![\"JD](\"https:\/\/www.coralynne.co.za\/blog\/wp-content\/uploads\/2026\/09\/GAIN-PIC-06.jpg\")
<\/a>According to JD Singleton, Comminution Director for Europe, Middle East and Africa (EMEA) at Weir, such advances are crucial to the mining sector in meeting its carbon emission goals while controlling costs. At the recent Mining Indaba Africa held in Cape Town in February 2026, Singleton was moderator of the session on Smarter Energy Use in Crushing and Milling, drawing insights from industry leaders and researchers.<\/p>\n\n\n\n
\u201cAn interesting element of the discussion was the recognition that the most efficient kilowatt-hour is the one never used,\u201d he explains. \u201cSelective mining and early waste rejection reduce the volume of material entering downstream circuits, lowering the energy required for size reduction. However, once material enters the plant, precision becomes critical.\u201d<\/p>\n\n\n\n
He points out that comminution phases in mineral processing remain primary consumers of energy in mining, requiring intense focus to reduce carbon emissions and operating cost.<\/p>\n\n\n
<\/a>\u201cCrushing and screening circuits operate sequentially, with each stage influencing the next,\u201d he explains. \u201cCorrectly configured primary and secondary crushers establish appropriate reduction ratioswhile accurate screening ensures that only genuine oversize material is returned for further breakage.\u201d<\/p>\n\n\n\n
By contrast, poor classification sharpness leads to unnecessary recirculation, increased energy draw and accelerating wear. He explains that Weir\u2019s comminution portfolio is structured around this stage-specific optimisation philosophy. <\/p>\n\n\n
<\/a>\u201cWeir\u2019s solutions draw upon its ENDURON range of primary crushers, secondary crushers and highpressure grinding rolls (HPGRs) as well as our vibrating screens, advanced exciter systems, screen media and ESCO wear components,\u201d he says. \u201cThese technologies are complemented by digital condition monitoring through Weir\u2019s NEXT Intelligent Solutions platform.\u201d<\/p>\n\n\n\n
In terms of how technology has advanced, Singleton points to HPGR installations as an illustration of quantifiable savings. Suitable HPGR applications have demonstrated reductions in energy intensity of 5 kWh per tonne compared to more conventional alternatives. <\/p>\n\n\n\n
\u201cOver large throughputs, this translates into meaningful reductions in power demand and operating expenditure,\u201d he says. <\/p>\n\n\n