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State of the art design Uniform aeration of clinker bed Maximum heat recuperation High reliability due to wear and heat resistance Low power consumption
IKN Coolers meet all requirements of a modern cement production plant: ! Bed aeration for maximum heat recovery ! Clinker transport supported by grate aeration ! Reduction of power consumption by avoiding bed aeration with a stationary clinker layer ! Complete pyro process lines supplied in association with PSP Engineering ! Mechanical design for maximum reliability ! Grate surface with high wear resistance
Rear view of the IKN Pendulum Cooler for 10.000 t/d at UCC, UAE
In pursuit of a marketable application below the level of entire coolers, IKN developed the aerated and sloped fixed inlet. The first five to ten rows of a grate cooler were replaced by stationary and enclosed air beams arated by individual ducts. The air beams allow high pressure aeration and powerful horizontal jets. The results of the fixed inlet in terms of process and service life proved to be outstanding and the new design found broad acceptance by cement producers. The fixed arrangement of the air beams became a new standard in clinker cooling on grates. PENDULUM SUSPENSION Traditionally, roller supported moveable frames sink during use. To overcome this IKN developed the Pendulum Suspension System. The moveable frame is no longer supported on rollers but is suspended on wearless spring steel straps. Gradual sinking during operation cannot occur.
This success was the basis to advance to the modification of the movable section and further to grate coolers. In order to render the mobile section of the grate as wear resistant as the fixed inlet, the IKN Pendulum Cooler was developed with a wearless suspension of the mobile frame.
The thrust gaps between moveable and fixed rows remain uniform. Extended life time of the cooler grate and maximum heat transfer between cooling air and clinker are the rewards.
LINEAR PENDULUM SYSTEM - LPS 3D model of the Linear Pendulum System An increasing number of cooler retrofits challenged IKN to shorten the pendulum straps in order to cope with restricted building heights; a new version of a wearless grate suspension was developed. The patented system is called LPS for Linear Pendulum Support. The pendulum support is based on the principle for linear mechanical movement. The LPS has a height of 1.3 m x 1.6 m only, which can be easily integrated into the cooler under grate housing. Outside of the cooler no additional foundations are required. The LPS had to perform a 1.5 million strokes test run with a simulated clinker bed. The optimum layout and its durability were confirmed by various tests and calculations performed by the University of Hanover. The first installation has been in operation since April 2003 at Leube Zement, Austria. To date no wear or fatigue was observed.
Optional Features
Roll Crusher Compared to a hammer crusher there are no chain curtain, grizzly bars and no kiln stops caused by large lumps or coating pieces. Electric power and wear is lower. The IKN Roll Crusher is equipped with up to six rolls for cooler capacities from 1,900 t/d to 13,000 t/d.
TDE (Tube Dust Extractor) The small amount of clinker fall through is discharged automatically by a tube dust extractor. This sturdy mechanical device is operated for just 30 minutes a day. Installation height is reduced in comparison to other cooler designs as no hoppers are needed.
Heat Shield A Heat Shield can be installed into the cooler located near the neutral point. It is often used when IKN Pendulum Coolers have a mid-air extraction. The heat shield stabilizes the process in the entire system and keeps mid-air temperatures at a constant level.
Kiln Outlet Seal IKN offers a large kiln hood with its own outlet seal to reduce dust return to the kiln. Tertiary air will be taken from the top of kiln hood. The temperature of secondary and tertiary air will be identical at all times. Extra high secondary air temperature is avoided so that the cooler can be operated with higher and more stable heat recuperation.
A high degree of precision in design and fabrication of the movable gaps prompted the elimination of air ducts and the return to compartment aeration after the stationary inlet (KIDS). KIDS, stands for a revolutionary success in clinker cooling mechanically and process. Typical heat savings are 20 to 100 kcal/kg depending on current performance. IKN guarantees savings in terms of cooler losses which result in a reduction of kiln fuel consumption.
Left: KIDS of a 2.750 t/d IKN Pendulum Cooler at St. Marys Cement Co., Canada
Hydraulic Power Pack The hydraulic drive is essential for the availability of the cooler and the entire kiln line. Each unit is assembled and tested in I K N s own workshop. The hydraulic drive allows an asymmetrical travel profile with slow forward motion and a fast retract stroke. Such operation increases the transport efficiency and balances the discharge into the clinker conveyor.
The Challenge Recent years have seen the design and construction of several clinker production lines of capacities of 10,000 to 13,000 tons per day. The Middle East market area has the largest number. IKN has become market leader in high capacity coolers. The IKN Pendulum Cooler has proven to be the right concept for each size of coolers. After earlier modifications of most of the 10,000 tpd coolers in South East Asia the IKN Pendulum Cooler has been chosen for several 10,000 and 11,000 tpd coolers in Middle East. The worlds largest coolers with 3 x 13,000 tpd at Conch Cement have been ordered from IKN at the end of 2009. In the course of the time IKN has developed into a full range supplier for cement plants. The product range has been diversified and the entire pyro process has been integrated into the IKN structure. Together with the sister company PSP, IKN is able to design and supply complete cement plants. Comminution and plant contracting is handled by PSP uprgrades, modifications and new installations of preheaters, kiln and coolers are embedded into IKN activities.
Undergrate of IKN Pendulum Cooler lifted in one piece at St. Marys Cement Co., Canada - 50m of kiln shell supplied by IKN
www.ikn.eu
IKN GmbH is a leading supplier of clinker cooling technology operating in all major markets of the international cement industry. With over 100 employees and offices in USA, India, Singapore, and Brazil, IKN has been involved in the design and construction of clinker coolers for cement plants since 1982.
IKN Ingenieurbro-Khlerbau-Neustadt GmbH Mittelstrasse 4 - 5 31535 Neustadt, Germany Tel. +49 5032 895 0 Fax +49 5032 895 195 email: sales@ikn.eu www.ikn.eu
The author reserves the right to modify products and/or their parameters without prior notification. 2010 IKN GmbH