OUTOTEC HIGMILL – ENERGY-EFFICIENT

HIGH-INTENSITY GRINDING
With global ore grades declining and the demand
for commodities continuing to increase, mining
companies require new ways to cost-effectively
BENEFITS
• High energy efficiency with patented
liberate minerals and maximize recovery levels. GrindForce rotor technology
The Outotec HIGmill® is an advanced and • Reduced CAPEX with small footprint
and simple flow sheet
energy-efficient fine and ultra-fine grinding • Simple operation with multiple control
solution that relies on proven technology. The modes
• High availability with long intervals
mill takes advantage of gravitational forces and between maintenance shutdowns
GrindForce™ rotor technology to produce a finer
grind for mineral liberation.
2

AN INTRODUCTION TO THE OUTOTEC HIGMILL

The Outotec HIGmill comprises a mill body, a shaft with

grinding discs, shell-mounted counter rings, and a
gearbox and drive. Grinding beads fill approximately 70%
of the grinding chamber, with rotating discs stirring the
charge and grinding taking place between the beads by
attrition. Depending on the application, there can be up to
30 discs or grinding stages.

Feed slurry is pumped into the mill via a bottom

connection, and as the flow transfers upwards it passes
through each consecutive grinding stage. The final FINISHED FINISHED
product discharges in an open atmosphere at the top PRODUCT PRODUCT
of the mill. The open design lowers costs and enables
a simpler control, valving, and instrumentation system
compared to pressurized vessels. The tall, narrow mill
body arrangement significantly increases grinding
efficiency by ensuring that the grinding media is evenly
distributed and that mineral particles remain in constant
contact.

Classification is performed automatically at each stage

of the grinding process. Larger particles are forced
to the periphery, where the highest-intensity grinding
occurs, while smaller particles travel up the mill to the
next grinding stage, preventing overgrinding. This multi-
stage arrangement eliminates the need for external
classification and recirculation, providing a very steep LOW-INTENSITY HIGH-INTENSITY
particle size distribution after a single pass. GRINDING ZONE GRINDING ZONE
(fine particles) (coarse particles)
Applications
The HIGmill is suitable for a wide range of fine and ultra-
fine grinding applications, including:
• Concentrate regrinding, including gold, copper, moly, GRINDFORCE STATIC COUNTER
ROTORS DISCS
platinum, lead, and zinc
• Iron ore fine grinding
• Tailings regrinding
• Slag and fly ash grinding for recovery of recyclable
metals
• Tertiary grinding

SLURRY AND GRINDING

MEDIA FEED

The multistage arrangement of

The HIGmill’s tall, narrow mill body arrangement ensures
that the grinding media is evenly distributed and that mineral

the HIGmill eliminates the need

particles remain in constant contact.

for external classification and

recirculation, providing a very
steep particle size distribution
after a single pass.
 3

ENERGY EFFICIENT AND PROVEN TECHNOLOGY

Proven technology
Since its introduction more than 50
years ago, HIGmill has been used
in a broad range of applications
including the ceramics, pigment,
paint, paper, and pharmaceuticals
industries. More than 200 units have
been installed around the world,
including several 5000 kW units that
have been in operation for over 20
years. These are the largest fine-
grinding mills in the world.

Efficient GrindForce technology

Invented for hard-rock applications,
the patented GrindForce system is
unique to the HIGmill and allows
for optimal shear-force mixing and
volume utilization – leading to more
efficient grinding. Vanes on the
GrindForce rotor surface ensure that
the velocity of the rotating rotors and
the media bed they are in contact
with is approximately equivalent,
eliminating any shear or slippage
between the media bed and the rotor
surface, reducing wear.

Compared to conventional flat-

surface discs, the vaned rotors also
enable a significant improvement
in grinding efficiency to the target
grind size thanks to the improved
media agitation and improved power
transfer between the rotor surface
and media bead mass.

GrindForce’s vaned rotors enable a significant improvement in grinding

efficiency to the target grind size.

100.0
Specific Grinding Energy (kWh/t)

10.0

1.0
10.0 Particle size (µm) 100.0
GrindForce rotor Flat discs

Specific Grinding Energy (kWh/t) versus the particle size (P80, µm) showing consistent
reduction in energy consumption of approximately 30% for the GrindForce rotors compared
to flat discs.
4
 5

COMPACT LAYOUT AND EASY OPERATION

A compact, simple installation and process Variable-speed drive system for precise control
The typical HIGmill flow sheet for regrind circuits is HIGmills are powered by squirrel cage induction motors
simple and straightforward. Regrind feed from flotation and a variable speed drive (VSD) system. The VSD system
goes to a scalping cyclone. The cyclone overflow bypasses is used for starting the mill under load as well as for
the HIGmill and the cyclone underflow is pumped into the speed adjustment during operation. The system allows
mill, where the target product size is produced in a single precise control precise control over product size. This in
pass. As there are no recirculating loads, the pumps, turn enables greater stability for downstream processing
piping, and mill cylinder volume can be significantly downstream processing by adjusting for upstream
reduced. The layout of the plant is optimized through the variability such as feed rate or feed size. The VSD
HIGmill’s small footprint with a vertical orientation and system also allows for a reduction in operating costs by
high power intensity. optimizing the rotor speed.

Quick maintenance with long service intervals Grinding media addition

The HIGmill has been specifically designed for quick A fully incorporated grinding media handling and storage
and safe maintenance. A significant cost benefit is system is included. The media is added automatically to
that an overhead crane is not required during routine the grinding chamber to maintain the required filling set
maintenance. With the mill installed on structural point and specific energy input.
supports, the main shaft and shell liners are lowered
and lifted using specially designed tools, including a Stirred milling for particle-size reduction utilizes an
maintenance trailer. abrasive-type grinding mechanism. Ceramic grinding
media is resistant to abrasion and is an ideal media for
For maintenance purposes, the grinding media can stirred milling, especially when compared with steel.
be drained from the mill without opening the grinding
chamber, reducing manual handling and minimizing
safety risks for maintenance personnel. Media is removed
safely by opening a drain valve at the base of the closed
grinding chamber and allowing it to flow into collection
bags or a transfer hopper for reuse.

Open-circuit configuration
Because it has multiple grinding stages in a single unit,
the HIGmill operates in an open-circuit configuration
and without recirculating loads. A pre-scalping cyclone
prior to the mill can remove the fines from the feed so
only the coarse particles are passed to the HIGmill. The
mill feeds in one end and discharges at the other end,
with slurry passing through the multiple grinding zones
with no particle short-circuiting and no requirement for
recycle streams. The HIGmill discharge is the final correct
particle size for the downstream process. Since the mill
can achieve the target product particle size in an open,
single pass, this results in significant total installed Capex
cost savings.

Maximized process efficiency with on-line

particle-size control
Outotec HIGmill offers a unique on-line control solution
which utilizes an Outotec PSI® on-line particle size
analyzer to automatically measure the product particle
size. The particle size measurement is then used
to adjust the target for the Specific Grinding Energy
(the amount of energy per unit of material needed to
achieve the final product size). This control scheme will
provide an extremely consistent product particle size to
downstream processes regardless of variability in the feed Ceramic grinding media is resistant to abrasion and ideal for
particle size. stirred milling.
6

TESTING, SCALE-UP, AND DELIVERY

Testing
Outotec operates several mobile and stationary HIGmill
test units with different mill sizes, and these testing
services are available globally. Baseline test work with the
HIG5 (5 kW/6-liter) test mill requires a minimum of 4 kg
of dry test material. On-site testing is possible with the
HIG25 (25 kW/25-liter) containerized mobile test unit or
HIG75 (75 kW/200-liter) pilot mill.

The stationary test units are located at the Outotec

Research Center in Finland. Additional testing can be
performed at our research center, which develops metal
processing technologies, processes, and equipment. Our
expertise covers the entire processing chain from ore to
metal, starting with mineralogical analysis.

Scale-up
Outotec utilizes proven 1:1 scale-up methodology from
laboratory to production mills, backed by experience of
sizing more than 200 mills in the range of 75 to 5000 kW.
The exact same grinding mechanism, power intensity, tip
speed, media size and type, slurry density, and continuous
relative flow rate are used in the test work. This results in
the same Specific Grinding Energy (SGE, kWh/t) to achieve
the target grind size (P80, µm) as is achieved in full scale.

Delivery
HIGmills are typically pre-assembled in the factory and
shipped in standard shipping containers where applicable.
The mill sections are preassembled and prepared for
installation on site. This design concept reduces site labor
costs and ensures quick installation.

A typical delivery includes:

• Scalping cyclone with feed pump
• Feed, mixing, and storage tanks
• Feed pump
• Media addition systems for grinding media
• Motor and drive components
• Gearbox and oil supply system
• All instrumentation and controls, as well as motor
control center
• PLC control with human machine interface (HMI)
• Vertical process package engineering and plant model
 7

On-site testing is possible with the containerized mobile test unit.

SERVICES AND SOLUTIONS THAT BOOST

Finland, March, 2019

YOUR PERFORMANCE AND PRODUCTIVITY
Maintaining the efficiency of your operations and protecting your profitability
with the right technology is critical to staying ahead of the competition. As your
service partner, Outotec ensures that our solutions have the maximum impact on
performance and productivity throughout your plant’s life cycle.

We are committed to understanding the unique

business needs of your mineral processing operation.
We collaborate with you to develop a safe, sustainable,
and reliable service solution based on our deep process BENEFITS
knowledge, leading technologies, and operational and • Improved health and safety
maintenance expertise. • Improved environmental efficiency
Full service portfolio • Improved equipment and process
Our extensive service portfolio and customized solutions
efficiency
cover all phases of your equipment’s life cycle – from • Decreased operating cost
maintenance inspections and spare parts to modernization • Improved capital efficiency
and upgrades. Your tailored performance solution will
be delivered with mutually agreed targets and shared
responsibilities to meet your long-term goals. We can build
solutions for individual projects or ones based on broader
service agreements.

Outotec has locally available and experienced operation

and maintenance (O&M) support personnel. Outotec O&M
ASSESS
support services is a complete solution package under
which we take extended responsibility for the condition and
performance of the equipment after project delivery.
YOUR CUSTOMIZED
Outotec services PERFORMANCE SOLUTION
• Maintenance Services DESIGN
VERIFY

• Spare and Wear Parts

• Upgrades
• Advisory Services
• Operations Services
• Remote Services
• Training Services

D ELIV E R

Outotec provides leading technologies and services for the sustainable use of Earth’s natural resources. As the global leader in minerals
and metals processing technology, we have developed many breakthrough technologies over the decades for our customers in metals
and mining industry. We also provide innovative solutions for industrial water treatment, the utilization of alternative energy sources and
the chemical industry. Outotec shares are listed on NASDAQ OMX Helsinki. www.outotec.com

Outotec® is a registered trademark. Copyright © 2019 Outotec Oyj.  All rights reserved.