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HPGR pilot plant testwork

In partnership with Köeppern Machinery Australia (KMA), ALS Metallurgy has available a state-of-the-art pilot HPGR unit at its Balcatta premises. The unit is available for bulk test work trials to determine specific HPGR design and operation parameters, or alternatively the HPGR can be used as a production unit to produce HPGR (“micro-cracked”) feed for downstream process assessment. This is a two-way commercial alliance, which means clients can approach KMA directly to commission HPGR testing at ALS. Or it may be more commercially appropriate or efficient to have the HPGR package included in a wider testwork program with ALS. Neither scenario is too onerous and ALS’s only objective to facilitate our clients’ HPGR crushing needs.


HPGR evaluation & engineering studies

The KMA HPGR unit located at ALS is a second-generation machine incorporating studded rolls of 1000mm diameter and 250mm width with nominal throughput capacity of 40tph on a continuous basis, which can reach a maximum rate of 60tph. Additionally, the HPGR is installed with a full SCADA system for accurate data capture at each stage of the HPGR process operation. To align with the ALS core value ‘Safety as a Priority’, as well as our comprehensive HSE standards and procedures, the HPGR is equipped with high powered dust extraction and can be fully enclosed via tailored tenting systems to allow for the evaluation of potentially hazardous ore types.

All process design parameters such as roll speed and specific pressing force can be evaluated and optimized. Key operational and equipment sizing parameters for full scale engineering design include deliverables for Process specific throughput constant (m-dot), Specific pressing force and Net specific energy consumption as well as wear rate estimation.

Specimens of flake generated during batch HPGR testwork are collected for flake density and competency testing performed by Additionally, the HPGR Köeppern Machinery Australia.

Typical HPGR bulk preparation usually requires crushing the sample to P100 :32 mm. Once prepared and blended, the general order of an HPGR testwork program is as follows:

For each test, the HPGR products are split at the product conveyor using a diverter gate into centre, edge and waste products. Representative sub-samples of the centre and combined edge products are prepared via a rotary sample divider and subjected to particle size distribution analysis.

During the HPGR test, experimental data is recorded every 100ms via a PLC control system measuring roller gap; pressing force; fixed and floating shaft torques; and power consumption.

This data allows for in-depth process analysis and sizing of HPGR presses for industrial design, CAPEX and OPEX.

Other related services

Bulk crushing via HPGR is available as part of larger metallurgical testwork programs in the production of suitably sized product for downstream testing including pilot scale flotation or magnetic separation testwork or heap leach evaluation testwork.

Don't quite see what you're looking for or need more information?

ALS understands that HPGR program are very project specfic.

Please contact us for further details.

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Associated testwork services

Related testwork

HPGR test products can be utilized as part of larger metallurgical testwork programs in the production of suitably sized product for downstream testing including:

Click on the above links or contact us for further information. We can integrate a full program for you if required.