High pressure grinding rolls

HRC™ 8
HRC™ 800
HPGR for high-quality manufactured sand and aggregate
production
Whether you are looking to produce high-quality manufactured sand, turn waste materials into sellable products or work
with difficult feed materials, the Metso HRCTM 8 and HRCTM 800 are the perfect machines for those applications.
Produce manufactured sand Turn waste materials into high-quality sellable products fines content without creating any packing or crusher overload.
The demand for economical and efficient ways to produce These machines are suitable for specific difficult applications
crushed sand is growing, as natural sand deposits located where materials that are waste from the crushing and screening Maintain high-quality with low cost per ton
near growth centers are being depleted and environmental process can be reprocessed to obtain good HRC 8 and HRC 800 produces the highest quality products
regulations are getting stricter. As a result, manufactured sand high-quality sellable products. with improved shape and relatively low energy and wear parts
is becoming a high-demand commodity. consumption. It delivers unbeatable performance in aggregates,
Overcome difficult applications manufactured sand, mining, industrial minerals and recycling
HRC 8 and HRC 800 takes manufactured sand to the next HRC 8 and HRC 800 design offers a unique and efficient applications with the lowest possible cost per ton.
level by providing a simple yet robust design, a low cost of crushing effect and can work in difficult applications with low
operation, and improved product shape and gradation. crushability feed materials (very hard), moisture, clay and high
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Less power consumption in sand
production compared to other
technologies for the same volume of
net product

up to 50% less

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 Robust HRC™ high pressure grinding
rolls (HPGR)
HRC™ 8 and HRC™ 800 are based on a high-pressure grinding roll (HPGR)
technology and are optimized for the demanding requirements of high-
quality manufactured sand and aggregates production.

HRC 8 and HRC 800 uses a method of inter-particle Versatile product gradation
comminution by drawing in a bed of material between two HRC 8 and HRC 800 offers easy and very versatile
rotating rollers. They compress the feed material between adjustable product gradation. The product gradation does
two rotating rollers, one of which is in a fixed position not depend much on the adjusted space between the rolls
and another roller that is floating. The two rotating rollers but on the chock feed condition and the constant pressure.
generate such a high pressure that it grinds the feed Pressure can be adjusted to regulate the product gradation
material to the desired smaller grain size. curve.

Higher availability & reliability This feature facilitates the customer to meet any product
HRC 8 provides an optimal crushing force with the use of gradation specification requirements in manufactured sand.
adjustable hydraulic cylinders and variable speed.
Energy efficiency
One can also adjust the speed and pressure of HRC Thanks to the ability to handle a continuous stream of
depending on the material conditions and application material, HPGRs are considered to be energy efficient
requirements. Pressure influences the reduction ratio and grinding machines in general.
speed influences the throughput.
HRC equipment goes a bit further. They direct the feed
The feed chute arrangement allows for the crushing cavity to material straight to the crushing zone and adjust the speed
operate under chock feed condition all the time optimizing and pressure in order to avoid wasting energy.
the rolls wear pattern and even load distribution on the
surface of the rolls. HRC 8 and HRC 800 can achieve energy efficiency up to
90% depending on the process configuration and product
The patented Arch-frame differentiates from traditional specification. This is possible because the HRC technology
HPGR equipment with its anti-skewing features that eliminate can minimize the circulating load to the crusher compared to
variation in product gradation and prevents bearings from other technologies in similar applications.
being damaged due to misalignment.
Environmentally friendly
HRC 8 and HRC 800 are designed to be environmentally
friendly with minimized noise and dust emissions.

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Robust HRC™
high pressure
Higher availability &
grinding rolls reliability

Reduced operating costs

HRC grinding rolls are known for the robustness and
longevity of wear components. It gives excellent wear life of
the rolls and less downtime with easy replacement of rolls.
Reduced operating
The anti-skewing arch frame design prevents bearings from costs & less downtime
being damaged due to misalignment, which will also save
effort and resources.

Safe and ease of maintenance

The key to improving safety during maintenance is to
minimize the need for maintenance.

With HRC HPGR, downtime has been reduced by using

robust components and high-pressure rock-on-rock
crushing enables long wear life of the manganese tires and
Safety & ease of
energy-efficient operations. maintenance
The patented split shaft allows for the tires to be replaced
quickly, without full machine disassembly, making the
changeout of wear components easy and effortless.

Crusher is also encapsulated with guards to eliminate the

risk for the operators during operation - operator cannot
access the moving parts. In case of uncrushable in the feed
accumulator in the hydraulic system avoid breakdown.
Flexible operating
The required service is made easy with a simple design that parameters
allows changing the critical parts easily.

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 Designed for the aggregate industry

HRCTM 8 and HRCTM 800 high pressure grinding rolls are the ideal
machines for the aggregate industry where fine products must meet a
defined end-product specification.

Ideal for producing manufactured sand Turn difficult feed into a valuable product
HRC 8 and HRC 800 are particularly productive in producing HRC 8 and HRC 800 crushers work in applications where
manufactured sand for asphalt and concrete production. other crushers cannot. They can handle small in size and
The quality of manufactured sand can be adjusted and very difficult feed materials, that are difficult to process
optimized, which reduces the amount of cement and asphalt by any other technology, with high abrasiveness, low
in the mix of concrete or asphalt. crushability, moisture, fines, even clay and turn them into a
valuable product.
HRC 8 and HRC 800 deliver a perfectly cubical shape
for concrete and asphalt sands. They also produce more Some of those products may need a further process to
fines with fewer unwanted microfines in the final product remove the excess of ultra fines (<0.075 mm) already in the
compared to other technologies in manufactured sand. feed, wet or dry, depending on the final use of the end
product.
• Ideal shaping (cubical or angular)
• Gradation according to customer needs Soft and hard rock applications
• Fine particles • Manufactured sand
• Gravel pits, pea gravel
Turn waste materials into products • Asphalt sand
These machines are suitable for specific difficult applications • Concrete sand
where materials that are waste from the crushing and • Industrial minerals
screening process (materials with low mass gradings, difficult • Recycling
to crush by a VSI or other types of compression crushers) • Re-crushing waste materials
can be reprocessed to obtain good high-quality sellable
products.

In some applications, the non-saleable waste materials can

be processed by the HRC 8 or HRC 800 to correct the
gradation curve and particle shape, converting them into
high-value sellable products.

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 1. Turn waste materials into sellable products
Improved shape

2. Improve the efficiency of the (existing)

sand manufacturing process
Better reduction and less circulating load

3. Optimize the cost of the sand

manufacturing operations
Lower energy and wear consumption

4. Cope with tough applications and

conditions
Small top feed sizes and a high % of fines

This solution is
in the feed

Planet Positive
5. Do all the above in an environmentally
friendly way
Minimized noise & dust
Planet Positive portfolio focuses on the most impactful
technologies in our sustainable offering. Out of four
focus areas, this solution creates value and positive
impact on the following:

Energy efficiency and emissions

HRC 8 and HRC 800 consume less energy than any
other technology in the same application to obtain the
same net product volume.

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HRC equipment can convert quarry waste into a
sealable product, reducing the pollution from earth
moving equipment doing the double handling of
those large volumes of waste materials. At the same
time, since it replaces the use of natural sand, it saves
the loading and hauling of natural sand to the cities
avoiding fuel burning and pollution.

reasons to select
Even more, HRC equipment produces such good
quality sand that it reduces the demand of water and

HRCTM 8 & HRCTM 800

cement in the concrete mix, and also in asphalt.

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 HRC crusher automation
HRC 8 and HRC 800 are available with Metso crusher Continuous monitoring and control minimize risks
automation which controls and monitors crusher Metso HRC automation helps to prevent costly downtime
and ancillary equipment helping to achieve the best by monitoring operating pressure, temperatures, rollers RPM
performance and protection to the machine maximizing and other key parameters in your crusher. The protection
uptime and safety. Crusher automation is provided as a is activated in steps, starting from informative warnings,
complete package, including fully automated hydraulic then progressing to inform and log data for operational
circuit controls, hydraulic unit motor starters and electrical improvement, troubleshooting, and eventually shutting down
cabinets. The proven and tested software can be set up the crusher to protect it whenever needed.
for application specific conditions, and the whole system is
not just easy to install and commission, it’s easy to use, too. Consistent performance
In addition, the equipment can be controlled by remote Crushing optimization helps to provide constant throughput
control for improved safety and comfort. at all times. IC crusher automation provides instant process
information to the operator. The automatic feed rate control
helps to maintain the optimal material level in the crusher,
which helps you to achieve and maintain the best performance
at all times.
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Parts and services

Genuine Metso OEM wear and

spare parts are the best choice to
minimize maintenance issues and
increase longevity.

Our global distribution logistics network ensures that Metso

OEM spare and wear parts are available when you need
them.

With both standard and engineered-to-order parts, Metso

can ensure that you have the support your crushers need.

Spare parts Wear parts

• Frame parts • Rolls
• Shafts • Cheek plates
• Mechanical Seals • Liners
• Hydraulic systems

Helpful service tools

HRC 8 and HRC 800 are delivered with safe-to-use tools
for maintenance tasks. This includes a shaft lifting tool, shaft
removal tool for quicker and safe shaft replacement. All
these tools are standard delivery from Metso.

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 HRCTM 8:
Simple design for maximum performance
Hydraulic cylinders

Feed chute
Accumulator assembly
(hidden)

Arch frame

Reducers

Base
Shaft assembly

Roll Dimensions Installed power Unit weight Maximal Roll Top size* Typical Capacity** Max specific press Crusher dimensions
Dia x Width Speed (RPM) force LxWxH

800 x 500 mm 2 x 75 kW 12.9 t 30.2 32 mm 60 - 90 tph 2.5 N/mm2 2.8 x 3.9 x 1.7 m

31.5” x 20” 2 x 100 HP 28,440 lbs 30.2 1.25” 66 - 99 Sh.T 362.6 psi 110” x 153” x 66”

* Varies per application.

** Varies per application, values based on nominal equipment speed, values are for machine throughput.

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HRCTM 800:
Higher pressure for more reduction
Shaft assembly
including roll
Hydraulic cylinders
Covers

Electric motor

Reducers Arch frame

Torque arms
Base

Roll Dimensions Installed power Unit weight Maximal Roll Speed Top size* Typical Capacity** Max specific press Crusher dimensions
Dia x Width (RPM) force LxWxH

800 x 500 mm 2 x 110 kW 18 t 30.2 32 mm 86 - 120 tph 4.5 N/mm2 2.7 x 4.3 x 2.5 m

31.5” x 20” 2 x 147 HP 39,683 lbs 30.2 1.25” 95 - 132 Sh.T 652.7 psi 106” x 169” x 98”

* Varies per application.

** Varies per application, values based on nominal equipment speed, values are for machine throughput.

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 HRC:
Typical installation
Saku Pursio

Max feed size 30 mm

Waste SD 2.7 t/m3 Coarse SD 2.7 t/m3
fractions Cr 35 % sand Cr 35 %
granite Abr 1398 g/t granite Abr 1398 g/t
t/h

Warnings
Humidity max. not really a
20 m3 limitation for the crusher %, but for
the screen yes normal condition
Application must be validated at the
order phase

HRC 8
Speed 28.2 rpm
Pressure 131 bar

Compact CVB1845-2
Sep 3.2 mm
Sep 2.4 mm

Bypass 0-25-50-75-100 %

Concrete sand:
4.75 => 100%
2.4 => 80/100%
Fine sand 1.18 => 50/80%
0.6 => 25/60%
0.3 => 10/30%
0.150 => 2/10%

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HRC with VSI combination to increase sand production in
existing circuit Saku Pursio

Feed 600 mm coarse Material characteristics considered:

Metrial: granite
Solid density: 2.7 t/cum
Crushability: 57 %
Contamination: free from clay
Moisture: 2 %

Existing
grizzly feeder
Existing Nordberg® C106 jaw crusher Add-on Metso HRC 8 high pressure
grinding roll crusher
Existing primary product
stockpile - 4000T Proposed
surge bin
Slot sizer Existing
Metso
vibrating feeder Metso
TKP10-20 vibrating feeder
Existing
Existing Nordberg® Barmac TKP8-17
tunnel feeder B7150SE 840DTR
2xTKP10-20 VSI crusher with
IC 3 automation
Existing Nordberg® GP220
cone crusher (200 kW) Metso HRC8
IC50C crushing automation high pressure
grinding roll crusher
Motors: 2 x 75KW

Quarry fines should

always be tapped
Existing Metso Metso
compact CVB screen TS 3.3 screen
2060-4 deck

Sand bin

Main product
manufactured sand
Product Product
12 - 24 mm 5 - 12 mm 13
 HRC in open and closed circuit

100
100
Open circuit Closed circuit
90
90
Feed material Feed material
Amphibole 0-30 mm, 80 Amphibole 0-30 mm,
80
crushability 32% crushability 32%

70 70

60 60

% passing
% passing

50 50

40 40

30 30
1 N/mm2 1 N/mm2
2 N/mm2 1.5 N/mm2
20 20
1.5 N/mm2 2 N/mm2

10 2.5 N/mm2 10 2.5 N/mm2

Avarage Feed Avarage Feed
0 0
0,01 0,1 1 10 100 0,01 0,1 1 10 100
Sieve Size Sieve Size

* Curves shown here are for indicative and display purpose only. Those may vary as per actual process and site condition.

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Case: LOGO Durango, Mexico

HRC 8 increase
sand production
and ensure
flexibility

Challenge Solution Results

Increase sand production by recrushing 19 mm and 12 mm HRC 8 was introduced in the circuit to perform a demo by HRC 8 process adjustable to customer’s sands needs, quality
gravel rock which is completely unsalable waste material for feeding 19 mm top rock size feed from the stockpile: 60% < and production volume, it depends on the combinations of
customer. Customer plant was not producing enough sand 16 mm on feed, very clean with no fines below <15 mm. the crusher setting parameters.
for internal needs, and they were buying it from competitors.
Recirculating +6 to -9 mm rock with ST 3.8 Double deck Flexible operation, especially when there is not enough
To increase and ensure asphalt sand fines (200 mesh /0.075 screen helped to increase sand production. quantity of fines present in the feed, closed circuit operation
mm) content to a minimum 15% (in Mexico asphalt plants with oversize recirculation helps to fill up voids in crushing
want to get filler together with sand). Conducted various tests with different rolls speed, start chamber, also reducing the start gap helps in the process.
gap and pressure to achieve the product gradation and
Deliver consistent quality of produced sand for concrete and production rate as per customer requirements. Not too many parameter options can be adjusted to control
asphalt sand to reduce cement and asphalt consumption the ultra-fines production, this characteristic depends more
respectively. Metso HRC technology is a very versatile machine to on the feed material properties, but with the wide range of
minimize or maximize the <200 mesh (0.074 mm) content operating pressures, the HRC technology is the best option
in the final product and to achieve different manufactured for those requirements.
sand product gradations adjusting the operating gap and
specially the operating pressure.

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Metso is a frontrunner in providing sustainable technologies, end-to-end solutions
and services for the aggregates, minerals processing and metals refining industries

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