- The document discusses Metso's HRCTM state-of-the-art HPGR technology. - Key innovations of the HRCTM include reducing edge effect through the use of flanges on the rolls. - Advantages of the HRCTM over traditional HPGRs include improved grinding performance, increased wear life of parts, and reduced capital and operating expenses for mining operations.

1. Metso HRC™
state-of-the-art
HPGR technology

2. © Metso© Metso
Content
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• HPGR basics
- Advantages over SAG mill
• The HRC™ key innovations
- Reducing edge effect through the use of flanges
• HRC™ advantages over traditional HPGR’s
• An even better HRC™ coming soon
• Conclusions

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HPGR
basics
3 © Metso© Metso

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Metso HRC™
7 © Metso© Metso

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This is the Metso HRC™ HPGR
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Feed system
Main hydraulic cylinders
Patented
Arch-Frame assembly
Drive train assembly
reducer, cardan shaft, safeset coupling,
motor & VFD
Base frame
assembly
Stabilizing cylinders
for positioning and maintenance

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HRC™ HPGR product line
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Model Name Roll Dimensions
Diameter (mm) x
Width (mm)
Maximum
Installed
power (kW)
Maximum
Installed
power (HP)
Nominal
Roll Speed
(RPM)
Top size
(mm)*
Typical
Capacity
(tph)*
HRC™800 740 x 400 2 x 110 kW 2 x 147 HP 30.2 18 86 - 120
HRC™1000 1000 x 625 2 x 260 kW 2 x 349 HP 25.8 25 211 - 295
HRC™1450 1450 x 900 2 x 650 kW 2 x 872 HP 21.4 36 530 - 742
HRC™1700 1700 x 1000 2 x 900 kW 2 x 1207 HP 19.1 43 723 - 1012
HRC™2000 2000 x 1650 2 x 2100 kW 2 x 2816 HP 19.1 50 1650 - 2310
HRC™2400 2400 x 1650 2 x 3000 kW 2 x 4023 HP 19.1 60 2376 - 3326
HRC™2600 2600 x 1750 2 x 3700 kW 2 x 4962 HP 19.1 65 2958 - 4141
HRC™3000 3000 x 2000 2 x 5700 kW 2 x 7644 HP 19.1 75 4500 - 6300
*Varies per application, capacity based on nominal equipment speed and a specific throughput
of 250 - 350 ts/m3h, values do not include circulating load

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HRC™
Advantages

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Advantages: Better Performance
• HRCTM shows an improvement in
grinding performance due to flanged
rolls  Reduced edge effect.
• Table shows typical improvements
observed at pilot and industrial scale.
• Reliable flange operation has only been
proven in a machine fitted with anti-
skew.
• Metso is the only OEM who has a
proven solution for reliable operation of
flanges and anti-skew.
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Variable
Proven Benefits
compared with
Traditional HPGR
Specific Capacity + 20%
Fresh Feed + 20%
Gap + 25%
Specific Energy - 10%
Circulating Load - 40%
Product Size P80 -10%

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Advantages: Improved Wear Life
• Uniform wear through roll length, no
bathtub effect or premature studs
failures (no wash out) like
conventional HPGR’s
• Typical HRC3000 wear performance
(for copper ore):
• Rolls: 15,000-20,000 hours
(6,000-9,000 hours typical for HPGR’s)
• Flanges: 8,000 hours
• Edge blocks: 8,000 hours
Flanged roll after 16,200 operating hours in
copper ore application
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Advantages: Reduced CapEx and OpEx
• The HRC3000 is the largest and proven HPGR
available in the market and it’s capable to
process up to +100 KTPD of fresh feed.
• HRC3000 can effectively reduce the amount of
auxiliary equipment compared with multiple
HPGR lines resulting in…
• Lower CapEx and OpEx of the plant due to
smaller and simpler building
• Less maintenance man-hours required and
less equipment to be maintained
• Better dust control due to less transfer points
and bins
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Advantages: Increased Reliability and Availability
• Crushing circuit will require less auxiliary equipment with one HRC3000:
• Less conveyor belts, feeders, chutes, bins and transfer points
• Complexity is reduced therefore it can obtain higher availability due to less auxiliary
equipment needing maintenance:
• Example: Tripper car in the feed bin
• We estimate 2 additional points (%) in run time of the circuit compared with a circuit of
multiple HPGR’s
Typical Layout with Multiple HPGR’s
Layout for One HRC3000
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Advantages: 2ry Crusher in Open Circuit
• The HRC3000 has a 3 meter diameter roll which means larger feed gap than
smaller HPGR’s.
• Larger feed gap means that bigger rocks can be fed to the machine therefore
secondary circuit can be arranged in open circuit reducing the footprint in the
plant even further.
• Additionally the MP2500 is the largest cone crusher available. It was specially
designed to reduce plant footprint and consequently CAPEX as it can replace
two MP1250’s
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One MKIII 6089
One MP2500
One HRC3000
Two BM 27 x 44
CAPEX Saving Circuit for ~100 ktpd

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Advantages: +5 years of continuous operation
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• Average Roll speed of 15-16 rpm of 21 rpm max. This is ~30% available capacity
• 92% availability
• Almost 20,000 hours of tire life
• It’s the largest HPGR operating in mining application
-
10.000
20.000
30.000
40.000
50.000
60.000
70.000
80.000
90.000
Averagedailythroughput(mtpd)
HRC3000 Throughput

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We are making
the HRCTM
even better
© Metso© Metso

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The same HRC™ advantage - operating
with flanges
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Even crushing force
reduces the tire wear:
• promoting even wear
across the width of the
tires
• allows for innovative
carbide stud compositionReduced
circulating loads in closed
circuit applications:
• potential to design auxiliaries
(screens, conveyors) for lower
recycle rate
• alternatively, potential for a
smaller aperture on the
screens, generating a finer
product
Increased
breakage rates
provide higher
energy efficiency
Higher specific
throughput
increases unit
capacity
Finer product
in open circuit
applications: potential
to be applied
in broader range
of applications
© Metso© Metso

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Arch Frame replaced with
new Anti-Skew Assembly
(Patent Pending)
• CapEx eliminated
• CapEx eliminated
• Maintenance
requirement reduced
Next Generation HRC™
The same performance but lowered total CapEx cost
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Transport Cart eliminated
Stabilizing cylinder
eliminated

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Next Generation HRC™
Delivering lowered total CapEx cost
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• Total CapEx reduced
• ~80% of the components / assemblies are the same
• Floor space reduced
• Total height reduced
• Foundation requirement reduced

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Next
Generation
HRCTM
• HPGR technology offers a better efficiency and
OpEx than SAG mill circuits.
• Better Total Cost of Ownership and financial
returns, specially in large plants and hard ores
• Major differences are anti-skew system and
flanged rolls that allows following advantages:
o Best process performance
o Reduced wear life
o Larger Machine  Reduced CapEx and
Higher Reliability
• The same performance of the Patented Arched
Frame design; new Anti-Skew Assembly
(Patent Pending) and flanged rolls.
• Optimized to deliver lowered total CapEx
Conclusions
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Compared
with SAG
mills
Compared
with
Conventional
HPGRs