COMMINUTION & CRUSHING
production rate, operating conditions and comminution method.“ This evaluation shifted the focus from individual machines to overall process performance,” Astec said. For primary crushing, the operation required high throughput with minimal fines generation to protect downstream conveying and separation systems. A granulator-style crusher from Astec’ s Pennsylvania Crusher line was selected for its ability to handle friable materials efficiently while maintaining tight control over top size. Interchangeable screen plates and precision-toothed forged steel hammers allowed operators to adjust sizing without major downtime, extending wear life and stabilising feed to secondary circuits, the company explained.
Run-of-mine coal presented an additional challenge due to tramp material and debris entering the system. In this portion of the plant, a breaker-type crusher provided simultaneous size reduction and debris rejection. Astec explained:“ By removing unwanted material early in the process, the operation reduced downstream wear, lowered maintenance hours and improved overall system reliability – key contributors to improved plant availability.”
Where harder, more abrasive materials were encountered, reversible impact crushing technology was introduced. High reduction ratios and adjustable impact settings enabled the operation to process slag-like inclusions while limiting fines generation and power draw. This proved especially valuable in maintaining consistent product quality for mineral separation and combustion-related applications.
Secondary and tertiary crushing stages focused on refining particle size for improved separation efficiency. Excessive fines had previously limited performance in fluidised bed and screening applications. Crushers engineered specifically to deliver consistent sizing with minimal fines helped stabilise these downstream processes, improving efficiency and reducing operational variability, Astec explained. To further enhance size control, the operation incorporated roll-based crushing solutions from Astec’ s Gundlach Crushers portfolio. It explained:“ Multi-roll crushers apply shear forces rather than impact, producing a more uniform particle distribution with fewer fines. This approach proved particularly effective for coal, limestone and potash, where particle shape and size consistency directly influence handling and separation performance.”
Astec concluded:“ This case highlights the importance of treating comminution as a strategic process rather than a single equipment decision. By leveraging Astec’ s application-focused crushing technologies and aligning them with material properties and operational goals, mining operations
44 can achieve meaningful gains in efficiency, durability and mineral separation performance.”
Composites for comminution
When it comes to consumables in the comminution process, Bradken’ s Composite Mill Liners continue to make a name for
Made from rubber, steel and cast inserts, Bradken’ s composite liners can offer various advantages against a range of wear mechanisms including corrosion, abrasion and impact
themselves.
Made from rubber, steel and cast inserts, these liners can offer various advantages against a range of wear mechanisms including corrosion, abrasion and impact. They can be customised to meet application and safety requirements to deliver: reduced power draw, increased charge in the mill, strategic movement of weight around the mill, increased size and parts in the mill, and extended campaign life and reduced ball requirements to achieve the chosen grind. The composite liners can also be matched with the steel equivalent to optimise wear life and maintenance shutdowns.
The company has been investing heavily of late on expanding its service offering.
This includes expanding its Bradken Lima composite mill liners site by 2,700 sq. m to continue supporting customers in South America. Bradken said the expansion will increase its delivery capacity through the addition of a dedicated warehouse for used liners, with the new space supporting its circular economy initiative and reinforcing its recycling program.
This now means the facility has 6,750 sq. m to manufacture wear protection solutions with a focus on safety, sustainability and innovation.
“ Our Lima facility has more than 10 years of experience designing and manufacturing composite liners,” the company says, adding that it has manufactured more than 35,000 liner pieces for installation across all sizes and all types of mills.“ This accumulated experience, knowledge and expertise allows us to offer optimised liner designs that maximise the operating efficiency and performance of customers’ mills by extracting the maximum value from their mills.”
The company added:“ We are committed to composites, expanding our Lima facility and building global capacity with a new composite plant in Coimbatore, India, on the same site as our world-class foundry.”
Bradken can deliver composite and steel mill liners across five dedicated sites globally, it says.
The selection of a chosen composite mill liner is not left down to chance, with Braken’ s engineering team conducting multiple simulations before settling on the right profile for the most efficient mechanics inside the mill.
The company can offer several products here, including Linings ® Polywear R60A, Linings Polywear SL and Linings Polywear SCL linings.
The Polywear R60A is mostly used as SAG and ball mill liners, fitted inside the shell and / or head liners. The rubber lining would mainly be used in ball mills in the classic plate bar design, Bradken noted.
The Polywear SL, which includes wear resistant steel, wear resistant rubber and structural steel, comes into play in SAG mill liners and balls, specifically in the shell and / or feed cover.
The Polywear SCL, also used in SAG and ball mills, is made up of rubber composite liners with high resistance laminated steel inserts( 500-550 HB) and high chrome cast inserts( 650 HB). The solution has, according to Bradken, demonstrated longer wear life and uniform wear than CrMo castings in high abrasion grinding.
Sizing up manganese opportunity
In the sizers market, MMD recently reported on its Australia-based subsidiary having been awarded a significant contract to supply an MMD 625 Primary Sizer and MMD 500 Secondary Sizer to Element 25 Ltd for the Butcherbird Expansion( BBX) project in the Pilbara of Western Australia.
The new equipment will support a substantial increase in manganese production at the Butcherbird Manganese Mine.
Under the contract, MMD Australia( West) Pty Ltd. will supply a complete sizing package comprising an MMD 625 Primary Sizer designed for high-capacity primary ore reduction; and MMD 500 Secondary Sizer for providing consistent, controlled product sizing; a critical spare parts
International Mining | MARCH 2026