Raw material high pressure grinding roller(HPGR)

Tongli High Pressure Grinding Roller (HPGR) is a type of modern and energy-efficient comminution technology used for reducing the size of various ores and minerals especially cement raw material and clinker through high-pressure interparticle crushing. It's often used as an alternative to traditional grinding methods. The main function of an HPGR is to apply high pressure to the feed material, causing it to undergo interparticle breakage rather than traditional grinding mechanisms, which involve impact and abrasion. This interparticle breakage leads to a more energy-efficient process and can result in improved product quality with a reduction in overgrinding. HPGRs are particularly suitable for hard and abrasive ores.


Tongli raw material HPGR Introduction

Tongli High Pressure Grinding Roller (HPGR) is a type of modern and energy-efficient comminution technology used for reducing the size of various ores and minerals especially cement raw material and clinker through high-pressure interparticle crushing. It's often used as an alternative to traditional grinding methods. The main function of an HPGR is to apply high pressure to the feed material, causing it to undergo interparticle breakage rather than traditional grinding mechanisms, which involve impact and abrasion. This interparticle breakage leads to a more energy-efficient process and can result in improved product quality with a reduction in overgrinding. HPGRs are particularly suitable for hard and abrasive ores.

Raw material high pressure grinding roller structure

Tongli HPGR consists of two counter-rotating rolls with diameters ranging from a few centimeters to several meters, depending on the application. The rolls are typically made of wear-resistant materials to withstand the high pressure and abrasion. The rolls are equipped with a variety of surface configurations, such as studs or grooves, which help to grip and compress the feed material as it passes between the rolls.

Grinding Rollers: The central component of an HPGR is the pair of counter-rotating rolls. These rolls are typically made of wear-resistant materials and have a specific surface pattern or texture to help grip and compress the feed material.

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Frame and Bearings: The rolls are mounted within a sturdy frame, which also contains the bearings that support the rolls' rotation. These bearings are subjected to significant forces and pressures, so they need to be designed to withstand these conditions.

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Hydraulic System: HPGRs operate by exerting high pressure on the feed material between the rolls. A hydraulic system is used to apply and control this pressure. It consists of hydraulic cylinders that push the rolls together and maintain the desired pressure level during operation.

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Feed Chute: The feed chute is where the material to be processed is introduced into the HPGR. It guides the material between the rolls and ensures a consistent and controlled feed.

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Drive System: The rolls are driven to rotate in opposite directions by a drive system. This system can include motors, gearboxes, and other components that provide the necessary torque and rotational speed.

Control System: A sophisticated control system is used to manage and regulate the operation of the HPGR. It monitors factors such as pressure, feed rate, roll speed, and other parameters to optimize the crushing process and ensure efficient operation.

Discharge Conveyor/bucket elevator: After the material has been processed through the HPGR, a discharge conveyor is used to transport the crushed material away from the equipment for further processing or handling.

Design principles of raw material high pressure grinding roller

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High Pressure: The rolls exert significant pressure on the feed material, causing it to be crushed or ground between the rolls. This pressure creates microcracks in the ore particles, making them more susceptible to subsequent grinding processes.

Particle Size Reduction: HPGRs are commonly used as a final stage of ore comminution before ball milling or other grinding methods. The technology is capable of producing finer product sizes compared to conventional crushers or mills.

Energy Efficiency: HPGRs generally consume less energy per ton of processed material compared to traditional grinding methods, which can lead to cost savings and reduced environmental impact.

Liberation of Valuable Minerals: The microcracks created by the high pressure help in liberating valuable minerals from the ore matrix, making them more accessible for downstream extraction processes.

Reduced Water Usage: HPGRs can reduce the need for water in the grinding process, which is beneficial in regions with water scarcity or where water conservation is important.

Specifications of raw material high pressure grinding roller

Specification:

Roller diameter:

(mm)

Roller width:(mm)

Input size:(mm)

Power:(kw)

Capacity:(t/h)

TL 600-200

600

200

≤25

2*75

20-25

TL 800-350

800

350

≤30

2*132

40-60

TL 1000-400

1000

400

≤30

2*160

80-100

TL 1200-450

1200

450

≤40

2*220

120-140

TL 1200-500

1200

500

≤40

2*250

135-155

TL 1200-600

1200

600

≤40

2*280

150-170

TL 1200-800

1200

800

≤40

2*300

165-185

TL 1400-650

1400

650

≤45

2*500

240-270

TL 1400-700

1400

700

≤45

2*550

280-350

TL 1400-800

1400

800

≤45

2*560

300-400

TL 1400-1200

1400

1200

≤45

2*800

350-450

TL 1500-1000

1500

1000

≤45

2*710

450-500

TL 1600-1200

1600

1200

≤50

2*800

600-650

TL 1600-1400

1600

1400

≤50

2*1140

700-750

TL 1700-1300

1700

1300

≤55

2*850

730-760

TL 1800-1200

1800

1200

≤60

2*1250

750-800

TL 1800-1600

1800

1600

≤60

2*1600

900-1000

TL 2000-1200

2000

1200

≤60

2*1550

1000-1100

TL 2000-1600

2000

1600

≤60

2*2500

1200-1300

TL 2200-1600

2200

1600

≤60

2*2650

1250-1350

TL 2400-1800

2400

1800

≤60

2*2800

1400-1600

TL 2600-1800

2600

1800

≤65

2*3750

1800-2000

TL 3000-2000

3000

2000

≤65

2*5500

2000-3000

Note: * Diameter refers to the grinding roller inner diameter.

HIGH-TECH ENTERPRISES

Modern intelligent processing base integrating R&D, production and sales.

Zhejiang Tongli Heavy Machinery Manufacturing Co., Ltd (Formerly known as Tongxiang Coal&Mining Machinery Factory) established in year 1958 is a member of the Chinese National Building Material Machinery Association. Tongli is on the vendor list of designated production enterprise of the Ministry of Coal Industry. ISO9001、ISO14001、ISO45001 certified, accredited as High-tech & new technology enterprise of Zhejiang Province. With 65+ years of experience, Tongli has earned first class R&D and manufacturing capabilities, dedicated to provide satisfactory manufacturing equipments for global customers.   

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Machines & Equipments

After years of development, there are more than 650+ sets of heavy machinery manufacturing equipments in our workshop, some of them are as follows:

Ф12m CNC Horizontal Lathe
Ф12m CNC Horizontal Lathe

One of the largest equipment in our factory, the maximum processing diameter is 12 meters, and the maximum processing length can reach 26 meters. This Lathe is specially crafted for processing mega cylinders.

Ф12m CNC Vertical Lathe
Ф12m CNC Vertical Lathe

One of the super-large equipment in our factory, the maximum processing height can reach 6 meters, and the maximum processing diameter can reach 12 meters, which ensures that the accuracy of the cylinder flange can reach the required level.

Ф5.3x18M CNC Horizontal Lathe
Ф5.3x18M CNC Horizontal Lathe
One of our advanced equipment for machining the Barrel, milling the end face and out surface with precision 0.05mm.
180mm CNC Universal Bending Machine
180mm CNC Universal Bending Machine
Numerical control with high precision, Maximum Bending Thickness : 180mm
Ф6.5х20m large annealing furnace
Ф6.5х20m large annealing furnace
Annealing will make the metal inner organization reach or near equilibrium, to obtain the good performance .By this large Furnace, we can anneal the shell by whole.
Ф6.5х20m Sandblasting room
Ф6.5х20m Sandblasting room
Remove all the rust and other impurities on the surface by sandblasting in this room to prolong the service life of the Painting.
4x12m Gantry CNC boring and milling machine
4x12m Gantry CNC boring and milling machine
  • Workbench effective size: 4000*12000mm;

  • Gantry Width: 4900mm;

  • Processing height: 4000mm;

  • Three angled milling heads, square ram;

  • Load-bearing 350 tons;

  • CNC system: SIEMENS 840D.

GKU40Ex80 Moving Beam Gantry Five-sided Machining Center
GKU40Ex80 Moving Beam Gantry Five-sided Machining Center
  • Workbench effective size: 3000*8000mm;

  • Gantry width: 4100mm;

  • Load-bearing: 80t;

  • Spindle speed: 2000RPM

  • CNC system: SIEMENS 840D.
2x4m Newway PM2040HA Moving Beam Gantry Machining Center
2x4m Newway PM2040HA Moving Beam Gantry Machining Center
  • Workbench effective size: 2000*4000mm; 

  • Processing Width: 2800mm;

  • Processing Height: 1100mm;

  • Full-CNC milling heads;

  • PLC: Siemens.
5x14M Vertical Boring&Milling Machine
5x14M Vertical Boring&Milling Machine
  • Workbench effective size: 4500x5000mm

  • Processing Length: 14000mm;

  • Processing Height: 5000mm;

  • CNC system: SIEMENS 840D.

6.3x11M VERTICAL BORING&MILLING MACHINE
6.3x11M VERTICAL BORING&MILLING MACHINE
  • Workbench effective size: 5000x5000m;

  • Processing Length: 11000mm;

  • Processing Height: 6300mm;

  • CNC system: SIEMENS 840D.
Ф12m and Ф10m Gear Hobbing Machine
Ф12m and Ф10m Gear Hobbing Machine
The required equipment to machine the girth gear, the maximum diameter of our gear-hobbing machine is 10m and the maximum module is 40.
Ф16х5m CNC Cutting Machine
Ф16х5m CNC Cutting Machine
Ensure precision of steel plate and other raw materials, avoid the error of manual operation.
Ф16х5m Edge Planer
Ф16х5m Edge Planer
Remove the burrs to make the welding preparation of steel plate have good roughness and ensure the angle of welding preparation angle.
Three-Phase Electric Arc Furnace
Three-Phase Electric Arc Furnace
Raw Materials for casting is produced from our own workshop to ensure the quality of the casting. 

Honors and Qualifications

Features of Tongli high pressure grinding roller

01

65+ Years of Experience

Founded in 1958 Tongli is a leading company specialized in the design and manufacture of complete HPGR systems in the global market.

02

Versatility

Tongli HPGR can handle a wide range of materials, including raw materials, cement clinker, and additives, making is highly versatile for different cement production.

03

Patented Design

Tongli held independent intellectual property rights, developed core technologies of mechanical, and electrical systems provide high reliability at all events.

04

Reliability

Tongli high pressure grinding roller, its quality is time proven and well recognized by global customers, all the metal castings are produced in our foundry we provide one step solution to fabricaction and metal casting.

Industry Knowledge extension

What is the application of high-pressure grinding roller HPGR?

Cement Industry: HPGRs have found applications in the cement industry for grinding clinker and raw materials.

Ore Crushing: HPGRs are commonly used to crush ores and minerals to a finer size before further processing. This can enhance the efficiency of downstream processes like grinding, flotation, and leaching.

Diamond Liberation: In the diamond industry, HPGRs are used to liberate diamonds from the ore matrix, as diamonds are very hard and require specialized methods for extraction.

Iron Ore Pellet Feed Preparation: HPGRs can be used to prepare the pellet feed by reducing the size of iron ore concentrates before balling or pelletization.

Copper Ore Processing: HPGRs are employed in copper ore processing to improve the liberation of copper minerals and reduce the energy consumption of downstream grinding processes.

Gold Ore Processing: In some gold mining operations, HPGRs are used to reduce the particle size of gold-bearing ores to enhance the efficiency of gold recovery methods.

What is the difference between high pressure roller press and ball mill?

High Pressure Grinding Roller (HPGR) and ball mills are both commonly used comminution equipment in the mining and minerals processing industry. However, they operate on different principles and have distinct advantages and disadvantages.

Principle of Operation:High Pressure Grinding Roller (HPGR): HPGRs use two counter-rotating rolls to exert high pressure and compress the material being processed. This pressure causes inter-particle breakage and helps to create microcracks within the material, enhancing its overall comminution. HPGRs are more efficient in terms of energy consumption compared to traditional grinding methods. A ball mill is a rotating cylinder filled with steel balls that grind the material to a fine powder. As the ball mill rotates, the balls 'cascade' and crush the material between themselves and the inner walls of the cylinder.

Particle Size Reduction Mechanism:The main mechanism of particle size reduction in HPGRs is the application of high pressure, which causes inter-particle breakage and generates a more uniform product with fewer fines compared to traditional grinding methods. The microcracks produced also expose more surface area for subsequent leaching or further processing.

Particle size reduction in ball mills occurs mainly due to impact and attrition between the balls and the material being ground. The size reduction achieved by ball mills tends to be more heterogeneous, with a wider range of particle sizes produced.

Product Quality:HPGRs tend to produce a more uniform product with fewer fines, which can be advantageous for downstream processes such as leaching or flotation. The microcracks produced during HPGR grinding can also improve the liberation of valuable minerals from the ore matrix. Ball mills can produce a wide range of particle sizes, which can be beneficial for some applications but might require additional processing steps to achieve the desired product quality.

Maintenance and Wear:HPGR: The wear on HPGR rollers and lining materials can be significant due to the high pressure and forces involved. Maintenance and replacement of worn components can be more challenging and costly. Ball mills experience wear on the grinding media and liners, which can also require regular maintenance and replacement. However, the maintenance procedures for ball mills are generally more straightforward compared to HPGRs.