What is the most efficient way to reduce particle size in mining engineering?

The most efficient way (and cost effective) to make big rocks into little ones is by blasting. Achieving the correct fragmentation profile in the blast is the first step in an efficient and effective downsteam process. Load and Haul is affected signficantly by the fragmentation and this is where the most cost is incurred in open pit mining. And just because the waste is not processed further this is no excuse to neglect the fragmentation parameters. The ore blasted to an optimal size can reduce the downstream throughput, maintenance cost and energy requirements.

Blast it right in the first instance. Good drill and blast practices. Calibrate the blast energy to the rock properties through effective design to achieve the desired fragmentation. This results in less crushing, better haulage and eventually higher mill throughput.

The efficiency to reduce the particle size should start at design stage by using established mining software. The engineers should run simulation blast and do small trial blast. Once this stage is successful, the next critical stage is the quality control and amylases. The holes must be drilled to designed depth, burden, spacing and changing. Understanding the geology of rock is very critical before the above stages are implemented.

Most efficient way to reduce particle size is through Blasting. Generating a fragmentation profile most suitable for downstream operations can significantly improve entire value chain.

One of the most efficient methods is mechanical comminution. This method involves the use of mechanical forces to break down large particles into smaller ones. Mechanical comminution can be achieved through dry milling, wet milling, and high-pressure homogenization. Another method is precipitation, which involves the use of dissolution in an appropriate solvent . However, this method is not as efficient as mechanical comminution. The choice of method depends on several factors such as the type of material being processed, the desired particle size, and the equipment available. It is important to choose the right method to ensure that the process is efficient and cost-effective.

The blasted ore can be broken by rock breakers before the primary crushers. This can be done at ore pass screens or at screens before the crusher pits

The comminution process is not just jaw, ball, cone, or any other impact crusher type. Small-Scalers can often use traditional methods like hammer and chisel versus advanced techniques like pneumatic or hydraulic hammers, expansion agents, homemade blasting, or even natural processes like weathering or fire on rock depending on factors such as the scale of the operation, desired results, safety considerations, and environmental impact. Traditional methods may be suitable for small-scale operations. Larger-Scale projects benefit from mechanized or controlled techniques, considering efficiency and safety measures with sophisticated techniques and blasting or hammering. Not sure if the article implying crushing happens at the extraction.

By definition primary comminution is applied to the feed from the mining face. Arguably, that feed is a product of the blasting practices and so what is labeled "primary" is actually the second step in size reduction of particles. Primary comminution is any mechanical means of reducing raw feed from the mining operation to a consistent size/consistency for further sizing (grinding) or processing.

The first process to reduce the size of big blasted rock received at the plant from the mine and prepare these rocks to the next stage of reduction, which is secondary crushing. Huge crushers like jaw and gyratory crushers are the most common machines for this purpose. It is also important to notice that, in this primary process, some fines, soil, by-products or contamination, are removed from the flow of the plant at this stage, so the material after the primary comminution is more pure and clean.

La communition primaire représente l'étape de concassage primaire qui vise à réduire la granulométrie des matériaux en utilisant un concasseur à mâchoires, à percussion... La taille des particules étant toujours grossière devra nécessiter une autre étape de réduction granulométrique.

I will add that small-scalers can sometimes use agricultural grinders (like corn grinders) for small amounts of colluvial and hardened clay-like materials. The smaller pebbles or fragments type will go under a several ton metal rock wheels, guillotine type drop hammers, and fire.

The steps involved in the mining procedure and the final extraction of minerals, make the process simple yet powerful. However, with large-scaled mining locations, the classification of beneficial ores, has been a tedious task. Advances in Geo-Navigation and small-data computing has helped to identify the type and density of ores

The steps involved in the mining procedure and the final extraction of minerals, make the process simple yet powerful. However, with large-scaled mining locations, the classification of beneficial ores, has been a tedious task. Advances in Geo-Navigation and small-data computing has helped to identify the type and density of ores

After the first reduction of size, the second process of the plant is the secondary reduction, which afines the final product, reduces the size of rock including the production of sand, or prepares the material for more size reduction and next stages. The selection of the secondary crushers are very influenced by the abrasiveness of the materials, using impactors for low content of silica, and cone crushers for high, as the most common. There is also an autogenous crushing provided by the Vertical Shaft Impactors, where the crushing is made rock against rock, and very recommended for abrasive rocks too. This type of crushers are more used in the tertiary crushing.

Le broyage secondaire est un processus qui vise à réduire le minerai à la taille micrométrique. Il est réalisé au moyen de broyeurs notamment les broyeurs à boulets... Cela a pour objectif d'atteindre la maille de libération du minerai pour permettre un récupération optimale lors du traitement chimique comme la lixiviation en tas, en cuve...

A Jig is a density separation method where very dense materials will fall out of the general flow of material. I have seen native copper and gold recovery in jigs between the primary crusher and grinding or between grinding steps.

I believe it all starts at the face from drilling and blasting. Proper and desired fragmentation should be achieved at the face so that the other processes follow smoothly and we reduce power and wear costs due to oversize materials proceeding to the plants.

The most efficient way to reduce particle size often involves a combination of comminution methods like crushing or grinding, depending on the materials. For classification, small-scale operations might use basic screening methods. Large-scale operations could employ more advanced equipment like hydro-separators or classifiers to achieve higher precision in separating particles based on their properties. Small-scale miners may face limitations due to budget constraints, opting for more straightforward, cost-effective screening methods. Large-scale operations can invest in sophisticated equipment, enabling finer control over particle separation and ensuring optimal efficiency.

Classification plays a crucial role in ore beneficiation and makes the extraction of economically viable and valuable minerals not only easier but also ensures they are of the desired grade.

Good drilling to fix the appropriate burden and spacing together with timing and the right choice of explosives assure excellent fragmentation and good blasts, making the life easier to the next processes of loading, hauling, crushing and screening. Cost reduction and profitability of mining and plant operations are assured with an optimum fragmentation from blasts. A good maintenance assures the plant running efficiently, but the good size of rocks assures a high availability of the plant and less repairs. The right selection of key parameters to operate, which includes fixing the crusher setting, flow capacity, size of machineries, screening area, ….. optimises the operation of the plant.

The scale dictates the complexity and extent of optimization measures, but the fundamental principles of considering ore characteristics, process objectives, and equipment details apply across scales. Small-Scale Mining Due to resource constraints, optimizing comminution and classification will involve more straightforward equipment choices—essential crushers and screens focusing on cost. Large-Scale Mining These operations will invest in more advanced and efficient machinery, allowing precise control over particle size reduction and classification processes.

Desde mi punto de vista lo principal es tener el conocimiento adecuado del tipo de yacimiento (por lo gral se tiende a usar la misma tronadura, carguio, etc de igual manera todas las faenas que es el inicio del error). Posterior a esto es optimizar las mallas de perforación para obtener una buena fragmentacion y hacer un uso eficiente de la energía el resto ya es avanzar en cada etapa del proceso hasta llegar al destino asignado

The choice of a crusher, whether primary or secondary, should be based on the aforementioned properties of the ore(hardness, abrasiveness, coarseness etc) to avert consistent breakdowns over time and loss of useful working hours. Moreover, while emerging technology now produces new crushers that can skillfully combine the functions of primary and secondary crushers at a go, careful consideration needs to be taken to ensure that the material's hardness falls within the acceptable capabilities of the crushers.

I disagree, comminution can't be the most effective way to size reduction in mining engineering. Due to the following reasons. a. The sizes of the particles needed in mining engineering is way larger that what comminution is providing hence it will be time consuming for the specific size to be achieved hence render the operation uneconomical. b. The amount of waste materials in a mining operation is quite enormous thus if it was to be separated on-site using comminution methods a lot of energy will be required to achieve that hence it will be uneconomical. c. The productivity of the mining operation will be reduced if commination is to be used as the primary method of size reduction due to the vast amount of materials to be excavated....

Reduction of Particle Size in Mining Engineering for me, begins in the Mine Planning Boardrooms. Decision on the final destination of material is key, whether the materials are going to the mills, waste dump or for a sea defence project will inform greatly. From the Minefield, Geotechnicians and Blasting Engineers needs to understand the strength of the in-situ, unleash the appropriate blast patterns that will produce a well fragmented material for the mills for easy communition after blasting or others meant for dumps or boulders for special projects.

It is always a balance. D and B is the cheapest form of comminution and should be used as effectively and efficiently as possible. I guess it’s a balance with putting enough energy to reduce the size but not too much to throw it so you can keep track of the order waste boundaries.

...hence making the operation not meeting its target hence resulting in losses. The three reasons I provided above makes me confident to vote for Drilling and Blasting as the most effective way to reduce material sizes in mining engineering.