COMMINUTION
TerraSource Global ’ s recent M & A activity is allowing it to make more inroads into the crushing and comminution space , with several brands that have applications across the soft- and hard-rock space .
Whether for primary , secondary , or fine grinding ( tertiary or ultra-fine grinding ), selecting the right crushing equipment enhances productivity , reduces maintenance and minimises fines . TerraSource says it provides the expertise and solutions to optimise material reduction via comminution processes across various industries .
TerraSource says the CAL Reversible Impactor from It outlines four basics to consider
Pennsylvania Crusher is the preferred solution for hard , before even getting to the equipment abrasive materials and ideal for industries handling
selection stage , including : material slag , metallic dross , foundry sand , tungsten carbide and other challenging materials type , desired output size and production rate , operating conditions and comminution type . By understanding these factors , companies can make strategic choices that optimise efficiency and cost-effectiveness in their crushing and grinding operations , the company says .
The Pennsylvania Crusher TKK Granulator , for example , is a powerful primary crusher for coal , limestone , gypsum and other friable materials . It is designed for high-capacity , precise material reduction with minimal vibration and downtime . Built for reliability and durability and engineered for efficiency , it features interchangeable screen plates , slotted openings and precision-toothed forged steel hammers that enhance performance and extend wear life , the company says . Alternatively , the Pennsylvania Crusher Bradford Breaker provides a dual-function of size reduction and debris removal , making it a top choice for run-of-mine coal , according to TerraSource .
TerraSource labels the CAL Reversible Impactor from Pennsylvania Crusher as the preferred solution for hard , abrasive materials and ideal for industries handling slag , metallic dross , foundry sand , tungsten carbide and other challenging materials . These machines provide an adjustable crushing solution with extended hammer life and deliver high reduction ratios up to 35:1 , minimal fines generation and low power consumption .
When a secondary or tertiary crushing step is required for fluidised bed combustion and power plant applications , the Pennsylvania Crusher Coalpactor is a good choice , TerraSource says . These machines improve combustion efficiency by delivering consistent particle sizing with minimal fines generation .
For mining operations seeking low fines production and precise size control , TerraSource highlights Gundlach Multi-Roll Crushers for coal , coke , potash and limestone . These machines shear material rather than crushing it for improved particle distribution .
For high-capacity , primary crushing of hard materials like limestone , coal and aggregates , Pennsylvania Crusher jaw crushers are designed for first-stage reduction , handling large feed sizes in mining and aggregate operations .
And when ultra-fine grinding is needed in chemical , fertiliser and industrial mineral applications , TerraSource recommends the Gundlach Nanosiz-R / R-HC . The machine ’ s compact roll design makes it ideal for tight spaces while still handling high-volume processing , it explains .
For potash , salt and chemical processing , comminution must achieve precise particle control while minimising waste . The Gundlach Cage-Paktor uses a cage mill design for fine crushing and controlled top-size classification . However , Gundlach Multi-Roll Crushers are far more prevalent in these industries , TerraSource says , featuring 3D crushing technology with intermeshing continuous tooth roll design and precise roll timing to deliver uniform cubical products while minimising slabbing . For operations requiring fine reduction with high efficiency , the Gundlach Nanosiz-R and Nanosiz-R HC stand out , offering fine granulation with low operating costs , the company added .
technology advances and time in the market with plus-20 years of extensive operating experience in hard rock .
When the HPGR Pro technology was introduced by TK Mining in 2020 , it was promoted as offering up to 20 % more throughput capacity , up to 15 % energy savings and up to 30 % extended roll life from units with the same size envelope as its predecessor .
ENDURON excitement building
Weir is also continuing to build major market share in the HPGR space with its ENDURON ® technology .
It claims the ENDURON solution provides significant improvements versus traditional tumbling mill technology with energy savings of up to 40 % and , in turn , a lower carbon footprint .
Bjorn Dierx , Weir , Director HPGR and Process Engineering , explained : “ There is an increased focus on sustainability across the mining sector driven by , among others , local communities , investors and miners themselves . At the same time , there are tighter regulatory conditions around environmental permitting , all of which contributes to a broad commitment across the industry to adhere to best practice ESG standards .
“ There is also a growing recognition that cleaner production of higher quality concentrate isn ’ t just beneficial for the environment , it also improves the miner ’ s bottom line .”
The ENDURON HPGR is part of a transformational flowsheet Weir is advocating for to help confront some of these market challenges , in addition to the fact that new orebodies are increasingly located in remote , arid regions . “ As a result , we ’ re seeing a shift towards dry mineral processing and the deployment of satellite processing plants ,” Dierx added .
The mining community is becoming less risk averse when it comes to more widespread adoption of technologies like HPGRs and vertical stirred mills , according to Dierx .
“ Apart from HPGR adoption in highly competent rock processing , we ’ re also increasingly seeing interest in deploying HPGRs to process soft to moderate competent ores , particularly in high tonnage applications because of the low operating expense nature of the technology ,” he said . “ They ’ re also being deployed in hybrid arrangements next to SABC circuits to provide flexibility when harder ore is anticipated during life of mine .”
And both greenfield and brownfield mines could reap these benefits .
“ Many mines that have been operational for decades are now experiencing reduced throughput and increased operating costs as they are mining harder rocks and HPGR-based circuits are one of the ways they ’ re ensuring their operations remain viable ,” Dierx said .
“ We ’ ve had some very successful brownfield installations that have simplified the flowsheets and delivered a more efficient grinding solution . For instance , we collaborated with Tuprag ’ s Kişladağ gold mine in Türkiye to upgrade their
18 International Mining | MARCH 2025