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B LO G : M I N I N G M I N D S
NOV 20, 2019

WRIT TEN BY

METSO'S GRINDING EXPERTS

Why skewing is not beneficial for your HPGR

It’s a fact that all High Pressure Grinding Rolls (HPGRs) skew, but some are designed to do so more than others. We are not skewing
around when we say that skewing is not beneficial to the operation of your HPGR. Many have made claims to suggest otherwise;
however, in this blog, we set the record straight by debunking three common myths about skewing.

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Rising energy costs and declining ore grades are setting new challenges for the mining industry. As a result, there is demand for more energy-efficient
circuits, with reduced number of operating machines. High Pressure Grinding Rolls utilize advanced technology to offer more energy-efficient grinding with
increased throughput capacity and minimal maintenance activities. For many mines, the HPGR is a popular grinding solution to achieve cost savings and
improved availability. Like any great solution, the HPGR does face some challenges in the field, particularly in the case of skewing.

Many HPGR operators will admit that they struggle with feed variance and segregation. Typically, these issues have pushed HPGR manufacturers to
implement skewing control systems to regulate skewing within a tight tolerance. So, what is the truth? Our assessment – every HPGRs skews, but machine
designs that promote skewing do not improve the operation of the HPGR. Here are the facts about three common myths around uneven pressure
distribution across the width of the rolls and skewing. Before shining light on the myths around skewing, let us define the causes for uneven pressure
distribution as these are leading the way towards understanding skewing and the limitations around this operating condition.
 Defining the Edge effect and Feed size segregation
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To operate HPGRs most efficiently, it is desired to have an even pressure profile across the width of the roll. Generally, the two main causes of uneven
pressure distribution are the edge effect and feed size segregation. Looking at these two conditions, edge effect is a consequence of an HPGR design with
static cheek plates, while feed size segregation is causing the HPGR to skew.

Edge effect

In traditional, non-flanged HPGRs, the pressure across the rolls is uneven, caused by a phenomenon called “edge effect”. This happens because ore bypasses
the comminution process on both sides of the rolls. Static cheek plates are used to keep the material in between the rolls when it is being crushed and
therefore to minimize the edge effect. However, the ore flow through the compression zone also has a directional component pressing against the static
cheek plates, creating friction, slowing down the ore, causing a gradient within the mass flow. The gap between the cheek plates and the rolls increase,
allowing ore to bypass, causing the pressure drop. This means that the smaller the distance between the rolls and the cheek plates, the better is the
reduction of the edge effect. It also means that skewing can only be tolerated within a small range to avoid contact between the rolls and cheek plates.
Some cheek plates are designed with springs to minimize the gap and to allow the roll to press the cheek plate sideways when skewing. This, however,
causes significant wear on the roll and cheek plate which reduces the life of both components and subsequentially increases the edge effect.

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Edge effect is the impaired comminution performance at the edges of the HPGR rolls due to a reduction in crushing pressure

Feed size segregation

Feed size segregation causes an uneven pressure profile across the width of the roll and therefore skewing. Skewing is a result of the uneven pressure
distribution caused by the segregated feed.

Setting the record straight: Three common myths about skewing

#1 - Without skewing, material will not crush across the full width of the roll if material is segregated.

HPGRs utilize two counter-rotating rolls in order to effectively crush ore. Hydraulic cylinders apply very high pressure to the system, causing inter-particle
comminution as the feed travels between the two rolls. Segregated feeds or inconsistent particle sizes are common with HPGRs, resulting in uneven
pressure across the roll.

However, when skew is mechanically controlled under stricter tolerances, ore can be crushed across the full width of the rolls. With a flanged roll design,
material is drawn into the crushing zone, maximizing the amount of crushed ore, significantly reducing the amount of material that bypasses the rolls and
therefore eliminates the edge effect. As a result, circulating loads are reduced and rolls wear more uniformly, confirming that fines are closer in size and are
evenly crushed across the rolls.
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Non-flanged roll after 10,702 hours vs. Flanged roll after 16,200 hours (flanges removed)

#2 – Skewing helps tramp material pass through the rolls.

In fact, it’s the opposite. If a piece of tramp material larger than the operating gap passes through the rolls, it will always cause damage to the HPGR rolls.
The tramp metal reduces the contact area into a small portion of the roll’s surface and therefore creates a high, localized pressure. This force will have
minimal impact on the average pressure of the cylinder or the forces seen at the bearings. As a result, the HPGR will not “react” to this event. Even though all
HPGRs have tramp metal control systems, skewing will not aid in passing the oversized metal through the rolls.

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Comparing the performance and consistency in pressure across the width of HPGR rolls. Traditional cheek plates vs. flanged roll design

#3 – Skewing helps to even pressure across the full width of the roll.

All machines with static cheek plates are designed to control skewing via the hydraulic system. Pressure is reduced on the skewing side of the roll with the
smaller grinding gap (distance between the two rolls) in order to make them parallel. The controller starts to intervene at a few millimeters of skewing.
However, reducing hydraulic pressure causes the overall grinding force to reduce and results in coarser HPGR product.

Alternatively, HPGR models with flanges have proven to greatly diminish the edge effect and significantly improve process performance. To ensure the safe
use of flanged rolls, skew is mechanically controlled within a very small range to avoid component damage.

Skewing the boundaries

Metso’s HRC™ HPGR solution uses a patented arch-frame to mechanically control skewing and allow for the safe use of a flanged roll. Our unique design
helps to eliminate downtime associated with skewing and improves reliability by preventing misalignment as well as component damage. Learn how
Metso’s HRC™ is skewing the boundaries, the right way. Watch the video > (https://www.youtube.com/watch?v=_UU3mpfeEkw&feature=youtu.be)
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Increasing Metso’s flanged tire design helps to increase specific (/GLOBALASSE TS/SALESHUB/DOCUMENTS -
throughput throughput by 19% at the Morenci Pilot Plant. --
EPISERVER/HRC_TAKING_HPGR_EFFICIENCY_TO_THE

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THROUGHPUT

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Nov 20, 2019

Why skewing is not beneficial for your HPGR

It’s a fact that all High Pressure Grinding Rolls (HPGRs) skew, but some are designed to do so more than others. We are not skewing around when we say that
skewing is not beneficial to the operation of your HPGR. Many have made claims to suggest otherwise; however, in this blog, we set the record straight by
debunking three common myths about skewing.

(/blog-hub/mining-minds/why-skewing-is-not-beneficial-for-your-hpgr/)
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Nov 6, 2019

Keeping an eye out for grinding mill dropped charge and two ways to prevent it
Dropped charge, also known as frozen or locked charge, occurs when solidified material inside a horizontal grinding mill does not cascade when the mill starts
rotating at start up. Instead, it is lifted and then free falls onto the mill shell. Dropped charges experienced in large ball mills can be heard and felt hundreds of
meters away and can be confused with an explosion or earthquake on-site, such is the force of the impact. In many cases, these types of events can cause
permanent damage and deformations to the mill shell and its flanges, leading to unplanned downtime.

(/blog-hub/mining-minds/how-to-prevent-grinding-mill-drop-charge/)
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DIGITALIZATION

Oct 23, 2019

Five levels of minerals processing plant autonomy – From regulatory controls to full auto-pilot
How do you automate the minerals processing plant? It is not a very easy question to answer, partly because many look at it as an all-or-nothing endeavor. This
could not be further from the truth though, there are multiple levels and phases that mining operators go through. Making sense of the possibilities is a great
first step.

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