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.

Vermiculites and phlogopites can be exfoliated by chemical and thermal treatment methods to obtain chemically inert, adsorbent, fire-resistant, low-density materials with excellent thermal and acoustic insulation properties. The water content of the clay generally determines the extent of exfoliation and the presence of interstratification is claimed to increase the rate of exfoliation. Considering the strong interaction between water and microwaves, the effect of microwave power on exfoliation characteristics of vermiculites and phlogopites after treatment with water and hydrogen peroxide solution were studied at 600, 950 and 1300 W for microwave exposure times of 10, 20, 30, 60, 120 and 300 s. It was observed that the water molecules in the interlayers of the individual flakes were driven off quickly by microwave treatment causing layer separation in the samples. The vermiculite sample showed 2.8 and 5.6 times, respectively, the exfoliation ratio of the phlogopite samples, in accord with their water contents.

Microwaves are a form of electromagnetic radiation commonly used for telecommunications, navigation and food processing. More recently microwave technologies have found applications in fibre-reinforced polymer composites, which are increasingly used in aircraft structures. Microwave energy can be applied with low power (up to milliwatts) for non-destructive testing and high power (up to kilowatts) for heating/curing purposes. The state-of-the-art applications at high power include curing, three-dimensional (3D) printing, joining and recycling, whereas low-power microwave techniques can provide quality checks, strain sensing and damage inspection. Low-power microwave testing has the advantage of being non-contact, there is no need for surface transducers or couplants, it is operator friendly and relatively inexpensive; high-power microwave energy can offer volumetric heating, reduced processing time and energy saving with no ionising hazards. In this paper the recent research progress is reviewed, identifying achievements and challenges. First, the critical electromagnetic properties of composites that are closely related to the heating and sensing performance are discussed. Then, representative case studies are presented. Finally, the trends are outlined, including intelligent/automated inspection and solid-state heating.