ABB, the power and automation technology group, has launched RollXtend™, a new state-of-the-art drive system feature to improve HPGR performance and roller life in mining. This advanced control system is based on real-time load sharing between the rollers, which gives significant advantages in terms of throughput optimisation, minimising operational and capital expenditures, and improving the health and safety of the operators.

The system allows the operator to manage the torques delivered by each roller in real time. Speed match is maintained even with differential roller loads, reducing slip to a minimum and reducing roller wear in general.
As rollers start to wear (after a certain period of operation), they experience different wear rates based on many factors like feed size, ore characteristics, hopper positioning etc. RollXtend technology provides the flexibility to adjust the load taken by each roller based on the wear they are experiencing, such that both rollers can be made to wear uniformly and, as a result, improve the overall lifetime of the roller pair.

In terms of maintenance, RollXtend also has significant advantages. Currently HPGRs require regular inspections and maintenance to ensure damage to studs is contained and the equipment continues to perform efficiently. To facilitate roller inching for inspection, operators need to disengage the main drive and engage an auxiliary drive. This operation is time consuming and poses safety hazards for workers. With the RollXtend drive system, inspection and maintenance can be carried out without disengaging the main drive.

ABB says that the benefits of RollXtend are better appreciated in the long term, as the system extends the lifetime of the whole HPGR (not just the rollers), offers a better maintenance experience and provides the operational flexibility to improve the crushing process performance.