During crushing, ultra-fine, dust and fines are inevitably created. Fines are particles broken down smaller than the size an operation actually needs. They’re typically produced when material is over-crushed: rock that’s already at or near the target size gets broken again, or particles are ground down through compression and attrition inside the crusher. Softer or more friable materials tend to generate more fines, which makes the choice of crushing method especially important. Fines generation in some circumstances can quietly erode profitability and pose real risks to the environment. In these situations reducing fines generation is therefore essential, not just for maximising material yield but also for ensuring environmental compliance. Achieving this starts with choosing the right equipment for your mineral processing needs.
The cost of excessive fines
Lost yield and product quality
Excessive fines both represent wasted energy. Producing optimally sized material, optimises energy use not only from the crusher, but also from downstream processes and equipment. Another added benefit is that the process also recovers more saleable product.
Tailings footprint
Reducing unnecessary fines generation can help improve downstream handling and processing efficiency. In some applications, producing less fine material can also improve dewatering and reduce the amount of space needed for storage.
Environmental hazards
The accumulation of ultrafine particles and dust can present environmental challenges. In applications involving sulphide-bearing ores, generating fewer fines can reduce the amount of mineral surface exposed to air and water, potentially reducing the conditions that contribute to acid generation and the risk of contamination of groundwater or waterways through erosion and runoff.
Reducing unnecessary fines can also help minimise dust generation and improve material handling, while potentially reducing some of the environmental risks associated with fine waste materials.
Environmental and regulatory implications
Failing to manage or contain fine particle tailings and wastewater properly can result in significant penalties, Environment Protection Orders (EPOs), and reputational damage. Mining environmental regulations are enforced by agencies such as the Department of Energy, Mines, Industry Regulation and Safety (DEMIRS) to mandate improved operational practices across the resources sector.
How MMD Sizer technology minimises fines
Compared to conventional crushers, MMD Sizers take a fundamentally different approach to size reduction, and the results speak for themselves.
- The MMD Sizer's unfailingly accurate product size, with minimal fines, maximises yield whilst minimising fines and dust generation.
- We have designed our hard rock sizers using a modern approach to crushing, producing an accurate, well-shaped product with minimal fines and methodically efficient breaking.
- Unlike conventional crushers, which rely on compression to break material (a process that generates significant fines), MMD Sizers use a low-speed, high-torque chopping and breaking action. This more efficient method reduces material to the required size with far less degradation, protecting both product value and the environment.
- By optimising fragmentation at the source using the right machinery, operations can conserve energy, recover more product and drastically minimise waste.
Minimise fines at the source with MMD
Reducing fines produced is a critical factor in some applications for protecting yield, controlling costs and meeting environmental obligations. As regulatory scrutiny increases and margins tighten, choosing the right crushing technology has never been more important.
MMD Sizers offer a proven way to minimise fines at the early crushing stage, helping operations improve product recovery, reduce waste handling costs and stay ahead of compliance requirements.
Ready to see the difference the right equipment can make? Get in touch with the MMD team to discuss how Sizer technology can be applied to your operation.
