ote outotec hpgr comminution solutions eng web[1]

7/27/2019 OTE Outotec HPGR Comminution Solutions Eng Web[1]

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Benefits

Capital savings

Performance security

Project development and design for

efficient operation

Know-how and track record

Process and project simulation

Automation

Lifecycle solutions

Reliable proven technology with a large

reference base

Outotec® HPGR

Comminution solutions

Outotec offers a large portfolio of comminution

solutions, including high pressure grinding rolls (HPGR),

for meeting various demands with lower energy input

Increasing prices have highlighted the importance of

energy-efficient solutions. The mining industry alone

consumes approximately 4% of the world’s energy andhalf of this is resultant from crushing and grinding

operations. Outotec HPGR solutions are energy-

efficient technology packages for comminution circuits

that enable processing of harder ores.

By choosing Outotec’s comminution solutions with Outotec

HPGR, customers benefit from proven technology, advanced

automation solutions, optimized ramp up and optimal

process outcomes. In addition to HPGR, Outotec's existing

grinding technologies include AG mills, SAG mills, Ball

mills and HIGmills (high intensity grinding). Adding HPGR

technology into our portfolio positions Outotec as having one

of the broadest ranges of competencies in comminution.



Outotec HPGR comminution solutions

customer value:

Capital savings

• Possibility of single point responsibility

• Reduced total project costs with

competitive technology pricing

Performance security

• Whole process optimized with

performance guarantees

Project development and designfor efficient operation

• All equipment information available

to support mineralogy-based test

work and flow sheet development

• Modular technology-based basic

engineering provides accurate plant

model that does not require modifications

during the project implementation –

saves time, resources and money

• Best practices from two major global

companies applied for process design

and project implementation

Lifecycle solutions

• Streamlined training and one source services

Reliable proven technology with

a large reference base

High pressure grinding rolls are emerging as an important

comminution technology in the minerals process industry.

The technology has already established its position in

the liberation of diamonds and hard rock applications in

primary comminution. The HPGR process consumes less

energy than conventional grinding, resulting in reduced

operational costs and enhanced sustainability.

Outotec’s high pressure grinding rolls are designed

and manufactured by Köppern, which has over

100 years of experience in HPGR R&D, testing and

manufacturing. The Köppern manufactured high

pressure grinding rolls have many successful working

applications worldwide. Outotec high pressure

grinding rolls feature a unique design and state-

of-the-art technology. Reliable HPGR technology

combined with Outotec’s comminution experience and

plant process know- how provide process reliabilitywith minimum maintenance downtimes and hence

high plant availability.

HPGR operation

The HPGR comminution process is based on the

introduction of coarse feed material into the preset

gap between two counter-rotating rolls; a fixed roller

and a floating roller. The fixed roller is supported by

the press frame and the floating roller by hydraulic and

pneumatic systems.

During high pressure comminution, the feed material

is exposed to high pressures that crush and fracture

the densest of materials. Due to the relatively uniform

loading of the material in the compression zone, the

very short retention time of the material in the HPGR

and the minimal energy required to transport material

in the press, the process requires less energy input

compared with conventional crushers and mills.

Outotec HPGR solution is an excellent roller press

design, ensuring process reliability and ease of

maintenance. The highly developed wear protection

materials provide long service life and steady operation.



Improved throughput and increased

availability with studded tires

Outotec’s high pressure grinding rolls are manufactured

from highly wear resistant material, which is essential

to reduce the operating costs and to improve the

commercial viability of minerals mining and processing

plants. The rolls are equipped with studded tires that

are designed and built for maximum performance and

durability. The unique design optimizes the stud and

edge performance.

Outotec HPGR presses designed for maximum

reliability and ease of maintenance

Outotec’s HPGR solution has a patented hinged frame

mechanism that allows rapid roll replacement by

lowering the frame members at each end and retracting

the rollers on slide-ways for removal. In addition,

external access to the wear parts of the feed system

is provided, an essential for the maintainability of the

equipment.

Spherical self-aligning roller bearings are employed

in order to withstand short-time skewing of the

rollers during operation. The bearing housings are

optimized by FEM calculations and deliver optimal

force transmission of the hydraulic pressure onto

the roller body. Continuous grease lubrication, a well

engineered sealing system against dust contamination

and constant temperature control greatly reduce the

risk of premature bearing failure and avoid unplanned

equipment shutdowns.

Rigid power transmission through planetary gearboxes

avoids unwanted machine vibrations. The entire drive

train is supported by a patented torque arm system

that forms an integral part of the roller press. Spring-

loaded adjustable cheek plates seal the roller edges

and guide the material stream between the rollers,

thus effectively utilizing the entire roller width for the

comminution process.

The computer-controlled hydraulic system incorporates

proportional valve technology, ensuring the most

favorable operating conditions in the HPGR and

resulting in maximized efficiency and grinding results

under optimized working pressures.

In the comminution

circuit, Outotec

HPGR can in certain

instances decrease

energy consumption

and influence the

downstream processes

with improved

performance of the

flotation, leaching,

thickening and filtration

operations. These effects

are mostly attributable

to the incipient cracking

of particles resulting

from the high stresses

present in the HPGR

compression zone.



F i n l a n d ,

J u l y 2 0 1 3 .

[email protected]

www.outotec.com

Copyright © 2013 Outotec Oyj. All rights reserved.

Outotec provides leading technologie s and services for the sustainable use of Earth’s natural resources.

As the g lobal l eader i n m in er als a nd metals proces sing technology, Ou tot ec has d evelop ed over decades

many breakthrough technologies. The company also provides innovative solutions for industrial water

treatment, the utilization of alternative energy sources and the chemical industr y.

Outotec shares are listed on NASDAQ OMX Helsinki.

Testing services help achieve optimal results

In the early phase of operations, Outotec can offer

industrial scale pilot test work for customer-specific

applications. These pilot scale tests are performed

at Köppern’s facilities and are designed to providecustomers with a variety of options to explore the

applicability of high pressure comminution for a specific

material or mineral. The test work can range from

single pass comminution with different roller surfaces

to an all encompassing closed circuit including selected

downstream processing steps in an effort to find the

optimum solution for the customer, both technically

and commercially.

The Outotec Comminution Plant design is based on:

Best process layout practices Compact footprint and minimized elevation

Ease of operation and maintenance

Optimal sizing, pumping distances,

retention times and energy consumption

Health, safety and environmental quality

Know-how and track record

Outotec HPGR comminution solutions are based on

decades of know-how in building complete comminution

and concentrate plants and a long track record of

successful project deliveries.

Process and project simulation

Successful projects are ensured by optimal circuit and

equipment configurations. Outotec’s in-house HSC

simulation tool provides a model for different process

options with the given throughput and target levels. With

optimal circuit and equipment configurations, Outotec

is able to provide process and performance guarantees

for the operation, as well as process optimization after

commissioning.

Easy and fast ramp up

Fast ramp ups can be guaranteed by using simulation

tools that enable the balance and optimum particle

size to be found quickly. The fastest way from project

to commercial production is through an efficient andtrouble-free ramp up. The design phase, technology

selection, automation solutions and successful

commissioning are all key factors.

Automation solutions for comminution

Using automation and control tools in the ramp up enable

a fast track execution and optimized process right from

the beginning. Outotec’s automation tools enable a quickly

balanced operation and optimized process results.

Expert control systems make running the process fasterand more rational. Expert control systems are reliable

and can handle several variables simultaneously.

Outotec has the process expertise and experience in

communition and automation. Combining these two in

the ACT control tool provides customers a transparent,

dynamic and optimized comminution environment.

Outotec’s unique process control tools – the particle

size analyzer (PSI) and ACT automation control tools –

ensure the fastest possible ramp up. With transparent

control actions, operators can monitor what is taking

place in the process, as well as learn and understand

the changes made to the process. ACT is a self-learning

environment that constantly seeks the optimal process

status 24/7. It offers an open, variable and intuitive

development environment in which customers have

the possibility to develop and integrate their own logics

with the comminution circuit control with less effort.

In addition, Outotec offers various lifecycle solutions

where the customers’ equipment and process can berun and monitored remotely all over the world providing

on time analysis and support.

ote outotec hpgr comminution solutions eng web[1]

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