Let’s remember a little bit of theory, and more specifically, what grinding is and by what methods it is carried out at the enterprises in industry. The intensity of many technological processes depends on the value of the total surface area of processed solid materials. The higher this index is, the grinding is more effective. Increase in this indicator is achieved by reducing the size of pieces of material (grinding), which in turn ensures the quality of the finished product. The process of reducing the size of material is called crushing or grinding. Often crushing is defined as the reduction of only large pieces. This process is done in crushers. The process of grinding smaller pieces is called milling. This process is mostly carried out with ball mills, which use grinding balls as the grinding media. Fuel (coal), raw materials (rocks, ores), semi-finished and finished products are crushed. Grinding is called coarse if pieces with cross-sectional size of 1000 to 200 mm, medium and intermediate – in the range of 250 to 50 mm, small in the range from 50 to 20 mm and fine (grinding) – in the range from 25 to 3 mm and less. The overall degree […]
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More photos at photo gallery Energosteel is glad to find a partner of the raw materials supply for the production of steel grinding balls! In September, the Energosteel delegation visited the production facilities of a metallurgical plant specializing in the production of high quality round steel bars. The plant produces round bars from billet square of its own production. Due to this factor, prices for long products from this manufacturer are very competitive in the market. The metallurgical enterprise produces long products using the continuously cast billets technology. Due to the continuously casting and crystallization, a complete uniformity of the structure of the bar along its entire length is achieved. During crystallization, the formed metal bar is constantly moving up and down relative to the mold by means of small cylinders located in the stream. This reduces the number of cracks (defects). A strong electromagnetic field is created around each stream, which allows the formation of the proper crystal structure of the billet. A round bars are rolled from such a square billet with an already homogeneous and initially structure. Also, in the case of production technology by continuous casting, metal losses for trimming the ends of bars are sharply reduced […]
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We have repeatedly given evidence that the use of grinding balls in grinding material is more effective than the use of a cast iron cylpeb. Since we have a semi-industrial mill, we decided to conduct comparative tests. The subject of comparative tests were two types of grinding media: ukrainian production cast-iron cylpebs 27 * 32 and steel grinding ball 30mm produced by Energosteel. Fig. 1 Cast-iron cylpeps 27*32 and steel grinding ball 30mm The purposes of comparative tests are: Determination of cast-iron cylpebs wear and a steel ball with a diameter of 30 mm wear in the grinding process under equal conditions; Determination and comparison of grinding fineness under the same operating conditions of the tested grinding media. Comparative tests of grinding media were carried out in a semi-industrial two-compartment mill which is installed directly at the plant “Energosteel”. The inner drum of the mill consists of two equal chambers, separated by a partition wall without openings. The rotational speed of the mill drum is 45-51 rpm. Material was crushed simultaneously in two chambers of the mill. Each chamber was loaded with 25 kg of grinding media. Before loading, the entire assortment was weighed and the average diameter of the […]
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Despite the difficult time for our country, we do not stop fighting for the quality of our products – steel grinding balls. In June 2022, the testing laboratory of Plant Energosteel LLC successfully passed the regular certification for the compliance of the measurement system with the requirements of DSTU ISO10012:2005 “Measurement management systems. Requirements for measurement processes and measuring equipment”. The State Enterprise «Kharkiv Regional Scientific and Production Center of Standardization, Metrology and Certification» carried out the audit. Upon completion of the audit, the experts did not issue any comments or recommendations, which indicates the perfection of the measurement system and issued certificate No. 01-0032/2022 on the compliance of the measurement system with the requirements of DSTU ISO10012:2005. An addition to the certificate is on two sheets, since our laboratory has significantly expanded the scope of its activities, introduced new tests to check the quality of products. Improving and guaranteeing the quality of our products is the foundation of Energosteel production no matter what!
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Today we would like to consider a simple, but very important issue. We often say, “you need to choose the right diameter of the balls”. However, the products of all manufacturers are different, and now there is no single generally accepted standard for classifying grinding balls by diameter. Therefore, we decided to expand this concept and help you not to make a mistake when choosing the required size of grinding media. As you know, the quality (technical characteristics and classification) of grinding media, which are produced and used in Ukraine, is regulated by the state standard: DSTU 8538-2015. This document specifies the requirements for the physical and chemical parameters of steel grinding balls produced by any of the methods (casting, forging / stamping, cross-helical rolling) and the classification of these products depending on their characteristics. It also spells out the requirements for the size of the grinding media and the possible deviation in the diameter. Here is a table from DSTU 8538-2015, which indicates the classification of steel grinding balls according to geometric dimensions (diameter). According to the table there are two concepts: conditional diameter and nominal diameter. The conditional diameter is the name of the classification group whose grinding […]
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We recently announced that we have researched the ceramic ball market. We were very interested in this niche. Having understood in detail the technology of using ceramic grinding balls, we had the idea to compare the specific consumption of a ceramic and steel ball. So, in some industries (for example, in cement), along with steel balls, ceramic balls are also used. The main requirement is that when using ceramic balls, the lining of the mill must also be ceramic. In June of this year, our laboratory of metals was equipped with a semi-industrial two-chamber mill, earlier we wrote about it here. Only a few weeks passed the mill was installed and connected to the power supply. Our technical department developed a test methodology that regulated all stages: preparation, grinding, sampling and analysis of the data obtained. The grinding (mill work) lasted 50 hours. The mill turned around at a speed of 45 revolutions per minute. Balls with a diameter of 40 mm were used as a grinding medium. In total, 1000 kg of material was crushed (500 kg in each of the chambers). Every 2 hours, the mill replaced the crushed material (quartz sand). Before the start, a geometric measurement […]
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Grinding balls, depending on their purpose, can be made of various materials, including ceramics. We are seriously interested in the ceramic grinding ball market. For example, most recently, our marketing department conducted a market study of this grinding media type. Ceramic grinding balls are used in the grinding industry, which does not tolerate grinding of harmful impurities and milling, which changes the color of finished products, used in ball mills with the aim of creating a thin grinding, which is necessary in the manufacture of silicate products, cement, glass, paint, lacquer etc. The researched type of grinding balls are used for both liquid and dry grinding types. Ceramic grinding balls are characterized by strength and low abrasion. Aluminium oxide (alumina) balls are very common among grinding ceramic balls. Among the types of ceramic (or alumina) balls, the most common are uralite, alubit, corundum balls. They are produced from the same material (alumina) and are differ only with the content of alumina (%): uralite – 75%; alubit – min 92% (on the Mohs scale – 9); corundum – 95% – the hardest and wear-resistant. In Ukraine, the market for ceramic grinding balls has formed an import-oriented model. Because ceramic balls are […]
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The selection of suppliers is a responsible and important process for us. As we wrote earlier, we approach this issue with special control, since the quality of our products is a priority. On June 13 this year, we visited the plant of the largest manufacturer of hot-rolled steel bars in Eastern Europe, which owns several plants in Poland. The plant occupies 60-70% of the metallurgical market in Poland. This plant rolls round bars of unique steel grades from square billets of its own production. It is very important for us that this manufacturer can meet all our requirements for round bars. This means that we can be sure of the high quality of our steel grinding balls when using this type of raw material. The enterprise impressed with its large-scale well-groomed territories, the number of workshops, and, most importantly, with its attitude towards environmental protection. The production process is automated and well-established using little manual labor with the latest modern equipment from the leading supplier Danieli. The Energosteel Company thanks the representatives of the plant for the warm welcome and the opportunity to visit their production facilities. We are confident that in the future we will be able to establish […]
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Being a market leader means constantly improving yourself and your production. Energosteel Company follows this rule and each time offers its clients new solutions for the use of grinding balls. Not so long ago our metal laboratory was equipped with a semi-industrial two-chamber mill. This mill operates in closed mode. The method of grinding is dry. The two chambers are separated by a blank partition, which allows two types of grinding balls to be tested simultaneously. Specialists of Energosteel together with research institutes of Ukraine developed two methods of laboratory tests. These methods regulate the test process and guarantee the objectivity of the results obtained. The main objectives of the planned tests are: Comparison of the specific flow rate of different grinding balls under identical operating conditions. Comparison of the grinding quality of the material when using different grinding balls. It should be noted that by various grinding balls, we mean not only different in type (shape) grinding media, but also geometrically identical grinding balls made of different grades of steel. Thus, in the future we plan to provide our partners with recommendations that will help to choose the most effective grinding balls, taking into account the specific operating conditions.
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We have written many times that the high quality of the produced steel grinding balls is the main priority for Energosteel. We are meticulous in our choice of round steel supplier to achieve this. We use strict controls to ensure the consistently high quality of our steel grinding balls. After all, even seemingly insignificant defects on the surface of round steel bars have a direct impact on the grinding balls quality. In June this year, representatives of Energosteel held a series of meetings on the supply of the main raw materials for the grinding balls production with the leading manufacturers of round steel in Europe. Especially notable was the visit to the company that manages the modern steel plant and has strengthened its position as a leading domestic and foreign supplier with over 120 years of experience. The plant produces hot-rolled steel from the billet of its own smelter, which uses scrap metal to produce steel. The plant and its management made a huge impression on the representatives of our company: huge areas, well-groomed territory, modern equipment from Danieli (the third largest supplier of equipment for the metalworking industry in the world). The plant’s capacity is more than 100 thousand […]
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Despite everything, we continue to work and develop cooperation with the leading manufacturers of round bars in Europe. Thus, in May of this year, a meeting was held between representatives of Energosteel and a potential supplier of round steel bars. This metallurgical plant specializes in the production of high-quality alloyed steel grades and is the undisputed leader in all of Europe. Based on the results of the negotiations, the stages of development of further cooperation were outlined. We are confident that the agreements reached at the meeting will have positive results for both sides. Energosteel thanks the company representatives for the friendly welcome. We sincerely hope for a long-term fruitful and mutually beneficial cooperation.
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The high quality of products is the key to successful competition in the market. Therefore, each manufacturer pursues two goals: cost reduction and improvement of quality indicators of products. Today we will talk about mining and processing plants. We have already noted that most of the mining and processing plants, according to the recommendations of our specialists, have conducted a number of tests over the past 2-3 years to reduce the diameter of the grinding balls used. The result of such changes was a finer grinding (disclosure of the “grain”), which in turn increased the content of the useful element in the industrial product. This method is very effective in the conditions of the mining and processing plants, which are designed using a three-stage scheme of crushing rock. This scheme is in most cases common in the post-Soviet space. A two-stage scheme with a small (up to 4-5) number of sections is mainly used abroad. Changing the diameter of grinding balls in this case does not always bring the desired result. In this case, the installation and introduction of an additional ball mill into the enrichment scheme has the maximum expediency. In other words, an additional grinding unit is introduced […]
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We continue to introduce our readers to interesting queries that come to us for miscalculation of grinding balls assortment. The first request, in 2022, came from Belgium. The company is a cellulose grinding company. Cellulose shredding is the first and so far only case where the conversion of natural cellulose into hydrate cellulose is done without chemical action on cellulose. Cellulose can be grinded in different types of ball mills, namely tubular, planetary or vibration mill. In our case, a ball mill of 2500x3000mm is used for grinding; the main electric motor has a power of 160kW. The armor in the mill is made of rubber, wavy-shaped plates with small elevators. The load of the mill is 20t. The grinding media is a 50 mm diameter steel balls. This grinding process is characterised by two factors: Flammability of the ground medium in the ball mill; The periodic type of grinding. One grinding cycle lasts 8 hours. We want to note that our specialists first encountered such a production. We studied cellulose grinding in ball mills. The most important factor in the choice of grinding balls (for these conditions) is the complete absence of a possible split of balls during operation. […]
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Sometimes we face a situation where our clients consider the possibility of using cast-iron (chromium-alloyed) balls in ball mills at mining and processing plants. Our specialists have studied this topic and we wish to share the results with you. The highly chromium balls are mainly used exclusively in cement milling in Ukraine, the Russian Federation and practically all over the world today. This is due to the nature of the shredding process in the industry: dry grinding, stopping of the mill, usually once every 3-4 months, low hardness (abrasiveness) of the ground material. However, in the processing industry, where wet milling is used, the situation is fundamentally different. The last attempt to use chromium balls in Ukraine was in July 2016. We have tried to gather as much information as possible about all tests of this type of grinding balls. For the sake of objectivity, we averaged the results (specific consumption) of each test and multiplied by the current value of cast-iron (chromium-doped) balls. Thus, we obtained a universal measure of shredder cost per ton of ore with cast-iron balls. Below are the results of our calculations: During the period 2014-2016, several industrial tests were conducted at Ukrainian mining and […]
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More photos at photo gallery A significant event for the mining industry of the Eurasian region was the largest and most comprehensive exhibition that covers all aspects of the industry: from mining equipment to grinding balls is Mining Turkey Fair 2021. The Mining Turkey 2021 exhibition was held from December 9 to 12 in Istanbul, at the Tüyap Fair Convention and Congress Center. The delegation of the Energosteel company found the opportunity to present its products (steel grinding balls of European quality) to the industry professionals and visited the exhibition together with company PROSES MUHENDISLIK DANISMANLIK INSAAT VE TASARIM A.S ..that is its official representative on the Turkish market. Within the framework of this exhibition, Energosteel representatives held business meetings with partners and clients who have shown great interest in our company and products, negotiated with leading consumers of steel grinding balls who want to cooperate with us. The interest in the products of our company and the recognition of the Energosteel brand by visitors and participants of the exhibition gives us confidence that we are moving in the right direction and motivates us to new achievements.
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Have you ever wondered how the process of grinding occurred in the 17th and 18th centuries? It was at this time, according to historians, the industry of mineral processing was emerging. Which grinding media were the first in use? What did the ball mills look like and what design? By chance we came across a video in which the author came up with a very bold and interesting theory about this topic. In short, according to the author, many of the cannons (especially large calibre – diameter of 100mm and above) are actually ball mills for grinding iron ore. All external and structural alterations of the mill drum were introduced already in the early 19th century and presented to the public as artillery pieces (cannons, mortars, etc.) of past eras. Let’s face it, a rather bold assumption, and many specialists of the «enrichment» branch will take it as a joke. About the grinding media. The first mention of steel grinding balls that we’ve found takes us back to 1633. The annual report of Ustyuzhno-Zhelezopolskiy plant (Novgorod Governorate) indicates that during that year they produced 422 tons of this production. This is more than 338,000 balls. They range in diameter from […]
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In October of 2021, Testing Laboratory of «Energosteel Plant» LLC expanded the measurement sphere and introduced a new test of steel grinding balls. It is a measurement of coercive force (thermal deformation voltage). Test Laboratory of «Energosteel Plant» LLC successfully passed the test on compliance of the measurement system with the requirements of DSTU ISO 10012:2005 «Measurement Management Systems. Requirements for measurement processes and measuring equipment» and received Supplement 2 from 13.10.2021. to certificate 01-0043/2019, which gives the right to carry out this test officially. The coercive force is measured by means of a structuroscope-coercimeter . This test relates to the non-destructive control of mechanical properties and microstructure of steel metal products by magnetic method. The control of tensile-thermal deformation of steel grinding balls is aimed at improving the heat treatment of our products, which gives the consumer confidence that our products will not be destroyed during the mill operation.
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