Process Technology

Energy-saving advanced technology

High-Pressure Grinding
The energy-efficiency of crushing and grinding processes is becoming an increasingly important issue for the ore processing and cement industries. More than half the energy consumed in the mining industry is used in crushing and grinding operations.

As the goods content in the ores becomes leaner, the mineral industry is reaching for harder and poorer ores, placing more emphasis on the importance of energy-efficient crushing and grinding.

One of the main benefits of the high-pressure comminution process is the reduction in energy requirements when compared with conventional crushing and grinding methods. When applied in combination with roller press technology, the resulting high-pressure grinding roller (HPGR) circuits offer many potential economic advantages in comparison to equivalent semi-autogenous grinding (SAG) circuits, such as:

  • lower specific energy consumption
  • reduced grinding media consumption
  • smaller machine footprint
  • shorter equipment lead times
  • higher machine availability.
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High-pressure comminution technology has gained popularity steadily since the 1980s and today HPGR machines are regarded as state-of-the-art technology in the mining and diamond industries. And the list of applications continues to expand into such industries as iron ore, copper, gold and many more.

Increasing costs of electrical energy coupled with the worldwide initiative to reduce CO2 emissions means that this energy-efficient technology will become indispensable in a wide spectrum of ore processing applications. 

Wear Protection
The adoption of high-pressure comminution technology has led to significant energy savings as well as reduced costs for wear material. But the conventional welded rolls used predominantly in the past in HPGRs were subject to rapid and excessive wear.

Köppern responded to this challenge by developing the unique HEXADUR® and HYBRIDUR® wear  protection systems for use in high-pressure comminution processes. Read more about wear protection