Industrial Solutions

Pyro­
processing
for the
­minerals
industry.
High-quality and innovative
solutions for individual application.
2 3

ThyssenKrupp Polysius Minerals Pyroprocessing

As one of the world’s leading companies in the plant engineering field, ThyssenKrupp Polysius has the comprehensive know-how that
is needed in order to supply the minerals, mining, metallurgical, refractories, lime and chemical industries with innovative but tried and
tested processes, plants and system configurations. ThyssenKrupp Polysius supplies pyroprocessing systems for ...

4 the burning of lime

ThyssenKrupp Polysius systematically Our strong performance applies across declining mineral resources efficiently
consolidates process and plant know-how the board: to complete production lines, and to make intermediate products and 4 the pre-reduction of nickel and manganese ores
to create innovative concepts for the individual products and plant modifications. residual materials usable.
4 the direct reduction of direct reduction and chrome ores
thermal processing of a very broad range
of materials, offering optimum customised Excellent technological competence is the Sustainability and the protection 4 the treatment of mineral secondary raw materials, intermediate products and residues
solutions, including drying, preheating, key to our success and simultaneously the of our environment and climate is one
calcining, reduction, burning, sintering, day-to-day basis for developing first-class of the central corporate objectives of 4 the calcination of aluminium, bauxite, magnesite, dolomite, titanium oxide, chrome ore, soda, phosphate etc.
cooling and pelletising systems. and innovative solutions for individual ThyssenKrupp Polysius.
4 the sintering of magnesite and dolomite
applications – an ability that is valued and
ThyssenKrupp Polysius is a highly-compe- trusted by customers all over the world. 4 the production of expanded clay and flooring plaster
tent partner for project development, project
elaboration, design, delivery, erection, The constant guiding principle of our 4 the concentration of phosphates
commissioning and comprehensive service engineers is to design innovative machines
4 the extraction of oil from oil shale
activities. and processes to use the world’s ever
4 5

1 2 4 5

Kilns: rotary kiln, preheater, multiple hearth Large picture: Waelz-processing kiln in Germany for processing filter dust from electric furnace steel plants into secondary
zinc concentrate. Pictures 1 & 2: Plant for drying and pre-reducing nickel ore in Venezuela. Fig. 3: DOPOL® cyclone preheater.

furnace high temperature shaft kiln and ...

Fig. 4: Gas fired high temperature shaft kiln in Saudi Arabia for the hard burning of lime. Fig. 5: Two multiple hearth furnaces
(17 hearths) for calcining natural magnesite.

The core units of pyroprocessing systems are kilns. Our scope of supply and services not only includes the core equipment but also Multiple hearth furnace: this type of High temperature shaft kiln: this type of
the upstream and downstream plant sections, the electrical equipment and instrumentation and the erection and commissioning. The furnace can be used for processing very kiln was developed in close co-operation
requirements of the customer dictate the design criteria and the optimum kiln system for the customer’s needs is then configured with fine-grained materials at very precise with the refractories industry for sintering
the aid of laboratory test processes, computer simulations and calculations. Custom-tailored. Innovative. Reliable. temperature profile settings. raw materials for refractory applications.

Rotary kiln: robust and reliable construction, low resource con- directed at high production capacities with low operating and capital The multiple hearth furnace is ideal: Main applications:
sumption, high operating reliability and low specific operating expenditure. For this reason, preheater/precalciner systems are 4 for calcining industrial minerals such as 4 direct sintering of magnesite, bauxite,
expense and capital costs are the most important factors in the important components of a modern kiln line. Depending on the magnesite, dolomite, limestone and clay, fireclay, dolomite and
success of ThyssenKrupp Polysius kiln systems. material particle size range, multistage cyclone preheaters or shaft 4 for calcining flotation concentrates and 4 sintering of calcined materials in a
preheaters are used. ThyssenKrupp Polysius offers preheater/ filtercake, e.g. from synthetic MgO two-stage process for e.g. magnesia,
Rotary kilns are used for burning, calcining, reducing, roasting, calciner concepts that are suited to a very broad range of produc- production, dolime, alumina, magnesia-alumina
volatilising or sintering a very broad range of materials. The directly tion capacities and are ideal for both new plant investments and 4 for the pyroprocessing of ores, minerals, spinels and chrome magnesia spinels.
fired rotary kiln can be designed for either the wet or the dry plant conversions. earths and sands, or
process and can be combined with different preheater systems
4 for the thermal treatment of residues. The high temperature shaft kiln works with
– e.g. with cyclone or shaft preheaters – to achieve high productiv- The fundamental characteristics of a cyclone preheater are:
temperatures of up to 2,200°C. Its main
ity while simultaneously reducing the energy consumption. Our minimum energy requirement thanks to effective heat recuperation
characteristics are flexibility in the achieve-
scope of supply includes large-diameter rotary kilns on 2, 3, 4 or and low pressure drop, outstanding efficiency due to high rate
ment of specific temperature ranges and
more supporting roller stations. of material collection in the cyclones and uniform material distri-
profiles as well as its high thermal efficiency.
bution over the gas duct cross-section, and high availability due
Preheater: today’s requirement profile for rotary kiln processes is to time-tested, reliable design and execution.
6 7

The POLCAL® system was specially

developed for the short-time processing
of fine-grained materials.

Materials with particle sizes of 0 to 2 mm

are processed by the gas suspension
method.

The POLCAL® not only performs the

preheating, but also the calcining – without
requiring an additional unit, such as a rotary
kiln. It can be used in combination with
a shaft-type flash dryer to process moist
materials energy-efficiently.

Phosphate ore calcining plant: The ore is

first comminuted in a hammer mill with
shaft-type flash dryer and the dried product
is then calcined in a POLCAL® gas
suspension thermal reactor. Cooling takes
place in a multistage flash cooler.

POLCAL®
the gas suspension preheater with calciner ... for fine materials
Thanks to the modular design
and the range of different
One or more cyclone stages can addition-
cyclone types, tailor-made
ally be used for the subsequent cooling. configurations can be created
without any problem.
The thermal energy transferred to the air
as the material cools down can be reused
in the process – a further bonus for the
energy balance.

Natural gas, oil, coal and calorific offgases

are ideally suited for use as fuels.

A POLCAL® system
in the Netherlands for
calcining FGD-gypsum.
8 9

The Fluo Solid Cooler –

a fluidised bed cooler –
is specially designed for
cooling ultrafine materials.

In many plants it is necessary to cool down a thermally treated product before further
processing or outfeeding. With rotary coolers, shaft coolers, flash coolers, fluidised bed
coolers and, last but not least, the POLYTRACK® – the latest member of the cooler family
– ThyssenKrupp Polysius offers a very broad range of products providing „cool“ solutions
for widely differing applications. A common feature of all our coolers is that the waste
heat from the cooling process is recuperated for the pyroprocessing, minimising the
overall energy requirement.

The flash cooler operates according to the silo, so that no vertical conveying equip-
same principle as the shaft-type flash dryer. ment is needed. cross-current cooler without any moving
Ambient air is intensively mixed with the hot parts contains tube coils through which
material in the riser pipe. The heated air For many processes the robust rotary water is circulated. A small volume flow of
can be used in other processes (e.g. as cooler is the optimum solution – either for air or nitrogen continuously agitates the
secondary air for burning processes). direct cooling of the material with air or material and enables highly efficient heat
Rotary dryer for indirect cooling with water. High throughput transfer to the cooling water in the tube
nickel ore in Brazil. Even if several flash coolers are connected rates, easy handling, great flexibility for coils, thus assuring low product tempera-
in series, their footprint is often smaller than coping with fluctuating material properties tures.
that of, for instance, a rotary cooler. and quantities, high availability and low
Another advantage is that no water supply maintenance requirement speak for the
and treatment system is required. rotary cooler.

If a flash cooler is used in combination with The fluidised bed cooler is an excellent
Shaft-type flash dryer
a cyclone, it is easily possible to discharge solution for indirect cooling of ultrafine
in a lime production plant the dried material directly into the top of a materials, e.g. dusts. The compact
in Australia.

Dryers Coolers
A large portfolio for a very broad range of applications
ThyssenKrupp Polysius offers a broad range of effective systems for drying mineral raw Flash cooler in a
lime production plant
materials. Directly or indirectly working rotary dryers and shaft-type flash dryers are only
in Australia.
two examples of our many different processes.

The rotary dryer, a reliable and low-main- rotary dryer can be combined with a screen product is normally collected in a cyclone.
tenance machine for high throughput rates, in the discharge device in order to split the Hot flue gas from a combustor or offgases
can handle even materials with difficult product into different particle size fractions. from other pyroprocesses are ideal drying
properties. Whether installed as a stand- media. The dryer can be combined with
alone unit or in conjunction with other The shaft-type flash dryer is designed for a hammer mill and a separator in order to
machines, rotary dryers are ideal for drying rapid and gentle drying of fine-grained obtain a required product grain size range.
– and optionally for preheating/pretreating materials. Excellent mixing of the material As a system component of a larger process,
fine-grained and lumpy materials. They can and good flow conditions assure very high the shaft-type flash dryer is therefore
be used for product-specific processing by drying speeds so that even extremely moist excellent for equalising fluctuations in raw
changing-over between parallel flow and materials can often be dried in just a few material properties.
counterflow and by varying the temperature seconds. The low material retention time
of the supplied hot gas. Energy-efficient makes the system very flexible, because
and cost-effective operation is achieved by it can be adapted quickly and easily to
utilising hot offgas, for instance from a variations in the properties of the material,
downstream kiln process. If required, the such as feed moisture content. The dried
10 11

Plant owners demand coolers that are

4 high-performance,
4 compact,
4 low-wear,
4 flexible in use,
4 favourably-priced,
4 reliable in operation and
4 easy to maintain.
This highly complex list of requirements is
exactly fulfilled by the advantages reliably
provided by the POLYTRACK® cooler. Its
numerous innovative process and design
details make POLYTRACK® a future-oriented
mechanical and process technological
solution.

The variable forward stroke speed of the

transport tracks results in optimum transverse
distribution of the material over the entire
width of the cooler, allowing compensation
for off-centre material discharge from the kiln
and reliably preventing fritting of the material
on the grate.

Proven. Reliable. Future-proof. POLFLAME®

POLYTRACK® cooler made by ThyssenKrupp Polysius The rotary kiln burner for numerous fuels
POLYTRACK® advantages at a glance Modern rotary kiln burners not only have to assure full combustion of widely differing types of fuel, but also have to do so for frequently
changing fuel mixtures. This far from simple requirement profile is reliably fulfilled by the POLFLAME® burner.
The POLYTRACK® is a combination of a static, horizontal aeration floor and an above-floor material transport system. Its convincing
advantages are the very high material transporting efficiency and strict separation of the functions of transportation and aeration, due to: The POLFLAME® is designed for burning a Impressive POLFLAME® characteristics are: These advantages make the POLFLAME®
very broad range of fuels – standard fuels burner highly interesting, not only for new
4 optimum transverse distribution of the material resulting in uniform and efficient or secondary fuels, as a single fuel input or 4 variable adjustment without interrupting plants but also for system replacements
cooling of all particle size fractions over the entire width of the cooler, as a complex fuel mixture. operation in the course of plant upgrades.
4 extremely low overall height, 4 complete combustion of the different
Thermal outputs range from 10 MW to 300 fuels within the burnout zone
4 very high thermal efficiency, MW.
4 high rate of fossil fuel substitution by
4 robust, low-wear and easy-to-maintain design providing outstanding availability and secondary fuels
4 consistent modular construction. 4 constant combustion and high flame
stability at different burner settings
4 Moreover, the POLYTRACK tolerates fluctuations in the kiln process; its flexible and
®

high-performance material transportation system copes with even the most difficult 4 reproducible setting of the flame shape
operating conditions. depending on kiln operating conditions
and type of fuel
4 and easy operability of the adjusting
device.
12 13

Modern concepts
for lime production.
Lime and dolomite are essential raw materials, for instance in the steel industry, the Rotary kiln with
shaft preheater in
chemicals industry, agriculture, for building materials and for flue gas cleaning. They have
Germany.
made a crucial contribution to many achievements of our modern world.

Since the beginning of 2006, Maerz The company’s range of products com-
Ofenbau AG of Zurich has been a member prises diverse shaft kilns, rotary kilns,
of the ThyssenKrupp Polysius Group and rotary kilns equipped with shaft or cyclone
became the lime competence centre within preheaters and POLCAL® gas suspension
the Group as a result of the bundling of calciners.
lime activities.

Maerz develops future-oriented standards

on the basis of its comprehensive know-
how. The firm offers a complete range of Lime production plant in
products for lime manufacturing, from the Australia. The material –
dune sand – is processed
single machine to complete plants, in order
in a shaft-type flash dryer,
to provide customer-specific solutions for Maerz parallel-flow cyclone preheater and
the desired size of plant and the occurring regenerative lime shaft Annular shaft kiln rotary kiln before being
limestone size range. kiln in Mexico. in Saudi Arabia. cooled in a flash cooler.
14 15

1 2 3 4 5 6

Research, development and service Large picture: Significant success factors for research and development work at Polysius are interdisciplinary teamwork and the capability to employ a broad range of different instruments,
e.g. the scanning electron microscope with connected MLA (Mineral Liberation Analyser) software. Fig. 1: Rotary kiln for pilot plant tests. Fig. 2: High-temperature kiln for crucible tests
up to 2,200°C. Fig. 3: CAD design. Fig. 4: ThyssenKrupp Polysius has built up a global network of service centers for the minerals industry. Located close to customers and equipped with

Made for the Future top-end workshop machines, these ensure quick and expert maintenance and servicing of all wear-intensive machine components. Fig. 5: Gas analysis and temperature measurement.
Fig. 6: POLSCAN® service for checking the rotary kiln geometry.

Excellent technological competence is the key to winning over and retaining customers, as well as to exploiting growth potential in Our service concept. All around the world, plant managers on the raw material processing sector are coming under increasing pressure
existing and new markets. with regard to competitiveness and costs. The changing basic conditions on the world markets make it necessary to find a strong,
reliable and innovative partner.

Innovations are crucial for the economic units, on improving the operating eco- The R+D Centre has laboratories for In addition to the everyday challenges of ThyssenKrupp Polysius offers a broad range
success of the ThyssenKrupp Polysius nomy and on increasing the plant avail- chemical, physical and mineralogical plant operation, the production process has of services, stretching from plant inspection
Group – whether they involve the advance- ability. investigations. to be constantly checked with regard to and maintenance to performance of
ment of existing products or the opening economy of operation and competitiveness. measurements, supply of spare parts and
up of new fields of application for proven We also perform laboratory, testing and There are departments dealing with If necessary, the equipment has to be put implementation of complex plant conversion
technologies and services. development work for customers on a technical calculations, measurements and in future-oriented condition by incorporating and modernisation projects.
contract basis. process and design development. the latest technological developments or
The crucial thing is to press ahead reso- spare parts.
lutely with the innovations and implement The ThyssenKrupp Polysius Research and And there is the test plant facility, which
them quickly. Development Centre is among the world’s contains “miniature production lines” On the basis of our comprehensive
foremost establishments for technological (including mills, kilns and a workshop) knowhow, specialists from ThyssenKrupp
At ThyssenKrupp Polysius, development development in the minerals, mining and where comminution tests, burnability tests Polysius diagnose weak points in the plant
work is focused on innovations aimed at iron and steel producing industries, as well and wear tests are performed, compo- operation, offer solutions and assist in the
the efficient use of raw materials and as the refractories, lime and chemicals nents tried out and environmental effects elimination of problems.
resources, on achieving larger production industries. observed.
Industrial Solutions
Resource Technologies

thyssenkrupp Industrial Solutions AG

Graf-Galen-Strasse 17
59269 Beckum, Germany
Tel.: +49 2525 99-0
E-mail: [email protected]
www.thyssenkrupp-industrial-solutions.com

© 2016 Product specifications and prices are subject to change without notice or obligation. The photographs and/or drawings in this document are for illustration purposes only.
The operation values are considered to be approximate and will be finally determined on the basis of the specific task and the material characteristics. The only warranty
applicable to our equipment is the standard written warranty applicable to the particular product and sale and thyssenkrupp makes no other warranty of accuracy, reliability,
completeness, merchantability or fitness for any purpose, express or implied. Products and services listed may be trademarks, service marks or trade-names of ­thyssenkrupp
and/or its subsidiaries in Germany and other countries. All rights are reserved.