FLSmidth has solidified its position as a global leader in high-pressure grinding roll (HPGR) technology by securing 15 orders in 2024, including two of the largest HPGR units in India. Known for energy efficiency, reduced operating costs, and enhanced throughput, HPGRs deliver stable grinding performance while minimizing environmental impact, demonstrating FLSmidth’s trusted expertise and innovation in comminution solutions.
What Are HPGRs and How Do They Improve Mining Efficiency?
High-pressure grinding rolls (HPGRs) are advanced comminution machines that use two counter-rotating rolls to crush ore. Unlike conventional crushers, HPGRs apply high pressure, which reduces energy consumption and eliminates the need for grinding media. This technology ensures more uniform particle size, enhanced throughput, and longer equipment life, making operations more cost-effective and environmentally friendly.
How Did FLSmidth Achieve 15 HPGR Orders in 2024?
FLSmidth received seven HPGR orders earlier in the year, along with a strategic agreement for six more units. The latest Indian order adds two of the largest units worldwide, bringing the total to 15 orders or commitments for 2024. This demonstrates customer confidence in FLSmidth’s ability to deliver reliable, high-performance solutions while supporting installation, commissioning, and ongoing maintenance.
Which Innovations Are Included in the Latest HPGR Technology?
The new HPGR units incorporate the HPGR Pro technology, offering up to 20% higher throughput, 15% energy savings, and up to 30% longer roll life. This is achieved through optimized roll design, advanced wear materials, and precise control systems. FLSmidth’s continuous innovation ensures HPGR units remain efficient, durable, and suitable for a wide range of hard rock mining applications.
| HPGR Performance Metrics | Standard HPGR | HPGR Pro |
|---|---|---|
| Throughput Increase | – | +20% |
| Energy Savings | – | 15% |
| Roll Life Extension | – | 30% |
Where Is FLSmidth Expanding Its HPGR Installations?
FLSmidth’s recent orders include installations in India, adding to its global footprint across more than 20 countries. With over 20 years of experience in hard rock operations, FLSmidth remains the market leader in HPGR deployment, processing millions of tonnes of ore and supporting clients with full-service agreements covering installation, commissioning, and ongoing technical support.
Why Are HPGRs Considered Environmentally Friendly?
HPGRs reduce energy usage significantly compared to traditional comminution equipment. By eliminating the need for grinding media and providing more stable grinding operations, HPGRs lower greenhouse gas emissions and reduce material waste. These benefits align with modern mining sustainability goals while improving operational efficiency and lowering total costs.
Rettek Expert Views
"FLSmidth’s consistent focus on efficiency and innovation is closely aligned with Rettek’s mission to provide durable, high-performance wear parts. HPGRs equipped with advanced carbide components enhance equipment lifespan and reduce operational downtime. Companies investing in such technologies not only gain production efficiency but also strengthen their sustainability practices, which is increasingly critical in today’s mining environment."
How Can Mining Operations Maximize HPGR Benefits?
To fully leverage HPGR advantages, operators should combine high-quality wear parts with proactive maintenance schedules. Rettek’s carbide tips and studs are engineered for maximum durability in high-pressure environments, extending roll life and reducing replacement frequency. Integrating monitoring systems and predictive maintenance further enhances throughput, safety, and energy efficiency.
Conclusion
FLSmidth’s 15 HPGR orders in 2024 underscore the growing adoption of energy-efficient, environmentally conscious grinding solutions. By combining advanced HPGR technology with Rettek’s durable wear parts, mining operations can achieve higher throughput, reduced operating costs, and longer equipment life. Strategic investment in HPGRs not only boosts efficiency but also supports long-term sustainability and operational resilience.
FAQs
Q1: What makes HPGRs more efficient than traditional crushers?
HPGRs use high pressure between counter-rotating rolls to crush ore, reducing energy consumption, eliminating grinding media, and delivering more uniform particle sizes.
Q2: How does HPGR Pro improve performance over standard HPGRs?
HPGR Pro offers up to 20% higher throughput, 15% energy savings, and 30% longer roll life through optimized roll design and advanced wear materials.
Q3: Why are Rettek carbide wear parts important for HPGRs?
Rettek carbide tips and studs enhance durability, reduce downtime, and maintain consistent performance under high-pressure conditions.
Q4: Can HPGRs support sustainability goals in mining?
Yes. They lower energy consumption, reduce greenhouse gas emissions, and minimize material waste, aligning with modern sustainability standards.
Q5: Who can benefit most from HPGR technology?
Large-scale hard rock mining operations seeking cost-effective, energy-efficient, and environmentally friendly comminution solutions will gain significant advantages.