McLanahan is helping mining operations reduce dust and downtime with smarter, greener solutions.
Australian mining operations are under increasing pressure to improve sustainability across the board, and that starts with the basics: how rocks are crushed.
For McLanahan global sales director – mining Lee Hillyer, reducing energy use, dust, noise and waste in crushing is a critical opportunity for greener, more efficient operations.
“Crushing alone accounts for about 45 per cent of energy use across an entire mine site,” Hillyer said during a recent webinar. “So getting crusher selection right can make a huge difference.”
From selecting the most suitable equipment to leveraging smart technology, Hillyer outlined practical ways operations can lower their environmental impact without compromising output. He broke down the environmental advantages and drawbacks of five common types of primary crushers: gyratory, jaw, sizer, feeder breaker and impact crushers.
Gyratory crushers are high-capacity machines capable of handling large feed sizes and hard rock. However, they come with high capital costs, a large footprint and elevated energy consumption.
“Gyratory crushers are among the most power-hungry options and also tend to produce a lot of dust and fines, which impacts downstream systems and increases maintenance demands,” Hillyer said.
Jaw crushers are a proven and widely-used option, offering durability and cost-effectiveness. But they can struggle with sticky or wet material and produce excessive fines.
“Jaw crushers have limitations in capacity and require a substantial structure to support them,” Hillyer said. “From an environmental point of view, they’re not ideal for every application.”
Sizers, Hillyer said, present one of the greener options as their compact design and low-speed, high-torque action deliver significant reductions in dust, energy use and wear.
“Sizers are ideal for handling wet or sticky ore and have one of the lowest energy draws on the market,” Hillyer said.
“In some cases, they operate at just 30 to 40 per cent of their installed power.”
Feeder breakers, which combine feeding and crushing in a single unit, are another efficient choice for soft or friable material like coal. They require little civil work, can be installed at ground level and create minimal dust.
“They’re not suitable for hard rock applications, but when used correctly feeder breakers deliver low capital and operating costs with a compact footprint,” Hillyer said.
Impact crushers, on the other hand, offer high reduction ratios and produce a cubical product, but are generally unsuitable for abrasive or hard materials due to their relatively high operating costs and fines generation.
Thinking holistically
One of the most effective ways to reduce energy consumption and wear is to pre-screen material before it enters the crusher.
“This is something I talk about passionately,” Hillyer said.
“Removing fines before they reach the crusher improves throughput, reduces wear and lowers opex (operational expenditure).
“In some cases, we’ve seen operating costs cut to a quarter of what they were by adding a simple screening step.”
McLanahan uses vibrating grizzly and apron feeders, depending on material type. For sticky material, apron feeders and sizers are often the best pairing.
“Pre-screening can also allow for a smaller, lower-power crusher, which reduces your overall energy and capital costs,” he said.
Hillyer stressed the importance of matching crusher type to the material’s hardness, abrasiveness, moisture content and clay composition.
“Selecting the wrong crusher can increase downtime, wear and energy costs,” he said.
“If you try to run a feeder breaker on hard rock or put a jaw crusher on soft ore, you’re setting yourself up for problems.
“If your secondary crusher needs a specific product size, or if you’re trying to protect your belts and screens, it all starts with the primary crusher.
“It’s about getting the full plant to work together efficiently.”
Condition monitoring is becoming standard in modern crushing circuits. McLanahan offers real-time insights into bearing temperatures, power draw and throughput rates, allowing for predictive maintenance.
“We’re seeing more sites use data to catch faults before they lead to failure,” Hillyer said. “A hot bearing caught early might mean a simple change-out. If you let it run, it can lead to shaft damage and extended downtime.”
Condition monitoring also improves safety by reducing the need for personnel to conduct inspections or emergency repairs in high-risk areas.
Hillyer also highlighted ore sorting as a powerful tool. By separating waste from ore before it reaches the crusher or mill, operations can reduce water use, energy draw and tailings.
“If you can remove waste early, you’re not putting it through your crushers, screens or mills,” he said. “That saves energy, reduces wear and lowers your water demand. It also means fewer tailings and more efficient processing.”
Ore sorting can also reduce the size of required equipment and infrastructure, improving the economic viability of lower-grade deposits.
“Green mining starts at the front end,” Hillyer said. “If we choose the right equipment, use pre-screening, and monitor our machines intelligently, we can reduce emissions, improve recovery and lower costs.”
McLanahan continues to refine its sizer and feeder breaker technologies, offering compact, efficient systems that align with modern mining and environmental goals. With the right equipment in place, Hillyer said mining can move towards operations that are more cost-effective and sustainable.
This article appeared in the October issue of Australian Mining magazine.
