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Getting more out of high pressure grinding rollers

Published by
World Coal,

ABB, a leading power and automation technology group, has launched RollXtendTM, a new state-of-the-art drive system feature to improve high-pressure grinding rollers (HPGR) performance and roller life in mining.

This advanced control system is based on real-time load sharing between the rollers, which gives advantages in terms of throughput optimisation, minimising operational and capital expenditures and improving the health and safety of the operators.

The system allows the operator to manage the torques delivered by each roller in real time. Speed match is maintained even with differential roller loads, reducing slip to a minimum and reducing roller wear in general.

As rollers start to wear (after a certain period of operation), they experience different wear rates based on many factors, such as feed size, ore characteristics, hopper positioning, etc. RollXtendTM technology provides the flexibility to adjust the load taken by each roller based on the wear they are experiencing, such that both rollers can be made to wear uniformly and as a result improve the overall lifetime of the roller pair.

In terms of maintenance, RollXtendTM has added advantages. Currently, HPGRs require regular inspections and maintenance to ensure damage to studs are contained and the equipment continues to perform efficiently.

To facilitate roller inching for inspection, operators need to disengage the main drive and engage an auxiliary drive. This operation can be time consuming and pose safety hazards for workers. With the RollXtendTM drive system, inspection and maintenance can be carried out without disengaging the main drive.

RollXtendTM has long-term benefits since the system extends the lifetime of the whole HPGR (not just the rollers), offers a better maintenance experience and provides the operational flexibility to improve the crushing process performance.

Edited from press release by Harleigh Hobbs

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