High pressure grinding rolls (HPGR) are used for size reduction of ores and rocks. They compress the feed material between two rotating rollers, in which one of them is in fixed position and another is in floating. HPGR has found applications typically in diamond extraction. HPGR provides flexible crushing solutions as it is suitable for both new installations and upgrades in the mining and construction industry. Moreover, it is a highly energy-efficient technology for comminution and involves short-term exposure of raw materials such as iron ore to very high pressure. This pressed material can be directly fed to a ball mill of a particular size, thereby making it possible to reduce the specific power consumption of the entire mill system and to increase the throughput of the ball mill. HPGRs are expected to replace semi-autogenous (SAG) mills and ball mills in due course of time.
The global high pressure grinding roller (HPGR) market is estimated to account for US$ 547.6 Mn in terms of value by the end of 2027.
Market Dynamics- Drivers
1. Increasing demand for high-efficiency and low emission comminution solutions is expected to drive growth of the global press grinding roller (HPGR) market during the forecast period
Comminution is the reduction of solution materials from the average particle size to smaller particle sizes. It is done by crushing, grinding, cutting, vibrating, or other processes. Comminution is the highest energy-consuming process in mining activities. According to the Coalition for Eco-Efficient Commination (CEEC), the grinding and crushing process alone consumes an average of 53% of the total energy consumed on the mining site and accounts for more than 10% of the total mining cost. Currently, mineral processing plants are operating below the optimal energy efficiency levels and hence are exposed to increased costs related to high energy consumption and carbon constraints, which is the amount of carbon emitted in the environment. As a result of this, mining industry is compelled to adopt novel technologies such as HPGR. It offers increased finesses and reduces the downstream energy requirements in ball mining and macro-cracking. Therefore, these factors are expected to drive growth of the market during the forecast period.
2. Declining ore grades are expected to propel the global high pressure grinding roller market growth over the forecast period
The average grade of ores is declining worldwide, owing to continuous exhaustion of high-grade ore bodies. Besides this, the value generated by obtaining the desired mineral after mineral processing is declining. As a result of this, the operating cost has increased, while at the same time, cost of commodities and minerals has not increased in a similar proportion. HPGR offers better solution to these challenges, providing better output. Hence, these factors are expected to propel the global high pressure grinding roller (HPGR) market growth over the forecast period.
APAC held dominant position in the global high pressure grinding roller (HPGR) market in 2019, accounting for 33.3% share in terms of value, followed by North America, Europe, and Row respectively.
Figure 1: Global High Pressure Grinding Roller (HPGR) Market Share (%), in terms of Value, By Region, 2019
Market Dynamics- Restraints
1. High capital cost associated with HPGR is expected to restrain growth of the global high pressure grinding roller (HPGR) market during the forecast period
Installing HPGR system requires a significant capital investment. It has been observed that HPGRs can lead to increased material handling and it also generates increased quantity of dust. Thus, these factors are expected to restrain growth of the global high pressure grinding roller (HPGR) market during the forecast period.
2. Constant maintenance is expected to hinder the global high pressure grinding roller (HPGR) market growth over the forecast period
Although HPGR system offers numerous advantages, it still requires frequent maintenance and repair operations. Furthermore, frequent maintenance and repair operations can increase the overall cost of the entire system, which in turn, is expected to hinder the global high pressure grinding roller (HPGR) market growth in the near future.
1. Rising use of HPGR in hard rock mining can present lucrative growth opportunities
HPGR is becoming increasing popular for hard rock treatment due to rising energy and steel media costs. Furthermore, advent of wear abetment technology and significant design enhancements has led to successful implementations and pilot demonstrations HPGR on extremely tough ores. HPGR pilot plant demonstrations at the Newmont Lone Tree gold mine in Nevada, the U.S. in 2009, Boddington Gold Project in Western Australia in 2010, and the use of HPGR technology by the mining company Anglo American Platinum PPL at its Mogalakwena platinum mine are some such instances.
2. Base metal liberation segment can provide major business opportunities
HPGRs are majorly operational in diamond mines and iron ores. However, it is used in combination with ball mills or as a standalone device, it can offer numerous advantages such as fineness, quality of the ultimate product, and improved throughput. Hence, the HPGR comminution solution is expected to witness significant growth in base metal liberation. It can help in mining metals such as copper, nickel, lead, and nickel.
Figure 2: Global High Pressure Grinding Roller (HPGR) Market Value (US$ Mn), 2017 - 2027
The global high pressure grinding roller (HPGR) market was valued at US$ 345.0 Mn in 2019 and is forecast to reach a value of US$ 547.6 Mn by 2027 at a CAGR of 6.2% between 2020 and 2027.
1. Research and development activities among market players
Key companies in the market are focused on research and development activities, in order to enhance the product portfolio. For instance, in May 2012, FLSmidth launched CataMax, a catalytic filter solution with the capability of reducing organic hydrocarbon emissions. In June 2014, ABB launched my Location Intelligence to provide increased personal safety and production efficiency.
2. Inorganic growth strategies by key market players
Major market players are involved in organic strategies such as collaborations and partnerships, in order to gain a competitive edge in the market. For instance, in March 2013, Koppern Group partnered with Outotec Corporation. This helped the company in strengthening its comminution product range, which includes high intensity grinding (HIG) mills, semi-autogenous (SAG) mills, pebble mills, ball mills, and autogenous (AG) mills. In April 2013, KHD Humboldt Wedag International AG partnered with Weir Minerals for HPGR technology due to which the company would be receiving royalty payment on sale of HPGRs and its equipment.
Value Chain Analysis
The raw materials required to manufacture HPGR are metal, steel, rubber, plastic and other basic materials. A number of sub-components required for the manufacturing process are produced by tier 2 suppliers operating on small margins. Tier 1 suppliers are closely integrated with HPGR manufacturers for the production of specific components such as drive systems. The original equipment manufacturers (OEMs) purchase raw materials from global and domestic suppliers. Individual parts required for manufacturing HPGRs are either produced, or purchased and organized to form new machinery by OEMs. Research and development activities are very important to lower production costs and reduce the use of wearable parts in HPGRs. Apart from this, research and development is also essential in customizing the HPGR as per the customer’s requirements. Finished goods are either deployed directly or via dealers at the mining sites. In the HPGR industry, after sales service is a very crucial part of the value chain, as buyers rely heavily on the OEM maintenance services.
Global High Pressure Grinding Roller (HPGR) Market - Impact of Coronavirus (Covid-19) Pandemic
Metal and mining industry has been effected by the COVID 19 in many ways. First of all key players operating in the industry closed their production sites in order to reduce the spread of COVID 19. Furthermore, the demand of metals such as copper, iron and other remained low as automotive and electronics industries production was partially shut down particularly in India and China. Considering the negative effects on the mining industry, global high pressure grinding roller (HPGR) market witnessed shrink in the business, and it is expected to recover slowly over the year.
Key players operating in the global high pressure grinding roller (HPGR) market are FLSmidth & Co. A/S, Metso Oyj, Koppern Group, CITIC Heavy Industries Co. Ltd. (CITIC HIC), ThyssenKrupp Industrial Solutions AG (Polysius AG), SGS S.A., KHD Humboldt Wedag International AG, Outotec Oyj, and ABB Ltd.
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