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HPGR - High Pressure Grinding Roll for the Minerals Industries

HPGR - High Pressure Grinding Roll for the minerals industries

FLSmidth is a world wide supplier of HPGRs. HPGR technology has been used in the cement industry for many years, and due to the success and effectiveness of this machine FLSmidth has invested in the development of HPGR technology for minerals industries specically to hard rock applications such as copper, gold, iron ore, and many others. HPGR equipment is a modern and very energy-efcient comminution technology. During its relatively short history, HPGR technology has undergone signicant development with machine roll wear surfaces & control philosophy. The HPGR, developed by FLSmidth, ranks among the most advanced and efcient units available. Its design incorporates the vast experience and expertise gained since HPGR technology was rst introduced. If HPGRs are run correctly ball mills can be downsized and use smaller grinding media which will reduce steel ball consumption in the BM circuit substantially. HPGR also promotes micro fracturing to expose minerals encased within the particular ore which increases liberation via recovery.

Global Installations
Canada 2 China 6 Columbia Denmark 1 2

India 9 Indonesia 10

A exible solution The HPGR is a exible solution, highly suitable both for upgrades and for new installations. Upgrading may increase capacity by up to 80 percent, while the total specic energy consumption of new installations may be reduced by 20-30 percent compared with conventional grinding systems. The most typical process congurations are described on pages 9-13.
Besides the cost-saving features already mentioned, the HPGR is characterised by: Long wear part life Low operational and maintenance costs Short shutdown for wear part replenishment

Korea 6 Malaysia Saudi Arabia Thailand 1 3 7

Turkey 2 United Kingdom 1

How it works & benets In high-pressure grinding roller comminution the feed material is exposed to very high pressure for a short time. The high pressure causes the formation of microcracks in the feed particles and generates a substantial amount of ne material.
The pressed material can be fed directly to a given size ball mill, making it possible to increase the throughput of a given size ball mill and reduce the specic power consumption of the whole mill system.



Advanced skew control The FLSmidth HPGR press incorporates roller skew control via the hydraulic power unit.This system keeps the two roller assemblies parallel during operation, thus reducing grinding pressure deviation across the roller width which in-turn increases the consistency of the grinding process. Tramp control The FLSmidth HPGR includes a new to the industry, patent-pending hydraulic system capable of accommodating large shocks.This system helps protect the critical roller surface from incidents such as tramp metal bypassing upstream metal detectors. The FLSmidth system utilizes a specially congured hydraulic accumulator which instantly activates without a PLC needing to shift hydraulic valves.

Gabled frame A gabled frame allows for easier maintenance and replacement of the roller assembly. Step 1: 1. Remove upper L-gable pins 2. Support gearboxes 3. Disconnect gearboxes Step 2: 1. Swing out L-gable Step 3: 1. Pull xed roller towards L-gable 2. Remove xed roller from HPGR 3. Remove cheek plates/feed gate 4. Pull moveable roller towards L-gable 5. Remove moveable roller from HPGR 6. Install new moveable roller 7. Pull new moveable roller to position 8. Install cheek plates/feed gate 9. Install new xed roller 10. Pull new xed roller to position 11. Swing in L-gable Step 4: 12. Install 2 upper L-gable pins 13. Reconnect gearboxes 14. Install safe guards

Step 1

Step 2

Step 3

HPGR - High Pressure Grinding Roller


3 12 11 10 1 2 13

8 9

1. Studded Roll 2. O il-lubricated spherical roller bearing 3. P lanetary reduction gear 4. T orque arm arrangement 5. S afety release coupling

6. Two variable speed drives 7. H ydraulic pressurising cylinders 8. N itrogen-lled bladder accumulators 9. Bottom frame

10. Top frame 11. Feed Gate 12. Hinged L-shape end section 13. Elastomer shear pad 14. Feed Chute

Product Range
Area, m2 Diameter, m Width, m Feed particle size, F100, mm 0.15 0.58 0.26

0.36 0.9 0.4

0.60 1.17 0.51

0.90 1.36 0.66

1.25 1.48 0.85

1.60 1.6 1

2.00 1.74 1.15

2.50 1.92 1.3

3.00 2.12 1.41

3.60 2.3 1.57

4.20 2.5 1.68

5.00 2.7 1.85













Product Specications
Surface speeds Motor power Throughputs Specic press forces 0.8m/s to 2.4m/s 100kw to 5800kw 100t/h to 3000t/h 3000Kn/m2 to 5500Kn/m2

Roll Congurations

Main component description

bearing housings prevent the rollers from touching each other when pressurised without feed and permit adjustment of the minimum gap. Each of the two rollers has a separate drive. Each roller has a shaft mounted planetary gearbox connected to the other gearbox by a balanced torque arm system. The patented balanced torque arm system reduces foundation costs and complexity by taking the torque through the other gearbox and not down to the foundation. Both drives include a safety release coupling between reducer and motor. The HPGR is equipped with a hydraulic pressure system which ensures that the pressing force is kept practically even during the comminution process. In addition, it protects the press against overloading.

Drive conguration

The frame The frame is built up of parts tted together by removable pins. The upper and lower frame, linked by vertical end sections, together form a horizontal U-frame. The U-frame is closed by an L-shape end section that is hinged to the lower frame and folds down for easy removal of the roller assemblies. This frame encloses and supports the bearing housings of the roller assemblies and carries the hydraulic cylinders of the pressurising device. The bearing housings slide on the lower frame.
The upper frame supports a feed chute and the dust casing, which encloses the two roller bodies to reduce dust. Extraction parts are available in extreme cases.

HPGR Roll exposed

Rollers One roller is xed while the other is horizontally movable and is pressed towards the former by four hydraulic cylinders. The position of the movable roller depends on the characteristics of the material fed to the press. Spacer shims between the roller

Roller wear lining FLSmidths rolls are supplied with a lining of tungsten carbide studs. The studs provides a longer roller wear life than its predecessor hard-faced smooth surfaces. In addition to the increased wear life due to this material change, the inserts also protrude out of the roller surface which assists in promoting the formation of the self protecting autogenous layer across the roller surface. This stud extension also achieves better throughputs, unlike the hard face rolls which experience slippage due to the lack of traction. FLSmidth has a dedicated research and development team that is involved in ongoing research into new and better materials to prolong the life expectance of these roll surfaces.

Feed control gate To facilitate control of the choke feed press, FLSmidth has introduced a motorised feed control gate located just above the roller surface. The feed control gate is only required for choke feed.
The gate is used for smoothening the feed start and is suitable for trimming the press to optimum operation. It is also used for adjusting the throughput or power consumption of presses working with feed material of varying draw-in characteristics and/or friction characteristics.

machines. The panel is connected to the central control system. The panel is used for testing and running in the machine as well as for troubleshooting, independent of the central control system. The control panel includes a display that indicates status of the machine and has facilities for starting and stopping, making parameter changes, etc. The local control panel is delivered ready for use, thus saving engineering time during installation.

Local machine control The roller press has its own local control panel (PLC), similar to other complex

Feed control gate

Advanced wear surface concepts

FLSmidth is currently conducting a substantial amount of research and development into HPGR wear surface. The six main areas of focus include: 1. Variations of stud compositions, to get a better understanding of the nature of the carbide to the specic ore which it is treating. 2. Compositions of the roll body base material. 3. Getting a better understanding of the formation of the autogenous build up, and the impact on the wear life of the roll. 4. Using the roll surface conguration to counter the effects of the pressure curve. 5. Installation and retention of tungsten carbide studs. 6. Understanding the relationship of optimal press force to cake formation and effective liberation without causing downstream inefciency due to poor de-agglomeration.

HPGR product cake

Floating roll

Discharge product conveyors

Primary crusher-secondary cone crushing-HPGR-ball mill circuit option

This option, in comparison with conventional Primary crusher-SAGBall mill circuit, can potentially save signicant amount of energy even including all the ancillary equipment (conveyors, screens, storage bins, dust collection and control system) associated with this design. This energy saving is more prominent for harder and more competent ore bodies. Furthermore the cost of steel

ball consumption associated with the SAG Mill is also eliminated. Some SAG circuits can experience huge uctuation in mill throughput when the Run of Mine (ROM) ore hardness varies, in contrast this option that will provide a more stable feed rate to downstream process, which can be very important to otation, leaching and other hydrometallurgical applications.


Pebble crushing-with HPGR incorporation option

In SAG milling applications, critical size material can build up and limit mill throughput especially for more competent ores. Typical to alleviate this, use is made of a pebble crusher and the recycle crushed product is returned back to SAG or advanced to the ball milling circuit. An alternative approach is to add an HPGR after the pebble crusher. This conguration

allows a signicant portion of ner product to be generated and passed directly into the ball milling circuit. This results in a more effective usage and balancing of the available energy. As the HPGR product contains signicant micro-fracturing it can help to reduce energy used in the ball milling circuit.


Iron Ore processing option

HPGR technology has been applied in various forms to iron ore processing. By incorporating it as one of the stages of crushing and combining it with dry magnetic separation the

downstream ball milling circuit can be reduced in size as a signicant portion of harder barren silicates can be removed from the process.


Heap Leach concept option

For heap leach application, compared with conventional three-stage crushing, the HPGR as tertiary crushing will produce ner material with greater micro-fracturing characteristics. Tests have conrmed that the HPGR will make a more

desirable agglomeration product, which in turn will increase leach pad permeability, minimise dry spots, promote better aeration, and ultimately the potential for faster leaching rates and higher metal extraction.


Gold processing concept option

As HPGR interest has grown in the minerals industry, there has been growing interest in certain metal owsheets such as gold. Due to the platy nature of gold HPGR technology

can be incorporated into a comminution circuit and allow improved metal recovery as well as potential energy savings.


Customer Services

Customer Services FLSmidth is your One Source for spare parts, service, maintenance, asset management, and operational services. Our Customer Services provide a wide range of services for mineral processing equipment and systems including raw material testing, process design, equipment installation, troubleshooting, process and mechanical analysis, and commissioning of new plants. Customers are our most important assets. Once we have designed and installed your processing systems, we do everything possible to provide the tools to ensure that those systems continue to operate at optimum levels, all the time. It is by no means a radical concept. Indeed, everyone promises it; we deliver it! Operations and Maintenance Our Customer Services experts have the know-how to optimise your maintenance and shutdown management programs. We can help plan your preventive maintenance programs, manage scheduled repairs, and even implement these programs for you.

Rebuilds & Modernisations Keep your equipment current with the latest advancements to enhance your operations and provide for better efciencies. FLSmidth can rebuild your equipment or provide the most current state-of-the-art equipment improvements and/or system upgrades for operational efciency and enhanced functionality. Quality & Reliable OEM Parts Contact our trained service personnel to get authentic, high quality, original equipment manufacturer (OEM) spare and replacement parts for your equipment.
FLSmidth is the only place to nd eld engineers and technicians trained specically to deal with the unique characteristics of this equipment.

Engineering Services FLSmidth provides the services required to engineer, procure and construct in virtually every major industrial market from Mining, Metals & Minerals to Hydrocarbon Processing and Hazardous Incineration.
We have multiple full-time engineering teams trained in each discipline. These personnel use the most current resources, training and software to provide the best available solutions to your project.


Research & Development

Ore Characterisation & Process Mineralogy Labs FLSmidth is adding state-of the-art Ore Characterisation & Process Mineralogy Labs to support their Metallurgical Services, Engineering and Plant Construction. The labs will also serve mining companies for exploration, mine site geology, expansions, feasibility studies, plant support optimisation, owsheet development, and environmental work. The laboratories are being expanded during 2011 and are targeted for startup during 1st quarter of 2012. They will be staffed with highly experienced process mineralogists and will encompass the most advanced laboratory technology.
This will include: Quantitative XRD Rietveld Mineralogy SEM and Optical Microscopy Automated Mineral Analysis NIR Data Base Development Clay Analysis The labs will work in close cooperation with the existing and expanding FLSmidth Dawson Metallurgical Test Center. Mineralogical Laboratory Services will include Ore Characterisation & Process Mineralogy Plant Surveys Lab Technology Development Lab Design Lab Automation Training in Geo-Metallurgy

Laboratory and Tech Center HPGR client support Key Test Parameters Ore Mineralogy Abrasion Wear Index Specic Press Force Index Breakage Characteristics UCS Specic Throughput Metallurgical Tests Modeling & Scale-Up
Test Center Program Exploratory HPGR Tests HPGR Leach Tests HPGR Float Tests HPGR Pilot Testing of Ore Types Customer Specic Tests

Pilot unit testing

FLSmidth Salt Lake City, Inc. Technology Center where the ore characterisation & process mineralogy labs, and other testing facilities are located.

HPGR support ofces



Moscow Walluf Milan Beijing

Salt Lake City

Orillia Bethlehem


Lima Votorantim Santiago




Minerals Processing Technology Center FLSmidth Salt Lake City 7158 S. FLSmidth Dr. Midvale, UT 84047-5559 Tel: +1 801 871 7000 Fax: +1 801 871 7001 Email: info.slc@smidth.com

Brazil FLSmidth Ltda. Tel: +55 15 3416 7400 Email: smidth@smidth.com.br Canada FLSmidth Ltd. Tel: +1 705 325 6181 Email: sm-ca@smidth.com Chile FLSmidth S.A. Tel: +56 2 290 0000 Email: sm-cn@smidth.com

Peru FLSmidth S.A.C. Tel: +51 - 1-708 0500 Email: smidthperu@smidth.com South Africa FLSmidth Pty Ltd Tel: +27 - (0)10 210 4000 Email: sm-za@smidth.com United Kingdom FLSmidth (UK) Ltd. Tel: +44 1788 555 777 Email: s.uk@smidth.com

Australia FLSmidth Pty Ltd Tel: +61 2 4320 4700 Email: info.australia@smidth.com

Copyright 2011 FLSmidth A/S. ALL RIGHTS RESERVED. FLSmidth is a (registered) trademark of FLSmidth A/S. This brochure makes no offers, representations or warranties (express or implied), and information and data contained in this brochure are for general reference only and may change at any time.

Rev. 9/2/2011 al-us