Key Benefits

  • Lower operating power required
  • Creates microcracks for downstream processes
  • Provides a more stable grinding operation for variable ores
  • Reduces the need for and consumption of grinding media

HPGR - Today's technology for today's mines

Our HPGR is flexible enough to be highly suitable for both brownfield expansions and greenfield installations. The wide variety of ways our customers are already using the machine shows just how helpful the technology is.

Our HPGR is a perfect complementary tool to work in conjunction with, and even enhance the performance of traditional grinding mills and fixed-gap crushers. The HPGR exposes feed material to very high pressure for a short amount of time. The compression typically causes the rock to crack and cleave along the grain boundaries, weakening the rock structure and exposing the ore particles. This high pressure also creates a large amount of fines and causes the formation of microcracks in the larger particles, lowering the Bond work index of the ore and reducing the ball mill power required downstream.

F-Series HPGR

The F-Series HPGR is our full size machine used in large mining projects throughout the world. Operation, maintenance and service personnel collaborated to create this modern HPGR design. With it, you get a reduced footprint, convenient and safe handling for heavy components and improved shipping.


F Series HPGR  High pressure grinding roller

S-Series HPGR

We re-designed our legacy roll press to upgrade it and optimise it for mining duty, and the result is our S-Series HPGR. Though this series is meant for smaller projects, plants and retrofits, it is packed with plenty of the same features that are in our larger models. And the smaller size means that your machine can be shipped partially or fully assembled, resulting in a faster installation.

S series HPGR High pressure grinding roller

High pressure grinding roll - saving energy and providing results

The HPGR truly is a unique comminution product. It weakens rock structure and exposes ore particles, making it an attractive option for heap leach applications.

HPGR for Primary Grinding
HPGR in Pebble Crushing Circuit
HPGR for Heap Leach Circuits
HPGR in Finish Grinding Circuit
Primary Grinding

HPRGs add efficiency to the primary grinding circuit for highly competent and complex ore bodies. HPGR product has microcracked particles which weakens the boundaries and lowers the Bond work index. This reduces the amount of ball milling power required downstream.

 


Pebble Crushing

Our HPGR is great at de-bottlenecking your problematic pebble circuit. You know how easy it is for hard pebbles to get caught in circulation, small enough to escape the mills but too large to make it through your screening process. Our solution is to crush the pebbles with a cone crusher and then feed them to an HPGR. This arrangement will crush the pebbles enough that that you can feed the product directly into the ball mill sump.

 


Heap Leaching

If higher recoveries and faster leach kinetics is important to you, HPGR should be a consideration for your heap leach flowsheet. The microcracking in HPGR product lends itself nicely to the heap leaching process. HPGR inclusion in heap leaching can be a viable retrofit to existing operations as well as for original plant designs. 

 


Finish Grinding

The future of mining is dry comminution circuits that minimise wasted power, water consumption and carbon production. This circuit also provides downstream benefits:

 

  • The consumption of grinding media is eliminated
  • The finished, ground material can be immediately stored, creating a buffer, and allowing the downstream plant to be fed at a consistent rate
  • Air separators provide a product with a narrower particle size distribution

 

Benefits of our HPGR in minerals processing:

  • Improved metallurgy due to microcracking of coarse particles
  • HPGR is one of the most power efficient tools in comminution
  • Higher availability than conventional crushers
  • Reduced need for and consumption of grinding media
  • More stable grinding operation for variable ores

Efficient and advanced crushing with High Pressure Grinding Rolls

FerroCer® Impact Wear Panels

The lower section of our HPGR feed chute, which typically experiences the highest wear, is lined with FLSmidth’s patented FerroCer® Impact Wear Panels. Our wear panels have proven to greatly outperform conventional wear plates in this application where the feed ore is often large, very hard, and highly abrasive. These panels are easy and safe to install, while providing the longest possible wear life. Learn more about where else in your plant operation you can optimize your durability with FerroCer® Impact Wear Panels.

FerroCer Wear Panels for HPGR

Torque-sharing arm

The planetary reducers are shaft mounted to the rolls and are linked together via the torque sharing arm assembly. This saves you money because it eliminates the cost of additional foundation structure and hardware to bear the torque arm reaction forces.

 

This feature also allows the drive train to be captured and held in place during roll change-out using our (optional) drive retraction cradle, which further optimises the roll change-out time and makes the procedure safer.

HPGR Torque arms

Hinge-mounted, dual-acting cylinders

Mounting the hydraulic cylinders to the frame with hinges allows maintenance personnel to safely access and inspect these components without getting inside the framework of the HPGR. For any maintenance that required removing the cylinders, overhead access is free and clear of the frame with the hinges in the outboard position. “Dual-acting” means that no special tools are required to separate the rolls to clear tramp metal. By simply reversing the oil flow, the hydraulic cylinders can be used to retract the rolls and allow the tramp to fall through, getting the machine back online quickly.

FLSmidth HPGR hinge mounted cylinders

Oil-cooled bearings

The HPGR has a skid mounted tank with a lubrication oil conditioning system that supplies clean filtered and temperature conditioned oil to the roll bearings. A constant flow of oil carries the contaminants and heat that are generated in operation away from the bearings to maximising uptime. The lubrication oil system instrumentation monitors and protects the system. In contrast, conventional grease lubricated units are messy, require frequent relubrication and must be water cooled.

Key takeaways

  • No greasing or cleaning required
  • Longer bearing life
  • Grit and heat are quickly removed from the bearings

Advanced skew control

We designed the hydraulic pumping system to the cylinders with advanced skew control (ASC) and use linear variable differential transducers (LVDTs) to monitor the system. As skewing starts to occur in the floating roll, the ASC system adjusts the press force applied to the hydraulic cylinders, keeping the roll assemblies as near parallel as possible during operation, while at the same time maintaining interparticle contact and grinding efficiency over the roll width.

 

Differing frame types for specific applications

There are two frame styles offered for industrial applications. The S-Series, which incorporates a traditional box frame design, has been optimised for smaller plants. The F-Series, using our express frame, accommodates the need to handle and operate larger and heavier components.

 

We designed and built our express frame for a faster and safer replacement of the roll surfaces. With the minerals processing industry trending towards larger equipment, we specifically developed the express frame to handle larger, heavier components in a safer and easier manner.

 

This new frame uses a tapered pin and bushing concept. Removal of the tapered bushing creates more clearance space for inserting and removing pins. A wedge jacking system takes the load off the pins for quick extraction and replacement.


HPGR Standard

Sizes Type Roll Diameter
[mm]
Roll Width
[mm]
Grinding Force
[kN]
Motor Power
[kW]
Length
[mm]
Width
[mm]
Height
[mm
]
PM0 9/7 950 650 2,700 2x220 3,240 1,860 3,800
PM1 11/8 1,100 800 3,400 2x450 3,750 2,150 4,600
PM3 14/8 1,400 1,000 4,300 2x500 3,735 2,164 5,400
PM4 17/10 1,700 1,000 7,000 2x800 4,490 3,030 6,800
PM5 20/10 2,000 1,000 8,600 2x1,600 5,950 3,000 7,500
PM6 20/15 2,000 1,500 11,000 2x1,850 6,020 3,460 8,000
PM7 20/17 2,000 1,650 13,500 2x2,500
6,550 3,640 8,800
PM8 24/17 2,400 1,650 17,000 2x2,800 7,725 3,820 9,000
PM9 26/18 2,600 1,750 20,000 2x3,400 8,500 4,150 9,700
PM10 30/20 3,000 2,000 25,000 2x5,000 9,500 4,600 11,000
 
 

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