how to select a hpgr for iron ore

By mid 2008, 35 HPGR units had been installed at diamond mines since 1986, some 42 had been deployed at iron-ore processing operations since 1995 and 35 had been delivered to hard-rock mining companies, mostly since 2004, according to Rene Klymowsky and colleagues 1.

Online prediction of pressing iron ore concentrates in an …

The HPGR is situated in the boundary between the end of the pellet feed preparation step and the beginning of the pellet formation process (Campos et al., 2021a). The machine occupies a critical position aiming to increase the BSA of the iron ore concentrate and deliver a more homogenous product to the downstream operation.

A methodology to predict the HPGR operational gap by

The iron ore was tested under two different moisture contents of 3% and 6%, while the copper ore was tested using one moisture content of 3.5%. With each sample, three pilot-scale HPGR tests were conducted using different specific forces (total of 9) and three PPT using different sample volumes (a total of 15, copper ore were made in …

Developments in HPGR technology

Today, the iron-ore industry uses HPGRs to prepare pellet feed for finishing grinding after wet-ball milling and filtering. The wet-ball mill product is more readily filtered without the need to grind it to the final product size. Since HPGRs can process fine ores at moistures of up to 10%, they are used to perform the final stage of grinding.

Energies | Free Full-Text | An Energy Efficient Advanced

The test results stated that the higher roller speed led to finer products for gold and iron ore. An increase in roller speed caused lower proportions of fine and coarse particles to be produced for bauxite and iron ore. It was found that the rolls speed has a significant effect on the grinding efficiency in HPGR.

Pressing iron ore concentrate in a pilot-scale HPGR. Part 1

Typically, HPGR (high-pressure grinding rolls) and ball mills are used to improve the SSA value of iron ore concentrate [8, 9]. This operation reduces particles …

Case Study of Dry HPGR Grinding and Classification in Ore Processing

This publication summarizes some of the features and experiences with dry HPGR processing. A descriptive iron ore case study will be presented illustrating the process steps and equipment design ...

How HPGRs compare to conventional milling | Weir

Within this highly-compressed bed of rock, an Enduron® HPGR delivers as much as 5N/mm in pressure, significantly reducing even highly-competent ores, such as diamond, gold, copper and coarse iron ore, while achieving throughputs of up 9,000 t/h that ball mills can't match. Offloading (S)AG Mills pebble crushing via HPGR

Pressing iron ore concentrate in a pilot-scale HPGR. Part 1

The present work studied the performance of a pilot-scale HPGR pressing an iron ore concentrate under a variety of conditions that are consistent with pre-grinding. As already observed by Van der Meer and Leite (2018) for iron ore pellet feed pressing …

Our Dynamic HPGR Technology for Mineral Grinding | Weir

Enduron® high pressure grinding rolls (HPGR) can handle a wide variety of ores and particle sizes from fine pellet feed all the way up to coarse grinding of 75mm magnetite iron ore.. When it comes to feed material characteristics, the specific ore type is not detected by an Enduron® HPGR, however ore hardness, size and bed compressibility are important …

Comminution and classification technologies of iron ore

Most of the high-grade hematite iron ores are typically subjected to simple dry processes of crushing and classification to meet the size specifications required for direct shipping ore (DSO). This involves multistages of crushing and screening to obtain lump (−31.5 + 6.3 mm) and fines (approximately −6.3 mm) products.

How to avoid errors in HPGR product characterization

Both standard HPGR lab scale test or industry measurement deliver high amounts of samples. Those samples contain a certain moisture range. For iron ore concentrates the value of 0-12 % can be found on several worldwide installations with HPGR. Due to the high amount of sample of >100 kg the material has to be representably splitted.

Enduron® HPGR – the principal choice in iron ore

"With its ability to reduce grinding energy by as much as 40% without the need for process water and extending its low impact benefits when combined with dry air …

Development of a Novel Grinding Process to Iron Ore

The grinding tests were performed feeding a blend of 80% ore A (compact and harder) and 20% ore B (porous and brittle). The variable parameters evaluated were mixture …

(PDF) Methodology and Model to Predict HPGR Throughput …

The throughput model was developed. using machine learning techniques and calibrated using pilot-scale HPGR tests and piston press tests. The resulting model has an R. of 0.91 with an average ...

Outotec on HPGR's leading edge

The major enhancements in HPGR technology are the Outotec pioneered flanges, rotating side plates, which provide demonstrated increased productivity and energy efficiency by effective eliminating the edge effect. The roll gap is more efficiently sealed as the flanges run very close to the opposite rolls edge (this is allowed for by …

Iron Ore Concentrate Particle Size Controlling Through

Nowadays, the HPGR (high-pressure grinding rolls) is an intermediate step between filtering and balling in the most modern iron ore pelletizing operation. The operation debottlenecks filtering process and reduces pressure over the typical milling process to control particle size to the balling. The present study evaluated aspects of …

How Energy Efficient is HPGR?

This paper reviews recent HPGR applications for the processing particularly of copper, gold, platinum, PGM-Ni-Cu and iron ores. HPGR technology is discussed with respect to energy efficiency. The harder the ore the greater the energy savings are likely to be. Typical energy savings of 10-20% can be expected when installing HPGR vs. a SAG mill.

Enduron High Pressure Grinding Rolls

that the adoption of HPGR brings even bigger energy savings per tonne of ore processed. As a result, most greenfield projects processing hard (competent) rock include HPGR as part of their standard comminution flow sheet. Downstream capacity uplifts of up to 40% make Enduron® HPGR a great solution for brownfield optimisation.

how to select a hpgr for iron ore

First HPGR delivered for iron ore pellet feed 2014 New HPGR machine sizes introduced ranging from 1.0m to 2.54m roller diameter 2018 More than 880 roller presses supplied to 68 countries ... » select suitable HPGR

Online prediction of pressing iron ore concentrates in an …

The HPGR process lies after the concentration and filtering processes (Campos et al., 2021a).As such, the moisture content of the HPGR feed is around 8 ± 0.5%, which is close to the maximum that is recommended for pressing iron ore concentrates (Van der Meer, 1997).Table 1 summarizes the main HPGR settings and ranges allowed …

Online prediction of pressing iron ore concentrates in an …

The HPGR process lies after the concentration and filtering processes (Campos et al., 2021a).As such, the moisture content of the HPGR feed is around 8 ± …

High pressure grinding rolls (HPGR)

High pressure grinding rolls (HPGR) are used for size reduction or rocks and ores. They compress the feed material between two rotating rollers, one of which is in a fixed position and another roller that is floating. The …

Mechanism of magnetite iron ore concentrate morphology …

The grinding method and its associated parameters strongly affect the physical properties of the iron ore concentrate. Ball milling (BM) and High-pressure grinding rolls (HPGR) are commonly employed for grinding iron ore concentrate [18], [19], [20]. In BM, the particle size was decreased by impact and attrition breakage, whereas size …

Pressing iron ore concentrate in a pilot-scale HPGR

The work takes advantage on recent advances in the HPGR mathematical modeling, beyond selecting an industrial-scale iron ore pelletizing plant as a case study for model application.

Iron Ore Concentrate Particle Size Controlling Through

The operation debottlenecks filtering process and reduces pressure over the typical milling process to control particle size to the balling. The present study evaluated aspects of …

Perfecting Hard-Rock High Pressure Grinding Performance

Normally, it is the HPGR supplier's prerogative to choose the drive supplier; the end user normally buys the HPGR with the drive systems included. ... and the Mogalakwena and Northam platinum installations plus the Assmang BKM iron ore project in South Africa, including the wear history of the rolls and on-going development programs intended ...

Development of a Novel Grinding Process to Iron Ore

2.1.2 Ore Blend Grinding at HPGR and Ball Mill. The ore blend was ground in a pilot-scale HPGR (1 m diameter × 0.32 m width) at a maximum feed rate of 50 t/h. The ground product was recirculated to the HPGR feeding hopper five or seven times, wherein every recirculation steps a sample was gathered for moisture and size distribution …

Aspects of HPGR in Iron Ore Pellet Feed Preparation

For iron ore pellet feed preparation from fine iron ore concentrates, at sizes below 1 mm and generally at a high moisture content ranging between 7 % and 12 %, HPGR

(PDF) Physicochemical Problems of Mineral Processing

An effect of a grinding method, that is ball mill and high pressure grinding rolls (HPGR), on the particle size, specific surface area and particle shape of an iron ore concentrate was studied.

(PDF) Development of a Novel Grinding Process to …

The work takes advantage on recent advances in the HPGR mathematical modeling, beyond selecting an industrial-scale iron ore pelletizing plant as a case study for model application.

Why gold mines are adopting HPGRs to increase production …

How HPGR improves gold recovery. There are two main ways mines recover gold ore from the gangue, and HPGRs can assist with each process. One of them is heap leaching and for mines using this process, we've found that the most efficient setup is to have a HPGR perform tertiary grinding immediately prior to recovery, completely avoiding the use of a …

High Pressure Grinding Rolls for Minerals

duty. In the iron ore industry, most of the machines are found in pellet feed applications. How-ever, there are a few notable examples where HPGRs are used for coarse iron ore grinding – in Chile, Mauritania and the USA. The first large scale attempt at applying HPGRs to harder and more abrasive copper and gold ores was in 1996 at Sierrita.

Online prediction of pressing iron ore concentrates in an …

The digital assistant receives real-time information of an industrial-scale HPGR pressing of iron ore concentrates and uses the Modified Torres and Casali model to predict the main HPGR ...

(PDF) HPGR effect on the particle size and shape of iron ore …

The work takes advantage on recent advances in the HPGR mathematical modeling, beyond selecting an industrial-scale iron ore pelletizing plant as a case study for model application.

Scale-up of HPGR in size reduction of iron ore pellet feed

Abstract. Iron ore pellet feed pressing has been one of the first and most successful applications of High-Pressure Grinding Rolls (HPGR) in the minerals industry. Vale S.A. has been one of the ...

Enduron® HPGR – the principal choice in iron ore

"With its ability to reduce grinding energy by as much as 40% without the need for process water and extending its low impact …

Pressing iron ore concentrate in a pilot-scale HPGR. Part 1

An iron ore concentrate sample was ground separately in a pilot-scale HPGR mill in multiple passes and a dry open-circuit ball mill to increase the specific surface area of particles.

CONSIDERATIONS FOR MULTISTAGE HPGR GRINDING …

Figure 1. Example of HPGR Product Sizes for Single and Double Pass Operation. Depending on the screening efficiency, the recycle load for a 3 mm cut size would

HPGRs Grind Out Larger Role in Plant Productivity | E & MJ

NRRI acquired the HPGR via Weir Minerals from the shuttered Magnetation iron ore tailings recovery operation in Grand Rapids, Minnesota. Both organizations are sharing the cost of maintenance. thyssenkrupp's new HPGR Pro model uses rotating sideplates on the fixed grinding roll — a design innovation claimed to enable improved material feed ...