KEYNOTE: HPGR in Gold Leach Applications – an Overview
The fine material produced by an HPGR will have similar process characteristics, with the added advantage that micro-fracturing results in a smaller apparent crush size. Other positive aspects of HPGR use in leaching increasingly confirm the value of this technology not only as a high(er) throughput, power- and steel-wear saving comminution ...
Model:Morrell HPGR and ball mill
Discussion. This model requires that the product of the secondary crusher and HPGR be coarser than 750 µm. This is reasonable as no HPGR circuit operates anywhere near that size range (as of 2020). There is a minor correction required for open circuit secondary crushing (the 1.0 factor becomes 1.19). In theory, open circuit operation would ...
High pressure grinding rolls HRC
the optimal crushing force 7 Maximizing crushing efficiency and circuit capacity Unleashing the innovative technology, created a revolutionary HPGR crushing circuit that challenges traditional expectations. +20% throughput +120 million metric ton of processed ore +60,000 hours of operation-15% energy consumption HRC™ for …
Why HPGRs are revolutionising mill circuits | Weir
The high pressure of HPGR's "bed-breakage" creates micro-cracks in the ore, promoting improved mineral recovery at coarser size fractions. This means less leaching acid is required and percolation periods are shortened, reducing costs and maximising recovery in less time. In the diamond industry, the HPGR acts as a selective grinder ...
The Effect of HPGR and Conventional Crushing on the …
Comparative high pressure grinding rolls (HPGR) and cone crusher pilot-scale tests were conducted using Upper Group 2 (UG2) platinum-bearing ore in order to determine the impact of micro-cracks in HPGR products toward energy requirements in ball mills and the degree of liberation. The ball mill was fed with HPGR and cone crusher …
Energy and Cost Comparisons of HPGR-based …
The HPGR-ball mill circuit comprises a reverse-closed secondary crushing circuit prior to a closed HPGR circuit, followed by a reversed-closed ball-mill circuit with cyclones (See Figure 2). The vibrating screen …
Application of population balance model to HPGR crushing
Application of the model. The research on application of the population balance model to HPGR crushing was commenced using cement grinding data and gone through mineral data. Dundar (2012) fit the cement grinding data that was acquired by Aydogan (2006) to population balance model. Dundar (2012) back-calculated the …
Benchmarking: Bond
HPGR model: Quantity 4. HPGR motor 5600 kW (actually 2 × 2800 kW) Adjust the mechanical efficiency to get E crush of 1.9 kWh/t (E HPGR of 1.4 kWh/t), results is mechanical efficiency of 0.30. Bond/Rowland SSBM Circuit model: Set the crusher product size to 6000 µm. Circuit feed size 160 000 µm and product size 100 µm.
How HPGRs compare to conventional milling | Weir
High Pressure Grinding Rolls have lower maintenance overheads than ball and rod mills, primarily because the grinding media in conventional mills needs to be replaced on a more regular basis. This makes HPGRs more flexible when it comes to meeting your campaign timings. When tyres do wear down and need to be replaced, the Enduron® HPGR's ...
ECEL™ HPGR I PERFORMANCE PARTS High pressure …
to stage crushing alone. HPGR inclusion in heap leaching can be a viable retrofit to existing operations as well as for original plant designs. HPGR flowsheet considerations for; open circuit, closed circuit (with screen), or edge-recycling provide flexibility in the design to meet the particle size distribution needed to optimise your heap
High Pressure Grinding Rolls for Zinc and lead ores
However, this project increased throughput from 17 Mtpa to over 23 Mtpa (within 4 years operation). The secondary crush product feed 75mm to HPGR crusher. At the time it was the largest HPGR model (Polycom 24/17-8) from the OEM Polysius (ThyssenKrupp). Feed rate to the HPGR crusher / feed bin was approx 1,800 wtph, and 40% recirculating load.
PROCESS INTEGRATION AND OPTIMISATION OF THE …
stockpile with 40,000 tonnes of live capacity, which then feeds the secondary crushing circuit. The secondary crushing circuit consists of three single deck banana screens and five 746 kW MP1000 secondary crushers. One additional screen was installed in 2010, and in 2011 a sixth secondary crusher was installed. Secondary crushing is a closed ...
Perfecting Hard-Rock High Pressure Grinding Performance
Chris Morley, now with Ausenco Minerals, will discuss HPGR Flowsheets—The Next Generation, examining the practicalities of simplifying the design of HPGR-based circuits by adopting open-circuit operation for the secondary and/or tertiary crushing stages, with a view to reducing capital costs and thus eliminating or reversing the capital cost ...
High-Pressure Grinding Roller Presses for Minerals …
» minimal energy requirement for material transport in the HPGR » small and 100 % active high pressure grinding zone. Different ores Feed material and HPGR product after sizing Primary and secondary crushing Screening at 20–50 mm Screening at 4–12 mm Water Classi˜cation and ball mill Hydrocyclone HPGR Water Ore storage Downstream process
Video: Building the world's largest HPGR
The HRC™3000 is to date the largest HPGR ever put into operation. At the time of writing, it has operated for over 11,000 hours. During that time, a total of 46,100,000 tons have …
Outotec on HPGR's leading edge
Secondary crushing in combination with tertiary HPGR application, both in closed circuit configuration, potentially allows to substitute AG or SAG grinding when just …
Downstream Crushing Options for Secondary, Tertiary …
The rock breaks and falls out the bottom. These types of crushers are usually applied as tertiary or quaternary crushers with less than 2" (75 mm) feed or smaller. Some Vertical Shaft Impactors can be used as secondary crushers with larger feed. Vertical Shaft Impactors are very application-specific. They are sensitive to abrasive …
Comminution and classification technologies of iron ore
Finally, lines 5, 6, and 7 consist of primary jaw crushing, secondary and tertiary cone crushing, closed circuit HPGR and closed-circuit ball milling, wet magnetic separation, reverse flotation, further magnetic separation, filtration and concentrate regrinding in a HPGR to achieve a final concentrate with fine product size for pellet plant ...
on HPGR's leading edge
The HPGR's efficiency is achieved by inter particle crushing, ie the pressing force is applied to a material bed allowing for multiple interparticle breakages within the high pressure/fracture zone. This requires a void volume into which the breaking material bed can be compressed and also friction between the particles to allow for …
Flowsheet considerations for optimal use of high pressure …
Larger HPGR's in the future may receive a coarser secondary crushed material. This does not automatically mean a modest size reduction; the bulk of the size …
Predicting the overall specific energy requirement of crushing…
Secondary crushing followed by HPGR followed. ... Iran). SHAP precisely assessed multivariable relationships between the monitored operational variables and correlated them with the HPGR P 80. SHAP values showed relationship magnitudes among variables and ranked them based on their effectiveness on the P ...
HPGR APPLICATION IN AUSTRALIA
secondary and HPGR crushing effectively replaces the relatively energ y in-efficient SAG . mill. These studies require comprehensive ore property data as well as the robust process .
Predicting the overall specific energy requirement of crushing…
Secondary/tertiary crushing followed by ball milling (Crush/ball). Details of the calculations for each circuit are given in the Appendix A as worked examples. Summary results are shown in Table 1 and indicate that overall the SABC circuit requires the highest specific energy, whilst the HPGR/ball and Crush/ball circuits give lower values which ...
High Pressure Grinding Rolls
Profile and condition of the crushing liners is critical to deliver the best distribution of energy into the crushing chamber. Low-bulk-density feeds reduce throughput. Maximum product bulk density is 1.9 …
HRC™e high pressure grinding rolls (HPGR)
The HRC™e high pressure grinding rolls (HPGR) is evolving the industry standard for grinding efficiency. Using innovative technology of flanges and an anti-skew assembly, the HRC™e HPGR brings an energy efficient and high throughput solution while reducing operational costs. Energy efficiency. Improve energy efficiency by up to 15%.
High-pressure grinding on a whole new level
M ajor design breakthroughs by Minerals in high pressure grinding roll (HPGR) technology at Freeport-McMoRan Inc's (FCX) Morenci open-pit mine in Arizona have resulted not only in the world's …
A closer look at increasing HPGR efficiency through
The HPGR crushing circuit at the pilot plant includes two wet vibratory screens, primary and secondary, along with an HRC HPGR with 750 mm by 400 mm rolls operating in closed circuit, as shown in Fig. 3. The fresh feed to the HPGR crushing circuit is tertiary-crushed material with a top size of approximately 25 mm.
HPGR: WHY SKEWING IS A REQUIREMENT FOR …
A second source of uneven feed to the HPGR can be segregation, where one side of the HPGR is mostly fed with coarser particles, while the other side receives more fines. Figure 3 shows a schematic illustration of feed segregation prior to the HPGR (Van der Meer & Maphosa, 2011). Similar to the impact of the uneven feed in the
Predicting the overall specific energy requirement of …
Secondary crushing followed by HPGR followed. Conclusions. An approach has been formulated in which the specific energy requirements of comminution circuits …
Trade-Off Realities in HPGR vs. SAG Milling—A Practical …
The secondary screen undersize reports to the HPGR feed bin, which has 540 t live capacity. A belt feeder, in combination with HPGR roll speed, is used to maintain choke feed conditions to the HPGR. A single Köppern Ø2.0 m x 1.85 m HPGR is used for the tertiary crushing stage. This is fitted with 2 x 2,200 kW variable speed motors.