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Polysius Minerals.

Engineering made by Polysius.

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Polysius
A company
of ThyssenKrupp
Technologies
2 Polysius Minerals Technology.
Present all around the world.

As one of the world’s leading


companies in the plant engi-
neering field, Polysius has the
comprehensive know-how that
is needed in order to supply the
mining, metallurgical, refracto-
ries, lime and chemical indus-
tries with innovative but tried
and tested processes, plants
and system configurations.

Again and again, Polysius


produces convincing solutions
for pyroprocessing and grind-
ing applications, proving itself
a reliable partner in all regions
of the world.

The high availability, low


energy requirement and good
environmental compatibility
of the large number of plants
that we have installed speak
for themselves.
Our product range: 3

Nickel ore
Drying systems: rotary dryer, shaft-type flash dryer
Calcining systems: rotary kiln, POLCAL®
Iron ore
Treatment plants: SAG mills, ball mills, POLYCOM®
Concentrate-grinding plants: ball mills, POLYCOM®
Additive grinding plants: ball mills, roller mills
Gold/copper ore
Dry grinding plants: SAG mills, ball mills, DOUBLE ROTATORs®
Concentrate-grinding plants: SAG mills, ball mills, POLYCOM®
Heap leaching plants: POLYCOM®
Diamond ore
Grinding plants: POLYCOM®, scrubbers
Lime/Limestone
Grinding plants: ball mills, roller mills, POLYCOM®
Calcining systems: rotary kilns, POLCAL®, shaft kiln, shaft preheater,
shaft cooler
Grinding plants for
flue gas desulphurisation: ball mills, roller mills
Coal
Grinding plants: ball mills, roller mills
Injection systems: dispensers, POLOP®
Steel
Injection systems: dispensers, POLOP®

Process engineering
for the preparation of chrome ore, oil shale, magnesite, dolomite, soda, phosphate
ore, bauxite ore, anhydrite, gypsum, vanadium ore, steel plant dusts ...

Dryers: rotary dryer, shaft-type flash


dryer
Preheaters: cyclone preheater, shaft
preheater
Kilns: rotary kilns, POLCAL®, shaft
kilns, multihearth furnaces
Coolers: cyclone cooler, shaft cooler,
rotary cooler, fluidised bed
cooler

Diamond, gold, copper, steel, oil ...


4 Grinding technology
Convincing concepts.

Grinding is one of the most


energy-intensive production
stages and therefore has a
substantial energy-saving
potential. The main demands
made on grinding plants
are low operating costs and
high availability, even when
grinding extremely abrasive
materials.
5

Grinding plants from Polysius


have established themselves
worldwide in the minerals
industry because of their
convincing concept, robust
construction and outstanding
availability. The very broad
range of different mill types
offers the right system for
every application.

Preparation plant for 108,000


tonnes of copper ore per
day in Peru. The primary ore
grinding stage consists of four
POLYCOM® high-pressure
grinding rolls, while four wet
process ball mills perform the
final grinding.
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7

Copper ore grinding in Peru:


The primary ore grinding is performed by four POLYCOM® high-
pressure grinding rolls, each equipped with 2,500 kW drives and rolls
of 2.4 metre diameter (Top pictures),
while the final grinding takes place in four wet process ball mills
powered by 12 MW ring motor drives (Large picture).

High pressure comminution tion for fluctuations in the proper-


ties of the feed ore.
The economic and gentle process-
ing solution. 60 % of the high- Roller mills
pressure grinding rolls installed
in the minerals industry are from Roller mills integrate three process
Polysius: the POLYCOM® operates stages into a single unit: drying,
convincingly all around the world, grinding and separating. Their
comminuting copper ore, gold ore, range of applications includes
iron ore, diamond ore, platinum limestone, additive and coal grind-
ore, coal, granulated blast furnace ing.
slag, limestone, cement clinker Autogenous mills and ball mills
and other mineral raw materials. for wet and dry grinding
This type of mill ensures low Polysius builds autogenous /
operating expenses (in compari- semi-autogenous and ball mills
son to other systems, both the with circumferential bearing
power consumption and the costs assembly and girth gear or ring
for wear parts are significantly motor drive. For special applica-
lower), high throughput rates (a tions, Polysius offers DOUBLE
high-pressure grinding roll can ROTATOR® and AEROFALL mills.
replace several reduction crushers)
and metallurgical advantages in
the downstream process stages.

Because of the short material


dwell time in the mill, the machine
settings can be quickly altered, The largest SAG-mill with circumferential
DOUBLE ROTATOR® bearing assembly (10.4 m diameter, 11,000
comminuting gold ore (252 tph making the process easy to control kW drive power) and ball mill for grinding
throughput) in the USA. and permitting rapid compensa- 1350 tph of gold/copper ore in Australia.

Autogenous mills breaking Mounting the bearing Ball mill grinding


diamond ore in Angola shoes of a large SAG limestone for flue gas
(throughput: 400 tph each). mill with circumferen- desulphurisation at The COMBIFLEX® system is a
tial bearing assembly. a power station in particularly economical drive con-
Korea.
cept:

The drive unit is integrated into


the housing for girth gear and
sliding shoe bearing. High drive
power requirements are met by a
Roller mill
for limestone double COMBIFLEX® system or
grinding. ring motor.
8 Pyroprocessing.
Success through experience.

Waelz-processing kilns in Germany


for processing filter dust from electric
furnace steel plants into secondary
zinc concentrate.

Machines and plants from Polysius


ensure consistent product quality,
minimum power requirement due
to optimum heat recuperation,
outstanding availability and good
resource utilisation.

Polysius systematically consoli-


dates process and plant know-
how to create innovative con-
cepts for the thermal process-
ing of a very broad range of
materials, offering optimal cus-
tomised solutions for drying,
preheating, calcining, reduc-
tion, burning, sintering, cooling
and pelletising. Two RCE multihearth kilns (17 hearths)
for calcining natural magnesite (2 x 300
tpd output). The multihearth kiln can
also be used for magnesite, lime,
dolomite, molybdenum, copper, nickel,
active carbon, vanadium, zinc and
residue treatment, as well as for the
pyroprocessing of filter cake and pasty
materials.

Phosphate ore calcining plant for 450,000 2nd picture from left: Plant for drying and pre-reducing
tonnes per year. The ore is comminuted in nickel ore in Argentina. The 180 tph plant consists of
a hammer mill with shaft-type flash dryer a rotary dryer and two long rotary kilns (5.0 m diameter,
and the dried product is then calcined in 120 m long).
a POLCAL® gas suspension thermal
reactor. Cooling takes place in a multistage 3rd picture from left: Rotary dryer for nickel ore in Brazil
flash cooler. (3.4 m diameter, 22 m long; feed material moist, 104 tph).

Right:
AT processor for oil shale processing
(8.2 m diameter, 62.5 m long).
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10
Modern concepts
for lime production.
11

A Maerz parallel The increased demand for Maerz develops future-oriented


flow regenerative
lime shaft kiln
steel has led to numerous steel standards on the basis of its
for 360 tpd of works extension plans all comprehensive know-how. The
burnt lime and around the world – but mainly firm offers a complete range of
3 RCE lime shaft
kilns, each for
in Asia and South America. products for lime manufactur-
150 tpd of burnt This has naturally resulted ing, from the single machine
lime, in the USA. in a high demand for kilns for to complete plants, in order
burnt lime production and to provide customer-specific
dolomite calcination. solutions for the desired size
of plant and the occurring lime-
Since the beginning of 2006, stone size range.
Maerz Ofenbau AG of Zurich
has been a member of the The complete spectrum of
Polysius Group and became the products comprises diverse
lime competence centre within shaft kilns, rotary kilns with
the Group as a result of the shaft preheaters for very high
bundling of lime activities. production capacities and
POLCAL® gas suspension ther-
mal reactors for the calcination
of ultrafine lime.

Maerz 350 tpd lime production plant in Australia.


parallel-flow The material – dune sand – is processed in a
regenerative shaft-type flash dryer, DOPOL® cyclone 200 tpd annular shaft
lime shaft kiln preheater and rotary kiln before being cooled kiln for lime manufac-
in Mexico. in a shaft-type flash cooler. turing in Saudi Arabia.
12 Metallurgical injection technology.
Reliability and operating economy.

For more than 40 years,


Polysius has been a compe-
tent partner of the iron and
steel industry in the field
of metallurgical injection
technology.

Hot metal desulphurisation tems for the production of from left: Hot metal desulphurisation plant with
two treatment stations.
metallurgical lime for hot metal Positioning the ladle for desulphurisation of the hot metal.
Use of the dip-lance process
desulphurisation and steel Desulphurisation in progress.
for desulphurising hot metal Injection of filter dust into the electric arc furnace.
treatment.
in ladles is a fundamental
prerequisite for the production Conditioning of converter
of high-grade steels, enabling slag
sulphur contents to be reduced
Converter slags with a low
to as little as 0.001 percent.
free lime content are a valuable
Having built more than 50 such basic material for road con-
plants all around the world, struction.
Polysius possesses compre-
hensive know-how. Our injec- The injection of SiO2 is an
tion systems can be used with effective method for targeted up to 10 %. Polysius supplies
all commercially standard minimisation of the lime con- injection systems to suit the
reagents, such as CaO, CaC2 tent. properties of the respective
and Mg, and as mono-injection, filter dust.
Having built the world’s first
co-injection, or multi-injection industrial slag conditioning Blast furnace injection
processes. plant, Polysius possesses both systems
Steel treatment the plant technology and the
For the blast furnace process,
process knowhow for reducing
For the last 30 years, Polysius the content of free lime in con- Polysius supplies efficient and
has been supplying injection verter slags to as low as 0.1 reliable systems for grinding
systems for steel treatment percent. and injecting diverse reagents
whose extremely precise agent and energy carriers, such as
metering assures high operat- Filter dust recycling carbon, waste plastics, titanium
ing economy. oxide, fine ore, filter dust, slag
The amount of filter dust pro-
components and recycled ma-
The injection of CaSi, CaO / CaF2 duced during the steel produc-
terials.
and CaC2 for desulphurising tion process results in high
steel and modifying inclusions disposal costs. Some application examples for
provides numerous benefits, blast-furnace injection systems
To minimise these costs, the
such as low spending on treat- are x the injection of titanium
filter dust can be injected into
ment agents, short treatment oxide for increasing the hearth
the molten steel (e.g. during
times and precise setting of the refractory lifetime x the use of
crude steel production in an
target figures (e.g. the sulphur filter dusts from the steel indus-
electric arc furnace).
content of the steel). try as a valuable raw material
and x the use of waste plastics
Lime production plants
This process not only reduces
the dust quantity by up to 50 % for producing reduction gas as
The Polysius range of products but also increases the zinc con- a low-priced alternative to coke
includes kiln and grinding sys- centration in the filter dust by and heavy oil.
13
Research, development and
service – made for the Future.
14

Excellent technological competence


is the key to winning over and
retaining customers, as well as to
exploiting growth potential in exist-
ing and new markets.

Increasing the size of production units and im-


proving the operating economy of production
plants by reducing their power requirement and
boosting their availability are main development
priorities. Polysius has taken on these challenges
and is pushing back the technological frontiers
through specifically directed research and devel-
opment strategies. We also perform laboratory,
testing and development work for numerous cus-
tomers on a contract basis.

Our research centre with its modern equipment


is one of the leading institutions for technological
development in the basic industry.

Grinding plants for


testing and develop-
ment work.

To determine the
comminution proper-
ties of different feed
materials, a number
Rotary kiln plants for pre- of laboratory-scale
heating, calcining, reducing, POLYCOM® high-
sintering etc. of, for pressure grinding rolls
instance, iron, nickel and are available.
vanadium ores, mineral raw
materials and secondary
intermediate products.
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QUADROPOL® for the performance of grinding tests. CAD designs. POLSCAN® service for checking
the rotary kiln geometry.

Polysius service concept On the basis of our comprehensive knowhow, Polysius specialists
diagnose weak points in the plant operation, offer solutions and
In addition to the everyday challenges of plant operation, the
assist in the elimination of problems.
production process has to be permanently checked with regard
to economy of operation and competitiveness. If necessary, the Polysius offers a broad range of services, including plant inspec-
equipment has to be put in future-oriented condition by incorpo- tion, measurements, maintenance and the procurement and sup-
rating the latest technological developments or spare parts. ply of spare parts.

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