HPGR Brochure.ashx

7/22/2019 HPGR Brochure.ashx

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HPGR - High Pressure Grinding Roll

or the Minerals Industries


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HPGR - High Pressure Grinding Rollor the minerals industries

FLSmidth is a world wide supplier o

HPGRs. HPGR technology has been

used in the cement industry or many

years, and due to the success and

eectiveness o this machine

FLSmidth has invested in the

development o HPGR technology or

minerals industries specically to hard

rock applications such as copper, gold,

iron ore, and many others.

HPGR equipment is a modern and

very energy-ecient comminution

technology. During its relatively short

history, HPGR technology has

undergone signicant development

with machine roll wear suraces &

control philosophy.

The HPGR, developed by FLSmidth,

ranks among the most advanced and

ecient units available. Its design

incorporates the vast experience and

expertise gained since HPGR

technology was rst introduced.

How it works & benets

In high-pressure grinding roller

comminution the eed material is

exposed to very high pressure or a

short time. The high pressure causes

the ormation o microcracks in the

eed particles and generates a

substantial amount o ne material.

The pressed material can be ed

directly to a given size ball mill, making

it possible to increase the throughput

o a given size ball mill and reduce the

specic power consumption o the

whole mill system.

I 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 racturing

to expose minerals encased within the

particular ore which increases

liberation via recovery.

A fexible solution

The HPGR is a fexible solution, highly

suitable both or upgrades and or

new installations. Upgrading may

increase capacity by up to 80

percent, while the total specic

energy consumption o 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 eatures

already mentioned, the HPGR is

characterised by:

Long wear part lie

Low operational and

maintenance costs

Short shutdown or 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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3

Features

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 o the grinding process.

Tramp control

The FLSmidth HPGR includes a new to

the industry, patent-pending hydraulic

system capable o accommodating

large shocks. This system helps

protect the critical roller surace rom

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 shit

hydraulic valves.

Gabled rame

A gabled rame allows or easier

maintenance and replacement o 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 rom HPGR

3. Remove cheek plates/eed gate

4. Pull moveable roller towards

L-gable

5. Remove moveable roller rom

HPGR

6. Install new moveable roller

7. Pull new moveable roller to

position

8. Install cheek plates/eed 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 sae guards

Step 1

Step 3

Step 2


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HPGR - High Pressure Grinding Roller

5

3

4

1

12

14

9

2

10

7

8

11

13

1. Studded Roll

2. Oil-lubricated spherical

roller bearing

3. Planetary reduction gear

4. Torque arm arrangement

5. Saety release coupling

6. Two variable speed drives

7. Hydraulic pressurising

cylinders

8. Nitrogen-lled bladder

accumulators

9. Bottom rame

10. Top rame

11. Feed Gate

12. Hinged L-shape end section

13. Elastomer shear pad

14. Feed Chute

6


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5

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, mm25 27.5 30 35 37.5 40 45 50 55 60 65 70

Product Specications

Surace speeds 0.8m/s to 2.4m/s

Motor power 100kw to 5800kw

Throughputs 100t/h to 3000t/h

Specic press orces 3000Kn/m2 to 5500Kn/m2

Roll Congurations


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Main component description

The rame

The rame is built up o parts tted

together by removable pins. The

upper and lower rame, linked by

vertical end sections, together orm a

horizontal U-rame. The U-rame is

closed by an L-shape end section that

is hinged to the lower rame and olds

down or easy removal o the roller

assemblies. This rame encloses and

supports the bearing housings o the

roller assemblies and carries the

hydraulic cylinders o the pressurising

device. The bearing housings slide on

the lower rame.

The upper rame supports a eed

chute and the dust casing, which

encloses the two roller bodies to

reduce dust. Extraction parts are

available in extreme cases.

Rollers

One roller is xed while the other is

horizontally movable and is pressed

towards the ormer by our hydraulic

cylinders. The position o the movable

roller depends on the characteristics

o the material ed to the press.Spacer shims between the roller

bearing housings prevent the rollers

rom touching each other when

pressurised without eed and permit

adjustment o the minimum gap.

Each o the two rollers has a separate

drive. Each roller has a shat mounted

planetary gearbox connected to the

other gearbox by a balanced torque

arm system. The patented balanced

torque arm system reduces

oundation costs and complexity by

taking the torque through the other

gearbox and not down to the

oundation. Both drives include a

saety release coupling between

reducer and motor.

The HPGR is equipped with a

hydraulic pressure system which

ensures that the pressing orce is kept

practically even during the

comminution process. In addition, it

protects the press against overloading.

Roller wear lining

FLSmidths rolls are supplied with a

lining o tungsten carbide studs. The

studs provides a longer roller wear lie

than its predecessor hard-aced

smooth suraces. In addition to the

increased wear lie due to this

material change, the inserts also

protrude out o the roller surace

which assists in promoting the

ormation o the sel protecting

autogenous layer across the roller

surace. This stud extension also

achieves better throughputs, unlike

the hard ace rolls which experience

slippage due to the lack o traction.

FLSmidth has a dedicated research

and development team that is

involved in ongoing research into new

and better materials to prolong the

lie expectance o these roll suraces.

Drive confguration

HPGR Roll exposed


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7

Feed control gate

To acilitate control o the choke eed

press, FLSmidth has introduced a

motorised eed control gate located just

above the roller surace. The eed control

gate is only required or choke eed.

The gate is used or smoothening the eed

start and is suitable or trimming the press

to optimum operation. It is also used or

adjusting the throughput or power

consumption o presses working with eed

material o varying draw-in characteristics

and/or riction characteristics.

Local machine control

The 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 or testing and running

in the machine as well as or

troubleshooting, independent o the

central control system.

The control panel includes a display that

indicates status o the machine and has

acilities or starting and stopping, making

parameter changes, etc. The local control

panel is delivered ready or use, thus

saving engineering time during installation.

Feed control gate


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Advanced wear surace concepts

FLSmidth is currently conducting a

substantial amount o research and

development into HPGR wear surace.

The six main areas o ocus include:

1. Variations o stud compositions,

to get a better understanding o

the nature o the carbide to the

specic ore which it is treating.

2. Compositions o the roll body

base material.

3. Getting a better understanding o

the ormation o the autogenous

build up, and the impact on the

wear lie o the roll.

4. Using the roll surace

conguration to counter the

eects o the pressure curve.

5. Installation and retention o

tungsten carbide studs.

6. Understanding the relationship

o optimal press orce to cake

ormation and eective

liberation without causing

downstream ineciency due to

poor de-agglomeration.

HPGR product cake

Floating roll Discharge product conveyors


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9

Primary crusher-secondary conecrushing-HPGR-ball mill circuit option

This option, in comparison with

conventional Primary crusher-SAG-

Ball mill circuit, can potentially save

signicant amount o 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 or

harder and more competent ore

bodies. Furthermore the cost o steel

ball consumption associated with the

SAG Mill is also eliminated. Some

SAG circuits can experience huge

fuctuation in mill throughput when

the Run o Mine (ROM) ore hardness

varies, in contrast this option that will

provide a more stable eed rate to

downstream process, which can be

very important to fotation, leaching

and other hydrometallurgical

applications.


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Pebble crushing-with HPGRincorporation option

0

In SAG milling applications, critical

size material can build up and limit

mill throughput especially or more

competent ores. Typical to alleviate

this, use is made o 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 ater the

pebble crusher. This conguration

allows a signicant portion o ner

product to be generated and passed

directly into the ball milling circuit.

This results in a more eective usage

and balancing o the available energy.

As the HPGR product contains

signicant micro-racturing it can help

to reduce energy used in the ball

milling circuit.


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11

Iron Ore processing option

HPGR technology has been applied in

various orms to iron ore processing.

By incorporating it as one o the

stages o crushing and combining it

with dry magnetic separation the

downstream ball milling circuit can be

reduced in size as a signicant

portion o harder barren silicates can

be removed rom the process.


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2

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-racturing

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 or aster

leaching rates and higher metal

extraction.


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13

Gold processing concept option

As HPGR interest has grown in the

minerals industry, there has been

growing interest in certain metal

fowsheets such as gold. Due to the

platy nature o 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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4

Customer Services

Customer Services

FLSmidth is your One Source or spare

parts, service, maintenance, asset

management, and operational

services. Our Customer Services

provide a wide range o services or

mineral processing equipment and

systems including raw material

testing, process design, equipment

installation, troubleshooting, process

and mechanical analysis, and

commissioning o 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

or you.

Rebuilds & Modernisations

Keep your equipment current with the

latest advancements to enhance your

operations and provide or better

eciencies. FLSmidth can rebuild your

equipment or provide the most

current state-o-the-art equipment

improvements and/or system

upgrades or operational eciency

and enhanced unctionality.

Quality & Reliable OEM Parts

Contact our trained service personnel

to get authentic, high quality, original

equipment manuacturer (OEM) spare

and replacement parts or your

equipment.

FLSmidth is the only place to nd eld

engineers and technicians trained

specically to deal with the unique

characteristics o this equipment.

Engineering Services

FLSmidth provides the services required

to engineer, procure and construct in

virtually every major industrial market

rom Mining, Metals & Minerals to

Hydrocarbon Processing and

Hazardous Incineration.

We have multiple ull-time

engineering teams trained in each

discipline. These personnel use the

most current resources, training and

sotware to provide the best available

solutions to your project.


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Research & Development

Ore Characterisation &

Process Mineralogy Labs

FLSmidth is adding state-o the-art

Ore Characterisation & Process

Mineralogy Labs to support their

Metallurgical Services, Engineering

and Plant Construction. The labs will

also serve mining companies or

exploration, mine site geology,

expansions, easibility studies, plant

support optimisation, fowsheet devel-

opment, and environmental work.

The laboratories are being expanded

during 2011 and are targeted or

startup during 1st quarter o 2012.

They will be staed 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 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 o 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

acilities are located.


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Bethlehem

Mexico

Lima

Santiago

Votorantim

UK

Milan

JohannesburgPerth

Gosford

Beijing

Moscow

Salt Lake CityWalluf

Orillia

www.fsmidth.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

Minerals ProcessingTechnology Center

FLSmidth Salt Lake City

7158 S. FLSmidth Dr.

Midvale, UT 84047-5559

Tel: +1 801 871 7000

Fax: +1 801 871 7001

Email: [email protected]

Australia

FLSmidth Pty Ltd

Tel: +61 2 4320 4700


BrazilFLSmidth Ltda.

Tel: +55 15 3416 7400


Canada

FLSmidth Ltd.

Tel: +1 705 325 6181


Chile

FLSmidth S.A.

Tel: +56 2 290 0000


PeruFLSmidth S.A.C.

Tel: +51 - 1-708 0500


South Arica

FLSmidth Pty Ltd

Tel: +27 - (0)10 210 4000


United Kingdom

FLSmidth (UK) Ltd.

Tel: +44 1788 555 777


HPGR support oces

Documents

HPGR Brochure.ashx