Metso transforms grinding roll inspection with remote monitoring solution

Metso has launched a new solution for monitoring its next-generation HRCe high-pressure grinding rolls (HPGR) to optimize efficiency.

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

“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,” Stefan Sakendorf, director of HRC at Metso, said.

“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,” he added.

Metso launched the HRC high-pressure grinding rolls for comminution circuits in mineral processing plants in 2014, setting an industry standard for HPGR solutions. 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.

The HRCe – the latest evolution – provides the same benefits in wear, circulating load and power consumption while improving the layout and serviceability. Launched in 2020, the HRCe comes with a decreased installation capex compared to the HRC. The changes in design allow for maximum productivity with proven technology that leads to superior grinding efficiency.

The HPGRSense takes the HRCe to a new level by providing safe, remote, real-time insights and predictive maintenance capabilities, ensuring optimal performance and longevity of the grinding rolls, Metso said.

The monitoring solution is part of the Metso Plus Sense series of intelligent instruments covering the entire minerals process, helping customers to optimize their process performance and minimize their operating costs.