HPGR - High pressure grinding roller

The HPGR is a flexible crushing solution, highly suitable both for upgrades and new installations

HPGR Express Frame
  • Overview
  • Design

Benefits

  • Long wear part life
  • Low operational and maintenance costs
  • Short shutdown for wear part replenishment
  • Up to 20-30% reduced energy consumption

 

Features

  • Avanced skew control
  • Tramp control
  • Express Frame for easier maintenance

 

The HPGR, developed by FLSmidth, ranks among the most advanced and efficient crushing units available. 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.

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 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.

 

 

Express Frame

The frame is a fabricated and machined steel welded assembly consisting of upper and lower sections with a pinned gable end section. This gable end is a solid casting. The use of pins allows a frame which is simple to erect and requires a minimum of lay down space for removing the roller assemblies. This Express Frame also incorporates a split-rail technology, in which the bearing notch slides in between two rails. 

FLSmidth's Express Frame is designed and built for the rapid replacement of mineral application roll surfaces.

Rollers

Roller modules comprise the finished tire, shaft, bearings, and bearing housings all as a single unit assembly. The Express Frame F-series HPGR utilizes the fixed roller module as the fixed end of the frame. This fixed roller module has the frame pin holes incorporated directly into the bearing housing casting. 

Roller wear lining

FLSmidth's roll sleeve surfaces are provided with tungsten carbide inserts for wear protection. Edges of the roll also incorporate tungsten carbide sections to improve the protection of that portion of the roll. 

Feed control gate

To facilitate control of the "choke feed" press, FLSmidth introduces a motorized feed control gate located just above the roller surface. (The feed control gate is only required for choke feed). The gate is used for smoothing the feed start and is suitable for fine tuning of HPGR to optimize 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 control

The HPGR has its own local control panel (PLC). The panel is connected to 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 to use, thus saving engineering time during installation.

Elimination of water cooling system

As the machine is equipped with oil lubrication, the requirement for water cooling is omitted/eliminated.


Downloads

HPGR Brochure
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Putting HPGR technology through its paces
Article published in June 2013 Mining Magazine

FLSmidth opens world-class HPGR suitability and design testing facility
Article published in August 2013 Mining Magazine

Estructura especificamente disenada para aplicacion de rodillos de moliend de alta presion (HPGR) en el procesamiento de minerales
Article written by James Pownell, FLSmidth HPGR global product manager

Fundamentals of Roll Surface Functionality & Wear in Operation
This paper provides direction in consideration when designing an ore-type roll surface and operator guidelins to optimize HPGR roller life and effectiveness in the grinding circuit