How the Neles NDX positioner stabilized copper processing in Zambia
In the rugged terrain of Zambia’s Copperbelt province near Kitwe lies one of Southern Africa’s most productive copper mines. Operated by a multinational mining group, this major producer runs a large flotation plant that has long faced a critical challenge common in the region: valve control instability under severe operating conditions.
A process under pressure
Copper ore extraction is just the beginning. The ore must undergo a demanding flotation process involving aggressive chemicals, high humidity, dust, and intense vibration. In this environment, actuators and valve positioners are vital for maintaining stable flow control and pressure. Any instability leads to lost recovery, reduced output, and increased costs.
Unfortunately, the site experienced repeated breakdowns with previously installed positioners. Despite trying multiple brands, none withstood the harsh conditions long enough to ensure consistent plant performance.
A smarter, more resilient alternative
After years of battling unreliable valve control and frequent breakdowns, the site needed a solution that could truly withstand the Copperbelt’s harsh conditions. The turning point came when Valmet’s flow control team, in collaboration with distributor partner Frasmac Limited, introduced a tailored upgrade: the Neles™ NDX™ intelligent valve controller.
With its contactless magnetic position sensing and industry-leading vibration resistance, the Neles NDX valve controller delivered a new level of performance. The retrofit solution, complete with custom mounting brackets and expert installation support, proved not only technically superior but also operationally transformative. It turned an unstable, maintenance-heavy process into a reliable and efficient operation with zero unplanned interruptions.
Immediate results
- Improved process stability across the entire flotation circuit
- Reduced air consumption thanks to the NDX controller’s efficient pneumatic relay
- Eliminated unplanned failures or breakdowns
- Enabled rapid ROI as the customer ordered 10 additional units immediately
Customer confidence built on collaboration
What set this success apart was not just the product, but the partnership. Led by Valmet’s Sub-Saharan Africa team and supported by the on-ground expertise of our valued channel partner Frasmac Limited, the project was marked by close collaboration, technical clarity, and swift execution.
Together, the team helped the customer move from reactive maintenance to predictive stability. The mining group now considers us a trusted valve automation partner for future upgrades across other sites.
In one of the continent’s most challenging industrial environments, Valmet’s Neles NDX positioner has proven that smart design, deep industry knowledge, and localized service can deliver not just better valve performance, but better business performance.
Valmet flow control portfolio at the Zambian copper mine
In addition to the Neles NDX intelligent valve controller, the customer operates a wide selection of Valmet flow control products tailored for demanding slurry and process conditions. These include FlowroxTM pinch valves in various sizes, Neles ND9 and ND7 controllers and valves, as well as JamesburyTM and Neles EasyflowTM ball and butterfly valves.
Together, this comprehensive flow control portfolio supports the copper mine’s long‑term reliability and ensures consistent performance across its most demanding process areas, providing a solid foundation for future upgrades.
For more information, contact Sugeshan Pillay, sugeshan.pillay@valmet.com, Regional Sales Manager, in Sub Equatorial Africa at Valmet Flow Control business line.
Sugeshan Pillay
Regional Sales Manager, Valmet Flow Control business line
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