One of the new features is a variable cooler inlet slope between 10° to 15° to adjust to the prevailing clinker conditions. For fullertype coolers, the grate beams serve as air compartments. Ikn roll crushers can be used for other materials than clinker. The grate is made of steel, and the cold air keeps it sufficiently cool to avoid melting or burning. At the end of the cooler, the clinker is discharged into the roll crusher and is broken to a size of less than 30mm before being transported to the storage facilities. A new control strategy for ikntype coolers sciencedirect. Air leaves plate through coanda nozzle in direction of clinker.
The clinker cooler grate assembly produced by ikn gmbh is comprised of. Grate cooler cross flow heat exchange through clinker bed with cold air grate movement. Cement case study booklet final for print global innovation. The clinker progresses through the cooler by moving moreorless horizontally along the grate, and so the direction of the cooling air is. How does clinker cooler reduce cement production energy. Clinker cooler 2 clinker cooler reduce clinker temperature from approx. However, despite the new market introductions, no great improvements have been made with regard to cooler efficiency and the cooling principle. 20 feb 202 cool down ikn pendulum cooler and kids are designed to reach low clinker outlet. High capacity ikn clinker coolers mr huybens bernard, ikn. This highefficiency clinker cooler increased the heat recovery rate by 13% and.
Hot fine clinker reaches end of the cooler high wear on grate plates hot air flows in exhaust air duct clinker is not cold at the end of the cooler recuperation is not optimum no grate cooler can influence the clinker flow over the cooler width. The cooler is particularly designed to recirculate vent air to boost the whrs. Training 32 32 new generation coolers 6 other new types of cooler. 1400 o c to approx 100 200 o c the heat of the incoming clinker is recuperated in the secondary air of kiln an efficiency of incoming clinker heat usually lies within 65 75% 3 clinker cooler type 1. Providing information for people working in cement plants, those who want to improve the way they work. Clinker cooler hammer crusher rotor clinker coolers rotary pdf youtube jan 214 asset list amp delivery listgrain hammer mill manufacturer. Apr 05, 2020 the cooler consists of a pendulum suspended grate with cds, smart blades grate system, hydraulic drive and.
The clinker bed in a pendulum cooler is characterized by a. Wp heidelc, vdz, ikn oxyfuel cooler prototype and upscaling. The innovative oxyfuel clinker cooler prototype has been tested during the last 6 months, as part of the eu research project cemcap. Be the number one choice for clinker cooling technology. Ikncool down savings of thermal 20 kcalkg cl on average. 30% reduction in energy by cooler modification with ikn. The main power consumption of a clinker cooler is its cooling fans.
The grate cooler in a cement plant cools and transports the cement clinker. This technology is the retrofitting of the existing system. Clinker coolers content tasks of clinker cooler theory and definitions grate coolers cooler upgrade clinker crusher rotary coolers holcim group support definitions recuperation is the recovery of heat contained in the hot clinker 1300 to 1450c at the kiln discharge to be used in the kiln system for the process substituting fuel. It uses the new clinker inlet distribution system to distributor the clinker on the grate. Cemex balcones plant ours reprinted from world cement ieeeiaspca conference 2012 ieee. A new control strategy for ikntype coolers request pdf. Germany ikn completes new kiln line at burglengenfeld plant. The essential characteristic of a grate cooler is a layer of clinker spread on a moreorless horizontal perforated grate, through which cold air is blown. The initial development of the ikn pendulum cooler started more than 30 years ago.
In fact, it has meanwhile become difficult to keep track of the current cooler generation. Sealing the clinker outlet against false air intake remains a challenge. 10,000 tpd clinker cooler for the new line at ucc, ikn gmbh, germany. If all the 250 mtpa clinker produced is cooled by ikn coolers based on savings of power by 1. The pendulum cooler is designed in close accordance with the cross flow principle. Ikn vs others maintenance description units ikn groupa groupb groupc plant name utclrawan#2 plant a plant b plant c plant d plant eold cooler power kwht 3. 000 tpd cooler will be two stage, equipped with an intermediate roll crusher. 5 kwht on average you can supply free power for months for a city like jodhpur conclusion. Grate cooler and scope of the project design requirement for the ikn pendulum cooler was a capacity of 3000 tons per day with a clinker outlet temperature of 65°c above ambient and an efficiency of 72 per cent.
The manual is only an attempt to create awareness on energy management and. A cooling grate, for cooling and transporting of cement clinker having at least one. Ingenieurburokuhlerbauneustadt gmbh is a privately owned, mediumsize company, specialising in the design and manufacturing of coolers and pyro lines for the production of cement clinker. By further refining the best elements of proven cooler designs, the flsmidth crossbar cooler gives the. Ikn pendulum clinker coolers, 5000 tpd 2 units new surplus, never installed, complete with all.
By d touil 2006 cited by 37 the concept of the exergy analysis is applied to a grate cooler of a cement production facility. Latest developments in high efficency clinker cooling. Ikns complaint alleges cpts clinker cooler frame elements, marketed under the name. The projectscope of work process and design features. The ikn pendulum cooler, cement industry technical conference, ieeeiaspca, pp. Will provide the balance of the raw grinding and the pyroprocessing system as well as of the. A significant improvement in grate cooler efficiency was gained in the late 180s with ikns introduction ofair beams at the inlet to the cooler. The cemcap partners ikn, heidelbergcement and vdz have successfully. 7 m 3, the air consumption efficiency will be 15% lower than that of other cement. The cooler is offered with an ikn roll crusher located at the cold end. Oxyfuel clinker cooler prototype cemcap is a horizon 2020 project with the objective to prepare the grounds for cost and resourceeffective ccs in european cement industry.
Enjoy the videos and music you love, upload original content, and share it all with friends, family, and the world on youtube. A single stage ikn pendulum cooler for 6000 tpd ieee xplore. For chemical analysis of the clinker, to a manual clinker extraction point. Calportland invests for energy efficiency better buildings. To reach this ambitious target, all factors that would contribute to a quick installation had to. 100°c, with maximum possible heat going back to the kiln. The grate area will be sized for a clinker outlet temperature of 65c above. Energy efficiency with ikn pendulum cooler knowledge. Two of them, the kiln hood and the taduct, supply hot gases to the rotary kiln and preheater. Concrete vs cement whats the difference howden clinker comes out of the kiln as extremely hot small dark. None of these studies have used infrared camerabased measurements. The clinker bed in a pendulum cooler is characterized by a temperature profile and vertical segregation of particles. Top level new products clinker cooler grate plates gold mining. First cement clinker produced with oxyfuel cooler technology the cemcap partners ikn, heidelbergcement and vdz have successfully managed to produce cement clinker using the oxyfuel cooler technology.
Installation of ikn cooler at ultratech cement, rawan cement. Because the cooling step decisively affects the quality of the produced cement clinker, we think that the use of infrared technology in the clinker cooler is an essential tool for process monitoring. First cement clinker produced with oxyfuel cooler technology. Pdf energy and exergy analysis of clinker cooler in the. A large kiln hood with a low air speed of 5ms connects kiln and cooler. Clinker particles come into intimate contact with the air. Suitable layouts have been developed by ikn using dynamic. The cooling of the clinker is modelled by a gassolid series of. Tertiary air temperature at cooler take off is around 870 0c as against the normal value of 70 0c for modern plants. Engineering the future ikn gmbh is a privately owned medium size company, whose root and strength within the cement industry is the field of clinker cooling. Download citation the ikn pendulum cooler the pendulum cooler is. Infrared measurement, estimation, reflectance, temperature distribution, clinker cooler, cement plant, industrial application.
The decision was made to perform the entire cooler modification over a kiln outage of 50 days flametoflame. 7 cool down the ikn pendulum cooler over 500 installations of clinker inlet. 4m dia x 66m 3,300 tpd clinker cooler ikn clinker silo. Savings in power of india if all clinker is cooled by ikn 66 mw. The industrial oxyfuel cooler will most likely be a full recirculation cooler 3. 8 kcalkg clinker which is reflected in low cooler heat recuperation efficiency of 61 % against recommended value of 7580 % for modern coolers. Chinese cooler projects big coolers, big challenges ikn. By d gauthier the grate cooler is fully implemented into the gas flow in order to. Blue circle training 27 27 ikn clinker inlet distribution system kids. Ikn is assignee of the 555 patent, and its parent, ikn gmbh, manufactures clinker cooler grate assemblies comprised of the grate elements that are the subje ct of the 555 patent. Marco lindemann lino 1 johannes ruppert 1 robert mathai 2 simon becker 2 1vdz ggmbh, düsseldorf, germany 2 ikn gmbh, neustadt, germany contact. 3 m 3 under standard conditions to cool 1 kg clinker from 1400.
If the air consumption per kilogram of clinker cooling is reduced from 2 m 3 to 1. Latest trends in clinker cooling cement lime gypsum. An ikn roll crusher is positioned after the cooler sections. As an epc contractor, ayoki will source all the equipment for the clinker cooler upgrade from ikn gmbh, germany, a statement from raysut. Because kiln rotation separates fine and coarse grains across the kiln and because each require different air pressures for cooling, traditional grate coolers produce red rivers of hot, fluidised clinker that flow to the. Three further offtakes deliver energy to the coal mill and the waste heat recovery system while the remaining heat leaves. Influences of the oxyfuel cooling medium on mineralogy and. Clinker coolerclinker coolerreduce clinker temperature from approx.
1400 oc to approx 100 200 oc the heat of the incoming clinker is. Problem with cooling fan of ikn grate cooler page 1 of 2. , and the power consumption of the whole system is about 7 kwh. 3 + 3c clinker grinding mill were supplied by loesche. Pdf the effects of grate clinker cooler on specific energy. 30 reduction in energy by cooler modification with ikn. 2015 ikn started the construction phase of the oxyfuel clinker cooler prototype. In the course of the rapid cooler development in recent years, new generations of grate coolers have come onto the market. The adaptivepredictive control used is based on that described in 464748, which has already been used in other applications such as wastewater treatment plants 4,50, clinker coolers 51. The experimental work was the testing of an oxyfuel clinker cooler in an industrial. Valentina bordei, thyssenkrupp, discusses the optimisation of clinker coolers to meet industry demands for energy efficiency and low. The essential characteristic of a grate cooler is a layer of clinker spread on a moreorless horizontal perforated grate, through which cold air.
Feb 20, 2017 at the discharge end, the cooler is fitted with clinker crusher to break. Design and function competitive advantage ikn was awarded the contract to supply the three largest clinker coolers ever built, which reach capacities of 13,000 td. As a new static inlet in the clinker cooler, were installed. 1 in the united states district court for the eastern. 2021 ikn clinker coolers have one movable row of coanda wing plates followed by two fixed rows. Tongling and wuhu clinker production lines, the ikn pendulum coolers have a total of six hot gas offtakes. Air leakage in the entire oxyfuel system cooler, kiln, preheater, heat exchangers, transport systems etc.
This is an overview of the process of choosing, designing and building a new clinker cooler for a. Ikns german parent, ikn gmbh, and cemprotec, another german entity, both. The project is the redesigning of the grate system with ikn plate type system, which will increase the cooler recuperation efficiency. With the company foundation in 182, ikn revolutionized the cement industry with the development of the clinker inlet distribution system called kids. Cooler size can be smaller compared to an air cooled cooler 4. Raysut cement to upgrade clinker cooler for savings oer. Decision to replace its clinker cooler to an ikn pendulum cooler to improve the reliability of its clinker cooling see figure 1. Each frame element in thegrate assembly embodies theclaims in the555patent, which ikn, theu. Cooler losses contribute to about 1051 1 5 kcalkg clinker for a modern fourth fifth generation. By j von wedel 2005 the ikn kids, short for clinker inlet distribution system, transfers the landed clinker to the 4.
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