The world market for grinding balls is about 5 million tons. According to forecasts from analytical publications, by 2025 consumption of grinding balls is expected to increase substantially. This is primarily due to an increase in the production of iron and non-ferrous ores and an increase in industrial construction. For example, while world production of iron ore was 3 billion tons in 2020, it is expected to increase by 571 million tons by 2025. It should be noted that due to the gradual depletion of the raw material base for the extraction of the useful component, it is necessary to process the rock in increasing volumes and to grind the ore more carefully. Grinding balls tend to wear out (from 0.5 to 2 kg/t) and their acquisition costs are estimated to be between 20 per cent and 35 per cent of the total production costs. In view of this fact, the increasing durability of grinding balls over the past few years has become increasingly urgent. «Energosteel» Company follows this trend, constantly improving the quality characteristics of steel grinding balls produced by our plant. Thus, we have mastered industrial production of steel grinding balls of increased volume hardness. Grinding balls of […]
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In September, our company received a request to calculate the cost of grinding balls assortment. The composition of the assortment was specified in the request: Steel ball 36.8mm in diameter – 43 pc.. Steel ball with a diameter of 29.7 mm – 67 pc. Steel ball with a diameter of 25.4mm – 10 pc. Steel ball 19.1mm in diameter – 71 pc. Steel ball 15.5mm in diameter – 94 pc. We immediately contacted the sender of the request. It was one of the equipment suppliers for industrial laboratories, specializing in the mineral processing industry. This assortment is needed to complete one of Bond’s test mills, which will be delivered to one of Kazakhstan’s ore processing factories. Bond Ball Mill is required to determine the crushing capacity of various ores according to the Bond standard. The Bond index makes it possible to determine the power of the mill needed to produce the required size of the material and, therefore, to determine its model. The net Bond index is determined from the dry grinding of the ore under investigation in the laboratory ball mill. We have written more about this here before. The Bond Mill can also be used to determine or […]
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Manufacture of grinding balls LLC «Energosteel Plant» was launched almost 15 years ago – in far 2007. The enterprise was established during a period of market change, when the quality of the product became dominant in the choice of the product. The plant was built using the most modern equipment. Thanks to the application of advanced technologies and cooperation with a number of research organizations from the very beginning we have been able to achieve the best quality of grinding balls in Ukraine. Today, the threshold of more than 500,000 tons of steel grinding balls has been crossed! The steel grinding balls are the Energosteel’s business card. Ball-rolling production is equipped with two lines with a capacity of more than 70,000 tons per year. Since 2018, production volumes have increased by more than 40%. This was made possible by the continuous modernization of equipment and the introduction of the second line of rolled steel grinding balls. LLC «Energosteel Plant» produces the most complete line of steel grinding balls with diameter from 20 to 125 mm. Moreover, LLC «Energosteel Plant» is the first Ukrainian enterprise where the production of steel grinding balls with increased volume hardness (to 65 HRC). Their qualitative […]
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In the selection of grinding balls, the consumer is mostly based on hardness (hardness group) and chemical composition of the balls. The selection does not take into account such factors as the geometrical parameters (design) of the ball mill, the possibility of changing the technological parameters of the production process (quantity of material supply to the mill, dense modes, etc.). These factors have a significant influence on the grinding process, the grinding balls and the formation of internal stresses in the balls. Energosteel specialists constantly carry out research in the direction of production improvement. In this publication we will discuss the topic of intensity of internal stresses depending on the grade of steel from which the steel grinding balls were made. The steel (analogue Gr.2) was chosen as the material to be analysed and is ideal for the production of 25-80mm high hardness steel balls, i.e. grinding balls that operate in cascade or mixed mode. However, the use of this grade of steel is not always appropriate for the production of 90-125mm diameter steel balls. So what is the secret? As shown in Figure 1, steel Gr.2 has a critical point Mh – the beginning of the 200 ̊С martensitic […]
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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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Not long ago, we announced the appearance of the 6th hardness grade in DSTU 8538:2015. The innovations were more focused on the volumetric hardness of grinding balls. In this article, we want to talk about the fact that even a high value of this indicator does not guarantee high quality. The volumetric hardness of grinding balls is a calculated measure of hardness that generalizes (averages) its value over the entire volume of the grinding ball. The volumetric hardness (VH) is calculated by the formula: where Hsurf, H0,25,H0,5, H0,75, Hc, – the hardness at a distance from the surface of the grinding ball in parts of the radius. Frequently comparing our grinding balls with competitors, the end-user makes a simple comparison of this indicator. In other words, where the value is higher, it is better. This is not always true. For illustration below we shall give a comparison of hardness of steel ball with diameter of 80mm 6 of hardness grade (volume hardness – 59 HRC) of «Energosteel Plant» production with forged ball (volume hardness – 57 HRC) of one foreign producer: As shown in figure, both samples have approximately the same volumetric hardness. In fact we observe that the ball (analogue) is considerably […]
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For the production of grinding balls, Energosteel uses hot rolled round bar from medium and high carbon and low-alloyed steel according to DSTU 8538: 2015. Alloying steel is mainly done by introducing elements that reduce the propensity of steel to corrosion destruction or elements that change the more dangerous form of corrosion to a less dangerous one (e.g., the transition of intercrystalline corrosion to uniform). Steel is most commonly injected with chromium, nickel, aluminium, silicon and molybdenum, separately or jointly, in different ratios. The presence of these elements in sufficient quantities makes steel resistant to corrosion in water, in the humid atmosphere, in solutions of many acids and alkalis and in the atmosphere of dry gases at high temperatures. The erosion resistance increases in steels with a high carbon content. According to DSTU 8538:2015, grinding balls of the “High C” and “High C + Cr” hardness group of production «Energosteel» are made of steels with high content of carbon and alloying elements. In the production of steel grinding balls of “Average C” hardness groups, Energosteel uses steels specially developed by the company’s specialists in conjunction with suppliers of hot-rolled round products, which provide a change in the mechanical properties of […]
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In August 2021, the specialists of Energosteel Company had a business trip to our client in Georgia. This buyer of grinding balls is the first export end-user of our products. The key purpose of the visit is to collect necessary technical information on the operation of steel grinding balls produced by LLC «Plant «Energosteel» in industrial conditions of the client. We will go into more detail about this. Now the whole process of grinding at the customer’s factory has shifted to use steel grinding balls (60 HRC) of 100mm and 60mm diameter. Similar grinding balls of 43 HRC were previously used. Distinctive features of grinding at this enterprise are the following factors: The sufficiently hard and abrasive ore. The grinding is carried out in two-stage sections. Small geometrical dimensions of ball mills, which do not exceed 22-23 cubic meters. Various types (both in shape and material) of armor plates, which are installed in the mills of the first stage. Experience shows that the transition from one type of grinding body to another (any change – the material, size, hardness, etc.) is not always as easy as it seems. In most cases, adjustments have to be made to the process of shredding. Changes […]
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Business meetings with partners are an important part of our business. Email, Skype, mobile phones and other gadgets have come into our lives, but important issues, discussing prospects for cooperation, sharing ideas and experiences we continue to resolve through negotiation. So, the other day TK Energosteel had a seminal business-meeting with a partner who supplies our grinding balls to one of the largest European copper mining and production companies. In 2021, our cooperation reached a new stage of development in connection with the supply of high quality steel grinding balls with high volumetric hardness. According to the Ukrainian DSTU 8538:2015, the grinding balls correspond to the 6th hardness group (to 65 HRC). The balls are characterized by equally high hardness values over the entire cross section of the ball – from the surface to the center, which reduces the percentage of wear to minimum values, and low consumption. In the first half of 2021 the export of steel grinding balls of production «Energosteel» in this region increased more than three times compared to the same period of 2020, and our partner has entered into the five largest buyers of our products. The 2021 tender for the purchase of steel grinding […]
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Automatic grinding media loading into mill most uses in aerated concrete production. 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 fed into the mill and opens the flap after reaching a certain volume and then grinding balls load into the mill. For example, the grinding media specific consumption is 10 kilograms per 1000 tons raw materials grinding. After 1000 tons material loading into the mill, the flap opens for a certain time and 10 kg of grinding balls should enter in grinding channel (approximately 33 pieces of 40 mm grinding balls). Then flap closes and the grinding balls feeding stop. A similar work scheme observed under the condition the person (miller) engaged in flap opening/closing. We draw your attention, it is very important to correctly calculate the grinding balls consumption in order to avoid the mill overloading or underloading by grinding media. The mill loading can […]
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The grinding process is the most energy-intensive part of the production chain for all enterprises. In this regard, each enterprise seeks to lower grinding costs by installing high-capacity ball mills (taking into account plants’ working areas). The grinding capacity of a mill is directly related to its geometrical dimensions. As larger the volume of the mill is, as greater its productivity should be. The largest mills have proven to be used at ore-processing plants. The largest mill seen by Energosteel’s specialists was the first-stage grinder at one of the Russian ore-processing plants. It was 5,500×6,500 in size and had a working load of 270 tons of grinding balls. The ore-processing plant located in Kazakhstan broke all the records. This plant’s ball mills are really huge. The plant’s enrichment scheme includes two types of grinding mills – a SAG mill (semi-self-grinding) and a BALL mill (ball grinding). The semi-self-grinding mill (SAG) is 12.192 m in diameter and 7.01 m in length. Its capacity 898 cubic meters. The operating load is 626 tons. The mill is fed 125 mm grinding balls. The ball mill (BALL grinding) is 8.34 m in diameter and 13.26 m in length. Its capacity 782.06 cubic meters. The […]
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The main document, that regulates the quality of steel grinding balls produced by Energosteel Company, is the standard DSTU 8538:2015. We have repeatedly informed our readers about this standard in the News section, as well as of any changes made to this document. Thus, in DSTU 8538:2015, compared to the previous version, DSTU 3499-97, the 5 hardness grade of grinding balls was significantly underestimated. However, change#3 «returns» the improved quality characteristics of grinding balls to standard. The change#3 was adopted by Order 87 of 11.03.2021 and entered into force on 01.07.2021. What gives us this change#3 to DSTU 8538:2015? First of all, the quality improvement of our products – this is where the 6th hardness grade of grinding balls appeared! Table 2a, which indicates the hardness of grinding balls with high surface and volumetric hardness, supplements the standard. Table 2a Nominal diameter of balls, mm Grade hardness of grinding balls 6 Hardness HRC / HBW, not less than Surface hardness Volumetric hardness From 15 to 55 inclusive 65/653 64/640 60-70 60/590 58/567 80-100 58/567 55/534 110-120 56/545 50/477 What is also important, in this change, amendments were made to section 7: “Grinding balls are fire, explosion and radiation safety products […]
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The steel grinding balls produced by Energosteel Company can be used as grinding media in ball mills, regardless of the armor plates material (steel or rubber). The technical specialists of Energoteel constantly keep their fingers on the pulse and are always aware of all technological changes in our customers’ factories. For example, in our practice, there have been cases where our customers have decided to replace steel armoured plate with rubber. We have provided all information confirms the rubber armor plates use doesn’t affect to the Energosteel steel grinding balls work quality in any way. Energosteel Company specialists have announced benefits the client will receive during use this armor plate type: reduction of the grinding media specific consumption ; increase the armor plate service life; reduction the power consumption, needed for the mill rotation. During several months of interaction of steel grinding balls with rubber lining, all technological parameters of grinding were normal. By contrast, during the period of use of the rubber plate, there was a decrease in the actual grinding balls consumption compared to the planned rate. Thus, Energoteel is fully involved in such technological changes in the enterprises of our clients, and always follows the process of […]
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In June 2021, Energosteel received a request for miscalculation of the grinding balls. It would seem that the classic workings of our company, which for more than 12 years has been specializing in the production and sale of high quality steel grinding balls. The only difference in this request is the grinding material – zinc. This project is only at the initial miscalculation stage. Therefore, the input data are very limited. It is known that to produce a powder it is necessary to grind pieces of zinc, which have passed the stage of crushing on a hammer crusher. After crushing, the material is more homogeneous and the pieces have geometrical dimensions of 3-5mm. Planned capacity is the grinding of 400 kg per hour. The customer asked for advice on what equipment and grinding balls can be used in these conditions. Mechanical grinding of compact metals is widespread in powder metallurgy. The grinding can be crushing, abrasion. It is most appropriate to use mechanical grinding in the production of brittle metal powders and alloys such as Si, Be, Cr, Mn, Al alloys with Mg, etc. In our case, it is necessary to scale up viscous plastic metals (Zn, Al, Cu). The […]
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We have reviewed in some detail the technical characteristics of different grinding bodies that are currently used for shredding materials. There are also rare types of grinding balls on the market. Today we will consider technical characteristics of steel casting balls, define their advantages and disadvantages for both producer and the customer. It would seem that any steel plant could produce goods like cast steel balls. However, in practice this type of grinding balls is very rare in the market. In general, the diameter of these grinding ball ranges from 30mm to 60mm. Cast steel balls refer to steel balls up to 15mm in diameter, which are used in bearings. The main reason why steel grinding balls are not produced by casting is the high cost of the production process. Cast steel balls are not competitive on the market because of that the casting method has a number of technological features that negatively affect the quality of the final product. Despite the fact that the steel cast ball is thicker than the cast iron, this advantage is reduced to «zero» due to a number of the following factors: the incorrect spherical shape of grinding bodies significantly reduces the quality of […]
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The grinding media market of Ukraine is developing under the influence of many factors and is divided into the market of steel grinding balls and the market of cast-iron balls and cylpebs. According to Energoteel Company’s estimates, the volume of the grinding media market of Ukraine is about 220,000 tons. Local producers cover 94%. Steel rolled balls undertake the most significant share (80%) in consumption structure. The market share of cast-iron grinding bodies is less than 20% and decreases each year. This is primarily because the use of steel grinding balls in comparison with cast-iron grinding bodies provides better grinding and lower specific consumption of grinding bodies. It is of particular relevance that the decrease in the consumption of cast-iron cylpebs from 7% in 2018 to less than 2% in 2020. This form of grinding bodies was historically invented in the Soviet era, as it was impossible at that time to produce small-diameter balls by casting. Gradually, this type of grinding bodies has become obsolete due to the more efficient use of the grinding balls assortment of small diameter, which fill the «emptiness» in the mill and contribute to the thinner grinding of raw materials. There are about 10 manufacturers […]
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Each industrial enterprise has two main objectives: to reduce the production cost and to improve the product quality. The only way to achieve such objectives is to select and adopt modern technologies. Thus, one of our partners in 2020 has reached the final stage of the largest project – launching of a new technological complex for production of finished products at the mining and processing factory. This complex includes additional crushing and enrichment sections, a new electrical substation, and a system for transferring prepared raw materials and finished products. Additional conveyor lines connect all these sections. Almost all equipment for grinding rock is produced by Metso Outotec. The ball mill with internal volume of drum 382 m3 attracted special attention of Energosteel specialists. The rate of loading of this mill is 570 tons of steel grinding balls. Grinding is wet. Metso Outotec recommended the use of an assortment of steel grinding balls. Now this mill is loaded with steel grinding balls 90mm of LLC “Plant “Energosteel” production (Ukraine). Note that the selection of the diameter of grinding media for effective grinding took place in several stages: assortments of grinding balls of different diameters (from 60mm to 120mm) were used. In […]
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It is relatively easy to achieve high (64HRC and above) hardness of grinding balls. All that is required is the instantaneous hardening (sharp drop in temperature) of the produced grinding balls. However, every one of you will say that grinding balls will be very brittle. And you’ll be absolutely right. Many grinding media manufacturers ignore all technological requirements of steel grinding balls production and «chase» high level of surface hardness. In the production of steel grinding balls, Energosteel uses a unique method that allows carrying out the heat treatment of finished grinding balls, which allows producing grinding balls of increased hardness with minimum internal voltage of the metal. This method implies setting the optimum temperature of the heating of the rolled round bar before the rolling. The temperature is selected according to the rolled round bar diameter and the chemical composition of the steel. After the formation of the ball, initial hardening in a hardening drum in a liquid medium is made. After the hardened drum the balls, which still has a high temperature and internal voltage of the metal, are self-tempered. It allows to avoid «spotted» hardness. Despite the complexity of this phase, Energosteel clearly meets all process parameters, […]
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