POLCAL gas suspension calciner

POLCAL gas suspension calciner

Developed for thermal treatment of fine-grained materials, our POLCAL gas suspension calciner can also be used as a preheater to enhance efficency and reduce operating costs.

Fine-grained materials are a field where thyssenkrupp can point to decades of experience. The expertise gained over this time was invested in the development of our POLCAL sy gas suspension calciner with an optional preheat function.

Operational benefits of POLCAL

Proven design - Tailor-made solutions - Low energy consumption

In the POLCAL system feedstocks with grain sizes from 0-2 mm – and in special circumstances even up to 4 mm – are thermally treated using the gas suspension method. POLCAL gas suspension calciners, which are available with a diameter of up to 8.4 meters , consist of up to six cyclone stages arranged one above another and a calciner riser duct for drying , preheating and pre-calcining the material. The daily output can be as little as 100 and as much as 8,000 metric tons , and process temperatures can be as high as 1,200° C. In this way a finished product is created with no need for an additional unit such as a rotary kiln.

One or more cyclone stages can be used for cooling. The heated air from these stages is used as secondary air in the combustion process. For very moist materials a flash dryer can be installed upstream, which is beneficial for the equipment’s energy balance. Another advantage of the POLCAM system’s modular design and range of different cyclones is the high degree of flexibility in designing a plant that is specially tailored to your requirements.

POLCAL as a preheater

We can also offer you the POLCAL system with a preheater function . The flue gas from the kiln process is passed through the preheater and transfers its heat in countercurrent to the material. The installation of a preheater greatly reduces the kiln’s fuel energy consumption while at the same time making more intensive use of the kiln , i.e. making it more productive. Our preheater concepts are fine-tuned to the most varied production capacities for both new investments and plant conversions.

gas suspension calciner - Wide range of fuels

Natural gas, oil, coal, and calorific off-gases are ideally suitable for use as fuels in the POLCAL system. Fossil fuels are usually fed into the calciner via several injection points. Installation of an additional combustion chamber is recommended for starting the operation or if the material has to be kept separate from direct contact with the flame for process-technological reasons.

POLCAL - Your future-proof solution

To ensure correct dimensioning of the POLCAL system, the properties of the raw materials and fuels are tested in our central research center to ensure all the systems and plant components are optimally designed. Thanks to numerous innovative process and design details the POLCAL gas suspension calciner offers you a future-proof solution – with or without the preheater function.

Boost your efficiency with our Maintenance Assistance System (MAS)

The Maintenance Assistance System is a software framework that can be configured to fit various types of machines for several applications like mining technologies, materials handling and mineral processing.

Find out more about our Maintenance Assistance System (MAS)
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