# pressure grinding rolls versus sag mills

### High Pressure Grinding Rolls (HPGR)

HPGR vs. SAG Advantages • Significant energy cost savings • Reduced grinding media consumption • Reduced overall operating costs • Reduced footprint • Higher mechanical availability • Faster Equipment Delivery • More Environmentally Friendly Disadvantages • Can increase initial capital costs • Increased material handling

### How HPGRs compare to conventional milling

Aug 19, 2019 Ball, SAG and rod mills all require their grinding media to be regularly replaced, unlike a HPGR. High Pressure Grinding Rolls have lower maintenance overheads than ball and rod mills, primarily because the grinding media in conventional mills needs to be replaced on a more regular basis.

### High Pressure Grinding Rolls (HPGR) in Comparision to SAG ...

This paper examines the development of several order of magnitude trade-off studies to evaluate the application of High Pressure Grinding Rolls (HPGR) technology in comparison to the SAG mill grinding technology. These studies were prepared by Wardrop Engineering Inc. on eight different projects at various magnitude tonnages.

### high pressure grinding rolls versus sag mills

Nov 27, 2013 ... High Pressure Grinding Rolls are Not roll crushers! High Pressure .... SAG Mill Circuits typically benefit from pre-crushing or pebble crushing. Get Price

### HIGH PRESSURE GRINDING ROLLS—A PROMISING AND COST ...

High pressure grinding rolls were successfully intro-duced in the cement industry in the late 1980s and enabled appreciable reduction in energy consumption. Promptly ... SAG mill is a “neck stage” and there is sufficient margin of power of ball mills. Various flow charts can be selected subject

### HPGR High Pressure Grinding Rolls

Jul 14, 2016 By shifting more of the particle liberation to the high-pressure grinding roll, substantial savings in power consumption can be achieved. HPGR test results published by Grier (1992) on gold ores from the Mt. Todd project showed significant energy savings for a HPGR/Ball Mill circuit as compared to a SAG/Ball Mill plant.

### What's the Difference Between SAG Mill and Ball Mill ...

The working principle of the self-grinding machine is basically the same as the ball mill, the biggest difference is that the sag grinding machine uses the crushed material inside the cylinder as the grinding medium, the material constantly impacts and grinding to gradually pulverize.

### Grinding Mills - an overview ScienceDirect Topics

SAG mill product feeds two parallel ball mills of 6.6 m×11.1 m (internal diameter×length), each with a 9.7 MW twin pinion drive. The ball mills are operated at a ball charge volume of 30–32% and 78.5% critical speed. The SAG mill trommel undersize is combined with the ball mills’ discharge and pumped to two parallel packs (clusters) of twelve 660 mm diameter cyclones. The cyclone underflow from each line reports to a ball mill

### High Pressure Grinding Roll for advanced crushing FLSmidth

Lower operating power required. Creates microcracks for downstream processes. Provides a more stable grinding operation for variable ores. Reduces the need for and consumption of grinding media. Optimise your results with a high pressure grinding roll,

### A structured approach to the evaluation of the energy ...

and SAG mill circuits in hard ore applications by P. Rosario*† and R. Hall† Synopsis The application of high pressure grinding rolls (HPGR) has been growing in the mining industry for the last 10 to 15 years. The major benefits supporting this trend are better energy efficiency, improved grinding capacity, and higher metal recovery in

### Grinding Mills - an overview ScienceDirect Topics

The high unit capacity SAG mill/ball mill circuit is dominant today and has contributed toward substantial savings in capital and operating costs, which has in turn made many low-grade, high-tonnage operations such as copper and gold ores feasible. Future circuits may see increasing use of high pressure grinding rolls (Rosas et al., 2012).

### Autogenous and Semi-Autogenous Mills - ScienceDirect

Jan 01, 2016 A typical SAG-HPGR-Ball mill circuit suggested by Patzelt et al. is shown in Figure 9.6, where the pebbles from the SAG mill are crushed in the high-pressure grinding rolls. It is a general observation that SAG mills are helpful for grinding where wide variations in

### CMIC-backed novel comminution technology hits ...

CAHM, according to CMIC, provides a more efficient alternative to high pressure grinding rolls and SAG mills, while the MonoRoll variant is designed for finer grinds and to replace inefficient rod and ball mills. In a recent post, CMIC said hot commissioning of the MonoRoll at COREM’s testing facility, using some of the 300 t of ore ...

### (PDF) THE DECISION TO OPT FOR HIGH PRESSURE GRINDING ROLLS ...

The Cadia East Project used HPGR to improve the energy efficiency of an existing SAG mill based circuit when moving from the treatment of open pit ore to a much more competent and potentially ...

### Gold processing 101 - Mining Magazine

However, the SAG route is more power-intensive and, for very hard ores, comes with some process risk in predicting performance. More recently, a hybrid solution has become available in the form of high pressure grinding rolls (HPGRs), which can replace the third stage of crushing and also the SAG mill.

### High Pressure Grinding Roll for advanced crushing FLSmidth

High pressure grinding roll - saving energy and providing results. The HPGR truly is a unique comminution product. It weakens rock structure and exposes ore particles, making it an attractive option for heap leach applications.

### SAG Mill Comminution (SMC) Test SGS

SGS's comminution experts use the SAG Mill Comminution (SMC) test to characterize ore samples, an important first step to grinding circuit design, optimization and production forecasting. Read more The SMC test is an abbreviated, less expensive version of the JK Drop-weight test.

### Barry Wills' Blog: The impact of milling costs on total ...

Jan 06, 2014 It has been shown, for example, that the replacement of a SAG mill with a HPGR in a conventional SAG-ball circuit may reduce grinding energy consumption by 15–20%. Taking into account additional savings, such as media and liner wear, it was found that a grinding cost saving of 25–35% was potentially achievable with the use of HPGRs in such ...

### HRC™ - Metso Corporation - PDF Catalogs Technical ...

Developing the next generation of HPGR world’s largest most advanced HPGR The HRC is the first and only HPGR designed from the ground up specifically for hard rock applications with the singular objective for providing the lowest total cost of ownership Metso HRC™ Pushing the boundaries with pioneering design Metso’s innovative and most advanced HRC™ helps you to get more value from ...

### SMC Test® Minerals Processing Comminution Testing - SMC ...

In conjunction with the Bond ball mill work index they can be used to accurately predict the overall specific energy requirements of circuits containing: AG and SAG mills, Ball mills, Rod mills, Crushers, High Pressure Grinding Rolls (HPGR).

### Publications - SMC Testing

Modelling The Influence On Power Draw Of The Slurry Phase In Autogenous (AG), Semi-Autogenous (SAG) And Ball Mills Ore Change, Ball Load And Material Flow Effects On An Energy Based SAG Mill Model Overall Specific Energy Requirement Of Crushing, High Pressure Grinding Roll And Tumbling Mill Circuits Physical And Morphological Characteristics Of ...

### Process improvement opportunities in comminution circuits ...

Application of High Pressure Grinding Rolls (HPGRs) and implementing hybrid comminution circuits (ie, HPGR-SAG mill) requires proactive control of the feed size distribution to each unit. Application of Vertical Tower Mills (VTMs) and other fine grinding equipment to achieve a finer grind size, while maintaining the throughput, requires ...

### Comparing energy efficiency of multi-pass high pressure ...

Comparison of the performance of Flowsheet A (3.0 N/mm 2 ) against the first two stages of Flowsheet C. Note that the 0.25 m high pressure grinding rolls (HPGR) outperforms the 1.0 m HPGR in the subsequent grinding stage.Fig 7 -Relationship between measured cumulative specific energy and the amount of new fines passing 75 µm generated.

### High-pressure grinding rolls: model validation and ...

SAG mills [23]. However, compression in the pre-crusher stage ofasingleparticlecompression[8–10],mainlywithmul-tiple contactpoints[24,25],ispredominantinHPGR.Moreover, the wide range of speciﬁc pressing forces under which HPGR works, have a great inﬂuence on the breakage behaviour. In the single particle

### Energy and Cost Comparisons of HPGR-based Circuits E MJ

A comprehensive energy and cost study compared an existing SAG mill-based circuit at the Huckleberry mine with two proposed circuits involving comminution technologies that are associated with energy efficiency: high-pressure grinding rolls (HPGR) and high-speed stirred mills. The specific energy requirements, expressed as kilowatt-hours per ...

### (PDF) THE DECISION TO OPT FOR HIGH PRESSURE GRINDING ROLLS ...

The Cadia East Project used HPGR to improve the energy efficiency of an existing SAG mill based circuit when moving from the treatment of open pit ore to a much more competent and potentially ...

### CMIC-backed novel comminution technology hits ...

CAHM, according to CMIC, provides a more efficient alternative to high pressure grinding rolls and SAG mills, while the MonoRoll variant is designed for finer grinds and to replace inefficient rod and ball mills. In a recent post, CMIC said hot commissioning of the MonoRoll at COREM’s testing facility, using some of the 300 t of ore ...

### HPGR High Pressure Grinding Rolls Weir

Used in mining applications for the last 30 years, high pressure grinding rolls (HPGR) reduce particles by compressing and crushing the feed between two counter rotating, parallel rollers with a small gap between them. ... Where HPGR technology has replaced traditional methods of crushing and grinding such as SAG or ball mills, customers have ...

### Gold processing 101 - Mining Magazine

However, the SAG route is more power-intensive and, for very hard ores, comes with some process risk in predicting performance. More recently, a hybrid solution has become available in the form of high pressure grinding rolls (HPGRs), which can replace the third stage of crushing and also the SAG mill.

### Publications - SMC Testing

Modelling The Influence On Power Draw Of The Slurry Phase In Autogenous (AG), Semi-Autogenous (SAG) And Ball Mills Ore Change, Ball Load And Material Flow Effects On An Energy Based SAG Mill Model Overall Specific Energy Requirement Of Crushing, High Pressure Grinding Roll And Tumbling Mill Circuits Physical And Morphological Characteristics Of ...

### SMC Test® Minerals Processing Comminution Testing - SMC ...

In conjunction with the Bond ball mill work index they can be used to accurately predict the overall specific energy requirements of circuits containing: AG and SAG mills, Ball mills, Rod mills, Crushers, High Pressure Grinding Rolls (HPGR).

### Alex Doll - Principal Consultant - Alex G Doll Consulting ...

Both Semi-Autogenous Grinding (SAG) mills and High Pressure Grinding Rolls (HPGRs) create more product fines than cone crushers or rod mills. Many recent HPGR papers claim benefits of these additional fines (often referred to as “microcracking”) when comparing to

### HRC™ - Metso Corporation - PDF Catalogs Technical ...

Developing the next generation of HPGR world’s largest most advanced HPGR The HRC is the first and only HPGR designed from the ground up specifically for hard rock applications with the singular objective for providing the lowest total cost of ownership Metso HRC™ Pushing the boundaries with pioneering design Metso’s innovative and most advanced HRC™ helps you to get more value from ...

### Gold processing 101 – AMC Consultants

However the SAG route is more power-intensive and, for very hard ores, comes with some process risk in predicting performance. More recently, a hybrid solution has become available in the form of high pressure grinding rolls (HPGR’s), which can replace the third stage of crushing and also the SAG mill.

### [PDF] SAG MILL TESTING - AN OVERVIEW OF THE TEST ...

Several grindability tests were developed over the years to design grinding circuits or optimize existing operations. Each test has its own strengths and weaknesses and it is imperative to select the proper test procedure(s) to meet project deliverables and minimize the risk of a project. Pilot plant testing of large bulk samples historically constituted the traditional approach for AG or SAG ...

### Mining Non-Ferrous - CITIC-Heavy Industries Co. Ltd

CITIC HIC manufacture a full range of Grinding Mills for the Mining Sector. ... 80% with the largest mills supplied to date being a Ø7.9m x 13.6m 2x8.5MW Ball Mill and a Ø11m x 5.4m 2x8.5MW SAG Mill , being the largest in China. Vertical Stirred Mills (CITIC Stirred Mills - CSM) ... CITIC HIC has a full range of High Pressure Grinding Rolls ...

### Major Mines Projects Penasquito Mine

The SAG trommel screen undersize (minus 19 mm material) discharges to a common sump. Secondary grinding is performed in four ball mills, operating in closed circuit with cyclones. Ball mill discharge is combined with SAG mill trommel screen undersize and the combined slurry is pumped to the primary cyclone clusters.

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