Polysius
Get the best from your process optimization
— on site and remotely.
Key figures strip
- Whole chain
- The entire process sequence, not one machine
- 6 parameters
- Characteristic process data determined
- On site & remote
- The inspection does not require everyone to travel
- Immediate
- Assistance in implementing immediate actions
What We Measure
The focal point here is evaluating current process data and operation logs. Depending on the inspection scope, we determine the following characteristic process data:
Temperature
Emissions
Volume flow
Material and gas composition
Pressure
Mass flow
The Whole Chain
The inspection covers the entire process sequence, including all key machines and units. The table below maps the stages to the machines in this set.
| Process step | What the inspection looks at here | Machines |
| Raw material preparation | Feed rate and regulation, false air in the crushing and feeding system, material moisture and composition entering the circuit | Double Roll Crusher, coarse feed valve |
| Raw grinding | Throughput and specific energy, gas volumes and pressure drop, separator efficiency, moisture and drying | quadropol®, dorol, sepol® separator |
| Preheater & calciner | Temperature profile through the stages, gas composition, cyclone collection efficiency, false air, fuel substitution rate | prepol® SC, dip pipes, tertiary air damper |
| Rotary kiln | Thermal profile, specific heat consumption, burner settings and flame behaviour, false air at inlet and outlet seals | Rotary kiln, polflame® VN |
| Clinker cooling | Cooling air volumes and distribution, heat recuperation, clinker outlet temperature | polytrack® clinker cooler |
| Cement grinding | Throughput and specific energy, product fineness, separator efficiency, internal circulation, mill ventilation | Ball Mill, polycom®, sepol®, fines cooler |
| Across the line | Operating parameters and mode of plant operation as a whole — how the stages interact rather than how each performs alone | laboratory automation |
Data and Logs
The focal point here is evaluating current process data and operation logs. Before a single new measurement is taken, there is a record of what the plant has been doing — and reading it properly is most of the work.
Current process data — what the control system has been recording all along
Operation logs — what the operators wrote down, which is where the events live that the data alone does not explain
Local industrial measurements where the existing data is not enough, carried out on request
Checking the operating parameters and the mode of plant operation — not only the values, but how the plant is being run
On site and remotely
Evaluating data and logs does not require everybody to be in the same room. Where the examination can be done remotely, it is – the same principle that lets our experts monitor operational and quality parameters from the virtual control room.
Every revamp is scoped along four steps
We identify where operating costs are generated across the plant — from energy consumption to wear, availability and process stability
Mechanical audits, PROCESS AUDITS and on-site inspections reveal how machines and processes interact in real operation. This makes hidden cost drivers visible
Based on the assessment, we define a tailored modernization strategy
We support you from planning and implementation through to the ongoing process
Your Added Value
| Operating parameters checked | Checking the operating parameters and the mode of plant operation — both what the settings are and how the plant is actually run |
| Detailed condition knowledge | Detailed knowledge of the process-technological condition of the plant, as a basis for every decision that follows |
| Training of personnel | Process-technological training of your personnel, so the findings stay in the plant after we leave |
| Immediate actions | Assistance in the implementation of immediate actions — the things that can be changed now, rather than waiting for a project |
Our process-technological examinations form the basis for determining the efficiency of overall processes or subprocesses.