Used in mining applications for the last 30 years, HPGR technology has streamlined the transition between mineral grinding and crushing by accepting larger-sized particles compared to ball mills, and producing finer-sized particles than cone crushers.
In service since the mid-eighties and used primarily in cement production, high pressure grinding rolls are increasingly being deployed as tertiary and quaternary crushers in mineral comminution circuits, dealing with tougher ores including iron, gold, copper and diamonds.
HPGR technology uses inter-particle grinding to reduce particle size and increase grinding efficiency by transferring pressure to particles from multiple directions. The breaking and fracturing of particles only happens when the material compressive strength is exceeded.
Given high pressure grinding rolls (HPGR) are pressure controlled rather than gap controlled, they ensure the right pressure is applied to suit the material being processed.
Within the grinding circuit, we manufacture the following HPGR technology and grinding equipment:
For more information about our HPGR technology, please contact our team today.
There are numerous benefits associated with using HPGR technology within aggregate and mining grinding applications.
Where HPGR technology has replaced traditional methods of crushing and grinding (e.g. SAG or ball mills), it has:
On average, comminution is responsible for 25% of the final energy consumption of an average mine site. And, despite improvements in the design of SAG (Semi-Autogenous Grinding) mills, the adoption of high pressure grinding rolls (HPGR) takes energy savings to a completely different level.
As a result, most greenfield projects processing hard (competent) rock, include HPGR as part of their standard comminution flow sheet.
The Benefits of Enduron® High Pressure Grinding Rolls (HPGR)
Enduron® high pressure grinding rolls (HPGR) can handle a wide variety of ores and particle sizes from fine pellet feed all the way up to coarse grinding of 75mm magnetite iron ore.
When it comes to feed material characteristics, the specific ore type is not detected by an Enduron® HPGR, however ore hardness, size and bed compressibility are important considerations.
Our Enduron® HPGR can fit into a wide array of mining and aggregate applications within both wet and dry classification including:
With low energy consumption, low maintenance requirements, excellent throughput capacity and high availability, Enduron® high pressure grinding rolls (HPGR) are a proven way to improve the efficiency of aggregate and mineral grinding circuits. Setting the benchmark for energy efficient grinding, they use dynamic skewing to provide best-in-class wear life for mining applications and are fast becoming the go-to technology for greenfield projects. Our Enduron® HPGR portfolio ranges from pilot machines to large format production machines including the world’s largest operational roller surface, capable of processing over 118,000 tons of ore per day. For high availability and operational stability, there’s no better choice than the internationally renowned Enduron® HPGR.
Recommended Industries: Mining, Sand and Aggregates
Enduron® high pressure grinding rollers (or rolls) are the primary grinding tools of the Enduron® HPGR. Built to last, these grinding rolls contain a superior autogenous wear layer that effectively protects their surface and improves their overall nipping properties. They are a high quality product with a low operational cost. With the advanced frame design of the Enduron® HPGR, replacement rollers / tyres can be exchanged within a single 24-hour shut down.
Recommended Industries: Mining, Sand and Aggregates
Case Study: How Our Enduron® High Pressure Grinding Rolls (HPGR) Transformed this Sand and Aggregates site
When it comes to the success and reliability of your HPGR, having a proactive servicing and spares strategy is critical.
In order to warrant fast exchange of wear parts, complete roller assemblies (including shafts, tyres, bearing arrangements) are supplied along with the machine as well as strategic rotable parts which are fundamental to delivering high machine availability.
When tyres reach their end of life and are scheduled to be removed during scheduled annual shutdowns, the spare roller assembly will be installed within 24 hours allowing the machine to continue processing the ore.
The worn tyres will subsequentially be removed from this roll set and new tyres will be installed before this set becomes a new rotable again.
All of our grinding equipment and machinery is backed by our unrivalled Weir Minerals service centre network. This means that our on-the-ground staff and dedicated service facilities are here to support you, regardless of your site's location.
We can assist at any time and understand both upstream and downstream conditions to deliver the greatest energy, water and ownership cost savings providing: