New FLS KREBS® OSA Determines Particle Sizes Directly in Process Stream

Why It Matters

Real‑time particle size data enables immediate circuit tuning, cutting energy waste and boosting flotation or leaching recovery. The subscription model lowers financial barriers, accelerating adoption of digital monitoring in mineral processing.

Key Takeaways

• Real-time OSA measures particle size up to 4 mm directly in stream
• Intrusive vibration sensor eliminates manual sampling and reduces human error
• Integration via OPC UA and Modbus TCP enables live process trending
• Subscription model removes upfront CAPEX, includes installation and support
• Continuous data helps prevent over‑grinding, saving energy and improving recovery

Pulse Analysis

Traditional mineral processing plants rely on periodic manual sampling and laboratory analysis to gauge particle size distribution. Those methods are labor‑intensive, prone to human error, and can take hours to return results, creating a blind spot in grinding circuit performance. As ore grades become more variable and energy costs rise, operators are seeking faster, more reliable data streams to maintain optimal throughput and product quality.

The newly introduced KREBS® OSA addresses these challenges with an intrusive, pulse‑based vibration sensor that sits directly in the mass flow. Each particle impact generates a measurable signal that advanced algorithms translate into a full size‑distribution profile in real time. The analyser supports customizable size ranges up to 4 mm and feeds data through OPC UA or Modbus TCP, allowing seamless integration with existing control systems for live trending and historical analysis. By eliminating the need for manual grab samples, the OSA reduces operator exposure, cuts sampling errors, and provides continuous insight that can be acted upon instantly.

Beyond the technical advantages, FLSmidth’s subscription offering removes the traditional capital expense hurdle. Customers receive installation, calibration, software licensing, spare parts and field service under a predictable, fixed‑price model, with options for monthly or multi‑year terms. This aligns costs with budgeting cycles and accelerates digital adoption across the mining sector. The combination of real‑time visibility, energy‑saving process control, and a low‑risk financial structure positions the KREBS® OSA as a catalyst for higher efficiency, safer operations, and improved ore recovery in a competitive market.