Crushing operation from a mineralogical class perspective: insights from comminution parameters, crusher performance, and liner wear

• Reponses of six distinct rock and ore samples were examined for jaw crushing conditions. • Internal correlations between the comminution parameters were established. • Comminution parameters were predicted as a function of mineralogical composition. • Bond A i indicated jaw plate wear effectively. • Kick’s constant ( C k ) demonstrated dependence on B CWi . This research investigates the link between the mineralogical composition of rock types and their response during jaw crushing. The study focuses on the effects of mineralogy on comminution parameters, crushing performance, and jaw liner wear. Six representative rock and ore types—gold, lead–zinc, polymetallic, basalt, limestone, and dolomite—were characterized through a comprehensive testing program, including the drop-weight test (DW, A × b parameter), Los Angeles abrasion (L.A.), Bond crushability work index (B CWi ), Bond abrasion index (A i ), and point load test (PLT). Internal relationships between these comminution parameters were established, and regression models were developed to relate each parameter to the mineralogical compositions of the samples. Pilot-scale jaw crusher experiments were then conducted under varied feed size distributions and closed-side settings (CSS) to evaluate crushing responses and measure plate wear as functions of mineralogical composition. In addition, metal composition trials were carried out on the jaw plates to assess how different alloy contents influenced the wear mechanism and to identify the most durable configuration. The pilot test results were further analyzed through Kick’s law, linking the Kick constant (C k ) to the comminution parameters. Overall, the study demonstrates how mineralogical and metallic characteristics jointly govern size reduction and wear mechanisms, offering a practical framework for predicting crusher performance and supporting operational (OPEX) and capital (CAPEX) optimization in industrial comminution systems.