The aim of LLC «Energosteel Plant» is production and delivery in the specified time and in the full volume of grinding media that meets all requirements of consumers. The quality management system for the production of steel grinding balls is certified in accordance with the requirements of ISO 9001:2015. Annually «Energosteel» carries out a quality management audit in order to maintain the efficient functioning of the quality management system. Thus, in the beginning of September the state enterprise “Kharkiv Regional Scientific and Production Center of Standardization, Metrology and Certification” carried out an audit on the conformity of the Quality Management System LLC «Plant «Energosteel» to the standard DSTU ISO 9001:2015. Energosteel received the certificate UA 8O072.33671383.1.2021. This document is a reliable proof of the quality level of steel grinding balls produced by «Energosteel Plant». Working according to ISO 9001 standards, LLC «Plant «Energosteel» increases its competitiveness on the domestic and international markets, constantly improves production processes and satisfies customers’ needs as efficiently as possible, complies with the requirements of foreign partners and provides steel grinding balls of the best quality.
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We have emphasized in our articles that it is very important to observe the requirements specialized GOST when preparation the grinding ball surface for the hardness measuring. In this publication, we will give one example that will demonstrate the dependence of hardness measurements results on the correct surface preparation. In February 2021, we received a complaint from one of our clients. We are talking about steel grinding balls 120mm in diameter. 10 grinding balls were selected for the quality control. All samples were prepared for hardness measurement. The surface hardness test showed an average hardness of 49.37HRC. Furthermore, the range of values oscillated from 31HRC to 60HRC. The results of the firmness measurements differed significantly from those noted in the batch certificate. In order to resolve this situation, we have requested the above samples. The presence of the «overburn» metal and the high roughness of the measuring surface were observed on all samples. All these facts indicated that the preparation of the hardness measurement surface was not in compliance with all the requirements. All the samples received were once again prepared at the Energosteel Laboratory. The results showed that the mean hardness of the samples obtained was 58.2HRC. The range was […]
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Business relationships – are a guarantee of the company’s success. Regular customers – are the gold reserve of our company. This week, one of the key meetings took place with our partners, relations with whom we have been building for more than 10 years. During all these years, not only business relations have developed between our companies, but also relations of mutual understanding and mutual assistance in the difficult conditions of a market economy. Joint participation in various projects and events has brought our teams together. This meeting was dedicated to a wide range of issues from different areas of our business, and we are confident that the agreements that were reached at it will bring results. We would like to express our gratitude to our partners for the visit, for the fact that, observing all quarantine restrictions, we were able to find the strength and time and hold a joint strategically important meeting.
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To date, only two enterprises in Ukraine use vertical mills: one is a cement producer and the other is a ore-processing plant. Both enterprises have been reliable partners of Energosteel Company for more than 10 years. This type of mill is used to achieve maximum grinding of the material. As a rule, the finesse of grinding is in the limit of minus 20 microns. The capacity of such mills shall not exceed 6mm. The grinding in such mills takes place in a vertically arranged screw which rotates and mixes the material with grinding media – steel grinding balls of 11-20mm in diameter. Such mills are seldom refilled. This is due to some technical inconvenience and the long waiting period for such work. Therefore, to maximize the economic impact of such mills, only high-quality grinding balls should be used. At the moment Energosteel Company is negotiating the possibility of carrying out industrial tests – application of steel grinding balls of our manufacture. To sum up, we note that the Vertimills belong to the equipment of thin grinding. For efficient operation, the grinding material should be shredding in the ball mills.
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Summing up the year 2020, we can very calmly state that Energosteel’s grinding balls compete with similar products of world producers. Thus, we have significantly increased sales in the foreign market. At the beginning of 2021, we received several requests to calculate the grinding balls assortment for the loading into ball mill. In this article, we will consider the one of the requests from a company based in Yemen that specializes in cement production. Production parameters: Inside diameter: 4.2 meters Total inside length: 13 meters Production capacity: 75±10t/h (Closed circuit, ordinary carbonate cement, specific surface area: ≥320m2/Kg) feeding size≤5mm, moisture≤0.5%, air speed in mill ≥0.5m/s. Mill rotary speed: 15.8±0.1r/min Charging capacity of grinding medium: 230 ton. The raw material for cement production has a high abrasion rate. Consequently, when calculating the assortment the balls with increased volumetric hardness have been taken into account. Into the first chamber of two-chamber mill is loaded with balls from 80 to 40 mm in diameter. The second chamber is loaded with balls from 40 to 25 mm in diameter. The calculation the average diameter of the grinding ball in each chamber showed that the following assortment of grinding balls should be used for maximum […]
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In January, we take stock of the work done, draw conclusions and plan. We summed up operations in 2020. What about SEO promotion? The results of the 2020 SEO-promotion compared to 2019 we’ve presented in the figure below: In 2020, the number of visitors to our site increased by 6%, and traffic by 7%. The top 10 most popular pages among our readers are: Grinding media & grinding balls Investigation methods the metals and alloys structure The system of a ball mill Steel pearlite class The operating principle of the ball mill Contacts Manufacturing Ukrainian cement plants Ukrainian mining & processing enterprises Types of grinding mills for raw materials . We are glad that our materials in the corporate site are useful to our audience and arouse interest of our customers. In 2021, we will prepare useful information for all specialists of the industry.
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The New Year is a time for stocktaking. We all reflect on the question: What have we achieved over the past year? The past year has been a challenging one for many of us. The COVID-19 pandemic has defined the entire past year and the waves of lockdown have become a problem not only for individuals, but also for businesses. However, despite the crisis, the past year has been a year of challenges as well as advances for Energeteel. The highlights of the past year are as follows: The exports share in 2020 increased by 19%. The number of customers increased by 3.7%. The production of steel grinding balls of high hardness (60-65 HRC) increased twice in 2020 as compared to 2019. In 2020, numerous industrial tests of our products were carried out at the customers’ enterprises in Ukraine and abroad, started ball mills with Energeteel balls at the new aerated concrete plant. An important achievement in the past year was the new service on the site — “Calculation Of The Filling Degree The Ball Mill with Grinding Media”. This service has become useful for many of our customers of steel grinding balls. Last year, Energeteel increased its presence on […]
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We have repeatedly referred to the term “the mill filling rate by grinding balls”. At first glance, it is a simple term, which means the necessary quantity of grinding balls in a ball mill for the most effective grinding of the material. The filling rate may be expressed in two ways in the technical documentation: by indicating the mass of grinding media or by the percentage filling by grinding media of the internal mill drum. It is important to understand which values should be used in practice. This is particularly important in industrial trials, where every unaccounted tone of grinding balls can affect the outcome. Given the long-term nature of industrial trials, the error in the calculations increases and substantially distorts the results. For example, the filling rate of ball mill (78 cubic meters) is 44% (according to the technical documentation for the mill). Knowing the bulk weight of grinding balls, we understand that for the efficient operation of the mill it is necessary to load 374 tons of grinding balls. However, the internal diameter of the ball mill gradually increases during the operating time. This is especially true when using a steel lining. We understand that increasing the volume […]
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Grinding balls are the main component in the grinding materials process in the production of cement, electricity, gas concrete, glass, silicate products and the production of metals. Grinding balls are used as a grinding medium in the ball mills for the production of the above products. Grinding balls are classified as consumables; their cost is fully included on the cost of the finished product. It is well known, the cost of grinding balls is about 30% of the total costs of grinding process. Therefore, it is very important to use high-quality grinding balls in the grinding process. The question is how to convince the customer of the grinding balls quality? Energosteel Company is 100% sure about the quality of its own production and is ready to provide guarantee for its grinding balls. In general, the following indicators are the subject of warranties: Fracture rate of grinding balls in the ball mill; The service life (specific consumption) of grinding balls. However, the guarantee availability depends on specific operating conditions and is provided after careful technology analysis of the shredding process technology on a case-by-case basis. In turn, the customer, who received the grinding balls and the quality guarantees are provided on […]
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The activity of «Energosteel» company associated with the need to deliver the goods — grinding balls, raw materials and components. In many cases, the cost of delivery has quite a large share of the company’s total costs, so the optimization of these expenses paid a great attention. Logistics of our company is an integrated process designed to promote the creation of customer value with the lowest total cost, customer satisfaction of our grinding balls and facilitate production and marketing activities. Logistics and customs clearance department of company «Energosteel» chooses the best route and the type of vehicle for delivering grinding balls worldwide. Grinding steel balls for ball mills can be delivered in bulk or in big bags, in barrels or containers or though another most effective means for the customer. In calculating the cost of the delivery the grinding balls, experts of Energosteel consider not only the price segment of the shipping cost, but also customer requirements for the method of delivery (type and specifications of the vehicle) that may affect the safety of goods on the route and the speed of its acceptance and / or unloading, which reduces delivery costs. One example of an individual approach to the […]
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We continue to tell our our readers about various calculations of grinding balls for mills. We remind you that you can make a calculation by clicking on the link. The customer specializes in the production of construction mixtures. The production parameters are as follows: Ball mill with one camera. Lining of the inner drum: steel plates of type “wave”. Dry grinding method. Shredding material is a mixture of limestone in which dolomite is heavily present. The material size in the feed of the ball mill is 0-20mm. Grinding requirement is the residue on a sieve 007 not more than 15%. It has been calculated that the average diameter of the grinding balls in the mill should be between 60 and 61 mm in order to reach the required fineness of grinding under the given conditions. Loading the mill is 40-43% in order to reach the maximum capacity of the mill. It is 9-10 tons of grinding balls in physical terms. Since the material for grinding is quite abrasive, we recommended the use of grinding balls of high hardness. As a result, we have recommended to the client such grinding balls assortment: 80 mm – 3 tons; 70 mm – 5 […]
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On November 10, 2020 the online conference “Prospects for Cooperation: Ukraine – Canada” was organized by the of Ukrainian Chamber of Commerce and Industry, Alberta-Ukraine Chamber of Commerce, the Embassy of Ukraine in Canada and other partner organizations. The purpose of the event is to discuss ways to expand trade and economic cooperation between Ukraine and Canada, establish effective partnerships between companies of the two countries. At this online conference, Emma Turos (Executive Director of the Canadian-Ukrainian Chamber of Commerce) presented the company «Energosteel». After the presentation to the manufacturer of steel grinding balls, Emma Touros drew the attention of Vitaliy Milentyev, Representative of the UCCI in Alberta – President of the Alberta Ukraine Chamber of Commerce. The conference was also attended by other production companies of Ukraine, which have already established cooperation with Canada and proved by example that export to Canada is possible despite the considerable distance between the two countries. Such conferences are an excellent opportunity to intensify contacts and increase trade. The Canadian market is closer than it may seem at first.
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Ball mills use in all industries needs a material grinding. Steel grinding balls use as grinding media in such mills. In this article, we will consider the steel grinding balls use in coal grinding. Coal grinding is preparatory process to a creating mixture for combustion in boilers at thermal power plants. To a high-quality fuel creation for the TPP units furnaces (fuel has the coal basis), needs to achieve the maximum material grinding degree and maximally reduce the coal dust moisture content. Fuel drying and fuel grinding can be carried out separately or jointly in one unit. If these processes occur separately, then coal dried in drying drums and ground in short ball mills. The ratio of drum length to the drum diameter is usually 1.5: 1. The 40 mm grinding balls of the 2nd and the 3rd hardness groups have used for coal grinding at thermal power plants in USSR. This is due to a fairly low hardness indicator of the grinded material and absence the grinding balls with higher hardness groups, in the past. Following the coal grinding world practice, Energosteel company specialists among the first offered for customers to use grinding balls the 4-th and 5-th hardness groups for coal grinding. Numerous […]
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Let us consider another calculation of grinding balls assortment for the initial loading of a clinker ball mill. We have obtained all necessary data through the online service on our website. Note that this customer is not a resident of Ukraine and it was not possible to source the specifics of customer’s production. The customer specializes in cement production. The production parameters are as follows: The inner drum of the ball mill is divided into two chambers. The lining of the first chamber is steel slabs with elevators. The lining of the second chamber is rubber slabs of the type “wave”. Dry grinding method. Grinding material is a mixture of limestone (chalk, marble or other) in 75% and 25% clay. The size of the material is 13-15mm. Grinding requirement: residue on a sieve (size of 80μn) is not more than 7%. Since cement production material is sufficiently abrasive, it is necessary to use grinding balls with increased hardness. We have refined the material parameters of the armour platingin the first chamber and recommended to our client to use the balls with the volume hardness of at least 60 HRC. The coefficient of grinding for the mill is 22-25 per cent […]
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The calculation of the filling degree the ball mill with grinding media is a unique online service on our website. Recently our potential customers often use this service. We therefore decided to share with you the results of the calculation of the range of grinding ball assortment, which our specialists recommend on a case-by-case basis (request). Customer specialization is the production of various mixtures for construction works. Production parameters are as follows: Single-chamber ball mill 1400x7100mm. “Wave” lining plates Dry grinding method. Shredding material is slag (by-product or waste from metal production). The material size in the power of the ball mill is 1mm. Grinding requirement is the residue on a sieve (size of 80μn) not more than 5%. It is necessary to remember that the hardness of the lining plates should be 10-15% higher than the hardness of the grinding balls used. Filling rate of grinding balls for this mill is 25-27 per cent of the total internal volume, i.e. approximately 13-15 tons of grinding balls. The calculation of the average diameter of the grinding ball in the mill showed that it is necessary to use 23.74mm steel grinding balls for maximum effective grinding. Knowing that the loading rate […]
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The ball mill launching is one of the most complex technical processes in material grinding. The need for the method of the ball mill launching arises in two cases: “Start” of new production (expansion of existing plant); The ball mill launch after the preventive maintenance and/or emergency stop. The correct way to launch a ball mill after the preventive maintenance and/or emergency stop was discussed earlier in our publication. We recall that this methodology was developed in cooperation with the Belgorod State Technological University of Mr. V.G. Shukhov. This method has proven its effectiveness in practice. A lot of our clients “have adopted it” and use it constantly. We have faced with the task of launching a ball mill for new production recently. We will not disclose all information, just say that this enterprise is in Ukraine and it will declare itself on the building materials market in the near future. At the end of 2019, the technologist of new production approached us in order to help him to complete the ball mills with the necessary of grinding balls assortment. Based on the results of the completed questionnaire, we have proposed optimum grinding balls assortment, which will ensure maximum effective […]
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In the previous article, we talked about one of the steel structure investigation method (the fracture method) and its application in the steel grinding balls production. Today we will discuss the possibilities of using this method in production. The opportunity of using the fracture method consists in determining the correctness of rolling stand settings and as a result, in determining the product quality steel grinding balls. As it’s known, the steel structure after rolling has a certain texture. Rolling texture is a structure formed during hot plastic deformation, characterized by the elongation of the grains in the direction of deformation and the predominantly crystallographic orientation of the crystallites. The base billet for the production of steel grinding balls is a hot rolled round bar, produced by a longitudinal rolling method. The steel grinding balls are produced by the cross-rolling method, the texture is the meridians along the rolling axis. Based on this standard, it is possible not only to determine the depth of the tempered layer, but also to assess the correctness of rolling stand settings and make changes in the settings in time to avoid unnecessary internal voltage, defects of grinding ball structure and improve the product quality.
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The durability of steel grinding balls is determined not only by their hardness, but also by the quality of the steel macro and micro structure. The structure of the steel from which steel grinding balls are made is studied using the fracture method. This method consists in determining the steel structure by looking at its fracturing or a specially prepared surface (in the case of Energosteel -templets). This gives an idea of the general structure of the metal and the presence of defects therein. We would like to draw your attention to the fact that this method differs from fractography, because it does not apply magnifying instruments. Fracture method can be attributed to the first stage of fractographic analysis – visual examination. Fractography aims at determining the causes of the balls fracture, while fracture method used in our plant aims at improving the grinding balls quality, thus preventing splits during the use of grinding balls. What is a fractis? The fractis is the surface of the sample split when it breaks. In order to get the split of the steel grinding ball, the «Energosteel» plant uses an impact drop machine. But the destruction of our grinding balls is not so […]
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The issue of energy efficiency is one of the main one at any enterprise. The grinding process in the ball mill is highly energy intensive, because grinding process accounts for up to 45% of total energy consumption. It is not possible to estimate the power consumed by the mill drive without taking into account all the factors influencing the grinding process, such as the contact of grinding balls, their impact, the transfer of mechanical energy from one grinding ball to another, and then to the mill drum. Much research from classical theories to modern works is aimed at determining the power consumed by the drive of ball drum mills. The power absorbed by the drive can be divided into useful and harmful components which are spent on: the grinding of new material entering the mill; the lifting the steel grinding balls to a certain height; the lining and grinding balls wear; losses in mechanical transfer. The power consumed by the mill drive shall be calculated by the formula: where: Р0 – the power spent on rotating the mill drum and the output of the grinding load of the specified operating mode, kW; Рхх – the power expended to overcome friction […]
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