FLSmidth Secures Landmark $54 Million Order for Major Copper Expansion in Chile

In a significant development for the global mining equipment sector, Danish engineering giant FLSmidth (FLS) has announced a substantial order valued at approximately $54 million (DKr360 million) to supply crushing and grinding equipment for a major copper mine expansion project situated in northern Chile. This pivotal contract, booked in the third quarter of 2026, underscores the continued investment in large-scale, high-efficiency mineral processing technologies to support the burgeoning demand for critical minerals.

The agreement positions FLSmidth to deliver a comprehensive suite of key machinery, including what will be the world’s largest gyratory crusher and several large-scale mills. This suite of equipment is central to the comminution circuit of modern copper operations, designed to process vast quantities of ore with enhanced energy efficiency and reliability. The long-term nature of such projects is evident in the planned installation and commissioning schedule, which is set for late 2029 and early 2030, reflecting the meticulous planning and extensive lead times inherent in major mining expansions.

Technical Prowess: Advanced Comminution for High-Capacity Operations

The core of FLSmidth's order for the Chilean copper project lies in its provision of cutting-edge comminution equipment, meticulously engineered for high throughput and optimal performance. The scope of supply details several flagship machines, each representing a significant advancement in mining technology:

• World’s Largest Gyratory Crusher: Central to the primary crushing stage, FLS will deliver a 1,600 × 3,300 TSUV gyratory crusher. This colossal machine is equipped with a powerful 1,500kW motor and features a self-aligning main shaft assembly. Gyratory crushers are indispensable in modern large-scale mining operations, responsible for the initial reduction of run-of-mine ore to a size manageable for downstream processing. The sheer scale of this unit signifies the project's ambitious production targets and the need for robust, high-capacity primary crushing capabilities.
• Large-Scale Grinding Mills: The order includes one 40ft × 29ft semi-autogenous grinding (SAG) mill and three 28ft × 48ft ball mills. These mills are critical for the secondary and tertiary stages of comminution, further reducing the ore particle size to prepare it for mineral separation processes. The combined installed power of these mills exceeds 90MW, highlighting the massive energy requirements for comminution and the scale of the processing plant.
• Advanced Mill Technologies: The mills will incorporate several innovative features designed to maximize efficiency and operational longevity. These include gearless mill drives, which offer superior reliability, reduced maintenance, and improved energy efficiency compared to traditional geared systems. Furthermore, the mills will be fitted with FLS Armor mill liners, known for their enhanced wear resistance, which translates to extended operational uptime and reduced replacement costs. The inclusion of the latest self-aligning main bearings further contributes to the mills' reliability and ease of maintenance.
• Record-Breaking Components: Adding to the technical impressive array, the package also features the largest SAG mill trommel screen supplied by FLS to date. Trommel screens are crucial for separating finer materials from coarser ore exiting the SAG mill, ensuring optimal feed for the subsequent ball mills. Additionally, the three 28ft × 48ft ball mills will be the largest of their kind to be installed in Chile, underscoring the project's ambition to set new benchmarks in operational scale within the nation’s copper industry.

Beyond the core machinery, the contract also encompasses commissioning services and a comprehensive one-year supply of operating spare parts. This inclusive approach is vital for ensuring a smooth start-up phase and sustained operational continuity during the initial critical period of the mine expansion.

Strategic Partnerships and Project Execution

The successful execution of large-scale mining projects like this copper expansion in Chile hinges on strong collaboration between equipment suppliers, mine owners, and engineering, procurement, and construction (EPC) contractors. FLSmidth's involvement extends beyond mere equipment delivery, as the company is coordinating closely with the project’s EPC contractor. This collaboration is essential for seamlessly integrating FLS's specialized equipment and technical expertise into the overall project design and ensuring adherence to complex timelines.

Qasim Abrahams, FLSmidth Products Business Line President, emphasized the significance of this collaborative approach: "This significant order reflects the trust placed in our proven crushing and grinding technologies. Working closely with our customer and the EPC contractor, we are bringing together our process expertise and equipment technologies to support reliable, energy-efficient performance and maximise productivity throughout the life of the operation." His statement highlights not only FLSmidth's technological capabilities but also its commitment to acting as a strategic partner, leveraging its deep process knowledge to optimize the entire mineral processing circuit for the mine owner.

FLSmidth’s reputation in the industry is built on a long history of supporting mineral processing operations globally, particularly with high-throughput, large-scale equipment. Their specialization in crushing and grinding technologies makes them a preferred choice for projects demanding robust and efficient comminution solutions, especially for base metals like copper where economies of scale are paramount.

Chile's Enduring Role in Global Copper Supply

This investment in northern Chile further solidifies the nation's unparalleled position as the world's leading copper producer. Chile’s vast mineral endowment, particularly in copper, has historically made it a cornerstone of global supply. With increasing global demand for copper – driven by the accelerating transition to renewable energy sources, electrification of transportation, and widespread infrastructure development – expansions of existing operations and development of new mines are critical.

Copper is an indispensable metal for the modern economy. Its exceptional electrical conductivity makes it vital for wiring, electronics, and electric vehicles, while its thermal conductivity is essential for heat exchangers. The push towards decarbonization mandates a significant increase in copper supply, making every major expansion project, such as the one FLSmidth is equipping, a crucial component in meeting future industrial needs. Projects in Chile benefit from established mining infrastructure, a skilled workforce, and a supportive, albeit increasingly stringent, regulatory environment.

The Drive for Efficiency and Productivity in Modern Mining

The specifications of the equipment supplied by FLSmidth reflect broader industry trends emphasizing efficiency, productivity, and sustainability. The deployment of the world's largest gyratory crusher and record-setting grinding mills speaks directly to the mining sector's pursuit of economies of scale. Larger equipment generally allows for higher throughput rates, which can significantly reduce operating costs per tonne of ore processed, thereby enhancing the economic viability of projects dealing with lower-grade ore bodies.

Furthermore, the focus on energy-efficient solutions, such as the 1,500kW motor on the crusher, the substantial combined power of over 90MW for the mills, and particularly the gearless mill drives, addresses both operational cost control and environmental stewardship. Energy consumption in comminution circuits accounts for a significant portion of a mine's total power usage, making any advancements in efficiency critical. Reliable performance, facilitated by features like self-aligning main bearings and durable FLS Armor mill liners, translates directly into increased operational uptime and reduced maintenance expenditures, which are key performance indicators for any mine manager.

Long-Term Vision and Future Outlook

The timeline from order booking in Q3 2026 to commissioning in late 2029/early 2030 underscores the inherently long-term nature of investments in the mining sector. Such a lengthy project cycle necessitates a robust long-term vision from both the mine owner and its technology partners, demonstrating confidence in future commodity prices and sustained global demand for copper.

For FLSmidth, this order reinforces its market leadership in providing advanced comminution solutions for large-scale operations, particularly within the vital Latin American mining landscape. It serves as a testament to their engineering capabilities and their strategic focus on developing equipment that meets the evolving demands of the industry for higher capacity and greater efficiency. For the unnamed copper mine, this expansion project is poised to significantly increase its production capacity and enhance operational efficiencies, securing its future contribution to the global copper supply chain. This substantial investment not only bolsters Chile’s mining economy but also plays a critical role in supporting the broader global transition towards a more electrified and sustainable future.