Processing in mining is one of the most energy-intensive stages in the mining lifecycle, accounting for a significant portion of a mine’s total energy consumption.
Comminution, the process by which big chunks of rocks is reduced in size by crushing and grinding, is typically the single biggest user of energy in a mine site as diesel in mining operations is split across multiple different equipment types and this makes comminution a natural target for identification of energy savings opportunities able to have the largest impact (MINING ENERGY CONSUMPTION 2021 – CEEC (Coalition for Eco Efficient Comminution), n.d.).
Here’s a look at technologies encouraging energy efficiency in mining processing:
- Advanced crushing technologies: There are the Vertical Roller Mills (VRM) which basically use a rotating table and rollers to grind ore, Stirred Mills which use a rotating stirrer to agitate grinding of ore in a chamber and Autogenous Grinding (AG) and Semi-Autogenous Grinding (SAG) Mills.
- High-Pressure Grinding Rolls (HPGR): Unlike traditional ball mills, is a technology that uses two counter-rotating rollers to crush ore under high pressure, where ore is fed into the gap between the two rollers and are crushed by the pressure exerted between the particles themselves with low energy input.
- Sensor-Based Ore Sorting: Sensor-based sorting use sensors (e.g. X-ray, optical and laser) to separate ore from waste rock early in the process. This therefore reduces the amount of material that needs to be processed, saving energy.
- Coarse Particle Flotation (CPF): This is an advanced flotation technology designed to float coarser particles and reduces the need for excessive grinding, therefore reducing energy consumption.
These innovations not only reduce costs and enhance sustainability, but also lower carbon emissions, ensuring the industry meets both economic and ecological imperatives.
What equipment are you running at your operation to boost energy efficiency?
References:
https://www.mdpi.com/2075-163X/9/9/523#:~:text=The%20article%20gives%20an%20overview%20of%20the%20development,raw%20materials%20and%20introduces%20various%20applications.%201.%20Introduction
https://www.sciencedirect.com/science/article/pii/S0892687523005137
MINING ENERGY CONSUMPTION 2021—CEEC (Coalition for Eco Efficient Comminution). (n.d.). Retrieved March 19, 2025, from https://www.ceecthefuture.org/resources/mining-energy-consumption-2021
