Stabilising copper processing in Zambia with Valmet’s Neles NDX positioners
After years of battling unreliable valve control and frequent breakdowns with previously installed positioners, a mine site on Zambia’s renowned copperbelt has found a solution that could withstand the conditions.
Copper 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.
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, Valmet says. The retrofit solution, complete with custom mounting brackets and 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, according to the company.
The immediate results Valmet claimed included:
- 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; and
- Enabled rapid return on investment as the customer ordered 10 additional units immediately.
What set this success apart was not just the product, but the partnership, Valmet says. Led by Valmet’s Sub-Saharan Africa team and supported by the on-ground expertise of Frasmac Limited, the project was marked by close collaboration, technical clarity and swift execution.
Valmet said: “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 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 Flowrox pinch valves in various sizes, Neles ND9 and ND7 controllers and valves, as well as Jamesbury and Neles Easyflow 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, according to Valmet.
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