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Ore Crushing & Milling

Right Size, Right Liberation. Every Tonne Counts Downstream.

Comminution sets the ceiling for everything that follows it. MSA Consulting sizes, designs, and troubleshoots crushing and milling circuits so your ore arrives at the right particle size to liberate value — without wasting energy or steel getting there.

Fit-For-OreCircuit Design
Energy-AwareComminution Efficiency
Liberation-ReadyDownstream Recovery

Comminution Testwork

Measuring how hard your ore actually is before a crusher or mill is ever sized.

  • Bond work index (crushing, rod, ball)
  • SAG mill comminution (SMC) testing
  • Abrasion & impact hardness testing
  • Particle size distribution analysis

Crushing Circuit Design

Primary through tertiary crushing sized to feed a consistent, controllable mill circuit.

  • Primary, secondary & tertiary stage selection
  • Crusher sizing & equipment selection
  • Screening & closed-circuit configuration
  • Feed & product size distribution targets

Milling Circuit Design

SAG, ball, and rod mill circuits configured to hit your target grind, reliably.

  • SAG/AG & ball mill circuit design
  • Grinding media & charge selection
  • Cyclone & classification optimisation
  • Target P80 & liberation size definition

Circuit Optimisation & Debottlenecking

Getting more tonnes and better grind out of the plant you already have.

  • Throughput & bottleneck diagnosis
  • Energy consumption & efficiency review
  • Liner & media wear optimisation
  • Process control & survey-based tuning

Simulation & Modelling

Testing circuit changes on a model before committing capital or downtime to them.

  • JKSimMet & comminution modelling
  • Mass balance & circuit simulation
  • Expansion & upgrade scenario testing
  • Capacity forecasting under variable ore

Comminution Audits & Reviews

Independent checks on an existing circuit's performance against design intent.

  • Plant surveys & performance benchmarking
  • Design-vs-actual gap analysis
  • Equipment condition & wear reviews
  • Prioritised upgrade recommendations

Our Comminution Workflow — From Ore Hardness to Target Grind

A methodical path from testwork to a circuit that performs at the design tonnage.

1

Test

Ore hardness & grindability measured through standard testwork.

2

Design

Crushing & milling circuit sized around the testwork & target grind.

3

Simulate

Circuit performance modelled & stress-tested before commissioning.

4

Optimise & Audit

Running circuit tuned & benchmarked to keep tonnage and grind on target.

Circuit undersized or underperforming? Get the grind right first.

Request Crushing & Milling Support