Measurement of wear pattern of studs on High-Pressure Grinding Rolls (HPGR)

The application of high-pressure grinding rolls (HPGR) in iron ore processing is expanding. However, to maximize their utilization, it is crucial to understand the impact of various parameters on their operation, given their advanced technology. Wear is an essential factor that needs to be considered when operating these mills. Failure to manage wear can lead to substantial costs and a decline in machine efficiency, as well as the efficiency of the comminution circuit. Therefore, it is imperative to control the wear rate of rolls by adjusting the machine accordingly. This research aims to measure the wear pattern of HPGR rolls in the primary grinding circuit of the Sanabad Iron Beneficiation Plant in Iran. The results indicated that the wear rate of the studs along the rolls was not uniform but rather concave, and the maximum wear rate was observed in the central part of the rolls. The wear rate of the studs on the fixed roll was higher than that of the floating roll. For the current mill, the predicted useful life of the rolls was estimated to be between ۱۲۰۰۰-۱۳۰۰۰ hours, considering the operating time of ۸۰۰۰ hours of the current HPGR.