3806 XXXI International Mineral Processing Congress 2024 Proceedings/Washington, DC/Sep 29–Oct 3
flotation. This may be an avenue for HPGR to be used as
finishing grinding for a coarse particle flotation circuit.
For conditions where the entire mineral processing cir-
cuit is dry circuits have been developed in which HPGR is
applied as the final grinding stage (Burchardt et al., 2011).
Such a circuit can be attractive for roasting in gold dry mag-
netic separation of iron (Burchardt et al., 2011). A plant
such as this is majorly advantageous for sites with water
restrictions. HPGR’s applicability to remote sites given
onsite maintenance, low water needs, lower power needs,
simpler operation are enticing advantages.
CONCLUSION
HPGR’s roles as crushers and grinders has been proven
in the diamond, iron, copper, gold, and platinum indus-
tries. The history and development of HPGR through its
advantages and overcoming its hurdles indicates HPGR is
‘mature’. Proposed novel circuit designs are further advanc-
ing HPGR’s capabilities, emphasizing its advantages while
shrinking its hurdles. HPGR synergies with concentra-
tion processes of heap leaching and magnetic separation
matches HPGR’s integration into holistic flowsheets of the
future. The application of HPGR transforming from being
a theoretical energy efficient crusher to a keystone member
of holistic flowsheets which augment metal recoveries and
minimize energy consumption.
Considering the pressures on industry to achieve sus-
tainable mining, HPGR advantages are attractive (Tbl.
1). These advantages have been tempered by the hurdles
that came alongside them. Under correct market and site
conditions HPGR is a logical replacement for AG/SAG.
However, the viability of HPGR’s capability to entirely
replace AG/SAG milling is questionable given AG/SAG
millings versatility. Still there are opportunities for further
development:
• Methods to reduce HPGR CAPEX without compro-
mising operation.
• Distribution of a universally accepted laboratory test
for HPGR predictions.
• Methods to allow for HPGR treatment of soft duc-
tile ores.
• Further development on combining final stage
HPGR grinding with wet concentration methods.
ACKNOWLEDGMENTS
The authors would like to thank Demir Engineering of
Edmonton Alberta for providing stud images, Tim Napier-
Munn (Figure 1) and Maarten van de Vijfeijken (Figure 6)
for figure reprint permissions, the University of Alberta for
providing student funding, and John Forster for his knowl-
edge sharing and support of this work.
REFERENCES
Amelunxen, P. 2011. Not another HPGR trade-off study!
Minerals &Metallurgical Processing, 28(1).
Amelunxen, P., Berrios, P., &Rodriguez, E. 2014. The SAG
grindability index test. Minerals Engineering, 55:42–
51. doi: 10.1016/j.mineng.2013.08.012.
Baawuah, E., Kelsey, C., Addai-Mensah, J., &Skinner, W.
2020. Comparison of the performance of different
comminution technologies in terms of energy effi-
ciency and mineral liberation. Minerals Engineering,
doi: 10.1016/j.mineng.2020.106454.
Ballantyne, G. 2019. Quantifying the Additional Energy
Consumed by Ancillary Equipment and Embodied in
Grinding Media in Comminution Circuits.
Batchelor, A. R., Jones, D. A., Plint, S., &Kingman, S.
W. 2016. Increasing the grind size for effective libera-
tion and flotation of a porphyry copper ore by micro-
wave treatment. Minerals Engineering, 94:61–75. doi:
10.1016/j.mineng.2016.05.011.
Baum, W., &Ausburn, K. 2011. HPGR comminution for
optimization of copper leaching. Mining, Metallurgy &
Exploration, 28(2):77–81. doi: 10.1007/BF03402391.
Bond, F. 1961. Crushing and Grindability Calculations.
Process Machinery Department. Milwaukee. Allis-
Chalmes Industrial Press Department.
Bulled, D., &Husain, K. 2008. The Development of a
Small-Scale Test to Determine Work Index for High
Pressure Grinding Rolls. 8.
Burchardt, E., &Mackert, T. 2019. HPGRs in Minerals:
What do more than 50 Hard Rock HPGRs Tell us for
the Future? (PART 2 – 2019). SAG Proceedings, 29.
Burchardt, E., Patzelt, N., Knecht, J., &Klymowsky, R.
2011. HPGR’S in Minerals: What do Existing
Operations Tell Us for the Future? SAG Proceedings.
Chandramohan, R., Foggiatto, B., Lane, G., Meinke, C.,
Ballantyne, G., Reeves, S., &Staples, P. 2023. A
Review of SAG Milling—History of Mill Selection and
Testwork Analysis. SAG Proceedings.
Daniel, M. 2007. Energy efficient mineral liberation using
HPGR technology. University of Queensland.
Daniel, M. J., &Morley, C. 2010. Can Diamonds go all
the way with HPGRs? The Southern African Institute of
Mining and Metallurgy.
Davaanyam, Z. 2015. Piston Press Test Procedures for
Predicting Energy–Size Reduction of High Pressure
Grinding Rolls. 306.
flotation. This may be an avenue for HPGR to be used as
finishing grinding for a coarse particle flotation circuit.
For conditions where the entire mineral processing cir-
cuit is dry circuits have been developed in which HPGR is
applied as the final grinding stage (Burchardt et al., 2011).
Such a circuit can be attractive for roasting in gold dry mag-
netic separation of iron (Burchardt et al., 2011). A plant
such as this is majorly advantageous for sites with water
restrictions. HPGR’s applicability to remote sites given
onsite maintenance, low water needs, lower power needs,
simpler operation are enticing advantages.
CONCLUSION
HPGR’s roles as crushers and grinders has been proven
in the diamond, iron, copper, gold, and platinum indus-
tries. The history and development of HPGR through its
advantages and overcoming its hurdles indicates HPGR is
‘mature’. Proposed novel circuit designs are further advanc-
ing HPGR’s capabilities, emphasizing its advantages while
shrinking its hurdles. HPGR synergies with concentra-
tion processes of heap leaching and magnetic separation
matches HPGR’s integration into holistic flowsheets of the
future. The application of HPGR transforming from being
a theoretical energy efficient crusher to a keystone member
of holistic flowsheets which augment metal recoveries and
minimize energy consumption.
Considering the pressures on industry to achieve sus-
tainable mining, HPGR advantages are attractive (Tbl.
1). These advantages have been tempered by the hurdles
that came alongside them. Under correct market and site
conditions HPGR is a logical replacement for AG/SAG.
However, the viability of HPGR’s capability to entirely
replace AG/SAG milling is questionable given AG/SAG
millings versatility. Still there are opportunities for further
development:
• Methods to reduce HPGR CAPEX without compro-
mising operation.
• Distribution of a universally accepted laboratory test
for HPGR predictions.
• Methods to allow for HPGR treatment of soft duc-
tile ores.
• Further development on combining final stage
HPGR grinding with wet concentration methods.
ACKNOWLEDGMENTS
The authors would like to thank Demir Engineering of
Edmonton Alberta for providing stud images, Tim Napier-
Munn (Figure 1) and Maarten van de Vijfeijken (Figure 6)
for figure reprint permissions, the University of Alberta for
providing student funding, and John Forster for his knowl-
edge sharing and support of this work.
REFERENCES
Amelunxen, P. 2011. Not another HPGR trade-off study!
Minerals &Metallurgical Processing, 28(1).
Amelunxen, P., Berrios, P., &Rodriguez, E. 2014. The SAG
grindability index test. Minerals Engineering, 55:42–
51. doi: 10.1016/j.mineng.2013.08.012.
Baawuah, E., Kelsey, C., Addai-Mensah, J., &Skinner, W.
2020. Comparison of the performance of different
comminution technologies in terms of energy effi-
ciency and mineral liberation. Minerals Engineering,
doi: 10.1016/j.mineng.2020.106454.
Ballantyne, G. 2019. Quantifying the Additional Energy
Consumed by Ancillary Equipment and Embodied in
Grinding Media in Comminution Circuits.
Batchelor, A. R., Jones, D. A., Plint, S., &Kingman, S.
W. 2016. Increasing the grind size for effective libera-
tion and flotation of a porphyry copper ore by micro-
wave treatment. Minerals Engineering, 94:61–75. doi:
10.1016/j.mineng.2016.05.011.
Baum, W., &Ausburn, K. 2011. HPGR comminution for
optimization of copper leaching. Mining, Metallurgy &
Exploration, 28(2):77–81. doi: 10.1007/BF03402391.
Bond, F. 1961. Crushing and Grindability Calculations.
Process Machinery Department. Milwaukee. Allis-
Chalmes Industrial Press Department.
Bulled, D., &Husain, K. 2008. The Development of a
Small-Scale Test to Determine Work Index for High
Pressure Grinding Rolls. 8.
Burchardt, E., &Mackert, T. 2019. HPGRs in Minerals:
What do more than 50 Hard Rock HPGRs Tell us for
the Future? (PART 2 – 2019). SAG Proceedings, 29.
Burchardt, E., Patzelt, N., Knecht, J., &Klymowsky, R.
2011. HPGR’S in Minerals: What do Existing
Operations Tell Us for the Future? SAG Proceedings.
Chandramohan, R., Foggiatto, B., Lane, G., Meinke, C.,
Ballantyne, G., Reeves, S., &Staples, P. 2023. A
Review of SAG Milling—History of Mill Selection and
Testwork Analysis. SAG Proceedings.
Daniel, M. 2007. Energy efficient mineral liberation using
HPGR technology. University of Queensland.
Daniel, M. J., &Morley, C. 2010. Can Diamonds go all
the way with HPGRs? The Southern African Institute of
Mining and Metallurgy.
Davaanyam, Z. 2015. Piston Press Test Procedures for
Predicting Energy–Size Reduction of High Pressure
Grinding Rolls. 306.