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Project goals
Develop a highly efficient HPGR
capable of handling the full plant
capacity of 63,500 mtpd
Seek to eliminate problems generally
associated with HPGR technology
(edge effect, skewing)
HRC3000 specifications
Roll size: 3m diameter x 2m wide
Installed Power: 2 x 5,700 kW
Weight: +900 metric tons
Timeline
Building the worlds largest HPGR the HRC3000
at the Morenci Metcalf Concentrator
Project Timeline
2010 2011 2012 2013 2014 2015
Pilot Plant
Pilot Plant Planning & Design
Pilot Plant Installation & Commissioning
Pilot Plant Testing
HRC3000
HRC3000 Design
HRC3000 Manufacturing
HRC3000 Installation & Commissioning
Metcalf Concentrator
Metcalf Definition & Engineering
Metcalf Construction
Concept: Arch-frame
Building the worlds largest HPGR the HRC3000
at the Morenci Metcalf Concentrator
Bolt-on flanges
flanged roll
non-flanged roll
Concept: flanged roll design
Building the worlds largest HPGR the HRC3000
at the Morenci Metcalf Concentrator
500
Crushing Pressure (MPa)
200
100
0
0 20 40 60 80 100
Roll Width
Tire Width(mm)
(mm)
Standard cheek
Traditional plate Plates
Cheek design Flanged roll
Flanged Tiredesign
Design
Pilot plant testing
Building the worlds largest HPGR the HRC3000
at the Morenci Metcalf Concentrator
Predicted* Actual**
Operating gap (mm) 99 99 101
Specific throughput (ts/m3h) 276 320 328
Circulating load (%) 58 85 41 55
60
Stud & Surface Height (mm)
50
40
30
~80% life remaining
20
10
0
0 2000 4000 6000 8000 10000 12000 14000 16000
Crushing Hours
Flanged Stud Height Flanged Surface Height Non-Flanged Stud Height Non-Flanged Surface Height
Conclusions and learnings
Building the worlds largest HPGR the HRC3000
at the Morenci Metcalf Concentrator