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HPGR - High Pressure Grinding Roll for the Minerals Industries
HPGR - High Pressure Grinding Roll for the minerals industries
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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 specifically to hard rock applications such as copper, gold, iron ore, and many others.
HPGR equipment is a modern and very energy-efficient comminution technology. During its relatively short history, HPGR technology has undergone significant development with machine roll wear surfaces & control philosophy.
The HPGR, developed by FLSmidth, ranks among the most advanced and efficient units available. Its design incorporates the vast experience and expertise gained since HPGR technology was first introduced.
How it works & benefitsIn 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 fine 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 specific power consumption of the whole mill system.
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.
A flexible solutionThe HPGR is a flexible solution, highly suitable both for upgrades and for new installations. Upgrading may increase capacity by up to 80 percent, while the total specific energy consumption of new installations may be reduced by 20-30 percent compared with conventional grinding systems. The most typical process configurations 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
Global Installations• Canada 2
• China 6
• Columbia 1
• Denmark 2
• India 9
• Indonesia 10
• Korea 6
• Malaysia 1
• Saudi Arabia 3
• Thailand 7
• Turkey 2
• United Kingdom 1
• USA 2
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Features
Advanced skew controlThe 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 controlThe 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 configured hydraulic accumulator which instantly activates without a PLC needing to shift hydraulic valves.
Gabled frameA gabled frame allows for easier maintenance and replacement of the roller assembly.
Step 1:1. Remove upper L-gable pins2. Support gearboxes3. Disconnect gearboxes
Step 2:1. Swing out L-gable
Step 3:1. Pull “fixed roller” towards
L-gable2. Remove “fixed roller” from HPGR3. Remove cheek plates/feed gate4. Pull “moveable roller” towards
L-gable5. Remove “moveable roller” from
HPGR6. Install new “moveable roller”7. Pull new “moveable roller” to
position8. Install cheek plates/feed gate9. Install new “fixed roller”10. Pull new “fixed roller” to position11. Swing in L-gable
Step 4:12. Install 2 upper L-gable pins13. Reconnect gearboxes14. Install safe guards
Step 1
Step 3
Step 2
HPGR - High Pressure Grinding Roller
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1. Studded Roll
2. Oil-lubricated spherical roller bearing
3. Planetary reduction gear
4. Torque arm arrangement
5. Safety release coupling
6. Two variable speed drives
7. Hydraulic pressurising cylinders
8. Nitrogen-filled bladder accumulators
9. Bottom frame
10. Top frame
11. Feed Gate
12. Hinged L-shape end section
13. Elastomer shear pad
14. Feed Chute
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Product Range
F150 F360 F600 F900 F1250 F1600 F2000 F2500 F3000 F3600 F4200 F5000
Area, m2 0.15 0.36 0.60 0.90 1.25 1.60 2.00 2.50 3.00 3.60 4.20 5.00
Diameter, m 0.58 0.9 1.17 1.36 1.48 1.6 1.74 1.92 2.12 2.3 2.5 2.7
Width, m 0.26 0.4 0.51 0.66 0.85 1 1.15 1.3 1.41 1.57 1.68 1.85
Feed particle size, F100, mm
25 27.5 30 35 37.5 40 45 50 55 60 65 70
Product Specifications
Surface speeds 0.8m/s to 2.4m/s
Motor power 100kw to 5800kw
Throughputs 100t/h to 3000t/h
Specific press forces 3000Kn/m2 to 5500Kn/m2
Roll Configurations
Main component description
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The frameThe frame is built up of parts fitted 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.
RollersOne roller is fixed 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
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.
Roller wear liningFLSmidth’s 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.
Drive configuration
HPGR Roll exposed
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Feed control gateTo 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.
Local machine controlThe roller press has its own local control panel (PLC), similar to other complex
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.
Feed control gate
Advanced wear surface concepts
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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 specific 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 configuration 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 inefficiency due to poor de-agglomeration.
HPGR product cake
Floating roll Discharge product conveyors
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Primary crusher-secondary cone crushing-HPGR-ball mill circuit option
This option, in comparison with conventional Primary crusher-SAG-Ball mill circuit, can potentially save significant 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 fluctuation 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 flotation, leaching and other hydrometallurgical applications.
Pebble crushing-with HPGR incorporation option
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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 configuration
allows a significant portion of finer 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 significant micro-fracturing it can help to reduce energy used in the ball milling circuit.
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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 significant portion of harder barren silicates can be removed from the process.
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Heap Leach concept option
For heap leach application, compared with conventional three-stage crushing, the HPGR as tertiary crushing will produce finer material with greater micro-fracturing characteristics. Tests have confirmed 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.
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Gold processing concept option
As HPGR interest has grown in the minerals industry, there has been growing interest in certain metal flowsheets 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.
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Customer Services
Customer ServicesFLSmidth 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 MaintenanceOur 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 & ModernisationsKeep your equipment current with the latest advancements to enhance your operations and provide for better efficiencies. FLSmidth can rebuild your equipment or provide the most current state-of-the-art equipment improvements and/or system upgrades for operational efficiency 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 find field engineers and technicians trained specifically to deal with the unique characteristics of this equipment.
Engineering ServicesFLSmidth 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.
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Research & Development
Ore Characterisation & Process Mineralogy LabsFLSmidth 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, flowsheet devel-opment, 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 coopera-tion 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 supportKey Test Parameters• Ore Mineralogy• Abrasion Wear Index• Specific Press Force Index• Breakage Characteristics• UCS• Specific 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 Specific Tests
Pilot unit testing
FLSmidth Salt Lake City, Inc. Technology
Center where the ore characterisation &
process mineralogy labs, and other testing
facilities are located.
Bethlehem
Mexico
Lima
Santiago
Votorantim
UK
Milan
Johannesburg Perth Gosford
Beijing
Moscow
Salt Lake CityWallufOrillia
www.flsmidth.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.
Minerals Processing Technology CenterFLSmidth Salt Lake City7158 S. FLSmidth Dr.Midvale, UT 84047-5559Tel: +1 801 871 7000Fax: +1 801 871 7001Email: [email protected]
Australia FLSmidth Pty LtdTel: +61 2 4320 4700Email: [email protected]
BrazilFLSmidth Ltda.Tel: +55 15 3416 7400Email: [email protected]
CanadaFLSmidth Ltd.Tel: +1 705 325 6181Email: [email protected]
ChileFLSmidth S.A.Tel: +56 2 290 0000Email: [email protected]
PeruFLSmidth S.A.C.Tel: +51 - 1-708 0500 Email: [email protected]
South AfricaFLSmidth Pty LtdTel: +27 - (0)10 210 4000Email: [email protected]
United KingdomFLSmidth (UK) Ltd.Tel: +44 1788 555 777 Email: [email protected]
HPGR support offices
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