The high-pressure grinding rolls (HPGR) technology is increasingly being considered for hard ore comminution due to its significant benefits in energy consumption compared to conventional semi-autogenous grinding (SAG) mill circuits. It has been shown that HPGR circuits can reduce the energy requirements by 10 to 40% [ 1, 2, 3, 4 ].
The Coalition for Energy Efficient Comminution (CEEC) has been established and is supported by a broad range of mining sector companies keen to accelerate awareness, knowledge transfer and, by implication, improve energy and cost outcomes in the substantive area of comminution. HPGR - CEEC (Coalition for Eco Efficient Comminution) Toggle navigation
High-pressure grinding rolls (HPGR) are an accepted, but continuously expanding, comminution technology. The copper industry has a growing need to process harder ores with progressively lower...
abrasiveness (in an HPGR) are most suitable to comminution in an HPGR. The larger the benefit, the easier the decision can be made in favour of a 'new' (higher risk) technology. The growth of HPGR in minerals applications clearly shows this phenomenon. The case for HPGR in hard rock applications is a combination of the above factors.
Plant Concept SAG Circuit HPGR Circuit Equipment 1 x SAG Mill 9.8 MW 1 x Secondary Crusher 750 kW 1 x Pebble crusher 450 kW 1 x HPGR 4.0 MW 2 x Ball Mills 5.6 MW each 2 x Ball Mills 5.6 MW each Screens and conveyors 0.5 MW Screens and Conveyors 1.5 MW Total drive capacity installed 21.95 MW 17.45 MW
The obtained results proved that the application of HPGR devices in given copper ore comminution circuit may improve the effectiveness of downstream grinding process what leads to improvement of ...
1. Introduction. Since its first application by the Swedish company LKAB in 1993 , the High-Pressure Grinding Rolls (HPGR) has reached an outstanding position in pellet feed preparation prior to green ball formation.Vale S.A. was responsible for one of the main successful applications that followed, when it introduced the technology to some of its pelletizing plants of Complexo de Tubarão ...
This is where the POLYCOM HPGR and the latest HPGR Pro development was carried out, which is now the main FL offering in this growing comminution technology market. Ralf Martens, the FL Head of Service Center at Ennigerloh recently stated that the first batch of 5+1 HPGRs of PM8 size 24/17 had been completely assembled and ready for ...
Get access Abstract Many researchers have discussed the advantages of the pressure breakage mechanism and the importance of high-pressure grinding rolls (HPGR) in the hard minerals industry but the impact of this machine on the final product of the comminution circuit at an industrial scale has been less studied.
Based on the current work and previous investigations, it was found that HPGR comminution within a crushing circuit, in specific instances, can result in 2 − >10% increases in copper extraction. The tested variables are crush size, rock type and copper mineralogy dependence. Various other process parameters may also be optimized.
The SABC and HPGR options both produce a ball mill P80 of 125 microns. Energy consumption associated with comminution circuit ancillary equipment was included in the operating cost analysis. SABC and HPGR grinding circuit ancillary equipment includes reclaim feeders, conveyors, lube systems and screens.
HPGR vs. SAG Advantages Less Significant energy cost savings Reduced grinding media consumption Reduced overall operating costs Reduced footprint Higher mechanical availability Faster Equipment Delivery More Environmentally Friendly Disadvantages Can increase initial capital costs Increased material handling Increased dust Energy
There is a significant drop in comminution efficiency when the voids between rocks falls below 20%. It requires a much larger force to initiate rock breakage in a packed bed. Rock shape was recently noted for its influence in the T 10 protocol and A x b constants in the 2015 publication indicated in the study .
In service since the mid-eighties and used primarily in cement production, high pressure grinding rolls are increasingly being deployed as tertiary and quaternary crushers in mineral comminution circuits, dealing with tougher ores including iron, gold, copper and diamonds. HPGR technology uses inter-particle grinding to reduce particle size and increase grinding efficiency by transferring ...
logging information and comminution measurements, which were used to develop models for comminution indices (i.e. A×b, BWI, and throughput) based on inherent geological variability. Domains were identified using predicted A×b, BWI, and throughput models. In this case, the predictive models indicated that class-based comminution
Benchmarking energy efficiency requires three measurements: comminution power, rock throughput and the resulting size reduction. The first two measurements are fairly objective, however, the third is subjective and could be measured in numerous different ways.
HPGR . Equation 1 for HPGR's crushers is written as: f x f x 2. 1 h h 3 ih. 4 2 W S K M x x. 1 (9) S. h = coarse ore harness parameter as defined by equation 8 and with K. s. set to 35 . K. 3 = 1.0 for all HPGRs operating in closed circuit with a classifying screen. If the HPGR is in open circuit, K. 3. takes the value of 1.19. x. 1 = P. 80 ...
Dry comminution technologies, such as High Pressure Grinding Rolls (HPGR) and Vertical Roller Mills (VRM), have been successfully used in other industries such as cement and coal for decades,...
High Pressure Grinding Rolls (HPGR) technology is accepted as an energy-efficient and cost-effective alternative for treating specific mineral ore types. HPGR technology has been advancing within manufacturing facilities and research centers since its first installation in 1985. Over the last three decades much of the literature on HPGR
The system supplies a copious amount of filtered and cooled oil to the bearings to flush away contaminants and carry away heat generated by bearing friction and the heat generated during normal operation. This, along with an improved sealing arrangement for the bearings, provides long service life for the bearings.
HPGR offers several potential benefits including reduced energy consumption, higher throughput and lower costs of downstream grinding operations (Rule et al., 2008, Saramak, 2012, Tromans, 2008), as well as more intense comminution and higher separation recovery in comparison to other crushers (Meer and Maphosa, 2012, Saramak et al., 2017).
Using conventional comminution, an ore might require grinding to p80 = 45µm (~325 mesh), for example, to liberate the valuable components, e.g. magnetite, from gangue, e.g. silica. Inter-particle comminution in HPGR may break some ores along grain boundaries thereby liberating valuable minerals from gangue at a much coarser particle sizes.
For efficient HPGR comminution, this points to operating HPGRs at low reduction ratios and to the removal of fines in recycle systems if the HPGR is to produce a finished product. A system consisting of rolls that operates at high pres-sure was conceived by Schönert to translate the breakage of a confined particle-bed into a continuous form. The
The HPGR products are characterized by a fine particle size and the micro-cracks formation in individual particles, which appears in downstream grinding processes, decreasing their energy...
Hence, there is a crucial need to investigate the effect of different comminution methods on the micro-crack generation in finer ore particles, the dominant size fraction in agitation leaching. The objective of the current study is to investigate the effects of HPGR comminution on the particle properties and subsequent gold agitation leaching.
CAHM per Nordell ) and a HPGR (Figure 1b) machine, of a similar size with two surface textures, illustrated by Köppern Hexadur and Studs in their isometric views. Herein, we will demonstrate how CAHM achieves significant gain in comminution efficiency over HPGR. We used an advanced Discrete Element Method (DEM) tool trade named ROCKY .
comminution degree (Sx) of HPGR product, however, individual results greatly depend on physical and mechanical properties of feed material. Increasing of pressing force affects the press productivity, because higher force acting on the floating roll move it towards the fixed one and, as a result, the gap is decreasing, too.
The comminution process based on HPGR generates a higher fines proportion compared with the ball mill circuit by breaking down the minerals due to the pressure applied over the particles and to a greater extent owing to friction and shear forces acting among the particles in the particle bed [ 1, 11 ].
in ore grinding it has proven their benefits as compared to conventional comminution circuits. However, it is still possible to increase the HPGR advantages by applying the right flowsheet. Concepts like screen recycling versus edge recycling and progressive grinding are options for optimization of HPGR application for an individual ore.
A comminution circuit of three-stage crushing and one-stage milling was adopted by configuring the tower mill after HPGR. As shown in Fig. 1, the primary crushing involves a C80 Jaw crusher comminuting the ROM ores from − 350 to − 70 mm for feeding the secondary crushing.In secondary crushing, a GP100M cone crusher is closed with a YA1836 circular vibrating screen to generate − 12 mm ...
High-pressure grinding rolls (HPGR) are an accepted, but continuously expanding, comminution technology. The copper industry has a growing need to process harder ores with progressively lower grades, more challenging metallurgy and increasing demand for efficient bacterial leaching applications. This has resulted in a major focus on HPGR use in a crushing circuit. If the industry is to ...
HPGR's role in plant optimisation Mineral processing sometimes came under a harsh spotlight in recent years due to the segment's contribution to energy consumption, with more efficient technologies such as High-Pressure Grinding Rolls (HPGR) seeing increasing take-up. HPGRs can take larger proportion of the comminution work than most think
HPGR technology uses inter-particle grinding to reduce particle size and increase grinding efficiency by transferring pressure to particles from multiple directions. The breaking and fracturing of particles only happens when the material compressive strength is exceeded.
HPGR was expected to consume less energy per tonne of ball mill feed compared with conventional solutions It was also expected that ball mill specific energy consumption would be lower (compared with conventional solutions), this resulting from incipient cracks present in BM feed particles High mechanical and process availability
(Morley C, 2008) High pressure grinding roll (HPGR) technology has been the subject of many technical presentations in the minerals comminution fraternity ever since the technology was first introduced as an energy efficient comminution device that revolutionized cement grinding plants.