Palmar de Bravo, Mexico (Completion 2016)
thyssenkrupp Polysius commissioned a turnkey 3,500 tpd cement production line. The new line was constructed alongside the cement production line that was set up by Polysius in 2006. The first line had already been prepared for the connection of the second line. The integration of the new line more than doubles the clinker capacity of the works.
Saraburi, Thailand (Completion 2015)
thyssenkrupp Polysius recently commissioned the new cement production line with a capacity of 10,000 tonnes of cement clinker per day. thyssenkrupp Industrial Solutions supplied the main components, from the raw material preparation system, to the clinker manufacturing process and the fuel preparation system. The POLCID® master control system is responsible for plant control, and a POLAB® laboratory automation system is to ensure product quality in every phase of the process.
Silifke, Turkey (Completion July 2015)
thyssenkrupp Polysius supplied the complete kiln line, 10,500 tpd cement clinker, which commenced operation in July 2015. The kiln line consists of a 5-stage, 2-string DOPOL® preheater with PREPOL® calcining system, a rotary kiln with POLFLAME®-VN clinkering zone burner, and a POLYTRACK® clinker cooler with intermediate roll crusher.
Hainan, China (Completion July 2012)
The main components supplied by thyssenkrupp Polysius for this plant were:
two raw-grinding systems, each consisting of a roller mill for a rated raw-meal output of 475 tph,
the kiln system with a 5-stage, 2-string DOPOL preheater with PREPOL-MSC calcining system, the rotary kiln (7.2/6.2 m x 96 m long), the POLYTRACK clinker cooler and a POLFLAME-VN clinkering zone burner.
Lagunas/Mexico (Completion October 2012)
The QUADROPOL QMC is the latest roller-mill generation, which was developed especially for cement and granulated-blast furnace slag grinding. The turnkey cement grinding plant is designed for a throughput of 175 tonnes per hour.
Solnhofen, Germany (Completion April 2012)
After less than 7.5 months between the contract award and commissioning, the new future-oriented POLAB Shuttle system took over the quality monitoring functions from the old laboratory automation system. It has since proven to be innovative, flexible and extremely reliable.
Santiago de Anaya, Mexico (Completion December 2012)
Turnkey project: The plant comprises the following main components: a longitudinal blending bed for 2 x 13,000 tonnes of limestone, a tangential blending silo for raw material storage and the kiln system consisting of a DOPOL 5-stage preheater with PREPOL-MSC, a rotary kiln (4.0 m diameter x 56 m length) with POLFLAME-VN clinkering zone burner and the POLYTRACK clinker cooler. The clinker grinding system consists of a POLYCOM high pressure grinding roll, a SEPOL separator and a ball mill. It has a rated cement output of 135 tph. The cement is stored in a multi-compartment silo
quadropol®
Cemento de Bolivia
Cementos de Bolivia ordered a 3,000 tons per day kiln line, successfully commissioned in 2019. This was an EPC contract to the German-Spanish polysius-Imasa-Valoriza consortium. The contract included a QMR² 38/19 for raw grinding and a QMC² 45/23 for cement grinding.
After the shortest time, the plant was able to meet the project’s design parameters, fulfilling all process/technical guarantees.
Please also refer to: Vilaseca, M, PEG Consulting Group LLC, USA. “The making of Oruro”. International Cement Review (January 2020)
Cementos Cibao S.A.
Cementos Cibao S.A., cement producer in the Dominican Republic, continues the modernization process and ordered a cement mill type QMC² 40/20 for grinding different cement types. Compact plant arrangement with service tower, quadropol® vertical roller mill and main filter are part of the supply. Optimized mill operation will be supported by a digitalization package incl. intelligent mill controller.
The mill is operating very successful since mid of 2021.
The quadropol® concept for coal or pet coke grinding, with adapted table speed and high efficiency separator sepol®, ensures a safety mill operation and serves reliable the kiln burning process.
Mombasa Cement Ltd. ordered a QMK² 24/12 with three roller units for the 5,000 tons per day kiln line. In addition, the raw material grinding process will be supported by a QMR² 48/24.
For the 4,000 tons per day kiln line Shiva Cement Ltd. contracted a quadropol® vertical roller mill for grinding pet coke with a QMK² 32/16.
The same mill size QMK² 32/16 is running in Indonesia for years now, grinding and drying lignite.
Yamama
Yamama Cement ordered two 10,000 tons per day kiln lines. For raw material grinding four QMR² 48/24 are contracted, while for cement grinding four polycom® high pressure grinding rolls as a combi grinding system are considered due to material properties.
The four mills are operating very successful since mid of 2021. The final set-up of the mills resulted in good operation performance. The material feed moisture is 2.61 %, which means it is fairly dry. At the end the injected water quantity, required on the table during operation, is only 0.78 %.
Please refer also to: thyssenkrupp “A holistic approach“. International Cement Review (September 2021)
The installed 4,000 tons kiln line at Afyon Cimento is successfully in operation for many years, showing truly equipment reliability and stable plant performance. For raw material grinding a quadropol® vertical roller mills QMR² 45/23 was contracted to serve the kiln line, while for cement grinding two identical QMC² 45/23 were considered for grinding different cement types. The request for interchangeable parts for the three mills was fulfilled and represents still a holistic approach. For coal grinding a QMK² 32/16 completed the grinding portfolio.
The cement mills are equipped with high efficiency separators to achieve cement qualities with a fineness up to 5 000 cm2/g acc. to Blaine.
polysius® booster mill
The polysius® booster mill in operation in an industrial pilot installation
The polysius® booster mill in operation in an industrial pilot installation
In 2017 a pilot installation was commissioned in a grinding plant in Turkey. For two years, the mill operated in fly ash grinding, the results in product quality and high energy efficiency convinced to keep the mill. Since the second half of 2019, this mill upgrades an existing ball mill grinding circuit of the integrated cement production, achieving an increase in production capacity and also in cement quality.
Several trials were conducted with different cement types. This led to an increase of the CEM I 42.5 N cement production by some 20 percent, up to 56 from 45 tph. Furthermore, a higher compressive strength at nearly the same Blaine surface area indicates an additional potential for production increase by adjusting the cement quality. Second positive result was the significant quality improvement. By switching on the new mill, the compressive strength of the cement was able to meet the CEM I 52.5 R requirement, while maintaining the original production rate. The starting point was the CEM I 42.5 R at a rate of 38 tph.
Re-use and refurbishment of existing components allow a successful and efficient project execution
Re-use and refurbishment of existing components allow a successful and efficient project execution
Project description
Ashaka Cement contracted thyssenkrupp Polysius to modernize a feed conveyor and spillage.
Parts of the old apron conveyor and spillage conveyor were removed and replaced with the new machine components. It was possible to retain the existing drives, the main and longitudinal beams.
Results
Reduction of power consumption by 10 %
Cost savings through maintenance optimization by 20 %
Cementa AB - turnkey project for cement mill
Cementa AB - turnkey project for cement mill
Manufacturing and assembly of mill shell section for Cement mill 2, replacement of the bearings and sealing systems (inlet and outlet) as a turnkey project.
Customer: Cementa AB
Location: Slite, Schweden
Re-use and refurbishment of existing components allow a successful and efficient project execution
Project description
Cementos del Norte contracted thyssenkrupp Industrial Solutions to modernize a apron feed conveyor.
Parts of the old apron feed conveyor were removed and replaced with the new machine components. It was possible to retain the existing drives, the main and longitudinal beams, and the drive and return shafts. The existing drive shaft was re-machined while all other components were delivered as new items.
Results
Reduction of power consumption by 10 %
Cost savings through maintenance optimization by 20 %
Customer: Cementos del Norte
Location: Honduras
Plant type: Crushing plant for cement production
Service type: Plant modernization
Mixture of reused and new components allows a cost efficient and fast project execution
Mixture of reused and new components allows a cost efficient and fast project execution
Project description
Cemex contracted thyssenkrupp Polysius to exchange a cement mill. A special challenge, the exchange had to be completed on turn key basis.
Parts of the cement mill were removed and replaced. It was possible to retain the motors, bearings and gear rim, pinions.
Customer: Cemex (today: Lafarge/Holcim)
Location: Beckum, Germany
Plant type: Cement grinding plant
Service type: Plant modernization
Upgrade of separator increases output and saves investment costs
Upgrade of separator increases output and saves investment costs
Project description
Ciplan contracted thyssenkrupp Industrial Solutions to increase the performance of their separator. The time frame for the modification is usually between 5 and 12 days depending on the size and circumstances on-site.
Results
Increasing of separator efficiency
Increasing of grinding plant production
Energy savings
Customer: Ciplan-Cimento Planalto S.A.
Location: Brasilia, Brazil
Plant type: Cement grinding plant
Service type Plant modernization & performance increase
Replacement of new efficient components into existing structures increase plant efficiency and save costs
Replacement of new efficient components into existing structures increase plant efficiency and save costs
Project description
HeidelbergCement contracted thyssenkrupp Industrial Solutions to exchange a powder cooler Ø 2,5m x 6,5m. As special challenge, the exchange had to be completed in 15 working days on turn key basis.
Parts of the old powder cooler were removed and replaced with the new bigger machine. It was possible to retain the substructure and water system.
Results
Increase of productivity
Less power consumption by 35 %
Customer: HeidelbergCement
Location: Schelklingen, Germany
Plant type: Cement grinding plant
Service type: Plant modernization & performance increasing
HeidelbergCement AG - turnkey project for kiln roller station
HeidelbergCement AG - turnkey project for kiln roller station
Project description
Cement plant
Manufacturing and assembly of kiln roller station II (turnkey project) with a splined kiln tyre. Manufacturing and assembly of kiln roller station III with slipping tyre was already done in 2008.
Customer: HeidelbergCement AG
Location: Schelklingen, Germany
Replacement of components with tailor-made concepts save costs
Replacement of components with tailor-made concepts save costs
Project description
Huasheng contracted thyssenkrupp Polysius to modernize two kiln clinker coolers.
thyssenkrupp Industrial Solutions delivered the modular cooler concept POLYTRACK.
Results
For two lines the existing Sinoma coolers were replaced with POLYTRACK with intermediate crusher
Cost savings through maintenance optimization by 15 %
Throughput was increased
Clinker end temperature was decreased drastically
Cooler efficiency was increased
Customer: Huasheng
Location: China
Plant type: Plant for cement production
Service type: Plant modernization
JIMAH Power Plant - repair after fire damage
JIMAH Power Plant - repair after fire damage
Project description
Repair after fire damage. Fabrication and erection of main elements of the carrying steel structures under-carriage and upper-carriage plus parts of the tripper-car. Renovation of machine parts and parts of conveyor system.
Customer: JIMAH Power Plant
Location: Mukim Jimah, Malaysia
Equipment: Stacker Reclaimer SR - 2
Märker Zement GmbH - delivery & assembly of mill slide ring
Project description
Delivery and assembly of mill slide ring as well as extension of grinding track of department 2.
Customer: Märker Zement GmbH
Location: Lauffen am Neckar, Germany
Mixture of refurbished and new components allows a cost efficient project execution
Mixture of refurbished and new components allows a cost efficient project execution
Project description
National Cement contracted thyssenkrupp Polysius to revamp their crushing plant. As a special challenge, thyssenkrupp had to retrofit a crusher from a third party.
Parts of the crusher were reengineered, removed and replaced with new machine components. It was possible to retain the existing drives and crusher housing.
Results
Improvement of the performance
Less investment costs compare to complete new crushing plants by 50 %
Customer: National Cement Company
Location: Cairo, Egypt
Plant type: Crushing plant for cement production
Service type: Plant modernization & expansion
Rotary kiln with graphite block seal- effective sealing, designed for easy mounting
Rotary kiln with graphite block seal- effective sealing, designed for easy mounting
Project description
The client PHOENIX decided to install our new designed kiln outlet sealing system with graphite blocks.
A special challenge was the short delivery time for creating the technical drawings and manufacturing. And of course the installation for this unknown prototype during 10 days.
Results
False air reduced
Performance increased
Increased secondary air use
Clean and safety burner platform
Customer: PHOENIX Zementwerke
Location: Beckum, Germany
Plant type: Plant for cement production
Service type: Spare parts
Installation of new components into existing structures saves costs for our customers
Installation of new components into existing structures saves costs for our customers
Project description
P.T. Semen Tonasa contracted thyssenkrupp Polysius to deliver a rollsizer and integrates it into the process. As special challenge, the existing concrete structure, feed and discharge conveyor had to be re-used.
Results
Improvement of the performance
Due to wear reduction, 30 % costs reduction for maintenance
Less investment costs compared to complete new crushing plants by 50 %
Customer: P.T. Semen Tonasa
Location: Indonesia
Plant type: Plant for cement production
Service type: Plant modernization & optimization
Rohrdorfer Zement - renovation of kiln plant
Project description
Comprehensive renovation of kiln plant with planetary cooler and upgrading to state-of-the-art technology within planned budget and timeline.
Customer: Rohrdorfer Zement, Portland cement plant
Location: Rohrdorf, Germany
Replacement of components with cost saving thought-out assembly concepts
Replacement of components with cost saving thought-out assembly concepts
Project description
SCHWENK Zement KG contracted thyssenkrupp Polysius to modernize their kiln cooler. thyssenkrupp delivered the modular cooler concept POLYTRACK. To reduce the plant downtime, the cooler was preassembled beside the existing cooler. After the disassembly of the old cooler the complete POLTRACK was moved on rails into his final position.
Results
Cost savings through maintenance optimization by 15 %
25 % assembly time reduction, due to preassembly beside the existing cooler
Location: Germany
Plant type: Plant for cement production
Service type: Plant modernization
Schwenk Zement KG - modernization of feed apron conveyor
Schwenk Zement KG - modernization of feed apron conveyor
Project description
SCHWENK Zement KG contracted thyssenkrupp Polysius to modernize a feed apron conveyor. As special challenge, the conversion had to be completed in 20 working days during the coldest weeks of the year (- 20 °C and freezing rain).
Parts of the old apron conveyor were removed and replaced with the new machine components. It was possible to retain the existing drives, the main and longitudinal beams and the drive and return shafts. The existing drive shaft was re-machined while all other components were delivered as new items.
Results
Reduction of power consumption by 10 %
Cost savings through maintenance optimization by 20 %
Customer: SCHWENK Zement KG
Location: Karlstadt, Germany
Plant type: Crushing plant for cement production
Service type: Plant modernization
Training of international customers in Germany and on site
Training of international customers in Germany and on site
Project description
Practical exercises and theoretical lectures of operating and maintenance staff and in 15 different training units.
Participants: 156
Duration: 67 days
Languages: German, English, French, Spanish
Location: Beckum, Germany & on site
Replacement of new efficient components into existing structures increases plant efficiency and saves investment costs
Replacement of new efficient components into existing structures increases plant efficiency and saves investment costs
Project description
Yanbu Cement contracted thyssenkrupp Polysius to deliver a wobbler. As special challenge, tkIS has to contracted this machine on EPC basis including using of the existing substructure.
Results
Less wear at the crusher rotors
Increasing of crusher plant capacity by 20 %
Less invest cost compare to complete new crushing plants by 50 %
Customer: Yanbu Cement
Location: Yanbu, Kingdom of Saudi Arabia
Plant type: Plant for cement production
Service type: Plant modernization & optimization
Re-use and refurbishment of existing components allow a successful and efficient project execution
Re-use and refurbishment of existing components allow a successful and efficient project execution
Project description
Vissai Cement contracted thyssenkrupp Polysius to deliver our new custom made POLFLAME kiln burner.
A special challenge was the implementation into the existing structure.
Customer: Vissai Cement Company
Location: Ninh Binh, Vietnam
Plant type: Plant for cement production
Service type: Plant modernization
Installation of new components into existing structures save invest costs and increase the performance of the complete unit
Installation of new components into existing structures save invest costs and increase the performance of the complete unit
Project description
Zementwerk Hatschek contracted thyssenkrupp Polysius to install a new separator. The time frame for the modification is usually between 10 -12 days depending on the size and circumstances on site.
Results
Increasing of separator efficiency
Increasing of grinding plant production
Energy savings
Customer: Zementwerk Hatschek
Location: Gmunden, Austria
Plant type: Cement grinding plant
Service type: Plant modernization & performance increase