Energosteel Company successfully passed the technical supervision by the certified quality management system the steel grinding balls production for compliance with DSTU ISO 9001: 2009 in June 2017. State Enterprise “Kharkivstandartmetrologiya” conducted technical supervision. The audit purpose was compliance the quality management system to the planned activities, to the DSTU ISO 9001: 2009 requirements and to the requirements for quality management systems established by the organization; implementation and support effectiveness. The technical supervision results conclusion: The quality management system of Energosteel Company meets the requirements DSTU ISO 9001: 2009 «Quality management systems. Requirements».
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We have considered earlier in detail how to calculate the bulk weight of new grinding media and grinding media loaded into the mill. For many years experience of industrial tests conduction, Energosteel Company specialists noted, not all enterprises have the ability for correctly and quickly measure the grinding balls bulk weight. Let us remind you in order to measure the bulk weigh of grinding balls uses container with regular geometric shape (cube) and volume no less than 1.0 cubic meter. Therefore, the Energosteel Company management decided equip production with two containers meet the specified requirements. This will allow to providing all necessary measurements with minimal error and a time spent minimum and give the results to our customers. Both containers (tubs) have the correct geometric shape – a parallelepiped with sides 118х118х110cm. The each container volume is 1.53 cubic meters. We would to remind, the calculations results will be more accurate if measuring container has a larger volume. Taking into account the crane scales technical parameters; Energosteel Company specialists decided the 1.53 cubic meters is the optimal container volume for the grinding balls bulk weight determination with the minimum error. Crane scales should annually check. Energosteel Company employees measured the […]
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We considered the preparation Methodology for conducting industrial tests in our last publication. The next step is industrial test conduction. During the entire test period, the tested mills work in the normal mode, all the requirements prescribed in the Methodology must be observed. Responsible persons at the enterprise should daily provide all current information on the mill’s performance – the productivity, the preloaded grinding media quantity, etc. by any convenient mode (by phone, e-mail, etc.). It is very important to correctly and accurately measure the grinding media quantity in the mill during industrial tests. Measurements perform in mill by measuring the following parameters: the mill inner drum diameter; the mill inner drum length; the distance from the drum mill center to the surface of grinding balls. Measurements taken at three points: mill power point, at mill center point and in mill unloading point. Two measurements are taken at each point: first measurement make in the “hollow” between the armor plate lifters, the second measurement make on the uppermost part of the armor plate lifter. Then, the obtained measurements averaged (by the arithmetic mean) and used in further calculations. The measurements can make by any measuring device – laser or ordinary […]
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We have come to the industrial test stage for a complex works on the preparation Methodology for conducting industrial tests and it signing. Methodology for conducting industrial tests is the main document completely regulates the testing process, starting from the grinding balls incoming inspection to final test results calculation. The main thing is that all members directly related to industrial tests from both sides (the enterprise and grinding media supplier representatives) should participate in the Methodology writing. Members from third side (for example the specialized scientific and technical organizations) can participate in industrial tests. Let’s consider the main points and briefly describe their content. The title page. It must include all industrial tests participants and their positions. The enterprise and testing grinding media indicates on the title page. The title page certified with industrial tests participant’s signatures and enterprises seals. The introduction (the test object). This chapter indicates the test place (a factory, a section, a mill number, etc.) and clearly describes the testing grinding media physical and technical characteristics. As a rule, this chapter also describes the current situation in the grinding process – grinding media type, their specific consumption and other ball mill (section) technical and technological parameters […]
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There is a rapid rise in prices tendency in the world. The prices increase for iron ore and coking coal, quotations increase for a square billet and scrap metal. This is entails the raw materials prices increase for the steel grinding balls production. In this regard, Energosteel Company expands the raw materials suppliers. Energosteel delegation held meetings with potential partners, visited raw materials producers enterprises to assess the offered products in August 2017. Close acquaintance with the representatives of the companies and the format of live communication given the opportunity to identify the most optimal suggestions which will allow us to offer our customers the grinding balls with most appropriate to their requirements for price and quality.
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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 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. Energosteel Company key strategic directions aimed at improving the products quality, developing new sales markets and expanding export supplies. Thus, 65% of Energosteel steel grinding balls sold on the domestic market, while 35% were exported during the first 6 months 2017, versus 75% and 25% respectively for the same period in 2016. The exports increase became possible due to sales increase in 4.5 times to the CIS countries, as well as through the new markets development in the directions – the EU, the CIS, the Middle East countries and the Baltic States. The customer numbers increased on 6% in January-June 2017. The realization structure of grinding balls different harnesses. The production volume of grinding balls fifth hardness group increased by 2 times in January-June 2017, comparison to the same period in 2016. […]
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We had describe two main methods for full-scale industrial tests conducting (method with a new grinding balls; method by replacing grinding balls) in previous article. We will consider the third method in this article. This method is not as popular as the two previous ones and it is an intermediate step, between the technical and economic negotiations and industrial tests conduction. This method calls “the labeled ball method” by technicians. The specificity of this method is problematic determination the exact specific consumption of tested grinding media, according to the industrial tests results. This indicator can only be predicted (measurement error can be more than 15%). This method used when needs to determinate grinding media material (cast iron chemical composition, various steel grades) optimally suitable for specific grinding conditions. This method essence is that a certain amount of marked grinding balls load into the ball mill with grinding media. Marked grinding balls need to be weighed and their geometric dimensions should be determined before loading into the ball mill for a reference comparison point formation. The marking grinding balls method depends on their production method: – Steel rolled balls marked by drilling holes in them at 0.25-0.30R depth. If grinding media […]
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We continue to consider the main stages of industrial tests. In this article, we consider the next stage in full-scale industrial tests conducting – the testing method determination. Two methods (variants) use for industrial tests conducting in practice: tests providing with a new grinding balls; tests conduction by the replacing grinding balls method. The first test method implies the new grinding balls loaded in empty test mill. As a rule, this is assembly of grinding balls. The assembly average diameter should be equal to the grinding balls average diameter in the operating mill (prior to the spent grinding balls unloading). We indicated two ways for determination the average diameter of grinding balls in a mill at our previous articles (The grinding balls bulk weight in mill without unloading grinding media and The grinding balls bulk weight in fully unloaded mill) . This method use when the mill put into operation after major repairs. This method advantages: there is 100% guarantee, all mill performance refers to the testing grinding balls during industrial test; the shorter testing period; there is no need to purchase additional grinding balls volume. The second testing type used when there is no possibility to overload mill with […]
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More photos photo gallery Energosteel company delegation composed of sales and technical support department’s representatives visited Azerbaijan partners in July 2017. One of the mining & processing enterprise-partner was visited together with Proses Mühendislik Company. The main purpose of business trip was conduction technical, economic and commercial negotiations and acquaintance with the new management team of some partners. As a business visit result, our technical specialists evaluated Energosteel grinding balls performance at customer enterprises. This allowed us to determine the directions for improving the grinding process at client plants. Also, negotiations successfully held about grinding balls sales increasing and developing even more effective cooperation in this region. We would like to express our sincere gratitude to our partners for the warm welcome, excellent work and open tone of the negotiations. It was a pleasure working with you!
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We continue the articles rubric, where we cover the main stages of conducting full-scale industrial tests. The next industrial tests stage is the testing place determination. The testing place determination for tests conduction depends directly on the client’s production capacity. If client has only one mill for material grinding, then choice is obvious. In most cases, our customers have several “knots” for material grinding; therefore, testing place determination is an important objective before industrial tests starting. Consider the option when the client has several ball mills and each mill operates according to an individual grinding scheme. Such material grinding scheme can be found in a gas-concrete or cement industry, i.e. mills operate independently of each other, but generally have a total power (a hopper). In this case, need to select for industrial test a mill launched into production after major repairs (armor replacement, electrical equipment repair, etc.). Also, the indicators adopted for further comparison by the test results, select at this stage. As a rule, these are planned indicators. They are prescribed in the documents regulating the production process. Similarly, the comparison can occur with operation results the “neighboring” mill or with the mill’s indicators attained before repair. We draw […]
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We began considered set of measures needed to perform for qualitatively industrial tests such way, that results could be projected at whole plant technology. In this article, we will consider the second and third stages of industrial tests, namely: – Responsible person’s identification. They are directly involved in industrial tests; – The industrial tests tasks and objectives definition; Seems, the responsible persons identification stage is quite simple, but in fact, this is not so. Many employees of various company services involve in industrial tests conducting, starting from the warehouse employees and ending with the main enrichment (technical director) of the enterprise, where industrial tests planned. All employees who directly or indirectly can influence on the industrial tests result (compliance with the Test Procedure requirements) should be informed about the experiment. To each employee assign the tasks aimed at the proper conduct of industrial tests.It is important, all employees involved in the experiment should be informed that the representative of grinding media manufacturer has the right to receive any information regarding the test conduct (within the limits specified in the Methodology).Summarizing, we can safely say, the both sides participants of experiment (the client and the grinding media producer) form a single […]
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Energosteel company delegation visited the Ukrainian-Belarusian business forum on the 21th June 2017. The forum was organized within the framework of the President of Belarus Alexander Lukashenko visit to Ukraine and aimed at developing trade and economic relations between the two countries. Over 300 Ukrainian and 90 Belarusian companies attended the forum. The business elite of two countries discussed ways for develop bilateral cooperation in trade, engineering, industrial production, agriculture, infrastructure construction, etc. Particular attention was paid to the Ukrainian-Belarusian cooperation issue for the export to the third parties markets, including the European Union countries. A ceremony of signing 16 commercial contracts between Ukrainian and Belarus enterprises held within the framework of the event. Energosteel used the Ukrainian-Belarusian business forum as an exceptional opportunity to meet, establish connections and do business with potential partners and existing key market players in the region.
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As we noted earlier, for many years experience in grinding media market Energosteel Company specialists have conducted many industrial tests to evaluate the steel grinding balls performance produced by Energosteel at production bases of our customers. Industrial tests conducting is an activities complex aimed at organizing, implementation monitoring (observance of all conditions prescribed in the Methodology), and indicators calculation characterizing current and final test results, recommendations development for grinding process changes. As general rule, the customer’s technical and economic department completely revises the normative parameters of the material grinding process (most costly part the finished products production) following the results of such tests. This shows the importance of the various tests accuracy and quality. The main stages of industrial tests are below: The technical and economic negotiations conduction for research objects determination; Responsible person’s identification. They are directly involved in industrial tests; The industrial tests tasks and objectives definition; The testing place determination; The testing method determination; The testing technique preparation; The industrial tests conduction; The summing up of industrial tests. Each of the above-mentioned stage includes the technical and economic measures complex covering decision making on all possible factors that can directly and/or indirectly affect to the final result. […]
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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 […]
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The metals and alloys structure distinguishes by: the macrostructure, the microstructure and the fine structure. There are three methods for their investigation: Macroscopic analysis Microscopic analysis X-ray diffraction analysis and X-ray flaw detection The macroscopic analysis. Macrostructure is the metals and alloys structure that can be visible with small magnifications by a magnifying loop (up to 30 times max). The macrostructure investigated by macro analysis. Metals are non-transparent substances and their structure investigated in the fracture or in specially prepared samples (macrosections). The sample cuts from a certain location in a certain plane, depending what examine (casting, forgings, stamping, rolling, welded or thermally processed details) and what needs to identify (primary crystallization, structural heterogeneity, defects breaking the metal continuity). Therefore, the samples cut from one or more ingot places (or billet, or detail) in the longitudinal and transverse directions. The sample (template) surface leveled on the emery wheel and then ground. The template etched in special reagents after grinding. The reagents differently dissolving the structural components and irritate the defects. Macroanalysis reveals: the fracture type (brittle, viscous); the size, shape and location of grains and cast metal dendrites; the ingots and castings defects(shrink sleeves, gas bubbles, cracks); the defects breaking […]
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Material science is an applied science studies the interrelationships between the metals and alloys composition, structure and properties under different conditions. Studying this discipline allows the rational selection of materials for a particular application. Metal science is a constantly developing science continuously enriched by new steels and alloys creation, which stimulate progress in all science and technology fields. Material science exists for about 200 years as a science, despite the humanity used metals and alloys for several millenary before our era. Scientific results allowing start meaningful study all accumulated knowledge by humanity for the whole time of using metals appeared only in the 18th century. Researches of French scientist René Antoine de Réaumur (1683-1757) has been great importance in the metals nature study. He conducted researches of the grains structure in metals in 1722. English scientist Grignon in 1775 drew his attention to the columnar structure formed during the iron solidification. He owns a well-known picture of dendrite obtained with the cast iron slow solidification. M.V. Lomonosov (1711-1765) was the first in Russia who has scientifically comprehended the metallurgy and foundry problems. He wrote a training manual “The First Metallurgy Fundamentals in Ore Mining”, where he described the metallurgical processes […]
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The steel tempering – is a heat treatment process, when steel heated to a critical temperature and rapidly cooled. This treatment purpose is to increase the hardness and strength of the detail with a decrease its plasticity. The steel tempering in one environment This tempering is easier to perform, but it can’t be used for all steels and steel products. Rapid cooling of products with variable cross-section in a large temperature range contributes to occurrence the temperature unevenness and high internal voltages, called thermal voltages. In addition to thermal voltages, the austenite transformation to martensite creates additional structural voltages, because this transformation occurs with a volume increase. If detail has a complex shape or a variable cross-section, then volume increase passes unevenly and induces the internal voltages occurrence. The high voltages presence can induce the product warpages, leashes, and sometimes cracking. Cracking occurs if the internal voltages magnitude exceeds the ultimate strength. The more carbon content in the steel composition means more volumetric changes and structural voltages, and greater cracks risk. Steel with a carbon content more than 0.8% tempered in one environment when products have simple shape (balls, rollers, etc.). Otherwise, the steel tempering preferred in two environments or […]
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The rolling process of “Energosteel” grinding balls corresponds to high-temperature thermomechanical treatment significantly increases the products strength and hardness. HTTT provides the austenite deforms in thermodynamic stability area and then conduct hardening for martensite. Low tempering follows after hardening. The main aim of simple heat treatment is to exclude special heating for hardening from deformation (rolling) heating. Thanks to this, we get an economic effect. HTTT main goal is to increase the steel mechanical properties. The martensite inherits the substructure of recrystallized austenite formed during hot deformation, under HTTT. The best complex of mechanical properties achieves if martensite formed from austenite with a well-developed polygonized structure. Martensitic crystals completely imitate the dislocation subbands of the hot-deformed austenite. Dislocations interlacing inherited by martensite, also. The strength threshold, the fluidity threshold and substructure martensite characteristics increase under HTTT, as a result of the martensite crystals fragmentation by subgrain boundaries. We are only talking about substructure martensite characteristics enhance plasticity by strength increasing. HTTP allows obtain higher plasticity indices at the same strength, in comparison with simple hardening and tempering. Temper brittleness can be abruptly weakened with the HTTT help. In this case, the intra-grain destruction occurs instead of intergrain destruction typical for […]
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