A novel approach for the modelling of high-pressure grinding rolls

The HPGR technology has become more attractive to the copper industry because of its high throughput capacities and its low specific energy consumptions. A HPGR model, able to give enough information based on pilot plant testing, in order to back up HPGR engineering studies, was developed. The model was based on the physical phenomena of the grinding operation. The model parameters were fitted with pilot scale test results, corresponding to a Chilean copper ore, classified in two lithologies (andesitic and porphyrytic ores). Some sets of data were not used in the fitting stage, to test the predictive capability of the model. The pilot scale tests were performed at the facilities of two HPGR manufacturers, changing operating pressure and rolls peripheral velocity (only one of the manufacturers). The simulated specific energy consumptions and particle size distributions, compared with the experimental data, were considered good enough. The model was able to predict adequately throughput capacity, specific energy consumption and particle size distributions of the edge, centre and total products.