Mining is an industry driven by efficiency and productivity. Whether extracting valuable minerals, processing ores, or breaking down rocks, the efficiency of mining operations is directly linked to the equipment and tools used. One critical component in many mining processes is the use of mining balls, which play a pivotal role in crushing, grinding, and processing raw materials. In this article, we will explore the importance of high-quality mining balls, their characteristics, and how they can enhance mining efficiency. The Role of Mining Balls in Ore Processing Mining balls, often made from robust materials such as steel, serve as grinding media within crushing and grinding equipment like ball mills and SAG mills. These balls are essential for breaking down raw materials into smaller, more manageable sizes. In mining operations, the primary goal is to extract valuable minerals from ores efficiently, and the choice of mining balls can significantly impact this process. The Attributes of High-Quality Mining Balls When it comes to selecting mining balls for ore processing, several essential attributes set high-quality options apart: Durability: High-quality mining balls are built to withstand the harsh and continuous impacts of the mining process. They are designed to […]
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Milling is a fundamental process in various industries, from mining and metallurgy to ceramics and pharmaceuticals. It plays a pivotal role in reducing raw materials into finer powders or particles, making them suitable for further processing or use. One critical component that significantly influences milling efficiency is the choice of grinding media, with steel grinding balls being one of the most preferred options for many applications. In this article, we will delve into the world of steel grinding balls, exploring their importance, characteristics, and how they can enhance your milling efficiency. The Role of Grinding Media in Milling Before we dive into the specifics of steel grinding balls, let’s understand the broader context of grinding media in milling operations. Grinding media are essentially substances or materials used to facilitate the grinding process within a mill. They come in various shapes, sizes, and materials, each tailored to specific milling tasks. The primary function of grinding media is to break down larger particles or agglomerates into smaller, more manageable sizes. This process is crucial in industries where particle size distribution directly affects product quality, as is the case in mining, cement production, and chemical manufacturing. Achieving the desired particle […]
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More photos at photo gallery Representatives of the Energosteel company together with their partner the Proses Engineering company have already visited the mining industry exhibition for the sixth time, which took place this year on September 13-16 in Izmir at the Fuar Izmir exhibition center. The MINEX exhibition is aimed at visitors – industry experts, including employees of Turkish and international companies, as well as engineers, consultants, representatives of administrative institutions and scientists. In addition to local companies, participants from Finland, Spain, Great Britain, the Czech Republic, Poland, Canada, China, Iran and South Africa presented their products and services. The focus is on mining machinery, mineral processing machinery and grinding technology. Steel grinding balls produced by Energosteel are well known in the Turkish market. Representatives of our company have held a number of important meetings not only with Turkish consumers of our products, but also with buyers from Azerbaijan and India. The exhibition was very productive and fruitful, we hope that it will allow us to expand our presence not only in the grinding balls market of Turkey, but also in other countries, including the Near East.
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Mining balls, in various forms such as grinding balls, steel grinding balls, forged steel grinding balls, and rolled grinding balls, are indispensable components in the mining industry. These durable and precisely crafted spheres play a pivotal role in crushing and grinding raw materials, contributing to efficient material processing and resource extraction. In this comprehensive article, we will delve into the diverse types of mining balls, their manufacturing processes, properties, applications, and the future of this critical industry component. Diverse Types of Mining Balls Mining balls come in various forms to suit different mining processes and applications: Grinding Balls: Grinding balls are spherical components used in grinding mills to crush and grind raw materials, turning them into fine powders. These balls are essential in the mining industry to extract valuable minerals from ore. Steel Grinding Balls: Steel grinding balls are a subset of grinding balls, specifically made from high-quality steel. These balls are known for their exceptional hardness, impact toughness, and wear resistance. Steel grinding balls are essential in mineral processing, cement manufacturing, and other industries. Forged Steel Grinding Balls: Forged steel grinding balls are renowned for their superior properties. These balls undergo a meticulous manufacturing process […]
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Forged steel grinding balls are a fundamental component in the comminution process, playing a critical role in industries like mining, metallurgy, cement, and utilities. Their purpose is to grind materials into fine powders, essential for efficient processing and production. In this comprehensive article, we will delve into the manufacturing process, properties, applications, and advancements related to forged steel grinding balls. Manufacturing Process of Forged Steel Grinding Balls The manufacturing process of forged steel grinding balls involves several key stages, including: Raw Material Selection: The process begins with the careful selection of high-quality raw materials, primarily high-grade alloy steel. The specific composition of the steel is tailored to achieve the desired properties such as hardness, impact resistance, and wear characteristics. Heating and Forming: The selected raw materials are heated to a precise temperature, typically above the recrystallization temperature, in a controlled environment. Once at the appropriate temperature, the material is formed into the desired shape through forging or hammering processes. The intense pressure and shaping help in achieving the required spherical shape. Heat Treatment: Post-forging, the steel balls undergo a heat treatment process to optimize their mechanical properties. This involves quenching to achieve high hardness followed by […]
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More photos at photo gallery After Azerbaijan, the next stop was the country on the western part of the South Caucasus, sunny Georgia. We have been working with companies from various industries in this country for more than 14 years, particularly cement plants. Despite the global crisis, Georgia’s cement industry continues to develop. In the long term, demand for cement will be stimulated by massive infrastructure projects: the development of the building materials industry, housing construction and large-scale projects. It should be noted that today construction is one of the most dynamically developing sectors of Georgia. Long years of cooperation between our companies there hasn’t been a year we have not visited the production sites of our customers, conducted technical support at the factories. June 2023 was no exception. In the Georgian market, our main clients in the cement industry are small local plants that successfully compete with large foreign holdings. Despite significant competition among world manufacturers of grinding balls, our partners remain faithful to our products – steel grinding balls of «Energosteel» production. During the meeting with representatives of cement production plants, taking into account the wishes of the client regarding the terms of shipment and payment, we have […]
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More photos at photo gallery The driving forces of development of «Energosteel» company are customer orientation and constant expansion of sales markets. We have always been and will continue to be focused on building long-term partnerships with our customers in both developed and new markets. Despite these difficult times, we continue to visit our partners anywhere in the world. Thus, in June of this year, the delegation of «Energosteel» company, consisting of sales department, visited our clients in Azerbaijan, with whom we have a long history of partnership and with our long-time partner – PROSES MUHENDISLIK DANISMANLIK INSAAT VE TASARIM A.S. (hereinafter PROSES). During the meeting, technical and commercial negotiations were held on increasing and expanding the marketing of products in the regions of the South Caucasus, namely Nagorny Karabakh. The peculiarity of this region is that Nagorny Karabakh is rich in deposits of various types of metals. Mainly zinc, lead, copper, gold and iron. There are large deposits of marble and limestone, as well as raw materials for the production of cement, graphite, gypsum, sand, etc. In the long term in Nagorny Karabakh it is planned to build mines and ore-processing plants. Our partner PROSES will be the official […]
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We didn’t stop for a day! Despite these difficult times, ENERGOSTEEL continues to operate, supporting the Ukrainian economy and paying taxes. Every day, our employees come to the plant and, between sirens, continue to do their job in good faith, as we continue to deliver both in Ukraine and abroad. Timely and high-quality fulfillment of our obligations to domestic and foreign partners who trust us is of fundamental importance to us. The company continues to ship high quality steel grinding balls to customers in Poland, Bulgaria, Romania and other European countries. We feel a moral responsibility to continue to support production and provide our customers with high-quality steel grinding balls! Today is the time when we must unite to be stronger! We are together! We are working! The victory will be ours!
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More photos at photo gallery Mining Turkey is Europe’s largest mining exhibition, held every two years. The event covers all aspects of the industry, from mining equipment to grinding balls. Mining Turkey 2022 was held from December 15 to 18, 2022 in Turkey (Istanbul). The company PROSES MUHENDISLIK DANISMANLIK INSAAT VE TASARIM A.S. (the official representative of “Energosteel”) has found an opportunity to present our products (steel grinding balls in European quality) to the participants of the exhibition. During the exhibition, business meetings were held with partners and customers who have shown great interest in our company and products. We thank our partners for the opportunity to participate in the exhibition without being physically present at it.
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We continue to examine the process of grinding minerals in ball mills using steel grinding balls. In this publication, we will look at one experiment, the results of which reveal very informatively the grinding mechanism. In other words, we will try to understand how the grinding of rock particles in ball mills occurs in stages. The nature of the mechanical action of the steel grinding balls on the ore is determined by means of lead markers. During the experimental work, lead particles were loaded together with ore into the working chamber of the laboratory ball mill. At certain intervals in the mill the abraded material was extracted and the lead markers were separated by gravity using a flushing tray or a concentration table. In this way, it was possible to sequence the shape and size of the markers as well as the deformation marks on them. Based on this, the sequence of the grinding process was studied in detail. The research was carried out on a laboratory ball mill with a drum diameter of 42 cm and a length of 52 cm. The drum speed was 20 rpm, which corresponds to the cascade mode of the mill. The volume of […]
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Let’s remember a little bit of theory, and more specifically, what grinding is and by what methods it is carried out at the enterprises in industry. The intensity of many technological processes depends on the value of the total surface area of processed solid materials. The higher this index is, the grinding is more effective. Increase in this indicator is achieved by reducing the size of pieces of material (grinding), which in turn ensures the quality of the finished product. The process of reducing the size of material is called crushing or grinding. Often crushing is defined as the reduction of only large pieces. This process is done in crushers. The process of grinding smaller pieces is called milling. This process is mostly carried out with ball mills, which use grinding balls as the grinding media. Fuel (coal), raw materials (rocks, ores), semi-finished and finished products are crushed. Grinding is called coarse if pieces with cross-sectional size of 1000 to 200 mm, medium and intermediate – in the range of 250 to 50 mm, small in the range from 50 to 20 mm and fine (grinding) – in the range from 25 to 3 mm and less. The overall degree […]
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The grinding process in ball mills (where grinding balls are used as grinding medium) is one of the widely used methods in practice to reduce the size of material particles. There are quite a lot of works devoted to the detailed consideration of interaction process of the grinding balls with the particles of the material. At the same time, the number of works on the calculation of the optimal filling of the ball mill drum with grinding balls is quite small. As a rule, the optimal load is determined empirically, from theoretical studies it is possible to note the methods for calculating the best load E.V. Shelekhov, L.B. Levenson, E.A. Amosov. In the future, we will consider these methods in our publications. As you know, grinding of material can occur due to either falling of grinding balls (waterfall mode of the mill) or due to abrasion of material particles by rolling grinding balls (cascade mode). Let’s assume that grinding of material takes place in the waterfall mode. The falling ball gains energy due to acceleration in the field of gravity, and on impact the received energy is spent on destruction of a material particle. In order to grind the material […]
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More photos at photo gallery Energosteel is glad to find a partner of the raw materials supply for the production of steel grinding balls! In September, the Energosteel delegation visited the production facilities of a metallurgical plant specializing in the production of high quality round steel bars. The plant produces round bars from billet square of its own production. Due to this factor, prices for long products from this manufacturer are very competitive in the market. The metallurgical enterprise produces long products using the continuously cast billets technology. Due to the continuously casting and crystallization, a complete uniformity of the structure of the bar along its entire length is achieved. During crystallization, the formed metal bar is constantly moving up and down relative to the mold by means of small cylinders located in the stream. This reduces the number of cracks (defects). A strong electromagnetic field is created around each stream, which allows the formation of the proper crystal structure of the billet. A round bars are rolled from such a square billet with an already homogeneous and initially structure. Also, in the case of production technology by continuous casting, metal losses for trimming the ends of bars are sharply reduced […]
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We have repeatedly given evidence that the use of grinding balls in grinding material is more effective than the use of a cast iron cylpeb. Since we have a semi-industrial mill, we decided to conduct comparative tests. The subject of comparative tests were two types of grinding media: ukrainian production cast-iron cylpebs 27 * 32 and steel grinding ball 30mm produced by Energosteel. Fig. 1 Cast-iron cylpeps 27*32 and steel grinding ball 30mm The purposes of comparative tests are: Determination of cast-iron cylpebs wear and a steel ball with a diameter of 30 mm wear in the grinding process under equal conditions; Determination and comparison of grinding fineness under the same operating conditions of the tested grinding media. Comparative tests of grinding media were carried out in a semi-industrial two-compartment mill which is installed directly at the plant “Energosteel”. The inner drum of the mill consists of two equal chambers, separated by a partition wall without openings. The rotational speed of the mill drum is 45-51 rpm. Material was crushed simultaneously in two chambers of the mill. Each chamber was loaded with 25 kg of grinding media. Before loading, the entire assortment was weighed and the average diameter of the […]
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Despite the difficult time for our country, we do not stop fighting for the quality of our products – steel grinding balls. In June 2022, the testing laboratory of Plant Energosteel LLC successfully passed the regular certification for the compliance of the measurement system with the requirements of DSTU ISO10012:2005 “Measurement management systems. Requirements for measurement processes and measuring equipment”. The State Enterprise «Kharkiv Regional Scientific and Production Center of Standardization, Metrology and Certification» carried out the audit. Upon completion of the audit, the experts did not issue any comments or recommendations, which indicates the perfection of the measurement system and issued certificate No. 01-0032/2022 on the compliance of the measurement system with the requirements of DSTU ISO10012:2005. An addition to the certificate is on two sheets, since our laboratory has significantly expanded the scope of its activities, introduced new tests to check the quality of products. Improving and guaranteeing the quality of our products is the foundation of Energosteel production no matter what!
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Today we would like to consider a simple, but very important issue. We often say, “you need to choose the right diameter of the balls”. However, the products of all manufacturers are different, and now there is no single generally accepted standard for classifying grinding balls by diameter. Therefore, we decided to expand this concept and help you not to make a mistake when choosing the required size of grinding media. As you know, the quality (technical characteristics and classification) of grinding media, which are produced and used in Ukraine, is regulated by the state standard: DSTU 8538-2015. This document specifies the requirements for the physical and chemical parameters of steel grinding balls produced by any of the methods (casting, forging / stamping, cross-helical rolling) and the classification of these products depending on their characteristics. It also spells out the requirements for the size of the grinding media and the possible deviation in the diameter. Here is a table from DSTU 8538-2015, which indicates the classification of steel grinding balls according to geometric dimensions (diameter). According to the table there are two concepts: conditional diameter and nominal diameter. The conditional diameter is the name of the classification group whose grinding […]
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We recently announced that we have researched the ceramic ball market. We were very interested in this niche. Having understood in detail the technology of using ceramic grinding balls, we had the idea to compare the specific consumption of a ceramic and steel ball. So, in some industries (for example, in cement), along with steel balls, ceramic balls are also used. The main requirement is that when using ceramic balls, the lining of the mill must also be ceramic. In June of this year, our laboratory of metals was equipped with a semi-industrial two-chamber mill, earlier we wrote about it here. Only a few weeks passed the mill was installed and connected to the power supply. Our technical department developed a test methodology that regulated all stages: preparation, grinding, sampling and analysis of the data obtained. The grinding (mill work) lasted 50 hours. The mill turned around at a speed of 45 revolutions per minute. Balls with a diameter of 40 mm were used as a grinding medium. In total, 1000 kg of material was crushed (500 kg in each of the chambers). Every 2 hours, the mill replaced the crushed material (quartz sand). Before the start, a geometric measurement […]
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Grinding balls, depending on their purpose, can be made of various materials, including ceramics. We are seriously interested in the ceramic grinding ball market. For example, most recently, our marketing department conducted a market study of this grinding media type. Ceramic grinding balls are used in the grinding industry, which does not tolerate grinding of harmful impurities and milling, which changes the color of finished products, used in ball mills with the aim of creating a thin grinding, which is necessary in the manufacture of silicate products, cement, glass, paint, lacquer etc. The researched type of grinding balls are used for both liquid and dry grinding types. Ceramic grinding balls are characterized by strength and low abrasion. Aluminium oxide (alumina) balls are very common among grinding ceramic balls. Among the types of ceramic (or alumina) balls, the most common are uralite, alubit, corundum balls. They are produced from the same material (alumina) and are differ only with the content of alumina (%): uralite – 75%; alubit – min 92% (on the Mohs scale – 9); corundum – 95% – the hardest and wear-resistant. In Ukraine, the market for ceramic grinding balls has formed an import-oriented model. Because ceramic balls are […]
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The selection of suppliers is a responsible and important process for us. As we wrote earlier, we approach this issue with special control, since the quality of our products is a priority. On June 13 this year, we visited the plant of the largest manufacturer of hot-rolled steel bars in Eastern Europe, which owns several plants in Poland. The plant occupies 60-70% of the metallurgical market in Poland. This plant rolls round bars of unique steel grades from square billets of its own production. It is very important for us that this manufacturer can meet all our requirements for round bars. This means that we can be sure of the high quality of our steel grinding balls when using this type of raw material. The enterprise impressed with its large-scale well-groomed territories, the number of workshops, and, most importantly, with its attitude towards environmental protection. The production process is automated and well-established using little manual labor with the latest modern equipment from the leading supplier Danieli. The Energosteel Company thanks the representatives of the plant for the warm welcome and the opportunity to visit their production facilities. We are confident that in the future we will be able to establish […]
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