11IKN 016 0000 Pendulum Leaflet R1 110110 Folded Copy

IKN PENDULUM COOLER ! ! ! ! !

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 Pendulum Cooler In modern cement plants most decisions for investing in clinker coolers are based on the reliability of the cooler and the corresponding operating costs.

Benchmarks for high reliability and low operating costs are minimum wear and power consumption and optimal heat recuperation.

IKN Coolers meet all requirements of a modern cement production plant:

Rear view of the IKN Pendulum Cooler for 10.000 t/d at UCC, UAE

! 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

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.

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.

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.

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.

Undergrate with twin LPS System already aligned

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.

2.750 t/d IKN Pendulum Cooler at Cerritos Plant in Mexico

TDE (Tube Dust Extractor)

Heat Shield

Kiln Outlet Seal

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.

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.

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.

IKN Pendulum Cooler GRATE SYSTEM Narrow, inclined and curved slots in transport direction of clinker generate sharp jets of air with high dynamic pressure. The Coanda effect forces the jets to curve parallel to the surface of the grate plate. Fines are swept to the clinker bed surface and the Coanda Nozzles are completely engulfed by cooling air. During normal operation a temperature of 30° C to 40° C is measured close to the grate surface.

The Coanda Nozzles of the pendulum section are formed by several blades which are inserted into a common supporting frame. The curved air openings between the blades generate the desired horizontal Coanda jets. The surface of the frame is completely covered by the blades to form a grate surface which consists of small blades and no longer of entire grate plates. The supporting frame is no longer subject to wear. The small blades are loosely interlocked in the base frame. They are free of mechanical and thermal stress. This is important, because their material composition can be geared towards resistance against wear only. The blades are made as hard as clinker to increase the service life of the grate surface significantly. While each cooler has thousands of such blades, only single blade replacements have been reported.

Cutaway 3D model of a Coanda Nozzle with conventional Blades

Left: Grate plate assembly

Clinker Inlet Distribution System - KIDS

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.

Left: Hydraulic Power Pack at IKN’s test facilities

IKN Pendulum Cooler Satellite Cooler Replacements A specialty of IKN is the replacement of satellite coolers. The demolition of an existing satellite cooler and the installation of a preassembled Pendulum Cooler are accomplished during a routine annual outage. At Titan Cement’s Kamari plant an entirely preassembled Pendulum Cooler was laterally pushed into its final position on slide tracks. The entire on-site procedure took less than three hours to complete. The pendulum suspended mobile frame of the IKN cooler was supported on a steel structure which was part of the cooler foundation.

The support arrangement combines several advantages and permits a large degree of preassembly. In addition to the simple installation of steel supports, the design also requires little space by sharing a common foundation with the cooler housing without compromising the structural integrity of the pendulum system. Several other fast erection procedures were planned and executed by IKN within recent projects. Saving on installation time is a crucial issue in the design of IKN Pendulum Coolers especially for cooler replacements when the cooler installation is on the critical path.

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

Preassembled IKN Pendulum Cooler moved into position

3D model of the 10.000 t/d cooler at UCC

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 Ingenieurbüro-Kühlerbau-Neustadt GmbH Mittelstrasse 4 - 5 31535 Neustadt, Germany Tel. +49 5032 895 0 Fax +49 5032 895 195 email: [email protected] www.ikn.eu

The author reserves the right to modify products and/or their parameters without prior notification. © 2010 IKN GmbH