Applicable Material Hardness
Hard metallic ores and recycled waste materials: tungsten ore, tungsten sand, tungsten carbide scraps, hard alloy waste, magnetite, hematite, chromite, manganese ore, ilmenite, as well as copper, gold, silver, lead-zinc ores and tailings containing high-hardness gangue
Highly abrasive non-metallic ores: quartzite, silica, granite, basalt, diabase, gneiss, corundum, silicon carbide, garnet, diamond tailings
Industrial hard materials: ceramic waste, refractory materials, metallurgical slag, sintered lumps, cement clinker and other high-hardness bulk materials
Suitable for materials with uniaxial compressive strength of 100–350 MPa and Mohs hardness of 6–9 (eg., quartz ≈7, tungsten carbide up to 8.5–9).When processing high-hardness, high-brittle, and highly abrasive materials, its adaptability, stability and service life are significantly superior to conventional small-scale experimental crushers.
Working Principle
Based on the principle of bed crushing, a large number of material particles gather under high-pressure confined space and achieve bulk crushing through mutual contact and extrusion. Pressure continuously increases in the confined space, particle gaps shrink, stress is efficiently transferred between particles, and crushing occurs when the stress reaches the particle crushing strength.
The crushing characteristics of HPGR are high pressure, low speed, full feeding and material bed laminating crushing. Under high-pressure grinding force, the material bed is compressed, and the pressed materials turn into dense flat flakes full of cracks. These flakes have very low mechanical strength, contain a large amount of fine powder, and can even be crushed by fingers.
Equipment Advantages of HPGR (Compared with Conventional Crushers)
1.Particularly suitable for high-hardness and highly abrasive materials, with strong adaptability to materials of Mohs hardness 6–9.
It adopts high-pressure material bed laminating crushing relying on high-pressure static extrusion instead of impact striking, which can easily crush tungsten carbide and waste tungsten above HRA90. The crushing efficiency is much higher than that of conventional equipment such as hammer crushers, jaw crushers and impact crushers.
Conventional crushers directly crush materials through impact, shear and extrusion, involving direct hard contact between parts and materials. Even with tungsten carbide components, rapid impact wear, chipping and fatigue fracture still occur.
2.Suitable for Highly Brittle Materials with Low Over-Crushing
Tungsten carbide and waste tungsten are highly brittle, and conventional crushers tend to produce a large amount of useless fine powder, resulting in resource waste.HPGR features controllable roll gap and pressure to realize selective crushing, with uniform product particle size, low fine powder content and higher material utilization rate.
For example, tungsten carbide is hard but brittle. Small crushers apply impact and alternating loads, causing chipping, corner breakage and local fragmentation of WC tooth plates/roll shells, making long-term stable operation impossible. The extremely high maintenance frequency makes them unsuitable for continuous testing or production.
3.Stronger Wear Resistance and Lower Loss
When dealing with highly abrasive materials such as tungsten carbide, wearing parts of conventional crushers need to be replaced within weeks or even days.The roll surface adopts a high-strength wear-resistant alloy and carbide stud structure, which is wear-resistant, impact-resistant and edge-chipping resistant, greatly prolonging service life and significantly reducing maintenance costs.
Small crushers involve direct metal-to-material contact without material bed protection. Even with wear-resistant WC, continuous friction of high-hardness materials causes rapid ploughing wear, blunted edges and corners, and deteriorating crushing effect. Its service life is still only a fraction of that of HPGR.
5.Stable Discharge for Subsequent Recovery and Reutilization
Tungsten carbide scraps and post-welding waste tungsten are mostly used for recycling and remanufacturing hard alloys.HPGR produces uniform particle size and good particle shape, facilitating subsequent purification, separation, pulverization or re-briquetting and improving recycling value.
Conventional crushers usually produce coarse and highly fluctuating discharge, severe over-crushing, uncontrollable fine powder and no internal micro-cracks in particles. This leads to heavy subsequent grinding load, poor liberation and affected mineral processing/recovery indicators. They can “break materials” but fail to meet the quality and stability required by the process.
6.Low Energy Consumption, Low Noise and Stable Operation
Compared with conventional crushers of the same output, HPGR has lower energy consumption, less vibration and lower noise. It is suitable for continuous and large-scale processing of hard waste materials with more stable and reliable operation.
Small crushers are originally designed for soft to medium-hard materials. Their frame rigidity, bearing load and transmission system cannot match the high-intensity impact of high-hardness materials. Long-term operation causes severe frame vibration, bearing damage and greatly shortened service life of the whole machine.
At present, HPGR is widely used in fine crushing in metal mine concentrators, grinding in the cement industry, granulation in the chemical industry and fine grinding of pellets to increase specific surface area.It has the advantages of replacing fine crushing operations, realizing more crushing and less grinding, improving system production capacity, saving energy and reducing consumption, and featuring high reliability. It is an ideal equipment for secondary, fine and superfine crushing of metallic ores.
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