iron mine project
Conquer Your Most Challenging Iron Ore Reserves with Unmatched Efficiency
Struggling with declining ore grades, rising energy costs, and relentless pressure to optimize your bottom line? In today's market, maximizing yield from every ton of raw material isn't just an objective—it's a necessity for survival and growth. Legacy processing plants often become bottlenecks, unable to adapt to harder, more complex ore bodies without significant capital investment and operational overhaul.
We engineer solutions that turn these challenges into your most significant competitive advantage.
A New Paradigm in Iron Ore Processing: The Titan-Bond HPGR Circuit
The Titan-Bond High-Pressure Grinding Roller (HPGR) circuit represents a fundamental shift in comminution technology, specifically engineered for the demands of modern iron ore mining. This integrated system moves beyond traditional jaw crusher and SAG mill configurations, delivering a leap forward in energy efficiency, particle liberation, and overall plant throughput.
The Optimized Workflow:
- Primary Crushing & Feeding: Run-of-Mine (ROM) iron ore is pre-crushed and consistently fed to the HPGR feed hopper.
- Inter-Particle Comminution: The heart of the system. Two counter-rotating rolls apply extreme pressure, fracturing particles against each other. This method is vastly more efficient than impact or attrition-based grinding.
- Product Handling & Beneficiation: The compacted "cake" exiting the HPGR is discharged onto a conveyor. Its micro-fractured structure makes it exceptionally amenable to downstream magnetic separation, significantly improving Fe recovery rates.
Core Features Designed for Maximum ROI
What Technical Innovations Drive Superior Performance?
- Patented Roll Technology: Our custom-welded, tungsten carbide studded rolls are built for the extreme abrasiveness of iron ore. The unique stud pattern and base material provide a service life up to 50% longer than conventional options, drastically reducing maintenance downtime.
- Advanced Control System (ACS): Real-time monitoring of pressure, power draw, and roll gap allows for dynamic adjustment to feed variability. The ACS ensures optimal performance and protects the machine from damaging events like tramp metal.
- Flake Crusher Integration: To efficiently break up the compacted product cake for optimal conveyor handling, an integrated flake crusher is included as part of the standard package.
- Modular Design: Pre-assembled modules reduce civil works costs and accelerate installation by weeks, getting your project into production faster.
How Does the Titan-Bond HPGR Compare to Traditional Circuits?
When evaluating capital expenditure (CAPEX) and operational expenditure (OPEX), the Titan-Bond HPGR demonstrates clear economic advantages.
| Feature | Traditional SAG/Ball Mill Circuit | Titan-Bond HPGR Circuit | Your Advantage |
|---|---|---|---|
| Specific Energy Consumption | High (Typically 18-25 kWh/t) | Low (Typically 5-8 kWh/t) | Up to 60% reduction in grinding energy costs. |
| Grinding Media Consumption | Significant (Ball consumption) | Negligible | Eliminates media cost and related handling. |
| Particle Shape & Liberation | Rounded particles, less micro-cracking | Micro-fractured, cubic particles | Improves downstream recovery by 2-5%. Enhances pelletizing. |
| Noise & Dust Emissions | High | Low (Fully enclosed system) | Improved environmental compliance and workplace safety. |
| Footprint | Large | Compact | Reduces civil engineering costs; ideal for plant expansions. |
Technical Specifications: Engineered for Scale
The Titan-Bond HPGR is available in multiple sizes to match your project's specific capacity requirements.
| Model | Roll Diameter (mm) | Roll Width (mm) | Installed Power (kW) | Capacity* (t/h) |
|---|---|---|---|---|
| TB-HPGR 1000 | 1000 | 500 | 2 x 500 | 600 - 850 |
| TB-HPGR 1400 | 1400 | 800 | 2 x 1100 | 1,200 - 1,700 |
| TB-HPGR 1800 | 1800 | 1200 | 2 x 2000 | 2,500 - 3,400 |
*Capacity is dependent on ore characteristics including moisture content, work index, and feed size distribution..jpg)
- Operating Pressure: Up to 5.5 N/mm²
- Feed Size: Up to 100 mm
- Product Size P80: Adjustable from 6 mm to 25 mm
- Construction: Heavy-duty steel frame; wear surfaces protected by replaceable hard-faced plates.
Proven Applications: From Greenfield Projects to Brownfield Expansions
The Titan-Bond HPGR is not a theoretical solution; it is field-proven in some of the world's most demanding mining regions.
Application Scenarios:
- Greenfield Iron Ore Concentrators
- Brownfield Plant Expansions (replacing or supplementing tertiary crushers and mills)
- Processing of Hard Banded Iron Formations (BIF)
- Pellet Feed Preparation
Case Study: Increasing Yield at a Brazilian Hematite Operation
A major producer was facing declining head grades at their existing facility. Retrofitting a TB-HPGR 1400 circuit as a tertiary crusher allowed them to increase plant throughput by over 18% without expanding their energy infrastructure. Crucially, the micro-cracking effect of the HPGR led to a documented increase in Fe recovery during magnetic separation from ~92% to ~95%, adding millions in annual revenue.
Investment & Financing Options
We understand that major capital projects require financial flexibility. The Titan-Bond HPGR system is available through several acquisition models:
- Direct Capital Purchase: Full ownership with comprehensive manufacturer's warranty and service support.
- Lease-to-Own Program: Structure payments over a period that aligns with your project's cash flow.
- Performance-Based Contracting: In select cases, we can offer agreements linked directly to guaranteed throughput or energy savings metrics.
Our financial specialists can work with you to develop a model that meets your budgetary requirements.
Frequently Asked Questions
Q: How does an HPGR handle moist or sticky ores that can cause plugging?
A: Our design includes a robust mechanical frame and control system that can handle fluctuations in moisture. For highly sticky ores (<6% moisture), we offer optional side cheek plate heating systems to prevent material buildup..jpg)
Q: What is the typical maintenance schedule and what are the major wear components?
A: The primary wear components are the studded roll surfaces. Depending on abrasiveness, roll service life typically ranges from 8,000 to over 12,000 operating hours. Routine maintenance involves checking hydraulic systems and lubrication units—far less labor-intensive than maintaining a SAG mill.*
Q: Can this technology be integrated into my existing plant?
A: Absolutely. Our engineering team provides full feasibility studies for brownfield integrations. The compact footprint of the HPGR often allows it to be installed within existing building structures.
Q: What level of technical support do you provide post-installation?
A: We offer comprehensive support packages, from remote monitoring via our ACS platform through on-site technician assistance. Our goal is to ensure you achieve maximum equipment availability.