COMMINUTION & CRUSHING
Step change comminution
ABB has sold more than 160 GMD units and counting
This debate in the processing plant continues as the energy intensity of the size reduction process faces further scrutiny, Dan Gleeson reports
IM looks across the flowsheet to find the latest and greatest innovations in the mineral processing space, with a focus on bringing down the emissions associated with comminution and crushing.
It goes beyond the individual pieces of equipment – and even the processing circuit itself – to understand where the reductions can be made on a holistic basis.
An HPGR revolution on the cards
After a strong 2024 / 25, FLS believes the High Pressure Grinding Roll( HPGR) is entering a new phase of industry adoption – one that could fundamentally reshape comminution circuit design.
In 2024 / 25, the company secured 16 HPGR orders or commitments, underlining continued confidence in what has become one of the most energy-efficient grinding technologies available to the mining industry.
For Thomas Mackert, Global Product Line Manager for HPGRs at FLS, 2025, in particular, shaped up as a year of product innovation and project development.
“ Provided geopolitical conditions stabilise and commodity prices remain supportive, we expect a significant number of HPGR-based projects to be announced this year,” he told IM.“ And we see strong potential for FLS to play a major role in many of them.”
With 35 years of experience in HPGR applications in mining, FLS is no newcomer to the technology. Early flagship installations at hard-rock operations in Peru, Australia and South Africa helped establish HPGRs as a credible alternative to traditional SABC circuits.
The HPGR Pro can provide up to 15 % energy savings over the standard unit, FLS says
Today, that alternative is increasingly becoming a preferred option.
Case studies and technical papers published over decades have demonstrated not only energy savings, but also improved downstream performance and competitive total cost of ownership. As energy costs rise and ESG targets tighten, these factors are gaining new weight in project evaluations.
According to Mackert, the latest generation of HPGR installations is no longer focused solely on replacing conventional crushing or grinding stages. Instead, they are being integrated into fundamentally redesigned flowsheets that prioritise energy efficiency, operating costs and lifecycle performance over initial capital expenditure.
A notable example is an upcoming installation in India, where FLS is supplying two of the world’ s largest HPGRs – featuring 3 m diameter rolls with 2 m width – operating in conjunction with 3 mm screening. The fine undersize will then feed vertical mills.
“ These flowsheets – combining fine screening after the HPGR with vertical mills – may represent a more effective way of
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