Cylindrical grinding machine HPGR series

digitalPLC-controlledautomated

Overview
Optimise your results with a high pressure grinding roll (HPGR) designed for energy-efficient comminution of mining ores. Applicable to iron ore, precious metals and base metals, the HPGR promotes interparticle microcracking that improves downstream metallurgical performance such as heap leaching kinetics and liberation for flotation or leaching.

Key benefits

• Lower specific energy consumption compared with many horizontal grinding mills, particularly on very hard or highly competent ores.
• Improved grinding efficiency and productivity through induced microcracking of particles.
• Enhanced mineral liberation, benefiting flotation and leaching performance downstream.
• Higher operational availability and more stable grinding for variable ores than many conventional crushers.
• Reduced need for grinding media and lower media consumption.

HPGR product range
The product is offered as HPGR Standard with an optional upgrade to HPGR Pro. HPGR Pro introduces next-generation features that increase throughput capacity, improve power efficiency and extend roll wear life compared with conventional HPGR.

HPGR Pro upgrade features

• Rotating side-plates (RSPs): improve feed distribution, eliminate edge effect, produce a more uniformly ground product, reduce recirculation and extend roll service life.
• Mechanical skew limiter: a locking device that limits misalignment of the movable roll to maintain a uniform pressure profile and protect rotating side-plates; reduces outages and improves availability and product consistency.
• Stud detection system: laser-based monitoring of roll wear surfaces during operation; stores trending data, highlights defects with visual indicators, reduces manual measurement and supports roll-change planning.
• Oil-lubricated main bearings: continuous conditioned oil flow allows higher loads, lowers bearing temperature, removes grit and maximises bearing life; filtered closed-loop oil reduces lubricant consumption and environmental impact.
• Advanced Machine Protection System (AMPS): continuously monitors mechanical loads, warns operators when loads approach limits and can trigger alarms to process control systems to stop the machine to prevent prolonged overload; supports automated trending, analysis and reporting.

Applications and recommended uses
HPGRs are particularly effective for highly competent or variable ore bodies and are used in tertiary/quaternary crushing stages, as pebble crushers in SAG–ball mill circuits, or as final grinding for iron-ore concentrate (pellet feed). Suitable for both brownfield expansions and greenfield installations.

Technical specifications

• Model / series: HPGR (options: HPGR Standard; HPGR Pro upgrade available)
• Operation mode: dry or semi-dry grinding
• Industries: iron ore, precious metals, base metals and other mining applications
• Primary mechanism: interparticle compression between counter-rotating rolls causing microcracking to enhance liberation
• Expected roll lifetimes: typically about 8,000–20,000 hours in hard rock applications (dependent on ore abrasivity and operating conditions)
• Main advantages: lower energy consumption, higher availability, reduced grinding media consumption, more stable throughput and improved downstream metallurgical performance
• Upgradeable: standard HPGR models (machine sizes 4–10) can be retrofitted with Pro features including RSPs, mechanical skew limiter, stud detection, oil-lubricated bearings and AMPS