Engineering made by Polysius. Polysius
Transcription
Engineering made by Polysius. Polysius
Engineering made by Polysius. Polysius-Report 2000. April • April • Abril Juli • July • Julio Oktober • October • Octubre Februar • February • Febrero Mai • May • Mayo August • August • Agosto November • November • Noviembre März • March • Marzo Juni • June • Junio September • September • Septiembre Dezember • December • Diciembre A company of ThyssenKrupp Engineering Krupp Polysius tk Januar • January • Enero 2 Into a new millennium. We will accompany you into the future. 3 Dear business friends, Having to write the year 2000 at the top of our letters certainly takes some getting used to at first, but we are accustomed to living in a world of rapid changes and will presumably adjust quite quickly to using this »magic number«, just like we did after every routine turn of the year in the past. No turn of the year brings an abrupt shift in the course of the world, but it does give cause to stop and reflect on the months gone by, and to think about wishes, ideas and intentions for the future. And it is natural that the millennium date change prompted a more intensive contemplation of times past and future than is normally the case. In keeping with this spirit, this Polysius-Report reviews the most significant events of our past business year and informs you about numerous interesting orders and plant commissionings. I wish to take this opportunity to thank all our customers very sincerely for the trust shown in our company in the past. At the same time, may I assure you that we regard your confidence in our firm as an obligation for the future. It is, and will remain our aim to develop and build on existing business relationships that are based on many years of mutual trust and respect by providing convincing supplies and services, while simultaneously winning new business partners by demonstrating our capabilities. The world in which we meet as supplier and customer has altered substantially in the last few years and we can be sure that it will continue to change. However, independently of these market phenomena, the universal desire for quality and reliability will always be an essential factor in the selection of a plant supplier. Modern technologies that are tailored to the respective requirements will continue to be our company’s strength. For this reason, we will maintain our position as one the leaders in the research and development field. Our R & D work will guarantee the further development of essential plant components and the designing of effective new products, ensuring the ongoing availability of a comprehensive range of top-quality supplies and services. We very much look forward to implementing the industrial projects of the new millennium in trusting co-operation with your companies. Sincerely yours, 3,000 tpd cement production line during final assembly at Cementos y Concretos Nacionales in Mexico. Juergen Bauer Board Chairman Krupp Polysius AG 4 At a glance. Highlights 1999. January Turkey: Order for a 120 tph cement grinding plant. Brazil: 20th order for a SEPOL® highefficiency separator within 6 months. England: Start of commissioning of a static primary grate. France: A roller mill for granulated blast furnace slag grinding starts production. April Germany: Krupp Polysius Cement Day; commissioning of a POLAB® AMT laboratory automation system. Brazil: Start of a cement grinding plant commissioning. India: Order for a POLCID® NT process control system. Japan: Commissioning of a POLYCOM® high-pressure grinding roll for coal finish grinding. February May Germany: Order for a QUADROPOL® roller mill for raw material grinding; throughput: 130 tph. Brazil: 1,250 tpd cement production line starts production; order for 2 cement grinding plants for throughputs of 95 and 105 tph. United Arab Emirates: Order for a POLCID® NT process control system for controlling 3 cement production lines. Indonesia: Start of commissioning of a 600 tph raw material roller mill. Brazil: Handing-over of a 20 tph coal grinding plant. South Korea: Commissioning of 2 wet grinding plants for limestone. Germany: 2 Polysius technology forums; Order for a kiln-control POLEXPERT® KCE system. Turkey: Handing-over of a cement grinding plant; throughput: 144 tph of trass cement. England: Handing-over of a 44 tph cement grinding plant. Uzbekistan: Order for a 450,000 tpy phosphate ore calcining plant. Iran: Order for an autogenous mill. March June Spain: Order for a POLAB® AMT, 2 POLCID® NTs and 3 POLEXPERT® systems for mill and kiln system control. Germany: Order for a POLAB® AMT laboratory automation system and a POLAB® CNA online analyser. Uzbekistan: Order for a POLCID® NT process control system for a calcining plant. Spain: Order for a kiln line conversion for raising production capacity from 1,350 to 1,700 tpd. Poland: Order for a 150 tph cement grinding plant. USA: Order for a 5,500 tpd kiln line. Egypt: Follow-up order for a 4,300 tpd cement production line. 5 July October Poland: Kiln line modernisation successfully concluded; production capacity increased from 1,600 to 2,000 tpd. Ireland: Start of a cement grinding plant commissioning. USA: Commissioning of a POLAB® AMT laboratory automation system. Egypt: Handing-over of a 4,300 tpd cement production line. Germany: Handing-over of a hot metal desulphurisation and steel treatment plant. USA: Polysius Technological Seminar in Colorado Springs. Poland: Follow-up order for a kiln line conversion for raising production capacity from 1,600 to 2,000 tpd. Australia: Polysius seminar in Perth. Malaysia: Start of commissioning of a 950 tph limestone crushing plant and a circular blending bed with 29,000 t limestonestorage capacity. Germany: Order for a POLCID® NT process control system. August November Spain: Preheater successfully converted by integrating the PREPOL®-CC process. USA: Order for a 5,400 tpd clinker production plant. Australia: AT processor extracts first oil from oil shale. Tanzania: Order for one semiautogenous and one tube mill for gold ore comminution. South Korea: Two 25 tph limestone grinding plants (single-chamber wet mills with hydrocyclones) handed over to customers. Spain: Order for a turnkey granulated blast furnace slag grinding plant comprising a 70 tph roller mill, a longitudinal blending bed for 2 x 9,000 t storage capacity and a storage silo; Order for modernisation of a rotary kiln. September December Peru: 3 POLYCOM® units handed over. USA: Order for a 90 tph granulated blast furnace slag grinding plant. United Arab Emirates: Handing-over of a cement production line converted from 2,500 to 3,300 tpd. Egypt: Handing-over of a 4,300 tpd cement production line; Production startup of a 4,300 tpd cement production line. Germany: Polysius Autumn Seminar. Ivory Coast: Order for a tube mill. England: 50 tph granulated blast furnace slag grinding plant put into production. Mexico: Start of commissioning of a cement-grinding roller mill (output: 85 tph OPC or 80 tph pozzolanic cement). USA: Production startup of a 2,100 tpd cement production line. Turkey: Order for a POLCID® NT process control system. Poland: Order for a POLAB® laboratory automation system. 6 Orders and plant commissionings – 12 months in the year. …winter brings the first three. Brazil: 12 February 1999 1,250 tpd cement production line inaugurated at Companhia Minas Oeste de Cimento / Lafarge In Arcos, in the Brazilian state of Minas Gerais, approx. 230 km south-west of Belo Horizonte city with its 4 million inhabitants, a new 1,250 tpd cement clinker production plant was officially put into production on 12 February 1999. Krupp Polysius supplied the engineering up to the clinker conveying equipment, as well as the following main components for the kiln line: a DOPOL® ’90 cyclone preheater, a rotary kiln and a REPOL®-RS reciprocating grate cooler equipped with a roll crusher. In view of the fact that a substantial recovery is forecast for the Brazilian market as from the year 2003, which will result in an increased demand for cement, the plant design allows for upgrading to a capacity of 2,000 tonnes per day. 3rd QUADROPOL® order Rohrbach Zement GmbH & Co. KG was the third purchaser of the new but already proven Krupp Polysius QUADROPOL® roller mill. Their unit has a nominal grinding table diameter of 3,200 mm, a roller diameter of 1,600 mm and an installed power of 1,470 kW. As from April 2000 it will take over raw meal production for the rotary kiln, with an output of 130 tph at a fineness of 18 % R 90 µm. The new raw grinding unit will replace a smaller roller mill at the Dotternhausen cement plant. 20 SEPOL® separators sold to Votorantim inside 6 months In the 6 months up to January 1999, the Votorantim group, the biggest cement manufacturer in Brazil, awarded the Polysius member company in São Paulo orders for the supply and installation of 20 SEPOL® high-efficiency separators. The separators are for different petroleum coke grinding systems in various Votorantim cement plants. 7 Roller mill for granulated blast furnace slag grinding started up in France: 5,000 cm2/g achieved right from the outset Damp, abrasive, rich in iron and difficult to grind – these properties of granulated blast furnace slags represent a challenge for any grinding system. The fact that Krupp Polysius roller mills consistently achieve high finenesses and low energy consumption. was impressively proven once again at a new slag grinding plant at Les Moulins du Littoral in Dunkirk, France. Even during commissioning, the roller mill with its drive power of 1,200 kW ground 25.5 tph of blast furnace slag to a fineness of 5,000 Blaine from the outset and before any optimisation measures. The warranted fineness was 4,500 Blaine. Moreover, the feed material moisture content exceeding 14% was reduced to max. 0.3% in the finished product. Apart from the high moisture level, the iron content of 3% in the feed material places special demands on the grinding system. In addition to the iron separators installed in the feed equipment, two magnetic drums are connected in series in the external ground material circuit after the bucket elevator. With this system, preground material passes the magnetic drums four times (recycle ratio of 4), ensuring highly effective removal of the iron, the main cause of wear. Winter landscape in the Muensterland. Turkey: Bastas Baskent Cimento awards order for cement grinding system Polysius S.A., the French Subsidiary of Krupp Polysius A.G., were contracted by Bastas Baskent Cimento Sanayii ve Ticaret A.S. to supply a new cement grinding system of 120 tph capacity for its Elmadag plant, close to Ankara. The closed-circuit hybrid grinding plant consists of a POLYCOM® high-pressure grinding roll, a two-compartment separator tube mill running on sliding shoe bearings and driven by a 1,800 kW COMBIFLEX® drive unit and a SEPOL® high-efficiency separator. The plant design makes possible a future conversion to combi grinding mode by installing a disagglomerating separator. 8 …interesting activities in the springtime. Egypt: The Egyptian Cement Company (ECC) orders its 3rd plant The ECC again entrusted Polysius S.A. (French Subsidiary of Krupp Polysius A.G.) with the realisation of a turnkey cement production line for 4,300 tpd, and thus confirmed once more its confidence in the competence of Krupp Polysius. This was far-sighted decision – not least because with the commissioning of the new production line in 2001, there will no longer be any need for Egypt to import cement. The agreed scope of supply and services is based on the identical plant configurations already ordered by ECC from Polysius S.A. and covers a circular blending bed with a storage capacity of 50,000 tons, a 350 tph raw material ball mill with a SEPOL® high-efficiency Uzbekistan: Order for 450,000 tpy phosphate ore calcining plant separator, a raw meal blending silo, a five-stage single-string DOPOL® ’90 cyclone preheater with PREPOL®-AS-CC calciner system, the rotary kiln, a REPOL®-RS reciprocating grate cooler, a 50,000 t clinker store as well as a 220 tph cement grinding ball mill with SEPOL® high-efficiency separator. Also included in the scope of supply are a cement silo with 16,000 t storage capacity, cement loading and rotary packing stations as well as a POLAB® semi-automatic laboratory automation system. Cementos Alfa S.A., Spain: Conversion project raises production capacity from 1,350 to 1,700 tpd In May 1999, a customer in Uzbekistan awarded Krupp Polysius the supply contract for a calcination plant for 450,000 t of phosphate ore per year. The ore is first broken and dried in a hammer mill with flash dryer and subsequently calcined in the POLCAL® gas suspension thermal reactor. The calcined material is cooled in a multi-stage flash cooler. The hot gas is utilised in compound operation, making the plant particularly energy-efficient. Commissioning of the new plant is due to start in the second half of the year 2000. For the second plant conversion phase at their Mataporquera factory, aimed at boosting kiln production capacity from 1,350 to 1,700 tpd, Cementos Alfa S.A. commissioned Krupp Polysius in June 1999 to increase raw mill throughput from 110 tph to 130 tph by integrating a new SEPOL® high-efficiency separator and modifying the preheater. Commissioning is due to start in September 2000. 9 Iran: Autogenous mill ordered for iron ore comminution Thanks to the customer‘s positive experience with an existing iron ore dressing plant, Krupp Polysius received a follow-up order in May 1999 to supply an AEROFALL mill with a diameter of 9 m and an installed drive power of 3,000 kW. This unit will dry and grind up to 800 tph of iron ore. Daffodils – the first messengers of spring in Germany. USA: 5,500 tpd kiln plant Lehigh Portland Cement Company, a member of the Heidelberger Zement Group, commissioned Polysius to install a 5,500 tpd kiln plant in Union Bridge in the state of Maryland, approximately 100 km north of Washington. The new plant comprises a one-string, five-stage DOPOL® ’90 cyclone preheater with PREPOL®-CC-MSC precalciner system. The 5.2 m x 70 m rotary kiln will be driven via a self-aligning drive pinion. 10 … great activity in summer too. 5,400 tpd clinker production plant for the USA Australia: 19 August 1999: the first oil flows… Rich in oil shale… poor in conventional oil deposits – this situation forced Australian companies to search for solutions for extracting oil from oil shale – economically and by environmentally compatible means. The co-operation of many partners from all over the world made this ultra-modern project a reality at the Stuart plant, operated by Suncor Energy Management Pty. Ltd. Krupp Polysius delivered and installed the AT (Alberta-Taciuk) processor, a gigantic prototype with 8.2 m rated diameter, 62 m length and 2 x 1,250 kW drive power, designed for an input of 211 tph of oil shale and the production of 4,500 barrels of oil per day. The cold trials began on 1st June 1999, followed by hot trials and then by oil production on 19 August. 3 POLYCOM® units go into operation in Peru 100 % Petcoke with the PREPOL®-CC calcining system Aiming for the exclusive use of petcoke in the precalciner of their Mataporquera cement plant, Cementos Alfa S.A. of Spain decided on the PREPOL®-CC process. Krupp Polysius installed 2 combustion chambers in the preheater. Since the middle of August 1999 the kiln plant has been firing 100 % petcoke and producing outstanding operating results. In September, 3 POLYCOM® high-pressure grinding rolls, plus disagglomerators and SEPOL® separators were handed over to Cementos Lima S.A. Their decision to make exclusive use of POLYCOM® high-pressure grinding rolls for raw material and cement clinker grinding in the Atocongo plant resulted in part from a desire to install identical and interchangeable modules for energy-efficient grinding, and to reduce the spare parts inventory. The high availability of the 6 high-pressure grinding rolls now installed at the plant makes this possible. Holnam Inc., the largest of the Holderbank Group’s companies, is expanding its Portland plant in Florence in the state of Colorado. The new 5,400 tpd production plant for cement clinker has the following main components: a 450 tph roller mill for grinding raw material, a five-stage DOPOL® ’90 cyclone preheater with PREPOL®-MSC calciner system, and the rotary kiln. For cement grinding at an output rate of 220 tph a combination system comprising a POLYCOM® highpressure grinding roll and a tube mill with STATOPOL®-Cand SEPOL® separators will be installed. The order also includes a cement cooler and a roller mill for grinding 41 tph of coal. USA: St. Lawrence Cement orders large Polysius roller mill for granulated blast furnace slag grinding St. Lawrence Cement Inc. commissioned Polysius Atlanta to install a granulated blast furnace slag grinding system in its new granulated blast furnace grinding facility currently under construction in Camden, N.J. Once the plant is up and running, it will be producing 90 tph of ground blast furnace slag, using a Polysius roller mill with 4,200 kW drive power and a SEPOL® high-efficiency separator. The feed material has max. 15 % moisture content and max. 2 % iron content. 11 Heavy load… one of four roller units for a QUADROPOL® roller mill on its way to Arizona Portland Cement Co. in Rillito, USA. Each unit is 4.30 long, 3.00 m wide and 4.30 high, and weighs approx. 80 (!) tonnes. 2nd conversion phase at Fujairah Cement Ind. successfully concluded; output raised to 3,300 tpd In its first stage, the cement production line was upgraded from 1,600 to 2,500 tpd. The second conversion stage, taking the plant to an output of 3,300 tpd, was handed over to Fujairah Cement Ind. in Dibba, United Arab Emirates, in September 1999. The 2nd phase involved: increasing the raw material throughput from 120 to 220 tph by installing a tube mill, constructing a 110 tph cement grinding plant and installing a POLCID® NT process control system. The alterations to the kiln plant included: addition of a new DOPOL® dust collection stage, tertiary air duct and precalciner and conversion of the cooler. Egypt: Two at the same time – »A brilliant feat« 2nd ECC plant starts clinker production For the Egyptian Cement Company (ECC) and Krupp Polysius the 30th September 1999 is a day to remember. It marks the achievement of completing performance tests for the 4,300 tpd cement production line 1 and starting clinker production with the 4,300 tpd kiln line 2 on one and the same day. Milad Bishay, General Project Manager of ECC, put it like this in his congratulatory fax to Krupp Polysius: »I appreciate and admire the great effort made to complete the performance tests of kiln line I and also commence clinker production on kiln line II on the same day… It is a great event for Polysius, Orascom (OCI) and for ECC. In fact this is a precedent.« Wet grinding plant for Tanzania A Tanzanian customer ordered a wet grinding plant from Krupp Polysius for gold ore comminution comprising a SAG mill (8 m diameter, 6,200 kW drive power) and a tube mill (6.1 m diameter, 6,000 kW drive power). Both units incorporate the innovative and patented HYFLEX concept, comprising a sliding shoe bearing arrangement and COMBIFLEX® drive unit. This order raises the number of Krupp Polysius mills built according to this principle to over 130. Summer: Poppies in the cereal crop. 12 … autumn’s events. Poland: Conversion of 2nd kiln line boosts production from 1,600 to 2,000 tpd Immediately after Krupp Polysius completed the successful modernisation of their first kiln line in July 1999, Cementownia Nowiny S.A., owned by Dyckerhoff Zement International GmbH, decided on a conversion of their second kiln line. In September 1999, Krupp Polysius therefore received the follow-up order for quick upgrading of the plant using innovative solutions. The aim was to incorporate the new equipment with minimum interruption of production and to raise the output of the second kiln line from 1,600 to 2,000 tpd. The modernisation work, which affects the preheater, rotary kiln and cooler, will be concluded by July 2000. A two-compartment separator mill will also be installed as the cement grinding plant. For an output of 150 tph at 3,000 Blaine this plant will have a rated specific power requirement of only 34.5 kWh/t. After the production startup in early 2001 it will supersede the existing 7 mills. A short look at technology… to be continued in the year 2000 8-10 October 1999, USA. The great success of the previous technical seminars organised annually by the Polysius member company in Atlanta prompted over 80 participants plus accompanying persons to attend this year’s event in Colorado Springs. This seminar brings attendees from the American cement and minerals industries together. The initial joint session consisted of a series of interesting papers. This was followed by specific papers and intensive discussions for each industry. Naturally, the seminar was concluded by a lighterhearted programme of events that reflected the famed »American Way of Life«. Polysius factory automation: there are some moments that create a lasting impression... The few moments devoted to introducing the POLAB® AMT, POLCID® NT and POLAB® CNA automation components at the 1997, 1998 and 1999 Krupp Polysius Cement Day symposiums impressed the market in a big way. After all, these system components were not just marginal modifications of their predecessors, but completely new generations (in fact, the POLAB® CNA is a totally new development), that can be linked up to form a unified factory automation system with no interface problems. Just in the year 1999, Krupp Polysius booked 27 orders for POLAB® analysis systems and modernisations, as well as 33 orders for POLCID® process control systems, modernisations and extensions. In addition, Polysius commissioned 17 POLAB® and 14 POLCID® systems… 13 2,100 tpd cement production line for Florida Rock started production In December 1999 commissioning commenced at the 2,100 tpd cement production line of Florida Rock Industries Inc. The contract award in 1997 was the first in over 10 years for a completely new plant to be built on a green field site in North America. Krupp Polysius was commissioned to supply the following main components: a roller mill for grinding 175 tph of raw material; the kiln line, consisting of a two-support kiln, 4-stage DOPOL® ’90 cyclone preheater including PREPOL®-AS calcining system and reciprocating grate cooler; a POLAB® CNA online analyser; a POLCID® NT process control system; a 125 tph tube mill for cement grinding and conveying, storage and flow regulating systems. The wonderful colours of autumn. Control room with POLCID® NT at the Florida Rock cement plant. Turnkey granulated blast furnace slag grinding plant for North Spain At the end of 1999 S.A. Tudela Veguín decided to purchase a complete granulated blast furnace slag grinding plant for their Aboño plant in North Spain, and commissioned Krupp Polysius to supply a turnkey system. The contract signed on 2nd November 1999 includes: x a Polysius longitudinal blending bed for storage and homogenisation of 2 x 9000 t of granulated blast furnace slag x a roller mill including recirculating bucket elevator for producing 70 tph of blast furnace slag meal with a fineness of 4,500 Blaine x a storage silo 4,400 m3 blast furnace slag meal storage capacity) – equipped with tanker truck loaders and x conveying equipment to the individual plant sections and to the seaport at Gijón. 14 Krupp Polysius – worldwide. Krupp Polysius AG Graf-Galen-Straße 17 59269 Beckum / Deutschland Tel.: +49 - (0)25 25 - 99-0 Fax: +49 - (0)25 25 - 99-2100 e-mail: [email protected] http://www.krupp.com/polysius A company of ThyssenKrupp Engineering Polysius Ltd. The Brackens, London Road Ascot, Berks. SL5 8BE / England Tel.: +44 - (0)13 44 - 88 41 61 Fax: +44 - (0)13 44 - 88 64 38 e-mail: [email protected] Polysius S. A. 770, Avenue Guilibert de la Lauzière 13290 Aix en Provence / France Tel.: +33 - 4 42 - 16 61 00 Fax: +33 - 4 42 - 16 61 02 e-mail: [email protected] Polysius S. A. Pl. Manuel Gómez Moreno, s/n Edificio Bronce 28020 Madrid / España Tel.: +34 - (0)91 - 5 55 80 40 Fax: +34 - (0)91 - 5 55 47 89 e-mail: [email protected] Krupp Polysius Corp. 180 Interstate North Parkway Atlanta, GA 30339-2194/USA Tel.: +1 - 7 70 - 955 - 36 60 Fax: +1 - 7 70 - 955 - 87 89 e-mail: [email protected] Krupp Engineering de México S. A. de C.V. División Polysius Sierra Gamón # 120, 7° y 8° Pisos Lomas de Chapultepec 11000 México, D.F. / México Tel.: +52 - (0)5 - 2 84 01 00 Fax: +52 - (0)5 - 2 84 02 73 e-mail: [email protected] Krupp Projetos e Serviços Técnicos Ltda. Divisão Krupp Polysius Av. Brigadeiro Faria Lima 1572-14° andar São Paulo / SP / Brasil Tel.: +55 - (0)11 - 811 45 00 Fax: +55 - (0)11 - 8 67 81 44 e-mail: [email protected] Polysius de Argentina S.A. 25 de Mayo 596-Piso 14° (1002) Buenos Aires / Argentina Tel.: +54-11-43 11 60 46 / 7 Fax: +54-11-43 11 60 45 e-mail: [email protected] Krupp Polysius a division of Krupp Engineering (Pty) Ltd. 71 Nanyuki Road Sunninghill 2157 Republic of South Africa Tel.: +27- (0)11 - 236 - 10 00 Fax: +27- (0)11 - 236 - 11 25 e-mail: [email protected] Krupp Engineering Asia Pacific Pte. Ltd. Division Krupp Polysius 1 Scotts Road # 16 - 06, Shaw Centre Singapore 228208 Tel.: +65 - 7 35 01 22 Fax: +65 - 7 34 80 07 e-mail: [email protected] Krupp Polysius Division of Krupp Engineering (Australia) Pty. Ltd. 8 Business Park Drive Notting Hill, Vic. 3168/Australia Tel.: +61 - (0)3 - 95 58 86 66 Fax: +61 - (0)3 - 95 58 84 88 e-mail: [email protected] Final assembly of the large QUADROPOL® roller mill at Arizona Portland Cement Co., USA. 15