Global Mining Energy Efficiency Transition Spurs Surge in Demand for High Chrome Casting Balls
We speak in the common sense of the grinding ball, is divided into three categories: chrome casting ball, forged grinding ball, ductile casting ball grinding ball. But now the use of ductile cast iron grinding ball is very little, chrome casting ball and forged grinding ball use more common. Here to see the casting ball and forging ball what are the characteristics of each:
By casting melting method of manufacturing the steel ball is called chrome casting ball; do not need to melt casting, just after forging out of the manufacturing of the steel ball is called forged grinding ball. Although only one word difference between the two, the difference is great.
Forged grinding ball through direct high-temperature heating and then through the air hammer and other equipment forging shape, and then after a simple heat treatment, its chromium content of 0.1% to 0.5%, carbon content of less than 1.0%, after high-temperature forging manufacturing, the surface hardness (HRC) can be achieved ≥ 56 or more, but because of the material hardenability of the poorer, hardened layer of only 15 mm or so, so the hardness of the core is generally only 30 degrees and the larger the diameter of the steel ball, the greater the hardenability, the greater the diameter of the steel ball, the greater the diameter of the steel ball, the greater the hardenability. The larger the diameter of the ball, the worse the hardenability. Therefore, under normal circumstances, forged grinding ball using water quenching treatment.
From the abrasion resistance, after quenching and tempering treatment of high chrome casting ball (HRC ≥ 60) hardness is higher than the abrasion resistance of forged grinding ball is more than 2.5 times higher. Through comparison, we can see the obvious advantage of casting ball over forging ball. According to scientific tests: the ton of raw ore ball consumption of forged grinding ball is more than 2 times of chrome casting ball.
Open source wear-resistant use of fully automated heat treatment equipment, according to the size of the diameter of the ball, the use of four temperature zones for high-temperature heating, and the use of cooling process, and tempering and other aspects of the heat treatment, so that after heat treatment of high chromium ball, the core hardness is balanced, are maintained at 58-63HRC, and hardness and toughness to maintain a very scientific value, so that the ball hardness is high and good wear resistance.
According to the latest data of Global Market Insights, with the upgrade of global mining “cost reduction and efficiency” demand, the market size of high chromium alloy cast ball (Cr≥10%) is expected to break through **3.2 billion USD** in 2024, of which the Chinese suppliers rely on the “high hardness + low cost” double advantage of export share increased by 23% year-on-year. Low cost" double advantage, the export share increased by 23% year-on-year.
South African Gold Mining Project Reduces Costs by 23%
In 2023, Open Source Wear provided a Ø80mm high chrome cast ball replacement for forged ball solution for a South African gold mine:
Data Result:
▶ 18% reduction in ton of mine power consumption
▶ Ball replacement cycle extended from 45 days to 110 days
▶ Reduction of integrated O&M costs by US$230,000/year
