Polysius Minerals.

Engineering made by Polysius.

tk

A company of
ThyssenKrupp
Technologies
Polysius
2 Polysius minerals technology
with worldwide presence.

As one of the world’s lead-

ing companies in the plant
engineering field, Polysius
has the comprehensive know-
how that is needed in order
to supply the mining, metal-
lurgical, refractories, lime
and chemical industries
with innovative but tried and
tested processes, plants
and system configurations.
Again and again, Polysius
produces convincing solu-
tions for pyroprocessing,
grinding and metallurgical
injection applications, prov- Grinding technology
ing a reliable partner in all
regions of the world.

The high availability, low

energy requirement and
good environmental com-
patibility of the large number
of plants that we have
installed speak for
themselves.
Pyroprocessing

Metallurgical
injection technology
 3

The product range:

Iron ore
Preparation plants: SAG mills, tube mills, POLYCOM®
Concentrate-grinding plants: tube mills, POLYCOM®
Additive grinding plants: tube mills, roller mills

Gold/copper ore
Dry grinding plants: SAG mills, tube mills, DOUBLE ROTATOR®
Concentrate-grinding plants: SAG mills, tube mills, POLYCOM®
Heap leaching plants: POLYCOM®

Diamond ore
Grinding plants: POLYCOM®, scrubbers

Lime/limestone
Grinding plants: tube mills, roller mills, POLYCOM®
Calcination plants: rotary kiln, POLCAL®, shaft kiln, shaft preheater
Grinding plants
(flue gas desulphurisation): tube mills, roller mills

Coal
Grinding plants: tube mills, roller mills
Injection systems: dispenser, POLOP®

Steel
Injection systems: dispenser, POLOP®

Process development
Pyroprocessing: POLCAL®, precombustion chamber, kilns, fluidised bed
for: nickel ore, chrome ore, oil shale, magnesite, dolomite,
soda, phosphate ore, bauxite ore, self-levelling floor
screed, gypsum...
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 the grinding plants are low operating costs and high availability,
even when grinding extremely abrasive materials.
Grinding plants from Polysius have estab-
lished themselves worldwide in the miner-
als industry because of their convincing
concept, robust construction and out-
standing availability. The very broad range
One of three
of different mill types offers the right sys-
SAG mills
with 9.75 m tem for every application.
diameter and
2 x 4,000 kW
High-pressure comminution
drive power.
These mills POLYCOM® high-pressure grinding rolls
operate in
conjunction with tube mills for iron ore grind- provide substantial energy savings com-
ing in Iran. pared with conventional systems, as well as
reduced wear costs and improved product
qualities, e.g. in iron ore pellet manufac-
turing and copper and gold ore dressing.
Roller mill
for grinding
Roller mills limestone.

Roller mills integrate three work operations

POLYCOM ® in a single unit: drying, grinding and sepa-
high-pressure rating. Their area of application includes
grinding rolls
for iron ore
limestone, additive and coal grinding.
concentrate
in Brazil. Autogenous and tube mills for wet and
dry grinding
Polysius builds autogenous, semiautoge-
nous and tube mills with circumferential
Tube mill
bearing assembly and girth gear or ring for grinding
motor drive. For special applications, limestone for
Polysius supplies DOUBLE ROTATOR ® a flue gas
desulphurisa-
and AEROFALL mills. tion system in
a Korean
The COMBIFLEX® system is a particularly power station.
economical drive concept. The drive unit
is integrated in a joint housing for girth
DOUBLE gear and sliding shoe bearing. For high
ROTATOR® drive powers, a dual COMBIFLEX® system
for gold ore comminution (252 tph) or a ring motor is used.
in the USA.

Site
Largest SAG mill with circumferential bearing arrangement assembly
(10.4 m diameter, 11,000 kW drive power) and a tube mill of a large
for grinding 1,350 tph of gold /copper ore in Australia. mill shell.
 Diese Headline unterscheidet sich in 5
Farbe und Größe von der Titelseite.
Die Subheadline auch.

SAG / tube mill circuit incorporating

crushers and a POLYCOM® high-
pressure grinding roll.

System with secondary

crushers, a POLYCOM®
and tube mills.

Tube mill for grinding limestone

for flue gas desulphurisation systems
in power stations.
 6 Pyroprocessing.
Success through experience.

Pyroprocessing machines and plants from Polysius ensure consist-

ent product quality, minimum power requirement due to optimum
heat recuperation, outstanding availability and good environmental
compatibility.

Modern concepts for lime

1200 production
Output [tpd]

1000
Rotary kiln Based on comprehensive
800 know-how, Polysius devel-
POLCAL®
oped future-oriented stand-
600
ards and offers a complete
400 Shaft kiln programme of lime manu-
200 facturing products, ranging
0
from single machines to
1 2 3 4 5 6 7 8 9 10 20 30 40 50 60 70 80 90 100 200
Feed size [mm]
complete plants, ensuring
customised solutions in the
Polysius portfolio required plant size and limestone size range.
for lime production.

There are three main areas of application for our

lime kiln systems:

x For feed sizes of 15 mm to 200 mm and out-

puts of up to 600 tpd, the shaft kiln is the solu-
tion.

x For large capacities and limestone

feed sizes of 5 mm to 60 mm, the
rotary kiln with or without shaft pre-
heater is the appropriate pyroprocessing
system.

x If the feed size is below 2 mm, the

POLCAL® gas suspension thermal reactor POLCAL® thermal reactor
has established itself as the most suitable for lime production.
pyroprocessing system, with or without
subsequent rotary kiln, depending on the
desired product quality.

Lime production
plant for 350
tpd in Australia.
The material,
dune sand, is
processed in
flash dryer,
DOPOL® cyclone
preheater and
rotary kiln, then
cooled in a Annular shaft kiln for
flash cooler. lime manufacturing.
 7

Process development

The efficient production of

high-grade intermediate or fin-
ished products demands far
more than combining ideal
partial process steps or even
ideal individual machines. The
required success can only be
Phosphate ore achieved by considering the
calcining plant for
450,000 tpy. The
entire production process and
ore is comminuted optimising it as a whole, taking
and dried in a ham- due account of capital cost and
mer mill with flash Processor for oil shale treatment in
dryer and subse-
operating expenses. Australia. The gigantic processor
quently calcined (8.2 m x 62.5 m) has a rated capacity
in the POLCAL® For this reason, Polysius system- of 211 tonnes of oil shale per hour.
gas suspension
thermal reactor.
atically consolidates process and plant
The product is know-how to create innovative concepts for
cooled in a multi- the thermal processing of a very broad range
stage flash cooler.
of materials. Polysius offers a comprehensive
range of products covering the complete
field of thermal processing (drying, preheat-
ing, calcining, reduction, burning, sintering,
cooling, pelletising), as well as the diverse
product requirements of the customers.

Often, the contract work begins with inten-

sive material tests in our own Research and
Plant for drying and pre- Development Centre. If a new process or
reducing nickel ore. With a rated
product is to be employed, pilot scale tests
throughput of 180 tph of ore, this
plant consists of a rotary dryer are the first step and form the indispensa-
(4.4 m x 27 m) and two long rotary ble basis for the later plant.
kilns (5.0 m x 120 m).
8 Metallurgical injection technology.
Reliability and operating economy.
For more than 40 years, Polysius has been a competent
partner of the iron and steel industry in the field of metal-
lurgical injection technology.
Hot metal desulphurisation
and steel treatment processes
Reagent injection into the
molten metal by means of a
pneumatic pressure conveying
system and a dip lance is
used all around the world with
great success for hot metal
desulphurisation and steel
treatment.
Our injection systems can
be used with all commercially
standard reagents and agents,
such as CaC2, Mg, CaSi, C
and CaO, and as monoinjec-
tion, co-injection, or multi-
injection processes.
Polysius developed the MEPOL®
programmable control system
for regulating a very broad
range of injection rates, agent
quantities and mixture ratios.
This system ensures con-
sistent conveying and reliable
achievement of the metallurgi-
cal process objectives when
injecting reagents into molten
metal.
Injection systems can be
equipped with the POLEXPERT®
metallurgical process computer
to optimise the operating econ-
omy of the process.
Filter dust recycling
The amount of filter dust pro-
duced during the steel pro-
duction process results in high
disposal costs. Polysius filter
dust recycling systems have
proven extremely effective for
minimising these costs. Injecting
filter dust into the molten steel
during the crude steel produc-
tion process in the electric arc
furnace not only reduces the
dust quantity but also increas-
es the zinc content of the dust.
This process leads to a sub-
stantial decrease in preparation
costs.
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, titani-
um oxide, fine ore, filter dust,
slag components and recycled
materials.
Some application examples
for blast-furnace injection
systems are the injection of
titanium oxide specifically for
increasing the hearth refractory
lifetime, the use of filter dusts
from the steel industry as a
valuable raw material and the
use of waste plastics for pro-
ducing reduction gas as a low-
priced alternative to coke and
heavy oil.
Lance insertion unit for
hot metal desulphurisation
(double lance system).
 9

General view:
desulphurisation
system with two
injection stations.

Workstation
equipped with
modern control
and instrumentation
technology.

Multi-injection system
for desulphurisation agents
and additives.
Injection of filter
dust into the electric
arc furnace.
10 Research and Development.
Investment in the future.

No innovation, no future...
This statement has never been more appropriate: the ability to prevail
in the face of strong competition on the international markets requires
a great deal of innovation at a high technological level.

Increasing the size of produc- QUADROPOL®

roller mill for
tion units and improving the grinding tests.
operating economy of produc-
tion plants by reducing their
power requirement and boost-
ing their availability are main
development priorities. Polysius
has taken on these challenges
and is pushing back the tech-
nological frontiers through
specifically directed research
and development strategies.
We also perform laboratory,
testing and development work
for numerous customers on
a contract basis.

Our research centre with its

modern equipment is one of
the leading institutions for tech-
nological development in the
basic industry.

Laboratory To determine
rotary kiln for the comminution
pyroprocessing properties of differ-
test series. ent feed materials,
a number of labora-
tory-scale POLY-
COM® high-pressure
grinding rolls are
available.

Especially when a
high-pressure grinding
roll is to be used in a new process, it is
often sensible to previously test grind a
large amount of material or to incorporate
the high-pressure grinding roll into existing
pilot plants. For this purpose a mobile,
semi-industrial POLYCOM® is available on a
rental basis. The machine’s size and 50
to 100 tph throughput capacity allow the
realistic simulation of industrial processes.

Pyroprocessing pilot plant

in the test plant facility.
 11

Modern process
control system for
pilot plants.

Grinding plants for testing

and development work.

Good service is decisive.

POLCAL® system as In addition to the everyday
test arrangement. challenges of plant operation,
it is crucial to permanently
check the production equip-
ment with regard to operating
economy and competitiveness.
If necessary, the plant must
be returned to a future-oriented
condition by integrating state-
of-the-art technological devel-
opments or spare parts.

On the basis of Polysius’s

comprehensive know-how,
our experts diagnose weak
points in the plant operation,
offer improvement solutions
and assist in the elimination
of problems.

Polysius provides a broad

scope of services, ranging
from the first plant inspection
to raw material investigation
and analysis and to mainte-
nance, spare parts procurement
and spare parts delivery.