Sustainable Comminution Solutions
Weir’s latest white paper presents a transformative approach to mineral processing through innovative comminution flowsheets designed to address mining’s most pressing challenges — energy efficiency, water scarcity, and tailings management. Central to these solutions is the integration of ENDURON® High Pressure Grinding Rolls (HPGR), coarse particle flotation (CPF), and dry classification technologies, which collectively enable significant reductions in power consumption, water use, and carbon emissions.
The paper introduces the concept of parallel flowsheets, which diverge from traditional series-based circuits by enabling early gangue rejection and preventing overgrinding. This design improves energy efficiency by up to 38% compared to conventional SABC circuits and enhances tailings management through controlled particle size distribution.
Fortescue’s Iron Bridge project showcases a large-scale dry processing plant that eliminates tumbling mills and reduces operational costs.
EPCs and miners are positioned to lead the adoption of a full flowsheet-based approach, leveraging ore characterisation, sensor technologies, and modular equipment configurations to optimise plant performance. The white paper also highlights Weir’s commitment to supporting remote operations through strategically located service centres and as well as digital developments with NEXT intelligent solutions.
As the industry faces increasing pressure to develop remote, low-resource deposits, these sustainable comminution strategies offer a scalable path forward — enabling higher recovery, lower environmental impact, and improved operational resilience.
Download the white paper to learn more.