Polysius
Not sure which of these you need?
Scope, deliverables and what we need from you on site — set out per service area, so you can see which one answers your question before you pick up the phone.
polycom® - high pressure grinding roll
One of the principal reasons for the outstanding success of the high pressure grinding roll in the cement industry is its low power requirement. Today, this mill is employed all around the world for the grinding of cement raw material, cement clinker and granulated blast furnace slag.
The reliable and energy-saving grinding system
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.
Uneconomical plant components can be shut down and operating and maintenance costs can be saved.
polycom® units are used for throughput rates in excess of 2,000 tph. The mill feed material can be dry or moist with a largest feed grain size of up to 60 mm. If necessary, the material can be predried.
Polycom® Film
Maximize the performance, availability, and lifetime of your polycom® from thyssenkrupp Polysius.From inspection and optimization to advanced wear protection and component refurbishment, our portfolio ensures stable, efficient operation throughout the entire lifecycle.
Modernizations
Upgrade your existing grinding system to improve performance and efficiency.
Integration of polycom® into existing plants to increase throughput
Replacement of inefficient grinding components
Optimization of existing grinding circuits
Capacity increases without major plant expansion
The polycom® is particularly suited as an extension investment to enhance the performance of existing grinding systems and reduce operating costs.
Scope of modernization solutions
Machine protection & monitoring
MPS – Machine Protection System
Continuous monitoring of load values via sensors
High-frequency data analysis to detect load peaks
Automatic intervention before damage occurs
Increased machine availability and service life
Mechanical upgrades
Material guide plate
Improved rigidity and optimized material flow
Reduced bypass and wear
Increased throughput
Adjustable feed shaft
Optimized material distribution to the rolls
Improved running smoothness
Reduced skewing of the rolls
Hydraulic system upgrades
Hydraulic system automation
Protection against roll skewing and contamination
Automated flushing and monitoring
Increased system availability
Improved piston accumulator sealing
Reduced friction and leakage
Improved system response and lifetime
Lubrication & cooling
Optimized bearing seal
Controlled grease discharge
Reduced ingress of dirt particles
Increased bearing lifetime and lower maintenance costs
Circulating oil lubrication system
Defined oil temperature and viscosity
Improved cooling and reduced wear
Potentially significantly increased bearing service life
Closed cooling circuit
Controlled operating temperatures
Reduced corrosion and longer component lifetime
Stable and reliable operation
What is Smarter Mining?
If you want to increase material throughput without expanding your plant, small improvements aren’t enough. You need a system that redefines what efficiency means.
Legacy systems, fragmented structures, or a mixed fleet of machinery? For us, that’s not a limitation—it’s a starting point. We modernize and support our own systems and products as well as third-party systems. From core components to wear parts: everything in one plan, with one partner.
Together, we create an environment where every metric ton, every kilowatt-hour, and every hour counts, so your process runs even more efficiently.
Three service areas, one point of contact
Mechanical condition, process performance and parts supply are rarely separate problems. They are handled by separate teams — but you only deal with one of them.
References
Wear Optimization with Compound Cast Rolls – Germany
In a German cement plant, an existing polycom® HPGR was optimized through the implementation of advanced compound cast rolls.
The objective of this modernization was to achieve maximum wear resistance while minimizing
maintenance effort and lifecycle costs under continuous cement grinding operation.
Compound cast technology combines a highly wear resistant outer layer with a tough core structure, providing exceptional resistance against abrasion, fatigue and mechanical damage. This solution was specifically selected to ensure long-term operational stability under demanding cement grinding conditions.
PROJECT IMPACT
Only two maintenance shutdowns over 14 years of operation
Significant reduction in OPEX through highly wear-resistant spare parts
Proven long-term reliability compared to conventional roll solutions
Constant and reliable operating conditions
Current operating hours: 80,000 hours