INVESTIGATION OF A NOVEL HPGR AND SIZE CLASSIFICATION CIRCUIT

Patrick Pearce1, Claude Gagnon2, *Bern Klein3, Robert McIvor2, Sami Makni2, Fisher Wang3, Amit Kumar3
1
Natural Resources Canada
2
Corem
1180, rue de la Mineralogie
Quebec City, Quebec, G1N 1X7
3
University of British Columbia
517-6350 Stores Rd
Vancouver, BC, V6T 1Z4

(*Corresponding author: bklein@mining.ubc.ca)

Abstract

The aim of the Crush It! Challenge is to accelerate transformative solutions to reduce energy usage in the mill.
Natural Resources Canada supported competition for innovative energy-efficient comminution with a
contribution of $10 million. In total, 65 proposals were submitted from which 12 were selected as semi-finalists
and 6 were subsequently selected as finalists by an external Challenge Jury. Each finalist is eligible to receive up
to Cdn$800,000 to advance their concepts that will be judged in December 2020 when one will be selected and
award Cdn$5 million for advancement toward commercialization. This paper profiles one of the six shortlisted
proposals titled “Development of a Novel HPGR and Size Classification Comminution Circuit to Replace Ball Mills”.

Wet ball milling in closed circuit with hydrocyclones exclusively fills the role of the final stage of comminution
before the mineral separation circuit in the minerals industry. This includes those recently constructed plants
that use Crushing-HPGR-Ball Milling as an alternative to the most common SAG-Ball Milling circuit. The premise
of this work is that high-pressure grinding rolls (HPGR), in closed-circuit with some form of
classification/dewatering, can effectively replace ball milling in the final grinding step ahead of mineral
separation.

Keywords

Energy efficiency, high pressure grinding roll, HPGR, size classification

“The Crush It! Challenge

Crush It! (https://impact.canada.ca/en/challenges/crush-it) is one of Six cleantech challenges launched by

Natural Resources Canada (NRCan) as part of the Impact Canada Initiative. Challenges were co-developed with
industry experts and stakeholders to attract a diverse range of problem solvers to generate breakthrough
cleantech solutions to some of Canada’s biggest unsolved challenges. The Impact Canada Challenge platform is
part of a Government of Canada-wide effort to introduce innovative programming approaches to deliver
meaningful results for Canadians. NRCan will invest $75 million over four years in Six challenges: Women in
Cleantech Challenge, Power Forward Challenge, Crush It! Challenge, The Sky's the Limit Challenge, Indigenous
Off-diesel Initiative and Charging the Future Challenge.

“Our mining industry has positioned Canada as a leading mining nation and a center of global mining finance and
expertise. Improving the energy efficiency of crushing and grinding rock will create good jobs, reduce greenhouse
gas emissions and build a more sustainable mining sector. Congratulations to all the Challenge participants for
helping modernize a foundational industry in Canada” (Amarjeet Sohi, Canada’s Minister of Natural Resources,
May 2019).

What is the best way to save energy in the milling circuits of Canada’s mining industry? Is it smarter blasting and
ore sorting techniques that improve the quality of feed that enters the mill? Is it a novel grinding method that
more effectively transfers kinetic energy to rock inside the mill? Or is it a completely different solution altogether
– one that allows the liberation of valuable minerals from ore at a much lower energy input than grinding, such
as through a new chemical or biological process?

Comminution, the process of crushing and grinding rock to a reduced size as part of the process of liberating
valuable minerals, is extremely energy intensive. It accounts for upwards of 50% of mine site energy consumption
and up to 3% of all the electric power generated in the world. It represents a major cost to companies and is a
significant contributor to the industry’s greenhouse gas (GHG) emissions. However, innovative advances in this
process, particularly major breakthroughs, have been limited, and energy inefficient technologies remain the
industry standard. Finding and advancing innovative solutions that reduce how much energy is needed for
crushing and grinding is a key avenue to a cleaner, more productive, and globally competitive mining industry,
and an integral part of Canada’s pathway to a low-carbon economy.

With this context, the objectives of the Crush It! Challenge are to:

1. Accelerate innovative breakthrough advances in mining by tackling one of the industry’s most energy-
intensive and inefficient processes: crushing and grinding.

2. Mobilize innovators from inside and outside the mining industry to unlock a major step-change in this
area and grow ‘solver’ communities to enhance Canada’s mining innovation ecosystem.

3. Provide a unique platform to highlight promising research and development (R&D) ideas and help them
overcome barriers to prototyping and demonstration.

Improving the energy efficiency of Canada’s mines is critical to our transition to a low-carbon economy. Finding
and advancing innovative solutions that reduce energy use for crushing and grinding mined rock will reduce
greenhouse gas emissions, improve productivity and help our mining industry become more competitive.

Launched in October 2018, Crush It! challenged Canadian innovators to deliver game-changing solutions for
cleaner, more efficient rock processing. Of the 65 applications received, 12 semi-finalists pitched their ideas to
a seven-member jury of cleantech and innovation leaders in the mining sector at a public showcase event held
in conjunction with the #DisruptMining event in March. Eleven of the semi-finalists received $10,000 in micro-

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grants to help develop their proposals. In March 2019, six finalists were selected and became eligible for funding
of up to $800,000 each to advance their Crush It! concepts. In March 2021, a $5-million grand prize will be
awarded to the innovator demonstrating the best energy breakthrough in crushing and grinding rocks. Table 1
presents the list of 12 semi-finalists.

Table 1 – List of Crush It! semi-finalist with six finalists short indicated in Bold Italic
Lead Applicant Organization Proposal Title
University of Toronto Demonstration of Combined Microwave-Assisted
Erin Bobicki
CMIC (Canada Mining Comminution and Sorting for Energy Reduction in Mineral
Gillian Holcroft
Innovation Council) Processing
CTRI (Industrial Waste New Approach to Continuous Comminution via High Pulse
Hassine Bouafif
Technology Centre) Power (HPP)
High Optical Power Laser for Mining to Replace Drill and Blast
Georgi Doundarov Magemi Mining
and Crushing
Cliff Edwards Envisioning Labs Transcritical CO2 Pulverization
IntelliCrush: Advanced artificial intelligence tools to design
Philippe Gagnon COREM
eco-efficient comminution circuits
CMIC (Canada Mining CAHM – A Disruptive Grinding Technology that will
Gillian Holcroft
Innovation Council) Significantly Reduce Energy Consumption in Comminution
Targeted Microwave Heating Rocks! A Step-Change Energy
Tracy Holmes Jenike & Johanson
Reduction in Comminution
AI-Driven Dilution Control (Mine to Mill Optimization via Ore
Saeed Karimifard Motion Metrics
Sensing and 3D Imaging)
Development and Demonstration of HPGR Grinding and
Claude Gagnon COREM Novel Classification to Mineral Separation Circuit Feed Sizing
in Replacement of Ball Milling
Todd Parker Blue Spark Energy Crush Pulse
Eliminating the Crusher and Grinding Requirements Using the
Mark Sherry iRing
Blast to Create the Required Fragmentation
J. Lyall Workman Barr Engineering Blasting Down Crushing and Grinding Energy Consumption

HPGR Grinding and Novel Classification to Mineral Separation Circuit Feed Sizing

BACKGROUND
Size reduction by high pressure grinding rolls (HPGR) has slowly migrated to the mining/minerals industry, and is
now both used in plants, and considered for new projects, as a viable comminution step after crushing and before
final closed-circuit ball milling. Several notable hard rock installations include Cerro Verde Freeport-McMoRan
Copper-Molybdenum in Peru, Mogalakwena Anglo American Platinum in South Africa, Boddington Newmont
Copper-Gold in Australia, Grasberg Freeport-McMoRan Copper-Gold in Indonesia, CVRD Iron Ore in Brazil,
Kudremukh Iron Ore in India, El Brocal Lead–Zinc and Copper in Peru, CAP Minería Iron Ore in Chile, and SNIM
Iron Ore in Mauritania (Jankovic, Suthers, Wills, & Valery, 2015).

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Increased energy efficiency for comminution circuits using HPGR has been widely established. Researchers
mention energy savings of 10–50% compared to grinding by conventional rod and ball milling, or semi-
autogenous grinding (SAG) followed by ball milling (Daniel, Lane, & Mclean, 2010; Jankovic et al., 2015). Rosario
& Hall, (2010) showed a potential reduction of 25 to 30% in comminution energy by replacing SAG mills by
Crushing-HPGR, both followed by a final stage of closed circuit ball milling, in two design case studies. Wang et
al. (2013) showed that the total grinding circuit energy could potentially be reduced by 15% to 25% by replacing
a traditional SAG/Ball Milling circuit with a Crushing -2 stage HPGR circuit followed by stirred ball milling.

The reduction in energy usage resulting from HPGR comminution is governed by two factors: (1) the form by
which energy transmits to particles and (2) the particle/particle interactions (Abouzeid & Fuerstenau, 2009).
From the extensive research on single-particle and particle-bed breakage under compression and impact loading,
Schönert (1988) concluded that the highest efficiency for particle breakage is only possible through slow
compression of single particles. Schönert also observed that slow compression of a particle-bed consumes more
energy than single particle compression breakage but is still far more energy-efficient than loose-bed
comminution in a grinding mill, where energy transfer is inherently inefficient during particle/ball interaction due
to the hit-and-miss mode. Based on these observations, Schönert developed the HPGR technology for slow
compression breakage of a particle-bed.

Crushing-HPGR is typically considered an alternative to AG and SAG mills, but the highest comminution energy
consumption is often in the last stage of the grinding process, typically a ball milling circuit. Laboratory tests by
Metso and CSIRO using HPGR in closed circuit with air classification, to a P80 of 50 µm, show energy savings of
30% compared to HPGR with screening (at 3 mm) followed by ball milling (Jankovic et al., 2015). Weir is also
advocating this new circuit and has reported on recent project studies and operations (iron ore and limestone
processing) with final product sizes of 75 µm or finer, which enable as much as 50% energy reduction compared
to traditional circuits with tumbling mills (Rosario et al., 2016). These results show the energy benefits of particle
breakage under slow compression (Schönert, 1988) apply to sizes below which the HPGR is typically applied.

Note, dust control is a key issue with dry air classification. Wet closed-circuit ball milling with hydrocyclones is the
normal final stage of grinding. However, there are challenges for fine, wet classification in HPGR circuits. Operation
of the HPGR is constrained to low moisture feeds, limiting the recycle of the wet oversize. This might be addressed
by (a) limiting the amount of recycle; (b) adding a recycle dewatering step; (c) increasing the HPGR machine’s
tolerance to moisture; (d) an entirely new classification device; (e) full or partial edge recycle without classification.
High capacity fine screening perhaps offers the greatest potential for application of existing technology in this role.
However, such a circuit will require extensive optimization around its related design and operation.

Though the equipment exists, the HPGR grinding to final product size design would represent a major risk for any
new operation since it has not been demonstrated yet and conditions allowing such an operation are unknown.
Mining companies, engineering firms, equipment providers are not considering this in their current design since
the know-how is not developed yet. If it is foreseeable that this type of technology will be adopted in the future,
decades could go by before the first application of this type is commissioned. Aligned with the scope of the
Challenge program, this project aims to extend the HPGR’s known highly efficient breakage by compression
method to the final stage of grinding by developing a flowsheet for fine HPGR grinding and classification to
accelerate its introduction in the mining industry.

PROJECT DESCRIPTION
The project will achieve a step-change reduction in energy required for crushing and grinding by making efficient
use of HPGR comminution for fine grinding (down to a reference size of 100 µm) ahead of mineral separation.
Furthermore, it will find the best classification method for dealing with HPGR feed moisture constraints.

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Typically, HPGR cannot be operated efficiently when the feed humidity is above approximately 10% by weight.
The feasibility of using air classification to maintain a dry feed has been shown in the literature but was shown
to have limitations with coarse particles, which resulted in inefficiencies. Combining several wet or dry
classification technologies (screens, hydrocyclones, hydraulic separators, air classifiers, potentially with the
addition of a dewatering step) and engineering the HPGR feed to minimize the deleterious impact of humidity
has a large potential to extend the application of HPGR to fine grinding.

Air classification has been applied to HPGR comminution for dry application such as cement and has been evaluated
for hard rock applications as described above. With air classification, considerations include the effect of moisture,
the energy required for drying and classification efficiency. Recent advances in fine screening have led to the
replacement of classifying cyclones with wet vibrating screens (Wheeler and Packer, 2011). While screen oversize
will contain moisture, by blending with fresh feed to the HPGR, the moisture levels can be controlled to levels that
do not negatively affect the HPGR comminution. Excess fines in feed to the HPGR may result in energy dissipation
during compression without significant size reduction, therefore closed circuit and reverse closed circuit size
classification can also affect HPGR energy usage (Schönert 1996, Fuerstenau et al. 1991).

Ore samples from two operating mines will be tested in the project. The piston press test will be used to select
the pilot testing equipment and circuit design. Alternative classification methods will be investigated and tested.
Materials will be crushed to minus 35 mm (feed size constraint of the pilot HPGR), then ground by HPGR, in one
or more stages, closed by screens, hydrocyclones, or hydraulic separators, down to desired product P80. Energy
consumption for the HPGR will be recorded and classification performances will be analyzed. Piston press, HPGR,
and classification results will be used to simulate several options for grinding the ore down to final product sizing
with an HPGR. Results of small-scale piston press tests have been related to full-scale machine operation
(Davaanyam et al, 2015), and will be used to simulate HPGR-size classification configurations. The best option
will be tested experimentally in the pilot plant, and all significant energy consumptions will be recorded. They
will be compared with the energy consumption predicted by Bond for crushing and grinding the ore to 100
microns. Energy savings will be reported, as well as preliminary estimations of indirect energy savings for steel
consumption, and the environmental impact assessed.

Should the project be successful, it has the potential to impact most Canadian hard rock projects at the most
energy-intensive stage of comminution.

OBJECTIVES AND METHODOLOGIES

The project is divided into five sub-projects, each of whose objectives and methodologies is described below.

Sub-project 1: Assessment of Base Case Comminution Circuits

The objective is to determine the energy-size reduction relationship for the SAG/Rod Mill – Ball Mill circuits from
two operating mines. As a basis for comparison to the novel HPGR based circuit, the grinding circuits at two
operating plants will be surveyed. The first case will be the Copper Mountain mine in Princeton, British Columbia
which uses a conventional SAG Mill, Ball Mill, Pebble Crusher Circuit (SABC). The second case is the Newmont
Goldcorp Porcupine Gold mine (PGM) in Timmins, Ontario which has a traditional comminution circuit involving
primary and secondary crushing followed by rod and ball mill grinding.

The plant surveys will involve the collection of circuit feed samples along with information about plant tonnage
and mill power data, as well as hydrocyclone circuit products. Sufficient quantities of the sample will be collected
for characterizations as well as laboratory and pilot-scale test programs.

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The circuit feed samples will be characterized for size distribution, Bond Work Indices/grindabilities, and drop
weight test parameters (Axb or SMC DWI), and other properties as deemed appropriate. Cyclone overflow
samples’ size distributions will be measured. The plant circuit Operating Work Indices, and Bond and Morrell
circuit efficiencies, will be calculated (using the Global Mining Standards Group standard for plant comminution
circuit efficiency determinations, as described on their website).

The results of characterization testing along with the operating data will be used to simulate the process circuits
and to determine the base case energy-size reduction performance. The results will be used as the basis for
comparison to energy usage for the novel HPGR circuit. The testing of the samples will be conducted at COREM
as well as at UBC. A report will be prepared to provide the baseline for each of the mining operations that will
allow energy usage compared to the novel HPGR process. The results of all testing, as well as simulation
modelling for the two circuits, will also be summarized in the report.

Sub-project 2: Small Scale Testing - Initial Testing with Piston Die

Piston press testing will be conducted to bench-scale simulations of a range of HPGR circuit configurations and
assess the effect of variable levels to inform pilot-scale HPGR testing.

Fine HPGR comminution is envisioned as quaternary (4th) stage comminution such that feed to this stage is from
SAG milling in the case of Copper Mountain mine and rod milling in the case of the Porcupine mine. Piston press
tests along with models were developed at UBC to simulate pilot and full-scale HPGR operation (Davaanyam, 2015).
The tests are conducted at a bench scale and require small portions (240 cc) that can help define HPGR operating
conditions before proceeding to pilot-scale tests that require large (several tons) samples. At this stage of the
program, UBC will provide training to COREM to establish piston press testing capabilities at their research center.

The piston press tests allow prediction of the energy-size reduction relationship and product particle size and
size distribution. A piston press test program will be conducted to assess the effect of variables on HPGR particle
size reduction for each of the two ores. The variables that will be assessed include moisture content, pressing
force and feed particle size distribution (representing a range of size classification approaches). Statistical
experimental design will cover a full range of variable levels to allow the development of a fine HPGR energy
input-size reduction model.

A report will be prepared that summarizes the results of the piston press tests for each of the case study mining
operations. The report will present recommendations for locked cycle piston press and pilot-scale HPGR testing.
Included will be fine crushing models that represent HPGR breakage that show the effect of operating variables
on the energy size reduction relationship.

Sub-project 3: Small Scale Testing – Optimization Testing with Piston Die and Ideal (Lab) Screen Sizing for
Crushing-HPGR Circuit and Crushing-HPGR-HPGR Circuit Design
A locked piston press test procedure will be developed and validated against pilot-scale test results. Locked-cycle
piston press testing will be conducted to verify the recommendations of the preliminary small-scale tests. The
results will support the planning of the pilot-scale test program.

Based on previous pilot-scale closed circuit HPGR tests performed at UBC, a test program will be conducted to
develop and assess a locked cycle piston press test that simulates closed circuit HPGR operation. Two approaches
are considered when developing a locked cycle piston press test. The first approach relies on correlating the
piston press pressures to HPGR pressing force that represents the same energy input. The second approach
involves correlating the piston press pressure to the HPGR pressing force that generates the same product
particle size. In both cases, closed-circuit operation will be conducted using screens to simulate size classification.

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Results will be compared to pilot scale HPGR closed-circuit test results and specifically by comparing energy
inputs, product particle size distributions and circulating loads.

The locked cycle test will be used to simulate the HPGR circuit to assess the effect of operating variables including
pressing force, feed particle size distribution, circulating load, type of roll surface and moisture content. The
results will allow determination of optimum circuit arrangement and design variables for the HPGR to achieve
required P80 (2 ores). Size classification will be conducted by wet screening and drying of oversize to specified
moisture levels. It is recognized that this size classification method is likely sharper than used industrially and
therefore locked cycle results will represent an optimum case with respect to parameters such as product particle
size distribution and circulating load. Results will inform the pilot-scale HPGR test program. Results of locked
cycle testing will be summarized in a report with recommendations for pilot scale testing.

Sub-project 4: Size Classification Research and Dewatering Study

The objective is to identify and assess size classification and dewatering options for the novel HPGR process circuit.

In conventional ball mill circuits, size classification is achieved using cyclones with underflow recirculating to the
ball mill with a typical solid density of about 75% by weight. For the HPGR circuit, much lower moisture contents
are required. Therefore, either size classification methods are required or a system involving size classification
and dewatering is required. Subproject 4 will be divided into two sections, firstly review of technologies and
secondly testing of technologies.

The review of technologies will include compiling literature and company information about suitable size
classification and dewatering technologies. Dry size classification is not considered in this study as the feed to
the HPGR circuits will be in wet comminution stages. There is a range of technologies that are applied for non-
metallic ores including coal, potash and iron ore that may be applicable to base metal ores. Each of the
technologies will be ranked according to criteria that are relevant to their application to the HPGR circuit. Specific
criteria include energy efficiency (energy requirements of technology and effect on comminution circuit energy
efficiency), size classification efficiency (sharpness of separation), throughput, product moisture content,
product particle size distribution, and engineering design. The engineering design relates to the consideration of
space requirements, maintenance, and ease of operation. For size classification, technologies that will be
considered include hydrocyclones, hydraulic classifiers, screens, screw classifiers. Each of these will also be
assessed from the perspective of their product moisture levels. For dewatering, additional technologies include
dewatering screen, centrifuges (solid bowl/screen bowl) and filters. The ranking will be reviewed by engaging
subject experts.

The assessment will be based on published information and direct communications with suppliers. Samples will
be sent to test selected technologies. Testing will be conducted on selected technologies to assess their
performance for the two case study operations. Samples collected during plant surveys will be sent to the
technology companies to evaluate their performance. The pilot testing will be observed, and results and
recommendations regarding the selected technologies will be reported.

Sub-project 5: Pilot Equipment Testing of Selected HPGR Only to Final Separation Circuit Feed Flowsheets
The objective of this sub-project is to validate the selected HPGR fine grinding and size classification/dewatering
process and to demonstrate the effect of operating variables at the pilot scale.

Based on the results obtained from the piston-press and the size classification/dewatering testing, pilot-scale
HPGR tests will be conducted to evaluate the effect of various operation variables on the HPGR performance.
The pilot test will be conducted in three phases.

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Phase one of the pilot test will be performed in an open circuit configuration at recommended pressure and
moisture levels from the piston-press test results. The open-circuit pilot circuit testing will be conducted to
confirm the effect of specific pressing force and feed moisture content based on the piston-press test. These
pilot tests will also be used to directly calibrate the piston-press test results for energy and size-reduction
relationship to assist with interpreting piston press results. Pilot testing will also be used to monitor the
recirculating load ratio to access the suitability of a single or multiple stage HPGR operation. The product size
distribution from the open circuit HPGR test will dictate the necessity of multiple-stage HPGR and the potential
HPGR circuit including open HPGR, open-open multiple-stage HPGR setting or open-close multistage HPGR
settings. The possible screening requirements will be assessed as multi-stage screening may be needed to
achieve the required product size and moisture level. The optimum operating conditions for further closed circuit
HPGR pilot testing will be recommended from these tests. This will also provide information for a suitable
screening/dewatering technology that can produce products with required throughput and moisture levels.

Phase two of this sub-project will test the HPGR performance in closed circuit configuration with screening.
Closed-circuit HPGR testing will evaluate two options. For the first option, the HPGR test will be conducted on
ball mill cyclone underflow/screen oversize sample that will represent a reversed closed-circuit arrangement as
the fines will be removed prior to HPGR. The second option will involve conducting HPGR test on ball mill circuit
feed without removing any fines and the HPGR product will be wet screened/classified at a given cut size and the
oversize will be mixed with fresh feed in an appropriate ratio and re-fed to the HPGR. This would represent a
direct closed-circuit arrangement as the screening/classification will be conducted after the HPGR. The testing
will be conducted to achieve a steady-state operation to estimate the circulating load. The parameters to be
observed will include the total circuit energy consumption, re-circulating load, screening efficiency, and product
particle size distribution. Responses and implications to throughput, final product size distribution will be
observed. The overall energy requirements for achieving the steady-state circulating load will be determined that
will provide an estimate of potential energy savings over the base case scenario.

The final phase of this subproject will test the HPGR in closed circuit with selected size classification/dewatering
equipment to demonstrate the selected configuration. This stage will evaluate the potential energy savings in an
industrial-scale application. The HPGR and size classification/dewatering equipment performance will be
monitored with respect to energy consumption, recirculating load, screening efficiency, product particle size
distribution, and flotation feed characteristics.

ENVIRONMENTAL IMPACTS
Environment and Climate Change Canada estimates that the heavy industry excluding oil and gas accounts for
74.6 megatonnes of carbon dioxide equivalent (Environment and Climate Change Canada, 2017). Based on
preliminary laboratory results, it is expected that the new solution will be 20% to 30% more energy efficient than
a typical HPGR with screen and ball mill circuit. Based on a mean 20% efficiency gain for the design of three
major projects in Canada, the project would decrease Canada’s GHG by 2.25 megatons/year. Indirect energy
saving (steel consumables) and water savings are also expected but are not quantified at the present time.

DOWNSTREAM IMPACTS
Downstream impacts are ore specific. Yet, some benefits of fine HPGR grinding have been shown for rejection of
coarse gangue in magnetic separation (Liu, Tan, Liu, & Cao, 2018). Michaelis (2005) reviewed many potential
benefits of HPGR grinding for heap leaching, gravity recovery, and flotation. Most of the effects are driven by
1) the production of microcracks, 2) preferential liberation or 3) no steel balls as media.

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A few attempts have been made to compare the conventional circuit (crusher + ball mill) to the HPGR milling. Shi
et al. studied the enrichment vs recovery ratio of nickel and sulfur by size class in four platinum ore samples (Shi,
Lambert, & Daniel, 2006). They observed an 8% to 29% energy saving using the HPGR route with better results with
increasing ore hardness with Bond ball mill work indices varying from 20.3 kWh/t to 23.4 kWh/t. At P70=150 and
106 µm, there was no significant difference of grade-recovery curves between the conventional and HPGR
comminution for the nickel, but an improvement was observed for the sulphide when milled with an HPGR.

Microcracks can help increase the exposure of the valuable material for leaching and lixiviation. Improved
laboratory leach recovery and rates have been reported mostly for heap leaching and coarser particles (Dunne,
Goulsbra, & Dunlop, 1996). The impact of using HPGR for fine grinding on leaching is unknown. A positive impact
is expected. HPGRs are commonly applied to diamond operations because they preferentially break particles
along grain boundaries and therefore avoid breakage of diamonds. For the processing of metallic ores, liberation
along grain boundaries can enhance liberation to improve metallurgical recoveries with processes such as
flotation. Ball milling generates ultrafine particles that are more difficult to recover, therefore the HPGR product
particle size distribution may represent additional benefits.

UPTAKE POTENTIAL AND SCALABILITY

The key product of this project will be a methodology to design flowsheets using HPGR in closed-circuit with one
or several classification technologies including but not limited to fine screening, air classification, and
hydrocyclones. COREM owns a Weir HPGR and a Koppern HPGR is located at the University of British Columbia.
Thyssenkrupp is also supporting the project, as is Derrick Corporation, the high capacity fine screening
manufacturer and expert. Collaboration between the 3 major HPGR manufacturers and implication of different
mining companies (Goldcorp, Québec Minerai de Fer, Copper Mountain) either in COREM membership or
collaborator of UBC will cover a wide range of ore and different equipment, thus making the results independent
of a specific ore or HPGR technology. The synergy between academia, applied research, and manufacturers, will
provide full leverage for uptake and scalability.

The IP protection approach will be developed in consultation with project partners to maximize the marketing
and uptake potential of the entire Canadian, North American, and international mining industry.

The final product will be applicable to all Canadian mines and international projects. It is expected to be more
cost-effective for hard rock commodities and accessible geographic locations. COREM and its partners have
several channels to Canadian and international customers. Especially, Weir, Koppern, and Thyssenkrupp will be
direct path to customers and should decrease the customer acquisition costs. Furthermore, publications in peer-
reviewed journals with our academic partner are expected and should contribute to the diffusion of technology
in the industry. The main customer segments that will be targeted are new mining projects at the feasibility
stage, either mining companies or engineering firms. The main revenue stream for COREM and UBC will be
generated by performing pilot testing for the design of fine HPGR circuit. The main costs for COREM will be in
human resources and consumables to perform the tests. Manufacturers will increase the potential market of
their HPGR technology and mining companies will benefit in operating cost savings from superior technologies.

INNOVATIVENESS
Dry grinding has been used in the cement industry for many years for comminution of limestone, slag, and clinker,
using HPGR. Circuits closed with air classification have enabled the use of HPGR in the cement industry for final
product grind, reducing power and steel usage cost, and increasing capacity, while operating to make a high-
quality product as fine as 25 µm (der Meer, nol, & Strasser, 2012). Preliminary works are conducted around the
world by Metso and CSIRO and by Weir on the HPGR closed by air classifier for fine grinding. The proposed project

8 | SAG CONFERENCE 2019 VANCOUVER | SEPTEMBER 22–26, 2019

is highly innovative because it will combine, for the first time, fine HPGR grinding with dry and wet classification
methods. Water use, HPGR chute, and circuit configuration will be optimized to combine a highly effective
comminution process with the most efficient classification process. The project will extend the applicability of
HPGR to high humidity content and to lower product sizes. Furthermore, it will integrate the piston-die test in a
manufacturer-independent methodology of HPGR circuit design, which has never been done before. Finally, the
project will lead to an experimental methodology for the use of HPGR down to require separation circuit feed
sizing. This is actually lacking but has the potential to transform Canada’s mining industry.

ECONOMIC AND/OR SOCIAL IMPACT

Studies have shown that the most efficient form of comminution is achieved when a particle is crushed in slow
compression (Cimilli, 2008; Schönert, 1979). Still, ball mills are the most used device to grind particles down to
100 µm, even though 99% of the energy is lost in heat (Stairmand, 1976). The potential impact of the project is
the uptake of HPGR in later grinding stages. That has the potential to bridge the gap with energy-efficient devices
like stirred mills and open many new flowsheet possibilities. It could also double the potential market for HPGR.
The consequence would likely be a larger offer from the manufacturers which could lead to more competitive
CAPEX for the technology, faster commissioning, and better availability of the parts. Finally, the public confidence
in the mining industry could improve knowing that instead of wasting energy in inefficient devices that consume
about 3% of the world energy, we are researching the possibility of using the most energy-efficient comminution
technology known to mankind.

References

Abouzeid, A. Z. M., & Fuerstenau, D. W. (2009). Grinding of mineral mixtures in high-pressure grinding rolls.
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