Steel grinding balls for 40% more efficient cylpebs! Proved!!!

In this article, we will compare the grinding efficiency during using the steel grinding balls and the cast iron cylpebs (alloyed by chromium). We have been published the articles on our website where we have proved the use of grinding balls for grinding material is much more effective than the use of cast iron cylpebs, by mathematical calculations basis. Also, we have repeatedly mentioned all leading Ukrainian mining and processing plants, aerated concrete and cement plants have refused to use the cylpebs. To make this decision, the country’s leading enterprises only took into account the mathematical calculations, but some of them need to conduct the comparative tests.

ENERGOSTEEL Company conducted an industrial test for replacement the cast iron cylpebs (alloyed by chromium) by the steel grinding balls at one of the Ukrainian aerated concrete plants at the beginning of 2019.

Methodology for conducting industrial tests had developed together with the customer’s technical specialists. The test has been conducted by the substitution method. We have calculated and proposed the 25mm – 40mm grinding balls assembly for the first loading of a ball mill. Further mill loading has provided once a week. The quantity of loaded grinding media has calculated after instrumental measurement of the mill filling. Our technical specialists came to the client’s company every month to take measurements, in other cases, they received information online. The additional loading to the mill was provided by the 25mm, 30mm and 40mm grinding balls assembling, in order to preserve the granular composition of grinding media. The composition of the grinding balls assembly for each additional loading has calculated according to the results of the material grinding quality analysis for the previous period. The test lasted over eight months and a replacement period lasted two months.

Summarizing the results of this experiment, we verified in practice for a more efficient using the steel grinding balls (as economically and technologically) as grinding media than the cast iron cylpebs alloyed with chromium. Upon the test completion, a reduction of the grinding media specific consumption achieved to 37 %! The technological parameters of grinding became more stable and high-quality: the productivity feeding became the maximum possible for this mill, and the sieve residue (0.008) decreased from 11% to 7.5%.

The ENERGOSTEEL Company thanks to our partner for the opportunity for comparative test conduction at their production area. We want to note, all employees involved in the experiment by the client-side acted in a coordinated and open manner. All actions related to the grinding process were negotiated and agreed jointly. All the necessary data by the mill operation (sieve residue, productivity, ammeter indicators) have been provided on the agreed date – daily.

We sincerely hope at further cooperation will be mutually beneficial for both sides, and the use of steel grinding balls by ENERGOSTEEL production will only strengthen our client’s competitiveness in the market of aerated concrete blocks in Ukraine.