US Patent 13/873,838 filed in 2013 for Nano Technology Steel Formula and Process. Additional Claims filed in 2019.
VIRINA GRINDING BALL ADVANTAGE
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ULTRA FINE GRAIN MICROSTRUCTURE BALL HAS MUCH HIGHER ABRASION & WEAR RESISTANCE
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THOROUGH HARDNESS, CORE @ 63 HRC
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ANNUAL WEAR RATE @ 2.9 mm PER BALL
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ZERO DEFORMATION
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ZERO REJECTS
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HIGHER PRODUCTION
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LOWER ENERGY CONSUMPTION
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SORTING NOT NECESSARY
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EXTEND LINER LIFE
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REDUCED ENVIROMENTAL IMPACT
BUZZI CEMENT CAPE GIRARDEAU, MO WITH TWIN MILLS INSTALLED & NEW LINERS
HEAD TO HEAD COMPARISON OF WEAR RATE AND LINER LIFE
VIRINA VS BRAND M
BELOW ARE THE PICTURES OF 4 YEARS OF USED BALLS
Ultrafine Micro Structure with high sliding abrasion & impact resistance.
High ductility eliminates cracking and chipping.
New Virina cast ball @ 80mm
After 3 years wore down to 70.7mm
Annual wear @ 3.1mm.
Brand M with conventional coarse non- homogenous microstructure core hardness @ 56HRC, resulting in cracking and chipping, then deformation.
Deformed balls will lower production output, waste energy, shorten ball and liner life.
The Cement Plant switched out 28 tons of 90mm balls for top off to: 90mm, 80mm, 70mm and 60mm. The 28 tons are good for four years after top off.
After 3 years only round balls.
Will continue to stay round until under 50mm, then load into the 2nd chamber until rejected for being under sized.
70mm to 58.6mm
80mm to 70.7mm
90mm to 83.6mm
ANNUAL WEAR RATE @ 2.9mm
Cement plants have been paying for Brand M's rejects
Brand M with 5% rejects in year one.
Rejects of the original charge will continue to increase over next three years.
Majority Brand M are no longer round after 2 years.
Keeping these deformed balls in the mill will waste energy.
By year 5, will most likely need a fresh charge.
Virina has the only grinding ball with through hardness from core to surface @63 HRC
Stays round without any deformation
Crushes and grinds much better than any other brand on the market
Brand M without through hardness and coarse grain core @ 52 HRC
Too soft to crush and grind material efficiently
Waste energy tumbling deformed balls
Virina's perfectly round grinding balls will not deform for the life of the balls and will not damage the liner lifters.
This may extend the liner life by 2x
Round balls follow a predictable parabolic trajectory into the cataracting and impact zone for maximum crushing and grinding efficiency.
They will also roll over each other grinding the
materials in the shearing and tumbling zone.
Deformed balls will have an unpredictable trajectory and at times will damage the shelf of the lifter.
A deformed ball will slide on the liner surface and cause ball run.
The useful life of the lifter shelf determines the life of the liner, not the thickness. Most mills use only 25% of the liner weight before replacement
Virina Balls are good for 20 years.
After 3 years running in a Missouri Cement Mill our 70mm, 80mm and 90mm balls lost an average of 172g per year, while remaining round.
The Virina Advantage is our patented process that allows for uniform grain size and uniform hardness from edge to core.
Case study and Test results show that the design of Virina balls will save Energy and Labor. Extended ball life will reduce Environmental Impact as well as lengthen the life of your liner.
Virina nano grinding balls for your plant
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Buy a fresh charge only once
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Reduce top off by 50%
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Balls will stay round
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Through hardness @ 63 HRC
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Extend ball life
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No splitzer to remove
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No rejects to remove
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No annual sorting
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Increase production
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Decrease energy consumption
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Decrease labor hours
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Extend liner life
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Improve cement fineness
Suggest loading 11 tons of 90 mm balls for the 1st chamber and 11 tons of 50 mm for the 2nd chamber.
Calibrate or weigh the used ball at every stoppage.
After 12 months of a successful test then consider a full charge.
With full charge in both chambers, production output shall increase by 10+% with an energy reduction by 3%.
20 years free replacement of deformed grinding balls.