GRINDING MEDIA

 GRINDING MEDIA REQUEST FORM
 

 GRINDING MEDIA PERFORMANSE FORM
 

 ABRASION RESISTANT WHITE CAST IRON MATERIALS
 

 OPTIMISED BALL SIZE DISTRIBUTION
 

GRINDING MEDIA (BALLS,CYLPEBS)

Cemas has been producing top quality grinding media for the cement and mining industries with very high hardness and strength properties since 1982.

Small size balls (Ø 8 - Ø50)and cylpebs are produced at the fully automated.

Disamatic line.

Large size (Ø60Ø100) grinding media are produced at the HWS and Zimmerman fully automated molding lines.

Special Exothermic feeders are being used to prevent inner shrinkage.

Ø60 and Ø70 grinding medias are produced at the Disamatic line as well.

GRINDING MEDIA TECHNICAL DATA SHEET

TECHNICAL SPECIFICATIONS:

DIA (mm)

MATERIAL STANDARD

 

C %

 

Cr %

HARDNESS ( HRC )

15,17,20,25,30

CD 3013

2.9-3.1

12.0 – 14.0

60-66

35,40,50

CD 2613

2.5-2.7

12.0 – 14.0

59-65

60,70,80,90,100

CD 2218

2.1-2.3

17.0 – 19.0

58-64

Silpeps (mm)

 

 

 

 

12*12,16*16,19*19

CD 3013

2.9-3.1

12.0 – 14.0

59-65

22*22, 24*24,25*25

CD 3013

2.9-3.1

12.0 – 14.0

59-65

28*28,30*30

CD 3013

2.9-3.1

12.0 – 14.0

59-65

BROKEN GUARANTIES CONDITIONS:
Our breakage guarantees under normal operation conditions of ball mills and which is subjected to the ball mills not to be operated without fresh feed materials for more than 10 minutes :

In that case breakage;

a) Between % 0-2 : Within in the tolerances,

b) Between % 2-4 : The broken grinding media will be replaced free of charge, 

c) Over % 4 :  The mill circuit has to be completely investigated and audited by mill experts. According with mill audit result that means process conditions are evaluated. Then the amount of grinding media that we would guarantee to change will be negotiated with supplier and customer.

d) The above mentioned breaking Guarantee is valid only for 240 hours run time which is started under normal (optimum) conditions.

General Normal Working Conditions;
These all Guarantee Conditions are valid for the following optimum working conditions;

    • For the first chamber; the maximum ball diameter would be 90 mm and minimum ball diameter would be 60 mm, (Larger than 90 mm balls aren’t allowed in to the mill.)
    • For the second chamber; the maximum ball diameter would be 50 mm and minimum ball diameter would be 17 mm.
    • Broken lines etc. aren’t allowed in to the mill,
    • Chambers should be filled min %28,
    • The material filling in the first chamber should be seen grinding ball diameter as of 1/3,
    • The material filling in the second chamber is generally round 10 cm higher than ball charge level,
    • The mill should not be run more than 10 minutes without feed,
    • For the first & second chamber; the total amount of ball charge will be discharged and cleaning of balls and resizing of balls for every year.

For the other process conditions which are related with type cement and milling situations the Guarantee parameters would be recommended by supplier.


MINING SECTOR

Cemas has been producing grinding media for the mining industry for many years.

Cemas high cromium grinding media shows much greater resistance to erosion/wear during use against forged grinding media and the use of Cemascast grinding media in the mining industry continues to grow.

• The hardness difference between surface and center of a grinding ball is 2HRc in cast grinding balls versus 5HRc in forged grinding balls thereby increasing their consumption levels with increased usage.

• Cast grinding media has Chromium Carbide in its main structure giving it a much stronger martensitic structure versus forged grinding media.

• On forged balls grinding position is important. According to grinding position different abrasions occur This causes non-homogenous abrasions.This does not occur on cast balls.

Forged ball microstructure

Cast ball microstructure

GRINDING MEDIA CONSUMPTION (Gr media/ton raw material)

     
 

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