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Customer story

Efficiency gains at Sukari Gold Mine: How FLS delivered a faster, safer crusher upgrade

Centamin’s Sukari Gold Mine (SGM) in Egypt is one of the world’s largest gold-producing operations. To keep production high, every piece of equipment must run at peak performance. When SGM noticed their primary gyratory crusher was losing efficiency, they knew they needed a partner who could provide more than just a quick fix. They needed a long-term solution that would increase reliability and keep their people safe.

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The challenge: Overcoming mechanical roadblocks

SGM faced several serious technical issues with their 1400 x 2100 TS Gyro crusher that threatened to halt production. The primary problems included:

  • Structural damage: Two of the four foundation bolts holding the massive machine in place were broken.
  • Part failures: The countershaft was failing prematurely, and a crack had formed in the main hub of the bottom shell.
  • Wear and tear: The existing spider shields did not cover all areas, leading to fast wear on expensive components.

Centamin decided to replace the bottom shell rather than repair it to ensure future reliability. As the Original Equipment Manufacturer (OEM), FLS was the natural partner to lead this complex upgrade.

The strategy: Planning for a precision shutdown

To minimize the impact on gold production, we set an ambitious goal: a full shutdown and replacement in just 11 days. Our team of specialists worked side-by-side with SGM to plan every minute of the work.

We didn't just provide parts; we provided a complete roadmap for success. Our plan included:

  • Detailed resources: A full list of labor, tools, and equipment to avoid any last-minute delays.
  • Expert oversight: We sent a Lead Product Service Specialist and two field service engineers to guide the onsite teams.
  • Modular innovation: We designed custom lift lugs to move the crusher shells in large sections. This allowed us to remove the entire crusher in less than 24 hours so repair work on the foundation bolts could start immediately.

Innovation in action: Custom solutions for safety and speed

Our dedication to customer success means finding ways to work smarter. For this project, we introduced several purpose-built tools:

  • Custom maintenance stands: We gave SGM plans to build stands that allowed easy, safe access to crusher parts once they were removed.
  • Safe assembly tools: Special brackets allowed the team to assemble the hydroset to the bottom shell outside the crusher building, reducing congestion and risk.
  • The "wrap around" Spider shield: SGM became one of the first sites to use our new spider shield design. Unlike old models, this design wraps around the entire component, stopping wear before it starts and saving the mine significant money on replacement parts.

Increase throughput and availability with the latest upgrades for your gyratory crusher

Upgrades, rebuilds and exchange for crushers

The impact by the numbers:

  • Time saved

    The project finished 38 hours earlier than the 11-day target.

  • Safety record

    Zero safety incidents. As the team noted, not even a "Band-Aid" was required.

  • Operational gain

    The crusher returned to full feed ahead of schedule, protecting the mine’s production targets.

We are so appreciative of FLS' support throughout this project. The collaborative approach resulted in excellent execution from both teams and all works were carried out in a safe manner and completed 38 hours ahead of planned time.

Amr Houssana, Sukari General Manager, Centamin

Commitment to growth

This project was about more than just hardware. During the shutdown, the SGM crushing crew received hands-on, on-the-job training from our engineers. This transferred vital knowledge to the local team, ensuring they have the skills to maintain their equipment for years to come. At FLS, we don't just solve the problem of today; we innovate to ensure your success tomorrow.

Contact us today for expert crusher upgrades, retrofits, and exchanges

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