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

http://en.wikipedia.org/wiki/File:Ball_mill.gif


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


….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


….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


….AGNISTEELS MILL BALLS….


….EXAMPLES OF BROKEN/POOR QUALITY BALLS….












….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


....INDUCTION FURNACE....


….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


….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


….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)


….THE ALLOYING PROCESS….

ALLOYING ENTAILS FILLING OF THE INTERSTITIAL SPACE

OF THE IRON LATTICE, THUS MAKING IT MORE RIGID

AND HARDER


….THE ALLOYING PROCESS….

WE CAN ADJUST BALL HARDNESS TO MEET CUSTOMER’s NEEDS

THROUGH OUR SUPERIOR AND PRECISE ALLOYING PROCESS


…. THE ANNEALING a d HARDENING PROCESSES ….


….THE RESULT OF GOOD ALLOYING….


….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


Please give us the chance to work with you

Thank You

The End

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Presentation on forged mill balls production in South Africa