FLSmidth

We appointed a project manager, and it quickly became clear to him and his team that this was not a typical project. Unlike projects with clear requirement specifications, this was an innovation project focused on new development, where both the challenges and solutions were unknown from the outset. This made Kirkholm’s role unique—not only to develop the solution but to drive the innovation process by exploring, defining, and shaping the task itself.

Our project team maintained continuous dialogue with FLSmidth to address the evolving needs of the innovation project. By December 2022, concept development was progressing well. Kirkholm played a pivotal role in driving the process forward, especially when questions arose that neither FLSmidth nor DTI could fully answer. This phase highlighted our ability to navigate projects with inherent uncertainty, where the solutions were still being discovered, all while maintaining momentum and ensuring steady progress.

One of the first major milestones was aligning expectations with FLSmidth. Given the innovative nature of the project, it became clear early on that a fixed requirement specification was not feasible. In response, Kirkholm adapted its project model to embrace an agile and iterative approach, allowing flexibility in navigating the unknowns. Designers and engineers took on a range of roles—from design and construction to supplier coordination—ensuring that the project-maintained momentum despite ongoing uncertainties.
A prototype was developed, built, and tested in Denmark, serving as a significant turning point. It provided tangible proof of concept and demonstrated process-optimized functionality for full-scale production. Throughout the project, new customer requests were incorporated, highlighting the dynamic, evolving nature of the work. The team’s ability to remain flexible and adjust to emerging requirements was crucial to the project’s success – as it always is in innovative projects.

The project centered on the pyrolysis process, which separates steel and rubber by heating. But to turn the concept into a reliable machine would require innovative mechanical engineering and process optimization.

Kirkholm’s design featured a range of modular systems to facilitate separation. The machine was required to handle two distinct types of work pieces. Through close collaboration with suppliers and partners, Kirkholm created a solution that was both robust and ready for the future. 

The project required a broad set of competencies, ranging from project management and conceptualization to mechanical design, CFD simulations, and supplier coordination. This resulted in a multidisciplinary approach that provided great value to FLSmidth and the project. With a single point of contact, FLSmidth had easy access to all information and quick communication. Kirkholm streamlined solutions across disciplines, ensuring seamless integration, reducing complexity, and taking full responsibility for both challenges and delivering optimal results. It demonstrated our ability to take on end-to-end development tasks, even when the initial scope was undefined. The agile project approach and the adaptability of the team proved critical to the success of the development process.

Effective communication is essential, when you deal with a complex project. To bridge the gap between design and understanding, Kirkholm used Virtual Reality (VR) technology. VR models allowed FLSmidth and partners to visualize the machine’s structure and functionality, enhancing their grasp of the project’s scope and potential. By visualizing the machine in VR, Kirkholm made it easier for key stakeholders, such as electrical engineers, to understand their roles and requirements during the assembly process.

One of the most valuable insights from this project was the importance of defining the task itself — and how to do so in collaboration with FLSmidth. Without a formal requirement specification, Kirkholm’s engineers took the lead in shaping the project’s direction, a process that required flexibility, patience, and technical excellence. By doing so, Kirkholm showcased our capacity to handle the unknown and guide our customers through unknown territory.

“In a sense it seems like there are other customers who also struggle to define the task. They might know they need help, but they can’t quite figure out the path. They need help and guidance in defining the right direction. I think that’s been a fun journey to be part of, and just shows me what I already knew, that Kirkholm also can comprehend other projects, where no clear requirement specification has been made yet”

The above quote is from Jens Halsøe, reflecting on the project process and the absence of formal requirement specifications. Initially, he served as the conceptual designer and later took on the role of project manager.

The potential for future projects with FLSmidth has already been established as the case highlights both technical excellence and Kirkholm’s role as a strategic development partner, from concept to machine delivery. And as recycling and sustainability grow in importance within the mining industry, the value of such solutions will increase.

With the second version of the machine taking its baby steps in development and a deeper understanding of the customers’ needs, Kirkholm is well positioned to support similar projects. This case highlights both technical excellence and Kirkholm’s role as a strategic development partner, from concept to machine delivery.