3809
Evaluation of Bond Working Indices for HPGR Crushing
Products in Relationship to Selected Operational Parameters
Daniel Saramak, Katarzyna Leśniak, Agnieszka Saramak
AGH University of Cracow, Poland
ABSTRACT: The paper concerns investigations on energy savings and breakage effectiveness in HPGR. A
series of laboratory experiments in HPGR were carried out at various values of the pressing force in the press
and the various moisture levels of the feed material. Fineness analyses of HPGR products were carried out along
with the determination of Bond working indices for each crushing product. Specific mathematical models for
Bond working index and breakage intensity were calculated, measured through the yield of finest particle size
fraction and specific comminution degrees in relationship to the operating pressing force in HPGR and the feed
moisture. All models appeared to be highly accurate from a statistical point of view, and relationships of both
pressing force and the moisture appeared significant. In general, the pressing force showed an insignificantly
higher impact on the investigated effects, but depends on the type of specific model.
INTRODUCTION
HPGR devices found applications in more than 1,000
plants (Morley 2010), starting from cement clinker grind-
ing (Aydogan 2006), and mineral flour production, end-
ing with hard iron and non-ferrous ores (Morley 2003) and
were often applied into technological circuits as replace-
ment both for secondary and tertiary crushers and mills
(Abouzeid and Fuerstenau 2009 Saramak et al. 2010
Dundar et al. 2013) .Considerable energy savings are
among the immediate HPGR benefits, confirmed with
various investigations and industrial applications (Morrel
2009 Altun et al. 2011 Wang et al. 2013 Numbi and
Xia 2015 Sadangi and Das 2022). HPGR products can
be more easily milled in downstream grinding operations
in mills (Farzanegan et al. 2016 Liu et al. 2018), what
results from lower Bond working index value (Wi) and
have higher potentials of more effective recoveries of use-
ful minerals in flotation and leaching processes (Klingmann
2005 Saramak et al. 2014 Yin et al. 2017 Ma et al. 2021
Tong et al. 2021).
A number of different types of variables, connected to
the press, the course of the process, and the properties of the
material influence the final effectiveness, therefore investi-
gations are carried out on potential increases in crushing
effectiveness are carried out. For example, some general
models concerning simulation of HPGR operation were
worked out in terms of energy consumption and through-
put (Fuerstenau et al. 1991 Nagata et al. 2020 Tohry et
al. 2021). The other models contribute to the prediction
of the particle size composition of the products (Schneider
et al. 2009 Torres and Casali 2009 Campos et al. 2021
Chelgani et al. 2021 Guo et al. 2022). Several investiga-
tions have studied impact of the pressure, a primary opera-
tional parameter of HPGR, on achieved results in terms
of energy consumption, useful minerals liberation, and
beneficiation results (Daniel 2007, Saramak and Saramak
2020, Schneider et al. 2009). Effects of these works show,
among others, that the relationship between HPGR pres-
sure and the degree of liberation of useful minerals is pro-
portional, however the shape of this relationship may differ,
Evaluation of Bond Working Indices for HPGR Crushing
Products in Relationship to Selected Operational Parameters
Daniel Saramak, Katarzyna Leśniak, Agnieszka Saramak
AGH University of Cracow, Poland
ABSTRACT: The paper concerns investigations on energy savings and breakage effectiveness in HPGR. A
series of laboratory experiments in HPGR were carried out at various values of the pressing force in the press
and the various moisture levels of the feed material. Fineness analyses of HPGR products were carried out along
with the determination of Bond working indices for each crushing product. Specific mathematical models for
Bond working index and breakage intensity were calculated, measured through the yield of finest particle size
fraction and specific comminution degrees in relationship to the operating pressing force in HPGR and the feed
moisture. All models appeared to be highly accurate from a statistical point of view, and relationships of both
pressing force and the moisture appeared significant. In general, the pressing force showed an insignificantly
higher impact on the investigated effects, but depends on the type of specific model.
INTRODUCTION
HPGR devices found applications in more than 1,000
plants (Morley 2010), starting from cement clinker grind-
ing (Aydogan 2006), and mineral flour production, end-
ing with hard iron and non-ferrous ores (Morley 2003) and
were often applied into technological circuits as replace-
ment both for secondary and tertiary crushers and mills
(Abouzeid and Fuerstenau 2009 Saramak et al. 2010
Dundar et al. 2013) .Considerable energy savings are
among the immediate HPGR benefits, confirmed with
various investigations and industrial applications (Morrel
2009 Altun et al. 2011 Wang et al. 2013 Numbi and
Xia 2015 Sadangi and Das 2022). HPGR products can
be more easily milled in downstream grinding operations
in mills (Farzanegan et al. 2016 Liu et al. 2018), what
results from lower Bond working index value (Wi) and
have higher potentials of more effective recoveries of use-
ful minerals in flotation and leaching processes (Klingmann
2005 Saramak et al. 2014 Yin et al. 2017 Ma et al. 2021
Tong et al. 2021).
A number of different types of variables, connected to
the press, the course of the process, and the properties of the
material influence the final effectiveness, therefore investi-
gations are carried out on potential increases in crushing
effectiveness are carried out. For example, some general
models concerning simulation of HPGR operation were
worked out in terms of energy consumption and through-
put (Fuerstenau et al. 1991 Nagata et al. 2020 Tohry et
al. 2021). The other models contribute to the prediction
of the particle size composition of the products (Schneider
et al. 2009 Torres and Casali 2009 Campos et al. 2021
Chelgani et al. 2021 Guo et al. 2022). Several investiga-
tions have studied impact of the pressure, a primary opera-
tional parameter of HPGR, on achieved results in terms
of energy consumption, useful minerals liberation, and
beneficiation results (Daniel 2007, Saramak and Saramak
2020, Schneider et al. 2009). Effects of these works show,
among others, that the relationship between HPGR pres-
sure and the degree of liberation of useful minerals is pro-
portional, however the shape of this relationship may differ,