The high pressure grinding rollers (HPGR) were initially introduced in the mining industry to process kimberlite to liberate diamonds. The industry however, now uses the technology for mining of iron ore, copper ore, gold ore, and platinum ore. Growing demand for high efficiency and low emission comminution solutions owing to falling ore grades have propelled the growth of the global high pressure grinding roller market. The global HPGR market was worth US$247.7 million in 2013. Increasing demand for HPGRs is expected to bolster the market expansion at a CAGR of 5.9% during the period between 2014 and 2020.
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HPGR in Hard Rock Mining: A New Opportunity for Global HPGR Market
Grinding is one of the major challenges in mining and consumes around 75% of the energy in beneficiation and processing. High pressure grinding rolls technology is extensively used for multiple hard rock mining. The global HPGR market witnesses a huge opportunity to grow with the increased usage of HPGR in hard rock mining.
The HPGR is ideal for mining of hard competent ores that are highly resistant to traditional methods of comminution. The traditional methods depend on abrasion or impact for liberation. The HPGR, on the other hand, plays a combined role of preparing mill feed and negates any thought for considering the usage of tertiary and quaternary cone crushers. The HPGR provides a finer mill feed and greater efficiency compared to the traditional cone crushers.
How HPGR Works?
An advanced grinding roll in HPGR helps in the high pressure grinding. The conventional crushing rolls break down the particles by crushing between the two rolls. On the other hand, through HPGR, particles are broken by compression in a packed particle bed that is created by two counter-rotating rolls.
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HPGR versus Conventional SAG Mill
Though conventional SAG/ Ball mill would be more suitable for soft or high clay content ores, following are some of the points where HPGR scores over SAG/ Ball mill:
- Operating Costs: The operating costs of SAG/ Ball mill are comparatively higher than the operating costs incurred with the usage of HPGR technology.
- Longer Service Lifetime: Longer service lifetime of the grinding elements in HPGR and improved metal liberation owing to micro cracks in the ore make mine operators favor HPGRs over conventional SAG mills. With developments in wear surfaces and operating practices, the HPGR delivers continuous production over a long period of time without any major replacement of wear surfaces. In hard competent materials, the grinding rolls have displayed service life over 8000 operating hours.
- Shorter Installation and Commissioning times: Constant grinding results over time, coupled with shorter installation and commissioning time of HPGR is due to more compact design of the rollers.
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