Zambian Mining News The Premium Source of Information on The Zambian Mining Industry
Related Articles
KITWE – Zambia’s Copperbelt Mine has successfully mitigated chronic production bottlenecks by overhauling its valve control systems, signaling a shift toward more resilient automation in the region’s demanding extractive industry.
The facility, which handles high volumes of copper ore, had previously struggled with frequent equipment breakdowns and unreliable flow control, exacerbated by the aggressive chemical environment and intense mechanical vibrations inherent to the flotation process.
Operational stability in flotation circuits is critical for mineral recovery, as even minor fluctuations in pressure or flow can lead to significant metal loss and inflated processing costs. For years, the site faced repeated failures from various valve positioner brands that proved unable to withstand the pervasive dust and humidity. The resulting unplanned maintenance cycles not only hampered output but also drove up the site’s total cost of ownership for its automation assets.
The turnaround was facilitated through a strategic collaboration between Valmet’s flow control division and its regional partner, Frasmac Limited. The intervention centered on a transition to the Neles™ NDX™ intelligent valve controller, a system specifically engineered for high-vibration environments.
By utilizing contactless magnetic position sensing, the technology eliminates the mechanical wear points that typically lead to failure in conventional positioners, ensuring the precise dosing of chemicals and air required for optimal ore separation.
“Together, the team helped the customer move from reactive maintenance to predictive stability,” said Sugeshan Pillay, Regional Sales Manager for Valmet’s flow control business line. Pillay noted that the mining group now views the partnership as a blueprint for future upgrades, stating, “The mining group now considers us a trusted valve automation partner for future upgrades across other sites.”
The technical upgrade has yielded immediate industrial benefits, including a measurable reduction in compressed air consumption and the total elimination of unplanned downtime within the flotation circuit. The efficiency of the new controllers’ pneumatic relays has allowed the mine to optimize energy use, contributing to a rapid return on investment.
Following the success of the initial installation, the mining group immediately exercised an option to order 10 additional units to standardize its control systems.
This modernization effort is supported by a broader deployment of Valmet’s flow control portfolio, ranging from high-durability pinch valves for slurry handling to advanced butterfly and ball valves for process water management.
As Copperbelt operators face increasing pressure to improve margins amidst fluctuating global commodity prices, the move toward “predictive stability” is becoming an industry standard for maintaining a competitive edge in one of the world’s most challenging mining environments
