Optimization of Particle Size Distribution for Energy Reduction
Role
Project Manager
Budget
US$300,000
Annual Value / Savings
US$2,500,000
Annual Value Multiple
8.3x
Project context:
Particle size distribution links upstream blasting and crushing performance with downstream grinding energy, throughput and metallurgical recovery. The project focused on reducing energy consumption through more intelligent size-control decisions.
Expanded objectives:
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Analyze the relationship between ore fragmentation, crusher product size, mill feed size distribution and grinding energy intensity.
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Develop analytical models to identify particle-size targets that reduce comminution energy while maintaining throughput and recovery requirements.
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Quantify the sensitivity of kWh/t to changes in particle size, ore hardness, circulating load and operating set points.
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Provide operational guidance for balancing blast, crush and grind decisions across the mine-to-mill value chain.
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Support implementation of monitoring routines to track PSD, throughput, power draw and product-size compliance.
Value delivered:
Enabled energy-reduction opportunities in comminution by linking particle-size control with operating cost and plant performance.