Metso is launching the HPGRSense™ solution for optimising grinding efficiency through accurate monitoring of its HRC™e high-pressure grinding rolls (HPGR).

The HPGRSense is a stand-alone system that provides continuous simultaneous monitoring of the rolls, eliminating the need to stop the process for inspections, Metso says.

Stefan Sakendorf, Director, HRC at Metso, said: “HPGRSense is transforming roll inspection and wear measurement on HPGR rolls while avoiding the limitations of existing laser-based solutions. HPGRSense safely and remotely gives operators full visibility to the rolls’ condition during operation, thereby increasing their understanding of the rolls’ state. The scanning device uses an array of sensors to inspect the roll surface and, in combination with advanced analytics, to detect anomalies and measure wear. This empowers operators to respond quickly to roll damage, predict service life and maximize efficiency of spare stock holding. With this greater understanding, operators can maintain maximum productivity of their HRCe.”

Metso launched the HRC high-pressure grinding rolls for comminution circuits in mineral processing plants in 2014. Not only known for its improvement in energy efficiency, extended wear life and increased throughput, this innovation also pioneered the industry acceptance of flanges as superior grinding technology, Metso states.

Metso HRCe – the latest evolution – provides the same benefits in wear, circulating load and power consumption while improving the layout and serviceability, according to the company. The HPGRSense monitoring solution takes the HRCe HPGR to a new level by providing safe, remote, real-time insights and predictive maintenance capabilities, ensuring optimal performance and longevity of the grinding rolls.

HPGRSense is part of the Metso Plus Sense series of intelligent instruments covering the entire minerals process, helping customers to optimise their process performance and minimise their operating costs.