http://www.metso.com/miningandconstruction/mct_service.nsf/WebWID/WTB120106-22576-B1989/$File/042.

pdf
http://www.metso.com/miningandconstruction/MaTobox7.nsf/DocsByID/2A96B
B0DCEC26453C2257AFD002A5111/$File/HRC_Brochure_LR.pdf

The HPGR Comminution Unit is a relatively new technology patented by Dr.

Schonert in 1979. Originally designed for cement application in 1985, its energy
benefits were recognized and are now today applied to hard rock milling
applications. In 2012, the expiration of a more efficient and durable roll lining patent
has further increased the popularity of the HPGR.
HPGR is selected for the energy savings over traditional ball and rod mills due
to increased efficiency. This is of great interest for isolated mine site locations,
where the cost of power transmission and generation often comprise a large portion
of operating costs. The efficiency is a function of two main variables: applying a
force large enough to break the rock, and getting the target rock into a place where
it can be broken. (Metso) The HPGR satisfies both requirements by applying a
compressive force onto target rock already lined up in a breakable position. In
comparison, the SAG Mills metallic balls can apply sufficient force for breakage but
cannot efficiently control the rocks impact location (if it impacts anything at all)
during its spin cycles.

Further Advantages of HPGR

The generation of Micro-cracks from the intensely high pressure of the rollers
reduce the downstream energy requirements. In addition, the HPGR generates more
fines than the SAG Ball Mill, further reducing the downstream energy requirements.
Compared to ball and rod mills, no grinding media selection and replacement is
required, therefore reducing operating costs.
The HPGR is capable of achieving higher specific capacity than the SAG Ball Mill.

Disadvantages of HPGR
The product must undergo deagglomeration, therefore adding to the complexity of
the mill by requiring another unit operation compared to the SAG Ball Mill.
The feed to the HPGR must be uniform. Control of HPGR feed top size is crucial,
otherwise milling inefficiencies and even blockages may occur. The screens,
conveyors and bins associated to maintain top size add to operating costs. Also,
variable hardness and crushability of the HPGR will result in varying flake thickness,
density and fluctuating power requirements, therefore increasing processing
difficulty further downstream.

HPGRs can only fulfill crushing requirements for lower reduction ratios. Rock can
only be compressed to a certain point before the feed density reaches a maximum.
This is in comparison to the SAG Ball Mill, which has a much higher reduction ratio
range.
Roll linings undergo large amounts of friction and need to be replaced on a
continuous basis. In addition, the roll linings are sensitive to non-design material
such as tramp metals. Therefore, it must be removed and carefully monitored for,
increasing operating costs.
The HPGR feed must be relatively dry. Higher levels of water reduce throughput
capacity, and lead to higher roll lining wear.