Industrial Solutions

Autogenous, semi-auto-genous and ball mills for wet and dry grinding.High performance system configurations for every application.

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3 Autogenous and semiautogenous mills

3 Ball mills

3 Rod mills

3 Scrubbers

3 Lime slaking machines

Wet grinding Dry grinding

3 AEROFALL mills

3 Ball mills

3 Rod mills

3 Separators

3 Dryers

3 POLYCOM® high-pressure grinding rolls

3 Roller mills

As one of the world’s leading companies in the plant engineering field, ThyssenKrupp Industrial Solutions has the many years of knowhow that is needed in order to supply the minerals industry with innovative and high-quality, autogenous/semiautogenous and ball mills for wet and dry grinding.

High-performancesystemconfigurations...

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Grindingtestssupportthe

sizingoftheequipment.

Ourcontinuousdevelopmentandoptimisa-tionofmachineandplantconcepts,pro-cessesandequipmentguaranteescustom-ersstate-of-the-art,reliabletechnologywithhighenergyandresourceefficiencyandminimumoperatingexpenses.

Asasolutionprovider,wedevelopinnova-tiveprocessesandsystemsforourcus-tomers.Anetworkofdedicatedemployeesinourofficesallaroundtheworlddesignthesecutting-edgeturnkeysolutions.

Ourdevelopmentactivitiesandresultantinnovationsareorientedtowardsassuringsustainableenvironmentalpractices.Weconcentrateoncurrentkeytechnologiesinordertomaintainourleadingpositionwithregardtohighlyadvancedproducts.Ourgrindingsystemsfulfilthemoststrin-gentqualityrequirementsandprovidelong

servicelivesandlowmaintenancerequire-ment.

Weoffercomprehensivesolutionsrangingfromprojectelaboration,engineeringanddesign,delivery,fieldassemblyuptoplantcommissioning,includingcustomerper-sonneltrainingandservicecontracts.

Ourstrongperformanceappliesacrosstheboard:tocompleteproductionlines,indi-vidualproductsandplantmodifications.

Globalknowhowaswellasacomprehen-siverangeoftestequipmentinourRe-search&DevelopmentCentreandpower-fulsimulationtools,whichenableustodesigncomplexgrindingcircuits,havelaidthefoundationfordevelopinghigh-qualityandcost-effectivesolutionsforindividualapplications.

…foreveryapplication

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Millshellsandslidingshoebearingassemblies

Ballmills,autogenousmillsandsemiautogenousmillsfromThyssenKruppIndustrialSolutionswithdiametersabove8mand11mrespectivelyanddrivepowersexceeding22MWareinhighlysuccessfuloperationallaroundtheworld,grindingcopperore,goldore,ironoreandothermineralmaterials.

Themillshellsaredeliveredasasingleunitorsplitintoseveralparts.Large-diametermillshellsaretransportedtotheplantsiteinsections.Thesectionsarethenweldedtogetherorflange-con-nected.ThePOLWELD®fieldweldingprocessfromThyssenKruppIndustrialSolutionsisauniqueweldingconceptforassemblyoftubemillsontheplantsite.Thecustomerprofitsfromtroublefreeperformanceoftheworkandhighweldingquality.

Forthegrindingoforesthatformhighlyacidpulp,ThyssenKruppIndustrialSolutionsequipsthemillswithspecialcorrosionpreven-tionsystems.

WiththeuniquePOLWELD®siteweldingconceptfor

precisealignmentandweldingofthemillsectionsonsite,

ThyssenKruppIndustrialSolutionsoffersafavourably-priced

technicalalternativetoflangedmillshells.

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Mill shell

Since1976,ThyssenKruppIndustrialSolutionshasonlybuiltmillswithcircumferentialandslidingshoebearingassemblies.Morethan400suchmillsaremeanwhileinsuccessfuloperationallaroundtheworld,servingdifferentindustrialsectors.

Millswithcircumferentialandslidingshoebearingassembliesprovidethefollowingadvantages:

3 theycanuseallmilldrivesystemsonthemarket

3 thereisnoneedforcastingswiththeirassociatedmanu-facturinganddeliverytimerisks

3 themillinletandoutletcanbedesignedtosuittheprocesstechnologicalrequirements

3 duetotheshorterinletcylinder,criticalfeedmaterialsdonotcauseblockages

3 goodaccessibilityofthemillinterior

3 flangesarefewerandlighter,facilitatingtransportandassembly

3 thefoundationsaresmaller,reducingthemill’sfootprintandcuttingthecostofbuildings

3 idealforringmotordrives

Sliding shoe bearing assembly

Dependingonthemillsize,themillshellrunsontwo,fourorsixslidingshoesperbearingassembly.Anyradialeccentricityofthemillshellresultingfrombending,thermaldeformationsandmanufacturingtolerancesarecompensatedbythepivot-mountedsupportofthebearingshoes.Dependingontheexpectedload,themillisequippedwitheitherhydrodynamicorhydrostaticslidingshoebearingassemblies.

Hydrauliccylindersinstalledinthebaseofthebearingallowliftingandpositioningoftheentiremillinordertocompensateforfoun-dationsettlementortoinstallorremovebearingshoeswithoutcomplicatedsupportingofthemillshell.Loadcellsinthebaseofthebearingallowthemillweighttoberecorded.

Provensealspreventdirtorsplashwaterfromenteringthebearinghousing.Asthemillshellisaweldedassembly,therearenocom-plicatedandheavyendwallcastings.Straightmillendwallsoffertheadvantagethatthemilllinerplateshaveasimpleshapeandarequickandeasytoreplace.

Installationofasliding

shoebearingassembly.

Largemillshells

aretransported

insections

andweldedat

theplantsite.

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Drivesystems

COMBIFLEX® drive

TheCOMBIFLEX®drivecombinestheadvantagesoftheringmotordrive,suchasthelowestmaintenancerequirementandhighavail-ability,withtheadvantagesofanormalgirthgeardrive,suchasfavourablecapitalcost.Thegearunitwithitsintegralself-aligningdrivepinionsformsasingleunittogetherwiththegirthgear,slidingshoebearingassembly,slideringandaxialguide.EveryCOMBIFLEX®driveisequippedwithitsownauxiliarydriveunit.

COMBIFLEX®drivescanbedesignedassingledriveordualdrive.Ifextremelyhighdrivepowersarerequired,fourCOMBIFLEX®unitscanbeinstalledfortransmittingdrivepowersofuptoandexceed-ing30,000kW.

High operational reliability:Thankstoitsself-centringhardenedandgroundpinionsandtheuncomplicatedoillubricationsystem,thedriveunitprovidesopti-mumoperatingconditions.

Minimum maintenance requirement and low operating expenses:Thedriverequiresnoreadjustment.Insteadofthegreaselubri-cationofconventionaldrives,asimplecentraloilsupplysystemservesthegirthgear,pinion,slidingshoebearingandgearunit,alsosavingonthewastegreasedisposalcosts.

ThyssenKrupp Industrial Solutions selects the appropriate drive variant for the specific application requirements. COMBIFLEX®, ring motor and direct drives are among the well-tried and reliable high-performance systems. If requested, other types of drive and motor can also be installed.

Wetmillwithfour

COMBIFLEX®driveunits.

DrivepinionoftheCOMBIFLEX®drive:theself-aligning

drivepinionscompensatewobblingofthegirthgear.

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Direct drive

Anotherdrivesystem,intendedespeciallyforsmallermills,isthedirectdrive.

Ring motor drive

Theringmotorfeaturesnoncontacttransmissionofthedrivingtorquetothemillshellbymeansofmagneticforces.Asthisproducesnocomponentwear,thistypeofdriveprovideshighavailabilityandlongservicelife.

Anothersignificantaspectisthecontrollablespeed.Duetothehighercapitalcostsforringmotordrives,theyaregenerallyonlyusedifveryhighdrivepowersarerequired.

Shellsupportedballmillsareidealfortheuseofringmotordrives:

3 Becauseofthehighrigidityofthemillshell,troublefreetransmissionofthemagneticforcesisassured.

3 Duetotheindividualself-adjustmentoftheslidingshoes,thepolepadsattachedtothemillshellcanbecenteredinthestatoroftheringmotor.

SimilartotheCOMBIFLEX®drivesystem,thedirectdrivealsointegratesthegirthgear,drivepinion,andslidingshoebearingwithslideringintoasinglehousing.Thethree-stagegearunitwithintegralauxiliarydriveisinstalledseparately.

l.tor.Principleofthedirectdrive.

Tubemillwithdirectdrive.

SAGmillwithCOMBIFLEX®

driveforgoldoregrinding.

Ballmillwithringmotordrive.

Brakeofa

ringmotordrive.

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Flotation

Wetgrinding

Grindingisoneofthemostenergy-inten-siveproductionstagesandthereforehasasubstantialenergy-savingpotential.

Themaindemandsmadeongrindingplantsarelowoperatingcostsandhighavailability,evenwhengrindingextremelyabrasivematerials.

ThesedemandsaremetbyallgrindingplantsmadebyThyssenKruppIndustrialSolutions:Allaroundtheworld,ourauto-genousmills,semiautogenousmillsandballmillsareknownforextremelyhighavailabilityrates.

SAGandballmillforthe

wetgrindingofgold/copperore

inAustralia.

Plantconfigurationof

thefirstgeneration.

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Flotation

Thecoreissuesofplanttechnologyde-velopmenthavealwaysbeenreducingthepowerrequirementandraisingthethrough-put.

Thefirst-generationplantsconsistedofgrindingcircuitswithathree-stagecrushingsystem,primarymillsandsecondarymills.

Inthesecondgeneration,SAGmillsre-placedthesecondandthirdstagesofthecrushingsystemandalsotheprimarymills.

Exampleconfiguration

forthesecondgeneration.

SAGandballmillforthewetgrinding

ofgoldoreintheDominicanRepublic.

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Flotation

Allaroundtheworld,minesarehavingtoworkoredepositswithdecliningmineralcontents.Asacon-sequence,grindingplantsinthemineralsindustryarebeingdesignedforeverincreasingthroughputcapacities.

Grindingsystemsofthethirdgenerationalsoassurecost-effectiveprocessingandsparinguseofre-sources.

Inthisrespect,thecombinationofPOLYCOM®high-pressuregrindingrollandballmillrepresentstech-nologicalcompetencefortomorrow’sworld.Thesesystemsaretheonlyoptionforprocessingmaterialswithstronglyvaryinggrindability.

CopperoreprocessinginSouthAmerica:

theprimaryoregrindingstageconsistsoffourPOLYCOM®

high-pressuregrindingrolls,whilefourwetprocessball

millsperformthefinalgrinding.

Exampleconfiguration

forathird-generation

grindingcircuit.

Drygrinding

Inthemineralsindustry,drygrindingplantsareprimar-ilyusedwhenthedownstreampreparationprocessrequiresdrymaterial,orinordertosavevaluablewaterresources.

PlantsfromThyssenKruppIndustrialSolutionsareinsuccessfuloperationallaroundtheworld,grindinganddryinggoldore,ironore,ironoreconcentrate,lime-stone,cementclinker,limeandcoalaswellasothermineralrawmaterials.

Single-compartment mill

Thecrushedfeedmaterialcomponentsaredosedtothesingle-compartmentmill,wheretheyaredriedandground.Thegroundmaterialismechanicallydis-chargedviaadischargediaphragmattheendofthesingle-compartmentmillandthenfedtoadynamicseparatorforclassificationintofineproductandover-size.Theoversizedmaterialisreturnedtothemillforregrinding.

Fordryingthemillfeedmaterial,

thesingle-compartmentmillis

equippedwithadryingchamber.

Single-compartment

airseparatormillwithdrying

chamberforironoregrinding.

Thesingle-compartmentmillisidealforthe

grindingoffine-grainedfeedmaterial.One

typicalapplicationisthecombinedgrinding

anddryingofironoreconcentratewithahigh

feedmoisturecontent(uptoapprox.8%).

High-efficiencyseparatorsminimisethepower

consumptionofdrygrindingsystems.

ThyssenKruppIndustrialSolutionsseparators

enableadjustmentoftheproductqualityduring

operationtosuitcurrentrequirements.

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DOUBLE ROTATOR®

TheDOUBLEROTATOR®grindingprocessinvolvesdrying,pregrinding,separating,finegrindingandrenewedseparating,allinonesystem.Thematerialcomponentsaredriedinadryingchamber,thenprimarygroundinthecoarsegrindingcompart-ment.Afterleavingthemillviathecentraldischarge,thematerialisconveyedtothehigh-efficiencyseparatorforclassificationintofineproductandoversize.

Mostoftheoversizematerialisfedtothefinegrindingcompartment,whileasmallproportionisreturnedtothecoarsegrind-ingcompartmenttoimprovetheflowprop-ertiesofthemillfeedmaterial.Thematerialgroundinthefinegrindingcompartmentalsoleavesthemillviathecentraldis-chargeandisthenclassified.

Thehotgasesrequiredfordryingthemat-erial,aswellasthegasquantityneededforventilatingthemill,areextractedviathecentraldischargeandroutedtoaseparator.

Theseparatorsplitstheentrainedmaterialintocoarseandfinematerial,andthenthecoarsematerialissuppliedtothehigh-effi-ciencyseparatorforpostseparation.Thefinishedmaterialcontainedinthegasstreamiscollectedinacyclone/filtercom-binationordirectlyinthefilter.Evenifalargeflowvolumeofgasisneededfordry-ingverymoistmaterials,thishasnonega-tiveeffectonthegrindingprocess,asitisonlydrawnthroughthecoarsegrindingcompartment.

TheDOUBLEROTATOR®isnotsensitivetofeedsizefluctuationsandissuitableforgrindingeventhehardestandmostabra-sivematerials.

Themill’sdivisionintotwogrindingcom-partmentsandtheintermediatematerialseparationpermitoptimumadaptationtothecoarseandfinegrindingrequirementsoftherespectivefeedmaterial.Comparedwithothertubemillsystems,theDOUBLEROTATOR®thereforehasthelowestspecificpowerrequirement.

Flowsheetofagrindingplant

withDOUBLEROTATOR®.

Picturetopleft:

DOUBLEROTATOR®forgoldoregrindingintheUSA.

As large balls are used in the coarse grinding

compartment, the mill can handle lumpy feed

material. Depending on the type of material,

the feed size can range up to 50 mm – and in

special cases even more

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AEROFALL mill

ThyssenKruppIndustrialSolutionsoffersAEROFALLmillsasautogenousorsemi-autogenousmillsfordryingandgrinding.

Alargediameter:lengthratioischaracteris-ticforthesemills.Unitswithupto10.5mdiameter,4,500kWdrivepowerand1,200tphthroughputhavebeeninstalled.

Thefeedmaterialcanhavealumpsizeofupto500mm.

Onefundamentaladvantageofthismillisthatitevenacceptsstickymaterialsthathavemoisturecontentsofupto20%.Ifthismillisused,secondaryandtertiarycrushersarenotrequired.

Themillliningisfittedwithlifterbarsandguiderings,theso-calleddeflectors.Asthemillrotates,thematerialisliftedbythebarstothepointwhereitcataractstothebottomofthemill.

Thecomminutionprocessisthusper-formedautogenouslybymaterialimpactingonmaterial.Thedeflectorsguidethefallingmaterialtothemiddleofthemill,improvingtheautogenouscomminutioneffect.

Theseparatorandthecyclonesinstalledinthegrindingcircuitseparatethefineandcoarsematerial.Insemiautogenousmills,thecomminutionprocessisassistedbyaddingasmallchargeofgrindingmedia.

Flowsheetofagrindingplantwith

AEROFALLmill.

Centraldischargeofa

DOUBLEROTATOR®forgoldore

grindingbythedryprocess.

AEROFALLmillfor

ironoregrinding.

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SecuringandshapingthefutureResearch and Development.ThyssenKruppIndustrialSolutionshastheknowhowandtheequipment(theresearchcentrewithitsultramodernmachinesisoneoftheworld’sleadingdevelopmentestablishmentsforbasicmaterialtechnology)toprovideasuitableplantconceptfortheindividualpropertiesoftherespectiveore.

Fromlaboratory-scaletoindustrialreality:

Onthebasisofthematerialanalysis,ourcomprehensivematerialdatabaseenablesquickandreliableclassificationandevaluationoftheore’sgrindability,hardness,abrasivenessandagglomerationbehaviour,thusassuringoptimumsystemdesign.

High-performancesimulationprogramssupporttheselectionofmachinesandsystemsandforecastthewearrates,energyre-quirements,millcircuitmaterialbalances,etc.,thusassuringfu-ture-oriented,custom-tailoredplantsolutionswiththelowestpos-sibleoperatingexpense.

Thisappliesinequalmeasuretonewplants,theupgradingofex-istingfacilitiesandtheopeningupofnewfieldsofapplicationforproventechnologiesandservices.

Service.Inthiseraofhighlycomplexplantconfigurations,serviceisthebasisforachievingoptimumplantoperationandtherebymaintainingandstrengtheningthetrustandloyaltyofourcustom-ers.

Thankstoourglobalnetwork,ThyssenKruppIndustrialSolutionsispresentallaroundtheworld,providingcustomerswithahelpinghand–quicklyandreliably.

Inadditiontotheeverydaychallengesofplantoperation,thepro-ductionprocesshastobeconstantlycheckedwithregardtoecon-omyofoperationandcompetitiveness.Ifnecessary,theequipmenthastobeputinfuture-orientedconditionbyincorporatingthelat-esttechnologicaldevelopmentsorspareparts.Onthebasisofcomprehensiveknowhow,ourspecialistsdiagnoseweakpointsintheplantoperation,offersolutionsandassistintheeliminationofproblems.

Furthermore,ThyssenKruppIndustrialSolutionsoffersabroadrangeofservicesandpreventivecheckupsaimedatminimisingtheriskoflengthyplantstoppages:

Dialoguewithcustomersisessentialforthe

workofourscientists,developmentengineers

andserviceteam.Thecustomers’requirements

determineourthinkingandacting.

vmag [MAG]

3.75

2.50

1.25

0

5.00

POLWELD®.Theglobalmarketisdemandingtubemillswitheverincreasinggrindingcapacities.Duetothehigherthroughputre-quirements,thedimensionsofnewmachineshaveincreasedsomuchthatthemillshellshavetobetransportedtotheplantsiteinseveralsections.Usingoursiteweldingconcept,POLWELD®,expertsfromThyssenKruppIndustrialSolutionspreciselyaligntheindividualsectionsonsiteandthenweldthemtogether.Thisuniqueweldingconceptprovidesplantownerswithafavourably-pricedtechnicalalternativetoflangedmillshells.

POLDRIVE®.OurPOLDRIVE®serviceisprimarilyaimedatensuringgoodconditionofpinionsandgirthgears.POLDRIVE®isaspecialprecautionarycheckforlargetoothgearing,duringwhichthedriveunitsarepreciselyanalysedand–ifnecessary–appropriatemea-suresareproposedforachievingoptimumdriveunitservicelife.

Ball mill filling level measurement for dry process millsForsimplefillinglevelmeasurementbyMLC3amicrophoneisin-stalleddirectlyadjacenttothemilltoreceivetheproducedsoundwaves.Therecordedsignalsareanalysedandtransmittedtotheprocesscontrolsystem.Thealternativeprocessiswirelessfillinglevelmeasurement,inwhichthemeasuringmicrophoneismount-edonthemillshell.Thesignalsarethusinterference-freeand

thereforeprovideanevenmorepreciserepresentationofthemillfillinglevel.Themeasurementresultsaretransmittedtothepro-cesscontrolsystembywirelesslink.

POLRED®.ThyssenKruppIndustrialSolutionsintroducedPOLRED®asacomprehensiveserviceconceptforCOMBIFLEX®andplane-tarygearunits.POLRED®reducesstoppagetimesandgearunitdamage.Theconceptcomprisesseveralmodules(maintenance,onlineconditionmonitoringsystem,lubricants,wearpartsandspares).

High-performancecalculation

andsimulationprograms

supportourmachinesizingand

designingwork.

From top to bottom

DuringthePOLDRIVE®service,thegirthgearsand

pinionsareexaminedandappropriatepreventative

measuresareproposed.

ThankstoourPOLWELD®service,itisnoproblem

toassembleevenlargemillshellsdirectlyatthe

constructionsite.

Using the Discrete Element Method (DEM) we can simulate the motion

of the grinding balls in tube mills in order to optimise the grinding process.

© 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.

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thyssenkrupp Industrial Solutions AG Graf-Galen-Strasse 17 59269 Beckum, Germany Tel.: +49 2525 99-0 E-mail: info.tkfen@thyssenkrupp.com www.thyssenkrupp-industrial-solutions.com