WE DISCOVER POTENTIAL

SAMPLING,
PREPARATION
AND ANALYSIS
MINING
Good data. Sound decisions.
Strong margins.
SAMPLING, PREPARATION AND ANALYSIS
FACT SHEET
IMPROVED PROFITABILITY.
GREATER EFFICIENCY.
OPTIMUM QUALITY.
SUSTAINABILITY AUTOMATION
AUTOMATED LABORATORIES REDUCE LABORATORY AUTOMATION

IT ALL STARTS
EMPLOYEE EXPOSURE TO MANUAL OFTEN REDUCES LABOUR COSTS
HANDLING HAZARDS, NOISE EXPOSURE BY HALF OR EVEN MORE
AND DUST INHALATION

WITH RELIABLE DATA

Low grade deposits and the increasing cost of processing are dampening
ONE MINING COMPANY MILLIONS $ SAVED profitability across minerals industries. But could you be making more of your
THREE LABORATORIES – REPRESENTATIVE SAMPLING CAN SAVE mineral deposits? Representative sampling and accurate analysis provides the data
FIVE YEARS – 4.5 MILLION SAMPLES – MILLIONS OF DOLLARS IN INCORRECT you need to optimise all aspects of your exploration and mining processes.
ZERO TRIFR ORE GRADE ANALYSIS

EFFICIENCY EVALUATION
AUTOMATED SAMPLE PREPARATION THE SUBSTANTIAL COST OF IRRELEVANT DATA
SIGNIFICANTLY IMPROVES DATA QUALITY VARIABILITY IS NOT EASY TO DETECT,
AND CAN REDUCE MISCLASSIFICATION QUANTIFY, OR CORRECT. YOUR DECISIONS
OF ORE AS WASTE PRODUCT ARE ONLY AS GOOD AS YOUR SAMPLES Greater control over A sound basis for
the life of your mine making process decisions

WHAT YOU GET

36 MILLION REASONS WHY CORRECT SAMPLING AND

SAMPLE PREPARATION ARE IMPORTANT …
A GOLD RESOURCE DEFINITION SCENARIO

You have identified a resource of 1.18 million tonnes of ore, which you believe to
be grade 6.3 g/t Au. That’s about 240,000 oz gold. Your calculation includes a
relative standard deviation of 10%. That is 24,000 oz gold or US$36 million in gold
value. That’s roughly half the cost of a 450 tpd gold plant.
A better-quality product – Improved profitability
and the proof to back it up and process efficiency
Size matters. Understanding the value of better sample preparation and sub-sampling
is extremely valuable and goes a long way in reducing your exploration risks.

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SOLUTIONS
OVERVIEW
1
1.
Prospect. Insights to where to mine.
Types of sampling A C
From mineral exploration to mine development, good and analysis
samples, properly prepared and precisely analysed,
will help determine where and how to mine to get the B
most from your deposit.

■ Exploration F G E D 2.
■ Ore reserve and resource estimation
■ Mine development
Process. Improve your control.
Regular sampling and analysis helps you
2 adjust your process for optimum product
quality. From the mine to the stockpile and
beyond.
Metallurgical
cal accounting
■ Grade control
■ Process control
D
■ Quality control

D H D

3.
Product. Establish your worth. Sampling and analysis
Correct sampling and analysis of your A Laboratory samplers
product enables you to establish its worth, B Grade control laboratory
both as a seller and a buyer. Accuracy is C Exploration and ore characterisation laboratories
the key to building customer trust. D Sampling stations
Linear falling stream samplers
■ Inventory control Rotary falling stream samplers
■ Commercial transactions Cross belt samplers
Rotary and linear sample collectors
E Online analysis
F Process control slurry samplers
G Process plant laboratory
H Port shipment laboratory

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 Poorly designed geochemistry protocols can result
in elevated project risk by increasing variability.
PROSPECT: STRATEGIC DECISIONS
Critically, such variability produces both financial BEGIN WITH REPRESENTATIVE SAMPLES
and intangible losses. Sample collection, preparation The number of high-grade deposits is falling, yet demand for minerals
and assay procedures and equipment that are remains high. Making the right investment to ensure maximum profitability over the
longest possible term depends on sound data, which starts with analysis you can trust.
optimised to suit the ore type, together with QAQC
systems, will reduce variability".
Exploration demands reliable and timely data requirements. This includes total lifecycle support through the delivery
When it comes to defining investment viability, the laboratory plays of spare and wear parts and consumables. We also offer laboratory
a key role. Obtaining the right samples and making sure they are audits to help you achieve maximum efficiency, quality and safety of
properly prepared and accurately analysed – these are all critical your preparation and analysis systems.
steps in determining whether or not this multi-million-dollar
investment goes ahead.
The potential for quality errors can occur all the way along
With high sample volumes and often very low elemental levels, the sample chain from the field through to final analysis
it’s easy for contamination to occur, whether by mixing with other and reporting. Appropriate sampling, preparation and
samples or from the equipment itself. At best, these tainted samples handling protocols, together with well-chosen equipment,
are unusable – a waste of time and money. Worst case scenario can minimise uncertainty in the data.
they mislead your whole decision-making process.
Here is one estimate* of the amount of possible uncertainty:
With such high stakes, you need reliable sample preparation and
▪ Field sampling 10% to >100%
analysis equipment from a supplier who understands the challenges
▪ Storage and transport <1% to >100%
in the field. Which is why you need FLSmidth. Our long association
▪ Sample preparation and sub-sampling 10% to >100%
with the exploration industry ensures our products and services make
▪ Chemical preparation 5% to 20%
a positive impact in overcoming real-world geochemistry challenges.
▪ Measurement 1% to 10%
▪ Reporting <1%

Laboratory equipment for * Dr. Ed Paski, CMA 2005

exploration and mining operations
For over 30 years, we have led the way in engineering laboratory
sample preparation equipment. We pioneered the development of Safety by design
large-capacity pulverising systems using our unique bowl and disc All manual handling comes with risk. You can mitigate that risk by
grinding elements. Today our drying ovens, crushers and pulverising selecting equipment that is fit for purpose, safe to operate and
mills are used extensively on mine sites, exploration camps and in requires minimal maintenance. Our equipment is designed with these
commercial assay and research laboratories around the world. principles in mind: robust and reliable tools that cope with the rough
demands of mineral exploration job sites, while providing the
On the analysis side, our laboratory solutions provide precise testing accuracy required to guide good decision-making.
that gives confidence to mine exploration and development projects.
Readily transportable and relocatable containerised laboratories are Reliable data reduces exploration risk
a specialty, available fully-equipped and stocked if required. You can Mineral exploration isn’t a quick job. For every day the work goes
also make the most of the experience of our in-house laboratory staff, on, the cost goes up. Again, the onus is on the laboratory to provide
who help with all aspects of laboratory design. the information needed to get to work. Drill rigs have to be paid for,
whether they are being used or not. The quicker the turnaround on
We offer a total package of sample preparation, metallurgical testing sample analysis, the sooner decisions can be made on where to
and laboratory equipment solutions that cater to a full spectrum of drill next.

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 PROCESS: CONTINUOUS INSIGHTS The starting point of an efficient metal accounting
system is a precise understanding of the process
DRIVE OPTIMUM PRODUCTIVITY operations. It should rely on an accurate sampling
Your process moves fast. Can your lab keep up? Regular sampling and laboratory and measurement system".
analysis together with online solutions paints you the best picture of your product as it moves
through the process, giving you the data you need to drive efficiencies and save money.

Ore deposits are naturally occurring – they are bound to be irregular.

But with regular sampling and analysis, you can see those variations
coming and make the necessary adjustments accordingly. Whether that’s
ore coming from the mine or from the stockpile, it’s essential to know The importance of sampling –
exactly what you’re dealing with at all times to avoid pitfalls such as: copper process plant example:

▪ Low product quality At one copper process plant, the tails were sold to a
▪ Too high quality – using up the high-grade ore that shoud third party for treatment. This amounted to about 96,000
be used to extend the life of your mine tonnes of ore per day. Based on their calculations, the
▪ Process inefficiencies caused by unexpected plant assumed a tails grade of 0.15% copper, working out
material properties at about 144 tpd.
▪ Product forecasting problems
But after many years of making this assumption the plant
▪ Ore being misclassified as waste
installed a representative sampling station that revealed
the actual tails grade to be 0.2% copper, or 192 tpd.
Analysis that works as hard as your process The plant worked out that this difference in assumed
Process sampling has to be reliable to be effective. We use vs actual grade of copper cost them $105,600 per day.
specially designed equipment based on accepted sampling That’s $38.5 million per year for 20 years.
practises to extract samples throughout the process, preferably
The capex cost of a representative sampling system for
at points where there is a falling stream of product. This way,
tails stream? A comparatively meagre $500,000.
samples can be extracted quickly and easily from the full width of
the product stream using our linear or rotary samplers.

Our online analyser uses x-ray technology to provide continuous,

real-time elemental analysis of the slurry, ensuring you’re unlikely
to be caught unawares by changes in the process stream.
Benefits
Over in the laboratory, sample preparation and analysis is carried The benefits of representative sampling, best practice sample
out in our state-of-the-art automated laboratories. Automating these preparation and accurate analysis during minerals processing extend
tasks ensures that the sample bias is reduced, providing a solid basis beyond improved management of the process chemistry. You also
for monitoring and analysing process trends. The repetitive nature get a fuller understanding of your process, which makes it easier to
of analysis at this stage in the process is ideally suited to automated diagnose and solve problems as they arise, and to understand where
technologies, which deliver improved precision and reproducibility inefficiencies are occurring and what can be done about them.
while providing a full audit trail. Moreover, the results are calculated
quickly and precisely and reported automatically. Of course, All this process insight helps with overall communication – especially
automation also offers cost and capacity efficiencies, in addition to management, who are able to add this perspective to their
to safety benefits, compared with manual techniques. overview of operations and create a more informed flowsheet design.

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 PRODUCT: KNOW YOUR WORTH If the sampling is poor, the entire measurement
chain is corrupted at the outset – no amount of
Miscalculations can cost more than just money. If your product doesn’t meet the re-analysis can solve the problem".
required quality standards, you lose customer trust. On the other hand, if you are
underestimating your ore, you could be missing out on revenue. Representative sampling
and accurate analysis is the best way to ensure that everyone is getting a fair deal.

Our products and services have been designed to make a difference

in overcoming the challenges encountered every day at mining and
mineral processing operations, including:
Take this scenario as an example:
▪ Plant sampling
A manganese supplier is selling shipments at
▪ Sample transport
$7.50/1% Mn per tonne. With a shipment sold as 46% Mn
▪ Sample preparation with an acceptable variation of ±1% (i.e. 45.5 – 46.5%),
▪ Analysis that’s a value of $345/tonne. The supplier intended to
▪ Data collection and management supply 45.5% Mn, but due to sampling inaccuracies they
▪ Inventory management delivered 46.5% Mn. This 1% difference equated to a
$300,000 loss on one 40,000 tonne shipment.
▪ Sampling audits
This company was sending 50 shipments/year. If they
▪ Laboratory operation and maintenance were all 1% out, that’s a $15 million loss over the year.

The value of accuracy

With the high tonnage going through ports and railyards, it is critical
that you have a system in place that ensures the samples you are
analysing are truly representative. If you don’t, your buyers will. ▪ The accuracy of your mine plans
▪ Your knowledge of your resource basis
Best practice sampling ▪ The marketability of life of mine (LOM) products
Best practice involves firstly taking a representative primary sample ▪ The validity of your LOM project assumptions
from a conveyor. This is followed by degrees of subdivision, both in ▪ The reliability of supply
volume and particle size, to arrive at a manageable sample for
analysis that is representative of the original primary ore.
How can we help?
High tonnage sampling is our speciality. Our robust, reliable
We engineer complete sampling solutions to achieve this goal.
samplers are designed to withstand the rigours of fast-moving,
From small operators, to high tonnage mineral processing plants and
heavy and abrasive falling product. Sample collectors ensure samples
ore shipment loading, we have samplers suitable for all stages in your
are secure and contaminant-free for transport back to the laboratory,
process. Whether for primary, secondary, or tertiary sampling, or
where you have the choice of mechanical or automated size
further sample reduction, our sampling equipment is designed to
reduction and sample division technologies.
ensure the final sample presented for analysis is truly representative.
Of course, the discrepancy could work in their favour – but where
We also offer audits of your sampling systems and philosophy to
does that leave you? Out of pocket.
assist you with standards compliance and theory of sampling.
Operate with confidence
The more you know about your product, the more efficient your
operation will be. With accurate analysis, based on good quality,
well prepared samples, you can be confident in:

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 PROFIT. PERFORMANCE. PRODUCT. ■ 90% world share of robotic mining laboratories

WE UNDERSTAND ■ Largest robotic sample preparation and wet chemistry

laboratory in the world for Freeport

HOW ANALYTICAL DATA ■ Largest fully automated iron ore laboratory for BHP

IMPACTS YOUR BUSINESS ■ Largest laboratory automation project in the world,

sold to Anglo American. The size of a football pitch,
it includes 14 robots

You can trust us with your quality control chain. We have the equipment and the ■ More than 825 million tonnes of iron ore, 50% of the
expertise to deliver a solution that is tailored to your requirements. And having global export market, is shipped from Australian ports
designed and supplied many of the world’s biggest laboratories, we have the every year. The vast majority of this ore will be sampled
experience to support your laboratory projects. by Essa® mechanical samplers

You don’t need to be planning a world-first laboratory to come to

us. We support labs of all sizes and any age. If you’re concerned
about your existing laboratory operations, we can help. A lab audit
will identify any weak spots, enabling you to tighten up practises and
recalibrate equipment to get plant performance back on track.

A UNIQUE COMBINATION OF PRODUCTS, PROJECTS & SERVICES

PRODUCTS PROJECTS SERVICES

▪ Our robust samplers are Whether a greenfield or brownfield ▪ Audits on sampling systems
engineered and manufactured project, we have the solutions from and sampling philosophy
to conform to international sampling to analysis
sampling standards ▪ Assisting with standards
▪ Engineered, representative compliance and theory
▪ We’re pioneers of large sampling systems of sampling
capacity sample preparation
▪ Sample transport systems ▪ Audits on laboratories to
▪ We’ve developed practical to transport samples maximise the efficiency, quality
innovations in drying, automatically, safely and quickly and safety of your preparation
crushing and pulverising and analysis
equipment ▪ Manual laboratory
installations ▪ Operation and maintenance of
▪ We’ve designed online and laboratory automation systems
inline analysers to deliver ▪ Containerised laboratory
rapid process control data projects ▪ Training

▪ We offer specialist analytical ▪ Intelligent and flexible ▪ Spare and wear part supply
instruments and apparatus automated laboratory solutions
for the assay laboratory ▪ Installation, repair and maintenance

12 FLSmidth Sampling, preparation and analysis - Mining FLSmidth Sampling, preparation and analysis - Mining 13
OUR PRODUCTS
AND SOLUTIONS
Essa® Laboratory Equipment Automated Laboratory Solutions
We offer a total package of sample preparation solutions, including pulverising mills, bowl and Our automated laboratory solutions are designed to enhance quality and
disc grinding elements, crushers, dryers, sample dividers, XRF preparation and particle sizing reduce the health and safety risks associated with laboratory work. With the
equipment. We also design and supply metallurgical testing equipment and specialist equipment fast pace and high volume of minerals processes making it difficult for manual
and consumables for the assay laboratory. When it comes to thermogravimetric analysers, we laboratory operations to keep up, automation improves equipment utilisation
offer both automated and semi-automated options to suit your application. Our robust solutions and throughput, giving laboratories a way of working at speed, at high
cater to a full spectrum of requirements across the minerals industries. capacity, all while maintaining the highest possible quality control standards.
.
Essa® Dry Bulk Sampling Systems Automated laboratory solutions also provide a full audit trail.
To get a truly representative sample, it’s critical that your sampler’s cutter shape, positioning Intermediate steps are monitored, allowing for rapid troubleshooting,
and operation are designed so that every particle has an equal chance of being captured in a well as increased confidence in the accuracy of the analysis. Our remote
the sample. We engineer several different types of falling stream samplers to suit different flow asset management monitoring system further enhances performance and
sheets and applications, including linear and rotary samplers. Suitable for exploration, mining, maintenance optimisation. Finally – but importantly – occupational health
process plant, stockpiles and shipment loading and unloading, these samplers are designed and safety risks are reduced, as fewer manual handling steps are involved
for maximum uptime, minimal maintenance and a long life. with automated solutions.

Essa® Slurry Sampling Systems We take full responsibility for your entire laboratory automation project, from
Our range of slurry sampling solutions is well tested and proven to perform even in the most feasibility through conceptual design, to planning, installation, commissioning,
challenging of settings. And because we have complete flowsheet expertise, we take in all the full competency based training and handover.
important issues like material type, pipe routing, pump requirements, slurry flow, and sampler
location. With our specialist advice, you will have sampling systems positioned in exactly the Automating laboratory operations is not a “one size fits all” solution.
right place in your process to get the accurate results you need. Diverse commodities, different mineralogy, unique applications and specific
customer requirements all call for customised solutions.
PERI Online Slurry Analyser
TM

Our PERI Online Slurry Analysis System is a technologically advanced, customisable solution for We value the challenge to work with forward-thinking customers to engineer
your plant. The system uses the latest in x-ray technology to provide elemental analysis of the innovative bespoke automation projects covering almost every industry from
slurry and can handle 4 – 6 streams with a single multiplexer and up to 12 by adding a alumina to zinc. We’ve been doing it successfully for over 30 years.
second multiplexer.

Essa® JC1250 Jaw Crusher

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 Digital services. Further optimising
laboratory performance

▪ 24/7 remote equipment and

lab-wide monitoring
CUSTOMER STORY
▪ Global visibility anytime, anywhere on
any device

LAB AUTOMATION
▪ Proactive asset health monitoring –
minimising unplanned interruptions to
sample processing

DRAMATICALLY ▪ Maximise uptime – improved overall

equipment availability

REDUCES HEALTH
▪ Sample load optimisation – balancing work
load and wear between equipment

AND SAFETY RISKS

▪ Empowering fast, informed decisions –
confidently

▪ Early equipment fault detection –

help prevent catastrophic failures

▪ Cost effective maintenance –

profitability through reliability

▪ High quality diagnostic services

At a nickel laboratory in Australia,
lab employees would spend their days ▪ Optimised spares inventory
and nights preparing and analysing ▪ Scalable and fully flexible
samples. Working in shifts, they
completed analysis of 250 samples per
day. With the repetitive workload taking
Defining the project its toll on staff health, management
When it comes to laboratory automation, FLSmidth is a world leader. decided to investigate automated
The customer had done their research and came to us to see
laboratory solutions.
how we could help create a better working environment in their
laboratory. Together with the lab team, we embarked on a
six-week pre-feasibility study that culminated in a proposed
solution to design, build, install and commission five automated
laboratory preparation and analysis modules. This would both completed automatically. The module even includes an automated
eliminate the manual handling of potentially dangerous chemicals test tube sorter to eliminate the repetitive job of loading test tubes
and increase the sampling capacity of the lab. into position. Two analytical modules are in situ that are capable of
analysing all existing plant samples and future samples at a rate of
The solution up to 1200 samples per day – far surpassing the previous
The new lab includes highly innovative equipment, such as the 3D testing capacity.
particle sizer, which takes a photo of every nickel powder particle
and uses 3D imagery to calculate sizing distribution. Liquor The results
processing and powder preparation are taken care of without any The automated laboratory has delivered the health and safety
need for operator intervention. The digestion module uses benefits the lab team wanted – and more. With the increased
engineering controls to manage the process of using chemicals sample processing capacity, the customer has the ability to increase
and heat blocks to dissolve the nickel in solution. A robot dispenses the recovery of nickel and cobalt and reduce ammonia consumption.
the acids and handles all flasks from the point of entry until the task The plant is also well equipped to expand and diversify, given the
is complete, so there is no risk to the operator. Wash downs are also capacity and capabilities of its new laboratory.
 

16 FLSmidth Sampling, preparation and analysis - Mining FLSmidth Sampling, preparation and analysis - Mining 17
 Laboratory Equipment (Essa®)
Make the most of
your sample – our ▪ Electric and infrared
drying ovens
experience, combined ▪ Jaw crushers
with specialised ▪ Rolls crushers
▪ Manual and automated
equipment, systems, pulverising mills
2 2
software and service, ▪ Pulverising mill bowls
▪ XRF and XRD presses
provides a pathway to ▪ XRF bead fusion systems
superior analysis. ▪ Sample dividers
1
▪ Automated particle
size measurement 1
▪ Test sieves and
sieve shakers
▪ Thermogravimetric
Our extensive chemical and analysers
mineralogical knowledge, in-house ▪ Flux weighing, dosing
and mixing devices
laboratories and process expertise
▪ Fire assay flux mixing,
help you achieve:
multiload and
multipour systems
▪ Accurate and timely results
▪ Crucibles and cupels
▪ Improved quality and
traceability ▪ Foundry crucibles
▪ Superior hazard ▪ Ball and rod mills 4
management ▪ Bottle rollers
▪ Standards compliance ▪ Certified pressure filters
▪ Seamless integration ▪ Flotation test machine

We know what, where and Online Analysis 5

how to sample successfully. ▪ Sample multiplexers
When integrated with our ▪ Slurry analyser
automated laboratory solutions,
▪ Bulk material applications 6
we take your quality control and
productivity to a new level Laboratory Automation
of excellence.
▪ Laboratory information
Bulk Commodity Sampling (Essa®) management systems
▪ Automated sample
▪ Linear falling transport systems
stream samplers ▪ Automated sample
▪ Rotary falling stream samplers preparation systems 3
▪ Cross belt samplers ▪ Automated wet
▪ Sampling system dryers chemistry systems
▪ Sample collectors ▪ Automated analysis
▪ Sample feeders and size
1. ROTARY SAMPLE COLLECTOR
reduction equipment Life Cycle Services
2. BALL SCREW LINEAR PRIMARY AND
▪ Sampling stations
▪ Project solutions
▪ Performance monitoring SECONDARY SAMPLERS
▪ Remote service
technologies 3. BELT DRIVE LINEAR PRIMARY SAMPLER
Slurry Sampling (Essa®)
▪ Training courses
▪ Metallurgical accounting ▪ Spare and wear part supply 4. SYNCHRONOUS BELT DRIVE LINEAR
samplers ▪ Installation, repair PRIMARY SAMPLER
▪ On-line analyser samplers and maintenance
▪ Linear and rotary falling ▪ Commissioning services 5. BALL SCREW LINEAR
stream samplers ▪ Sampling system audits SECONDARY SAMPLERS
▪ Shark fin static cutters ▪ Laboratory audits
▪ Pressure pipe samplers ▪ Laboratory operation 6. AUTOMATED SIZE FRACTION AND
▪ Project solutions and maintenance services MOISTURE ANALYSIS LABORATORY

18 FLSmidth Sampling, preparation and analysis - Mining FLSmidth Sampling, preparation and analysis - Mining 19
 TOWARDS ZERO EMISSIONS IN MINING

Zero water Zero Zero energy

waste emissions waste

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FLSmidth A/S
Vigerslev Allé 77 Tel: +45 3618 1000
DK-2500 Valby Fax: +45 3630 1820 Copyright © 2020 FLSmidth. ALL RIGHTS RESERVED. FLSmidth and Essa are (registered) trademarks and
PERI is a trademark of FLSmidth. This brochure makes no offers, representations or warranties (express or
Copenhagen E-mail: [email protected] implied), and information and data contained in this brochure are for general reference only and may
change at any time.
20 FLSmidth Sampling, preparation and analysis - Mining