Criticality of Appropriate Control
System Design on High Pressure
Grinding Rolls
John Long, Bianca Foggiatto and Kevin Erwin
Outline
Introduction
Objective
HPGR Operation
HPGR Process Control
The Advanced Control Scheme
Implementation
Conclusions
Introduction
• HPGRs have not as yet achieved their full potential in hard-
rock applications mainly due to
– limitations of a rigid control scheme
– a “standard” set of control parameters primarily developed for cement
and iron ore applications
– “standard” control parameters fail to compensate for the substantial and
rapid variations in feed material encountered at most hard-rock
comminution plants
• An advanced control scheme can
– alleviate many of the problems encountered
– maintain the machine in operation under the wider range of conditions
– avoid the need to implement any physical modifications to the circuit
HPGR Operation
• Unique HPGR
circuit designed
for treating
crushed pebbles
from a SAG-
based circuit
and ore from a
secondary
crushing circuit
HPGR Operation
HPGR Operation
• When uneven particle size distribution is presented to the
HPGR feed, there are two major causes for HPGR trip events
– roller skew
– pressure control
• Comminution performance of the HPGR is adjusted by
– varying the hydraulic pressure on the floating-roll, whereby pressure
control is activated from:
• roll gap to minimize over/under pressurisation
• HPGR power when reaching high power limits
– adjusting the hydraulic pressure at each end of the floating roll to even
the gap between the floating and fixed rolls
HPGR Operation
• HPGR historian data prior to implementation of the advanced
control scheme
HPGR Process Control
• Main aspects of the operation of an HPGR that drive the
process control (Morley, 2010):
– the HPGR must be choke-fed to maintain comminution efficiency
• achieved by maintaining a steady level at the HPGR feed hopper
– the number of stop-start events must be minimized, as accelerated roll
wear occurs during feed run-up and run-down
• achieved by using variable speed drives on the HPGR rolls
• achieved by improving presentation of feed to the HPGR
Feed presentation to HPGR after
materials handling optimisation
(minimised segregation)
HPGR Process Control
• A typical HPGR control
logic scheme
• Metal detection also plays
an important role in the
operation of the HPGRs
– a metal detection event
causes a diverter gate to
divert contamination from
the HPGR feed, avoiding
stud breakage and uneven
wear of studded lining
The Advanced Control Scheme
• The advanced control scheme is applied for the optimization
of the control system on the HPGR consisting of
– modifications to the HPGR unit control logic
– dynamic control system alleviates complications encountered with
unusual feed patterns
• The modifications included
– dynamic skew control (RPC)
– pressurize on skew
– skew control sensitivity
– dynamic pressure control (HPC)
– priority control
– pressure control activation
– ‘First Out’ alarming
The Advanced Control Scheme
• Dynamic skew control (RPC)
– modification to the skew control so parameters are based on actual skew
reading
Existing RPC Action New RPC Action
12 12
10 10
4 Seconds X Seconds
8 On 8 On
6 6
4 4 Y Seconds
3 Seconds Off
2 2
Off
0 0
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
• Skew control sensitivity
– Increases skew control sensitivity on feed introduction by automatically
adjusting the skew engage/disengage points until the unit is choke fed
– allows more time to recover a skew condition
The Advanced Control Scheme
• Pressurize on skew
– Skew control to pressurize side with largest gap and relieve side with
smallest gap under skew conditions
– potentially remove skew events quicker while maintaining a higher
operating pressure
The Advanced Control Scheme
• Dynamic pressure control (HPC)
– modification to the pressure control to dynamically adjust the pressure set
point (up to a set maximum) for any given feed conditions
The Advanced Control Scheme
• Priority control
– modification to the priority control to seamlessly change between skew
and pressure control depending on which is closer to the trip point
• Pressure control activation
– modification to the pressure control activation to remove activation
based on skew and use zero gap to stop pressurization against stops
The Advanced Control Scheme
• ‘First Out’ alarming
– these alarms capture and display the first condition that was active when
the unit trips
– identifying the cause of a trip cuts down on the need for recovery time
and potential maintenance
Results
• HPGR historian data after the implementation of the
advanced control scheme
Conclusion
• Through incorporating dynamic control, a consistent
operation of the HPGR was achieved
– improved utilization
– decreased maintenance requirements
• The use of real time data and dynamic control systems allows
for a customized HPGR control based on feed material.
– smooth operation
– minimal number of trips
– minimal time lost due to maintenance
– more efficient HPGR performance
Acknowledgemen
