Introduction Some figures to introduce the subject Successively for coarse and fine grinding

How grinding balls are wearing Parameters to take into account concerning the impacts Deformation of grinding balls Grinding balls of tomorrow Several words about metallurgy Quality criteria of grinding balls

(Generations of grinding balls) Maintenance of grinding ball charges

Figures
Diameter (mm) (inch) Weigth (gr) Surface (cm2) Nbr balls Specific surface per mt m2/mt

90 80 77 70 64 60 50 40 38 35 31.75 30 25 23 22.22 20 17 15

1/2"

3" 2 " 2" 1 " 1 " 1" 7/8" 3/4" 5/8"

1/4 1/2 1/2

2,916.841 2,048.590 1,826.658 1,372.396 1,048.878 864.249 500.144 256.074 219.551 171.549 128.061 108.031 62.518 48.682 43.895 32.009 19.658 13.504

254.469 201.062 186.265 153.938 128.680 113.097 78.540 50.265 45.365 38.485 31.669 28.274 19.635 16.619 15.511 12.566 9.079 7.069

342.837 488.141 547.448 728.653 953.400 1,157.074 1,999.424 3,905.121 4,554.750 5,829.238 7,808.779 9,256.602 15,995.393 20,541.473 22,781.638 31,241.213 50,869.875 74,052.133

8.724 9.815 10.197 11.217 12.268 13.086 15.703 19.629 20.662 22.434 24.730 26.172 31.407 34.138 35.336 39.259 46.186 52.344

Figures The composition of the ball charges plays a major role in the grinding energy consumption:
particle size distribution of the feed hardness of the feed other factors like
motion of the charge % of moisture % of slag, pozzolana, ... open/closed circuit

Figures
Costs related to grinding media
grinding media consumption

energy consumption

grinding media charges removing and sorting

Figures

Characteristics and quality of the media :

excellent wear resistance adapted impact resistance excellent resistance to deformation manufacturing quality irreproachable and constant

BALL CHARGES FOR COARSE GRINDING CHAMBERS

Reduction from feed size between 0 and 5 to 100 mm down to product size 100 % < 1 to 2 mm Ball diameter 110 mm - 50 mm Working conditions Medium to high abrasivity Medium to high impact level

Wear factors
NORMAL 1. Abrasion of ground material

2. Friction between balls 3. Fatigue due to repeated impacts 4. Dry corrosion 5. Deformation
ABNORMAL

6. Excessive work hardening 7. Internal foundry defects

Wear factors

3. Fatigue due to repeated impacts

causes MICRO-CHIPPING slight chipping at the surface of the grinding media due to the hardness of the material

GRINDING BALLS WEAR ABRASION + CHIPPING 1 0.9

Wear rate in mm/100h

0.1 0.05 0.03

0.01 Violence of impacts

Clinker

Wear factors

6. Excessive work hardening

causes SCALING chipping on an important depth at the surface of the balls leading to the destruction of the balls

Wear factors
1. Abrasion of material to be ground 2. Friction between balls 3. Dry corrosion 4. Fatigue due to repeated impacts

High Cr cast iron grinding ball

martensitic matrix Chromium carbides

unstable phase

Grinding balls wear Abrasion

Hardness of ground material

<

Hardness of balls

low wear of balls

Grinding balls wear Abrasion

Hardness of ground material

>

Hardness of balls

high wear of balls

Mohs Scale

Other minerals Coal

1 Talc 2 Gypsum 3 Calcite 4 Fluorite

Knoop Hardness (+Shore) 20 35 40 124 136 216 (32) 175 235 305 (58)

Vickers Hardness (HV)

Metallic structures

Rc Hardness

HB (3T30)

5 Apatite Glas 6 Orthoclase Clinker

435 455 ~ 550 (72) 620 (84) 500-800 820 (98) ~ 840 1025 1330 1735 1800 2020 1800 2800 7575

36 110 140 200 190 70-200 170-230 300-460 318 423 440 300-600 544 640 740 500-1010 950 1020

110 200 (11) (13) (5-18) 30-45 43 44 30-55 48 51 60 (48) 65 68 (712) 301 400

Ferrite Austenite (12%Mn) Pearlite (alloyed)

Austenite (Cr. cast iron)

500 600

Martensite fx(C)

Silex 7 Quartz 8 Topaz Fondu Grenat

Hardness scales related to the Mohsscale

Fe3C 1430 1200-1600 (FeCr)7C3 1500 Mo2C 1800 1500-2000 2400 3700 10000 (FeCr)23C6 WC B4C/NbC

9 Corundum

10 Diamond

WEAR as a relation of the ratio existing between the hardness of the ABRASIVE (material to be ground) and the WEAR RESISTING MATERIAL

Ha/Hm Wear or Abrasivity (friction wear essentially)

Ha/Hm

5 Mohsscale

Hard Martensite

(FeCr)7C3

Gypsum

Pearlite

Clinker

Fe3C

10

GRINDING BALLS WEAR ABRASION 1 0.9

Wear rate in mm/100h

Gypsum

0.1 0.05 0.03

0.01 0 1 2 3 4 5 6 7 8 9 10 Ground product hardness scale / Mohsscale

Clinker

GRINDING BALLS WEAR ABRASION 1 0.9

Wear rate in mm/100h

0.1 0.05 0.03

0.01 6 7 Ground product hardness scale

Clinker

Impacts
90 mm

According to the volume of the ball

30 mm

~ 3000 gr

~ 100 gr

Impacts
IMPACT energy of a ball according to its diameter and the diameter of the mill
25.00

20.00 dia 110 mm dia 100 mm dia 90 mm 15.00 kgm dia 80 mm dia 77 mm dia 70 mm 10.00 dia 64 mm dia 60 mm dia 50 mm dia 40 mm 5.00

0.00 1 2 3 Mill diam eter 4 5 6

Quality WHAT IS A PROPER GRINDING BALL ?

MARTENSISTIC MATRIX CHROMIUM CARBIDES AUSTENITE a PERFECT SOUNDNESS

martensitic matrix

Chromium carbides

austenite

Metallurgy

Depth of penetration of the deformation according to the impact force

Metallurgy

Depending of the force yield deformation plastic deformation

Metallurgy
neutral fiber

TENSILE strength

Metallurgy Importance of tensile - compression stresses induced by impacts according to the quantity of residual austenite after quenching

LESS

MORE

CHARACTERISTICS OF THE MAGOTTEAUX GRINDING BALLS FOR COARSE MILLING High hardness throughout
martensitic matrix Cr carbides

martensitic matrix

Chromium carbides

Low potential of work-hardening

controlled low quantity of unstable metallurgical phase

Identical and homogeneous metallurgical characteristics for all the specimens Regular shape Perfect physical soundness

unstable phase

High hardness throughout Low potential of work-hardening

martensitic matrix Chromium carbides

unstable phase

Identical and homogeneous metallurgical characteristics for all the specimens

Same hardness and same homogeneous metallurgical structure are obtained thanks to :
martensitic matrix Chromium carbides

precise chemical composition oil quenching additional heat treatment clean manufacturing conditions

unstable phase

BALL CHARGES FOR FINISHING GRINDING CHAMBERS

Reduction from feed size 60% > 90 microns down to product size 10 - 20 % > 90 microns (C.C.) 5 % > 90 microns (O.C.) Ball diameter 60 mm - 15 mm Working conditions Generally smooth conditions No strong lifting effect Limited impacts

Wearing factors

1. Abrasion of the material to be ground 2. Friction of ball against ball 3. Deformation

CHARACTERISTICS OF THE MAGOTTEAUX GRINDING BALLS FOR FINE MILLING High hardness throughout
martensitic matrix Cr carbides

martensitic matrix

Chromium carbides

Controlled potential of work-hardening

controlled low quantity of unstable metallurgical phase

Identical and homogeneous metallurgical characteristics for all the specimens Perfect physical soundness Regular shape

unstable phase

Identical and homogeneous metallurgical characteristics for all the specimens

Same hardness and same homogeneous metallurgical structure are obtained thanks to :
martensitic matrix Chromium carbides

precise chemical composition high carbon content oil quenching clean manufacturing conditions

unstable phase

 High hardness throughout Controlled potential of work-hardening

martensitic matrix Chromium carbides

unstable phase

Metallurgy
Molding in cluster

Sketch of a mould filled up with liquid metal

Metallurgy

Shrinkage after solidification

Metallurgy

Magotteaux production
Magotteaux yearly produces more than 200.000 Tons of Grinding Media of which 65.000 tons for the cement industry in 10 factories Worldwide

Magotteaux production

All these grinding balls are produced according to the same manufacturing procedure quality control standards securing a same high level of constant quality

Magotteaux production

Besides the activity of producing excellent grinding balls, Magotteaux also offers the services of Process Engineers Magotteaux has a permanent program of research for new more cost effective grinding ball materials

Quality Insurance

Destructive and non destructive visual examination

Gas holes, sand and slag holes, cracks, appearing on surface, or after light fettling

Quality

Above big shrinkage which caused breakage Hereunder little shrinkage appearing after cutting and grinding.

Quality
Y

Sphericity check up

Quality

Swelling phenomenon
real

And tomorrow ...

GRINDING MEDIA cost

waste ENERGY cost