Mineral Processing Technologies Objective

This document outlines the technologies in the field of mineral processing to reduce the size of rock-like material. The exploration of next-generation technologies or improvements to existing methods for reducing the size of rock-like materials signifies a crucial facet of innovation in mineral processing. Breakage, grinding, crushing, cutting, and vibrating processes are fundamental in transforming raw ores into refined mineral products.  Advancements in mineral processing stem from the mining industry's drive for enhanced efficiency, sustainability, and economic viability. These technologies strive to surpass current limitations, offering superior methods that optimize energy efficiency and provide precision in controlling particle size distribution. Superior energy efficiency and precise size control are crucial for sustainable, cost-effective, and environmentally responsible mineral processing, contributing to the industry's evolution toward responsible and innovative practices.

This study aims to address the mentioned challenges associated with mineral processing technology.

The study answers the following questions –

What are Next generation technologies, or enhancements to existing technologies, which can reduce the size of rock-like material through breakage, grinding, crushing, cutting or vibrating, in order to provide:

• Superior energy efficiency and/or
• Greater control of particle size distribution than current methods used in mineral processing?

Recommendation on the advantages of the Mineral Processing Technologies and supported by the proof of concepts. These advantages includes:

• Superior energy efficiency
• Greater control of particle size distribution
• Cost-effective
• Improve quality
• Eco-friendly/Sustainable

While advancements in technologies for reducing the size of rock-like materials have made notable progress, several challenges persist in achieving optimal energy efficiency and precise control of particle size distribution. Traditional size reduction methods remain energy-intensive, and despite technological progress, certain approaches may still demand substantial power inputs, leading to heightened operational costs and environmental impact. The complexity of ore composition poses a significant hurdle, requiring constant adjustments to processing methods to maintain efficient size reduction. Selective fragmentation, targeting only desired ore particles while preserving gangue material, presents difficulties, potentially necessitating additional processing steps and increased energy consumption. Maintenance needs for advanced technologies can result in downtime, impacting overall efficiency, while high initial capital costs limit adoption, especially for smaller operations. Scaling up for industrial use faces challenges, and variability in mineral liberation across ores affects downstream processes. Overcoming these limitations is crucial for advancing technologies in mineral processing, and ongoing research aims to address these challenges and promote efficiency and sustainability.

Background Information

The mineral processing industry plays a pivotal role in the extraction and refinement of valuable minerals from raw ore. Size reduction of rock-like materials is a fundamental step in this process, involving techniques such as breakage, grinding, crushing, cutting, or vibrating. The efficiency of size reduction directly influences the overall efficiency of mineral processing operations, impacting energy consumption, production costs, and the quality of the final product.

Need of energy efficiency and the control of particle size distribution

Crushing and grinding have different techniques for the process of size reduction. While the crushing operation for size reduction is carried out by compression, impact and attrition have less impact. In the case of grinding, the attrition force is much more impactful and great. Both dry and wet conditions can be used to operate the grinding mill. The grinding media used for grinding purposes are most commonly spherical or cylindrical balls, causing a crushing action by striking the ore continuously, resulting in a size reduction. One end of the mill receives the material, while the other end removes the discharge. The size reduction strategy is heavily influenced by the amount of energy required for size reduction as well as the choice of crusher or grinder. In contrast, the amount of energy needed is determined by the rock’s starting size and hardness and the eventual product that must be produced.

In the past, the mineral processing industry found fine grinding undesirable due to disadvantages related to conventional milling (through tumbling mills). The only way to obtain the necessary grinds for the tougher minerals was to mill them for a lengthy time, which resulted in limited productivity and higher power usage.

Smaller media in closed circuits can help tumble mills produce fine grinds, but their ability to transmit kinetic energy to the media is still fundamentally limited. They also have significant areas where minimal media movement occurs (dead grinding zone), which reduces efficiency. Ultrafine grinding (UFG) mills overcome these constraints by utilising revolving stirrers inside a steel mill shell. Recently, new-generation mills have been gaining popularity in the finer comminution circuit for reducing specific energy consumption.

The autogenous/semi-autogenous mills were also used along with a ball mill for intermediate-size grinding. However, there is a new configuration of the grinding circuit composed of a high-pressure grinding roll and stirred media mills as a fine and ultrafine grinding unit, respectively, which is a recent trend. Stirred mills are compressive grinding mills with potential in the mineral- and cement-based processing industries for reducing the particle size from a few millimetres to a micron.

Each ore has a preferred particle size for economic reasons; too fine a grind and grinding expenses surpass any increase in recovery, whereas too coarse a grind and inadequate liberation restrict recovery in the separation stage. The amount to which the values are disseminated in the gangue and the subsequent separation method to be utilised will both affect the ideal grind size in liberating the grain, and the energy consumption is one of the main factors in grinding materials.

As grinding is one of the energy-consuming processes in the mining and mineral processing value chain, any effort towards reducing energy is a positive step. So, by adopting an advanced energy-efficient comminution circuit, there is a benefit towards minimising CO2 emissions.

Current methods for size reduction in mineral processing have reached a certain level of maturity, but there is a continuous drive for innovation to enhance energy efficiency and particle size control. The demand for improved technologies arises from the industry's need to optimize resource utilization, reduce environmental impact, and meet increasingly stringent product specifications. Therefore, exploring next-generation technologies or enhancements to existing ones is crucial for maintaining and advancing the competitiveness of mineral processing operations.

Controlling the particle size distribution (PSD)

Controlling the particle size distribution (PSD) in a grinding circuit is a crucial aspect of optimizing the overall performance and efficiency of mineral processing operations. The interplay of various factors, including feed characteristics, mill parameters, classification systems, and process optimization techniques, plays a pivotal role in achieving the desired PSD and ensuring efficient circuit operation.

Feed Characteristics: The feed characteristics, such as ore hardness, mineralogy, shape, and moisture content, significantly impact grinding performance and PSD. Harder ores require more energy and time for grinding, resulting in a finer product, whereas softer ores may yield a coarser product. Ores with high clay content or moisture can lead to issues like agglomeration and reduced classification efficiency. Monitoring and adjusting feed properties are essential for optimizing grinding conditions and achieving the desired PSD.

Mill Parameters: Mill parameters, including speed, load, media size, shape, and density, exert considerable influence on PSD. Altering mill speed or load can impact impact and attrition forces, affecting the fineness of the product. Media size and density also play a crucial role in grinding efficiency; smaller or denser media enhance efficiency and fineness, while larger or less dense media may have the opposite effect. Careful selection and control of mill parameters are necessary to attain the desired PSD and manage specific energy consumption effectively.

Classification System: The classification system, employing hydrocyclones, screens, or air classifiers, separates products into different size fractions and recycles coarse particles for further grinding. This improves PSD, grinding efficiency, and reduces overgrinding and energy consumption. However, parameters like cut size, sharpness, capacity, and pressure in the classification system influence PSD. Optimizing and regulating the classification system is vital to balance PSD and circuit performance, ensuring efficient separation of particles.

Process Optimization: Utilizing process optimization techniques such as simulation, modeling, and optimization tools is essential for analyzing and improving grinding circuit performance. These tools help identify and address bottlenecks, inefficiencies, or constraints limiting grinding capacity or quality. By exploring alternative scenarios involving changes in feed characteristics, mill parameters, classification systems, or process control, these techniques facilitate achieving optimal PSD and circuit operation.

In conclusion, achieving and maintaining control over the particle size distribution in a grinding circuit necessitates a comprehensive understanding and management of feed characteristics, mill parameters, classification systems, and continuous process optimization. By integrating these elements, operators can enhance overall efficiency, productivity, and product quality in mineral processing operations.

Recent Technology Development

In recent years, there have been significant advancements in mineral processing technologies aimed at achieving superior energy efficiency and greater control over particle size distribution. Ongoing developments include the refinement of High-Pressure Grinding Rolls (HPGR) technology, exploring the application of microwaves for selective weakening of mineral structures, and the evolution of Pulse Electrical Disintegration to reduce energy consumption during size reduction.

Innovations in selective fragmentation aim to enhance energy efficiency by targeting specific ore particles, while sensor-based sorting technologies, such as X-ray transmission and laser-induced fluorescence, enable selective processing of high-grade material. Advanced Process Control (APC) systems with real-time data and algorithms continue to optimize the grinding process, and research in nanotechnology and microtechnology is ongoing to achieve precise control over particle size distribution. Vertical Roller Mills (VRM) present an evolving alternative to traditional ball mills, offering advantages in energy efficiency and particle size distribution control. Please note that more recent developments may have occurred since my last update.

During our study, we come across with many recent technologies focusing on the usage of ultrasonic wave and microwave treatment along with milling, grinding, crushing, cutting, or vibrating process. Also, we come across with the technologies along with various sensor system used to improve the control of particle size distribution.

We encounter innovation in high-speed rotational ball mills that achieve efficient grinding, crushing, and pulverization of rock-like materials. The application of ultrasonic vibrations during grinding helps reduce friction between particles, resulting in more effective breakage and a finer particle size distribution. The ultrasonic method not only improves energy efficiency but also provides better control over the final product's characteristics. Pulsed laser ablation involves the use of short laser pulses to break down materials into smaller particles. This non-contact and highly controlled process offers advantages in terms of precision and reduced contamination. While primarily employed in nanotechnology, adapting this technique for larger-scale particle size reduction holds promise for industries requiring fine-tuned control over particle sizes.

Advanced cutting technologies incorporate robotics and AI for accurate, efficient cutting, while vibrational milling with smart controls dynamically adjusts parameters for optimal energy efficiency and precise particle size control.

Future Trends in Particle Size Control and Energy Reduction in the Mining Industry:

• Advanced Process Monitoring and Control: The future involves the integration of advanced sensing technologies and real-time data analytics for continuous monitoring and control of the grinding process. This enables quick adjustments to optimize particle size distribution and energy consumption.
• Automation and Artificial Intelligence: Increasing reliance on automation and artificial intelligence (AI) for the mining industry will play a significant role in optimizing grinding processes. AI algorithms can analyze vast amounts of data to make accurate predictions and control parameters for enhanced efficiency.
• Energy-Efficient Technologies: Research and development efforts are focused on the design of energy-efficient grinding technologies. This includes innovations in grinding equipment, such as high-pressure grinding rolls (HPGR) and stirred mills, which aim to reduce specific energy consumption and improve overall efficiency.
• Tailored Grinding Solutions: Customized and flexible grinding solutions that can adapt to the variability in feed properties will become more prevalent. Tailoring the grinding process to the specific characteristics of ore deposits can optimize particle size reduction.
• Sustainable Practices: The future of particle size control in the mining industry will emphasize sustainable practices. This includes exploring alternative methods of comminution that have lower environmental impact and energy requirements.
• Integrated Process Optimization: The mining industry will increasingly focus on holistic process optimization. This involves considering the entire mineral processing circuit, from blasting to grinding to classification, to achieve optimal particle size distribution with minimal energy consumption.
• In summary, the future of particle size control in the mining industry involves the integration of advanced technologies, automation, and sustainable practices to address the current challenges and enhance overall efficiency in particle size reduction processes.

In the quest for superior energy efficiency and precise control of particle size distribution, several next-generation technologies are transforming the landscape of rock-like material reduction. Innovations include high-energy ball milling, ultrasound-assisted grinding, electrodynamic fragmentation, pulsed laser ablation, advanced cutting technologies, and vibrational milling with smart controls. These advancements promise more sustainable and efficient processes across industries.

Mineral Processing Technologies Market Trend

The mineral processing industry is witnessing a dynamic shift towards sustainable and energy-efficient practices. Market trends indicate a growing emphasis on adopting technologies that not only enhance productivity but also minimize the environmental footprint of operations. This includes a focus on reducing energy consumption during size reduction processes, as well as achieving finer control over particle size distribution to meet evolving product requirements.

In addition, there is a heightened awareness of the economic benefits associated with improved mineral liberation and recovery. Efficient size reduction technologies contribute to higher yields of valuable minerals, reduced waste generation, and enhanced overall process efficiency. As mineral deposits become more challenging in terms of ore complexity and declining ore grades, there is an increasing need for innovative solutions that can address these challenges and unlock economic value.

Innovations build upon existing technologies, such as horizontal stirred mills like IsaMill and vertical media mills (tower mills and stirred media mills), which are gaining traction in the mining and mineral industries for ultrafine grinding.

The global crushing, screening, and mineral processing equipment market size was valued at $20614.1 million in 2020, and is projected to reach $40558.5 million by 2032, growing at a CAGR of 5.6% from 2023 to 2032. The crushing equipment is designed to reduce the size of large rocks, ores, and other solid materials into smaller, more manageable pieces. Furthermore, screening equipment is used to separate materials into different sizes or grades based on their particle size or shape. It is commonly employed after crushing to classify and separate the processed materials. Mineral processing equipment encompasses a wide range of machinery and tools used to process minerals and ores into valuable products. It involves various physical and chemical processes to separate and concentrate valuable minerals from ore materials. This equipment is used in industries such as mining, metallurgy, and mineral extraction.

The USGS (United States Geological Survey) Mineral Commodity Survey for 2015 lists more than 90 different minerals from abrasives to zirconium. Of these, 14 have a U.S. mine production of more than $1 billion in 2014. Source

Rising demand for metals such as steel, iron, and aluminum across infrastructure sectors is likely to increase the demand for mineral processing equipment during the forecast period. China and the United States are the most significant major coal-producing counties. However, China saw its sales slump between 2012 to 2016. Although in 2021, Australia and Russia saw a steady increase in coal production in the past decade. Also, Iron ore and Bauxite remain the fastest growing industries in the mineral processing equipment market. Iron production in Brazil and Australia has seen a massive increase, with companies investing in new mines to replace older ones. For instance, BHP approved 4 billion USD for iron ore-related projects in Western Australia, indicating growth for iron ore processing equipment.

Use of HPGR eliminates tertiary crushing in a conventional grinding plant. In some cases, it may even eliminate the need for a secondary crushing stage. As an energy-saving alternative to the SAG mill, HPGR is particularly suited for the pregrinding of hard, highly siliceous gold ores. This will help to downsize the ball mill while maintaining the throughput. In the pregrinding mode, HPGR use may result in energy savings of 15 to 30% and throughput increases of 20 to 40%. Source

The global high pressure grinding roller (HGPR) market size was valued at $399 million in 2021, and is projected to reach $701.1 million by 2031, growing at a CAGR of 5.8% from 2022 to 2031. Increase in industrialization and manufacturing industries in developing economies such as China, India, and the U.S. has led to increase in cement and ore & mineral processing plants, which is expected to boost development of the high-pressure grinding roller market.  In addition, the high-pressure grinding roll can reduce breakage size from 10-20mm down to 3mm or below, in comparison with conventional crushing and grinding equipment, thus leading to less energy consumption for grinding process. Source

Stirred media mills are increasingly replacing ball mills for fine and ultrafine grinding, typically having around 30–40% less power consumption than ball mills when grinding to the same product size.

With the continued development of new technologies and equipment, the potential for ultrafine grinding to revolutionise industrial processes continues to grow. From the literature, it is concluded that stirred media milling has a unique potential for ultrafine grinding in order produce particle sizes below 50 µm.  Both horizontal stirred mills (IsaMill) as well as vertical media mills (tower mills and stirred media mills) are gaining popularity in the mining and mineral industries for ultrafine grinding. The optimisation of the stirred milling process is very crucial for achieving efficient performance. So, further studies can be emphasised to analyse the process through statistical-based modelling tools. Empirical modelling studies can be carried out to visualise and understand the grinding mechanism of the stirred milling process in a better way. Also, a neural-based networking model can be developed by using data mining in the running plant to optimise and visualise the process. Source

The Particle Size Analysis Market size is estimated at USD 435.47 million in 2024, and is expected to reach USD 572.66 million by 2029, growing at a CAGR of 5.63% during the forecast period (2024-2029). The strong demand for the mining sector and continual support from the government for innovation are expected to further develop the market opportunity for particle size analysis. With a large base of untapped markets, such as Vietnam, Indonesia, and India, with vast raw material reserves and being a leading market for underground mining operations, the region is emerging as one of the biggest markets for mining activity. Australia is one of the largest markets for mining innovation.

The particle size analysis market is moderately fragmented with the presence of major players like Malvern Panalytical Ltd, Horiba Ltd, Agilent Technologies Inc., Microtrac Inc. (Verder Scientific GmbH & Co. KG), and Beckman Coulter Inc. Players in the market are adopting strategies such as partnerships and acquisitions to enhance their product offerings and gain sustainable competitive advantage. Source

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