High Pressure Grinding Roller (HPGR) Market: Industry Insights, Outlook and Forecast upto 2020

High pressure grinding rollers (HPGRs) provide flexible crushing solutions as they are suitable for both new installations and upgrades in mining and construction industry. With the increasing need for lower energy consumption and higher throughput rates, the demand for HPGRs is on rise in mining industry. The global HPGR market was valued at USD 247.7 million in 2013 and is expected to grow at a CAGR of 5.9% during the forecast period 2014 – 2020.

HPGR technology was introduced for crushing kimberlite ores in diamond mines during 1980s. In 1996, HPGR technology was successfully implemented in the iron ore industry. HPGRs are preferred for its lower energy consumption and higher throughput rates during the crushing and pre-crushing stages. The technology is becoming increasingly attractive for hard rock ore applications due to escalating energy and steel media costs. Moreover, with the wear abatement technology and significant improvements in design, HPGRs are expected to be increasingly preferred over other competing comminution technologies such as semi-autgenous (SAG) and ball milling.

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The major factor driving the HPGR market is the need for energy efficient comminution solutions. Since more than 50% of the total energy required for mining activities is used during the crushing and grinding process, energy efficiency plays a crucial role in the selection of comminution solutions. Moreover, with the declining ore grades of both ferrous and non-ferrous metals across the world, comminution solutions need to provide finer particles for better extraction of minerals. Iron is one of the most widely used metals and the use of iron ore to manufacture steel drives the need for iron ore beneficiation. HPGRs provide an effective solution to optimize energy consumption. Non-ferrous metals include precious metals such as gold and silver which need an optimum extraction index. Since the ores develop micro-cracks due to high pressure exerted in HPGR, leaching fluids cause higher liberation of precious metals. Moreover, gold particles do not get flattened in HPGR on account of its working environment. With the use of HPGRs, large, rare and valuable diamonds can be obtained thereby, increasing the value generated through the mining process.

The power rating chosen for drive systems for an HPGR is highly dependent on the roll size and material characteristics, among other features. Further, it has been reported that the distribution of particle sizes changes as per the change in power rating. In 2013, the 2 x 1,900 kW – 2 x 3,700 kW power rating range HPGRs held the largest market share in the total HPGR market in terms of revenue.

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In recent years, the global mining industry has been facing challenges due to investment restraints, slowdown in commodity markets and over-capacity, especially in the developed economies such as U.S. and West European countries. The current scenario in mining industry suggests that the market is mainly driven by manufacturing and mining activities in developing nations such as China, India, Indonesia, Mongolia, Chile, Peru, and Brazil among others. For the HPGR market, Asia Pacific had largest share in terms of revenue in 2013. The HPGR market in Asia Pacific is slated to grow at a considerable rate and is expected to continue dominating the market during the forecast period. Apart from this, increasing investments across Africa and Latin America in mining activities are emerging as an attractive opportunity for HPGRs.

The global HPGR market was concentrated in 2013. The key players in the HPGR market include Thyssenkrupp Industrial Solutions AG (Polysius AG), Koppern Group, FLSmidth Co. A/S, KHD Humboldt Wedag International AG, CITIC Heavy Industries Co. Ltd., and Metso Oyj.

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