Griding Media - Forged

FORGED BALLS - SUPERIOR  &  FORGED BALLS - EXTREME

FTRsteel has developed a strong & unique process to categorize each milling application with the aim to identify & supply the best-suited steel forged grinding media for horizontal ball mills including the selection of standard or high impact grades for SAG mills. The software, developed by our experienced engineers according to actual application process database, defines the right solution(s) by FTRsteel to reach optimal benefits for the endusers.
 

►FORGED BALLS - SUPERIOR 

Forged Balls - Superior class grinding media are  manufactured by precisely sampling at each production process step. The quality control engineers follow up all the steps in production in order to sustain the quailty of the balls manufactured according to pre-defined and international standarts.

At the last stage prior to packing, all the grinding media is 100% controlled manually and visually to prevent possible unshaped balls. This is one of the certifications FTRsteel apply that our quality procedures are secured technically before shipping, and accomplished 100%.

The raw material quality controls are performed according to pre-defined narrower and strict tolerances in order to secure the prodution at the first step starting from material quality inlet.

The Superior forged balls offer minimum 10% less wear rate (gr-wear/1-mton-ground-ore) compared to any other grinding forged media at the same working conditions.

 

 

General Specifications :
► Diameters from 20 mm (0.75’’) to 150 mm (6’’)
► Hardness from 50 HRc to 65 HRc
► Breakage rate: 3.0% max
► Fatigue impact test:  Ak. = 12 J/CM2 min  12000 times with a free falling dropping test machine of 6 meters.
► Packing :
                    1000 kg net in big bags for all diameters. Or,
                    935 kg net in steel drums for Ø20 mm (0.75’’) - Ø70 mm (2.75'') diameters,
                    915 kg net in steel drums for Ø80 mm (3.25’’) - Ø100 mm (4'') diameters,
                    850 kg net in steel drums for Ø110 mm (4.33’’) - Ø125 mm (4.92'') diameters,
                    800 kg net in steel drums for Ø130 mm (5.11’’) - Ø150 mm (5.90'') diameters.
                    The steel drums are transported on the ISPM-15 certified wooden pallets, or without pallets.
►10% less wear rate (gr-wear/1-mton-ground-ore) compared to any other grinding forged media at the same working conditions.
► The balls' mass and volume information are listed below. 

Nominal ball Approx. Approx. Approx.
diameters in mass per ball surface area number of balls/mton
Ømm g mm² (1000 kgs)
20 33 1257 30400
25 64 1964 15565
30 111 2829 9007
40 263 5029 3800
50 514 7857 1946
60 888 11314 1126
65 1129 13279 886
70 1410 15400 709
75 1735 17679 576
80 2105 20114 475
90 2998 25457 334
100 4112 31429 243
110 5460 37994 190
120 7105 45257 141
125 8007 49062 128
130 9037 53093 111
140 11287 61575 88
150 13878 70714 72

 

►FORGED BALLS - EXTREME

Forged Balls - Extreme class grinding media are unique and produced according to tailor-made calculations. Additional to FTRsteel's Superior Forged Balls, our team is able to develop all-of-a-kind and adopted to individual grinding process where forged balls are used.  After using our Superior Forged Balls and gathering all necessary data, the next step is to put the process parameters into the particular analysis. 

Our knowledge applies where impact & wear resistance, corrosion, energy savings and process improvements are required in the grinding processes, especially for balls are used.
FTRsteel has developed a strong & unique process to categorize each milling application with the aim to identify & supply the best-suited steel forged grinding media for horizontal ball mills including the selection of standard or high impact grades for SAG mills.
 
Our experts, Professor Dr. consultants, skilled team mates are ready to assist you, visit and follow your installations to conclude together the right choice(s) to adopt. Our specialized team members/engineers can recommend you the grinding media size(s) and alloy(s). Our team can also calculate the mill’s optimum filling degree according to several parameters such as mill type and size, material to be ground, specific operating parameters and of course the targets of each installation (more tons a hour, increased fineness of the finished product, energy saving,…), so, helping you with the savings on costs and optimizing cash-generation.
 
Forged Balls - Extreme class grinding media are unique and most beneficial ones in terms of cost per ton ground ore in your grinding process that is adopted to invidual circuits where forged balls are used.