MMD GROUP OF COMPANIES

TECHNICAL ARTICLE 1 MMD SIZERS

FIELD OF APPLICATION OF MINERAL

SIZERS

AUGUST 2013

Prepared by: Pablo Fuenzalida Orozco

MMD MINERAL SIZING (Chile) Ltda.

August 2013

Ebro 2740, oficina 1103, Las Condes, Santiago

MMD Group of Companies

1. INTRODUCTION

The principal purpose of the present report is to establish the extent of the field of
application of MMD sizers, and the resulting advantages of including this technology
in mining operations. Through analysis of real data, the report seeks to define how
the size range of mineral to be processed by MMD machines can be extended,
without the need to use either explosives or breakers and picks.

Conventional crushing processes as used in all mining operations entail a number of

stages which have become established over time. After the initial phase of reduction
through explosives, the mineral which emerges from the mine is of uneven size and
often needs to undergo further stages of size reduction. This may be done with
explosives once again or by using breakers and picks. Although there is no
established lower limit for ceasing reduction with explosives or breakers, rock is
usually considered suitable for processing with crushing equipment when it has a
maximum size of around a metre. This is the normally the top size that can pass
through grizzlies in the production level of underground mines exploited by
block/panel caving, and also the size of the opening of primary crushers in open pit
operations, which naturally varies between different mining operations.

In this article we explore how, with the use of MMD sizers, this one metre limit can
be increased.

2. LITERATURE REVIEW

Size reduction of mineral can be achieved by applying a variety of mechanical forces,

which include:

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All of the above have different energy requirements, depending on the type of
mineral. Nevertheless, if we consider that today’s large mines are found in sectors of
extremely hard and abrasive primary rock, a situation which will only intensify as
time passes and these mines get deeper, we need to look for new ways to reduce
mineral size using the minimum possible energy, something not easily achieved with
conventional technology.

2.1. Types of crushers

There are various different types of crushers, some in more common use than
others, which have different comparative advantages relative to one another. These
are:

 Jaw crusher.
 Gyratory crusher.
 Roller crusher.
 Impact crusher.
 MMD sizer.

Other types also exist but, generally speaking, these are the most commonly used.

2.2. Range of size reduction

The different stages of conventional crushing are summarised in the figure below:

2.3. Equipment used to cover this range

Different types of equipment are used for each of the stages mentioned. These are:

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of this article is strictly prohibited. All intellectual property rights are reserved.
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This demonstrates that the crushing stages start with a mineral size of around a
metre, each stage delivering a different product size, as the following figure shows.

We conclude that larger rocks, in this case > one metre, are broken with explosives
or breakers and picks.

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3. MMD SIZER MODELS

For more than 30 years, MMD has been manufacturing different models of mineral
sizers, the most popular of which are shown in the graphic below.

The field of application for each model – including feed size, product size and output
in tons per hour – is described below.

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3.1. MMD 500

The feed graph clearly indicates the sizes which this model is able to accept,
including sizes larger than a metre, depending on the mineral type. To define a
range, the following values are proposed: Nominal feed size: 300 to 500 mm (12” to
20”). As with all MMD Sizer models, a normal range of operation is considered even
though larger values may be possible.

Alimentacion
Feed MMDSizer MMD
500 500
Sizer
25,0%

20,0%

15,0%

10,0%

5,0%

0,0%
100
120
125
130
150
175
180
200
250
275
300
350
400
450
500
600
650
700
750
800
1000
1200
2000
ROM
mm
Partial frequency
Frecuencia parcial

The following graph shows product size. A range of 40 to 200 mm (2” to 8”) is
proposed. Once again, although it shows that even higher values can be obtained,
the aim is to define the optimum range within which the MMD sizer operates.

Descarga SizerMMD
Product MMD 500Sizer
500
30,0%

25,0%

20,0%

15,0%

10,0%

5,0%

0,0%
40 45 50 60 63 64 65 70 75 80 90 100120125150175180200250300
mm

Partial frequency
Frecuencia parcial

As regards output measured in tons per hour, this machine achieves between 300
and 1,200 tph.

This same analysis will be repeated for the other models of MMD sizers.

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3.2. MMD 625

Nominal feed size: 300 to 600 mm (12” to 24”).

Feed MMDSizer
Alimentacion 625MMD
Sizer 625
40,0%
35,0%
30,0%
25,0%
20,0%
15,0%
10,0%
5,0%
0,0%
150
200
250
275
300
350
400
450
500
600
635
650
700
750
800
1000
1200
90

ROM
mm
Partial frequency
Series1

Product size: Here the range extends between 40 mm to 200 mm (2” to 8”),
although there are existing mining operations which employ the 625 model to
produce up to 300 mm (12”) product.

Product MMD
Descarga 625 Sizer
Sizer MMD 625
40,0%
35,0%
30,0%
25,0%
20,0%
15,0%
10,0%
5,0%
0,0%
40 50 60 65 75 80 90 100 125 140 150 200 250 300
mm

Partial frequency
Series1

In terms of productivity, yield of up to 2,000 to 3,000 tph can easily be reached.

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3.3. MMD 850

Nominal feed size: 750 to 800 mm (30” to 32”).

Feed MMD
Alimentacion 850 Sizer
Sizer MMD 750
30,0%

25,0%

20,0%

15,0%

10,0%

5,0%

0,0%
250 300 350 400 600 700 750 800 1000 1200 1250 1500 2000 ROM
mm

Partial frequency
Frecuencia parcial

Product size: In this case, the primary size range is between 100 mm to 300 mm (4”
to 12”)

Product
Descarga Sizer MMD
MMD850
750 Sizer
30,0%

25,0%

20,0%

15,0%

10,0%

5,0%

0,0%
100 120 150 180 200 250 300 325 350
mm

Partial frequency
Frecuencia parcial

This sizer can produce up to 3,500 tph.

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3.4. MMD 1150

Nominal feed size: 1,450 mm (57”), although values over 2,500 mm (98”) can be
obtained.

Feed sizer
Alimentación MMDMMD1150 1.000
Sizer (35)
40%
35%
30%
25%
20%
15%
10%
5%
0%
1.000 1.200 1.300 1400 1.500 1.600 1.800 2.500 ROM
mm
Partial frequency
Frecuencia parcial

Product size ranges from 150 mm to 400 mm (6” to 16”).

Product
Descarga sizerMMD
MMD1150
1.000Sizer
60%

50%

40%

30%

20%

10%

0%
150 250 300 350 400
mm
Partial frequency
Frecuencia parcial

With this sizer model, yield of up to 3,000 tph is expected, although values of 5,000
have been recorded.

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3.5. MMD 1300

Nominal feed size: 1,300 to 1,700 mm (51” to 67”), with a nominal maximum size of
2,500 mm (98”).

Feed MMD
Alimentación sizer1300
MMDSizer
1.300(18)
(18)
60%

50%

40%

30%

20%

10%

0%
1.200 1.300 1.500 2100 2.500 ROM
mm
Partial frequency
Frecuencia parcial

Product size: Ranging between 200 to 450 mm (8” to 18”), although as the graph
shows, 300 mm to 350 mm is typical (12” to 14”).

Product
Descarga MMD
sizer 1300
MMD (18)
1.300
70%

60%

50%

40%

30%

20%

10%

0%
300 350
mm
Partial frequency
Frecuencia parcial

Productivity can reach 6,000 tph.

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3.6. MMD 1.500

Nominal feed 2,000 mm (79”) with maximum size of 3,000 mm (118”).

Feed MMD
Alimentación sizer1500
MMDSizer
1.500(18)
(18)
50%
45%
40%
35%
30%
25%
20%
15%
10%
5%
0%
2.000 2.500 3.000 ROM
mm
Frecuencia parcial
Partial frequency

Product range from 250 mm to 450 mm (10” to 17”)

Product
Descarga MMD1.500
sizer MMD 1500
60%

50%

40%

30%

20%

10%

0%
250 300 400 450
mm
Frecuencia parcial
Partial frequency

These machines can produce up to 14,000 tph.

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4. SUMMARY TABLE

Based on the preceding data, the following table summarises the field of application
of MMD sizers along with expected output in tph:

MMD SIZERS MMD 500 MMD 625 MMD 850 MMD 1150 MMD 1300 MMD 1500
Feed mm (in) 300-500 (12-20) 300-600 (12-24) 750-800 (30-32) 1000-1450 (39-57) 1300-1700 (51-67) 2000 (79)
Top size mm (in) > 600 (24) > 800 (32) > 1000 (39) > 2500 (98) > 2500 (98) 3000 (118)
Power kW (HP) 2-75 (100) 2-260 (350) 1-400 (530) 1-400 (530) 1-500 (670) 2-600 (800)
Tons 12 26 40 60 95 160
Product size mm (in) TPH TPH TPH TPH TPH TPH
0-50 (2) 300-600 500-1000
0-75 (3) 300-600 500-1500
0-100 (4) 300-600 500-2000 600-1200
0-125 (5) 400-1000 500-2000 600-1200
0-150 (6) 400-1000 500-2000 600-1200 700-1600
0-175 (7) 400-1200 500-3000 1000-2000 700-1600
0-200 (8) 400-1200 500-3000 1000-2000 700-1600 2000-4500
0-225 (9) 1000-2000 700-1600 2000-4500
0-250 (10) 2000-3500 750-2000 2000-4500 5000-6000
0-275 (11) 2000-3500 750-2000 2000-4500 6000-8000
0-300 (12) 2000-3500 1200-2500 2000-4500 6000-8000
0-325 (13) 1200-2500 2000-4500 6000-8000
0-350 (14) 2000-3500 3500-4500 6000-8000
0-375 (15) 2000-3500 3500-4500 6000-8000
0-400 (16) 2000-5000 4500-6000 8000-10000
0-425 (17) 4500-6000 8000-14000
0-450 (18) 4500-6000 8000-14000

Pablo Fuenzalida Orozco, MMD Chile, August 2013

5. RANGE OF MINERAL REDUCTION USING MMD SIZERS

When using conventional machinery, any mineral measuring over a metre must be
reduced with breakers and picks or explosives.

CHANCADO CONVENCIONAL
CONVENTIONAL CRUSHING

EXPLOSIVOS
EXPLOSIVES

MARTILLOS
BREAKERS
PICADORES
AND PICKS

3 2,5 2 1,5

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With MMD sizers, the range of size reduction achievable is substantially increased,
reaching up to 3,000 mm (118”) as the following figure shows.

CHANCADO
CRUSHING CON
WITHMMD
MMDSIZERS
MINERAL SIZERS

MMD 1500
MMD 850
MMD 1300 MMD 750
MMD 1000 MMD 500

3 2,5 2 1,5

In other words, MMD sizers can be used for size reduction with infeed ranging from
3,000 mm (118”) to 50 mm (2”). This whole range can be processed by crushing
machines without the need to employ explosives or breakers and picks.

6. FINAL RECOMMENDATIONS

Not only do MMD sizers increase the range of size available for reduction with
crushing machines, they also pose various comparative advantages which should be
highlighted:

 Low operational cost.

 High productivity (tons per hour)
 Low CAPEX, equivalent to 30% of the cost of a conventional installation as a
result of the minimal infrastructure required.
 Primary and secondary crushers can be installed together as one system, the
product of one directly feeding the other.
 Mineral management systems are substantially simplified both in open pit and
underground mining operations.
 With MMD sizers, the top size to start reduction with mechanical crushing is
increased from 1,000 mm (39”), (Conventional crushing) to 3,000 mm (118”).
 This shows that MMD sizers double the size range of mineral infeed size
which can be reduced with machinery, without requiring the use of explosives
or breakers and picks.

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