How to Reduce Costs with Forged Steel Balls
In many heavy industries such as mining, cement and steel, a significant portion of operating costs is related to the grinding process. Studies show that about 37% of the costs of a ball mill are spent on grinding media (and nearly 50% on energy consumption). Therefore, the selection of effective and durable grinding media plays an important role in reducing costs. One key solution in this regard is the use of forged steel balls, which, due to their higher strength and durability, can extend the life of the process and reduce media and energy consumption.
Advantages of Forged Steel Balls
The forging process (pressure alloying) causes the fine grain structure of the steel to become uniform and dense. As a result, forged balls have superior properties compared to cast balls. For example, international studies show that forged bullets have long-term wear resistance and stability; their uniform microstructure is almost free of internal voids or impurities that can lead to breakage. This solid structure allows forged bullets to maintain their size and shape better even after long periods of use, reducing the need for frequent replacement.
Forged bullets also have a very high impact toughness (coefficient of toughness); as seen in experimental tests, they are less likely to shatter under severe impacts and their fracture rate is very low. This is while cast bullets (especially those made of high-chromium cast iron) are more brittle and break more often under heavy impact conditions. Forged bullets also excel in terms of hardness and wear resistance: high hardness and a precise heat treatment process provide much greater wear resistance than cast bullets.
From an economic perspective, although the initial purchase cost of forged balls is higher than cast or ceramic balls, their durability and reduced maintenance reduce the total cost of ownership. For example, technical reports indicate that the increased life and reduced breakage of forged balls can significantly reduce the cost of frequent replacement and production line stoppages. Also, the higher mill efficiency with these balls reduces the energy consumption of the production unit. The following table provides a general comparison between the characteristics of cast, forged and ceramic balls:
| Feature | Casting bullet | Forged bullet | Ceramic bullet |
| Hardness and wear resistance | Relatively good (carbon-chromium); but has a hardness limit. | Very high (uniform microstructure and heat treatment). | Exceptional (materials such as aluminum oxide or silicon nitride) |
| Impact resistance | More brittle, high breakage rate | Highest (stronger in absorbing impacts and least breakage). | Less than steel (lower brittle resistance) |
| Service life | Medium (faster wear, need for early replacement). | Long (less wear, shape and dimension retention) | Very long (rare wear and high durability) |
| Initial Cost | Lowest Cost (simpler casting process) | Highest (more processing and melting costs, but economical in the long run) | Highest (special processing and expensive materials) |
| Energy consumption | Higher than forging (lower efficiency) | Lower (improved mill efficiency and energy savings) | .Lowest (lower density, less friction and faster process) |
| Product contamination | Possibility of metal contamination due to breakage. | Less metal contamination than casting (safe steel); suitable for dry and wet grinding. | Almost no contamination (neutral and free of additional metals) |
| Indicative applications | Dry cement mills (Prochrome media) and high-consumption materials. | Wet mills and impact conditions (mines and cement plants). | .Applications requiring high purity (pharmaceutical, food, electronics) and precision grinding. |
Cost Savings in Various Industries
The use of forged balls in various industries has several positive effects on cost reduction:
Mining Industries: Longer ball life and reduced breakage rate reduce the number of mill stops. The result is a reduction in ball replacements and savings on the purchase of grinding media.
Cement Industries: High chromium cast balls are common in cement mills (especially dry) where heat and wear are high. However, in many situations, forged balls can be used, which in practice provide superior grinding efficiency; experience has shown that forged balls are more suitable in wet mills and mineral processing. Higher grinding efficiency with forged balls helps reduce energy consumption.
Steel Industries: High media durability is important in ball milling processes in the steel industry. Forged balls, due to their hardness and better shape retention over time, provide consistent mill performance and reduce media maintenance and replacement costs.
Considering the above, a few key points can be summarized:
The long life and durability of forged balls reduces their consumption per ton of input material.
The hardness and uniform structure of these balls reduce maintenance costs due to their high abrasion and impact resistance.
Improving mill efficiency with these balls leads to reduced energy consumption and increased operational efficiency.
Sepahan Foolad Atashgah; A reputable domestic manufacturer
With over three decades of experience in the casting industry, Sepahan Foolad Atashgah Company (SFA) is one of the leading manufacturers in Iran. The company, utilizing advanced equipment (7 simultaneous melting furnaces with a capacity of 20,000 kg) and more than 250 specialists, has the capacity to produce approximately 25,000 tons of castings annually. Long experience in producing various steel and cast iron parts, including casting balls required by the steel, copper, cement and mining industries, demonstrates the commitment and expertise of this group. Thus, Sepahan Foolad Atashgah, as one of the reputable domestic suppliers, can meet the needs of industrial mills for durable steel balls.
Conclusion
The use of forged steel balls in industrial grinding processes is always associated with the goals of reducing costs and increasing productivity. Due to their dense structure and high hardness, these balls have a “longer lifespan” and “much higher resistance to wear and impact”. Although their initial purchase cost is higher, their longer lifespan and lack of frequent breakage reduce replacement costs and production line downtime. In addition, improving mill efficiency helps reduce energy consumption and increase efficiency. Sepahan Foolad Atashgah Company, with over thirty years of experience in producing cast parts, is one of the reliable suppliers of this type of bullets in the country.
By using forged steel bullets and comparing them closely with other options (cast and ceramic), the mining, cement, and steel industries can significantly reduce their operating costs and improve productivity.
