ChengDa Grinding Ball Study Cases
CASE 1: High Chrome & Cast Grinding Balls for Gold Mining Operation
Country: Peru
Industry: Gold Mining
Processing Plant Capacity: 5,000 tons per day
Mill Type: SAG + Ball Mill
Ore Hardness: Medium to high (Bond Work Index ≈ 14 kWh/t)
Pain Points:
High media wear rate (above 130 g/t)
Unstable product size distribution
Frequent mill stoppages for ball loading
Rising power consumption
CASE 2: High Chrome & CADI Grinding Balls for Cement Clinker Mill
Country: Vietnam
Industry: Cement Production
Plant Capacity: 2.4 million tons/year
Mill Type: Φ3.8 × 13m Cement Ball Mill (closed-circuit)
Feed Material: Clinker + gypsum + limestone additives
Pain Points:
High media wear rate (110 g/t)
Frequent micro-cracking & breakage in high-chrome balls
Over-grinding, unstable Blaine fineness
Increased energy cost and maintenance downtime
CASE 3: Forged Steel & Low Chrome Cast Grinding Balls for Coal Pulverizing System in a Power Plant
Country: India
Industry: Thermal Power Generation
Plant Capacity: 2 × 660 MW units
Mill Type: Horizontal tube coal mill (Φ2.6 × 5.0m)
Coal Type: Bituminous coal, ash content 18–22%
Pain Points:
Excessive ball wear (up to 150 g/t)
Frequent replacement causing downtime losses
Poor control of pulverized coal fineness (R90 > 12%)
Increasing energy consumption and imbalance between mills
CASE 4: CADI & High Chrome Grinding Balls for Iron Ore Pellet Plant
Country: Brazil
Industry: Metallurgy – Iron Ore Pellet Production
Plant Capacity: 6 million tons of pellets/year
Mill Type: Ball mill (Φ3.6 × 6.0m, wet grinding)
Feed Material: Magnetite concentrate (Fe ≥ 67%)
Pain Points:
Media deformation and flattening after 2000 hours
Abrasive slurry causing high wear rate (125 g/t)
Inconsistent product particle size affecting pellet strength
Frequent mill stoppage for media replacement
CASE 5: Forged Steel Grinding Balls for Aggregate & Sand Production Plant
Country: Saudi Arabia
Industry: Aggregate & Construction Materials
Plant Capacity: 1,200 tons/hour crushing & milling line
Mill Type: Ball mill (open-circuit, dry grinding)
Feed Material: Basalt and granite aggregates (Mohs hardness 6–7)
Pain Points:
Frequent breakage of local low-cost media (>2%)
High wear rate (around 145 g/t)
Irregular ball size affecting product consistency
Frequent downtime due to unbalanced ball charge