Advatages of Cost-Effective Cast Grinding Cylpebs
1. Low iron precipitation ensures the purity of the finished sand
Strict control of sulphur and phosphorus inclusions in the matrix ensures a dense, non-porous casting structure. The edges are optimised through stress relief, resulting in minimal chipping, slag loss and surface flaking during the grinding process, thereby significantly reducing the amount of iron powder and iron filings mixed into the sand. Combined with conventional magnetic separation processes, this effectively controls the total iron content in the finished sand, making it suitable for applications with strict requirements regarding iron impurities, such as glass-grade sand, foundry sand and industrial refined sand.
2. Kneading-style grinding ensures excellent grain shape in the finished sand
By replacing the point-contact impact crushing of steel balls with continuous cylindrical contact and kneading action, the sharp edges of the sand grains are uniformly rounded after grinding, resulting in a full and rounded grain shape. The proportion of needle- and flake-shaped particles is significantly reduced, and the grain shape coefficient better complies with national standards for construction and industrial sand, directly enhancing the market grade and selling price of the finished sand.
3. Low over-grinding rate, higher yield per tonne of sand
The grinding force is uniform and gentle, eliminating the problem of localised over-grinding caused by high-energy point impacts from steel balls. The production of ultrafine powder and stone powder is reduced by 10%–15 per cent, whilst the yield of finished sand meeting the required particle size specifications is significantly improved. This reduces waste from tailings and directly lowers the overall production cost per tonne of sand.
4. High hardness and wear resistance, suitable for hard siliceous materials
For small ball mills with a diameter of less than 2.6 metres, the alloy composition has been optimised for quartz sand and high-hardness siliceous materials. Their wear resistance far exceeds that of ordinary carbon steel segments and low-chromium general-purpose segments, resulting in low wear rates and extended replenishment cycles. under continuous grinding conditions for high-hardness sand and gravel, their service life is more than double that of standard carbon steel segments, equivalent to 70 per cent of high-chromium cast steel segments, thereby significantly reducing the consumption of grinding media per tonne of sand.
5. Flexible specification and grading, suitable for grinding sand to multiple mesh sizes
Standard dimensions range from φ20×25 mm to φ55×60 mm. Customised dimensions and mixed ratios can be tailored to the feed sand and gravel particle size and the required finished sand mesh size. The entire process—from coarse sand shaping to medium sand grinding and fine sand processing—can be completed within a single grinding compartment, simplifying media configuration and on-site operation and maintenance management.
6. Mechanical property benchmarks
Surface hardness: HRC 52–58
Chromium (Cr) content: 1–3
