A Case for Forged Mill Balls - EIZ Meeting, Livingstone, Zambia, 2008
Presentation on forged mill balls production in South Africa
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Transcript of Presentation on forged mill balls production in South Africa
Promoting forged grinding media in the mining industry
A comprehensive roadmap
by
Ken Seecharran (Process Consultant)
Forged Grinding Media in the Mining Industry
THE MILLING PROCESS
Forged Grinding Media in the Mining Industry
A MINE’s COST PROFILE
The cost profile of a typical mine is as follows:
• 10% power
• 10% diesel
• 10% explosives
• 10-20% labour
• 10 mining chemicals
• 10-20% maintenance spares
• 10% overheads and general administration, and
• 10% grinding media
IT IS THIS NICHE AGNISTEELS CAN EXPLOIT
Declining metal prices makes this a prerequisite
Forged Grinding Media in the Mining Industry
….THE WAY FORWARD….
IT IS RECOMMENDED THAT ATTENTION BE FOCUSSED ON CENTRAL AFRICA
• Ores of DR Congo and Zambia consume about 0.8kg of mill balls for
each tonne of ore milled
• This translates into a market of approximately 75 000 tonnes per annum
•This market comprises 3 types of mill balls, namely:
• appro imatel ⅓ ast steel alls
• appro imatel ⅓ hrome-alloy balls, and
• appro i atel ⅓ forged steel balls....THIS IS THE NICHE AGNISTEELS SHOULD EXPLOIT
• Agnisteels has the following distinct advantages, compared to its competitors
(mainly from China or south-east Asia)
• Manufacturing is based in Port Elizabeth so transportation cost is lower
• Lead time is shorter
• Technical support is a 2-3 hour flight away, and
• Manufacturing is based in a country with a formidable mining history
Forged Grinding Media in the Mining Industry
….BREAKING IN TO A NEW MARKET….
BECAUSE OF THE INERTIA OF THE MINING INDUSTRY, BREAKING IN TO
A NEW MARKET DOES POSE CHALLENGES, AS FOLLOWS:
•Cost effectiveness of the product is always paramount. It ought to be
stressed to the prospective customer that they need to look beyond
the $/tonne window. A holistic approach is a prerequisite. This comes
in the following form:
•$/tonne as a starter
• Quality of the ball. A poor quality ball has the following detrimental effects:
• Broken balls take up space in the mill and are too small to do useful work
• Broken balls contribute to iron (Fe) ions in the flotation or
leaching pulps, in both cases, metals recoveries are depressed
• Broken balls wear pumps/cyclones/mill liners and pipelines, and
• Broken balls leave less power to break rock, thus: Motor Power = Power to turn the mill + Power to tumble the charge + Power to break rock
• Decision makers in the mining industry come in three forms, as follows:
• Those promoted by virtue of experience, they will resist change and
are contented to go with the status quo until retirement
• Those with a combination of experience and qualifications. They stand a 50/50
chance of implementing change, and
• University graduates who are analytical and embrace change
BALLS PRODUCED BY AGNISTEELS ARE OF THE HIGHEST QUALITY
Forged Grinding Media in the Mining Industry
….AGNISTEELS MILL BALLS….
Forged Grinding Media in the Mining Industry
….EXAMPLES OF BROKEN/POOR QUALITY BALLS….
Forged Grinding Media in the Mining Industry
….EXAMPLES OF BROKEN/POOR QUALITY BALLS….
Forged Grinding Media in the Mining Industry
….EXAMPLES OF BROKEN/POOR QUALITY BALLS….
Forged Grinding Media in the Mining Industry
….EXAMPLES OF BROKEN/POOR QUALITY BALLS….
Forged Grinding Media in the Mining Industry
….EXAMPLES OF BROKEN/POOR QUALITY BALLS….
Forged Grinding Media in the Mining Industry
….EXAMPLES OF BROKEN/POOR QUALITY BALLS….
Forged Grinding Media in the Mining Industry
….OUR PRODUCTION PROCESS….
PRODUCTION IS BY MEANS OF INDUCTION FURNACES AND ROLL FORGING
THE FOLLOWING ADVANTAGES ARE CHARACTERISED BY THIS METHOD:
• Homogenisation of the melt due to efficient stirring
• Less oxidation loss (dross) because of no local overheating
• Highly accurate alloying process
• Well defined melt temperature
• High quality of the melt, even with cheap charge (scrap)
• High throughput because of fast melting and faster heating up of the melt
• High furnace efficiency
• Good working conditions for the furnace workers
• Environmentally friendly (minimal dust emission and no exhaust gas)
THE QUALITY AND COST SAVINGS FROM THESE BENEFITS ARE PASSED
ON TO OUR CUSTOMERS
Forged Grinding Media in the Mining Industry
....INDUCTION FURNACE....
Forged Grinding Media in the Mining Industry
….THE ANNEALING PROCESS….
THIS PROCESS IS A PREREQUISITE IN METAL WORKING
It involves heating the metal to above its crystallisation point, in the
process, atoms migrate in the crystal lattice and the number of
dislocations decreases, leading to the change in ductility and hardness
Forged Grinding Media in the Mining Industry
….AGNISTEELS’ RANGE OF MILL BALLS….
Agnisteels can offer the full spectrum of mill balls for the mining
Industry. This can cover applications for:
• SAG mills
• Ball mills
• Regrind mills, and
• Verti/Tower mills
PLEASE GIVE US THE CHANCE TO WORK WITH YOU
Our comminution consultant will assess your needs and make the
necessary recommendations, following a comprehensive plant audit
Forged Grinding Media in the Mining Industry
….ADDITIONAL HIDDEN BENEFITS…. OUR HOLISTIC APPROACH WILL IDENTIFY ALL POSSIBLE BENEFITS OF USING
OUR MILL BALLS. ONE AREA OFTEN OVERLOOKED IN USING A POR QUALITY
MILL BALL IS THE PEENING OF A MILL’s DISCHARGE GRATE
The detrimental effects being:
• Reduced mill throughput
• Overgrinding of the ore
• Increased power consumption, and
• Reduced liner life (a major cost component)
Forged Grinding Media in the Mining Industry
….THE ALLOYING PROCESS….
ALLOYING ENTAILS FILLING OF THE INTERSTITIAL SPACE
OF THE IRON LATTICE, THUS MAKING IT MORE RIGID
AND HARDER
Forged Grinding Media in the Mining Industry
….THE ALLOYING PROCESS….
WE CAN ADJUST BALL HARDNESS TO MEET CUSTOMER’s NEEDS
THROUGH OUR SUPERIOR AND PRECISE ALLOYING PROCESS
Forged Grinding Media in the Mining Industry
…. THE ANNEALING a d HARDENING PROCESSES ….
Forged Grinding Media in the Mining Industry
….THE RESULT OF GOOD ALLOYING….
Forged Grinding Media in the Mining Industry
….THE PRICING STRUCTURE….
Usually:
• 30% of the cost with a confirmed order
• 40% when the ship is loaded, and
• 30% when the ship docks at its destination
The downturn/downsizing in the mining industry means that there are
dozens of cancelled orders in China in which customers have lost their
30% deposit. That deposit, or a greater part of it, is passed on to new
customers as a discount
SUCH MOVE/TACTIC IS EPHEMERAL
.......AND WILL SOON BE EXHAUSTED
Forged Grinding Media in the Mining Industry
Please give us the chance to work with you
Thank You
The End
Any Questions?