High Pressure Grinding Rolls Product Description-ZYmining

High-Pressure Grinding Rolls

High-pressure grinding rolls (HPGR) are a type of comminution technology that utilizes a pair of counter-rotating rolls with varying inter-roller spacings. The rolls operate at a high pressure and are used in the mining and minerals processing industry for efficient grinding of ores. HPGR technology is employed to achieve a reduction in particle size and to generate a product with high energy efficiency.

Applied Materials
Non-ferrous metal ore such as bauxite, iron ore, iron powder and finely crushed cement raw materials, clinker, blast furnace slag, limestone and other materials in the ore industry.

Product Advantages
High-pressure grinding roll has low energy consumption and low pollution. It is a product series that responds to home energy saving and emission reduction, low carbon and environmental protection.
This product is equipped with a sealed roller cover, which can strictly control the diffusion of harmful dust and create an excellent production environment.
In the process of the grinding system The use of a high-pressure roller mill in the process can improve the production efficiency of the entire system.

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High Pressure Grinding Rolls Introduction

Technical Parameters

Working Principle

Advantages

Spare Parts

The HPGR (high pressure grinding rolls/rollers) is the core equipment of the grinding process.

High Pressure Grinding Rolls (HPGR) are a type of crushing equipment used in the mining and mineral processing industries. HPGRs use a high-pressure hydraulic system to compress and grind particles between two counter-rotating rolls, which reduces the size of the particles.

The machine reduces particles by compressing and crushing the feed between two counter rotating, parallel rollers with a small gap between them. This forces the rocks against each other and compresses the feed’s density to 80% of its solid volume, exceeding its compressive strength with equal pressure being applied to particles of all sizes.

One of the main advantages of HPGRs compared to traditional crushing methods is that they have a higher energy efficiency and can generate a finer end product. This makes HPGRs an attractive choice for many mineral processing applications, especially for hard and abrasive materials like diamonds, iron ore, and gold.

It first used in the cement industry, while nowadays, also have been used in many other industries like nonferrous metal processing, ferrous metal processing, precious metal processing, etc.

Model	Roller Dia.（mm）	Roller Width（mm）	Power （kw）	Feeding Size（mm）		Finished Size （mm）		Throughput （t/h）	Weight（t）
				Feeding Size（mm）		Finished Size （mm）
				Metal Ore (mm)	Powdered Iron（cm²/g）	Metal Ore (mm)	Powdered Iron（cm²/g）
				Metal Ore (mm)	Powdered Iron（cm²/g）	Metal Ore (mm)	Powdered Iron（cm²/g）
GM600-200	600	200	2X75	≤25	1100-1300	≤3	1400-1600	16-24	14
GM800-350	800	350	2X132	≤30	1100-1300	≤3	1400-1600	50-65	24
GM1000-300	1000	300	2X160	≤35	1100-1300	≤3	1400-1700	61-91	32
GM1000-400	1000	400	2X200	≤35	1100-1300	≤3	1400-1700	80-120	36
GM1000-500	1000	500	2X280	≤35	1100-1300	≤3	1400-1700	100-150	40
GM1200-500	1200	500	2X315	≤40	1100-1300	≤3	1600-1800	130-190	56
GM1200-630	1200	630	2X400	≤40	1100-1300	≤3	1600-1800	160-240	65
GM1200-800	1200	800	2X500	≤40	1100-1300	≤3	1600-1800	200-310	79
GM1400-800	1400	800	2X560	≤50	1100-1300	≤3	1600-1800	260-390	110
GM1400-1100	1400	1100	2X800	≤50	1100-1300	≤3	1600-1800	360-540	133
GM1700-1100	1700	1100	2X1000	≤60	1100-1300	≤3	1600-1800	530-800	179
GM1700-1400	1700	1400	2X1250	≤60	1100-1300	≤3	1600-1800	670-1000	208

The core theory of high-pressure roller grinding is material layer crushing through high pressure. The working principle is static pressure crushing. The crushing effect is got by pressing materials between the two slowly rotating rollers. The high-pressure roll grinding implements a material layer crushing, which is the mutual crushing between materials with very high crushing efficiency. Generally, the energy consumption of high-pressure roller grinding is greatly reduced compared to impact or shear-type crushing equipment.

How HPGR works

When the HPGR works, the two rollers make relatively slow movements. One of the rollers is fixed while the other is adjustable and is used to adjust the distance between the rollers. It is the way to control the pressure.

Normally, when the material is continuously fed to the two grinding rolls and goes through them, a certain force is given to the movable roller, thus the material is held by the two rotating rollers and moves downward with the rolls. At this time, in a certain area between the grinding rollers, the material particles will form a material layer.

With the uniform and stable high pressure (100-300MPa) from the rolls, the material particles are squeezed, cracked and crushed.

The output product size can be as low as 3mm.

Structure

High pressure roll grinding is normally used as super fine crushing process，which can be as the third or fourth stage of a crushing process, also can be used in the semi-autogenous grinding process for hard rocks.

The input material size for HPGR normally is 25~60 mm，and output size can be less than 3mm. The best input size and output can be chosen accordingly. There are several features compare to the traditional grinding process.

✪ 1. Big size reduction ratio

The output size from a normal crushing system is around 12mm, and the size reduction ratio around 5. But the size reduction ratio of HPGR can be up to 10 or even more. It is able to grind the ore from size 20-60mm to below 3mm.

✪ 2. High crushing efficiency, low energy consumption

Ores output from HPGR are with high ratio of fine particle, and the internal of the ore will have a lot of micro cracks. More fine particle and micro cracks will help to highly reduce the ore grinding cost. Compare to the crushing system which is made of cone crusher, rod mill, ball mill, for an HPGR system is with lower energy consumption for 20 to 50%.

✪ 3. Significantly improve the follow-up process like flotation, leaching, etc.

According to the practice of HPGR in the copper and gold mining industries. The micro cracks in the ores made by HPGR significantly improve the ore grinding efficiency, increases the mineral liberation degree, improves the flotation performance, and increases the recovery ratio of final concentrate ores.

✪ 4. In the leaching process, the micro cracks make the ore a better contact with the leaching liquid, which significantly increases the ore leaching ratio.

According to the research on copper ore leaching, by using the HPGR, the copper increases for 60% and leaching ratio increase for 2% to 6% compared to traditional crushing process.

✪ 5. Greatly improve diamond recovery rate in diamond project.

The traditional grinding machinery like ball mills, semi-autogenous grinding mills or other crushers reduce the particle size by impact, which will destroy the large diamonds. It causes great loss of the diamond value, and also increases energy consumption.

✪ 6. When using HPGR on crushing the diamond ore, the rolls gap can be adjusted (e.g. 25mm) to ensure that the large diamonds won’t be crushed.

Unique material layer grinding technology deeply squeezes the lean ore, which can increase the product recovery rate by more than 20%.