High Pressure Grinding Rolls

Process calculation of POLYCOM Cerrowal

Dipl. Ing.

W. Partsch

POLYCOM process calculation

Test-work and Results
Scale Up Wear Rates and Liner Lifetime

Simulation
Settings for start-up

Process description

POLYCOM Test Work

Test Unit
Data of test unit: Diameter of rolls: 0.71 m Speed of rolls: 0.29 - 1.10 m/s Width of rolls: 0.21 m Top feed size: 16 - 35 mm
Data logging:
feed rate, feed moisture zero gap ,cake thickness preset nitrogen pressure, zero hydraulic pressure operating hydraulic pressure power draw of motors circumferential speed of rolls

Calculation of process data:

specific throughput rate specific grinding force specific energy input

required for achieving a certain product fineness

POLYCOM Test Work

Test Results and Scale Up
1. Fineness over Press Force :
Grupo Tercer
100
80
Product Fineness, % passing

Product Fineness

Fineness % passing [%]

90 80 70 60 50 40 30 20 10 0
0.010 0.100 1.000 10.000 100.000

70 60 50 40 30 20 10 0 0 1 2 3 4 5 6 Specific Press Force, N/mm

Particle size [mm]

Feed R3.1 - 2.71 N/mm R3.2 - 3.74 N/mm R3.3 - 4.78 N/mm

Primer & Segundo

< 250 m

< 1 mm

< 4 mm

Tercer

< 250 m

< 1 mm

< 4 mm

Max. Specific Press Force required

POLYCOM Test Work

Test Results and Scale Up
1. Fineness over Press Force :
GrupoFineness Tercer Product
100 80

Max. Specific Press Force required

[%] % passing Fineness % passing Fineness, Product

70 60 50

90 80 70 60

4050 3040 2030 10 0

20 10 0
00.010 1
0.100

3 1.000

10.000

6 100.000

Specific Press Force, N/mm Particle size [mm]

Primer &Feed Segundo R3.1 < 250 m N/mm < 1 mm - 2.71

< 4 mm Tercer m - 4.78 < 1 mm < 4 mm R3.2 - 3.74 N/mm < 250 R3.3 N/mm

POLYCOM Test Work

Test Results and Scale Up
2. Spec. Power required over Press Force :
Energy vs Press Force
3.00 2.50 2.00 1.50 1.00 0.50 0.00 0.00 Prim & Segundo Grupo Tercer R = 0.9741 R2 = 0.8687
2

Specific energy, kWh/t

1.00

2.00

3.00

4.00

5.00

6.00

Specific Press Force, N/mm

Specific Power required at 3,5 N/mm2 Press Force

POLYCOM Test Work

Test Results and Scale Up
3. Spec. Throughput over Press Force :
Specific Throughput vs Press Force
300.0
Specific throughput, ts/hm

250.0 200.0 R = 0.7776 150.0 100.0 50.0 0.0 0.00

2

Specific Throughput at 3,5 N/mm2 Press Force

R = 0.2816

Prim & Segundo

1.00 2.00

Grupo Tercer
3.00

Primero Truncated
4.00 5.00 6.00

Specific Press Force, N/mm

POLYCOM Test Work

Test Results and Scale Up
4. Selection of specific throughput for industrial application : mdot obtained by test work : 230 [t x s/m3 x h] Correction factors for industrial unit : higher speed : higher moisture : circulating load : larger roll diameter : - 10 % - 5% + 10 % + 10 %

Result : mdot selected : 240 [t x s/m3 x h]

POLYCOM Test Work

Test Results and Scale Up
5. Influence of feed size on specific throughput : (Example Results of Test Work from Lone tree)
Specific Throughput vs % < 8 mm
Trunc open circuit 300,0 R2 = 0,1305 250,0
Spec. throughput, mts/hm

0 x 25 mm closed

0 x 38 mm closed

R2 = 0,0825

200,0 R2 = 0,5409

150,0

100,0

50,0

0,0 0,0 10,0 20,0 30,0 40,0 50,0 60,0 70,0 % < 8 mm in new feed

POLYCOM Test Work

Selection of POLYCOM Sizes

POLYCOM Sizing
Scale up Procedure
High Pressure Grinding Roll Sizing
1. Throughput M = m(ts/hm) x L (m) x D (m) x u (m/s) [t/h]

where m is the specific throughput in ts/hm

2. Grinding force F

= L (m) x D (m) x Fsp (N/mm) x 1000

[kN]

where Fsp is the specific grinding force in N/mm

6. Check Roll Diameter

3. Motor power P
X Safety factor

= Wsp(kWh/t) x M(t/h) x Factor / 2

[kW]

where Wsp is the specific energy input in kWh/t

4. Gear Box Size

5. Check Bearing size

POLYCOM Sizing
Sizing Criteria
Base Case : Hard Ore (Grupo Tercero; -50mm top feed size)

1. Production Rate :
2. Availability : 3. Re-circulating Load: (Product Screen 6mm)

100.000 tpd
90% 75%
4630 tph fresh feed 8100 tph total feed

4. Production Rate per Unit (@4 units)

2025 tph total feed

POLYCOM Sizing
Sizing Criteria Option 1
POLYCOM Size selected 22/17-8

Roll Dimensions Press Force Motor Power installed

: 2,2m dia x 1,65m wide : 17.000 KN : 2 x 2.500 kW

Rolls Speed (nominal) : 20,8 rpm@ 2,4m/s Throughput (m=240[ts/hm3]) : 2025 t/h @ nom. speed (dry basis) Specific Press Force : 4,21 N/mm2

Specific net Motor Power : 2,1 kWh/to

POLYCOM Sizing
Sizing Criteria - Option 2
POLYCOM Size selected 24/17-8

Roll Dimensions Press Force Motor Power installed

: 2,4m dia x 1,65m wide : 17.000 KN : 2 x 2.500 kW

Rolls Speed (nominal) : 20,8 rpm@ 2,61m/s Throughput (m=240[ts/hm3]) : 2410 t/h @ nom. speed (dry basis) Specific Press Force : 3,86 N/mm2

Specific net Motor Power : 1,76 kWh/to

POLYCOM Sizing
Sizing Criteria - Options
Polycom Type : Throughput : [t/h] Spec. Press Force : [N/mm2] Net.Spec.Power : [kWh/t]
Effects of a 2,4m dia unit : - Capacity could be increased if ball mills require this - Capacity could be increased if one Polycom is stopped for maintenance - Speed can be lowered by 18% -> increase of roll life to 7000 h (@GT ore)

Design 22/17-8 24/17-8 Requirement : 2025 4,21 2,10 2410 3,86 1,76 2025 3,5 1,7

- Less specific energy available at full feed (however feed rate can be throttled by adjustable feed gate)
- Price increase ~ 4% on unit price

POLYCOM Test Work

Wear Testing and Scale Up

Wear Protection System

- Life Time of Rolls - Test Work ATWAL Test POLYCOM
Data of test unit:

Diameter of rolls: 0.10 m

Width of rolls: 0.03 m Speed of rolls: 0.46 m/s Top feed size: 3.15 mm

Available roll surfaces: smooth Nihard IV, grooved Nihard IV,

hard facing, etc.

Wear Protection System

- Life Time of Rolls - Test Work Comparison to other ores tested :

Copper & Gold Ores

100 90 80 70 60 50 40 30 20 10 0 0 ATWAL wear rate, g/t Gold ores Copper
Gold ores Copper Cerro Verde

Diamond Iron ore

100

200

300

400

Unconfined compressive strength, MPa

Wear Protection System

- Life Time of Rolls Scale up Life time calculation CERROWAL
ATWAL
Test material Roller design Specific grinding force Feed size Moisture Roll diameter Roll width Roll speed N/mm mm % m m rpm m/s t*s/(m*h) tph t/m mm t/m Primero Nihard 4 0 - 3,15 1,0 0,10 0,03 82 0,43 131,59 0,169 2,25 1,70 7,90

ATWAL
Segundo Nihard 4 0 - 3,15 1,0 0,10 0,03 82 0,43 141,33 0,182 2,25 1,70 7,90

ATWAL
Tercer Nihard 4 0 - 3,15 1,0 0,10 0,03 82 0,43 142,72 0,184 2,25 1,70 7,90

Industrial Plant
Primero Studs 4 < 50 mm 3,0 2,40 1,65 20,80 2,61 240 2484 2,25 71 14,40 Primero Studs 4 < 50 mm 3,0 2,40 1,65 17,50 2,20 240 2090 2,25 71 14,40 Primero Studs 4 < 50 mm 3,0 2,20 1,65 20,80 2,40 240 2087 2,25 65 14,40

Industrial Plant
Segundo Studs 4 < 50 mm 3,0 2,40 1,65 20,80 2,61 240 2484 2,25 71 14,40 Segundo Studs 4 < 50 mm 3,0 2,40 1,65 17,50 2,20 240 2090 2,25 71 14,40 Segundo Studs 4 < 50 mm 3,0 2,20 1,65 20,80 2,40 240 2087 2,25 65 14,40 Tercer Studs

Industrial Plant
Tercer Studs 4 < 50 mm 3,0 2,40 1,65 17,50 2,20 240 2090 2,25 71 14,40 Tercer Studs 4 < 50 mm 3,0 2,20 1,65 20,80 2,40 240 2087 2,25 65 14,40

4 < 50 mm 3,0 2,40 1,65 20,80 2,61 240 2484 2,25 71 14,40

Specific throughput Throughput Cake density Theoretical cake thickness Density of wear material

Wear rates:
Delta radius / rev

m/100rev m/rev % mm/100h g/t

0,60150141 0,56899736 0,48175527 0,60150141 0,60150141 0,60150141 0,56899736 0,56899736 0,56899736 0,48175527 0,48175527 0,48175527 0,00602 100 2,96 26,00 0 0 0 0 0,00569 100 2,80 22,90 0 0 0 0 0,00482 100 2,37 19,20 0 0 0 0 0,00601501 0,00601501 0,00601501 0,00568997 0,00568997 0,00568997 0,00481755 0,00481755 0,00481755 100 100 100 100 100 100 100 100 100 0,75 1,08 35 4662 0 0 0,63 1,08 35 5542 0 0 0,75 1,18 35 4662 0 0 0,71 1,02 35 4929 0 0 0,60 1,02 35 5858 0 0 0,71 1,12 35 4929 0 0 0,60 0,87 35 5821 0 0 0,51 0,87 35 6919 0 0 0,60 0,95 35 5821 0 0

Wear life:
Wear material height

Operating hours
Wear material height Operating hours

mm h mm h

Wear Protection System

- Life Time of Rolls - Scale up Test Results (ATWI) : Primero Ore : 26,0 gr/t

Segundo Ore :
Tercer Ore :

22,9 gr/t
19,2 gr/t

Scale Up for a 24/17 operating at a nominal speed of 17,5 rpm : Primero Ore : 5.500 operating hours

Segundo Ore :
Tercer Ore :

5.800 operating hours

6.900 operating hours

Wear Protection System

- Life Time of Rolls - Scale up Gap size vs roll diameter
Gap size [ mm ]
80 70 60 50 40 30 20 m-dot = 200 225 250

1. Feed Size of Material

Gap is proportional to feed material diameter Max. feed size 1 to 1.35 times working gap Max. feed size for hard ores < working gap

10
0 0,5 1,0 1,5 Roll diameter [ m ] 2,0 2,5

Wear Protection System

- Life Time of Rolls - Scale up 1. Feed Size of Material

2. Moisture Content

Wear Protection System

- Life Time of Rolls - Scale up 1. Feed Size of Material
3.0 40000 35000

Microns per 100 revolutions

2. Moisture Content
3. Feed Size Distribution

2.7 2.4 2.1 1.8 1.5 1.2 0.9 0.6 0.3 0.0 0 507680 939836 1216194 1688550 1939958

1
Truncated Coarse

30000 25000 20000 15000 10000 5000 0 Feed F80

Revolutions
Incremental Microns per 100 Revolutions Cum Microns per 100 Revolutions Cum F80 Feed Size

Truncation

-> Increased of wear rate +73 %

Coarser Feed -> Increased of wear rate + 55 %

POLYCOM Sizing

Wear Rate - Scale Up - Results

POLYCOM Sizing

POLYCOM Product Sizes - Simulation

POLYCOM Sizing

POLYCOM Product Sizes - Simulation

Test results
Grupo Tercer
100

Simulation for ind. Application

Comparison Closed-Circuit Feed & Products
100 90 80
Cumulative % finer

Fineness % passing [%]

90 80 70 60 50 40 30 20 10 0
0.010 0.100 1.000 10.000 100.000

Simulated 40 mm Feed
Circuit feed Discharge Circuit product

70 60 50 40 30 20 10 0 0.01 0.1 1 Particle size, mm 10 100

Test R 1.2.4
HPGR Feed Discharge < 6 mm prod.

Particle size [mm]

Feed R3.1 - 2.71 N/mm R3.2 - 3.74 N/mm R3.3 - 4.78 N/mm

POLYCOM

POLYCOM Pre-setting

POLYCOM
Calculation of working pressure and working gap for pre-settings:

POLYCOM Pre-setting
Code word : Client : Polycom type: Material : Diameter : Width : vu : Size (0 - 9) : Hydr. cylinder dia.: N2-cylinder volume: Rho b : Rho c : mDot : [mm] [mm] [m/s] [mm] [l] [t/m3] [t/m ] [ts/m3s] [MPa] [mm] [bar] [bar] [t/h] [mm] [MPa] [MPa]
3

CERROWAL Phelps Dodge 24/17-8 Copper Ore 2400,00 1650,00 2.32 8,00 560,00 60,00 1.6 2.3 240,00 180,00 20,00 60,00 90,00 2200,00 69,00 131,00 180,00

pN2 = 60 bar p0 = 90 bar s0 = 20 mm

s0 = zero gap pN2 = pre-set N2 pressure p0 = initial hydr. pressure

pmax allowable : s0 : pN2 : p0 : M: smax : pmax at s0 : pmax at smax :

POLYCOM

POLYCOM Pre-setting
Calculation of Polycom grinding pressure from hydro-pneumatic spring system sa max = M * 1000 / L * u *c * 3.6
sa1 = (sa max s0 ) / 7 + s0 sa2 = (sa max s0 ) / 7 * 2 + s0 sa6 = (sa max s0 ) / 7 * 6 + s0
grinding pressure pmax actual [mm] [Mpa] 131 123 122 124 129 139 155 180 [bar] 124 144 161 177 192 205 218 230 [bar] 90 99 109 122 138 159 188 230
hydr. pressure at pmax allow.

Calculation of grinding pressure

250 240 230 220 210 200 190 180 130 170 160 110 150 140 90 130 120 170 190

150

gap

hydr. Pressure at pmax allow.

actual hydr. Pressure

s0 sa1

sa6 sa max

20 27 34 41 48 55 62 69

110 100 90 80 70 15 25 35 45 55 65 75

70

50

30

working gap [mm]

actual hydr. Pressure

grinding pressure pmax actual

grinding pressure [MPa]

hydraulic pressure [bar]

POLYCOM

POLYCOM Pre-setting
Calculation of Polycom grinding pressure from hydro-pneumatic spring system
vN2 Operation = pN2 pre-set / p0 * 2 * vN2 Design - (d / 100)2 * * (sa - s0) / 100 pmax = pa / sa1/2* k pa = pN2 pre-set * vN2 Design * 2 / vN2 Operation pmax = F * 1000 / D * L * k * ip

Gap s [mm] 20,00 27,06 34,12 41,18 48,23 55,29 62,35 69,41

Nip angle aip

N2- volume vN2 [l] 80 73,04590769 66,09181537 59,13772306 52,18363074 45,22953843 38,27544612 31,3213538

Hydr.- pressure pa [bar] 90 98,5681502 108,939359 121,7496993 137,9743015 159,1880052 188,1101523 229,8751211

Grinding force F [kN] 8866,831105 9710,968224 10732,7433 11994,82245 13593,27587 15683,25729 18532,67722 22647,37638

Grind. press. pmax [MPa] 131,1081988 123,4487828 121,5070009 123,609046 129,426524 139,4693879 155,200154 179,7562929

0,085391256 0,099323162 0,111528089 0,122523216 0,132609813 0,141981641 0,150772047 0,159077447

POLYCOM

M = L * s * u * cake *3.6

POLYCOM Pre-setting
Calculation of Grinding Force in subjection of working gap and - pressure
s = M / L * u * cake *3.6
F [kN] 12173,37751 14159,51004 15899,44431 17466,90968 18904,85489 20240,90272 21494,06308 22678,08088 pmax allowed [bar] 123,5620666 143,7216846 161,382344 177,2924118 191,8878255 205,4489618 218,1687746 230,1867775

F = pmax allowed * D * L * ip * k / 1000

pmax allowed = 180 MPa k = 0.2

F = dhydr 2 * * pa * 100
Gap s [mm] 20,00 27,06 34,12 41,18 48,23 55,29 62,35 69,41 Nip angle aip N2- volume vN2 [l] 80 73,04590769 66,09181537 59,13772306 52,18363074 45,22953843 38,27544612 31,3213538 Hydr.- pressure pa [bar] 90 98,5681502 108,939359 121,7496993 137,9743015 159,1880052 188,1101523 229,8751211

Grinding force F [kN] 8866,831105 9710,968224 10732,7433 11994,82245 13593,27587 15683,25729 18532,67722 22647,37638

Grind. press. pmax [MPa] 131,1081988 123,4487828 121,5070009 123,609046 129,426524 139,4693879 155,200154 179,7562929

0,085391256 0,099323162 0,111528089 0,122523216 0,132609813 0,141981641 0,150772047 0,159077447

POLYCOM

POLYCOM Process description

POLYCOM

POLYCOM Process description

Applied Grinding force and Reaction Force
Working Gap

FR

Compression angle

POLYCOM

POLYCOM Process description

Pressure from Surrounding particles

Fine fraction Micro-crakcs

Particle size distribution from HPGR

POLYCOM

POLYCOM Process description

Compression zones in operating (working) gap Bulk material Pre-breakage zone

Compression zone sp : nip angle (single particle) ip : nip angle (interparticle) Legend: asp = arccos (1 - (xmax/s - 1)* s / (1000 * D)) aip = arccos (1 - ( c / b - 1)* s / (1000 * D)) D: roll diameter [m] b: feed bulk density [t/m]

s: cake thickness [mm] c: density of compacted cake [t/m] xmax: maximum particle size [mm]

POLYCOM

POLYCOM Process description

Pressure profile in the compression zone

paverag
e

pressure

Angle of relaxation

Compression angle

ip

Compression angle aip = 180/ * SQRT (2 * s/D * ( cake / feed - 1))

POLYCOM

POLYCOM Process description

Comminution zones along the roller width

pressure P ave

Cheek plates By-pass box Edge zone Center zone

Roll width

POLYCOM
M = L * s * um * * 3.6

POLYCOM Process description

Throughput Calculation
M [t/h]: throughput L [m: roll width s [mm]: working gap um [m/s]: material velocity in the gap [t/m]: material density in the gap mdot [t*s/(m*h)]: specific throughput (calculated from the cake) C [t/m]: density of the pressed material (cake) D [m]: roll diameter s [mm]: working gap M [t/h]: throughput D [m]: roll diameter u [m/s]: roll speed mdot [t*s/m*h)]: specific throughput L [mm]: roll width

mdot cake = ( s / D ) * c * 3.6

M = mdot feed * D * L * u

The specific throughput rate mdot feed can be calculated as follows:

mdot feed = M / ( D * L * u )

POLYCOM

POLYCOM Process description

Calculation of Grinding Pressures
The specific grinding force feed can be calculated as follows:

= F / (1000* L * D)

[N/mm]: specific grinding force D [m]: roll diameter

F [kN]: grinding force L [m]: roll width

pave = F / (1000 * L * D/2 * aip) pave [MPa]: average pressure in material bed aip [ ]: nip-angle for interparticle comminution = 2 * / aip
F [kN]: grinding force D [m]: roll diameter L [m]: roll width

pmax = F / (1000 * k * D * L * a ip) = / (k * a ip)

pmax [MPa]: maximum pressure in material bed k []: material constant (0.18 0.23)

5 * /aip

POLYCOM
Power calculation

POLYCOM Process description

Ftangential F

PR = * T = 2 * * u / 60 * D/2 * sin * F
PR [kW]: motor power per roll T [m]: roll torque F [kN]: grinding force []: force action angle The total motor power P is then: [sec-1]: angular roll speed u [rpm]: roll speed D [m]: roll diameter

Force acting angle

P = 2 * PR = * u / 30 * D * sin * F
P [kW]: Total motor power D [m]: roll diameter F [kN]: grinding force

sin = Pshaft / 2 * u * F

PR [kW]: motor power per roll u [rpm]: roll speed []: force acting angle

The specific energy wsp can be calculated as follows:

Wsp = P / M

2000 * sin / mdot *

POLYCOM

POLYCOM Process description

Power calculation of one motor with - Variations
F

Ftangential

Force acting angle

2,2

2,4

2,6

2,8

Gap s [mm]

kW at shaft

20,00 27,06 34,12 41,18 48,23 55,29 62,35 69,41

717,9 786,3 869,0 971,2 1100,6 1269,8 1500,5 1833,7

789,7 864,9 955,9 1068,3 1210,6 1396,7 1650,5 2017,0

861,4 943,4 1042,7 1165,3 1320,6 1523,7 1800,5 2200,2

933,2 1022,0 1129,5 1262,4 1430,6 1650,5 1950,4 2383,5

1004,9 1100,6 1216,4 1359,4 1540,5 1777,4 2100,3 2566,7

POLYCOM Sizing
POLYCOM Cerrowal

Questions?