HPGR testing

HPGR evaluation & engineering studies

The KMA HPGR unit located at ALS is a second-generation machine incorporating studded rolls of 1000mm diameter and 250mm width with nominal throughput capacity of 40tph on a continuous basis, which can reach a maximum rate of 60tph. Additionally, the HPGR is installed with a full SCADA system for accurate data capture at each stage of the HPGR process operation. To align with the ALS core value ‘Safety as a Priority’, as well as our comprehensive HSE standards and procedures, the HPGR is equipped with high powered dust extraction and can be fully enclosed via tailored tenting systems to allow for the evaluation of potentially hazardous ore types.

All process design parameters such as roll speed and specific pressing force can be evaluated and optimized. Key operational and equipment sizing parameters for full scale engineering design include deliverables for Process specific throughput constant (m-dot), Specific pressing force and Net specific energy consumption as well as wear rate estimation.

Specimens of flake generated during batch HPGR testwork are collected for flake density and competency testing performed by Additionally, the HPGR Köeppern Machinery Australia.

Typical HPGR bulk preparation usually requires crushing the sample to P₁₀₀ :32 mm. Once prepared and blended, the general order of an HPGR testwork program is as follows:

• Feed Particle Size Distribution (PSD) Characterization. Typically consisting of sieve analysis on representative samples with sieve apertures ranging from 32 mm to 38 µm. These data will provide valuable insight into the direction of the subsequent test program and whether further bulk sample preparation is required to obtain a representative feed reflective of ‘real world’ HPGR feed size distributions.
• Fresh feed compacted and uncompacted bulk density & natural moisture content evaluation
• Bench scale Comminution testing [LINK]
• Batch HPGR Testing, evaluating:
• Specific Pressing Force
• Roller Speed
• Moisture content.
• Locked Cycle / Closed Loop HPGR Testing

For each test, the HPGR products are split at the product conveyor using a diverter gate into centre, edge and waste products. Representative sub-samples of the centre and combined edge products are prepared via a rotary sample divider and subjected to particle size distribution analysis.

During the HPGR test, experimental data is recorded every 100ms via a PLC control system measuring roller gap; pressing force; fixed and floating shaft torques; and power consumption.

This data allows for in-depth process analysis and sizing of HPGR presses for industrial design, CAPEX and OPEX.

Other related services

Bulk crushing via HPGR is available as part of larger metallurgical testwork programs in the production of suitably sized product for downstream testing including pilot scale flotation or magnetic separation testwork or heap leach evaluation testwork.

Don't quite see what you're looking for or need more information?

ALS understands that HPGR program are very project specfic.

Please contact us for further details.

Associated testwork services

Related testwork

HPGR test products can be utilized as part of larger metallurgical testwork programs in the production of suitably sized product for downstream testing including:

• pilot scale flotation
• magnetic separation testwork
• heap leach evaluation testwork

Click on the above links or contact us for further information. We can integrate a full program for you if required.