This article about industrial test №1.Replacement the 28x28mm cast iron cylpebs (surface hardness 44-47HRC) to the 40mm steel grinding balls with the fourth hardness group (surface hardness no less 61HRC). It should be noted, our client specializes in the aerated concrete blocks production. The first mill commission inspection was in early February 2018. Method without unloading grinding balls from the mill had used for grinding media average size determination in the test mill. We have made the geometrical dimensions measurements of the selected samples; we have determined the grinding media maximum and minimum dimensions. We have found the grinding balls average size is 37 mm in the mill. The cylpebs size varies from 15mm to 18mm in the mill. The steel grinding balls loading quantity was the same as the previously loaded cylpebs quantity (approximately 1 ton per day, with the continuously mill operation). 15 tons of the 40 mm steel grinding balls have been loaded into the mill since industrial test start. 15 tons – 43% of the mill load norm by grinding media. The 35 tons of grinding media is total mill loads. The mill electricity data consumption show the grinding media weight in mill has been above […]
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2018 year has begun for Energosteel company specialists by three full-scale industrial tests. Each test should solve a specific task for each client: Industrial test № 1 – the grinding process technological parameters comparison during use cast iron cylpebs and steel grinding balls as a grinding media Industrial test №2 – the comparison of specific consumption the steel grinding balls the fourth and fifth hardness groups (DSTU 8538-2015) produced by Energosteel; Industrial test № 3 – the grinding process technological parameters comparison during use the 80mm and 90mm steel grinding balls as a grinding media; All tests conduct at three different enterprises in Ukraine. The technical and economic negotiations have been held with each client before the tests began. Representatives of technical and commercial services participated in the negotiations. All technical and technological indicators for evaluation at tests have been identified and agreed upon. Energosteel Company specialists began to travel on business trips, visit the partners production capacities, conduct joint measurements, consolidate information about tested grinding media work and a grinding process technological parameters, determinate the occurred changes in the middle of February 2018. We will inform you about the progress of each test in our further articles. We hope […]
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Energosteel Company is Ukrainian manufacturer of forged steel grinding balls. Our products are designed for grinding of raw materials at ore mining and industrial processing facilities, energy generating companies, cement plants. Capacity of Energosteel Company is 60 000 tons of steel grinding balls per year. We are produce grinding balls with a diameter by 20mm to 125mm with high carbon content and the volumetric hardness from 60 to 65 HRC. 2017 year was not easy for the country’s metallurgical industry. Against the background of an annual reduction in steel, rolled metal and cast iron production, Energosteel Company has improved indicators of 2016. Thus, the grinding balls production increased by 11% in 2017, compared to 2016. Exports increased by 13% and amounted 32% of the sales in 2017. This became possible due to increased consumption in the CIS, the Scandinavian, the Middle East countries and the Baltic States. The customers number has increased by 2,5%. The production of grinding balls the fifth hardness group significantly increased on 31% in 2017. In general, the production of grinding balls the 5th hardness group amounted to 20% of the annual production volume. Let’s remind, Energosteel Company is the unique enterprise mastered the production of […]
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We have considered the steel grinding balls surface hardness measurement and the steel grinding balls hardness measurement at 1/2 radius depth in previous articles. We will consider the steel grinding balls volumetric hardness measurement in this article. The grinding balls volumetric hardness provides to confirm their compliance to the fifth hardness group. The volumetric hardness determines in two mutually perpendicular directions on the templates cut from the central part of the grinding ball. Their surface prepared in accordance with the requirements GOST 9012 and GOST 9013. It is necessary remove metal to the R distance from one side of grinding ball and to 1/2R distance from the other side in order to the sample stably stood on hardness tester table. The measurement points must be drawn with a pencil. We draw two mutually perpendicular straight lines for this, then each radius we halved and the rest radius parts we halved also. As a result, we obtain 6 measurement points on each straight line. They correspond to 0,25R; 0,5R; 0,75R and one common point R (the grinding ball center). We get 4 values on each part of the radius, except the center. The minimum and maximum values of the obtained hardness […]
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We have considered the steel grinding balls surface hardness measurement in the last article. Remind, we have conducted 4 hardness measurements during the hardness determination: three test measurements on vertices the imaginary equilateral triangle and one control measurement in the center of this triangle. We will considered the steel grinding balls hardness measurements at 1/2 radius depth in this article. This measurement conduct for confirmation grinding balls to the 4th hardness group (DSTU 8538:2015). The steel grinding balls hardness at 1/2 radius depth determines on one flat surface area prepared in accordance to GOST 9012 and GOST 9013 requirements by removing the ball metal to the required depth. It is necessary remove metal to 1/2 radius distance at each side of the grinding ball, in order to the sample stably stood on hardness tester table. At 1/2 radius distance performs four hardness measurements on two mutually perpendicular lines drawn with a pencil, the measurement points should correspond to 1/2 radius of the grinding ball. The minimum and the maximum hardness values ignore, and the hardness defined as arithmetic average value of the other two dimensions
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The grinding balls surface hardness defines on two diametrically opposite platforms. Four measurements perform at each platform for the hardness determination by Rockwell method. The first three measurements perform at the vertices of imaginary equilateral triangle with a side length from 5 to 8 mm. These measurements are tentative and the results don’t record in test report. The fourth measurement performs in the center of the triangle. This measurement’s result records in test report. You can previously draw points in the measurement locations for easy measurements. Three dots draw in form of triangle vertices and a fourth dot draws in form of center this triangle. Four measurements must be providing according to Rockwell hardness measurement method (GOST 9013): The first three measurements are not counted after the change of the tip, the working table or stand. The prints number in the hardness measurement; the processing method and the measurements results indicate in the normative-technical documentation for metal products. This measurement technique indicates in the DSTU in order to press the tip against to the grinding ball surface in these three measurements and obtain a fourth measurement with a minimum error. The device dial have several scales: Scale C – a […]
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The grinding balls samples should be prepared such way, that their properties will not changed as a result of mechanical or other processing. The grinding on a surface grinding machine is the best way to prepare the grinding balls surface for hardness measures. A special matrix has created for steel grinding balls. From 2 to 5 grinding balls placed in matrix and simultaneous polish them. The grinding balls placed in the matrix and fixed there to avoid the area skewing under hardness measurement. Surface grinding (surface polishing) includes the following movements: the cutting tool rotation – a grinding wheel PP 25A 250х40х76 25СМ, the grinding balls feeding by longitudinal and cross way, the grinding balls movement toward cutting grinding wheel. Coolant supplies to the contact point of grinding balls and grinding wheel during surface grinding. Coolant helps to avoid the surface overheating and the hardness measurement results distortion.
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Energosteel Company continues inform y about measuring the bulk weight of steel grinding balls produced by Energosteel. Weighing 90 mm balls have held in a container with a correct geometric shape – a parallelepiped with sides 118х118х110cm. The container volume is 1.53 cubic meters. The measurements results have shown in the table below. Table 1. The 90mm grinding balls bulk weight. (without shaking up) Parameter Container №1 Container volume, m3 1,531 Grinding media volume in container, m3 1,322 The container and grinding media weight (gross), t 6,860 The container weigh, t 0,880 The grinding media weight, t 5,980 The bulk weight, t/m3 4,600 The 90mm grinding ball bulk weight is 4,58 t/m3 in reference specialized literature. You can see the bulk weight parameters of 40mm, 50mm, 80mm, 90mm, 100mm and 120mm grinding balls in our articles. In the near future, we will provide you about the bulk weight measurements of grinding balls produced by Energosteel.
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Energosteel Company uses the “individual approach” principle in commercial and technical fields as main factor in building partnerships with customers. Energosteel Company takes into account the specifics of using grinding balls in the grinding process of each customer, regardless the consumption volume and activity type. Let’s take a look at some examples, when Energosteel helps customers in resolving issues related to the grinding media selection and use. One Ukrainian enterprise produces a technical steel shot. The final processing (crushing) carried out in ball mills. The customer uses 100mm grinding balls in production. The cast steel shot hardness is from 60HRC to 64HRC. The first shipped party of grinding media carried out according to the customer’s requirements for this product – a 100mm steel grinding balls with a surface hardness – 60HRC, the 0,5R hardness – 45HRC and produced by manganese steel grades. The client has noted after a certain period, the grinding media consumption and the grinding quality have not significantly increase and productivity decreased. Energosteel Company technical specialists arrived at client’s production plant, studied the steel shot production technology specifics, and analyzed other technical processes. Our specialists determined that mills have used as crushing equipment. The grinding process was […]
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Energosteel Company continues series of articles for inform our readers about measuring the bulk weight of steel grinding balls produced by Energosteel. A batch of 120mm steel grinding balls was produced in November. This is the maximum grinding balls diameter used in Ukraine. Grinding balls this batch corresponds to the fourth hardness group (DSTU 8538: 2015 / DSTU 3499-97). The measurements results have shown in the table below. Table 1. The 40mm grinding balls bulk weight. (without shaking up) Parameter Container №1 Container volume, m3 1,531 Grinding media volume in container, m3 1,471 The container and grinding media weight (gross), t 7,475 The container weigh, t 0,880 The grinding media weight, t 6,595 The bulk weight, t/m3 4,486 The 120mm grinding ball bulk weight is 4,52 t/m3 in reference specialized literature. Let’s summarize our articles series where we have reflected measurements results the bulk weight of steel grinding balls produced by Energosteel. You can see the bulk weight parameters of 40mm, 50mm, 80mm, 100mm and 120mm grinding balls in our articles. In the near future, we will conduct similar measurements on the 30mm and 60mm grinding balls. We hope, the obtained information will be useful for our readers. Upon completion the articles series […]
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Energosteel Company specialists continue to inform our readers about measuring the bulk weight of steel grinding balls produced by Energosteel. Recall, our production department has been equipped with two containers in order to measure the bulk weight of grinding balls. Both containers (tubs) have the correct geometric shape – a parallelepiped with sides 118х118х110cm. The each container volume is 1.53 cubic meters. A batch of 50mm steel grinding balls the fifth hardness group (DSTU 8538: 2015 / DSTU 3499-97) was produced in September. The measurements results have shown in the table below. Table 1. The 40mm grinding balls bulk weight. (without shaking up) Parameter Container №1 Container volume, m3 1,531 Grinding media volume in container, m3 1,005 The container and grinding media weight (gross), t 7,975 The container weigh, t 0,880 The grinding media weight, t 7,175 The bulk weight, t/m3 4,710 The 50mm grinding ball bulk weight is 4,70 t/m3 in reference specialized literature. So, you can read in our publications about bulk weight of 40mm, 50mm, 80mm and 100mm steel grinding balls Energosteel production. Energosteel Company will continue to inform you about calculation results the bulk weight of steel grinding balls with different diameters manufactured by our company.
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More photos at photo gallery Delegation of Energosteel Company together with official representative on the Turkish market – Proses Mühendislik Company took part the MINEX 2017 Fair in October 2017. This event held on the 18 – 21 October 2017 in Izmir (Turkey) together with the 6th International Congress of Mining Machinery and Technologies (IMMAT). Many Turkish and international companies participated in the congress and exhibition, organized by the Chamber of Mining Engineers of Turkey. Over 100 enterprises specialized in equipment production for the mining industry participated in the MINEX 2017 Fair. Organizations providing the integrated engineering solutions in the planning, reconstruction and modernization mining technology and minerals enrichment processes have visited exhibition. The MINEX 2017 Fair attended more than 5000 visitors from 27 countries. Meetings with the largest grinding balls consumers in the region were held as part of Energosteel Company products presentation. Technical and economic negotiations with ball mills producers were conducted too. It allowed us to formulate a strategy aimed at increasing Energosteel products sales in this region. Energosteel Company would like to express our sincere gratitude to our official representative on the Turkish market – the Proses Mühendislik Company for assistance in preparing and participation in […]
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Earlier we have considered the grinding process specifics in the aerated concrete production and we have mentioned about automatic devices for grinding media loading into a mill in automatic mode. In this publication, we will consider this issue in more detail. Automatic grinding media loading into mill most uses in aerated concrete production, because of these factors: The aerated concrete production is a fairly young technology and all modern techniques relating to the grinding process consider in the production design. The 40mm and 30mm grinding balls mainly use in the aerated concrete production. A small mills amount. In general, one or two ball mills use at the aerated concrete plant. The grinding material uniformity, etc. Let’s note, all foreign aerated concrete manufacturers use automatic grinding media loading. For today, only one enterprise has implemented this technology in Ukraine. What is this method of loading grinding media into a mill? This mechanism consists of two main parts: the container for grinding balls and the grinding channel for grinding media entering into mill. The container equipped with a movable flap. Flap movement can be adjusted (open / close) automatically or in manual mode. In automatic mode: computer monitors the raw material amount […]
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We have briefly considered the grinding process at enterprises following industries: minerals extraction and processing, cement production and coal grinding for thermal power plants. We will consider the material grinding process in the aerated concrete production in this article. There are more than 9 large plants produce building gas-concrete blocks in Ukraine today. All enterprises of this industry use single-chamber tube ball mills, as the grindable equipment. As a rule, these mills have 10 meters in length and 2.5 meters in diameter. The mill inner drum is protected by rubber armor plates with small lifters (“waves”). In addition to Ukrainian aerated concrete producers, Energosteel Company supplies grinding balls to more than thirty companies of this industry located in the CIS and near abroad. 40 mm steel grinding balls use as grinding media for aerated concrete production and 30 mm grinding balls sometimes use in addition. This is due to the fact that sand grinds in ball mills. Sand has a fine fraction, but very abrasive and hard. Grinding media operate in cascade mode “for abrasion”. That’s why the grinding balls with surface hardness at least 64HRC and 45HRC at 0.5R depth (the fourth hardness group according to DSTU 3499-97 / […]
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Energosteel Company specialists continue to inform our readers about measuring the bulk weight of steel grinding balls produced by Energosteel. Recall, our production department has been equipped with two containers in order to measure the bulk weight of grinding balls. Both containers (tubs) have the correct geometric shape – a parallelepiped with sides 118х118х110cm. The each container volume is 1.53 cubic meters. Thus, a batch of 40mm steel grinding balls the fifth hardness group (DSTU 8538: 2015 / DSTU 3499-97) was produced in September. The measurements results have shown in the table below. Table 1. The 40mm grinding balls bulk weight. (without shaking up) Parameter Container №1 Container №2 Average value Container volume, m3 1,531 1,531 Grinding media volume in container, m3 0,989 1,002 The container and grinding media weight (gross), t 5,625 5,615 The container weigh, t 0,950 0,880 The grinding media weight, t 4,675 4,735 The bulk weight, t/m3 4,730 4,726 4,728 The 40mm grinding ball bulk weight is 4,76 t/m3 in reference specialized literature. Energosteel Company will continue to inform you a calculation results the bulk weight of steel grinding balls with different diameters (from 25mm to 120mm) own production.
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The enterprises consumers grinding media have a question about right choise the grinding ball size (diameter) for the mill in order to achieve the required grinding quality. We noted earlier, this information can be obtained from several sources: – Technical documentation. It attached to the milling equipment (mill). Each mill manufacturer recommends certain grinding media type for mill operation under certain conditions: the crushed material parameters, the mill’s performance, the raw materials particle size in the mill’s “feed”, and the required grinding fineness (finished class content). – Past experience of a ball mill. It is possible to calculate the grinding media average diameter formed in the mill operation, during grinding media unload from mill (the grinding balls bulk weight in fully unloaded mill). – Other enterprises. It is possible to obtain the necessary data on a grinding media granulometric composition from other enterprises with a similar grinding process, including similar requirements to the grinding quality. Sometimes, the above sources use is impossible. There is a mathematical solution to this problem – the Bond formula. It uses to help determine the grinding media optimal size must be loaded into the ball mill for proper operation ensure. The calculation formula is below: […]
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More photos at photo gallery Energosteel Company delegation composed of sales and technical support department’s representatives visited Scandinavian partners in September 2017. Cooperation with costumers of this region began in March 2016 and it has managed to take a firm position in a very short time. Scandinavian direction takes a significant part of Energosteel company export. It became a possible, because consumers highly appreciated the quality of grinding balls fourth and fifth hardness groups and the price – quality ratio, as evidenced by regular supplies of these products. During the visit, the delegation met personally with the consumer’s leadership. The technical experts of both sides discussed the grinding process of raw materials at the enterprise, the operation conditions of the “Energosteel” grinding balls. It allowed making a correct assessment of our products performance and identifying areas for improving cooperation directions. Commercial negotiations aimed at expanding the products sales have successfully conducted. We would like to express our sincere gratitude to our partners for the wonderful welcome, excellent work and magnificent experience. It was very pleasant to work with you!
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Elements reducing the steel propensity to corrosion or elements changing the more dangerous corrosion form to less dangerous (for example, the intergranular corrosion transition in uniform one) specially introduced in steel composition during alloying. Chromium, nickel, aluminum and silicon separately or together in various proportions often introduce into steel. These elements presence in sufficient quantities makes the steel resistant in water, in humid atmosphere, in many acids and alkalis solutions and in dry gases atmosphere at high temperatures. Erosion resistance increases in steels with a high carbon content. Energosteel company uses such high-carbon steel, alloyed with chromium, manganese and silicon for the grinding balls fifth hardness group production (DSTU 3499-97 / DSTU 8538: 2015). Energosteel Company uses steel, specially developed our specialists together with hot-rolled round products suppliers for production grinding balls the 3-rd and 4-th hardness groups (DSTU 3499-97 / DSTU 8538: 2015). These steels contain a certain number of alloying elements (silicon, chromium, manganese, vanadium, molybdenum, titanium), that change the metal mechanical properties in micro volumes simultaneously increasing the corrosion resistance.
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We present to your attention an article series devoted to the corrosive wear of steel grinding balls. The grinding balls corrosion accelerated by the oxygen presence in the water. Moreover, a large oxygen concentration leads to a strong increase the medium corrosive activity. However, with a further increase in the oxygen content, the corrosion rate decreases as a result of passivation. The corrosion rate, like any other chemical reaction, depends strongly on temperature. The grinding balls corrosion rate may increase by several orders if the temperature rises by 100 degrees. The grouts very intensively destroy the grinding media steel at low pH values (0-7), i.e. at hydrogen ions high concentration. The corrosion process of steel slow down at pH values greater than 9. Ideally, the environment for the steel grinding balls operation in the mill should be with pH values greater than 9, without the free oxygen presence in water and with a temperature up to 50 degrees. Also, it is desirable to add inhibitors (substances retarding the corrosion process) to the medium
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