Criticality of Appropriate Control

System Design on High Pressure

Grinding Rolls
John Long, Bianca Foggiatto and Kevin Erwin
Outline
 Introduction
 Objective
 HPGR Operation
 HPGR Process Control
 The Advanced Control Scheme
 Implementation
 Conclusions
Introduction
• HPGRs have not as yet achieved their full potential in hard-
rock applications mainly due to
– limitations of a rigid control scheme
– a “standard” set of control parameters primarily developed for cement
and iron ore applications
– “standard” control parameters fail to compensate for the substantial and
rapid variations in feed material encountered at most hard-rock
comminution plants

• An advanced control scheme can

– alleviate many of the problems encountered
– maintain the machine in operation under the wider range of conditions
– avoid the need to implement any physical modifications to the circuit
HPGR Operation
• Unique HPGR
circuit designed
for treating
crushed pebbles
from a SAG-
based circuit
and ore from a
secondary
crushing circuit
HPGR Operation
HPGR Operation
• When uneven particle size distribution is presented to the
HPGR feed, there are two major causes for HPGR trip events
– roller skew
– pressure control

• Comminution performance of the HPGR is adjusted by

– varying the hydraulic pressure on the floating-roll, whereby pressure
control is activated from:
• roll gap to minimize over/under pressurisation
• HPGR power when reaching high power limits
– adjusting the hydraulic pressure at each end of the floating roll to even
the gap between the floating and fixed rolls
HPGR Operation
• HPGR historian data prior to implementation of the advanced
control scheme
HPGR Process Control
• Main aspects of the operation of an HPGR that drive the
process control (Morley, 2010):
– the HPGR must be choke-fed to maintain comminution efficiency
• achieved by maintaining a steady level at the HPGR feed hopper

– the number of stop-start events must be minimized, as accelerated roll

wear occurs during feed run-up and run-down
• achieved by using variable speed drives on the HPGR rolls
• achieved by improving presentation of feed to the HPGR

Feed presentation to HPGR after

materials handling optimisation
(minimised segregation)
HPGR Process Control
• A typical HPGR control
logic scheme

• Metal detection also plays

an important role in the
operation of the HPGRs
– a metal detection event
causes a diverter gate to
divert contamination from
the HPGR feed, avoiding
stud breakage and uneven
wear of studded lining
The Advanced Control Scheme
• The advanced control scheme is applied for the optimization
of the control system on the HPGR consisting of
– modifications to the HPGR unit control logic
– dynamic control system alleviates complications encountered with
unusual feed patterns

• The modifications included

– dynamic skew control (RPC)
– pressurize on skew
– skew control sensitivity
– dynamic pressure control (HPC)
– priority control
– pressure control activation
– ‘First Out’ alarming
The Advanced Control Scheme
• Dynamic skew control (RPC)
– modification to the skew control so parameters are based on actual skew
reading
Existing RPC Action New RPC Action
12 12

10 10
4 Seconds X Seconds
8 On 8 On
6 6

4 4 Y Seconds
3 Seconds Off
2 2
Off
0 0
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10

• Skew control sensitivity

– Increases skew control sensitivity on feed introduction by automatically
adjusting the skew engage/disengage points until the unit is choke fed
– allows more time to recover a skew condition
The Advanced Control Scheme
• Pressurize on skew
– Skew control to pressurize side with largest gap and relieve side with
smallest gap under skew conditions
– potentially remove skew events quicker while maintaining a higher
operating pressure
The Advanced Control Scheme
• Dynamic pressure control (HPC)
– modification to the pressure control to dynamically adjust the pressure set
point (up to a set maximum) for any given feed conditions
The Advanced Control Scheme
• Priority control
– modification to the priority control to seamlessly change between skew
and pressure control depending on which is closer to the trip point

• Pressure control activation

– modification to the pressure control activation to remove activation
based on skew and use zero gap to stop pressurization against stops
The Advanced Control Scheme
• ‘First Out’ alarming
– these alarms capture and display the first condition that was active when
the unit trips
– identifying the cause of a trip cuts down on the need for recovery time
and potential maintenance
Results
• HPGR historian data after the implementation of the
advanced control scheme
Conclusion
• Through incorporating dynamic control, a consistent
operation of the HPGR was achieved
– improved utilization
– decreased maintenance requirements

• The use of real time data and dynamic control systems allows
for a customized HPGR control based on feed material.
– smooth operation
– minimal number of trips
– minimal time lost due to maintenance
– more efficient HPGR performance
Acknowledgemen