Particle size analysis is the laboratory or online measurement process used to determine the size distribution of particles within a sample, providing critical data for circuit design, process control, and quality assurance. Common techniques include sieve analysis for coarser material, laser diffraction for fine powders, and image-based analysis for irregular particles. In bauxite operations, particle size analysis guides crusher and mill settings to achieve optimal feed size for digestion while minimizing energy consumption. In gold processing, particle size analysis is used to determine grind size targets, often expressed as P80 (the size below which 80 percent of particles pass), which directly correlates with gold liberation and recovery. In iron ore processing, particle size analysis supports blending decisions and determines whether material meets sinter feed, pellet feed, or lump ore specifications required by customers. In diamond processing, particle size analysis helps configure dense media separation and sorting equipment settings to match the specific size ranges present in the ore, minimizing the risk of stone loss or damage. Particle size analysis is typically conducted at multiple points in a processing circuit, including crusher discharge, mill discharge, and cyclone overflow, allowing metallurgists to monitor comminution efficiency and make timely adjustments that optimize both recovery and operating costs.
