Introduction: Overcoming Persistent Valve Control Challenges
For years, a leading copper mine in Zambia’s renowned Copperbelt region faced significant operational hurdles due to unreliable valve control and frequent positioner failures. Previous solutions from multiple brands failed to withstand the harsh process environment, resulting in monthly downtime averaging 12 hours and inconsistent plant performance.
Technical Environment: Demands of Copper Flotation
Copper ore processing relies on a rigorous flotation process, which exposes equipment to aggressive chemicals, high humidity, pervasive dust, and intense vibration. In such conditions, actuators and valve positioners are critical for maintaining stable flow control and precise pressure regulation. Any instability not only disrupts recovery but also leads to increased costs and reduced throughput.
Previous Issues: Unsuccessful Attempts at Reliability
Despite extensive efforts and the use of several positioner brands, none delivered the durability or reliability required. The site experienced repeated breakdowns, with unplanned failures causing notable productivity losses and increased maintenance demands.
Solution Implementation: Valmet Neles NDX Controller and Key Features
The turning point came when Valmet’s flow control team, together with distributor partner Frasmac Limited, introduced a tailored retrofit: the Neles™ NDX™ intelligent valve controller. This solution featured contactless magnetic position sensing—a technology that determines valve position without physical contact, eliminating wear and ensuring sustained accuracy even under extreme vibration. Additionally, its efficient pneumatic relayoptimises air usage by delivering precise and responsive air flow to the actuator, reducing energy consumption and operational costs.
Quantitative Outcomes: Measurable Performance Improvements
The deployment of the Neles NDX controller delivered immediate and quantifiable benefits:
- Process stability improved by 25% across the entire flotation circuit, leading to more consistent copper recovery.
- Air consumption was reduced by 15% owing to the controller’s efficient pneumatic relay.
- Downtime due to valve positioner failures dropped from 12 hours per month to zero, eliminating unplanned interruptions.
- The customer achieved a rapid return on investment, immediately ordering an additional 10 units following initial results.
Collaboration and Partnership: A Model for Success
This success was rooted in a collaborative approach led by Valmet’s Sub-Saharan Africa team and supported by Frasmac Limited’s on-ground expertise. The project was characterised by close teamwork, technical transparency, and swift execution. As the customer shared, “Together, the team helped us move from reactive maintenance to predictive stability. We now consider Valmet a trusted valve automation partner for our future upgrades.”
Comprehensive Portfolio: Supporting Long-Term Reliability
Beyond the Neles NDX intelligent valve controller, the mine benefits from a broad selection of Valmet flow control products well-suited for demanding slurry and process applications. These include Flowrox™ pinch valves in multiple sizes, Neles ND9 and ND7 controllers and valves, as well as Jamesbury™ and Neles Easyflow™ ball and butterfly valves.
Conclusion: Foundation for Future Growth
This comprehensive flow control portfolio ensures the copper mine’s ongoing reliability and consistent performance across its most challenging process areas. With proven quantitative results and a strong partnership, Valmet provides a robust foundation for future upgrades and sustained operational excellence in copper processing.