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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We have emphasized in our articles that it is very important to observe the requirements specialized GOST when preparation the grinding ball surface for the hardness measuring. In this publication, we will give one example that will demonstrate the dependence of hardness measurements results on the correct surface preparation. In February 2021, we received a complaint from one of our clients. We are talking about steel grinding balls 120mm in diameter. 10 grinding balls were selected for the quality control. All samples were prepared for hardness measurement. The surface hardness test showed an average hardness of 49.37HRC. Furthermore, the range of values oscillated from 31HRC to 60HRC. The results of the firmness measurements differed significantly from those noted in the batch certificate. In order to resolve this situation, we have requested the above samples. The presence of the «overburn» metal and the high roughness of the measuring surface were observed on all samples. All these facts indicated that the preparation of the hardness measurement surface was not in compliance with all the requirements. All the samples received were once again prepared at the Energosteel Laboratory. The results showed that the mean hardness of the samples obtained was 58.2HRC. The range was […]
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Business relationships – are a guarantee of the company’s success. Regular customers – are the gold reserve of our company. This week, one of the key meetings took place with our partners, relations with whom we have been building for more than 10 years. During all these years, not only business relations have developed between our companies, but also relations of mutual understanding and mutual assistance in the difficult conditions of a market economy. Joint participation in various projects and events has brought our teams together. This meeting was dedicated to a wide range of issues from different areas of our business, and we are confident that the agreements that were reached at it will bring results. We would like to express our gratitude to our partners for the visit, for the fact that, observing all quarantine restrictions, we were able to find the strength and time and hold a joint strategically important meeting.
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To date, only two enterprises in Ukraine use vertical mills: one is a cement producer and the other is a ore-processing plant. Both enterprises have been reliable partners of Energosteel Company for more than 10 years. This type of mill is used to achieve maximum grinding of the material. As a rule, the finesse of grinding is in the limit of minus 20 microns. The capacity of such mills shall not exceed 6mm. The grinding in such mills takes place in a vertically arranged screw which rotates and mixes the material with grinding media – steel grinding balls of 11-20mm in diameter. Such mills are seldom refilled. This is due to some technical inconvenience and the long waiting period for such work. Therefore, to maximize the economic impact of such mills, only high-quality grinding balls should be used. At the moment Energosteel Company is negotiating the possibility of carrying out industrial tests – application of steel grinding balls of our manufacture. To sum up, we note that the Vertimills belong to the equipment of thin grinding. For efficient operation, the grinding material should be shredding in the ball mills.
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Summing up the year 2020, we can very calmly state that Energosteel’s grinding balls compete with similar products of world producers. Thus, we have significantly increased sales in the foreign market. At the beginning of 2021, we received several requests to calculate the grinding balls assortment for the loading into ball mill. In this article, we will consider the one of the requests from a company based in Yemen that specializes in cement production. Production parameters: Inside diameter: 4.2 meters Total inside length: 13 meters Production capacity: 75±10t/h (Closed circuit, ordinary carbonate cement, specific surface area: ≥320m2/Kg) feeding size≤5mm, moisture≤0.5%, air speed in mill ≥0.5m/s. Mill rotary speed: 15.8±0.1r/min Charging capacity of grinding medium: 230 ton. The raw material for cement production has a high abrasion rate. Consequently, when calculating the assortment the balls with increased volumetric hardness have been taken into account. Into the first chamber of two-chamber mill is loaded with balls from 80 to 40 mm in diameter. The second chamber is loaded with balls from 40 to 25 mm in diameter. The calculation the average diameter of the grinding ball in each chamber showed that the following assortment of grinding balls should be used for maximum […]
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In January, we take stock of the work done, draw conclusions and plan. We summed up operations in 2020. What about SEO promotion? The results of the 2020 SEO-promotion compared to 2019 we’ve presented in the figure below: In 2020, the number of visitors to our site increased by 6%, and traffic by 7%. The top 10 most popular pages among our readers are: Grinding media & grinding balls Investigation methods the metals and alloys structure The system of a ball mill Steel pearlite class The operating principle of the ball mill Contacts Manufacturing Ukrainian cement plants Ukrainian mining & processing enterprises Types of grinding mills for raw materials . We are glad that our materials in the corporate site are useful to our audience and arouse interest of our customers. In 2021, we will prepare useful information for all specialists of the industry.
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The New Year is a time for stocktaking. We all reflect on the question: What have we achieved over the past year? The past year has been a challenging one for many of us. The COVID-19 pandemic has defined the entire past year and the waves of lockdown have become a problem not only for individuals, but also for businesses. However, despite the crisis, the past year has been a year of challenges as well as advances for Energeteel. The highlights of the past year are as follows: The exports share in 2020 increased by 19%. The number of customers increased by 3.7%. The production of steel grinding balls of high hardness (60-65 HRC) increased twice in 2020 as compared to 2019. In 2020, numerous industrial tests of our products were carried out at the customers’ enterprises in Ukraine and abroad, started ball mills with Energeteel balls at the new aerated concrete plant. An important achievement in the past year was the new service on the site — “Calculation Of The Filling Degree The Ball Mill with Grinding Media”. This service has become useful for many of our customers of steel grinding balls. Last year, Energeteel increased its presence on […]
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We have repeatedly referred to the term “the mill filling rate by grinding balls”. At first glance, it is a simple term, which means the necessary quantity of grinding balls in a ball mill for the most effective grinding of the material. The filling rate may be expressed in two ways in the technical documentation: by indicating the mass of grinding media or by the percentage filling by grinding media of the internal mill drum. It is important to understand which values should be used in practice. This is particularly important in industrial trials, where every unaccounted tone of grinding balls can affect the outcome. Given the long-term nature of industrial trials, the error in the calculations increases and substantially distorts the results. For example, the filling rate of ball mill (78 cubic meters) is 44% (according to the technical documentation for the mill). Knowing the bulk weight of grinding balls, we understand that for the efficient operation of the mill it is necessary to load 374 tons of grinding balls. However, the internal diameter of the ball mill gradually increases during the operating time. This is especially true when using a steel lining. We understand that increasing the volume […]
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Grinding balls are the main component in the grinding materials process in the production of cement, electricity, gas concrete, glass, silicate products and the production of metals. Grinding balls are used as a grinding medium in the ball mills for the production of the above products. Grinding balls are classified as consumables; their cost is fully included on the cost of the finished product. It is well known, the cost of grinding balls is about 30% of the total costs of grinding process. Therefore, it is very important to use high-quality grinding balls in the grinding process. The question is how to convince the customer of the grinding balls quality? Energosteel Company is 100% sure about the quality of its own production and is ready to provide guarantee for its grinding balls. In general, the following indicators are the subject of warranties: Fracture rate of grinding balls in the ball mill; The service life (specific consumption) of grinding balls. However, the guarantee availability depends on specific operating conditions and is provided after careful technology analysis of the shredding process technology on a case-by-case basis. In turn, the customer, who received the grinding balls and the quality guarantees are provided on […]
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The activity of «Energosteel» company associated with the need to deliver the goods — grinding balls, raw materials and components. In many cases, the cost of delivery has quite a large share of the company’s total costs, so the optimization of these expenses paid a great attention. Logistics of our company is an integrated process designed to promote the creation of customer value with the lowest total cost, customer satisfaction of our grinding balls and facilitate production and marketing activities. Logistics and customs clearance department of company «Energosteel» chooses the best route and the type of vehicle for delivering grinding balls worldwide. Grinding steel balls for ball mills can be delivered in bulk or in big bags, in barrels or containers or though another most effective means for the customer. In calculating the cost of the delivery the grinding balls, experts of Energosteel consider not only the price segment of the shipping cost, but also customer requirements for the method of delivery (type and specifications of the vehicle) that may affect the safety of goods on the route and the speed of its acceptance and / or unloading, which reduces delivery costs. One example of an individual approach to the […]
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