Jinan Haoyang Casting and Forging Co., Ltd. has launched new steel balls! Wear is reduced by 20%
New steel balls from Haoyang Casting and Forging Co., Ltd. are now available! 20% reduction in wear, a new cost-saving option for mining and cement enterprises
In the grinding process of mining and cement production, the quality of forged steel balls directly affects production efficiency and overall costs. Recently, Haoyang Casting and Forging Co., Ltd. (hereinafter referred to as "Haoyang") has officially launched the HY-II type high-maintenance forged steel balls through its own R&D. This product, with core advantages such as "low wear, high toughness, and strong adaptability", has been verified through actual testing. The wear of this product is as low as 0.8kg per ton of ore, which is 20% lower than that of traditional forged steel balls. The crushing rate is less than 0.3%, providing a new solution for domestic mining and cement enterprises to reduce costs and increase efficiency.
1. Technological breakthrough: Intelligent hot rolling process + composite heat treatment, creating "hard power" for wear resistance
Haoyang has been deeply engaged in the field of wear-resistant materials for many years. The launch of the HY-II type forged steel balls is a dual innovation achievement of the company in terms of process and materials. In terms of production processes, the company abandoned the traditional air hammer forging mode and introduced a complete set of intelligent hot rolling production line. Through the "automatic feeding - medium frequency induction heating (temperature control accuracy ±3℃) - computer numerical control rolling - online flaw detection" integrated process, each steel ball has a complete and continuous metal flow line, effectively eliminating internal porosity, cracks, etc., and the production efficiency has been increased by 18 times compared to traditional processes, with a daily production capacity of up to 50 tons.
The optimization of material formulation and heat treatment process is the core competitiveness of the product. The HY-II type forged steel balls adopt an exclusive formula of "65Mn B2 B3 base steel + C; Cr, Mo trace elements strengthening", after being processed by the "multiple quenching + isothermal tempering" composite heat treatment process, the surface hardness is stable at 60-64HRC, the hardness difference between the inside and outside is reduced to within 4HRC, completely solving the industry pain point of "outer hardness and inner softness" in large-diameter steel balls that are prone to cracking. In the drop ball impact test, this steel ball can withstand more than 25,000 impacts without breaking, and its toughness far exceeds the industry average.
"Our R&D team spent 18 months, adjusting the material formula and heat treatment parameters repeatedly for different regional mining ores and cement production conditions in various countries, ultimately achieving a perfect balance between 'wear resistance' and 'toughness'," said Mr. Wang, the technical director of Haoyang. "Take the actual measurement data of a certain iron mine as an example, after using the HY-II type steel balls, the grinding cycle of the ball mill was extended again, preventing the ball mill from frequent shutdowns, and the qualified rate of grinding particle size increased from 88% to 96%."
2. Customer testimony: Cost savings of 150,000 yuan per month for a cement group in Shandong
Before the new product launch, Haoyang had reached a pilot cooperation agreement with a large cement group in Shandong (producing 5,000 tons of cement clinker per day) and applied the HY-II type forged steel balls to the Φ4.2×13m cement mill. The group previously used traditional 65Mn forged steel balls, which had problems such as "more than 2.5 tons of broken balls per month, and needing to stop and clear the warehouse every 30 days", not only increasing procurement costs but also affecting production continuity.
Since the launch of the HY-II type steel balls in March this year, the pilot effect has been remarkable: On the one hand, the wear of the steel balls has decreased from 1.0kg per ton of cement to 0.8kg per ton, the monthly steel ball procurement volume has decreased from 18 tons to 14.4 tons, directly saving procurement costs of 8.600,000 yuan; On the other hand, the steel balls have a low roundness loss, the internal grinding efficiency of the ball mill is improved, the clearing cycle is extended from 30 days to 45 days, reducing the downtime by 15 hours per month, indirectly saving electricity and labor costs by approximately 64,000 yuan, reducing the monthly overall cost by 150,000 yuan, and saving an estimated 1.8 million yuan annually.
"The HY-II type steel balls from Jinan Haoyang truly exceeded expectations. Not only are they wear-resistant, but they are also highly adaptable. They do not require adjustments to our original grinding parameters; simply replacing them can be used directly," said Manager Li, the production director of the cement group. "In the future, we plan to replace all the steel balls in the cement mills with the HY-II type, further expanding the cost reduction effect."
III. Service Assurance: Customized Solutions + Rapid Delivery, Solving Customers' Worries
To meet the individualized needs of different customers, Jinan Haoyang also provides the "Exclusive Grinding Solution" service. For mining enterprises, the company will send technicians to conduct on-site inspections of the hardness of the ore, the type of the mill, and the grinding requirements, and customize the diameter of the steel balls (Φ20 - 150mm selectable) and the grading scheme; for cement and power enterprises, it provides "Steel Ball Usage Tracking + Grinding Parameter Optimization" full-cycle services to ensure that customers achieve the best usage effect.
In terms of delivery capacity, Jinan Haoyang relies on its production base in Zhangqiu, Jinan, and is equipped with 3 intelligent production lines. Regular-sized steel balls can be delivered "within 48 hours after placing an order", and the delivery cycle for special-sized customized products is no more than 7 days. At the same time, the company has reached strategic partnerships with logistics companies such as SF Express and Aneng, covering 300+ cities across the country, ensuring the rapid delivery of products to customer sites.
IV. Future Planning: Focusing on Green Production, Expanding Overseas Markets
When discussing future development, General Manager Chen of Jinan Haoyang said: "In the future, the company will continue to increase R&D investment, focus on promoting the 'Reused Waste Steel Ball Recycling' technology research and development, through the 'Crushing - Purification - Reforging' green process, achieve raw material recycling, reduce carbon emissions, and respond to the country's 'Carbon Neutrality' goals. At the same time, we have initiated overseas market layout and are currently negotiating cooperation with a certain gold mine in Southeast Asia, planning to introduce the HY-II type forged steel balls to the international market, allowing more overseas customers to enjoy the high-quality products and services of China's wear-resistant materials."
