Integrated solutions across the comminution flowsheet are setting Weir apart in the global mining sector, with the company’s ENDURON® range now offering complete circuit capabilities from crushing to screening. This holistic approach addresses the mining industry’s pressing need for energy-efficient processing solutions while maintaining high throughput and reliability standards.
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Comprehensive Comminution Portfolio Expansion
Weir has significantly expanded its market-leading ENDURON® high pressure grinding rolls (HPGRs) with a robust range of crushers and screens under the same premium brand, now further enhanced by in-house screening media. This integrated approach creates a seamless comminution circuit that delivers superior performance and efficiency. The development represents a strategic evolution for Weir, which has transformed from primarily being recognized for pump solutions to becoming a global leader in complete comminution systems.
“Combined with our renowned service culture and extensive global footprint, this creates a truly unmatched offering,” says JD Singleton, Weir’s Comminution Director for Europe, Middle East and Africa (EMEA). “In just 15 years, we have evolved from being primarily recognised for our high quality pump solutions to becoming a global leader in the comminution space.”
African Manufacturing Expansion and Market Impact
Weir’s large ENDURON® Elite double-deck banana screens have experienced significant demand, prompting the company to establish dedicated production capabilities at its Alrode facility south of Johannesburg. The expansion in Africa represents a strategic commitment to serving the continent’s growing mining sector, with the first units from the expanded plant expected to commence production later this year.
“Large vibrating screens are vital to complement large capacity crushing plants and HPGR circuits and our ENDURON Elite range is playing an important role in hard rock mining developments throughout Africa,” Singleton notes. The company’s recent contract with a leading brownfields mining project in Zambia demonstrates the growing adoption of these integrated solutions across the continent, according to recent analysis of mining equipment trends.
Groundbreaking Exciter Technology Innovation
Weir’s research and development efforts have produced the ENDURON® Elite ETX Exciter, a revolutionary advancement in vibratory screening technology. This patented innovation generates 1.28 mega newton force – equivalent to a fully laden A380 on take-off, 12 to 16 times per second – setting new global benchmarks for performance and reliability.
Having developed the initial LTX exciter capable of generating +1 mega newton force, Weir’s second-generation ETX exciter has been nominated for multiple technology awards. This reengineering of a 50-year-old mechanism demonstrates Weir’s commitment to pushing technological boundaries in comminution equipment, similar to how industry experts note technological innovation is transforming other industrial sectors.
Energy Efficiency Driving Comminution Adoption
The rising cost of electricity across Africa and globally has accelerated the adoption of HPGR circuits as energy-efficient alternatives to traditional semi-autogenous grinding (SAG) mill circuits. Weir’s integrated approach enables mines to significantly reduce power consumption while maintaining or improving processing capacity.
“A key factor behind the success of ENDURON HPGRs and our complementary crushers and screens in the circuit has been the rising cost of electricity, affecting not only South Africa but many other countries in Africa,” Singleton explains. This energy efficiency focus aligns with global mining trends toward sustainable operations and reduced environmental impact.
Enhanced Crusher Performance and Reliability
Weir’s ENDURON® range of jaw and cone crushers feature improved control and lubrication systems, coming standard with premier ESCO® crusher liners for extended operational life and reduced downtime. The latest generation of these crushers has recently been introduced, offering:
- Enhanced crushing efficiency through advanced chamber designs
- Superior wear protection with premium liner materials
- Intelligent control systems for optimized performance
- Reduced maintenance requirements and operating costs
Circuit Optimization and Customer Collaboration
Weir works closely with customers to optimize entire comminution circuits, comparing traditional SAG mill configurations with modern HPGR-based alternatives. This collaborative approach ensures that mining operations achieve optimal efficiency and productivity through properly integrated equipment selection and circuit design.
The company assists in comprehensive studies comparing circuits using primary crushers, SAG mills, and ball mills against configurations comprising primary crushers, secondary cone crushers, HPGRs, screens, and ball mills. This data-driven methodology helps mines make informed decisions about circuit design based on specific ore characteristics and operational requirements, with additional coverage available on evolving industrial certification standards.
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As Singleton emphasizes, “We work with customers at early project stages to ensure the comminution circuit is optimized for their specific needs, delivering maximum value throughout the equipment lifecycle.” This customer-centric approach, combined with technological innovation and manufacturing expansion, positions Weir’s integrated comminution solutions as a transformative force in modern mining operations worldwide, with related analysis highlighting similar integration trends across industrial sectors.
