EXCEL™

HPGR
HIGH PERFORMANCE PARTS

High pressure
grinding roll for
the mining industry

WE DISCOVER POTENTIAL
 A modern, energy-efficient Today's technology for
comminution technology today's mines
to meet the challenges Our HPGR is flexible enough to be highly suitable for both brownfield expansions
and greenfield installations. The wide variety of ways our customers are already using

of complex ores
the machine shows just how helpful the technology is.

Simple operation
Operation of the HPGR is easily controlled because press force
and roll speed are the only directly-managed parameters.
Operator training is easy and it only takes days to bring a new
unit to full production. Adjustments for changes in ore character-
istics or plant requirements are easy:
▪ Increase the speed of the rolls to raise the HPGR throughput.
▪ Decrease the speed of the rolls to lower the HPGR throughput.
▪ Increase the press force for a finer HPGR discharge.
▪ Decrease the press force for a coarser HPGR discharge.
FLSmidth has more than 70 roll presses
installed worldwide
▪ Various models to meet project needs
▪ Full range of sizes to meet capacity needs
▪ Proven HPGR designed specifically for mining industry
▪ Semi-industrial lab unit available for confirmatory
testing
▪ Experienced HPGR field experts on staff to get your
machine commissioned quickly

Key benefits

Lower operating Creation of Provides a more Reduces the need

power than microcracks for stable grinding and consumption
SAG and ball mills downstream operation for of grinding media
processes variable ores High pressure grinding roll

HPGR High Pressure Grinding Roll 3

 F-Series HPGR F-Series HPGR
Base component identification Features and innovations

FerroCer® Impact Wear Panels Express frame

The lower section of our HPGR feed chute, which typically Our express frame allows the roll surfaces to be replaced faster and
experiences the highest wear, is lined with FLSmidth’s patented more safely. Our field-proven split rail and pinned frame design
FerroCer® Impact Wear Panels which have proven to greatly minimise hardware and maximise sourcing options.
outperform conventional wear plates in this application where the
1 feed ore is often large, very hard, and highly abrasive. These panels
are easy and safe to install, while providing the longest possible
wear life. Learn more about where else in your plant operation you
can optimize your durability with FerroCer® Impact Wear Panels.

2
12

3 14

4
9
13
5
15
10 11
6
Express frame
16
7

Bearing
Oil lubrication
housings
A conditioned oil circuit lubricates
Heat the spherical roller bearings rather
M exchanger
(air/fan) 4 x 1 Gear than packing them with grease. A
flow divider
constant flow of oil to and from
the bearings means:
Cartridge
filters
1 operating/
1 stand-by
Return ▪ No greasing or cleaning required
lines
Skid-mounted
1. Feed chute 5 Cheekplates 9. Express frame 13. Planetary gear reducers ▪ Longer bearing life
2. FerroCer® Panels 6. Roll tire assembly 10. Hydraulic manifold 14. Torque sharing arm Oil-reservoir
LP Oil pumps
▪ Grit and heat are quickly removed
3. Feed shut-off valve 7. Roll shaft 11. Hydraulic cylinders 15. Dust enclosure M M 1 operating/
1 stand-by
from the bearings
4. Feed control gates 8. Bearing housings 12. Main drive motors 16. Roll access doors Heater Heater

4 HPGR High Pressure Grinding Roll HPGR High Pressure Grinding Roll 5
Hydraulic cylinders
Our dual-acting hydraulic cylinders mean that you do not need extra tools or rigging to
separate the rolls after a tramp or blockage event.
HPGR P150
They are hinge mounted so you have safe and unrestricted access to the cylinders
during inspections and maintenance. Product laboratory results

Laboratory testing is the first and most

important step for: Front Back

▪ Sizing the HPGR

▪ Determining power requirements
▪ Determining HPGR suitability

Hydraulic cylinders HPGR testing: SLC testing facility:

▪ Particle size ▪ Mineralogy
(feed, discharge, edge)
▪ HPGR testing
▪ Bond work index
Fixed ▪ Comminution testing
(feed & product)
▪ Downstream
Advanced skew controls ▪ Flake density & stability 3cm
As skewing starts to occur in the metallurgy
▪ Discharge screen ability
Pressure floating roll, our machine control ▪ Liquid and
system adjusts the hydraulic ▪ X-ray defraction solids separation We examine things like flake density, clay content and microscopy
pressure that is applied to each to compare ore bodies with one another, which helps to optimise
▪ Clay analysis ▪ Pilot testing
side accordingly to maintain the roll stud selection and roll pattern. This increases the wear life of the
surfaces as parallel as possible. This ▪ Microscopy ▪ Analytical HPGR components as the project evolves.
optimises grinding efficiency and
maximises the roll wear life.
Pressure

Floating Fixed

P150 HPGR Machine Specs

Torque-sharing arm
The planetary reducers are shaft mounted to the ▪ 500 mm diameter × 300 mm wide rolls
rolls and are linked together via the torque sharing
▪ 2 × 45 kW motors with VFDs
arm assembly. This results in savings as it eliminates
the cost of additional foundation structure/hardware ▪ Hydraulic pump skid with PLC system
to bear the torque arm reaction forces.
▪ Adjustable edge and center product dividers
This features also allows the drive train to be cap-
tured and held in place during roll change-out using
our (optional) drive retraction cradle. which further
optimises the roll change-out time and makes the
procedure safer.

6 HPGR High Pressure Grinding Roll

 F-Series and S-Series
Specs, mass and dimensions
F-Series HPGR is the full size machine for large mining We re-designed our legacy roll press to upgrade it and
projects throughout the world. Operation, maintenance optimise it for mining duty, and the result is our S-Series
and service personnel collaborated to create this HPGR. Though this series is meant for smaller projects,
modern HPGR design. With it, you get a reduced footprint, plants and retrofits, it is packed with plenty of the same
convenient and safe handling for heavy components and features that are in our larger models. And the smaller size
improved shipping. means that your machine can be shipped partially or fully
assembled, resulting in a faster installation.
F-Series design
Length 1 Length 2 Width Height Mass

Model No. Metric English Metric English Metric English Metric English Metric English

F1300 4.52 m 14'-10" 1.70 m 5'-7" 2.44 m 8'-0" 3.01 m 9'-11" 56,700 kg 125,000 lbs

F1600 5.17 m 17'-0" 1.95 m 6'-5" 2.79 m 9'-2" 3.45 m 11'-4" 84,800 kg 187,000 lbs

F2500 6.20 m 20'-4" 2.34 m 7'-8" 3.35 m 11'-0" 4.13 m 13'-7" 146,400 kg 322,800 lbs

F3200 7.11 m 23'-4" 2.68 m 8'-10" 3.83 m 12'-7" 4.74 m 15'-7" 220,200 kg 485,500 lbs

F3900 7.75 m 25'-5" 2.92 m 9'-7" 4.18 m 13'-9" 5.17 m 16'-11" 285,900 kg 630,300 lbs

F5000 8.53 m 28'-0" 3.22 m 10'-7" 4.60 m 15'-1" 5.68 m 18'-8" 380,500 kg 838,900 lbs

F6000 9.71 m 31'-10" 3.65 m 12'-0" 5.26 m 17'-3" 6.53 m 21'-5" 563,000 kg 1,241,400 lbs
F-Series HPGR S-Series HPGR

F-Series design
Approximate Approximate top
Model No. Roll area Roll diameter Roll width
throughput* feed size

F1300 1.26 m² 1.40 m 0.90 m 530 MTPH 35 mm 1.4 in

F1600 1.60 m² 1.60 m 1.00 m 800 MTPH 40 mm 1.6 in

F2500 2.47 m² 1.90 m 1.30 m 1,400 MTPH 50 mm 2.0 in

F3200 3.19 m² 2.20 m 1.45 m 2,100 MTPH 55 mm 2.2 in

F3900 3.84 m² 2.40 m 1.60 m 2,800 MTPH 60 mm 2.4 in

F5000 5.00 m² 2.70 m 1.85 m 4,000 MTPH 70 mm 2.8 in

F6000 6.00 m² 3.00 m 2.00 m 5,400 MTPH 75 mm 3.0 in

*Values represent approximate total throughput (fresh feed + recycle) and are based on a default specific throughout value of 250 ts/hm³
S-Series design
S-Series design Length 1 Length 2 Width Height Mass

Approximate Approximate top

Model No. Roll area Roll diameter Roll width Model No. Metric English Metric English Metric English Metric English Metric English
throughput* feed size

S360 0.36 m² 0.90 m 0.40 m 120 MTPH 25 mm 1.0 in S360 4.11 m 13'-6" 0.97 m 3'-2" 2.36 m 7'-9" 2.34 m 7'-8" 22,200 kg 48,900 lbs

S900 0.90 m² 1.36 m 0.66 m 350 MTPH 35 mm 1.4 in S900 5.10 m 16'-9" 1.44 m 4'-9" 2.97 m 9'-9" 2.56 m 9'-9" 42,600 kg 93,900 lbs

*Values represent approximate total throughput (fresh feed + recycle) and are based on a default specific throughout value of 250 ts/hm³

8 HPGR High Pressure Grinding Roll HPGR High Pressure Grinding Roll 9
 Primary grinding
Operational flow sheet
HPRGs add efficiency to the primary grinding circuit for highly
competent and complex ore bodies.
Over the last decade many customers have chosen HPGRs for
primary grinding ahead of ball mills where they would have
traditionally used SAG mills. Ore complexity, ore hardness, rising
electrical costs and the need to stabilize the downstream process
are just some of the reasons that more people are choosing
HPGRs.
HPGR product has microcracked particles which weakens the
boundaries and lowers the Bond work index. This reduces the
amount of ball milling power required downstream.
With a reduced load for the ball mills, you get a substantial
reduction in required motor power, lowered steel ball consumption
and increased grinding efficiency. The change from a SAG mill to
an HPGR in primary grinding results in a lower overall power
consumption the comminution circuit.
In comparison to using staged crushing as ball mill feed prepara-
tion, replacing the tertiary circuit with an HPGR frees up ball mill
capacity (or reduces the size of the ball mills and grinding media
consumption). Three factors contribute to this; HPGR product is
finer than conventional crushers meaning that a percentage of
the discharge stream is already of final product fineness, the
Bond work index is reduced due to microcracking, and the design
feed size to the ball mill is lowered.
Heap leaching
Operational flow sheet
If higher recoveries and faster leach kinetics is important to you,
HPGR should be a consideration for your heap leach flowsheet.
The microcracking in HPGR product lends itself nicely to the heap
leaching process. Cracking and cleaving along the particle grain
lines, and the weakening of the rock structure increases exposure
to the valuable ore particles, which enhances leaching kinetics.
With this, you get faster leaching and higher recoveries compared
to stage crushing alone. HPGR inclusion in heap leaching can be
a viable retrofit to existing operations as well as for original plant
designs.
HPGR flowsheet considerations for; open circuit, closed circuit
(with screen), or edge-recycling provide flexibility in the design to
meet the particle size distribution needed to optimise your heap
leach operation. Optimising the leaching process also lowers the
amount of leaching solution that is required over the life of the mine. Lab photo of microcracked particle

PRIMARY Flotation HEAP

GRINDING KREBS® LEACHING
gMAX®
FLOW SHEET Cyclone
FLOW SHEET
FLSmidth Surge
Manifold Surge Bin
Raptor®
Cone Bin
Surge Edge Recycled
Crusher
Bin Mobile
Conveyor
Next Phase Gold Phase and Stacking
System
H2O FLSmidth Weigh
H2O Ludowici® Belt
FLSmidth
Ball Mill Vibrating
Weigh Screen
Belt

Apron
Feeder
FLSmidth H2O
Ludowici® FLSmidth
Vibrating HPGR FLSmidth
Vibrating Stockpile HPGR
FLSmidth Screen
TS Gyratory Grizzly
Crusher
KREBS®
millMAX TM Fuller®
Pump Jaw
Crusher Leach
Pad
Sump FLSmidth
Raptor®
Cone
Stockpile Crusher Gold
Apron Smelt
Feeder FLSmidth Apron
Ludowici® Feeder
Vibrating Doré
Screen

10 HPGR High Pressure Grinding Roll

HPGR High Pressure Grinding Roll 11
 Pebble crushing Finish grinding
Operational flow sheet Operational flow sheet

Our HPGR is great at de-bottlenecking your problematic
pebble circuit. You know how easy it is for hard pebbles to get
caught in circulation, small enough to escape the mills but too large
to make it through your screening process. Sending these pebbles
back to the SAG mill until they are adequately sized works for softer
ores. Harder, more competent ores, however, can result in crushed
Optionally, the process can be simplified by operating the HPGR
in an open circuit and directing the discharge stream back to the
SAG mill in-feed.
The future of mining is dry comminution circuits that minimise
wasted power, water consumption and carbon production.
This circuit also provides downstream benefits:
■ The consumption of grinding media is eliminated.
■ The finished, ground material can be immediately stored,

pebbles that continually circulate. Circulating pebbles eventually creating a buffer and allowing the downstream plant to be fed at
rob your SAG mill of volume and create an operational bottleneck. a consistent rate.
■ Air separators provide a product with a narrower particle size
Instead of feeling trapped by the conventional solution of constant distribution.
recirculation, you can use our HPGR to leave the cycle behind.
Our solution is to crush the pebbles with a cone crusher and then With more than 125 years of experience and over 1,500 dry
feed them to an HPGR. This arrangement will crush the pebbles classification systems installed, we are the world leader in dry
enough that that you can feed the product directly into the ball mill process technology. We have a large selection of both static and
sump. The change balances your circuit by increasing the available dynamic classifiers to suit your project needs, including the best
volume of your existing SAG mill and maximizing capacity of your available air classifier in the industry. SEPAX® Separator
SAG mill
ball mills.

PEBBLE Flotation
FINISH
CRUSHING KREBS® GRINDING ID Fan
FLOW SHEET gMAX®
FLOW SHEET
Cyclone
Manifold
FLSmidth Baghouse
Raptor® Clean Air Surge Filter with
Cone Surge Drop Out Box
Bin Bin
Crusher
Next Phase Next Phase
H2O H2O FLSmidth Surge
Raptor® Bin
Cone SEPAX®
Weigh Crusher Separator
Belt FLSmidth
Ball Mill

FLSmidth H2O
HPGR
FLSmidth
H2O Ludowici®
FLSmidth Gyratory Vibrating
T5 Gyratory Crusher Weigh Static
Screen
Crusher Belt Grit
Separator
KREBS®
millMAX TM

Pump Stockpile
FLSmidth
SAG Mill FLSmidth FLSmidth
Ludowici® Sump
HPGR Product
Vibrating
Screen Storage
Apron
Apron Stockpile
Feeder
Feeder

12 HPGR High Pressure Grinding Roll HPGR High Pressure Grinding Roll 13
 Expand your business Raptor cone crushers handle
at less cost to the environment the toughest applications

Our HPGR and other environmentally friendly equipment can help you do more with less of a footprint.
Due to the flexibility of speed
Discover new ways of working that decouple environmental impacts from socio-economic growth. we have the most versatile and
productive crusher in the market.

info@flsmidth.com
A sustainable solution
A common sense investment in an HPGR does more than increase
Our goal is to help you reduce emissions and achieve your profit margin—it can also reduce your carbon footprint. We are
zero energy waste and zero water waste. We do this by constantly working to find innovative solutions that ensure you have
providing you with pioneering technology backed by
world-class knowledge.
equipment options that are both financially beneficial and environ- Superior Ludowici® screening
mentally responsible.
technology for improved
Our HPGR lowers your water and energy consumption because it
is a dry process and one of the most energy efficient options for results and high efficiency
comminution.

In addition to saving water and energy, the HPGR reduces thou-

sands of tonnes of grinding media annually to reduce your costs
We offer innovative screening
and protect the environment. solutions for your critical operations.

www.flsmidth.com

HPGR

Minerals Technology Center

FLSmidth
Tel: +1 801 871 7000
Fax: +1 801 871 7001 F-Series HPGR, successful
FLSmidth is a signatory to the United Nations Global Compact. We are fully
dedicated to supporting the Sustainable Development Goals and the Paris
7158 S. FLSmidth Drive
Midvale, UT 84047-5559
Email: info.slc@flsmidth.com
prospect for Turkish gold mine
USA
Climate Agreement.
Learn more at www.flsmidth.com

14 HPGR High Pressure Grinding Roll HPGR High Pressure Grinding Roll 15
 TOWARDS ZERO EMISSIONS IN MINING

Zero water Zero Zero energy

waste emissions waste

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FLSmidth A/S
Vigerslev Allé 77 Tel. +45 36 18 10 00
2500 Valby Fax +45 36 30 18 20 Copyright © 2021 FLSmidth. ALL RIGHTS RESERVED. FLSmidth is a (registered) trademark of FLSmidth.
This brochure makes no offers, representations or warranties (express or implied), and information and
Denmark info@flsmidth.com data contained in this brochure are for general reference only and may change at any time.