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Prediction of Circulation Load of Side-Flanged High-Pressure Grinding Rolls Closed-Circuit Crushing Li, Nan; Li, Lixia; Wang, Jiaqi; Liu, Zhe; Feng, Quan; Zhang, Qiang; Liu, Hui; Klein, Bern; Li, Bing

Abstract

To enhance the performance of the combined high-pressure grinding roller (HPGR) and tower mill (TM) process for −1 mm particle size, this study addresses the key technical challenges of insufficient material quantity (<100 kg) and complex experimental procedures in HPGR closed-circuit crushing tests by proposing a novel circulating load prediction method based on the principle of mass balance and first-order crushing kinetics. Using a side-flanged HPGRWGM6020 installation, systematic −1mmHPGR closed-circuit crushing tests were conducted on seven different ore samples under three specific pressing forces, with detailed characterization of the dynamic variations in product size distribution, specific energy consumption, and circulating load during each cycle. The results demonstrate that within the specific pressing force range of 3.5 N/mm² to 4.5 N/mm² when the crushing process reaches equilibrium, the circulating load stabilizes between 100% and 200%, while the specific energy consumption is maintained within 1–2.5 kWh/t. Notably, at the specific pressing force of 4.5 N/mm², both the circulating load and specific energy consumption rapidly achieve stable states, with ore characteristics showing no significant influence on the number of cycles. To validate the model accuracy, additional samples were tested for comparative analysis, revealing that the deviations between the model-predicted −1 mm product content and circulating load and the experimental results were less than ±5%, confirming the reliability of the proposed method.

Item Metadata

Title
Prediction of Circulation Load of Side-Flanged High-Pressure Grinding Rolls Closed-Circuit Crushing
Creator
Li, Nan; Li, Lixia; Wang, Jiaqi; Liu, Zhe; Feng, Quan; Zhang, Qiang; Liu, Hui; Klein, Bern; Li, Bing
Publisher
Multidisciplinary Digital Publishing Institute
Date Issued
2025-06-04
Description
To enhance the performance of the combined high-pressure grinding roller (HPGR) and tower mill (TM) process for −1 mm particle size, this study addresses the key technical challenges of insufficient material quantity (<100 kg) and complex experimental procedures in HPGR closed-circuit crushing tests by proposing a novel circulating load prediction method based on the principle of mass balance and first-order crushing kinetics. Using a side-flanged HPGRWGM6020 installation, systematic −1mmHPGR closed-circuit crushing tests were conducted on seven different ore samples under three specific pressing forces, with detailed characterization of the dynamic variations in product size distribution, specific energy consumption, and circulating load during each cycle. The results demonstrate that within the specific pressing force range of 3.5 N/mm² to 4.5 N/mm² when the crushing process reaches equilibrium, the circulating load stabilizes between 100% and 200%, while the specific energy consumption is maintained within 1–2.5 kWh/t. Notably, at the specific pressing force of 4.5 N/mm², both the circulating load and specific energy consumption rapidly achieve stable states, with ore characteristics showing no significant influence on the number of cycles. To validate the model accuracy, additional samples were tested for comparative analysis, revealing that the deviations between the model-predicted −1 mm product content and circulating load and the experimental results were less than ±5%, confirming the reliability of the proposed method.
Subject
HPGR; mathematical modeling; circulating load; closed-circuit crushing
Genre
Article
Type
Text
Language
eng
Date Available
2025-07-04
Provider
Vancouver : University of British Columbia Library
Rights
CC BY 4.0
DOI
10.14288/1.0449263
URI
http://hdl.handle.net/2429/91501
Affiliation
Applied Science, Faculty of; Non UBC; Mining Engineering, Keevil Institute of
Citation
Minerals 15 (6): 603 (2025)
Publisher DOI
10.3390/min15060603
Peer Review Status
Reviewed
Scholarly Level
Faculty; Researcher
Rights URI
https://creativecommons.org/licenses/by/4.0/
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CC BY 4.0