Usage of steel rods in rod mills

The first king, second king, and third king are all experts; in particular, Wang Jishun, who dealt with frequent rod breaks in the rod mills during the early stages of operation at HLHS, must have extensive experience in handling such issues. Moreover, slurry preparation is a relatively independent system; each set of grinders corresponds to one slurry tank, allowing sufficient time to address any issues that arise.

If the rod breaks, it becomes chaotic, which is a very troublesome issue. Are you using rubber linings? I recommend that you replace the steel lining plates right away

During the Asian financial crisis, there were many talented people there who had a thorough understanding of this subject.

When using steel rods, if high-quality materials are chosen – ones whose raw coal does not contain impurities such as iron pieces or wires – breaks in the rods will be fewer. In the case of rod breaks, since the inside of the rod mill is lined with rubber pads, these breaks can easily damage the pads and the lifting strips, and may even cause the rods to get stuck together, resulting in a mess of rods. If this situation is not detected in time, it will become too difficult to retrieve the rods from the mess.

Analysis of the broken rod phenomenon: (1) Causes: A. Material: internal porosity. Regarding the issues with steel billets in steel mills, only very large-scale mills are able to meet the stringent technical requirements involved, especially for those with a diameter of over 70 mm. While most steel mills can produce billets of this type, their compression ratio and hardenability are low, meaning that their microstructure is not dense enough. B. Process: The internal internal stress has not been relieved. Bar breakage is like an explosion, occurring from within; the process of producing steel bars in steel mills is similar to inflating a balloon – it is necessary to relieve the internal stresses in order to prevent bar breakage. (2) Solution: A. Focus on the materials. a. Try to use materials from **super-large steel mills** ； b. The new alloy material developed by our company was specifically created by industry experts in wear resistance from Tsinghua University and Dalian University of Technology, taking into account the conditions under which rod mills operate. It possesses excellent hardenability, and is produced by a **very large steel factory (under a confidential agreement). B. Processing technology: The steel rod processing technology developed by our company has been granted a **patent**; it significantly improves the wear resistance of the steel rods, and breakage does not occur (we will replace them free of charge if they break). C. The size specifications can be adjusted flexibly; generally, the steel bars supplied by steel mills are 6 meters long. If you use 4-meter long bars, then the 2 meters that remain will be wasted. Our company can produce bars to custom lengths. D. The wear-resistant steel rods produced by our company using new materials and processes extend their service life, reduce costs, and lessen the workload on workers. Don’t worry about stopping the mill and adding steel rods every day – it even **increases production**. Shandong Huamin Wear-Resistant Steel Rod Co., Ltd. Zhang Xun/Marketing Director Mobile: 13953147415 QQ: 549551716 MSN: huamin-steelball@hotmail.com Email: huamin.steelball@gmail.com Product catalog: http://www.steelrod.eb80.com/

Huamin Company produces 30,000 tons of steel rods for rod mills each year; it is the largest manufacturer of such steel rods in China, and its products are sold to more than 20 countries and regions around the world. Huamin steel rods are suitable for a wide range of users of rod mills and coal grinding mills, including quartz sand plants, mines, cement plants, power plants, silica sand plants, sand aeration facilities, coal chemical industries, concrete plants, and manufacturers of new building materials. Huamin wear-resistant steel rods differ from ordinary rolled round bars; they are specialized new types of wear-resistant steel rods designed for use in rod mills and grinders, having undergone special heat treatment. Their wear resistance is 4-6 times that of ordinary steel rods, resulting in significant economic benefits. The steel rods currently in use in the market are produced by steel mills through rolling processes; they require low technical standards, have very poor wear resistance, and result in high consumption during use, leading to significant waste of ** resources. The main problems are as follows: 1. High wear: Due to low hardness and poor toughness, the consumption of round steel is very high, which in turn increases the workload and costs in the magnetic separation process, and even affects product quality. 2. Sharp ends at both sides: The sharpness of the steel rod’s ends is caused by various factors. The main reason is that the ends of the steel rod in a rod mill come into contact with the material for longer periods and over a larger area compared to the middle part, resulting in a longer effective grinding time at those ends. Once there is a noticeable difference in the proportions between the ends and the middle that can be seen with the naked eye, such a steel rod is considered “failed,” as it can no longer perform effective grinding functions inside the mill. 3. Broken rod: The reason is porosity within the material. Regarding the issues with steel billets in steel mills, only very large-scale mills are able to meet the stringent technical requirements involved, especially for those with a diameter of over 70 mm. While most mills can produce such billets, their compression ratio and hardenability are low, meaning that their structure is not dense enough. Furthermore, since the internal stresses in the round steel bars are not relieved at the time of production, breakage occurs as if by explosion, starting from the inside. The process of producing steel bars in factories is similar to inflating a balloon; it is necessary to relieve the internal stresses in order to prevent the bars from breaking. 4. Bent rods: The main reason for bent rods is that the round steel has very low hardness and is relatively soft; therefore, it easily bends when subjected to external forces such as impacts in a grinder. Once one of the rods bends, it disrupts the parallel arrangement of the steel rods inside the mill (the rods run parallel to each other within the mill, and as material passes through the gaps between them, it is ground into small particles or powder). In mild cases, this disruption leads to reduced efficiency of the mill; in severe cases, the rods may be thrown out of the mill, posing a risk to the safety of the workers and causing damage to the mill as well as other production equipment. 5. Low production efficiency, and the qualified products do not meet the requirements. This problem plagues many companies for various reasons, and steel bars also have a significant impact on it. For example, issues such as an unreasonable ratio between steel rods of different diameters, inappropriate loading amounts, improper addition of steel rods, and failure to remove defective rods in a timely manner. Our company invested heavily to hire various experts to study this product, with the aim of developing steel rods with higher wear resistance to replace the current consumable steel rods in use domestically. After years of research, production equipment for new types of alloy wear-resistant steel rods, as well as manufacturing processes for grinding rods made from various materials, have finally been developed. The wear resistance of this wear-resistant steel rod is 4 to 6 times that of a steel rod manufactured by rolling. Each year, it is possible to **save hundreds of thousands of tons, or even tens of millions of tons, of steel. Huamin’s wear-resistant rod production process: Communicate with the customer to understand their requirements for the steel rods, after which the material, model, and quantity are determined; large-scale steel mills supply the raw materials; the raw materials are inspected upon arrival at the factory; quality improvement processes such as medium-frequency heating and quenching using the balancing method are carried out; further heat treatment steps are performed; the products are inspected, stored, and finally the customer is followed up. The new type of wear-resistant steel rod produced using the equipment and processes developed by our company boasts a wear resistance 4 to 6 times that of round steel, addressing issues such as high wear, rod breakage, bending, and sharp ends at both ends. The size specifications can be adjusted according to the customer’s requirements, enhancing flexibility and eliminating unnecessary waste. At the same time, it extends the service life, improves the production efficiency of the mill, reduces production costs, and lessens the workload on workers. This wear-resistant steel rod has the following features: (1) Its wear resistance is 1.5–2 times that of steel rods made by rolling, offering excellent wear resistance and helping customers save a significant amount of cost. (2) Produced using the latest methods, the dimensions can be adjusted to meet customer requirements, resulting in **greater flexibility and the elimination of unnecessary waste. (3) It extends the service life, reduces costs, lessens the workload on workers, eliminates the need to worry about stopping the grinder daily to insert steel rods, and **also increases production. Introduction to key parameters: 1. Diameter: 18mm–110mm. 2. Length: 2.5m–7m. 3. Hardness: Can be adjusted according to customer requirements; for standard products, the hardness is between HRC45 and 55. 4. The raw materials are sourced from large domestic steel mills, and round bars with special chemical compositions can be produced as per customer requests. We welcome customers from home and abroad to visit our company for discussions. We are committed to providing high-quality products, timely delivery, competitive prices, and satisfactory service as the foundation for long-term cooperation. Zhang Xun, Shandong Huamin Steel Ball Co., Ltd. 13953147415 QQ: 549551716 Answers to common questions: 1. Analysis of broken or bent rods: (1) Causes: A. Material: internal porosity. Regarding the issues with steel billets in steel mills, only very large-scale mills are able to meet the stringent technical requirements involved, especially for those with a diameter of over 70 mm. While most mills can produce such billets, their compression ratio and hardenability are low, meaning that their structure is not dense enough. B. Process: The internal internal stress has not been relieved. Bar breakage is like an explosion – it starts from within. The principle behind steel mills’ production of steel bars is similar to blowing up a balloon; it is necessary to eliminate the internal stresses in order to prevent bar breakage. (2) Solution: A. Focus on the materials. a. Try to use materials from **super-large steel mills** ； b. The new alloy material developed by our company (Huamin Grinding Rods) was specifically created by industry experts in wear resistance from Tsinghua University and Dalian University of Technology, taking into account the conditions under which rod mills operate. It possesses excellent hardenability, and is produced by a **very large steel manufacturer (under a confidential agreement). B. Treatment Process: The steel rod treatment process developed independently by our company (Huanmin Grinding Rods) has been granted a **patent**; it significantly improves the wear resistance of the steel rods and prevents breakage. C. Dimensions: The specifications can be adjusted flexibly. Generally, the steel bars supplied by steel mills are 6 meters long; if you use 4-meter long bars, then the 2 meters that remain will be wasted. Our company (Huamin Grinding Rods) can produce bars to custom lengths. 2. Hardness analysis of wear-resistant steel rods: The optimal hardness for these rods is between 45-50; values below this range result in the rods being too soft and not resistant to wear, while values above this range make them too hard and brittle, prone to breaking ； Furthermore, in terms of manufacturing processes, domestic manufacturers can only achieve an HRC hardness of over 45 on the surface of the steel rod for a maximum of one centimeter; beyond that distance, the surface becomes identical to that of a round steel bar. Our company (Huamin Wear-Resistant Steel Bars) produces wear-resistant steel bars for rod mills in accordance with international standards. Moreover, thanks to our proprietary manufacturing process (which has been granted a **patent**), the overall performance of these steel bars can be improved. For example, while ordinary steel bars have a surface hardness of HRC 45 and an internal hardness of HRC 10, our bars can achieve a surface hardness of HRC 50 and an internal hardness of HRC 25. 3. Differences between wear-resistant steel bars, steel bars, and round bars: Round bars are raw materials produced by steel mills; they are not finished products. Using them as steel bars for rod mills leads to various problems such as bar breakage and failure (with sharp ends at both ends). Their hardness is only 20, so they are completely not wear-resistant! Steel bars are produced through further processing of round steel; their surface hardness is 45-50, making the surface wear-resistant while the interior is not. In conclusion, wear-resistant steel rods are the true steel rods suitable for rod mills

We minimize the occurrence of broken or bent steel rods by increasing their hardness and straightness; after straightening heat treatment, the hardness of the steel rods is between 45–58 HRC, with a straightness level of less than 3 mm/m