AB HPGR Brochure

G-FES BU Minerals
Sales Training
CoE Minerals Processing
High Pressure Grinding Roll

(HPGR)
© Copyright BU Minerals. 2008
All rights reserved. - 1 -
Contents
 HPGR System Application & Functionalities
 HPGR Main Technical Parameters
 Overview of the Typical ABB Scope for HPGR Systems
 Major Advantages
© Copyright 2008 BU Minerals - 2 -
HPGR System Application and Functionalities
HPGR - Brief History
 In 1979 Schonert demonstrated that the inter particle comminution
required significantly less energy than the conventional technologies. This
discovery led to the development of the High Pressure Grinding Rolls,
 which in 1985 became commercially available and first used the cement
industry for the grinding of cement clinker. This process proved to reduce
the total energy consumption by up to 50%.
 This success paved the way for the HPGR’s to be used subsequently with
great success in the diamond industry in 1987 for the gentle liberation of
diamonds from the host kimberlite rock. This first application took place in a
South African diamond mine.
 In 1994 the HPGR made its way into the iron ore industry for relatively fine
ore grinding in pretreatment plants for pellet feeds.
 Hard-rock grinding was first attempted first in 1995 in a copper mine in

Arizona but grinding media wear was too high to justify economical
operation of the HPGR. Only 10 years later with the improvement of wear
protection systems have the roller presses been found in wide spread use
through out the world in the copper, gold and platinum mining industries.
Primary Grinding Finish Grinding
Combined Grinding
 Inter-particle comminution is the principle behind the high pressure

grinding.
 This method results in a much higher production of fines with less

Energy Consumption.
HPGR
Ilustration of high pressure Comminuted particle with large

inter-particle comminution number of internal cracks.
Feed
Hydraulic Pistons
Floating Roll Fixed Roll
Compression
Zone
Product
 Variable Speed Drive

 The variable speed drive system allows, by changing the speed of the
rolls, that different operating conditions, resultant of variations in the
specific throughput, be accommodated.
 Master Follower Control

 HPGR twin drives are softly coupled by the material going in between
the rolls and require that load sharing between the drives takes place.
The optimal operating conditions is than achieved, for some HPGR

designs, when there is a slight slip between the two rolls, “drooping”
HPGR System Application & Functionalities
Master
Speed
Control
Speed Set
Point
Follower Torque
Control with
Drooping
HPGR Main Technical Parameters
Applied Torque
Ft (I) T = F * sin(β) * (D/2)
F Motor Power
β
(II) P = T * ω → P = T * [(n/60) * 2π)]
Motor Power
From (I) and (II)
Fr (III) P = F * sin(β) * D * sin * [(n/60) * π)]
D
Machine Parameters Range for High Pressure Grinding Roller Press Design Trends
Roller Diameter (mm) 800 – 2800

Low Aspect Design

D W
Roller Width (mm) 200 – 1600 (W/D)
Circumferential Speed of Rollers (m/s) 0.9 – 1.9
Specific Pressing Force (kN/m²) 2000 – 8500 D W
Weight of Press including Gear Reducer (mt) 32 – 450
Motor Power (kW) 150 – 4000 High Aspect Design
Throughput (mt/h) 35 – 2000 (W/D)
Compressed Cardan Shaft Extended Cardan Shaft

Constant Torque Load Typical Parameters for a Polysius‘s HPGR
Operating Conditons
Torque-Speed Characteristic Curve
200
180
160
140
120
T/Tn (%)
Typical Motor Force Diagram No Material Feed

100 Material Feed
80 Material Feed (II)
60
40
20
0
0 25 50 75 100
n/nN (%)
Overview of the Typical ABB Scope for HPGR Systems
Low Voltage Solutions with ACS800
ACS800 Single Drive Aproach ACS800 Multi Drive Aproach
1 x Transformer 1 x Transformer
2 x Converter 1 x Converter
Multi Drive Line up
2 x Motor 2 x Motor
M M
~ ~
Typical HPGR power range covered by Typical HPGR power range

the ACS800 Single Drive: covered by the ACS800 Drive:
up to 1500 kW @ 690 V up to 1500 kW @ 690 V
Medium Voltage Solutions with ACS1000 and ACS6000
ACS1000 Single Drive System for HPGR ACS6000 Multi Drive System for HPGR
2 x Transformer
1 x Transformer
2 x Converter 1 x Converter
Multi Drive Line up
2 x Motor 2 x Motor
Typical HPGR power range covered by Typical HPGR power range covered by
the ACS1000 Single Drive: the ACS6000 Single Drive:
up to 2800 kW @ 3300 V or 4000V greater than 2800 kW @ 3100 V
ACS1000 Converter Single Line Diagram

ACS 1000 MV Variable Frequency Drive
Main Feeder Rectifier DC-Link & Inverter Output Sine
MV Converter Input Prot IGCTs Filter
Breaker
Supply Transformer
& Protection
I>> Prot
MV AC
Induction Master Drive
Motor
ACS 1000 MV Variable Frequency Drive

Main Feeder Rectifier DC-Link & Inverter Output Sine
MV Converter Input Prot IGCTs Filter
Breaker
Supply Transformer
& Protection
I>> Prot
MV AC
Induction Follower Drive
Motor
ACS1000 Converter – Water Cooled Unit Panel Lay Out
4200 mm for W1 frame size 4700 mm for W2 and W3 frame size
2000 mm
900 mm Water Cooled Range:

2000 – 5000 kW @ 3.3 kV;
1800 – 5000 kW @ 4.0 kV

ACS1000 Converter – Water Cooled Unit – Internal View
Control Sine filter Capacitor Rectifier and Inverter

Sine Filter Choke Common mode Choke DC Capacitors Cooling Unit

ACS1000 - Water Cooled Converters - Schematic View of the Cooling Circuit

ACS6000 Converter – Multi Drive Single Line Diagram

LSU INU
Line Supply Unit Inverter Unit
DC (+)
Motor
DC (NP)
DC (-)
Supply Clamping circuit Clamping circuit Phase modules EMC Filter

transformer
INU
Inverter Unit
Motor
Clamping circuit Phase modules EMC Filter

AC DC DC
DC AC AC
M M
ACS6000 Converter – Panel Lay Out

ACS6000 Converter – Internal View
Line Terminal Unit & Inverter Capacitor Water

Supply Control Unit Unit Bank Unit Cooling Unit
Unit
Special Motor Design

FUM
Fa
Possible motor design with two

angular contact bearings on Drive
Fg side. Special bearing shield
required.
Detailed Force Diagrams on Motor Bearings

Major advantages – Process Performance
 The roller press requires a twin drive application for its grinding rolls
that need to full fill the following process demands:
 Speed Control – Speed control on modern roller presses allows
higher level of versatility in regards on material properties and
increase overall performance.
 Control Performance – ABB’s drive control (speed-torque) allows
to respond instantly on the requirements of an inhomogeneous
material and in addition, it can create between the two rolls a slight
slip that optimize the crushing capabilities.
 Load Sharing – The drive has built-in mechanical oscillation
suppression to dampen any possible swinging in “Master-Follower”
configuration. In addition, the stochastic nature of DTC prevents
the mechanical system from oscillating in a predetermined
controlled frequency, avoiding resonance.

 Reliability – Since the variable speed drive system incorporates
proven standard components, it is extremely reliable
Major advantages – Torque Limitation
 Avoid Mechanical Breakage

 Reduce Mechanical Wear
Torque step T= 0...100%, speed 70 %
150
3ms
100
50
Phase A current
Phase C current
[%] 0
Motor torque
0 0.01 0.02 0.03 0.04 0.05 0.06
Torque reference
-50
-100
-150
Time [s]
Major advantages – Lower Mechanical Stress
Supply Voltage 3 * ...VAC 50Hz
 Mechanics PLC Ramp & S-func. Speed Ctrl Torque Handling DTC Mod.
0
0
Torque ref
1
1
1
0
 DTC against other
1 0
000
Sector 1
0
111
0
1
Out_u
1
0
0
0
1
Speed Set Speed ref err. Torque ref err. Out_v
+ Kp*Ti/s +
Driver
Point Torque
Out_w
- - Hyst.
PWM Patterned Flux ref

Flux
Hyst.
Solution +
+ Oscillation
Supression
Vdc
Sect.
 Master – Follower Torque actual
Motor Model
Measurements
I_a
handling
Configuration
I_b
Speed actual
AC
3 phases
Supply Voltage 3 * ...VAC 50Hz
Torque Handling DTC Mod.
0
0
Torque ref
1
1
1
0
1 0
000
Sector 1
0
111
0
1
Out_u
1
0
0
0
1
err. Out_v
+
Driver
Torque
Hyst. Out_w
-
Flux ref
Flux
Hyst.
+ Oscillation Vdc
Supression
+
Sect.
Torque actual
I_a
Measurements
Motor Model
handling I_b
DTC Other system

AC
3 phases
Major advantages – Integration with Control System
Fieldbus System
Ethernet, TCP/IP Backbone
Operation HMI
level HMI
System Bus
Control
level
PROFIBUS-DP PROFIBUS-PA
Device
level
Major advantages – Many available interfaces
Fieldbus Interfaces with ABB Drives

 Supported fieldbusses
 Profibus
 Modbus
 DeviceNet
 Ethernet
 AF100

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G-FES BU Minerals

High Pressure Grinding Roll

 HPGR System Application & Functionalities

 HPGR Main Technical Parameters

 Overview of the Typical ABB Scope for HPGR Systems

 Hard-rock grinding was first attempted first in 1995 in a copper mine in

Primary Grinding Finish Grinding

 Inter-particle comminution is the principle behind the high pressure

 This method results in a much higher production of fines with less

Ilustration of high pressure Comminuted particle with large

 Variable Speed Drive

 Master Follower Control

The optimal operating conditions is than achieved, for some HPGR

Roller Diameter (mm) 800 – 2800

Low Aspect Design

Compressed Cardan Shaft Extended Cardan Shaft

Torque-Speed Characteristic Curve

Typical Motor Force Diagram No Material Feed

Typical HPGR power range covered by Typical HPGR power range

ACS1000 Converter Single Line Diagram

ACS 1000 MV Variable Frequency Drive

ACS1000 Converter – Water Cooled Unit Panel Lay Out

4200 mm for W1 frame size 4700 mm for W2 and W3 frame size

900 mm Water Cooled Range:

1800 – 5000 kW @ 4.0 kV

ACS1000 Converter – Water Cooled Unit – Internal View

Control Sine filter Capacitor Rectifier and Inverter

Sine Filter Choke Common mode Choke DC Capacitors Cooling Unit

ACS1000 - Water Cooled Converters - Schematic View of the Cooling Circuit

ACS6000 Converter – Multi Drive Single Line Diagram

Supply Clamping circuit Clamping circuit Phase modules EMC Filter

Clamping circuit Phase modules EMC Filter

ACS6000 Converter – Panel Lay Out

Line Terminal Unit & Inverter Capacitor Water

Special Motor Design

Possible motor design with two

Detailed Force Diagrams on Motor Bearings

controlled frequency, avoiding resonance.

 Avoid Mechanical Breakage

Torque step T= 0...100%, speed 70 %

PWM Patterned Flux ref

Supply Voltage 3 * ...VAC 50Hz

Torque Handling DTC Mod.

DTC Other system

Fieldbus Interfaces with ABB Drives

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