HPGR
High Pressure Grinding Rollers, also known as HPGRs,
are an energy efficient comminution technology that was primarily developed for
crushing and fine grinding raw materials in the mining and minerals processing
industry. HPGR technology utilizes the fuller crushing effect of compressive
particle breakage as opposed to conventional impact, attrition or abrasion.
While HPGRs have mainly been adopted for minerals processing applications, they
are now increasingly being used for shaping and granulating applications in
other industries as well.
Working Mechanism of HPGR
High
Pressure Grinding Roller (HPGR) is the
feed material is pressed between two counter rotating, parallel rollers with a
small gap setting between them. The rolls have a hardened outer shell and are
pressed towards each other by hydraulic cylinders with a force of several
hundred tons. The high pressure and shearing forces generated between the two
rollers result in complete particle breakage and size reduction. The optimized
roll geometry used in HPGRs results in higher comminution forces than
conventional compression crushers.
Advantages of HPGR Technology
Some of the key advantages of high pressure grinding roller (HPGR) technology compared to conventional crushing
equipment include:
– Higher energy efficiency: HPGRs require significantly less energy for the
same amount of material size reduction compared to conventional crushing
methods. This is mainly due to the optimized compressive crushing mechanism
used.
– Improved particle shape and surface
characteristics: HPGR crushing produces much less fines but with a better
cubical product shape and surface texture. This results in improved downstream
processing performance.
– Less wear and maintenance: The grinding rolls used in HPGRs have a very
long lifetime and require less frequent roll changes due to the compressive
crushing mechanism employed.
– Compact footprint: HPGR systems
can deliver high throughputs in a compact footprint compared to conventional
crushers due to the design of the grinding rolls.
– Versatility: HPGR technology is
equally suited for coarse and fine size reduction applications, offering
versatility. The technology gap can also be adjusted tosuit different particle
size requirements.
Applications of HPGR Technology
Some common applications where HPGR technology is effectively utilized include:
– Cement and raw meal processing:
HPGRs are increasingly being used for grinding clinker, raw meal and cement in
place of traditional tube mills. This significantly boosts energy efficiency in
cement plants.
– Iron ore pellet feed preparation:
High pressure grinding roller (HPGR)
result in improved iron recovery and pelletizing properties compared to
cone crushers for generating iron ore pellet feed.
– Mineral sands processing: For fine
grinding high-grade mineral sand concentrates like leucoxene and rutile before
final drying and packaging.
– Limestone processing: For size reduction of limestone prior to use in flue
gas desulfurization systems, sugar processing plants etc.
– Industrial minerals: For grinding
kaolin, talc, potash and other industrial minerals where better particle shapes
and less fines are desirable.
– Recycling applications: For
comminution of glass cullets, recovered aggregate from construction and
demolition waste.
In high pressure grinding roller (HPGR) technology offers a viable and energy
efficient alternative to conventional comminution methods across a wide
spectrum of mineral processing, cement and other industrial applications. With
further advancements, adoption of this technology is likely to accelerate in
future.
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