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Investigation into laboratory scale tests for the sizing of high pressure
grinding rolls

Conference Paper · September 2011

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INVESTIGATION INTO LABORATORY SCALE TESTS FOR THE SIZING OF HIGH
PRESSURE GRINDING ROLLS

*S. Nadolski1, A. S. Bamber2, B. Klein and J. Drozdiak3

1
Koeppern Machinery Australia Pty Ltd.
73 Pavers Circle
Perth, Australia 6090
(*Corresponding author: [email protected])
2
BC Mining Research
122 – 1857 West 4th Avenue
Vancouver, Canada V6J 1M4
3
NBK Institute of Mining
517 – 6350 Stores Road
Vancouver, Canada V6T 1Z4

1
 INVESTIGATION INTO LABORATORY SCALE TESTS FOR THE SIZING OF HIGH
PRESSURE GRINDING ROLLS

ABSTRACT

In this paper we present the results of preliminary investigations into the applicability of new
laboratory scale tests for the prediction of operating gap and specific throughput in high pressure grinding
rolls (HPGR). The work is a part of the CAMIRO HPGR research program being conducted at the
University of British Columbia, which aims to develop a suite of small-scale tests and procedures for the
selection and sizing of HPGRs. A focus of the presented study is to test sample types in terms of their
terra-mechanics based characteristics and relate them to specific throughput and gap results from pilot
HPGR testing on the same samples.

KEYWORDS

HPGR, High Pressure Grinding Rolls, Direct Shear, Terra-mechanics, Piston Press, Friction

INTRODUCTION

Industry accepted laboratory scale tests are, by now, well established for the sizing and selection
of tumbling mills. However, there is an obvious absence of proven small scale tests for HPGR. For this
reason the assessment of an HPGR comminution flowsheet is typically attempted only once a sizeable
amount of sample is available, which presents a significant challenge to the increased adoption of this
energy-efficient grinding technology. A proven small-scale approach to HPGR testing is therefore required
to bridge the gap between scale-up capabilities of these competing comminution technologies (Bamber et
al 2009). The collaborative CAMIRO HPGR research program, which is centred at the University of
British Columbia (UBC) in Vancouver, aims to develop a small scale testing suite and procedure as a guide
to selecting High Pressure Grinding Roller Presses (HPGR) for hard rock ores. Results from small-scale
HPGR tests of potential relevance are compared to outcomes from a Köppern pilot HPGR located at UBC.
An example of this is the Static Pressure Test (SPT) test as developed by Bulled et al (2009), which
focuses on the prediction of specific energy requirements for a certain degree of size reduction. However,
few other relevant small-scale tests, particularly those focusing on throughput aspects are yet to be found.
A field identified with high applicability to comminution by HPGR is that of terramechanics, therefore
additional small scale tests from this area of knowledge targeting the HPGR operational gap and specific
throughput for a particular sample have been investigated, and preliminary results of which form the basis
of this paper.

A new approach to laboratory testing has been proposed which is based upon existing methods of
evaluating the trafficability of a soil for ground transport vehicles. Terra-mechanics is a wide field which
was selectively drawn upon based on the authors’ interpretation of its potential applicability to predicting
HPGR operational gap and specific throughput. In this respect, the characterization of soils and modeling
of wheel and soft terrain interactions, particularly the case of a rigid wheel traversing a soft terrain, was
identified as being potentially analogous to the study of HPGR roll and ore interactions.

Figure 1 shows a drawing of the rigid wheel and soft ground geometry as addressed in terra-
mechanics, which has obvious similarities to a depiction of HPGR rollers drawing in ore.

2
(Bekker, M. G. 1956)

Figure 1 - Geometry of wheel-soil interaction & HPGR rollers

Tests such as direct shear box and piston press tests are used in the field of terra-mechanics to
explore aspects of traction, sinkage and tractive effort for vehicles travelling on soft soil. Clear analogies to
the action of the HPGR roller on a feed sample can be seen, highlighting potential applicability of this field
to the problem. These tests were therefore adopted and investigated for their applicability in estimating
roller gap and throughput performance in HPGR. Further refinement of the investigated tests was carried
out based on the degree of correlation to test data generated on the same sample in the Köppern pilot
machine at UBC.

EXPERIMENTAL DESIGN

The experimental program was initially divided into three main components: HPGR pilot testing,
direct shear box testing and piston press testing. In order to establish a reference database, we carried out
pilot HPGR and laboratory tests on a wide range of ore types and machine parameters. A list of sample
types used is shown in Table 1.

Table 1 – Sample types used in the experimental program

Sample Type

Igneous Copper Nickel Sulphide

Mafic / Ultramafic Sulphides
Copper Porphyry
Volcanogenic Gold
Quartz
Iron Ore (Taconite)
Dolomite
Limestone
Kimberlite

The inter-relations of HPGR machine set-points and outcomes were also examined with a primary
focus on the sensitivity of machine throughput to these parameters. Direct shear box and piston press tests
were conducted with reference to methodologies used in terra-mechanics.

3
HPGR Pilot Testing

The Köppern pilot HPGR unit located at the University of British Columbia was used for the
HPGR testing component. The machine is a Köppern industrial-sized unit with a maximum capacity of
approximately 40 tonnes per hour which was built specifically for the purpose of pilot HPGR testing. In
comparison to typical industrial HPGR units, the pilot machine is designed with particular attention to
instrumentation, data-logging capacity and material handling layout. The high aspect ratio of the rollers
allows smaller amounts of sample to be used with a large diameter roll, where the large diameter increases
the scalability of the results to larger sized machines. The specifications of the Köppern pilot HPGR used
for the experimental program are shown in Table 2.

Table 2 – Pilot HPGR specifications

Sample Type Units Value

Roll Diameter [mm] 750

Roll Width [mm] 220
Installed Main Motor Power [kW] 200
Maximum Specific Pressing Force 2
[N/mm ] 8.5
Wear Lining [-] Profiled Hexadur®
Feed System [-] Gravity

Pilot testing was carried out in a systematic way using a similar approach irrespective of the
sample type. The results of three experimental conditions with variation in one input parameter were
typically generated for each sample type. The quantity of input parameters tested per sample was
dependant on the amount of sample available. All tests were carried out on feed having a top size of -32
mm and ranging in moisture content from 0 to 10% by weight. Tests were carried out at roll speeds of 0.6
to 0.92 ms-1 and specific pressing force settings of 2 to 5 N/mm2. The results of approximately 80 HPGR
pilot tests were input into a database and used as a reference for determining relationships between HPGR
parameters and the laboratory scale terra-mechanics tests performed.

Investigation into HPGR Input Parameters

The specific throughput constant is particular for the material type and pressing force used, and
represents the HPGR throughput achieved with a roll sized 1 m in diameter and width while operating at a
roll speed of 1 ms-1. The influence of HPGR test input parameters on the change in specific throughput was
initially analyzed.

For the pilot tests the operating gap of the machine as measured was divided by the diameter of
the roll and presented as relative gap. An average value of the relative gap was used from the stable
operating period of each test.

Input parameters were defined by feed conditions such as moisture and feed size distribution slope
as well as machine set-point parameters of specific pressing force and roll speed.

HPGR pilot test results were split into smaller groups according to sample type, each dataset
consisting of approximately three or four experimental conditions. Input parameter values were coded to a
unit less scale from -1 to 1 for each dataset. A first order linear relationship of the examined input
parameter to specific throughput was established for each experimental condition. Figure 2 shows the
relationship found for specific throughput and specific pressing force using different sample types.

4
 360

330
Specific Throughput [ts/hm3]

300
Series1
270 Series 2
240 Series 3

210 Series 4

180 Series 5

150
-1.5 -1.0 -0.5 0.0 0.5 1.0 1.5
Specific Pressing Force
Figure 2 - Specific throughput and specific pressing force

The analysis of pilot HPGR results showed that moisture and specific pressing force consistently
had an inverse relation to specific throughput. These results were found to be consistent with those
mentioned in literature (Fuerstenau et al, 2007; Austin et al, 1993). Feed moisture content was found to
have a stronger influence on specific throughput than specific pressing force for the tested ranges of
parameter inputs.

Investigation into HPGR Response Parameters

The association between the three response parameters (force, speed, moisture) and the specific
throughput constant was analyzed to determine the extent of any inter-relationships. Primarily the
measured operating gap and specific throughput were compared for a set of 80 HPGR pilot tests. The
dataset was not sorted according to machine parameters or feed type used. As often reported in literature, a
clear relationship between operating gap and specific throughput constant was found (Lim et al, 1997).
The operating gap is presented as a value relative to the size of the roller diameter. A linear function can be
fitted relatively well to the operating gap and specific throughput data, as shown in Figure 3, thus implying
that this relationship is significant even when variations in sample type are not accounted for.

5
 400
350
R² = 0.90
Specific Throughput [ts/hm3]

300
250
200
150
100
50
0
0.000 0.005 0.010 0.015 0.020 0.025 0.030 0.035 0.040

Relative Gap (s/D)

Figure 3 - Specific throughput and relative gap

The obvious association between specific throughput and relative gap confirmed that the
throughput potential for a given press size and operating condition can be approximated through
knowledge of an ore’s ability to move the floating roller. It is posited that this ability to move the floating
roller can be related to the terra-mechanics characteristics identified. Correlations to specific throughput for
net specific energy consumption and size reduction were carried out using the same dataset. However,
significantly lower linear correlations were found.

The relationship determined for the response parameters of net specific energy consumption,
relative gap and size reduction to specific throughput was analyzed. As in the previous investigations, the
response parameters were coded to a unit less scale from -1 to 1 in order to compare the degree of first
order inter-relationship to throughput on an equivalent scale. Nine datasets of approximately three to four
individual tests were used. Figure 4 shows the relationships observed for specific throughput and net
specific energy consumption.

330
Specific Throughput [ts/hm3]

Sample 1
300
Sample 2
270
Sample 3
240
Sample 4
210

180 Sample 5

150 Sample 6
-1.2 -0.8 -0.4 0.0 0.4 0.8 1.2

Net Specific Energy

Figure 4 - Specific throughput and net specific energy

6
 A similarly strong relation was found between the investigated response parameters. This was
primarily interpreted to be due to the variation in pressing force settings. All parameters investigated are
known to be affected by the degree of specific pressing force, hence it was considered that the investigation
into correlation using the overall dataset provided a more appropriate indication of the general inter-
relations.

Summary of HPGR Input Variables

On the premise of these pilot testing results, it was concluded that the specific throughput constant
and roll gap are inter-related to such a degree that clear potential exists for one of the two parameters to
be estimated from knowledge of the other. Therefore, it is possible that successful prediction of the HPGR
gap through small scale testing could allow for accurate derivation of a specific throughput value. The use
of a density value for the ore should improve the accuracy of deriving specific throughput from relative
operating gap and more work is required in this area.

The size of the relative gap is also referenced during HPGR application design, as it indicates the
suitable feed size as well as the top size of the HPGR product (Morley, 2009; Morrell et al, 1997). For this
reason the relative operating gap is a valuable HPGR sizing parameter and thus chosen as an aim of the
small scale testing.

INVESTIGATION INTO SMALL SCALE HPGR LABORATORY TESTS

As previously discussed, a clear need presently exists for an industry-accepted laboratory scale
procedure for characterization of samples in terms of HPGR operating potential. The majority of attempts
to date have focused on determining the HPGR motor power requirement to achieve a certain degree of
breakage. The focus of this section is to identify tests which provide information on the gap expansion and
throughput capability of a sample type, an area which has received relatively little attention in previous
studies on HPGR. Working towards the establishment of new small scale testing methodologies, the
applicability of terra-mechanics test procedures used for the assessment of terrain in terms of ground
vehicle locomotion was investigated.

Direct Shear Box Testing

The direct shear test comprises of two individual upper and lower sections which are filled with
test sample. A normal load is applied to the top of the specimen and one section is moved laterally in a
controlled manner. The second section, shown as the top section in Figure 5, is held stationary by a fixed
load cell. Thereby, the horizontal load recorded by the load cell is a measure of the shear force being
transferred by the specimen (Craig, 2004). Three or more normal loads are tested on a sample so that a plot
of the horizontal and normal forces can be made. The test is often used in soil mechanics to determine load
bearing characteristics of the soil, and subsequently adopted and modified for studies of terrain
trafficability.

7
 Figure 5 - Direct shear box test equipment

Figure 5 shows the equipment which is used for measurement of the internal shear properties of a
sample. The length and width of the sample container is 75 mm. A total horizontal displacement of 18 mm
could be achieved with the testing rig and approximately half a kilogram of sample was used per test run.
A feed top size of 4 mm was nominated based on studies carried out by Cerato et al (2006) which
suggested that the box width to diameter ratio should be greater than 6 when testing for shear angle as
stipulated by ASTM standards, to which guideline the rig was confirmed to adhere.

Experimental Procedure

Over the course of the development of the tests a standard procedure for testing was developed
based on interpretation of initial results. In order to reduce errors due to variation in initial packing of the
sample when filling the shear box, a repeatable compaction procedure was established through dropping of
a hammer from a set height. Standard soil shear testing procedures typically require a minimum of three
different normal loads to be applied for three individual shear runs (Budhu, 2006). To increase confidence
in results, five normal loads ranging from 10 to approximately 50 kg were used for each sample
investigation. In order to account for the effects of moisture on direct shear test results, the equivalent
moisture content was used as that for HPGR pilot testing. Pilot HPGR feed samples were screened at 4 mm
and tested at their original gradation. A shear rate of 1 mm per minute was used so that accurate recordings
of the change in shear load could be made.

Example test results are shown in Figure 6 for a quartz sample, where a distinct peak is apparent.
This type of curve was mainly found for relatively dry samples. When testing materials with a moisture
content greater than 2%, the recorded shear force would be relatively constant after a certain shear
displacement. In soil mechanics these characteristic curves are typically referred to as type II and type I
curves respectively.

8
 400

350 k 10 kg
300
Shear Force [N]

20 kg
250

200 30 kg
150
40 kg
100

50 52.4 kg
0
0 2 4 6 8 10 12 14 16 18
Displacement [mm]

Figure 6 - Typical direct shear box test results

80
70
60
Shear Stress (KPa)

50
40
30
20
10
0
0 20 40 60 80 100 120

Peak Critical State Normal Stress(KPa)

Figure 7 - Shear stress and normal stress

The frictional properties of ore samples were determined from each test using the terra-mechanics
based equation of Janosi et al (1961):

=( )(1 ) (1)

Where the measured shear force was substituted for soil thrust T, c is cohesion, p is the normal
stress, j is the shear displacement and k is the shear deformation modulus. In terra-mechanics thrust can be
simply described as the gross horizontal force which can be exerted onto a wheel for a specific wheel load
and geometry, set of operating conditions and soil parameters.

Different values of k were derived depending on whether a peak or critical state angle was
substituted for . The peak shear strength of a soil is a result of shearing resistance due to sliding, dilatancy
effects, crushing and the rearrangement of particles (Budhu, 2006). Critical state shear strength is defined
by a constant shearing resistance where the material density is constant for an increasing shear strain (Craig,

9
2004). Outcomes from the shear test were derived for peak and critical state conditions and input into the
thrust equation. Comparisons of the derived thrust to actual HPGR operating gap and throughput showed
that the best correlations were found when a peak shear value was input into the equation and the sample
was assumed to be cohesionless. The final equation was of the following form:

=( )(1 )+ 3 (2)

Where FSP is the HPGR specific pressing force used and 1, 2, and were fitted to recorded
HPGR operating gap s.

Application of Shear Test Results to HPGR Throughput

The results of fitted relative gap for all of the tested datasets compared to recorded values
presented in Figure 8.

0.035
R² = 0.69
Modelled Relative Roll Gap (s/D)

0.030

0.025

0.020

0.015

0.010

0.005

0.000
0.000 0.005 0.010 0.015 0.020 0.025 0.030 0.035
Pilot HPGR Relative Roll Gap (s/D)

Figure 8 - Modelled and recorded relative roll gap

To better understand the relationship between individual direct shear test outcomes and
throughput, stepwise regression was used to explore and rank potential linear relationships. The Matlab
stepwise regression algorithm was used with a parameter acceptance p-value of 0.05 and rejection value of
0.1. Coefficients were fitted to the coded parameters. The shear deformation modulus k was found to
consistently have a lower p-value than that of peak shear angle and was included by the algorithm as a
parameter for three of five datasets. Overall, the direct shear box test results provided a means to better
estimate throughput and roll gap when a terra-mechanics based parameter, shear deformation modulus k,
was also derived.

Discussion on Direct Shear Box Test Results

An important aspect of introducing a new test methodology is the confirmation that new unique
parameters are available for potential inclusion in a predictive model. As the shear tests were conducted at
a moisture content equivalent to that of the pilot HPGR tests, a possibility exists that the influence of feed
moisture on throughput is being simply reflected through the direct shear test results. To ensure that the
degree of fit achieved with shear test results was not purely due to this factor, a comparison of fit to
throughput was carried out. The results showed a considerably lower degree of fit when using moisture as

10
an input variable in comparison to the correlation achieved with shear test results, thus the direct shear test
results were considered to provide unique sample specific information which can be used with other
parameters for operating gap size prediction.

Piston Press Testing

A substantial amount of work has been carried out previously by researchers on the applicability
of piston press test results to predicting HPGR performance, primarily aimed at describing the
comminution effect for a certain energy input (Bulled, 2009; Daniel, 2003; Hawkins, 2007). The piston
press also has been used in predicting soil trafficability outcomes. With the aim of designing additional
small scale tests which can be used for the prediction of HPGR roll gap and throughput, this previous work
was drawn upon and applied to the use of hydraulic piston equipment at the University of British Columbia.
Similar to the previously outlined investigations, the piston press tests were carried out on sub-samples of
HPGR pilot test feed.

Piston Press Experimental Design

Compression tests were carried out using a 100 mm diameter piston and die assembly. A sample
top size of 4 mm and sample volume of 300 ml provided test geometries which were similar to the testing
guidelines established by Schönert et al (1996). The focus of the testing was to determine the axial
displacement of samples with respect to applied load. Pressures of up to 185 MPa were applied to samples,
which is within range of maximum nip pressures occurring in the HPGR. The strain of mechanical
equipment was subtracted from the strain measured with samples present in the die.

A challenge in applying piston press sinkage results to HPGR roll gap values is the lack in
knowledge of the pressure-sinkage curve in relation to roll angle. Attempts at deriving correlations
between piston press results and HPGR performance outcomes were carried out using two methodologies:

Application of piston press sinkage-pressure curves to HPGR specific pressing force

and roll gap outcomes
Application of piston press sinkage-pressure curves to HPGR compression angle

Piston Press Experimental Equipment

An instrumented hydraulic piston press, shown in Figure 9, was used to apply compression to
samples enclosed in a die. A maximum load of 165 tonnes could be applied in a controlled fashion to
piston and die assemblies. Axially located load cells were used to measure the load applied. Two load cells
were used for the study and had the following effective working ranges:

High pressure load cell: 10 to 160 tonnes

Low pressure load cell: 0.01 to 50 tonnes

The mechanical strain of the hydraulic piston press and die assemblies was measured for the full
range of hydraulic load application.

11
 Figure 9 - Hydraulic piston press

Piston Press Results

Direct application of sinkage to roll gap

From a range of piston tests, recorded sinkage was expressed as a function of applied piston
pressure. In this way, the theory that a lower operating roll gap would be recorded with more compressible
materials, could be tested.

From the investigation it was found that no direct correlation to roll gap could be achieved with
this methodology. A small degree of fit could be achieved with the low compression results, where
pressures up to 15 MPa had been applied, however, further work is required for verification. A similar
fitting exercise targeting specific throughput constant was attempted for the same datasets, however
indicators of fit showed a lower degree of correlation than found for the roll gap. Additional testing is
planned that considers differences in confinement between rolls and the piston press geometry.

Application of sinkage-pressure curves to HPGR compression angle

Knowledge of the roll pressure profiles in relation to rotational angle of the roll and roll width
allows a volume, similar to that shown in Figure 10 to be calculated with resulting units of force. Figure
10 shows a conceptual distribution of pressing forces on the roll surface.

12
 Figure 10 – Pressing forces on roll surface

The compression angle is defined as the angle at which normal roll pressure increases and material
stressing begins (Schönert, K. 1992). Assuming no slippage takes place between the roller surface and the
boundary layer material within the compression angle, a value can be calculated from pilot HPGR test
results.

The known setpoint hydraulic force can be used with a known material pressure-sinkage relation
to attempt a derivation of the compression angle. The results of low and high compression piston press
tests were combined so that sinkage in relation to pressures of 0.03 to 185 MPa was expressed in one
equation of exponential form. An example of a derived full compression curve for a quartz sample is
shown in Figure 11.

200
180
y = 0.3566e0.5408x
160
Piston Pressure [MPa]

140
120
100 Quartz
80
60 Fit

40
20
0
0 2 4 6 8 10 12 14
Sinkage [mm]

Figure 11 - Exponential pressure-sinkage curve

13
 The total horizontal roll force was represented through integration of the pressure sinkage function.
Substitution of sinkage with roll angle provided a means to solve for compression angle through
knowledge of the total pressing force. For all datasets, a value of approximately twice the actual recorded
compression angle was determined. The method used was based on the entire hydraulic pressing force
being applied evenly across the roll width, ranging from the compression angle to the nip. This is not fully
representative of the utilization of hydraulic forces in the HPGR. Calculation of the compression angle
from pilot HPGR results relies on accurate values of material bulk density being available. The bulk
density was measured using loose crushed HPGR feed samples. An improvement in results is expected
should a standardized compaction method, such as the modified Proctor density procedure, be used to
derive a repeatable measurement of material density.

ATTEMPTS AT MODELLING ROLL GAP

From initial investigations of HPGR pilot testing results it has been established that a significant
relationship between specific throughput and roll gap exists in HPGR processing. Roll gap was chosen as
the target parameter to be estimated through modeling due to the obvious dependence of throughput on
material density. Through knowledge of roll gap, it was posited that a sufficiently accurate estimation of
throughput could be derived.

HPGR input parameters, shear test and pilot press test outcomes were included in a linear step-
wise regression investigation. Previous screening exercises of HPGR input parameters and shear tests had
allowed the number of investigated parameters to be reduced. The first regression stage was aimed at
further screening of the available input parameters based on the degree of first order relations and a second
stage explored the significance of interaction between the parameters selected from the first screening stage.

Stepwise regression was carried out to determine the statistical relevance of the input parameters
determined from the propose terra-mechanics tests. HPGR test data was grouped according to specific
pressing force and roll speed settings. The feed to each HPGR test had been previously characterized by
shear test and piston press tests. The shear test outcomes which showed the highest degree of fit to gap and
throughput, were used in this stepwise regression analysis. The sinkage in mm measured at piston
pressures of 10, 20, 100 and 185 MPa were used as piston press related parameters and referred to as z(10),
z(20), z(100), and z(185), respectively. Additionally, moisture and bulk density were included in the
parameter matrix. All input parameters were coded to a dimensionless range of -1 to 1 and assessed using
the Matlab stepwise regression algorithm in relation to actual pilot HPGR operating gap. Table 3 shows
the input parameters which were statistically significant in terms of prediction of either gap or throughput
outcomes for any of the investigated datasets. A relatively low degree of fit was achieved for one data set,
having an R2 value of 0.56, showing that more work is required to determine the appropriate form of the
equation.

Table 3 – Stepwise regression results

No. of Roll Speed FSP

k Z(20) Z(100) R2
Tests (m/s) (N/mm2)

5 0.75 5 -2.8 0 0 0.97

5 0.9 4 0 -2.6 -0.5 0.99
9 0.75 4 -2.2 0 0 0.56
4 0.6 4 0 -3.2 0 0.99

From the investigation it can be seen that the shear deformation modulus and piston sinkage
occurring at a pressure of 20 MPa were selected as most significant by the step-wise algorithm based on
their p-values. Based on the first order step-wise regression results, a larger group of data was assessed

14
including input parameters, specific pressing force, z(20), and k, with the objective of checking for any
statistical significance of their interaction. Based on thirty two HPGR results, the variables found to
significantly improve the estimation of roll gap were parameter z(20) and the interaction variable for k and
specific pressing force. P-values of 0.03 and 1.5x10 -9 were found for z(20) and the k-FSP interaction
variable respectively, indicating that the interaction variable was considerably more valuable in improving
the predictive performance. The resulting equation for relative gap was of the following form:

= (20) ) (3)

Where B0 to B2 are fitted constants. A plot of modelled and recorded relative gap results is shown
in Figure 12. Application of the thrust equation from Janosi et al (1961) to the same data set resulted in a
significantly lower degree of fit to operating gap.

0.035
R² = 0.79
0.030
Modelled Relative Gap (s/D)

0.025

0.020

0.015

0.010

0.005

0.000
0.000 0.005 0.010 0.015 0.020 0.025 0.030 0.035 0.040

Relative Gap (s/D)

Figure 12 – Modelled and measured relative operating gap

DISCUSSION

Significant levels of correlation between piston press results to throughput or gap results from the
pilot HPGR tests were not established. Comparing a theoretical compression angle based on pressing force
and pressure-sinkage curves resulting from piston press tests showed only a small degree of correlation.
However, inclusion of further aspects regarding the distribution of pressure across the roll width, pressure-
extrusion curve and degree of pressure applied to the cheek plate walls may improve the attainable degree
of correlation. Derivation of the pressure-extrusion curve could also be achieved through a modified piston
press procedure where after reaching a set-point pressure, a controlled extraction of the piston could be
carried out while the pressure exerted by the extruding material is being recorded. Accurate nomination of
the setpoint pressure would require knowledge of the pressure occurring at the nip. The ability to account
for the distribution of applied hydraulic roll pressing forces for a certain material may allow accurate
estimation of the maximum pressure occurring between the rolls.

A relatively good prediction of operating gap was achieved through application of piston press
and shear test results. With respect to the source of the laboratory scale test results, further work needs to
be done based on non-linear models when assessing the predictive value of these tests. Exponential

15
equations cannot be transformed into linear models through substitution without creating new errors which
are dependent on the value of the input terms. Hence, a rigorous approach to non-linear modeling is also
required. An improved understanding of the utilization of hydraulic forces in the HPGR could in the future
be incorporated into a semi-mechanistic model which targets roll gap prediction. The interaction of specific
pressing force and shear deformation modulus was found to have the greatest linear correlation to actual
pilot HPGR gap. Therefore, the shear displacement required to reach the peak shear force for a certain
normal load is potentially a critical material specific parameter which may be used in the future for the
prediction of HPGR roll gap expansion and subsequently throughput performance.

Using a terra-mechanics based methodology a potential tool for characterizing feed material in
terms of HPGR throughput performance was made available. The direct shear test box in standard form has
limitations in the amount of normal load which is able to be transferred to a material sample. The size of
the box also restricts the range of shear displacement which is able to be tested. Further potential lies in
using shear test devices which allow for heavier normal loads and the application of larger shear
displacements through rotary motion. The analogy to terra-mechanics provided a basis for a non-linear
form of a predictive equation.

CONCLUSIONS

From the outcomes of the investigation it was found that the shear properties of a sample type
may potentially have significant relevance to the prediction of gap expansion. Further investigations into
deriving the shear deformation modulus for higher normal loads, equating to normal stresses of
approximately 20 MPa, may be of particular value in application to HPGR. Modified shear testing
equipment may allow a researcher to determine the shear properties of a sample and its compressibility due
to shear displacement, known in terra-mechanics as slip-sinkage, and normal load in one testing operation.
Additional research is required using the results of a testing device which simultaneously applies shear and
normal compression loads.

In retrospect, an improvement in roll gap prediction was achieved through preliminary application
of a parameter derived from a terra-mechanics based test. The presented work is directed at the challenge
of sizing roll geometry for a certain throughput requirement, thus contributing towards the overall aim of
the HPGR CAMIRO program. Ultimately the integration of new tests aimed at predicting HPGR roll gap
size and throughput with tests aimed at predicting HPGR energy and size reduction, such as the SPT test,
will considerably improve the tools available to suitably size and select an HPGR for a particular
comminution duty.

ACKNOWLEDGEMENTS

We would like to thank the University of British Columbia, the sponsors of the CAMIRO program and
the Natural Science and Engineering Research Council of Canada for supporting the conducted research. In
addition, Koeppern Machinery Australia and BC Mining Research contributed significantly to the material
outlined in this paper.

NOMENCLATURE

= shear angle
c = cohesion
D = roll diameter
FSP = specific pressing force
= specific throughput constant
j = shear displacement
k = shear deformation modulus
p = normal stress
s = operating roll gap

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T = soil thrust
z(p) = sinkage at normal pressure p

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