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    Comminution and crushing: flowsheet-wide energy strategies for mine planners

    March 4, 2026|

    Reviewed by Joe Ashwell

    First reported on International Mining – News

    30 Second Briefing

    Efforts to cut comminution emissions are centring on flowsheet-wide changes such as higher-pressure grinding rolls replacing SAG mills, coarse particle flotation to allow coarser primary grind, and in-pit or near-pit crushing to reduce haulage energy. OEMs are pairing more efficient cone crushers and stirred mills with digital load monitoring, ore characterisation sensors and advanced process control to stabilise circuits and avoid overgrinding. For mine planners and process engineers, the direction of travel is towards fewer, more energy‑intensive unit operations run at optimised throughput rather than incremental tweaks to legacy multi-stage crushing.

    Technical Brief

    • OEMs are integrating online ore hardness indices and real-time PSD sensors directly into crusher control loops.
    • Several flowsheets now use variable-speed drives on primary crushers to match blasting fragmentation variability.
    • Digital twin models of entire comminution circuits are being calibrated with plant data to test alternative layouts offline.
    • Some mines are trialling bulk ore sorting ahead of grinding, using belt-mounted XRT or PGNAA sensors to reject waste.
    • Process control packages increasingly combine mill load cells, acoustic monitoring and power draw to infer toe position continuously.
    • Case studies include brownfield plants reconfiguring transfer chutes and screen decks to debottleneck circulating loads without new mills.
    • For future projects, flowsheet selection is being driven by whole-of-mine energy and carbon models rather than unit kWh/t alone.

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    Prepared by collating external sources, AI-assisted tools, and Geomechanics.io’s proprietary mining database, then reviewed for technical accuracy & edited by our geotechnical team.

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