cement plant thyssenkrupp polysius

thyssenkrupp Polysius Products

thyssenkrupp Polysius with its brands polysius® and Maerz® is one of the few full-range suppliers for the cement industry – from individual machines, all the way up to complete plants. We also have compelling solutions for the modernisation of existing systems. We have unique expertise in the field of process engineering. In accordance with customer-specific requirements, we develop innovative machinery, technologies and processes to create intelligent production lines.

From the planning process, to construction, to the commissioning of plants, our clients have a single contact person. This accelerates procedures, prevents conflicts of interests, and ensures fast and trouble-free commissioning.

The trend in the global cement industry is moving towards the awarding of turnkey orders: from individual grinding plants to entire production lines.

Thanks to the application of ultra-modern production processes, our plants protect resources and the environment and guarantee plant owners maximum productivity and economy of operation.

Polysius product portfolio

Grinding

polysius® booster mill

The polysius® booster mill is an additional stage grinding solution, particularly efficient for finer grinding. Therefore, it enables customer to produce ultra-high performance cements or sustainable cements with a lower clinker factor without losing grinding capacity and gaining flexibility. The reduced specific power consumption, the beneficial particle size distribution, higher early strength and short project duration without significant downtime lead to a quick payback. The polysius® booster kit is completed with process know how as well as digital and laboratory services.

sepol® high efficiency separator

The higher the demands placed on the quality of ground material, and the lower the desired energy consumption of the overall grinding system, the more important is the efficiency of the separator. The sepol® high efficiency separator plays a key role in grinding systems equipped with tube mills, roller mills and high pressure grinding rolls.

Modular Grinding Plant

Gain the full potential of modular grinding: From construction to operation - supported by thyssenkrupp Polyisius!

Ball Mill

The proven classical option for cement grinding. Whether employed as a two-compartment separator mill in an independent grinding system, or in combination with a high pressure grinding roll, the Ball Mill is a robust and reliable alternative for cement and granulated blast furnace slag grinding.

polycom® high pressure grinding roll

For new plants, the polycom® is an economically superior concept compared to conventional systems. The polycom® is also predestined as extension investment to achieve maximum throughput increases of existing plants. With its low space requirement and the high capacity in relation to machine size, the polycom® can be easily integrated in existing plants.

quadropol® vertical roller mill

In the last years, thyssenkrupp has successfully continued stepwise the development process for the quadropol® vertical roller mill concept. This compact and modular conception includes the latest market requirements regarding compact plant layout, efficient operational process, reliable machine design and reduced unscheduled down time. Tailor-made solutions with interchangeable parts are also available.

Fines cooler

The fines cooler works on the principle of indirect heat dissipation: i.e. the coolant does not come into contact with the material being cooled and therefore does not affect the product quality.

Crushing

titan® Double-Shaft Hammer Crusher

The TITAN® Double-Shaft Hammer Crusher is used for crushing medium-hard rock. For wet limestone, wet marl, clay, chalk, gypsum and similar raw materials.

mammut® Single-Shaft Hammer Crusher

The mammut® crusher is uncomplicated and compact in design, rugged in its construction, extremely powerful and completely safe in operation and with a minimum maintenance requirement: Over the years, secured for itself a firm place in the cement, limestone and gypsum industry.

Impact Crusher

The thyssenkrupp Impact Crusher produces a single stage perfect feed material for a vertical roller mill. They crush medium-hard to hard material.

Double-Roll-Crusher

Double-Roll-Crushers are used for the crushing or medium-hard rock as well as for sticky and soft materials, i.e. clay, marl, limestone and similar raw materials. Sticky and soft materials are reliably crushed in 2 or 3 stages down to the required product size.

Roll Sizer

The Roll Sizer are capable of crushing medium-hard rock as well as sticky and soft material such as coal, clay, marl, limestone and similar raw materials. The material is crushed by shear- and tensile forces generated by high rotor torques at a low circumferential speed. Due to the arrangement of the crushing tools the fines in the feed can pass through the crushing rolls similar to a roller screen without being crushed.

Apron feeder

Apron feeders sturdy design has stood the test of time even under the harshest conditions in applications from cement production. They are used to feed a range of crushers with lumps of "run-of-the-mill" material up to two meters in size or as dosing systems for downstream drying and/or grinding processes.

Jaw crusher

Our jaw crushers are mainly desgined to crush medium-hard to very hard materials. They are used in mines and quarries as primary crushers to crush blasted rockpile in preparation for finish crushing or conveying.

Roller Screen / Wobbler

The roller screen wobbler is designed for the classification of coarse, wet, sticky and lumpy material. Our roller screen wobbler fits to various feed materials, for example rock, limestone, marl, mineral coal, lignite etc.

Mobility of Crushing Plants

Mobile thyssenkrupp crushing plants are in operation all around the world.

Mobile crushing plants make it possible to crush minerals directly at the site of extraction and synchronize to the rate of mining advance, into sizes ready for conveyor transport of the crushed material from the mining face to the processing plant.

Pyroprocessing

polytrack®

The polytrack® is the reliable clinker cooler of thyssenkrupp. The focal point of our quest for continuous innovation and optimization of the polytrack® reflects our commitment to meet the demands of the cement industry. With the polytrack®, thyssenkrupp offers a robust machine that keeps delivering high performance under challenging process conditions not only today, but for years to come.

prepol® SC

The prepol® SC is an add-on for the prepol® precalciner. It opens a new dimension in combustion: New sorts of wastes can be utilized resulting in a new level of fuel-cost savings.

dopol®

In the case of the cement industry, today's requirement profile for the manufacturing process is directed at high production capacities with low operating and capital expenditure. For every requirement an optimally customised DOPOL concept.

polguide Kiln Drive System

Rotary kilns can be equipped with our POLGUIDE drive system independently of the number of supporting roller stands. This drive type is a modern girth gear and pinion drive in which the girth gear and the pinion always have the same clearance, both in radial and in longitudinal direction. This assures optimum meshing of the teeth, no matter what operating state occurs.

polro® 2-support kiln

The POLRO rotary kiln has a statically determined support configuration on only two roller stations and has a direct drive system. The kiln shell with its splined tyres rotates on self-aligning rollers, which automatically adjust themselves to the momentary running conditions.

3-support kiln

Variable-speed electromechanical drive systems with planetary gearbox, splined tyres, pneumatic inlet and outlet seals, air-cooled inlet trough, hydraulic axial thrust system etc. are proven components of both the 2-support kiln and the 3-support kiln. If the length to diameter ratio exceeds 15, it is best to support the rotary kiln on three roller stations.

polflame®

The polflame® burner is an innovative clinkering zone burner to reduce fuel as a cost factor in your cement plant – by utilizing alternative fuels instead of fossil fuels.

Materials Handling

Tangential Blending Silo

The tangential blending silo is used for storing and homogenising the raw meal. It consists of the silo shell, the distributing system, the inner cone, the aeration surface with the discharge systems, the central mixing chamber, the aeration system and the dust collection filter.

Multipack Silo

There is a series of raw meals that become segregated in a tangential blending silo. This is often the case if the raw meal has a high quartz content. The multipack silo patented by thyssenkrupp Polysius can then be used.

Tangential Storage Silo

For the pure storage of fine-grained or powdery products such as filter dusts, coal dust or other additives, very different silos and bins which are adapted to the respective material properties are used.

Circular Blending Bed

The circular blending bed is used for storage and homogenisation of the main components such as limestone, limestone/marl/clay mixtures, clay or coal. Material can be stored and reclaimed simultaneously.

Longitudinal Blending Bed

The longitudinal blending bed is used for storage and homogenisation of the main components such as limestone, limestone/marl/clay mixtures, clay or coal. It consists of two stockpiles, with the material being stored according to the CHEVRON stacking method in one stockpile with the aid of a belt stacker, and the material from the other stockpile being reclaimed by means of a bridge-type scraper reclaimer that reclaims from the face of the stockpile.

Additive Storage

The storage facilities for correctives such as iron ore, bauxite or sand, and for additives such as gypsum, limestone or pozzolana, are usually designed as longitudinal stockyards. Often, coals are also stored in these longitudinal stockyards.

polysius® Belt Conveyor

Uncover the potential of our conveyor system, ideal not only for the cement industry but also for diverse applications requiring the transport of bulk materials. With five variations available, including one-direction, reversible, shuttle, discharge, and crusher discharge conveyors, the polysius® Belt Conveyor offers a versatile and efficient solution for transporting materials over distances ranging from 5m to approximately 1000m.

Automation

polab® AMT

The polab® AMT laboratory automation system is thyssenkrupp’s full-size solution for medium to very large cement plants. The polab® AMT is more compact and sampling handling is managed via an ABB industrial robot. The system is fully modular allowing for easy upgrades in the future. Its small footprint allows the system to fit easily into existing buildings, thus reducing investment costs.

polab® Linea

The polab® Linea laboratory automation system is thyssenkrupp’s full-size solution for medium to very large cement plants. The polab® Linea features a narrow design and sample transport via transport belts and handling units. The system is fully modular allowing for easy upgrades in the future. Its small footprint allows the system to fit easily into existing buildings in the plant, thus reducing investment costs.

polab® APM

The polab® APM combines a mill and press in one small unit with a minimum footprint. It is a patented grinding unit for efficient and gentle grinding, and optimises sample preparation for the different requirements of XRF and XRD.

polab® Cal

polab® Cal is the first automated calorimetry system that can be fully integrated into polab® laboratory automation systems, or used as a stand-alone unit in R&D and product development. polab® Cal samples are prepared and analysed fully automatically by adjusting binder composition, adjusting w/c ratio, mixing samples, introducing samples into the calorimeter (I-Cal Flex; Calmetrix®), and automated data evaluation.

AQCnet Software

polab® AQCnet represents our take on the next generation of laboratory control software. Everything is linked, everything is supervised. Over many years AQCnet has evolved from a tool controlling laboratory automation systems into a sophisticated toolbox for plant operation using quality control data.

polab® laboratory automation

Laboratory automation is the key to quality control in cement plants and mining, provides excellent ROI, and improves workplace safety. polab® laboratory automation offers a complete portfolio ranging from manual sampling stations to fully automated pneumatic sample transport, from semiautomatic sample preparation to custom-build, fully autonomous robotic laboratory automation solutions.

polcid®

polcid® is configured as an open automation solution providing both well-tried and innovative functions implemented with state-of-the-art computer technology.

Integrated Plants

Integrated Plants

In addition to the product and machinery business, we carry out the planning, supply, installation and commissioning of entire process groups as well as ready-to-use cement plants in the integrated plants category. Modern processes, methods and tools are used in engineering, project management and construction and commissioning.