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Real-Time Particle Size Measurement on Conveyor

Enabling Throughput, Recovery, and Process Optimisation

Overview

Particle size is one of the most critical variables in mineral processing, directly influencing liberation, recovery, and downstream efficiency. Conventional sampling and laboratory analysis introduce delays and often fail to represent dynamic process conditions.

Real-time particle size measurement on conveyors provides continuous, representative size distribution data—enabling immediate process adjustments and improved operational performance.

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Key Value Drivers

1. Improved Metallurgical Performance

Particle size governs mineral liberation and separation efficiency. Deviations from target size distributions can result in significant recovery losses.
Real-time measurement enables:
  • Consistent grind size control
  • Improved liberation and downstream recovery
  • Reduced overgrinding and associated metal losses
  • Better flotation, leaching, and separation performance

2. Increased Throughput and Energy Efficiency

Grinding is typically the most energy-intensive step in mineral processing. Oversized material reduces throughput, while excessive fines waste energy.
Benefits include:
  • Optimised crusher and mill performance
  • Reduced specific energy consumption
  • Increased plant throughput
  • Balanced grind size vs recovery trade-offs

3. Enhanced Process Control and Stability

Without real-time size data, operators rely on indirect indicators such as power draw or cyclone pressure.
Operational improvements:
  • Direct feedback for crusher gap and mill control
  • Improved cyclone and classification efficiency
  • Stable feed size to downstream processes
  • Rapid response to ore variability

Application Examples Across Commodities

Base Metals (Copper, Nickel, Zinc)

  • SAG and ball mill optimisation through continuous size monitoring
  • Improved flotation recovery via consistent liberation size
  • Early detection of crusher or mill performance issues

Gold

  • Control of grind size to maximise gold liberation without overgrinding
  • Improved leach kinetics in CIP/CIL circuits
  • Stabilised cyclone performance and classification efficiency

Diamonds

  • Prevention of over-crushing, protecting diamond integrity and value
  • Optimised sizing prior to Dense Media Separation (DMS)
  • Improved recovery through consistent feed preparation

Ferrous (Iron Ore, Manganese)

  • Crusher optimisation for consistent lump and fines production
  • Improved screening efficiency and product quality
  • Feed size control for sintering and pelletising processes

Coal

  • Control of product size for combustion efficiency
  • Improved wash plant performance and yield
  • Reduction of fines generation and associated losses

Why Conveyor-Based Measurement?

  • Continuous, real-time size distribution across the full material stream
  • Representative measurement compared to periodic sampling
  • Non-intrusive installation with minimal process disruption
  • Immediate feedback for advanced process control systems

Business Impact

Implementing real-time particle size measurement delivers measurable value:
  • Higher recovery and product quality
  • Increased throughput and plant efficiency
  • Reduced energy consumption in comminution circuits
  • Improved process stability and reduced downtime

Conclusion

Real-time particle size measurement on conveyors transforms a traditionally delayed laboratory variable into an actionable process control parameter. By continuously monitoring size distribution, operations can optimise grinding, improve recovery, and maximise overall plant performance.

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