1606 GB Minerals Image

8/8/2019 1606 GB Minerals Image

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PolysiusA company

of ThyssenKrupp

Technologies tk

Polysius Minerals.Engineering made by Polysius.


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2 Polysius Minerals Technology.Present all around the world.

As one of the worlds leadingcompanies in the plant engi-neering field, Polysius has thecomprehensive know-how thatis needed in order to supply themining, metallurgical, refracto-ries, lime and chemical indus-

tries with innovative but triedand tested processes, plantsand system configurations.

Again and again, Polysiusproduces convincing solutionsfor pyroprocessing and grind-ing applications, proving itselfa reliable partner in all regions

of the world.

The high availability, lowenergy requirement and goodenvironmental compatibilityof the large number of plantsthat we have installed speakfor themselves.


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Nickel oreDrying systems: rotary dryer, shaft-type flash dryerCalcining systems: rotary kiln, POLCAL

Iron oreTreatment plants: SAG mills, ball mills, POLYCOM

Concentrate-grinding plants: ball mills, POLYCOM

Additive grinding plants: ball mills, roller mills

Gold/copper oreDry grinding plants: SAG mills, ball mills, DOUBLE ROTATORs

Concentrate-grinding plants: SAG mills, ball mills, POLYCOM

Heap leaching plants: POLYCOM

Diamond oreGrinding plants: POLYCOM, scrubbers

Lime/LimestoneGrinding 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 millsCoalGrinding plants: ball mills, roller millsInjection systems: dispensers, POLOP

SteelInjection systems: dispensers, POLOP

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

Dryers: rotary dryer, shaft-type flashdryer

Preheaters: cyclone preheater, shaftpreheater

Kilns: rotary kilns, POLCAL, shaftkilns, multihearth furnaces

Coolers: cyclone cooler, shaft cooler,rotary cooler, fluidised bedcooler

Our product range:

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


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4 Grinding technologyConvincing concepts.

Grinding is one of the mostenergy-intensive productionstages and therefore has asubstantial energy-savingpotential. The main demandsmade on grinding plantsare low operating costs and

high availability, even whengrinding extremely abrasivematerials.


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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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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).

DOUBLE ROTATOR

comminuting gold ore (252 tph

throughput) in the USA.

Autogenous mills breaking

diamond ore in Angola

(throughput: 400 tph each).

Mounting the bearing

shoes of a large SAG

mill with circumferen-

tial bearing assembly.

Ball mill grinding

limestone for flue gas

desulphurisation at

a power station in

Korea.

The largest SAG-mill with circumferential

bearing assembly (10.4 m diameter, 11,000

kW drive power) and ball mill for grinding

1350 tph of gold/copper ore in Australia.

Roller mill

for limestone

grinding.

High pressure comminution

The economic and gentle process-

ing solution. 60 % of the high-

pressure grinding rolls installed

in the minerals industry are from

Polysius: the POLYCOM operates

convincingly all around the world,

comminuting copper ore, gold ore,

iron ore, diamond ore, platinum

ore, coal, granulated blast furnace

slag, limestone, cement clinker

and other mineral raw materials.

This type of mill ensures low

operating expenses (in compari-

son to other systems, both the

power consumption and the costs

for wear parts are significantly

lower), high throughput rates (a

high-pressure grinding roll can

replace several reduction crushers)

and metallurgical advantages in

the downstream process stages.

Because of the short materialdwell time in the mill, the machine

settings can be quickly altered,

making the process easy to control

and permitting rapid compensa-

tion for fluctuations in the proper-

ties of the feed ore.

Roller mills

Roller mills integrate three process

stages into a single unit: drying,

grinding and separating. Their

range of applications includes

limestone, additive and coal grind-

ing.

Autogenous mills and ball mills

for wet and dry grinding

Polysius builds autogenous/

semi-autogenous and ball mills

with circumferential bearing

assembly and girth gear or ring

motor drive. For special applica-

tions, Polysius offers DOUBLE

ROTATOR and AEROFALL mills.

The COMBIFLEX system is a

particularly economical drive con-

cept:

The drive unit is integrated into

the housing for girth gear and

sliding shoe bearing. High drive

power requirements are met by a

double COMBIFLEX system or

ring motor.


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8 Pyroprocessing.Success through experience.

Machines and plants from Polysiusensure consistent product quality,minimum power requirement dueto optimum heat recuperation,outstanding availability and goodresource 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.

Waelz-processing kilns in Germany

for processing filter dust from electric

furnace steel plants into secondary

zinc concentrate.

Right:

AT processor for oil shale processing

(8.2 m diameter, 62.5 m long).

Phosphate ore calcining plant for 450,000

tonnes per year. The ore is comminuted in

a hammer mill with shaft-type flash dryer

and the dried product is then calcined in

a POLCAL gas suspension thermal

reactor. Cooling takes place in a multistage

flash cooler.

2nd picture from left: Plant for drying and pre-reducing

nickel ore in Argentina. The 180 tph plant consists of

a rotary dryer and two long rotary kilns (5.0 m diameter,

120 m long).

3rd picture from left: Rotary dryer for nickel ore in Brazil

(3.4 m diameter, 22 m long; feed material moist, 104 tph).


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11Modern conceptsfor lime production.

The increased demand for

steel has led to numerous steel

works extension plans all

around the world but mainly

in Asia and South America.

This has naturally resulted

in a high demand for kilns for

burnt lime production and

dolomite calcination.

Since the beginning of 2006,

Maerz Ofenbau AG of Zurichhas been a member of the

Polysius Group and became the

lime competence centre within

the Group as a result of the

bundling of lime activities.

Maerz develops future-oriented

standards on the basis of its

comprehensive know-how. The

firm offers a complete range of

products for lime manufactur-

ing, from the single machine

to complete plants, in order

to provide customer-specific

solutions for the desired size

of plant and the occurring lime-

stone size range.

The complete spectrum of

products comprises diverse

shaft kilns, rotary kilns with

shaft preheaters for very high

production capacities and

POLCAL gas suspension ther-

mal reactors for the calcination

of ultrafine lime.

A Maerz parallel

flow regenerative

lime shaft kiln

for 360 tpd of

burnt lime and

3 RCE lime shaft

kilns, each for

150 tpd of burnt

lime, in the USA.

Maerz

parallel-flow

regenerative

lime shaft kiln

in Mexico.

350 tpd lime production plant in Australia.

The material dune sand is processed in a

shaft-type flash dryer, DOPOL cyclone

preheater and rotary kiln before being cooled

in a shaft-type flash cooler.

200 tpd annular shaft

kiln for lime manufac-

turing in Saudi Arabia.


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12 Metallurgical injection technology.Reliability and operating economy.

For more than 40 years,Polysius has been a compe-tent partner of the iron andsteel industry in the fieldof metallurgical injectiontechnology.

Hot metal desulphurisation

Use of the dip-lance process

for desulphurising hot metal

in ladles is a fundamental

prerequisite for the production

of high-grade steels, enabling

sulphur contents to be reduced

to as little as 0.001 percent.

Having built more than 50 suchplants all around the world,

Polysius possesses compre-

hensive know-how. Our injec-

tion systems can be used with

all commercially standard

reagents, such as CaO, CaC2and Mg, and as mono-injection,

co-injection, or multi-injection

processes.

Steel treatment

For the last 30 years, Polysius

has been supplying injection

systems for steel treatment

whose extremely precise agent

metering assures high operat-

ing economy.

The injection of CaSi, CaO / CaF2and CaC2 for desulphurising

steel and modifying inclusions

provides numerous benefits,

such as low spending on treat-

ment agents, short treatment

times and precise setting of the

target figures (e.g. the sulphur

content of the steel).

Lime production plants

The Polysius range of products

includes kiln and grinding sys-

tems for the production of

metallurgical lime for hot metal

desulphurisation and steel

treatment.

Conditioning of converter

slag

Converter slags with a low

free lime content are a valuable

basic material for road con-struction.

The injection of SiO2 is an

effective method for targeted

minimisation of the lime con-

tent.

Having built the worlds first

industrial slag conditioning

plant, Polysius possesses both

the plant technology and the

process knowhow for reducing

the content of free lime in con-verter slags to as low as 0.1

percent.

Filter dust recycling

The amount of filter dust pro-

duced during the steel produc-

tion process results in high

disposal costs.

To minimise these costs, the

filter dust can be injected into

the molten steel (e.g. during

crude steel production in anelectric arc furnace).

This process not only reduces

the dust quantity by up to 50 %

but also increases the zinc con-

centration in the filter dust by

from left: Hot metal desulphurisation plant with

two treatment stations.

Positioning the ladle for desulphurisation of the hot metal.

Desulphurisation in progress.

Injection of filter dust into the electric arc furnace.

up to 10 %. Polysius supplies

injection systems to suit the

properties of the respective

filter dust.

Blast furnace injection

systems

For the blast furnace process,

Polysius supplies efficient and

reliable systems for grinding

and injecting diverse reagents

and energy carriers, such as

carbon, waste plastics, titanium

oxide, fine ore, filter dust, slag

components and recycled ma-

terials.

Some application examples for

blast-furnace injection systems

are x the injection of titanium

oxide for increasing the hearth

refractory lifetime x the use of

filter dusts from the steel indus-

try as a valuable raw material

and x the use of waste plastics

for producing reduction gas as

a low-priced alternative to coke

and heavy oil.


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14 Research, development andservice made for the Future.

Excellent technological competenceis the key to winning over andretaining customers, as well as toexploiting growth potential in exist-ing and new markets.

Increasing the size of production units and im-

proving the operating economy of productionplants 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.

Rotary kiln plants for pre-

heating, calcining, reducing,

sintering etc. of, for

instance, iron, nickel and

vanadium ores, mineral raw

materials and secondary

intermediate products.

To determine the

comminution proper-

ties of different feed

materials, a numberof laboratory-scale

POLYCOM high-

pressure grinding rolls

are available.


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Polysius service concept

In addition to the everyday challenges of plant operation, the

production process has to be permanently checked with regard

to economy of operation and competitiveness. If necessary, the

equipment has to be put in future-oriented condition by incorpo-

On the basis of our comprehensive knowhow, Polysius specialistsdiagnose weak points in the plant operation, offer solutions and

assist in the elimination of problems.

Polysius offers a broad range of services, including plant inspec-

tion, measurements, maintenance and the procurement and sup-

QUADROPOL for the performance of grinding tests. CAD designs. POLSCAN service for checking

the rotary kiln geometry.

Documents

1606 GB Minerals Image