hpgr presentations.docx

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Performance Evaluation of Different Circuit Applications of

High Pressure Grinding Rolls

(HPGR)

Hakan BENZER



2006



Aim

To investigate the performance of different

circuit alternatives, in which HPGR is used

in various configurations



HPGR

1 Feed Unit2 Dosing Unit

3 Feed Regulation4 Roller 5 Motor, shaft system6 Cylindrial Roller Dri!e" #ydrauli $iston

% Frame& $ressure 'ystem 10()eration $latform



Liner Types



Circuit Types

Open Circuit Pre-grinding

#$*R

')litter



Circuit Types

Hybrid Grinding +ir 'e)arator

all Mill



Circuit Types

Closed Circuit Pre-grinding

Disagglomerator



Circuit Types

Semi Finish Grinding



Circuit Types

Finish Grinding



Industrial Data Set

Sampled Circuit Types

• Open Circuit Pre-grinding (! S"mpling#

• Hybrid ($ S"mpling#

• Closed Circuit Pre-grinding (! S"mpling#

• Semi-Finish Grinding ( S"mpling#



tudies !arried "ut

Sampling of the circuits

Determination of Size Distributions

and

Grindabilities

Mass Balancing

Performance Evaluation



#esign and "perational

$aria%les of the!ircuits

ampled

HPGR

CaseStudy

1

CaseStudy

2

CaseStudy

3

CaseStudy

4

CaseStudy

5Roll Length (mm) 530 550 530 1450 1400

Roll Diamete (mm) 1400 1200 1400 1000 1400Roll S!eed (m"s) 1#5$ 1#4$ 1#5$ 1#50 1#%1&!eational Pessue ('a) 150 134 111 120*o+ing Ga! (mm) 10#1 13#5 22#% 3#% 22#2Po,e Da, (+*) %3% %40 551 105$ 11%Ball &ill Power #raw 'k() *+* *-./ 01- *.// *+22



"pen !ircuit HPGR 3 !losed !ircuit Ball &ill

Grinding 4 !ase tud5 *

$0- Passing

$#22 mm

Gy!sum

2#4 t"h .ass

Clin+e 154 t"h 20#0 t"h

1#$$ mm

Cushed

HPGR

2#00 t"h

#2 mm

/un+e

/all ill

13%#$5 t"h

Dynami i Se!aato

Clin+e

/all illCiuit

50#1 t"h

&3eall

Ciuit

$%#%$ t"h

{RR 4#4

CS (+*h"t) 4#0

{RR 2$1

CS (+*h"t) 30#2

{RRCS (+*h"t) 34#2



33 m



"pen !ircuit HPGR 3 !losed !ircuit Ball &ill

Grinding 4 !ase tud5 *

%&%' %&'

P"rticle Sie

' '% '%%

C u m &

) P

" s s

i n g

'%%

*%

!%

+%

,%

%

.%

$%

%

'%

%

%&%%'

HPGR /eed obs&

HPGR product obs&

0& mill /resh /eedobs& C"l&

Sep& /eed obs&

Sep& re1ect

obs&



"pen !ircuit HPGR with Partial Rec5cling

3 !losed !ircuit Ball &ill Grinding 4 !asetud5

Gy!sum

$0- Passing

/all illCiuit

2(#5

{Ci1uit

Clin+e .ass

&eall

$#{ 1%#0 mm

1# t"h 10#0 t"h

4#5 mm

RR 3#5

CS (+*h"t)

{RR %%

CS (+*h"t) 20#%

RR 235

CS (+*h"t)



%4#5 t"h1# t"h 35#3 t"h 1# t"h

%$ m



"pen !ircuit HPGR with Partial Rec5cling

3 !losed !ircuit Ball &ill Grinding 4 !ase

tud5

%&%' %&'

P"rticle Sie (mm#

' '% '%%

C u m &

) P

" s s i n g

'%%

*%

!%

+%

,%

%

.%

$%

%

'%

%

%&%%'

HPGR /resh /eed obs&

HPGR disch"rge obs&Sep& /eed obs&

Sep& re1ect obs&

Product obs&

C"l&



H5%rid Grinding 4 !ase tud5 6

Clin+e

102#1 t"h

Gy!sum

%#52 t"h 442#$ t"h

2(#(

{Ci1u

it

5%#35 t"h $0- Passing

13#2 mm

43#1 t"h

&3eall10$#0 t"h

2 mRR 455

CS (+*h"t)



21#00 t"h

151#$ t"h



H5%rid Grinding 4 !ase tud5 6

'%%

*%

!%

+%

,%

%

.%

$%

%

'%

%

%&%%'

Clin2er obs&

Gypsum obs&

HPGR disch"rge obs&Sep& /eed obs&

Sep& re1ect obs&

Product obs&

C"l&

%&%' %&' '

P"rticle Sie

'% '%% '%%%

C u m &

) P

" s s i n g



!losed !ircuit HPGR 3 !losed !ircuit Ball

&ill Grindin 4 !ase tud -

HPGRCi1uit

Clin+e

122#21 t"h

Gy!sum

# t"h

$0- Passing 5$ t"h

/all illCiuit

55 t"h

%$ t"h

1$#5 mm

&3eall

Ci1uit

Disagglomeato

4%% t"h

2$ m

132 t"h

{

RR 30$

CS (+*h"t) $#0

{RR 2#15

CS (+*h"t) 13#%

{RR %%1

CS (+*h"t) 21#%



%0 m




&ill Grinding 4 !ase tud5 -

%&%' %&'

P"rticle Sie (mm#

' '% '%%

C u m &

) P

" s s i n

g'%%

*%

!%

+%

,%

%

.%

$%

%

'%

%

%&%%'

HPGR /resh/eed obs&Sep& /eed obs&

Sep& re1ect obs&

Sep& /ine obs&

C"l&




&ill Grinding 4 !ase tud5 -

3 c t u " l 4 / / i c i e n c y

P"rticle Sie (mm#



emi 3 7inish Grinding 4

!asetud5 +

HPGRCi1uit

Gy!sum

4#5 t"h

Clin+e 114#55 t"h

$0- Passing

12# mm

1#2 t"h

31 m11#14 t"h

SP6222#21 t"h

{&3eall

53 m

GR7D

Ci1uitSPR.&R

{RR 243

CS (+*h"t) #$

RR 41%

CS (+*h"t) 23#0



5$#$ t"h




!asetud5 +

%&%' %&' '

P"rticle Sie

'% '%% '%%%

C u m &

) P

" s s i n g

'%%

*%

!%

+%

,%

%

.%$%

%

'%

%

%&%%'

Clin2er obs&

Gypsum obs&

Sep& /eed obs&

Sep& re1ect obs&

C"l&

Sep& /ine c"l&




!asetud5 +

3 c t u " l 4 / / i c i e n c y

'

%&*

%&!

%&+

%&,

%&

%&.%&$

%&

%&'

%

%&%%' %&%' %&' '

P"rticle Sie (mm#



Result

s

HPGR Ciuit

RedutionRatio(8$0"P$0)

HPGR Ciuit

S!ei9inegyConsum!tion

(+*h"t)

&eall

CiuitRedutionRatio

(8$0"P$0)

&eall Ciuit

S!ei9inegyConsum!tion

(+*h"t)CaseStudy 1 4#4 4#05 : 34#1Case

Study 2 3#5 $#3 235 2#5CaseStudy 3 : : 455 2#$5CaseStudy 4 30$ $#02 %%1 21#%5CaseStudy 5 243 #$0 41% 23#03



Results

-he effiieny ur!es indiated that for the losediruit #$*R a))liations, air lassifiers .ereo)erated .ith high /y)ass ratios

-he grid se)arator .as found to /e ineffiient fordisagglomeration of flaes e. tehnologyse)arators are /eing used no. -hey are muh more

effeti!e



Results

!ompressed %ed %reakage

t ' % ( ) #

.%

$

$%

%

'

'%

-

%

- ', 5 '$& mm

- ''& 5 *& mm

- &, 5 .&+ mm

- '&'! 5 ' mm

- %&, 5 %& mm

% %& %&. %&, %&! ' '& '&.

4cs (26h7t#



Results

8mpact %reakage



Results

!omparison %ed vs impact



!onclusion

'%%

*%

!%

+%

,%

%

.%

%&%' %&' '

P"rticle Sie (mm#

C u m &

)

P " s

s i n g

6i

(26h7t#

4cs

(26h7t#

HPGR Circuit '& !

Pl"nt ' ',&' $*

Pl"nt *& ,

Closed Circuit HPGR-C"se Study .Pl"nt 'Pl"nt



!ase tudies Limestone and

Clinker

()en iruit eerise .ith different ore ty)e

$ressure ffet 'ide ffet

Open Circuit Roller Press



Open Circuit Roller Press

Grinding Limestone

Roller 8i"meter (mm# ''%Roller Length (mm# '%%%

9otor Po:er (26# %%

Roller Speed (rpm# $&!

C"p"city (t7h# $%%

S"mpling

Period

G"p (mm# Pressure (0"r# 9otor (3# C"2e

Thic2ness

(mm#Set Le/t5Right 9o;ing5Fi<ed

'

'.

+- '.* !! +&!$

!% ',% *, +&%!$ *% '+* '%$ !&-.

. '%% %* ''* +&,-

-

',

+% '.% *% *&-+

, !% ',% *. !&*

+ '%% '*. '%$ *&$+! ''% $ '', *&.'

Open Circuit Press Grinding



Open Circuit Press-Grinding

Limestone

100

%0

60

40

20

0

1 10 100 1000 10000 100000

Patile Si;e (m)

feed 14 mm "5 /ar 14 mm %0 /ar 14 mm &0 /ar 14 mm 100 /ar

C u m # - P a s s i n g g

O Ci it P G i di




Limestone

100

%0

60

40

20

0

1 10 100 1000 10000 100000

Patile Si;e (m)

feed 16 mm "0 /ar 16 mm %0 /ar

16 mm 100 /ar 16 mm 115 /ar

C u m #

- P

a s s i

O Ci it P G i di




Limestone

<=lem /as>n> ('a)

2"" mm

2&3 mm

y 41263 7 1265

R2 0&&21

1100

1050

1000&50

&00

%50

%00

"50

"00

650

600

y 256&" 73"%%&

100 120 140 160 1%0 200 220 240

&!eating Pessue ('a)

P o , e 1 o

n s u m ! t i o n ( + *

)

)*+(?@Gi

Ait+eBn> al oto0





Clin2er

Roller 8i"meter (mm# ''%

Roller Length (mm# '%%%

9otor Po:er (26# $'

Roller Speed (rpm# ',&!

S"mpling

Period

Pressure

(0"r#

9otor

(3#

C"2e

Thic2ness

(mm#

' '*, *+% $%=*

$% ''% *=-*

$ '!% !, $.=,




Clin2er

.ane /oyu (m)

/esleme

eG-

ilmi+i i/ C u m u l a t i 3 e P a s s i n g -

100

&0

%0

"0

60

50

40

30

20

10

1 10 100 1000 10000 100000

Patile Si;e (mm)

Feed

30& mm 1&6 /ar

2&6 mm 230 /ar

343 mm 1%0 /ar



Open Circuit Press-Grinding Clin2er

h) "t(etis!aa

e+ al>nl>A> (mm)

32%

326

C a ! a 1 i t y ( t " h )

332

330

3242& 30 31 32 33 34 35

Ca+e .hi+ness (mm)




/as>n? ('a)

)

m(m>A>ln>la

+e

C a + e . h i 1

+ n e s s ( m m )

35

34

33

32

31

30

2&

150 1"0 1&0 210 230 250

Pessue (/a)

i i i di li 2




/as>n? ('a)

!)m

a(> a !e

mo ot

ma!l.o

. o t a l o t o 2 m ! e e ( a m ! )

Pessue (/a)




Roller 8i"meter (mm# '.%

Roller Length (mm# +!%

9otor Po:er (26# '.%%

Roller Speed (rpm# %

*a) 8mm9 $ressure 8/ar9 $o.er 8:9 Ca)aity 8t;h9 < ')lit

040&2001 1sur!ey 22&5 1014% %3"50 155%4 5000

040&2001 2sur!ey 2205 &&2& %&664 20&2& 3000

040&2001 3sur!ey 216" &%34 %4&13 215%6 2000

040&2001 4sur!ey 21%% 10010 %5"10 20300 100

0%0&2001 1sur!ey 2024 1145% &01"0 1010" 5000

0%0&2001 2sur!ey 2005 &"41 %2215 11&52 5000

0%0&2001 3sur!ey 20&& &&2% %3450 1364% 5000

1"042002 %5/ar 1%04 10%5% &20"% 2%142 0

1"042002 &5 /ar 2043 13%46 1136%6 2&0%6 0

1"042002 105 /ar 2006 15514 12436" 2&0% 0





Clin2er

SideEfect

Fresh Feed

'ide$rodut

HPGR

Central$rodut all

Mill Feed




Open Circuit Press GrindingClin2er

Side Efect

.ane /oyu (mm)

esleme

=e

<50 =enar

0,01 0,1 1 10 100

?eG-i

ml i+i i/

C u m u l a

t i 3 e P a s s i n g -

100&0%0

"0605040302010

00,001

FeedCae

'ide ffet

Patile Si;e (mm)





Clin2er

Pressure Efect

.ane /oyu (mm)

001 01 1 10 100

ne?eG-

ilmi+i i/

/esleme

C u m u l a t i 3 e P a s s i n g -

100&0%0"0605040302010

0

0001

Feed%5 /ar

&5 /ar

105 /ar

Patile Si;e (mm)

O Ci it P G i di Cli 2




Pressure – Energy correlation

/as>n? ('a)

)*

+(@?G

ma

.o!l

. o t a l P o

, e ( + * ) 1300

125012001150110010501000&50&00%50%00

&0 100 110 120 130 140 150 160

Pessue ('a)

H b id G i di



Hybrid Grinding

olu 212

2&%5

olu 1

6123636

=a>an32

26%2

Se!# 7isinin E/DFye /es# ismi (-)

)

-(i

mite+.@

i ne4

mi i/

S ! e 1 i 9 i 1 4 n e

g y C o n s u m ! t i o n

( - )

3"

35

33

31

2&

2"

25

0 5 10 15 20 25 30 35

Se!aato Reet to the HPGR -

Cl d Ci it



Closed Circuit

?>+l>+ (mm)

"t(

etisa!a C a ! a 1 i t y ( t " h ) y 1&,1"&

25,%16

"50

"00

650

600550

500

450

400

20 25 30Ga!

35 40

Cl d Ci it



Closed Circuit

m

m(+>l+>?

/as>n? ('a)

G a ! ( m m

)

403%36

3432302%262422

20%0 &0 100 110 120 130 140

Pessue (/a)

Cl d Ci it



Closed Circuit

/as>n? ('a)

3

25 R R

5 0

4

35

2

15

&0 100 110Pessue (/a)

120 130 140

i i i



Comp"rison o/ Circuit Types

&!en CiuitPeginding

Hy'idGinding

Closed Ciuit Semi 8inishPeginding Ginding

irim ner?i -@etimleri 8<9

+AB De!ren @tmeli

#i/rit De!re =a)alB De!ren @tmeli

EarB 'onDe!re

S!ei9i negy Consum!tion (-)

100

%0

60

40

20

0



3>R S4P3R3T>O?

T4CH?OLOG@ AS48 FOR CL3SS>F>C3T>O?



3>R S4P3R3TORS

• ST3T>C

• 8@?39>C

B F>RST G4?4R3T>O?

B S4CO?8 G4?4R3T>O?

B TH>R8 G4?4R3T>O?

Forces"cting

m: particle massg: acceleration due to gravity

∆δ : particle-air density difference

*ra!itation

Drag Fore



G =

m& g &∆δ

(u −

v) D = c&a&δ &

c: drag coefficient

a: projected particle

area u: air velocity

v: particle velocity µ

δ

: air viscosity

f: functiondp: particle diameter

.her e

c =

f

d p (u − v)

µ

dr: rod diameter

Centrifugal

Fore C =mvr

d p ' E = '+

Gm)at Fore 8effiieny ofa)ture9

d −

d



r '+

p d r



D3?4 T@P4 ST3T>C S4P3R3TOR



PL3?T L3@OATED3?4 T@P4 ST3T>C S4P3R3TOR

HPGR

8yn"mic

Sep"r"tor

St"tic

Sep&100

&0

0"ll 9ill

"0

60

50

40

30

20

10

01 10 100 1000

$artile 'i>e8Hm9

%0

$ a r t i t i o n C o e f f i i e n t

D-S4P3R3TOR



D S4P3R3TOR

the 9eed is dieted do,nthough 'a99les to meet theising ai 9lo,# .he ,ea+om!ats ae 'o+en as theyollide ,ith the 'a99les andthe 9ine and oase !atilesae li'eated# .he oase!atiles an not 'e aied'y the ai 9lo, and slidedo,n to go 'a+ to the

ginding olls# .he 9ine!atiles ae entained in theai and s,e!t u!,adsthough a 9uthe set o9'a99les#



/affles

PL3?T L3@OATED S4P3R3TOR



1I'e)arator Filter Disharge

2Roller Disharge3I'e)aratJr Re?et4I'e)aratJr Fine

2 14

!!

"!

3 #!

$!

%!

&!

'!

(!

)!

!

!

*! !*! !!*! !!!*!

P"rticle Sie(m#

P " r t i t i o n C o e / / i c e n t



F>RST G4?4R3T>O? 8@?39>C S4P3R3TOR

8ist Geneation

D

R

C8K9

*

High negy(u!li9t o9 mateial)



S4CO?8 G4?4R3T>O? S4P3R3TOR

Seond Geneation

L+D

R D

G C

*

7ntemediate negy(u!li9t o9 mateial)



TH>R8 G4?4R3T>O? 8@?39>CS4P3R3TORS

.hid Geneation

C D

* R R(D

G8Gm)at9

Lo, negy(dis!laement o9

mateial)



PL3?T L3@OATE8@?39>C S4P3R3TORS

Filter

0"ll 9ill9ech"nic"l

Cl"ssi/ier



8@?39>C S4P3R3TORS-Per/orm"nce Comp"rison

100

&0

%0

"0

60

First *eneration

50

'eond *eneration

40#igh ffiieny 'e)arator

30

20

10

0

1 10 100 1000

$artile 'i>e 8Hm9

<

$ a r t i t i o n C o e f f i



CO9P3R>SO? OF TH4 8>FF4R4?T T@P4 S4P3R3TORS

Common characteristics of dynamic air separators are ;

- internal rotors that are also feed distribution plates,- airflows generated by internal or external fans,

- collision plates that assist rejection of coarse particles ,

Precision d%(microns# 0yp"ss ()# Feed R"te73ir u"ntity

St"tic %& ,% I'&%

'st gener"tion %&$-%&. % % '

nd gener"tion %&-%& '-% '-$ '&,

$rd gener"tion %&,-%&+ '%-' -' &%-&



CO90>?3T>O? OF TH4 ST3T>C 3?8

8@?39>C-DSJ S4P3R3TOR Feed

Fines +ir +ir

#ot gasor

Fresh +ir

Dynami 'e)arator Re?et

Coarse $artiles



PL3?T L3@OATEDSJ S4P3R3TOR

Cy1lone

S Se!aato Podu1t

Gas

Ra,

0ateial 100

&0

%0.u'e 0ill

"0

60High Pessue

Ginding Rolls 50

40

30

20

10

0

1 10 100

PatileSi;e(m)

- P a t i t i o n C o e 9 9 i 1 i e n t



POSS>0L4 S4P3R3TOR 38KAST94?TS 3?8 TH4>R 4FF4CTS

SEP+,+-., ,esulting Change

-/pe of +d0ustment B/ pass 1ines.utput

1ineness

M+23 1+3

More blades or larger diameter

1e4er blades or small diameter

5igher speed

SELEC-., BL+DES

More blades

1e4er blades

5igher speed 6if double shaft7



POSS>0L4 S4P3R3TOR 38KAST94?TS 3?8 TH4>R 4FF4CTS

D2+P5,+GM or 8+L8ES

9 opening

SEP+,+-., 1EED ,+-E

8aries 4ith the mill

circuit t/pe

SEP+,+-., 1EED

123E3ESS

8aries 4ith the mill

circuit t/pe

,.-., SPEED :

+2, 1L.; :

+))lies only to 2nd and 3rd generations

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