FlowSense
FlowSense
FlowSense detects ore handling deterioration in real time and enables proactive feedrate control before your plant begins to choke.
FlowSense continuously monitors ore flowability, cohesion and moisture behaviour across your processing plant, converting uncertain, reactive operations into measured, predictable, real-time intelligence. Find out how FlowSense can help you maintain stable throughput during below-water-table ore campaigns.
Ore Handling Intelligence for Processing Plants.
In iron ore processing, below-water-table ore is wet, cohesive, and notoriously difficult to handle. Sticky fines, chute buildup, hopper arching, screen blinding and surge bin ratholing can cause progressive throughput collapse — yet operators typically discover these problems only after the plant starts to choke. The challenge of managing unpredictable ore behaviour with delayed lab samples and conservative feedrate margins leaves significant production capacity on the table.
FlowSense offers an unparalleled approach to ore handling intelligence, continuously estimating flowability, bulk density, moisture behaviour, cohesion and segregation patterns in real time. This allows operators to understand how ore is behaving before handling problems develop — enabling dynamic feedrate optimisation that keeps the plant operating closer to its true capacity.
Stable Throughput.
Even with Difficult Ore.
At the heart of FlowSense is real-time ore characterisation. Unlike traditional approaches that rely on delayed lab results and operator experience, FlowSense provides continuous, objective measurement of ore handling quality — detecting the early stages of cohesion increase, clump formation and flow irregularity that precede chute blockages, crusher chokes and throughput collapse. Plants can safely increase feedrate when ore is flowing well, and proactively reduce it before difficult ore causes problems.
Yet FlowSense’s impact extends far beyond reactive problem avoidance. By introducing a new operational KPI — Material Handling Quality — FlowSense builds a quantitative foundation for better blending decisions, improved mine planning, predictive throughput modelling and long-term plant design optimisation. Over time, FlowSense creates an operational intelligence database linking ore types, moisture, particle distribution and plant performance, transforming ore handling from a reactive problem into a measurable and controllable process.
Case Studies
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Real-time ore handling intelligence and proactive feedrate control.
Unlock stable processing operations with FlowSense’s real-time ore handling intelligence and proactive feedrate control. Experience continuous visibility into ore flowability, cohesion and moisture behaviour across your entire processing plant — enabling 3–10% throughput improvement without capital expansion, reduced unplanned downtime from material handling failures, and confident operation during below-water-table ore campaigns.
