As ore grades decline and demand grows for critical minerals such as copper and lithium, mining operations are under increasing pressure to process more material while managing energy use, maintenance costs and emissions. High Pressure Grinding Rolls (HPGRs) have become an important part of this response, offering an energy-efficient comminution solution in many mining and mineral-processing circuits.
However, the operating environment inside an HPGR is exceptionally demanding. Bearings must withstand immense loads generated between the grinding rolls, alongside abrasive contamination, vibration and difficult lubrication conditions. When these factors are not adequately controlled, wear can become the dominant cause of premature bearing failure – affecting equipment availability, maintenance planning and overall plant performance.
Schaeffler has developed a portfolio of products and services specifically for HPGR applications in the mining and cement industries. The offering is designed to help operators improve reliability throughout the bearing lifecycle, from component selection and installation to condition monitoring, maintenance and remanufacturing.
Addressing the main HPGR challenges
Contamination is a persistent threat in mineral-processing environments. Fine abrasive particles can enter the bearing arrangement and mix with lubricant, accelerating wear and shortening service life. To help address this issue, Schaeffler offers sealed spherical roller bearing solutions that provide enhanced protection against environmental contamination while also reducing grease consumption.
The company’s spherical roller bearings in X-life quality are engineered for increased wear resistance, reduced friction and lower operating temperatures. Their optimised internal design supports improved load distribution and can contribute to a longer operating life in demanding conditions. Profiled rollers further reduce edge stresses that may develop under high-load and wear-intensive operating conditions.
For HPGR arrangements that require particularly high radial-load capacity, Schaeffler also offers four-row cylindrical roller bearings in X-life quality. These bearings are designed to withstand the substantial loads generated during grinding, while robust cage designs support reliable roller guidance and therefore a high dynamic capacity.
Purpose-built solutions for harsh operating environments
A key product highlight for HPGR applications is Schaeffler’s spherical roller bearing featuring the special H266 design. Developed for demanding operating conditions, the bearing incorporates a range of practical and performance-oriented features. These include profiled rollers, radial lifting holes and eye bolts, which support safer handling during mounting and dismounting. In addition, six lubrication holes in the outer ring ensure reliable and uniform lubricant distribution.
The H266A retains all the features of the H266 design and additionally features integrated seals to help protect the bearing from contamination while preserving the advantages of the specialized bearing design.
The H266B combines all the features of the H266A with pre-applied Arcanol LOAD1000 grease, providing a ready-to-use bearing solution for demanding HPGR applications.
Accurate installation is equally important to the bearing performance. Factory-measured radial internal clearance markings on the outer ring assist maintenance teams in setting the bearing correctly, helping to simplify installation and support dependable operation from the outset.
Lubrication designed for HPGR duty
Lubrication presents another major challenge in HPGR applications. At low speeds and high loads, the lubrication film can become thinner, increasing the risk of mixed friction and wear. The lubricant must therefore provide robust protection under conditions that are far more severe than those found in many conventional industrial applications
Arcanol LOAD1000 bearing grease has been developed for harsh HPGR operating conditions. Its blend of base oil, thickener and additives is formulated to protect bearings exposed to extreme loads and contamination risks. According to Schaeffler, the grease has demonstrated up to six times better wear protection than the DIN 51819 industry standard in FE8 testing, and it is OEM approved. By combining a purpose-designed bearing arrangement with appropriate lubrication, operators can work towards reducing wear, improving maintenance intervals and maintaining more consistent equipment performance
Supporting availability throughout the lifecycle
Reliable HPGR operation depends on more than the bearing itself. Schaeffler’s Industrial Lifetime Solutions portfolio provides complementary support for installation, maintenance and operational monitoring. This includes mounting tools and services, condition-monitoring solutions, specialty lubricants and technical support intended to help maintenance teams make informed decisions before developing issues lead to unplanned downtime.
Condition monitoring can provide valuable insight into the health of critical rotating equipment, allowing maintenance activities to be scheduled more effectively. In high-throughput mining and cement plants, this proactive approach can help reduce operational disruption and support a more predictable maintenance strategy.
Remanufacturing as a sustainable alternative
Sustainability is an increasingly important consideration in mining and cement operations, where equipment reliability and resource efficiency are closely linked. Extending the life of critical components can reduce material consumption, waste and the environmental impact associated with replacement parts.
Schaeffler’s remanufacturing service offers operators an alternative to purchasing new bearings where technically viable. By restoring suitable bearings, companies can reduce delivery times and costs while lowering the carbon footprint associated with producing and transporting replacement components. This makes remanufacturing a practical lifecycle solution for demanding HPGR applications.
The use of sealed bearing designs and advanced lubrication can further support sustainability goals by reducing grease consumption and waste. In addition, ductile-iron cages provide high toughness, wear resistance and efficient damping without lead content.
As HPGR technology continues to play an important role in the processing of gold, copper, lithium and other critical minerals, the reliability of supporting equipment will remain essential. An integrated approach – combining high-performance bearings, sealing, lubrication, monitoring and remanufacturing – can help operators protect availability, reduce wear and improve the long-term efficiency of their grinding circuits.
For mining and cement producers, the objective is clear: keep critical equipment operating reliably, safely and sustainably, even in the harshest processing environments.
When standard isn’t enough:
Schaeffler engineered-for-application solutions
New X-life Spherical Roller Bearing Design with mounting-friendly features
Designed to meet the extreme demands of HPGR applications, the new bearing design offers improved wear resistance, reliable lubrication, enhanced sealing, and easier installation.The result: Increased reliability, reduced downtime, and extended service life in even the most demanding operating environments