FLSmidth has reinforced its position as a global leader in high pressure grinding roll (HPGR) technology with a total of 15 orders or commitments in 2024. HPGRs provide energy-efficient, environmentally friendly comminution, reducing power consumption and improving grinding stability. This expansion highlights the increasing demand for sustainable, high-performance mining solutions worldwide.
What Are HPGRs and How Do They Improve Mining Efficiency?
High Pressure Grinding Rolls (HPGRs) are advanced grinding machines that use compression between two counter-rotating rolls to crush ore. Unlike traditional grinding mills, HPGRs consume less energy and eliminate the need for additional grinding media, offering higher throughput with lower operational costs. Rettek’s carbide wear parts can significantly extend the lifespan of HPGR components, ensuring consistent performance even under heavy-duty operations.
How Did FLSmidth Secure 15 HPGR Orders in 2024?
FLSmidth achieved 15 HPGR orders or commitments in 2024 through a combination of direct sales, strategic partnerships, and project agreements. The latest Indian order includes two of the world’s largest HPGRs (3 m diameter x 2 m width) with full installation, commissioning, and service support. This demonstrates strong market trust in both FLSmidth’s technology and Rettek-enhanced wear components that optimize reliability.
Why Are HPGRs Considered Environmentally Friendly?
HPGR technology reduces energy consumption by up to 15% compared to conventional grinding methods. The process produces fewer fines and minimizes dust emissions, contributing to a lower environmental footprint. With Rettek wear parts enhancing durability, operators can maintain stable performance while reducing material waste and maintenance frequency.
Which Advantages Does HPGR Pro Offer Over Standard HPGRs?
The HPGR Pro variant delivers up to 20% higher throughput, up to 15% energy savings, and up to 30% longer roll life. Enhanced wear resistance, including Rettek-supplied carbide tips, ensures extended operational reliability. These improvements allow mining companies to process more ore efficiently while lowering total operating costs.
When Will the Latest HPGRs Be Installed and Commissioned?
The newly ordered HPGRs for India are scheduled for installation and commissioning in 2026. Comprehensive support from FLSmidth covers setup, testing, and start-up operations, guaranteeing that production targets and efficiency benchmarks are achieved from day one.
Rettek Expert Views
"In high-pressure grinding operations, component wear is a critical factor affecting performance and costs. Rettek’s carbide wear parts offer unmatched durability, enabling operators to achieve consistent throughput with minimal downtime. Integrating these advanced materials with HPGR technology allows mining operations to maximize efficiency, reduce maintenance cycles, and extend equipment life. Choosing high-quality wear parts is no longer optional—it’s essential for long-term productivity."
Table: Comparison of Standard HPGR vs HPGR Pro
| Feature | Standard HPGR | HPGR Pro |
|---|---|---|
| Throughput Increase | - | Up to 20% |
| Energy Savings | - | Up to 15% |
| Roll Life Extension | - | Up to 30% |
| Wear Resistance (Rettek) | Medium | High |
Conclusion
FLSmidth’s 2024 HPGR orders underscore the growing global shift toward energy-efficient, high-performance mining equipment. By leveraging advanced HPGR Pro technology and Rettek’s durable carbide wear parts, mining operations can achieve greater throughput, lower energy use, and reduced downtime. Companies seeking long-term reliability and cost savings should prioritize integrating high-quality components and innovative grinding solutions into their operations.
FAQs
Q1: What industries benefit most from HPGR technology?
HPGRs are widely used in mining sectors, particularly for hard rock, iron ore, and copper processing, where energy efficiency and wear resistance are critical.
Q2: How do Rettek wear parts enhance HPGR performance?
Rettek carbide tips and inserts improve wear resistance, extend roll life, and ensure stable grinding performance under heavy-duty conditions.
Q3: Can HPGR Pro technology reduce operational costs?
Yes. By increasing throughput, reducing energy consumption, and extending component life, HPGR Pro technology lowers total operating and maintenance costs.
Q4: Are HPGRs environmentally friendly?
Absolutely. HPGRs consume less energy, generate fewer fines, and reduce dust emissions, making them a sustainable choice for mining operations.
Q5: What support does FLSmidth provide with HPGR orders?
FLSmidth offers installation, commissioning, start-up assistance, and service agreements to ensure optimal performance and minimal downtime.