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Metso HRC - Energy-efficient comminution technology

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METSO HRCTM-ENERGY-EFFICIENT COMMINUTION TECHNOLOGY

Birol Sönmez1, Renato Oliveira2, Alex Jankovic3, Walter Valery3, Murat Us4
1
Metso Process Technology and Innovation, 06370, Yenimahalle, Ankara, Turkey
2
Metso Process Technology and Innovation, Sorocaba, Brazil
3
Metso Process Technology and Innovation, Brisbane, Australia
4
Metso MAC Turkey MPS, 06370, Yenimahalle, Ankara, Turkey
…

Abstract: Energy efficiency has been attracting industry to high pressure grinding roll (HPGR)

Section 3
technology for years. Due to its energy efficiency and its suitability to upgrade existing ball mill
systems up to 250% of the original capacity, the roller press technology has been well established for
clinker grinding and originally applied in the cement industry treating relatively easily crushed
materials. Since then, it has been applied to progressively harder, tougher and more abrasive
materials. HPGR is gaining a greater acceptance in the mineral processing industry and has become
a competitive technology due to its lower specific energy consumption in comparison to conventional
fine crushing and AG/SAG mills, its efficient mode of grinding which does not required grinding media
and its downstream benefits as a result of micro cracks generated due to inter-particle breakage.
TM
Metso Hydraulic Roll Crushers (HRC ) being based on existing, well proven HPGR technology
provides modern, flexible and energy efficient solution for crushing hard rock with relatively low
moisture content and superior results in the size reduction of a variety of minerals.
TM
HRC technology is utilized in the comminution circuits in a number ways such as tertiary or
quaternary crusher, followed by a ball mill and pebble crusher in a SAG/AG, ball mill circuit for most
efficient use. Achieving consistent high pressure distribution across the width of the rolls is crucial for
the machine performance and sets the stage for more efficient size reduction downstream. Metso
HRC™ offer unique new innovative features, the anti-skewing Arch-frame – and the flanges in
particular – for improvement of equipment performance. This paper reviews the potential benefits of
HPGR technology to downstream processes. The main focus of this paper is to describe the basic
principles of the technology and the key of Metso patented innovations in the HRC™ HPGR design to
enhance throughput and energy efficiency.
Keywords: Energy Efficiency, Comminution, HPGR, Metso HRC.

(crushing and grinding) is the most energy

INTRODUCTION
The threat of global warming, increased cost of
energy, limited availability of water resources
and social and legislative pressures are creating
a need in the mining industry to reduce energy
and water consumption. Many mining
companies are now routinely accounting for the
energy and water consumed and greenhouse
gases produced per unit of final product and are
making special efforts to operate in a more
sustainable manner.
In addition to the challenges associated with the
demand for energy, water and the impact of
global warming, most of the high grade, easily
accessible and large scale mineral deposits
have been gradually depleting. In the future,
new mineral deposits are expected to be low
grade, hard, finely disseminated and difficult to
access. This results in increasing the energy
demand for mineral processing plants,
especially for comminution circuits. On the other
hand it is well known that comminution of ore
intensive and energy-inefficient stage of mineral
production. Therefore, improvements in
comminution efficiency can result in significant
energy savings and can have a large impact on
the operating cost of a plant, while conserving
resources and reducing greenhouse gas
emissions as well.
More sustainable technologies and practices are
required to make treating these massive, hard
and low grade orebodies viable. During the last
few decades, considerable improvements in
comminution efficiency have been achieved by
using energy-efficient technologies with the
ability to enhance energy utilization with some
adaption in novel flowsheet arrangements. One
such recognized technology is the high pressure
grinding roll, which was first introduced to the
cement industry for reliable pre-mill grind or final
product grind. HPGR technology is now widely
accepted for hard rock mining applications in
iron ore, copper ore, platinum ore, and gold ore.

XVI BMP Congress 131

A sharp increase in application of HPGR was
recorded in the last decade driven by the
benefits from energy efficiency and supported
by improvements in equipment reliability.
However, there are aspects of this technology
that can be improved to better use it in novel
flowsheet arrangements to result in further
energy reduction.
Metso’s latest development in comminution
equipment, the HRC™, is a major step in the
profitable application of HPGR technology.
Metso has developed innovative designs and
manufacturing capabilities to provide a unique
and efficient way for crushing that addresses the
issues currently facing HPGRs. With features
like the patented Arch-Frame and bolt-on flange
design, the HRC™ HPGR enhances this
technology to the fullest extent, optimizing the
reliability, capacity and energy efficiency of the
machine. HRC™-3000 model, the world's
largest machine of its kind, has been installed at
Freeport-McMoRan Copper & Gold's Morenci
copper mine in Arizona, USA.
HPGR TECHNOLOGY
Basic principals
A HPGR consists of two counter-rotating rolls –
one fixed and the other floating – in order to
effectively comminute the material. Hydraulic
cylinders apply very high pressure to the
system, causing inter-particle breakage
mechanism as the feed travels between the two
rolls, as seen in Figure 1.
Figure 1, Schematic of an HPGR comminution
The basic operating principle behind HPGRs
makes them very energy efficient: The feed
material is chokefed to the crushing zone, where
high pressure is applied to the bed of material in
a highly controlled manner. Particles larger than
the gap is broken by single particle comminution
and smaller particles forms a compressed bed
between the rolls enabling more efficient bed
132
breakage mechanics (Hilden et al. 2010). The
applied consistent high pressure sets the stage
for more efficient size reduction downstream, by
creating micro-cracks in the material. Figure 2
shows images of ore particles produced by
typical crusher (a) and HPGR (b). Tiny micro-
cracks weaken the particles, so that – even if
the particle is not shattered – subsequent fine
grinding requires the use of less energy to
achieve final product size. In leaching
operations, the creation of cracks along the
mineral ore boundaries and in the minerals allow
for better diffusion of reagents. This improves
the recovery of leaching process.
Figure 2, Particle from typical crusher and HPGR.
The material begins the comminution process at
the nip-angle, which is simply the angle at which
material is drawn into the rolls and enters the
crushing zone. As the material passes through
the rolls, it will reach a point where the distance
between the two rolls is the least. This is known
as the operating gap, and it is a variable
parameter that cannot be firmly adjusted for a
given machine. The operating gap directly
affects the throughput, and changes based on
pressure and material characteristics (hardness,
crushability, feed size distribution, top-size, etc).
The other adjustable main parameter is the roll
speed. It controls the press throughput. Speeds
of the rolls are also adjustable to obtain optimum
grinding conditions.
Choke feed
The concept is to maintain a minimum level in
the hopper so that ore is uniformly fed into the
rolls. The feed opening is designed to feed the
material at the nip angle to maximize
throughput. If the HPGR is fed at a lower nip
angle, the amount of potential breakage will not
be maximized, which will ultimately lower the
capacity. If the HPGR is fed at an angle greater
than the nip angle, slippage may occur, which
will increase wear and decrease throughput.
The choke-fed condition also prevents material
from impacting the roll. If a choke-fed condition
is not met, material falling directly from the
feeding belt conveyor could impact the rolls,
accelerating the wear.
XVI BMP Congress
Aspect ratio
The aspect ratio is the ratio between the
diameter and width (D/W) of the roll. A high
aspect ratio roll generally has better wear-life,
but higher capital cost and produces a slightly
coarser product due to the edge effect. The low
aspect ratio roll has slightly higher pressure in
the compression zone and produces a slightly
finer product, but generally has shorter wear-life
than a higher aspect ratio.
Cake formation
As the material passes through the operating
gap, the rock is compressed and can sometimes
form a cake or a flake (Figure 3). The
competency or resistance to breakage of these
cakes varies depending on the application.
Applications which have a high moisture content
and/or a high percentage of fines tend to
produce more competent flakes. Higher
pressure increases the likelihood of cakes to
form as well.
Figure 3, Cake product after passing through an
HPGR
Benefits of HPGR technology
HPGR technology presents promising benefits,
especially in energy savings and improved
downstream performance. The benefits of using
this technology has been attracting the mineral
and cement industries as they strive to find the
the most efficient and cost effective technologies
to process their materials. Key benefits of
HPGRs;
‡ Reduced operating costs
- Energy-efficient operation
- High throughput
- No grinding media required
‡ Micro-cracking
- Reduced downstream energy
requirements
- Improved recovery
XVI BMP Congress
The main driver of HPGR use in mineral industry
is comminution energy efficiency when
compared to conventional crushers and mills.
There is significant case study published
regarding energy savings and cost efficiencies
of the comminution process due to HPGR.
Energy savings ranging from 10 to 50 per cent
compared to grinding by conventional ball and
rod milling or semiautogenous grinding (SAG)
with ball milling have been achieved (Daniel et
al 2010, Rosario et al. 2008, Jankovic et al.
Section 3
2010, Hilden et al. 2010, Önol et al. 2012, Wang
et al. 2013). The reported energy and cost
savings depend on the circuit arrangements,
whether the grinding is being carried out wet or
dry, the hardness of the ore, the amount of
additional material handling operations and the
methods used to define the energy savings.
Many of these studies showed that HPGR is not
only energy efficient but also is cost-effective
grinding equipment. HPGR technology is “dry
processes” allowing control of slurry dilution
levels for downstream processing and avoiding
water losses. In addition, HPGRs do not use
steel grinding media. Steel grinding media has
high “embodied energy” which is defined as
energy consumed in production of the steel in
the liners and grinding media (Daniel et al.
2010) and can also potentially have negative
impacts on downstream processing such as
flotation. Energy and media savings can be
substantial where the ore is very tough and/or
electrical power costs are high. The advantage
of HPGR is reduced for softer ores and where
electricity is cheap (Morley 2006).
Micro-cracking is another advantage of HPGR
technology. Due to the reduced work indices
caused by micro-cracking of the HPGR product
particles and the increased fineness of the
HPGR product compared to conventional
crusher products, the capacity of downstream
ball milling increases while the specific energy
consumption decreases. It was reported in much
of the available literature that typical reductions
in the Bond ball mill work index of 10–25% can
be expected in applications where the HPGR is
followed by ball milling (von Michaelis 2009,
Amelunxen et al. 2011, Patzelt et al. 2006, van
der Meer et al. 2011). Some ore show little
improvement, whereas others show significant
improvement.
In addition to saving energy, using of HPGR as
a hard rock comminution alternative provides
some remarkable and useful effects for
downstream process such as gravity, flotation
and leaching as a result of micro-cracking
occurring within the particles. Micro-cracking
occurs predominantly at grain boundaries and
so improves liberation and leach solution
133
penetration (von Michaelis 2005, Morley 2006, ‡ Studded rolls to maximize roll life by
Ghorbani et al. 2011). Many comparative tests building up an autogenous layer.
reported in the literature demonstrated that
HPGR-treated ores yield better and faster gold Metso patented Arc-frame design
and copper heap leach recoveries (Baum et al.
Segregation of material in the HPGR feed may
2011, Shi et al. 2006, McNab 2006, von
lead to uneven process conditions and roll
Michaelis 2009, Kodali et al 2011). The
skewing causing uneven wear and inefficient
metallurgical benefits of HPGRs are highly ore-
specific and should be determined by the crushing due to difference in operating pressure
appropriate tests. across the width of the rolls. The skewing is a
condition where the rolls are not parallel to each
other and a common problem associated with
HPGRs. It causes unnecessary down-time and
METSO HRCTM TECHNOLOGY can potentially damage bearings. This issue was
TM
fixed in HRC by designing Metso’s patented
Metso’s latest development in comminution anti-skewing Arch-Frame (Figure 4).
equipment, the HRC™, is a major step in the
profitable application of HPGR technology.
Metso has made several key innovations to
traditional HPGR technology in order to increase
throughput and decrease total cost of
TM
operations. The conceptual design of the HRC
offers a unique and efficient way for crushing
that addresses the issues currently facing
HPGRs. With features like the patented Arch-
Frame and bolt-on flange design, the HRC™
looks to be a very powerful competitor in the
HPGR market by reducing operating costs,
minimizing downtime, and improving throughput.
Figure 4, Metso HRC™ HPGR machine with Arc-
Innovative design – unique strengths Frame
TM
The HRC 's ability to meet the demands of
This patented frame design formed the basic
industry is a result of its innovative design,
concept of the HRC™ HPGR and lead to many
which improves throughput and efficiency of the
other innovations. It provides an even gap
existing HPGR technology. Over 8,000 hours of
setting across the width of the rolls and limiting
testing including 4,000 hours in a pilot scale
skewing. This is created by a torsion tube that
plant have proven the design and efficiency of
TM connects both bearings, enabling the frame to
the HRC . Metso’s innovative design features
pivot in its base and absorb any unbalanced
include;
loads caused by a segregated feed. Anti-
‡ Anti-skewing Arch-frame to eliminate skewing arch frame also prevents damage to
downtime caused by skewing, the roller bearings, which often occurs with the
traditional HPGR design, caused by
‡ Flanges to maximize wear life and increase
misalignment, eliminates the need for spring-
throughput,
loaded cheek plates and enables use of flanges,
TM TM
The HRC provides with other notable benefits, which is the other design concept in HRC .
such as; This innovative design eliminates unnecessary
downtime caused by skewing, thus increasing
‡ The hydraulic cylinders, which are
operation availability.
positioned to create a compact design while
still providing excellent crushing strength,
Metso patented flange concept
‡ Dust enclosure to minimizes dust and
Material wants to naturally flow to the outside
reduces noise,
edges of the roll. This causes material to bypass
‡ Transporter to facilitate a safe and fast tire the crushing zone and escape on the edges,
replacement, resulting in a reduction of pressure. The uneven
pressure across the width of the roll causes the
‡ Feed hopper include liners designed for
center of the roll to wear faster than the outside
long life,
edges, and a bath-tub profile forms as can be
seen in Figure 5.

134 XVI BMP Congress


Figure 5, Bath-tub profile
(a): Very worn studded roll, (b): The difference in gap
across the width of the roll, (c): Straight edge placed
across the width of a worn roll
To address the edge-effect, spring-loaded cheek
plates for the sides of the rolls are used. As the
rolls draw in material, much of the material trying
to escape at the edges is retained by the cheek
plates, keeping it within the crushing zone. As
the part wears, the opening at the edge
increases and more material bypasses the
crushing zone. Due to the skewing of the rolls,
the cheek plates have to be kept at a small
distance from the edge of the roll.
The Metso flange design is unique to the HRC™
HPGR (Figure 6). The flanges help maintain
even pressure while crushing ore and keeps
more material from bypassing at the edges than
cheek-plates. This maximizes the amount of ore
that is crushed, resulting in finer the HRC
TM
product and lower circulating load. In addition,
the flanges achieve better wear-life than cheek-
plates because the flanges have more surface
area to wear and rotates with the material.
TM
Figure 6, HRC flange design
Flanges are designed for a fast field change-out.
They are segmented and can be bolted directly
to the roll. Flanges distribute pressure more
evenly along the width of the roll surface. This
XVI BMP Congress
eliminates the bathtub effect and reduces the
point loading on studs, thus decreasing the risk
of stud breakage during operation. This design
only works because of the anti-skewing Arch-
Frame. Currently, flanges are only used with
studded tires, and not the smooth manganese
tires.
Research into the benefits of using HRC™
HPGR design, which incorporates an Arch-
frame and a flanged roll solution was carried out
by Metso HRC team. Figure 7 summarizes the
Section 3
lab scale test results and shows that flanges
provides a more consistent pressure distribution
across the width of the roll, allowing for better
particle breakage at the edges of the rolls (Knorr
et al. 2013).
Figure 7, Pressure distribution across width of rolls
This team also conducted a series of pilot plant
HPGR tests within the frame of the collaborative
research program to determine how edge effect
can be reduced through innovations in the
TM
HRC design. Tests were carried out using a
750×400 mm HPGR with flanges and traditional
cheek plates. Comparative edge and total
product particle size distributions for both
designs are shown in Figure 8 (Knorr et al.
2013).
Figure 8, Comparison of HPGR discharge samples
As can be seen in Figure 8, for the same
operating pressure and roll speed, the flange
condition resulted in finer HPGR edge and
discharge size distribution. According to this
135
work, the use of flanges on the HRC™ HPGR
resulted in significant process improvements by
minimizing the edge effect. This reduction in
edge effect reduced the overall specific energy
by an average of 13.5% and lowered the
circulating load by an average of 24%, while
increasing the specific throughput by 19%.
Optimal crushing pressure
Metso’s hydraulic system delivers consistent
force to ensure the material is crushed at the
optimal pressure. The system is able to react
quickly to changing conditions during operation:
It includes pumps that continuously supply oil to
the main hydraulic cylinders, and a small
accumulator on the cylinders absorbs normal
variations in pressure. In the event of a pressure
spike or a change in pressure setting, oil
pressure automatically adjusts via a proportional
valve.
TM
Metso HRC ’s unique placement of the
hydraulic cylinders, above the crushing zone,
allows for a lower applied force while still
providing the same high crushing pressure. This
arrangement provides better protection for the
cylinders. The cylinder rod travels a greater
distance during normal operation, which ensures
the seals stay lubricated.
Wear Surface
Studded Roll: In hard-rock applications, the
studded roll is used to build an autogenous layer
of ore over the surface of the roll (Figure 9).
Tungsten-carbide studs are spaced across the
roll, and when operation begins the autogenous
layer adds a layer of protection to the roll to help
prolong the roll life. Too much moisture will
cause the layer to be washed away, and too
little moisture will inhibit the autogenous layer
from forming, so it is imperative to find the right
amount of moisture that will allow rock to adhere
to the rolls. The amount of acceptable moisture
will vary depending on the ore-type and the feed
size distribution, however typical moisture levels
are between 3% - 8%.
Figure 9, New studded roll without autogenous layer
(a), studded roll with an autogenous layer build-up (b)
136
Smooth Roll: For most non-metallic
applications, the manganese smooth roll is
applied for all types of ores. As the HRC™ starts
to crush the ore, the manganese surface
becomes harder increasing its resistance to
wear. Because this roll does not have studs, an
autogenous layer does not build up on the
surface of the rolls. In addition, the smooth rolls
have a lower nip angle than the studded rolls,
which decreases the capacity for a given
application.
Factors affecting roll wear;
‡ Operating Parameters
- Pressure - Higher pressures increase
wear rates,
- Roll speed - Increasing roll speed will
cause the roll to wear faster,
‡ Ore characteristics
- Abrasivity – Very abrasive ores will
increase wear on the roll
- Moisture - A high percent of moisture
can cause slippage and prevent the
autogenous layer from forming, which
will lead to high wear rates. On the other
hand, no moisture or a very low
percentage of moisture will inhibit the
autogenous layer from properly forming,
which will cause the roll wear to very
fast.
- Truncated Feeds - very coarse feed will
tend to wear the rolls faster than feeds
higher in fines because the fines act as
another layer of protection for the rolls.
‡ Roll Characteristics
- Aspect Ratio - Higher aspect ratios have
a longer roll wear life than a lower
aspect ratio machine processing the
same tonnage.
- Stud hardness – Harder studs tend to
have longer wear life than softer studs,
however if the studs are too hard
chipping could occur resulting in
increase wear.
‡ Power Draw
- Power draw, which will change based
on certain factors, (pressure, speed,
flange or cheek plate, ore
characteristics) has a direct effect on roll
wear. Increased power consumption
generally shortens the life of a roll in
terms of time, however, an efficient
machine will transfer most of the energy
into the comminution process. This may
increase the amount of desired product
XVI BMP Congress
 per roll-changeout even if the run-time is
not longer than a comparable, less
efficient machine.
Metso’s studded tungsten carbide surface
provides optimum wear resistance and supports
hard rock applications

HRCTM applications
A number of new large hard rock mining

operations have incorporated HPGR in their
grinding circuit instead of the conventional
comminution circuits (Morley, 2003, Rosario et
al. 2010; von Michaelis 2005, Hart et al. 2011).
TM
The HRC is ideal for high-tonnage, hard rock
applications and can be used as a tertiary,
quaternary or pebble crusher. Currently, several
TM
HRC units are in operation around the world.
It has been designed for use in diamond, iron
ore, copper, gold, platinum and various
industrial minerals.
Common circuits utilize high pressure grinding
rolls in a number of ways:
‡ Tertiary crusher, followed by a ball mill or
VERTIMILL® or heap leach process
(Figure 10 (a))
‡ Quaternary crusher, followed by a ball mill
or VERTIMILL® or heap leach process
(Figure 10 (b))
‡ In a pebble crushing circuit for a SAG/AG
mill (Figure 10 (c))
TM
When selecting an HRC model, ore top size,
capacity and overall circuit design should be
considered. Metso works to develop process
knowledge of the HRC™ HPGR for both metallic
and non-metallic applications. All tests are
performed using lab-scale and pilot scale HRC
units installed at Metso’s two different facilities
around the world and are designed in such a
way that they provide a variety of options to
explore the applicability of high pressure
comminution for customer-specific applications.
The test units have instrumentation that can
measure parameters such as roll speed,
pressure, operating gap, and energy
consumption.
Section 3
TM
Figure 10, Common circuits utilize HRC
Metso Process Technology and Innovation (PTI)
group provides lab and pilot-scale testing to
evaluate the size reduction performance of
TM
HRC operating in different circuit
configurations, develop process models and
scale up procedures for HRC
TM
application
(Jankovic et al. 2013).
CONCLUSIONS
HPGR utilization in processing plants has been
become widespread due to economical and
environmental reasons as a result of two
important benefits of HPGR: Reduced operating
costs (energy efficient operation, high
throughput, no grinding media required) and
micro-cracking (reduced down-stream energy
requirement, improved recovery).
Metso has an extensive history of technological
development and recognized as the world
leader in supply of comminution equipments.
Metso is constantly investing in both the
improvement of existing technology through the
reduction in energy, water and media
consumption and development of new
technology to meet and exceed industry
demands.
Metso’s latest development in HPGR technology
TM
called, HRC will play an important role in the

XVI BMP Congress 137

 industry with its unique strengths like anti-
skewing arch frame, flange concept and
innovative hydraulic system which delivers
optimal crushing pressure.
Main benefits of the HRC™ HPGR are:
• Increased circuit efficiency and capacity -
flanges direct material to the crushing zone,
maximizing the amount of ore crushed. In a
closed circuit pilot scale operation, this
amounted to over a 19% increase in circuit
capacity and over a 13.5% decrease in
circuit specific energy,
• Improved availability – patented Arch-frame
eliminates downtime associated with
skewing,
• Increased reliability – anti-skewing Arch-
frame prevents bearings from being
damaged due to misalignment,
• Reduced operating costs – energy
efficiency, longevity of wear components
including the studded tires and no use of
grinding media all contribute to low
operating costs.
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XVI BMP Congress