Reduction of Fragment Size from Mining to Mineral Processing: A Review

Abstract

Abstract: The worldwide mining industry consumes a vast amount of energy in reduction of fragment size from mining to mineral processing with an extremely low-energy efficiency, particularly in ore crushing and grinding. Regarding such a situation, this article describes the effects of rock fragmentation by blasting on the energy consumption, productivity, minerals’ recovery, operational costs in the whole size reduction chain from mining to mineral processing, and the sustainability of mining industry. The main factors that influence rock fragmentation are analysed such as explosive, initiator, rock, and energy distribution including blast design, and the models for predicting rock fragmentation are briefly introduced. In addition, two important issues—fines and ore blending—are shortly presented. Furthermore, the feasibility of achieving an optimum fragmentation (satisfied by a minimum cost from drilling-blasting to crushing-grinding, maximum ore recovery ratio, high productivity, and minimum negative impact on safety and environment) is analysed. The analysis indicates that this feasibility is high. Finally, the measures and challenges for achieving optimum fragmentation are discussed. Highlights: The effects of rock fragmentation on the whole size reduction chain from mining to mineral processing are described.The main factors influencing rock fragmentation by blasting are analysed.Main models for predicting rock fragmentation are briefly introduced and commented on.The feasibility, measures, and challenges of achieving optimum fragmentation are analysed.