You know exactly where your systems are, where they should be and the best way to get them there. Comprehensive and in-depth insight The Mining and Cement industries have come a long way in the past century. Where once analogue systems and labor human labor were the only options available, now, new technologies have revolutionised how we extract, transport, refine and catalogue valuable ore and other resources. But with these new technologies come new potential problems. And the more complex the system, the more difficult some of these issues become to accurately identify and address. Our electrical and automation audits are performed onsite by experienced electrical/automation specialists. Our auditors perform comprehensive evaluations, identifying any existing problems that may be harming your operation. Automated equipment will be evaluated while in operation and while static. Electrical systems will be tested and assessed for any possible issues that may be negatively impacting your business, as well as taking into account equipment energy use.
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SiloSafe Cement service
Produce high-quality cement and minimise production stoppage The SiloSafe Cement service addresses issues such as impeded cement quality development, lump formation, and coating on silo walls, which are all related to cement prehydration in the grinding process and in cement storage silos. Service to avoid silo blockages and improve cement quality Are you experiencing lumps and blockages in your cement silo, or a decrease in cement strength? These issues can be caused by less than optimal grinding and storage conditions. Our SiloSafe Cement service helps you prevent or remove the conditions that cause these issues, so you can stay focused on delivering high-quality product and running a successful business, achieving consistent revenues. The cause of cement lumps and blockages is often prehydration, which is the premature reaction of cement with water. Water is always present during cement production either through injection during grinding, as a vapour from gases, or from the feed materials. Therefore, it is vital to avoid the conditions that cause prehydration in your mill system and cement silos.
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Lab Audits
Evaluate the technical performance of your laboratory with a lab audit How confident are you about the reliability of your data? Could you be making process-altering decisions based on bad information? Don’t take that risk. A lab audit will check the reliability of your data and suggest improvements so that you can optimise your process – precisely and accurately. An opportunity to test your laboratory performance Data is the driver that allows you to ascertain and improve product quality, process efficiency and environmental performance. You use that to make decisions about how you might adjust the process for optimum results. But if the data you’re using is unreliable, how can you trust the results? You can’t. If the data is bad, the results might be worse. An imprecise or inaccurate reading of the Lime Saturation Factor (LSF), for example, might mean problems controlling your pyro process and a lower quality product. Poor quality could cost you customers – or worse. Is that a risk you are willing to take? A lab audit will identify any weak spots in your laboratory operations, enabling you to tighten up practices and recalibrate equipment to get plant performance back on track.
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Kiln Services
Prolong the lifespan of your kiln The kiln is at the heart of your plant and plays a vital role in production. Timely, on-site kiln maintenance, such as hot alignment and resurfacing of rollers and tyres, can extend equipment lifetime and minimise wear and tear. A comprehensive kiln health check includes alignment and reconditioning Achieving high kiln availability is essential to the competitiveness and profitability of your entire plant. You need to identify the root causes of kiln failure and eliminate problems before a breakdown occurs. Kiln services and maintenance help you avoid: Hot bearings Kiln cracks Wear on rollers and tyres Wear between kiln shell and tyres Lining failure Proactively prevent damage Instead of simply treating the symptoms, it’s really important to identify and deal with the root causes of kiln failure, such as kiln axis misalignment, kiln shell ovality/shell flex, kiln crank, and kiln axial misbalance. To keep your kiln at optimal health throughout its lifetime, we recommend our key kiln services: hot kiln alignment, and reconditioning of tyres and rollers.
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Cooler Services
Staying cool with preventative maintenance services It’s essential to bring red-hot clinker down to manageable temperatures. The clinker-cooler is working constantly for your plant and preventative maintenance is vital to keep availability high. You need to avoid excessive wear on components, and have the right spare parts on hand for planned maintenance. Maximise cooler availability and eliminate excessive wear To maintain overall plant capacity, your cooler must handle a constant throughput of clinker. Problems with the cooler can result in an unstable kiln, damage equipment, and influence the clinker quality. And excessive wear of cooler parts can lead to inefficient cooling processes and even production stoppages. A regular preventative inspection can eliminate many of the root causes of excessive wear and keep your cooler running smoothly. As well as inspections, our on-site cooler services include: installation, repairs and refurbishments, and upgrades and overhauls. Is your cooler always ‘all systems go’? A complete cooler analysis can help you reduce downtime and keep production levels high. A problem detected in one area can have its root cause in another. Using the latest fault-finding technologies, such as electronic data loggers and thermal cameras, we analyse each individual element in depth.
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pneumatic conveying services
KEY BENEFITS Enhance plant productivity with the highest possible reliable conveying capacity Reduce equipment downtime and minimise the risk of conveying pipe blockages Lower energy consumption and the cost of operation Easily upgrade your equipment and system Take advantage of industry-leading material and workmanship warranties Conveying & storage systems services ensure optimal material handling The right product in the right quantity and at the right location: an efficient and available pneumatic conveying system is vital. For more than 135 years, the world’s cement, mining, minerals, power generation, lime, alumina, steel, and pulp and paper industries have relied on us to meet their pneumatic conveying and storage needs. Maintain and enhance your pneumatic conveying and storage systems Pneumatic conveying is at the core of your material handling system. From initial installation to repairs, upgrades, and preventative maintenance, we offer you tailored cost-effective services to ensure optimised pneumatic systems. Use our expertise to help maintain and enhance your equipment, while reducing the cost of operation. Through years of innovation and experience, we’ve developed a vast global pool of specialist engineering resources, unique within the market, so we can fully support you at every stage of your operational process. Project planning and implementation for pneumatic systems Thinking of converting, extending, or modernising your pneumatic system? We support all phases of your project from customer-specific consulting, including on-site visits, to planning and engineering. You can rely on us for on-time order processing and installation and commissioning, including the transfer of the ready-for-production system to your site.
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Vertical Roller Mill Services
KEY BENEFITS Maximise mill performance Increase availability Longer vertical mill life Prevent unforeseen shutdowns Complete mill department analysis Maximise mill performance with a reliable maintenance strategy The vertical roller mill (VRM) is firmly established in cement plants all over the world. The biggest issues facing plants are not due to the equipment itself, but more to do with how well mill maintenance is understood and how the mill is looked after following commissioning. Straight-up services you can rely on to reduce vertical mill downtime To increase the reliability and availability of your mill equipment, you need an effective preventative maintenance approach. Our comprehensive mill services help to identify and eliminate root causes of performance bottlenecks, so that you can prevent: Excessive downtime Hydraulic system failure Contaminated lubrication oil Oil leakage from rollers Repeated failures Vibrations
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server upgrade service
KEY BENEFITS Minor repairs to major upgrades Customised solutions Experienced partner Is your process running optimally? No production facility is perfect – but we can try! Whether it’s throughput, reliability, operating costs, or environmental performance, there are always improvements to be made to any industrial process. Let us help identify the repair, retrofit or upgrade project that will give you a competitive edge. From minor repairs to complete upgrades – and everything in between Industrial processes are typically hard on machinery and high on energy consumption. Frequent maintenance stops, ongoing repair bills and high operating costs can put a big dent in your profitability. But technology is moving forward all the time. New wear parts, new machinery and new techniques could help you eliminate bottlenecks, reduce costs and improve your environmental footprint. What are you waiting for?
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air pollution control services
KEY BENEFITS Reduce unwanted emissions Meet regulations Save energy Maximise uptime Air pollution control services help reduce emissions and save energy Dealing with emissions responsibly and efficiently is a fact of life for today’s production facilities. Maintaining air pollution control equipment is critical for your production, profitability and the environment. In today’s world of strict emissions control, it’s a necessity. Supporting effective air pollution control solutions If your air pollution control equipment fails, you face shutdowns and loss of production. And, in addition, increased emissions due to poorly designed equipment not only impacts the environment, but can also cause extensive wear on other equipment, such as filter fans, which increases overall maintenance and operational costs. With our high degree of process knowledge and experience, FLSmidth is at the forefront of developing new technologies to optimise air pollution control equipment and solutions. We also understand the increasing legislative pressure to reduce emissions.
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mechanical power transmission gear services
KEY BENEFITS Improved gear performance for longer periods Reduce unplanned downtime Predictable maintenance costs Enhanced reliability Gearing up: services to enhance reliability and productivity When it comes to mechanical power transmission, the gear unit – such as the MAAG® GEAR CPU – is vital. It can be difficult to assess and repair but it needs to run safely and reliably, often under harsh conditions. Our range of services take the headache out of gear installation, overhauls and repairs, so you have a gear unit you can always rely on. Improve gear unit condition and performance Responsible for driving the production process at exactly the right speed and power, your business is totally dependent on the gear unit. It must operate efficiently and require minimal downtime. However, it is often the piece of plant equipment that is pushed to the limit of its capacity and subject to the most extreme wear and tear over many years. So you need high-quality and high-value solutions and services. Our experienced gear specialists ensure you get optimal equipment availability and uninterrupted production. Maintenance costs are also more predictable and we share knowledge with maintenance staff, helping to keep your gear unit in top condition at all times. We offer a complete range of gear overhaul and repair activities for all parts, including rotating parts, bearings, and designed components. This includes: Dismantling parts and evaluating their health Repairing and replacing parts Assembling and function testing
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Technical advisory
KEY BENEFITS Optimised performance Lower costs Improved reliability Optimise your operation with FLSmidth Technical Advisory Services We have several decades of experience in helping plants run smoothly. Benefit from our Technical Advisory Services as we help you install, start up, operate and maintain your FLSmidth and other OEM processing equipment throughout the lifecycle. Maximise system value through our Technical Advisory Services Our goal is to help your operation and systems run at the highest possible levels of productivity. To this end, we provide Technical Advisory Services custom-tailored to the success of your unique plant. As our customer, we want you and your operation to succeed and achieve peak levels of performance. Our qualified personnel are reliable and experienced and eager to assist you. Our Technical Advisory Services include: Quality assurance throughout installation Commissioning of systems and products Engineering services Scheduled services (such as PlantLine and other Service Agreements) Remote services via online computer access Performance check & optimisation Audits (bottleneck studies, process optimisation, maintenance process) Service visits for maintenance or troubleshooting Consultancy, inspections & surveys Training & seminars
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Gas Analysis Emissions Monitoring Services
KEY BENEFITS Reduce unforeseen stoppages Increase equipment availability and lifetime Reduce maintenance and increase equipment runtime Reduce emissions Short repair times Emissions and gas analysis services you can rely on Gas analysis systems are complex, so it’s essential that you get expert assistance with repairs, spare parts, and new products. Our service technicians are highly skilled and offer both remote and onsite support, so you can get world-class services for your gas analysis and emissions monitoring equipment. Keeping your gas analysis system problem-free and powerful Gas analysis systems are an essential part of production, and emission monitoring is at the heart of a plant’s compliance programmes. Regular maintenance of your gas analysis systems helps you reduce system downtime and optimise plant performance. To keep your gas analysis system running smoothly, we provide expert repair and maintenance services, including: Commissioning the system Preventative maintenance Service agreements Service hotline and call-outs Spare parts Training Online support and remote troubleshooting Consultancy Complaint resolution
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Feeding and Dosing Equipment Services
KEY BENEFITS Maintain dosing accuracy Save costs by pre-planning production outages Support for crucial spare-part management Increase machine life Lower operational costs Prevent wear damage to your dosing system and save costs The feeding and dosing system often works in harsh conditions and it’s important to know about the condition and status of the system to avoid the damaging effects of wear. The right maintenance at the right time can save you time and money. Know the status of your feeding and dosing equipment To run your plant profitably and efficiently, you need stable and accurate material dosing. Equipment must be able to dose small to huge amounts of material per hour. In a rough environment like industrial production, it’s impossible to completely prevent wear – and this applies in particular to the wear parts of your dosing systems, such as the rotor wheels and sealing plates. However, you can prevent potential unplanned downtime. Timing is everything To reduce the risk of wear-triggered downtimes, you can rely on our experience in feeding and dosing equipment. We know exactly when to inspect which part of your system and this means we can find the ideal time to carry out maintenance. The result is increased machine life, and reduced service and operation costs. Feeding and dosing equipment services include, for example: Visual inspection of the equipment Software update Exchange of wear spare parts Calibration of the system Spare part recommendation Software/data back up
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Liner Profiling Scanning service
KEY BENEFITS Extended liner life Improved wear Increased uptime Optimise wear life and productivity with liner profiling and scanning Extend the life of your equipment and better plan for regularly scheduled maintenance shutdowns. Our advanced liner profiling and scanning services use cutting-edge technology to give you the most accurate and actionable information about your liners, and what steps you can take to optimise your equipment wear life. Get vital equipment insight with liner profiling and scanning services Understanding the ways in which the mill lining wears is key to increasing uptime and accurately scheduling maintenance shutdowns. This is where the FLSmidth liner profiling and scanning services step in. Visually compare worn sets of liners against scans of new liners, so you can effectively gauge wearing trends and schedule vital maintenance. Our liner profiling and scanning services make it not only possible, but simple.
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Packing Dispatching Equipment Services
KEY BENEFITS Maintain efficient production performance Get rapid and secure spare-parts delivery Reduce operating costs Optimise plant productivity Upgrade and enhance your equipment Maintain high efficiency of packing and dispatch lines Your customers are waiting for products, so it’s crucial that packing and dispatching lines don’t delay delivery and that you can fulfill market requirements. Well-maintained equipment means you can dispatch products on demand. High-quality spares and programmed technical assistance increases the lifetime of equipment. Reliable Ventomatic® services for maintenance, spare parts, and support Successfully getting your product ready for delivery is essential to a well-functioning production cycle. We will make sure your equipment is efficiently installed and commissioned, and then we’ll take care of maintenance, on-the-job training, and help you troubleshoot any issues. Keeping your packing and dispatch equipment in excellent condition for productivity, we offer: Expert field-service visits Programmed maintenance services and audits Online technical support Fast spare-parts supply for programmed maintenance and for emergencies Equipment modernising and enhancement
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boosting plant maintenance services
Benefits produce more at lower cost, guaranteed turn uncertain costs into predefined fees improve the quality of your products increase your operational and process know-how continuously improve your business results boosting plant performance gain access to comprehensive support services and expertise. Choose from our flexible operation and maintenance (o&m) offerings, and make sure your plant achieves maximum and sustainable performance. o&m partnership to gain a sustainable competitive advantage whether you want to get expert assistance for the entire operation and maintenance of your plant or you are looking to add extra efficiency to a particular part of your operation, we have a solution that is right for you. Why do you need an o&m partner? collaborate with a partner you can trust to improve your plant. By building a partnership with us, you can take advantage of what we do best. At the centre of all our operation and maintenance services is the goal of adding value to your business.
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Gas Analysis services
KEY BENEFITS Optimise equipment utilisation and increase run factor Predicable assistance for trouble-free operation Ensure continuous safety for equipment and personnel Optimise process conditions Efficient global network for spare parts supply and service coverage Flexible service contracts to meet gas analysis equipment needs Your gas analysis equipment will eventually require an engineer, but a service agreement with us can decrease the likelihood of breakdown and reduce uncertainty. By planning timely repairs and having expert assistance on hand, you can increase your equipment’s life expectancy and enjoy predicable maintenance costs. Get the most out of your gas analysis equipment Without a gas analysis system, you are effectively running your plant blind and decreasing the potential for optimisation, while risking increased emissions. No two pyro processes are alike but we know that when it comes to combustion there will always be, from time to time, unstable conditions. The success of any solution depends on the success of the maintenance department. You have to keep the system in trouble-free operation so that you can use the data provided by the gas analysis equipment. Full service programme for your gas analysis solutions You can trust us to fully support you. Let us share our years of worldwide experience and process knowledge in the leading gas analysis solutions. We’ll ensure that you get the most out of the technology so you can optimise production throughput, as well as the cost of operations and the safety of people and machinery. Meeting whatever requirements you might have, we offer ad-hoc gas analysis services as well as full service agreements, including a support hotline.
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Fundamental Courses
Fundamental courses and seminars on your equipment and systems Focusing on broad based introduction to your equipment and operations, these courses are designed for newer staff or anyone moving into a new division. They are also an excellent overview for anyone looking to update their general knowledge.
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Maintenance Training Courses
Maintenance training courses and seminars Keeping your facility at maximum productivity is the top priority for your plant. Our maintenance training programmes are focused on daily and preventive maintenance practices on your plant equipment and systems to help you reach that goal.
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Operations Training
Operations training - courses, online training and seminars Your plant has unique challenges, ranging from increasing availability and production to cutting energy consumption and controlling emissions. Our operations training courses offer more than dry facts and abstract techniques – they instil new ways of thinking and working that can add value to your process far into the future.
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Process Control Systems Training
Process control systems training Attain the full benefit of your process control systems with our customised automation training courses, helping you to get the most out of your operating systems and achieve optimum production.
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