1. Classification testing services

(I) Raw material characteristics analysis

Chemical composition detection: Use X-ray fluorescence spectrometer (XRF) to accurately analyze the chemical composition of raw materials such as limestone, clay, iron ore, coal, etc. commonly used in cement plants. Determine the content of key components such as calcium oxide, silicon dioxide, aluminum oxide, and iron oxide to evaluate the grindability and corrosiveness of the raw materials. For example, limestone raw materials with high calcium content will cause chemical corrosion to cast ball forgings during the grinding process, and high-chromium alloy products with excellent corrosion resistance need to be selected.

Physical property testing: Use equipment such as Blaine permeability tester and laser particle size analyzer to test the physical properties of raw materials such as specific surface area and particle size distribution. Understand the initial fineness and particle grading of the raw materials to provide a basis for the reasonable selection of specifications and materials of cast ball forgings. For raw materials with small specific surface area and coarse particle size, cast balls with larger diameter and high impact toughness are required for crushing; while for raw materials with finer particle size, cast ball forgings with small diameter and high grinding efficiency are more suitable.

Hardness and humidity detection: Shore hardness tester is used to measure the hardness of raw materials, and moisture meter is used to detect the humidity of raw materials. When the humidity of raw materials is high, it will increase the adhesion during grinding, affect the grinding efficiency, and may accelerate the rust of cast ball forgings. According to the hardness and humidity data, adjust the surface treatment process of cast ball forgings, such as using special anti-rust coating to improve the service life of products in humid environments.

(II) Adaptability test of cast ball forgings

Laboratory grinding test: Build a small cement mill to simulate the actual grinding conditions of cement plants, and set the parameters such as speed, filling rate, ball-to-material ratio consistent with the production site. Mix alloy cast ball forgings of different specifications and different chromium contents with raw materials for grinding tests. By monitoring the power consumption, output, finished product fineness and other indicators during the grinding process, the adaptability of cast ball forgings to different raw materials is evaluated. For example, if a low-chromium alloy cast ball has low output and high power consumption when grinding high-hardness raw materials, it is necessary to consider replacing it with a high-chromium alloy cast ball or optimizing the grinding body gradation.

Wear and performance evaluation: After the test, the cast ball forgings after wear are weighed and measured, and the wear rate is calculated. The microstructural changes of the cast ball forgings are observed using a metallographic microscope to analyze the wear mechanism. At the same time, the finished products after grinding are tested for strength, setting time and other performances. Combined with the wear of the cast ball forgings, the impact on the quality of cement products is comprehensively evaluated to recommend the best product selection plan for customers.

Life simulation prediction: Based on laboratory grinding test data and actual production data of cement plants, a life prediction model for cast ball forgings is established. Considering factors such as raw material characteristics, grinding process parameters, and equipment operating conditions, the service life of cast ball forgings under actual working conditions of cement plants is predicted to help customers formulate scientific procurement and replacement plans and reduce equipment maintenance costs and downtime.

II. Complete set of equipment supply

(I) Cast ball forgings for cement mills

Accurate specification selection: According to the specifications and models of cement mills (such as open-circuit mills, closed-circuit mills), production capacity and grinding process requirements, the specifications of high and low chromium alloy cast ball forgings are accurately matched for customers. For open-circuit mills, since there is no powder selection equipment, larger diameter cast balls are required to ensure sufficient crushing capacity; for closed-circuit mills, the proportion of small diameter cast balls and cast forgings can be appropriately increased to improve grinding efficiency. At the same time, according to the functions of different chambers of the cement mill, the grinding body gradation is optimized, such as using large diameter cast balls in the coarse grinding chamber and small diameter cast balls and forgings in the fine grinding chamber to achieve the best grinding effect.

Customized material service: customized cast ball forging material service is provided according to the different raw material characteristics and working conditions of cement plants. For cement plants that grind high-hardness raw materials, customized alloy cast balls with high chromium content (chromium content ≥ 20%) and high hardness (HRC ≥ 60) are customized to improve the wear resistance of the product; for cement plants that grind highly corrosive raw materials, special alloy formulas and heat treatment processes are used to enhance the corrosion resistance of cast ball forgings; for cement plants that pursue low energy consumption and high output, new alloy cast ball forgings with high grinding efficiency are developed to meet the personalized needs of customers.

Strict quality control: During the production process, we strictly follow the ISO9001 quality management system, and implement full-process quality control from raw material procurement, smelting, casting, heat treatment to finished product inspection. Medium frequency induction furnace smelting is used to ensure uniform and stable chemical composition; advanced casting processes such as metal mold casting and centrifugal casting are used to reduce casting defects such as pores and shrinkage; through precise heat treatment processes such as quenching + tempering, the cast ball forgings are guaranteed to have good hardness, toughness and wear resistance. Before each batch of products leaves the factory, hardness testing, impact toughness testing, metallographic structure analysis and dimensional accuracy testing are carried out to ensure that the product quality meets or exceeds national standards and customer requirements.

(II) Supporting equipment and accessories

Supply of linings and partitions: Provide linings of various materials that match high and low chromium alloy cast ball forgings, such as high chromium cast iron linings, rubber linings, composite linings, etc., as well as partitions of different forms. According to the different parts and working conditions of the cement mill, recommend suitable lining and partition material and structure. For example, high chromium cast iron linings and high-strength partition plates are used at the feed end and coarse grinding bin of the cement mill due to the greater impact and wear; rubber linings can be used in the fine grinding bin to reduce noise and improve grinding efficiency. The design of the lining and partition plates fully considers the installation convenience and the fit with the grinding cylinder to ensure stable and reliable operation.

Powder selector and conveying equipment: Provide cement plants with high-efficiency powder selectors (such as centrifugal powder selectors, rotor powder selectors), bucket elevators, air chutes, screw conveyors and other supporting equipment. According to the production scale, process flow and product quality requirements of the cement plant, the equipment is reasonably selected and configured to achieve efficient transportation and precise classification of materials. The powder selector adopts advanced classification technology to ensure the stability of the finished product fineness; the conveying equipment has the characteristics of large conveying volume, low energy consumption, good sealing, etc., which reduces dust pollution and improves the quality of the production environment.

Equipment installation and commissioning service: Dispatch a professional installation and commissioning team to provide customers with one-stop equipment installation and commissioning services. Before installation, the equipment foundation is inspected and processed to ensure that it meets the installation requirements; during the installation process, the equipment installation drawings and specifications are strictly followed to ensure the accuracy of equipment installation. After the installation is completed, the entire grinding system is fully debugged, including the no-load test run and load test run of the cement mill, the classification efficiency debugging of the powder selector, and the linkage debugging of the conveying equipment. Through debugging, the equipment operating parameters are optimized to ensure that the system meets the designed production capacity and product quality standards. At the same time, on-site training is provided for customer operators to enable them to master the operation, maintenance and troubleshooting methods of the equipment.

III. After-sales service

(I) Regular return visits and maintenance

Return visit plan formulation: Establish a complete customer return visit system and formulate personalized return visit plans based on the customer's equipment usage and production needs. For customers who have newly installed equipment, the first return visit will be conducted within 1 month after the equipment is put into operation to understand the equipment's operating status and customer feedback; after that, regular return visits will be conducted every quarter. For old customers and customers with stable equipment operation, a return visit will be conducted every six months. The return visit method includes a combination of telephone return visits, on-site return visits and remote monitoring data analysis to keep abreast of equipment operation dynamics and customer needs.

On-site maintenance service: During the return visit, the technicians will carry professional testing instruments and commonly used maintenance accessories to conduct a comprehensive inspection and maintenance of the cement mill and supporting equipment. The inspection content includes the wear of the cast ball forgings, the wear and tightening of the liner and the compartment plate, the operating parameters of the equipment (such as current, voltage, temperature, vibration, etc.), the working status of the lubrication system and the sealing system, etc. For the problems found, timely treatment and maintenance are carried out, such as replacing the severely worn cast ball forgings and liners, adjusting the equipment operating parameters, repairing the lubrication and sealing system failures, etc. Ensure that the equipment is always in good operating condition, extend the service life of the equipment, and improve production efficiency.

Maintenance report and suggestions: After each return visit and maintenance, a detailed maintenance report will be submitted to the customer. The report content includes the equipment inspection, the problems found and the treatment measures, the equipment operation status evaluation, the wear parts replacement record, the follow-up maintenance suggestions, etc. At the same time, according to the equipment operation data and maintenance status, provide customers with suggestions for optimizing equipment operation and reducing costs, such as adjusting the grinding body grading, improving the operation process, etc., to help customers achieve efficient and stable operation of the equipment.

(II) Fault response and maintenance

24/7 service hotline: A 7×24-hour after-sales service hotline is set up, equipped with professional customer service personnel and technical support teams. When the equipment fails, customers can call the service hotline at any time for consultation and repair. The customer service staff will record the customer's fault description, equipment model, contact information and other information in detail, and immediately convey the fault information to the relevant technicians to ensure that the problem is handled in a timely manner.

Quick response mechanism: Establish a complete fault quick response mechanism and formulate different response strategies according to the severity of the fault and the customer's geographical location. For general faults, we promise to provide customers with remote technical support and preliminary solutions within 2 hours; for emergency faults, such as cement mill shutdown, serious equipment damage, etc., ensure that technicians are dispatched to the site with repair parts for repair within 12 hours. On the way to the site, the technicians maintain close communication with the customers and guide the customers to take necessary emergency measures to reduce equipment downtime and production losses.

Maintenance quality assurance: After the technicians arrive at the site, they will quickly diagnose the equipment failure and formulate a scientific and reasonable maintenance plan. During the maintenance process, we strictly follow the maintenance operation procedures and quality standards, use original accessories and high-quality maintenance materials to ensure the quality of maintenance. After the maintenance is completed, the equipment is fully debugged and tested, and no-load and load tests are carried out to verify whether the equipment performance has returned to normal. At the same time, we provide customers with precautions and maintenance suggestions for the use of the equipment after maintenance, and provide a certain period of warranty service for the maintenance parts. If the same fault occurs during the warranty period, we will repair it free of charge, so that customers have no worries.

(III) Technical training and support

Professional operation training: Provide free professional training services for cement plant operators, technicians and managers. The training content covers the performance characteristics of high and low chromium alloy cast ball forgings, the structural principles of cement mills and supporting equipment, operation methods, maintenance knowledge, common fault diagnosis and troubleshooting, etc. The training method adopts a combination of theoretical lectures, on-site practical demonstrations, and case analysis to ensure that trainees can deeply understand and master relevant knowledge and skills. After the training, the trainees will be assessed and issued training certificates to improve their operation level and equipment management capabilities.

All-round technical consultation: Provide customers with all-round technical consulting services. Customers can consult our technical experts at any time on equipment use, process optimization, product selection and other issues through various channels such as telephone, email, online customer service, etc. Our technical team will provide professional and detailed answers and suggestions in a timely manner, and regularly collect customers' technical problems and feedback, organize them into technical information and solutions, and share them with customers through online platforms or offline training to promote the improvement of customers' technical level.

Technology upgrade and innovation services: Keep up with the development trend of industry technology, continue to invest in research and development, and carry out technical upgrades and innovations for high and low chromium alloy cast ball forgings and cement mill equipment. For customers who have purchased our products and equipment, we will promptly convey the latest technical information and product upgrade plans, and provide personalized technology upgrade services according to customer needs and actual equipment conditions, such as replacing cast ball forgings with new wear-resistant materials, modifying powder selectors to improve classification efficiency, and optimizing the internal structure of cement mills to improve grinding performance. Through technology upgrades and innovative services, we help customers improve production efficiency, reduce energy consumption and costs, and enhance market competitiveness.