The operating-mode selection of the ball mill (sometimes called “the operating-mode of grinding media”) depends on three main parameters: The relative frequency speed of drum is equal to the ratio between the actual speed to critical speed of mill drum. Proxy critical rotation frequency of rotation of the drum is equivalent to a speed at which the inertia of balls rotational motion equals the gravity of this ball. In so doing, grinding media of infinitesimal size raised to the highest point are in dynamic equilibrium. Critical speed is calculated by the formula: where: D – inside diameter of ball mill drum, m. Ratio of grinding mill loading by grinding balls. Ratio of grinding balls volume to mill working volume is calculated by the formula: where: Gн – mass of grinding balls, kg; γ – apparent density of grinding media, kg/m3; L – drum length, m. Apparent density of grinding media depends on ball diameter and density of the material. Technological parameters of grinding: grinded material, requirement for the grinding, etc. The mill operation modes are as follows: The ”cascade” – the rolling the grinding balls inside the mill drum. Mixed mode – the rolling the grinding balls when part of […]
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On September 2, within the walls of Energosteel Company, the executive director of the Canadian-Ukrainian Association, Emma Turos, met with representatives of Energosteel, a manufacturer of steel grinding balls. At the meeting, both sides discussed the possibility of meeting and negotiating with Canadian customers and representatives of local municipalities, ways to finance the Canadian-Ukrainian project to supply steel grinding balls to Canada, and set priorities in working with the new region. Following the meeting, a plan for further development and cooperation of the company with Canadian partners was outlined.
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According to DSTU 8538:2015, grinding balls 50 HRC after heat treatment should be consistent with the standards shown in table 2 (DSTU 8538:2015), for example, for grinding balls with a nominal diameter of 120 mm, this is at least 50 HRC / 477 HB on the surface. Please note that information about the upper rate is not specified. The main standards for measuring steel grinding balls 50 HRC, according to the control methods prescribed in DSTU 8538:2015, is to determine only the hardness on the surface on two diametrically opposite sites. Thus, when production and supply of grinding balls 50 HRC, the testing Energosteel’s laboratory takes measurements only on the balls surface in accordance with the DSTU 8538:2015 standards. However, if the surface of produced grinding balls exceeds the minimum permissible values this does not mean that grinding balls quality does not comply with DSTU 8538:2015, because the upper limit of the norm is not regulated.
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As we have mentioned repeatedly in our articles, the right choose of lining plate is very important. 10-15 years ago there was only one main purpose of lining plates was protection of the mill hull from mechanical damage. To date, the design of the lining plates is based on the need to form a grinding line, which will ensure the maximum efficiency of the grinding process by steel grinding balls. Lining plates differ in size, material and method of attachment to the mill casing and the shape of surface. According to the type of profile, lining plates can be smooth, stepped wavy, combined, corrugated, cellular, heeled and other. Lining plate’s durability and the lift height of steel grinding balls depend on the geometric shape of the lining plate surface. When designing new types of liners one of the objectives is the reduction in slipping of grinding balls and grinded material over the lining surface, which improves the grinding quality and, as a result, increases mill productivity. Ring lining plates are more durable than liners with smooth and wave working surface. This is because the liners projections get stronger under the impact of the steel grinding balls. Figure 1 below shows […]
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Many companies are asking themselves: what is the need for ISO 9001? ISO 9001 certification of quality management systems helps businesses to develop and improve efficiency, as well as commitment to quality. For “Energosteel” the notion of quality means the ability to meet the expectations and needs of our customers on an ongoing basis and to be flexible to changes in these needs. So, Energosteel Plant LLC successfully passed the audit of certified quality management system in the production of steel grinding balls for compliance with ISO 9001:2015, at the end of July 2020. Audit was conducted by state enterprise “Kharkiv Regional Research and Production Center for Standardization, Metrology and Certification”. Energosteel Plant LLC confirmed the validity of the certificate without any comments and obtained a new certificate No. UA 8О072.33671383.1-2020 dated 03.08.2020 with a changed legal address. Working in accordance with ISO 9001 standards, Energosteel Plant LLC stands out on the market, because effective quality management allows us to meet the needs of our customers as efficiently as possible, to use time and money resources more productively, raise staff motivation and engagement to a new level, improving internal processes, to meet the requirements of foreign partners and to provide […]
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The widespread view that the oxidation process has a significant impact on the grinding balls consumption when wet grinding at the mining and processing plants recently. Cast grinding media producers use this argument often. We will try to look into the matter. Of course, oxidation process of grinding balls, especially steel grinding balls when wet grinding (free of corrosion resistant chemical additives) might be the case. Mainly, this is determined by water pH rate, used in the enterprise. The steel and cast iron chemical composition is most often introduced chromium, nickel, aluminium and silicon to minimize the corrosion process. The existence of these chemical elements in sufficient quantities provides steel and cast iron water-resistant in wet environments, in solutions of many acids and alkalis and in the dry gases at high temperatures. When the carbon content is high, the erosion resistance of steels increases. However, in some cases, the erosion proof is high when carbon content is low and the existence of the alloying elements. We use in our production just such a manganese, nickel and chrome doped steel. Grinding bodies’ corrosion so small that it does not actually affect the total grinding media depreciation in the ball mill. According […]
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Recently, Company Energosteel Ltd, a Ukrainian manufacturer of steel grinding balls, joined the The Canada-Ukraine Trade and Investment Support Project (CUTIS). In partnership with Ministry of economic development and Export Promotion Office this project will provide Ukrainian businesses with the information needed to export their goods to Canada and attract Canadian investments to Ukraine. From now on, Company Energosteel Ltd will not only be able to assert itself more confidently on the Canadian market of grinding ball consumers, but will also receive strong support during participation in trade fairs, exhibitions and B2B events aimed at expanding business connections with Canada, increasing export and attracting investment.
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Each producer that uses grinding in its production faced the situation when specific grinding media consumption exceeds the previously established norm. Generally, in the view of the consumers the single reason is the quality change of grinding balls used. Practice shows that in more than 80% of cases the change in the technological basis causes the increase of the grinding media consumption. These changes may be invisible to the employees of the production plant at first sight. Only a thorough analysis of grinding technology will help to understand the reasons for this situation. For years of experience in the grinding media market, we have compiled for you several main factors (reasons), which can affect the change of grinding balls consumption. Modifying the physico-chemical properties of grinding material. Changes to mill performance. Yes, such things do happen. Maintenance or upgrading of material supply conveyor can affect the speed and quantity of material loading to the ball mill. In the wet grinding, changing the flush density of the ball mill can significantly affect the grinding balls consumption. Everyone knows that for prevention not fully grinded material it is necessary either to load the grinding balls into the mill or to reduce the […]
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We announced the launch of an online service on our website recently. It helps customers accurately calculate the mass of grinding media in the mill. We received more than a dozen requests from our customers who took advantage of this service in a month. It may be noted, that the service is designed exclusively to determine the grinding balls mass of in a ball mill. We focus on this, because at the same time we received many requests, the purpose of which was the assistance in determining the grinding ball range when loading the mill from scratch. The difficulty of this calculation is to determine the average diameter of grinding balls in assembly, at which the required grinding quality will be achieved as soon as possible. As you know, there are two ways to determine the average diameter of the grinding media in the mill: the mathematical method and the selecting grinding media from the mill. We have already considered both calculation options in our publications. Specialists of «Energosteel» Company are always ready to help you to form and deliver the necessary assembly of grinding balls, which will reveal as much as possible the efficiency of grinding process at your […]
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The crushed sand is used in aerated concrete producing. The gypsum, cement and other additives are added to sand for the strength of the mixture. Sand is crushed in the ball mills, the type of grinding is wet ball milling. The steel grinding balls 25-40 mm in diameter are in the mill. Each manufacturer has its own milling requirements. On average, these requirements tend to the 15-18% of the sieve residue (8 microns). After grinding, the resulting mixture enters the hopper, in which it is constantly mixed using a “mixer”. The resulting solution is stirred until the homogeneous wet concrete is obtained. After that, foam is added to the industrial “mixer” where the solution was mixed. The concrete solution mixed with foam further is poured into molds. The foam concrete is conditioned for 4 hours after pouring. During this time, the process of initial capture occurs. Then the blocks are loaded onto pallets and transported for further drying. Energosteel company produces high-quality steel grinding balls optimally suiting for grinding quartzite (sand). To date, our customers include more than 25 companies that specialize in the production of aerated concrete blocks both in Ukraine and in the near abroad.
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In January this year, we launched a new service on our website. Therefore, for those of you who don’t know it yet, we recall that this service is intended for calculation of the filling degree the ball mill with grinding media. You will receive accurate calculation of the filling degree the ball mill with grinding media at the following link and by filling in the proper fields as quickly as possible. Our clients and customers of steel grinding balls provide feedback on the use of this service. According to the customers, this calculation allows: to determine correctly and quickly the amount of grinding media needed for loading the ball mill; significant savings of time for calculation of the filling degree the ball mill; to avoid the production stoppages. Based on the advantages of this service, it can be concluded that the main one is the reduction in the number of production stoppages, i.e. the saving of time. As we know, time is money. What about you? Have you already use this service? No? It’s time for the following link and to receive the important information for your production.
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For a month, we have been considering various methods for determining the energy indexes of material destruction. Common to all these tests under consideration is that all of them are based on the use of the third Bond theory. Despite the fact that this theory was proposed as early as the 1950s, its basic postulates are applied to date. All reviewed methods have been developed and tested by foreign specialized institutes. They are widely used throughout the world, including Ukraine and the countries of the Near Abroad. Currently, the development of new deposits is not as common as it was in the early 20th century. In most cases, these methods are used in the production expansion. When providing technical customer support, the specialists of the Energosteel Company also use some methods that allow optimally selecting and recommending the necessary grinding media to increase the grinding efficiency. Notably, the domestic Mechanobr Research Institute has developed several methods for determining the energy indexes of material destruction. We will try to consider them in our publications in near future. Follow the news on the Energosteel site!
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We have considered the falling dart test on JKMRC method needed for energy index calculating and is used to plan production capacities during the material’s grinding in an earlier article. The SMC method is a simplified falling load test that was developed in 2004. This test is carried out on the same equipment as the JKDWT test. The ability to test on one size type of the test material makes it less labor intensive and more applicable for the field development. For the test it is recommended to use a sample of particles with a particle size of -31.5 26.5 mm. Therefore, the calibration coefficient between the values of the two tests approaches one (A * b = 1). The result of the SMC test is the falling load index DWi, which is measured in kW * h / m3 and is calculated according to the formula: where: ρ is the average density of the test ore; A*b is the value of the combined parameter. Thereafter, the energy indexes of related equipment are determined and specific energy consumption of the ore preparation technological cycles are calculated using a statistical analysis of the available database compiled from the results of the […]
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It is no secret for many of our regular readers that one of the main advantages of cooperation with us is comprehensive 24/7 technical support regarding the use of our steel grinding balls. Despite this, we want to share this benefit with our new customers and website visitors. According to our clients’ numerous positive responses, we can safely say that we are on the right track. Energosteel specialists provide technical support to enterpriser consumers of steel grinding balls of various industries intertwine and conducts the selection of grinding balls assortment for further loading into the mill every day. Technical support department determines the weighted average diameter of grinding media into the ball mill and develops the recommendations regarding to the diameter variations of grinding balls in order to improve grinding equipment performance. What does the consumer get? Flow rates are declining significantly. Costs for the raw materials’ purchase are reducing. Cost of production is decreasing. The quality of the finished product is improving. In addition, technical support department provides qualified assistance in resolving issues regarding grinding technologies. Thus, the high level of interaction with our customers, typical for Energosteel, is a guarantee that your expectations regarding the grinding balls quality […]
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Different methods of calculation energy indexes required to choose grinding equipment have been considered on our articles last time. They are all classical, because its basic tenets have been announced in the 1950s. Falling dart test on JKMRC method has been developed at the Australian Research Centre JKMC in the 1990s. The ore durability is characterised by two types of crushed: the blow and the self-abrasion. This methodology includes single crushing of pieces through the impact load. The construction has wide range of the action energy, allowing for resistance determining of the material destruction at different energy levels. Particle size is divided into five ranges (-63+53, -45+37,5, -31,5+26,5, -22,4+19, -16+13,2 mm). Selected pieces are collected in dedicated sets for the consistent destruction. The parameters showing the durability of the test material regarding the impact – A and b (statistical record is A*b) and also parameter t10 showing the granulometric composition of the material under specific energy destruction (ECS) are the results of this test. The equation to determine the parameter A*b is as follows: t10=A*(1-e-bEcs) This methodology also provides the self-abrasion test of the ore particles in the laboratory mill 300 х 300 mm. The weight consists of a preliminary […]
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Let’s consider one more index that measures the physical-mechanical parameters of material that is planned to grind in ball mill. The abrasiveness index is addressed in this article. This index is necessary to forecast the speed of metal abrasion into the milling drum of the ball mill: grinding media, lining, pin etc. Material abrasiveness depends on specific conditions of the interaction between the material pieces and the metal in the grinding process. In determining abrasiveness index in laboratory conditions, it’s very important to follow all technological parameters of grinding chain. There are material selection, that is planned to grind, the parameters of water, rotational speed of drum, steel mark, the metal elements from which will interact with material. Let’s consider the standard valuation methodology. The installation, which consist of the rotating drum, is used. The dry material samples in size -19+12,7 mm and steel plate enshrining onto the shaft are loaded into the drum. The time it takes for test is 15 minutes and more. The abrasiveness index is calculated upon the formula: where m1 and m2 – the pre-test and post-test mass of steel plate, g; m1r и m2r – the pre-test and post-test mass of steel plate with […]
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You have read about grinding rate (G) a lot of time in our recent publications. Let’s try to figure out what that is and what factors can affect it. Grindability of a material is its capability for destruction in the ball mills. It is very important to understand clearly, which material will be crashed and which grinding requirements will be needed when planning of grinding process. With regard to the grinding requirements, it is simple in most cases: the thinner the grinding, the better. Grindability of the material depends on its specific physic-mechanical properties. The following method can be used for laboratory determination of shredding. The material sampling is crashed to 6 – 0 mm in size under constant conditions. The analysis of grinding results is conducted at regular intervals. The material is forced through a standard set of sieves (0300; 0200; 0150; 0100; 0074). The data obtained (time of grinding, sieve residue) shall be entered into the special table. As a rule, the requirement of 10 % sieve residue is consider as grinding standard. In such a case, the grindability to the largeness of 10 % sieve residue can be calculated as unit specific performance using the following equation: […]
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Energosteel Company strengthens its presence on the world stage by opening representative offices in key markets. To ensure sustainable growth, the company continues to focus not only on developed and mature markets, but also on the emerging markets of Asia, Central America and Eastern Europe. Thus, in confirmation of their intentions, in March 2020, partnership negotiations were held with representatives of Tarak Global Enterprises (India) as a result of which a new Energosteel representative office was opened in India. In its efforts to achieve only the best results, Energosteel makes every effort to work out and develop a technological process for the production of grinding balls, improving technical qualities and reflecting the unique identity of the company. In addition, by focusing on the new production line, Energosteel will be able to strengthen its position in export markets in a more pronounced way in future.
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The F. Bond ball mill We continue to consider the methods of grinding process planning based on the calculations of different energy indexes. In this article, we are going to consider the methodology for calculating index, which has a direct impact on the choice of SAG mills when engineering the grinding process. ВWi is the ball grinding work index. It is used to calculate the energy input (kW*h/t), that is needed to grind one ton of material of certain size (F100) in ball mill (D= 2,4 m) being in closed cycle with circulating loading 250 %. The formula for calculation the ВWi index is as follows: Where G is material grindability at the ball mill (g/r); F80 and Р80 – the mesh size whereby 80% of material is sieved in starting material and industrial product, respectively. There is usually a weight (15-20 kg) on 3,35 mm size to conduct the laboratory test. The material is grinded in the laboratory ball mill (305 х 305 mm) by dry method (without adding water). The weight of loaded grinding balls is 20-21 kg. The grinding balls selecting should to consist of grinding balls of different diameter to achieve the most accurate data. In that way, […]
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