The mining industry is heavily dependent on energy-intensive processes, such as rock breakage, which leads to significant operational costs. This paper explores microwave-assisted rock breakage as an innovative method to enhance the efficiency of comminution within the mining industry. It introduces a system that employs a Klystron microwave power source with a maximum output of 7.5 MW, using a $\mathrm{TM}_{010}$ single-mode cavity at 3 GHz, to channel energy inside a specially designed rock cavity. The paper emphasizes the importance of designing an efficient microwave cavity for this system, focusing on the cavity’s design and simulation. Through both simulated results (using HFSS software) and experimental observations, the study reveals the promising application of microwave technology in the field of mining. The simulated frequency response of the designed cavity (S11) is −22 dB, it demonstrates significant potential for reducing both energy consumption and associated costs. Additionally, the designed cavity is fabricated from aluminum and filled with polyether ether ketone material. The measured frequency response (S11) of the cavity at 3 GHz is −17 dB.

A comminution process is a material size reduction and separation process which is primarily used in the aggregates and the minerals processing industry. Knowledge related to equipment’s operation, raw material properties, operational strategies, control system, maintenance, etc. is needed to design a capable plant. New needs are arising from the industry for existing operational crushing plants such as investigation for improvements, upscaling, and downscaling of the capacity. The paper presents an application of simulation-driven development for a crushing plant in an existing gold processing plant. Due to the change in ore characteristics and the need for optimizing the cost of operation, it is required to investigate the opportunities for improvement and alternative options for downscaling the capacity of the plant. A systematic process for configuring, developing, and evaluating alternative concepts using a process simulation tool is presented. The results show the process of generating knowledge for alternative crushing plant operation settings and how the choices can be selected and eliminated using boundary conditions. The evaluation presents possible improvements and alternative concepts with their opportunities and pitfalls.

This study examined the comminution of fresh herbage, subsequent nutrient release, and the characteristics of swallowed boli from three physically and chemically contrasting forages during ingestive mastication by dairy cows. The extent and pattern of nutrient release will determine their availability to rumen microflora, and potentially influence their efficiency of use. The forages evaluated were perennial ryegrass (ryegrass, Lolium perenne L., cv Alto AR37), lucerne (Medicago sativa L., cv Torlesse) and chicory (Cichorium intybus L., cv Choice). Experimental design was a 3×3 cross-over with three forages and three consecutive 1-day measurement periods, conducted twice. Six non-lactating, pregnant, multiparous Holstein-Friesian×Jersey cows (Bos taurus) were used, with the first cross-over applied to three mature (10.1±0.61 years old; BW 631±64 kg) cows, and the second to three young (4.8±0.02 years; BW 505±19 kg) cows. Fresh cut forage was offered to the cows following partial rumen evacuation. Swallowed boli were collected directly at the cardia at the commencement, middle and end of the first feeding bout of the first meal of the day. Forage species did not affect the fresh weight of ingested boli (mean 169 g, P=0.605) but the proportion of saliva in boli varied between forage. Boli of chicory contained the greatest amount of herbage material and least amount of saliva, whereas ryegrass boli were the opposite. Boli fresh weight tended to increase as time in the meal progressed, but the age of the cow was not shown to affect any boli characteristics or nutrient release. Particle size reduction was affected by forage, with 31%, 38% and 35% of chicory, lucerne and ryegrass herbage reduced to <2 mm. There was little evidence of relationship between comminution and any physical or chemical characteristic of the forage, except in ryegrass where extent of comminution was moderately correlated with herbage strength. Proportional release of herbage soluble carbohydrate exceeded that of N during mastication. Differences in loss of N were moderately correlated with the amount of N in the herbage (R2=0.53) but herbage comminution was not strongly correlated with release of either N or carbohydrate. These findings illustrate the complex animal×forage interactions that occur during mastication, and that it is not possible to infer nutrient loss from herbage based on herbage characteristics as the driver for this differ between species.