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Process control

Enhance safety, productivity and uptime with process control system

A reliable process control system is essential to efficient mining operations. Our process control system benefits from comprehensive process and product knowledge to improve safety, reduce downtime and increase productivity across the flowsheet.

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Key benefits of process control systems

  • Tailor-designed and easier integration

    Our solution is tailor-made for the mining industry, focusing on your specific requirements. It perfectly balances functionality and performance, delivering a fast, advanced, yet easy-to-use system. Designed for flexibility, it supports a wide range of equipment types and ages, allowing engineers to tailor configurations for individual projects. Compatible with major PLC hardware brands like Siemens, Schneider, and Rockwell, it simplifies system upgrades and third-party integration. Our process control solution ensures your control system is ready for future needs, not just current ones.

  • Complete life cycle support

    We provide support through the complete life cycle – from the initial choice of product to commissioning and onto aftermarket services. Everything we do is backed by our expert team of engineers, project managers and support staff. We deliver on time and can upgrade your equipment and systems with little to no downtime to avoid production losses. You’ll also have access to around-the-clock support and troubleshooting from our team so you can be confident we’ll always be there to help.

  • Reduces costs through optimised productivity

    Our process control system provides a platform for automation, enabling equipment to run consistently at optimal conditions. By reducing operator error, automation systems minimise unplanned downtime, keeping throughput high, while boosting process efficiency and overall output. And with our proactive service module and advanced cyber security, we make sure that the control system itself is protected from unexpected stoppages. All of this means that you can be sure your plant is operating at its optimum efficiency.

  • Enables progress towards a more sustainable mine

    Process control system allows processes to be optimised according to plant conditions. Energy can be used more efficiently, reducing the water and power usage in production. Plant and equipment can be more finely controlled, reducing wear and tear – and the need for maintenance. And problems can be more quickly identified, limiting the risk of unplanned stoppages – and the waste of energy and production time on repeated start-ups. Meanwhile, remote support is available to maxmise availability and keep the operation up and running.

Our Process Control System

An advanced and adaptable digtialisation platform 

Our Process control system Platform has the functions you’d expect from a modern DCS system for effective operation of the mining process plant at all levels. Our Process Control Solution uses dedicated Programmable Logic Controllers (PLC) to control equipment, while providing an open interface. We support multiple PLC and MCC brands for the highest flexibility. As well as providing precise process control, our system also includes features to help you improve productivity and uptime, such as plant data management, trending, alarm management and data logging, resulting in a complete full-featured control system.

With SiteConnect, you can view plant data from wherever you are on your mobile device. This ensures you’re always aware of what’s going on onsite, even when you can’t be there in person.

As a complete partner, we’re there for you at every stage – from choosing the right solution, through installation, commissioning and start-up and for support with electrification and instrumentation, and beyond. You can also access additional services such as asset health, asset optimisation and our PerformanceIQ Hub, which offers 24/7 support and long term solutions. 

System and maintenance staff will enjoy the engineering benefits that come with our Control Library. This world-class control standard enables ultra-fast engineering and maintenance of consistent plant-wide implementation. Meanwhile, detailed diagnostic data from the controller and electrical devices can be accessed directly in the system. Operators will be able to take faster and better-informed decisions such as the combined trend and alarm view, advanced mimic symbols to support fast detection of upcoming limit violations, and root cause indications to quickly understand and eliminate stoppage. The Process Control System software also includes an advanced trending tool with high data resolution and long-term data logging of all tags, both analogue and digital, even without a historian. Collaboration is made easy with the inbuilt electronic logbook and notification system, as well the ability to email snaps directly from the operator interface to relevant staff. This is possible from both onsite control room, as well as remote operation centres.

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A software platform for your process control needs

Whether you are looking to control your FLSmidth equipment, a process area, your complete plant, including third-party machinery, our Process Control System software platform makes it happen effectively. It is the basis for our three digital automation solutions – Process Control, Asset health and Asset optimisation – that are sure to cover your needs.

Structured platform for digital optimisation

Digital optimisation is based on the provision of structured data. This is the fuel for advanced optimisation technologies, such as data analytics, machine learning and artificial intelligence. In combination with the Control Library, the software solution provides that fuel. Designed to be hardware agnostic, our process control platform can be used with many different popular PLC brands, ensuring data of consistent quality and structure to empower your digital journey.

Safeguard control system uptime with online condition monitoring

We understand how important it is to keep your control system running. Without it, production grinds to a halt. And every stoppage wastes time, energy and money, impacting the productivity of your plant. If you choose to add our secure online condition monitoring services that provide insights to potential system problems, the  Software Platform is protected against the risk of unplanned downtime.

Frequently asked questions

FAQs for process control systems

The success of the process control system lies on how effectively the software is written to control the process and to ensure the safety of the personnel and the equipment. FLS is well positioned in this aspect as an original equipment manufacturer and process designer. Our time-tested algorithms, safety interlock tables, fault analysis tools, process data tables ensures smooth and safe operation ensuring productivity at its peak. Our software seamlessly interfaces with our Advanced process control, condition monitoring and plant data management systems which further enhances the Process control system performances.

FLS provides control system for product and processes. Product control system is supplied along with select mechanical products. Process control system is supplied for a standalone process or a complete process line.