Metris HPGR ACE delivers model predictive control for High Pressure Grinding Roll (HPGR) comminution circuits in mining and mineral processing operations. By applying BrainWave® MPC to the key HPGR operating variables, HPGR ACE reduces product size variability, optimizes specific energy consumption, and improves throughput consistency — delivering more predictable downstream leach and flotation performance.

HPGR technology is widely used in mining for the energy-efficient comminution of hard, competent ores before further processing. The HPGR applies intense pressure between two counter-rotating rolls to create inter-particle crushing, producing a product with a high proportion of micro-cracks that improves downstream leachability and grindability. Consistent HPGR performance depends on maintaining the correct relationship between roll gap, pressing force, feed rate, and moisture content under varying ore hardness and feed size conditions.

HPGR ACE coordinates roll gap control, specific pressing force management, and feed rate adjustment to maintain the target product P80 and mass flow through the circuit. By compensating proactively for ore variability, the system reduces overgrinding, minimizes specific energy consumption, and maintains stable throughput to downstream grinding or leach circuits.