IKN Coolers for large clinker production lines High Capacity Clinker Cooling

IKN was founded in 1982 by Dipl.-Ing Karl von Wedel and is serving in the cement industry as a specialist in clinker cooling technologies. With a number of more than 500 installations worldwide the IKN grate system, consisting of patented Coanda Nozzles, fixed clinker inlet distributing system (KIDS) and wearless pendulum suspension has well proven its highly competitive position in the cement world. Over the past years, through the association with PSP Engineering a.s., the scope of supplies was successively extended to the full range of cement plant equipment. Celebrating its 25th anniversary in 2007 with a new record in sold installations, IKN is confident to meet the customer needs also in the future.

1. Economy of Scale 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 stands for the largest number. The huge cement demand in the area and economy of scale are the driving forces for building such large lines. The initial investment includes a number of fixed items like instruments for signals, which do not increase with capacity. Also the operating cost per unit is reduced by economies of scale such as the cost of supervisory man power and energy, thermal and electric, as both show some semi fixed portions.

2. IKN Market share in large capacity coolers The first table shows IKN involvement in this current trend by placing orders for clinker coolers for a number of the recent large kiln. In South East Asia during an earlier period IKN had already modified the majority of existing 10,000 tons per day clinker coolers. The success is based on the performance of the KIDS, short for clinker inlet distribution system serving as a fixed inlet. The KIDS spreads a uniform clinker bed to coolers of up to 6.8 m width. While the width of the existing large coolers in Thailand had been limited to 4.8 m IKN had stepped ahead to 5.6 m width for its own large capacity Pendulum Coolers at Thung Song in Thailand and at Sung Shin in Korea 5.6 m wide. That was back in 1997. For quite a period these coolers had been the widest in the industry. As bed depth is limited for still poorly understood reasons cooler width is the key to large transport capacity at reasonable length and frequency of the pusher strokes.

Table 1: Large kiln line projects outside China Project Country Siam City C. Saraburi #5 Siam Cement Khao Wong #1 Siam City C. Saraburi #6 Union Cement, Ras Al Khaimah Saudi Cement, Hofuf Saudi Cement, Hofuf ABMC, Abu Dhabi Conch Cement, Wuhu Conch Cement, Wuhu Conch Cement, Tongling Thailand Thailand Thailand UAE Saudi Arabia Saudi Arabia UAE China China China

Capacity in tpd 10,200 10,300 10,000 10,000 11,000 11,000 10,000 13,000 13,000 13,000

Type of installation KIDS KIDS KIDS Pendulum Cooler Pendulum Cooler Pendulum Cooler Pendulum Cooler Pendulum Cooler Pendulum Cooler Pendulum Cooler

Year sold 1996 1996 2006 2006 2006 2006 2007 2009 2009 2009

A number of earlier cases were precondition to the acceptance of IKN cooler technology for above large scale projects.

3. Siam City Cement, Thailand From 1996 to 2007 all 6 coolers of Siam City Cement were equipped with KIDS. Some of the investments took place despite of the Asian crisis. The most recent modification was carried out in October 2007 on the 10,000 tpd kiln #6. Including the earlier 10,000 tpd line all clinker coolers of Siam City Cement now operate with KIDS. The justifications for the complete set of modifications of Siam City Cements huge Saraburi plant were - more stable kiln operation - higher and more stable heat recuperation - reduction of maintenance on the clinker landing area as well as on the downhill grate

4. YTL and CIMA, Malaysia In order to improve the operation of their clinker coolers, the plants of YTL in Perak Hanjoong and CIMA in Negeri Simbilan installed a KIDS fixed inlet in their coolers in 2007. Both plants have reported expected operating data shortly after commissioning. CIMA was able to increase kiln production from 3,600 tpd to 4,000 tpd with no further cooler modification other than KIDS. YTL increased production from 5,000 tpd to 5,500 tpd and reported improved kiln stability as a precondition to consistently higher throughput at reduced heat consumption.

5. Indocement, Indonesia In Citeureup Indocement operates 9 clinker production lines of a total capacity of more than 11 million tones per annum. Back in 1996 for the lines #7 and #8, equipped with satellite coolers, two new grate coolers were ordered from the original kiln manufacturer. Only the satellite of line #7 was replaced by one of the new grate coolers with intermediate mid cooler roll crushers. Due to technical problems and due to the economic crisis the satellite of line #8 was converted only as late as 2006. IKN supplied a Pendulum Cooler to the hot stage, while the roll crusher and the cold stage of the cooler were still available from stock. The new grate cooler was commissioned in September 2007 and has been operated with the following data, which are still considered preliminary: Table 2: Cooler data of Indocement line #8 Production tpd Grate width m Aerated surface both stages m Loading t/m, day Cooling air Nm/kg clinker Secondary / Tertiary air from kiln hood C

5,500 4.6 130 42.4 1.90 1000 - 1040

6. Union Cement Company, UAE, 2,000 tpd Union Cement Company, UAE, ordered an IKN 2,000 tpd cooler for their line #3 in Ras Al Khaimah, which was installed on turn-key basis in 2002. Thanks to perfect alignment and diligent operation the cooler has operated for 5 years without causing any kiln stops and without any spares consumption. In the course of also diligent maintenance the edges of several rings of the roll crusher have been hard faced.

Fig. 1: First rows hot zone after 3 years: less than 1 mm wear

The results are in line with IKNs best cooler performances. Consequently, Union Cement selected another Pendulum Cooler for their new 10,000 tpd line.

7. Union Cement Company, UAE, 10,000 tpd The new line was erected in 2006. Production started early 2007. By June 2007 the customer reported a capacity of 10,800 tons per day reached shortly after start-up. Table 3 shows the main design specifications. Table 3: Cooler design data of UCC line #4 Production tpd Grate width m Grate length m Aerated surface m Loading t/m, day Cooling air Nm/kg clinker Clinker outlet temperature C

10,800 6.8 34 229 43.9 1.95 65 + ambient

The grate system consists of two parallel mobile frames of 3.4 m width each. They are connected by stiffeners to ensure a parallel movement of the mobile frames. At nominal production a grate speed of 15 strokes per minute only is achieved.

Fig.2: Mechanically coupled mobile frames with twin drives

The cooler is driven by two hydraulic cylinders installed at the front end and underneath of the fixed inlet of the cooler. The twin cylinders operate outside of dusty air compartments. They can be accessed any time. The air ducts handling the air outlet volumes are impressive. Tertiary is tapped from both sides of the cooler housing just behind the kiln hood. Tapping from the kiln hood would have called for an uncontrollable hood size.

Fig.3: Impressive air ducts

After three months of operation a successful acceptance test of the complete line including cooler took place. Union Cement Company reported a clinker temperature of 70 75 degrees C including ambient temperature most of the time (International Cement Review, June 2007, page 50ff).

8. Saudi Cement, KSA Currently, Saudi Cement extends the production capacity of its Al Hofuf plant by two new kiln lines of 11,000 tpd each. For both lines Pendulum Coolers were selected. Table 4: Cooler design data of Saudi Cement 11,000 tpd Production tpd Grate width m Grate length m Aerated surface m Loading t/m, day Cooling air Nm/kg clinker Roll crusher Number / m Clinker outlet temperature C

11,000 6.8 / 5.6 28 / 11 250 44.6 2.00 6 / 4.8 65 + ambient

Each cooler will consist of two stages separated by an intermediate roll crusher. The first stage is sized for a temperature of the crusher feed of 200 C only. Still water and air cooling of the rolls is provided.

The first grate will be driven by a pair of electronically synchronized hydraulic cylinders, while the second grate will be driven by a single cylinder. Both drives are located at the front end of the respective stage outside of the dusty under grate where they can be accessed at any time. The intermediate crusher will break up red hot coating pieces for final cooling and destroy the profiled clinker bed at the same time. Consequently, located uphill of the second stage, IKN provides another KIDS for the redistribution of the clinker, so that the outlet temperature of 65 C above ambient will be reached.

Fig.4: 11,000 tpd Pendulum Cooler under construction at Saudi Cement line #7 Erection works of the cooler were duly completed in 2007.

9. Activities in the Indian market IKN has sold and commissioned successfully various projects in India in the past. 38 KIDS and 10 Pendulum Coolers have been built for reputed companies as ACC, Grasim, Dalmias Birlas, Lafarge, Holcim and others. The IKN Pendulum Cooler at Lafarge plant Aresmeta suitable for a capacity of 5,100 t/d is in operation since 2002. It is operated at a rate of heat recuperation of 74% and on an average of 3.6 kWh/t of clinker for power consumption. After 24 months of operation not a single part had to be replaced. In the meantime the total maintenance costs for the IKN Pendulum Cooler at Aresmeta plant amount to less than 3 Rs per ton of clinker.

10. Particulars of large Pendulum Coolers The design of large Pendulum Coolers was challenged by clinker distribution to an exceptionally wide grate precise levels of the mobile frames precise movement of the mobile frames control of the drive forces

As stated above, the clinker distribution by the KIDS is the key to cooler performance. IKN has introduced clinker distribution as a separately marketed product for which other cooler suppliers have also created own brand names. Once and again IKN has discovered new aspects of the distribution function, the total of which constitutes the experience of IKN in this critical area. Stepping ahead to 5.6 m and recently further to 6.8 m grate width was undertaken after detailed studies and observations of the clinker behavior on own and other suppliers fixed inlets. Whether 6.8 m grate width represents a limit waits to be seen. Back in 1996, with regard to clinker distribution and heat expansion, the width of the coolers in Thailand was not increased proportionally with production. It was kept at conventional 4.8 m width and the increased number of transport strokes and corresponding wear were accepted. With the IKN design the size of the mobile structure of the Pendulum Cooler grows over proportionally with cooler width, i.e. with the span of the pendulum beams. For best performance precise level machining of the large mobile frames and precise transport motion ensure minimal width of the thrust gaps, which in turn limit unwanted air jets and corresponding wear. Level machining of the mobile frames required larger shop equipment and improved measurement procedures. IKNs approach of building precise grates makes use of the patented Linear Pendulum System (LPS) suspending the mobile frames. The objective of narrow thrust gaps was referred to as gap management although thanks to the LPS gap management forms part of the initial installation and not of the annual maintenance or daily operation. Contrary to IKNs former long pendulum straps located inside of under grate housing extensions the LPS is integrated in the side walls of the under grate, which has made laser alignment easier. For a multitude of mobile frames intermediate LPS supports may be installed within the under grate. Linear Pendulum Suspension, a smooth metallic grate surface and horizontal COANDA air jets contribute to the hydraulic power requirement of 0.22 kWh/t only.

Fig.5: Linear Pendulum System LPS

Fig.6: Pendulum supports waiting for installation

In conventional coolers with standard hydraulic systems, the movement of the grate is based on eccentric movement. Using proportional valves and limit switches only, a parallel movement control of the mobile frame could not be realized sufficiently at high stroke numbers. In case of 4.8 m wide conventional coolers the grate speed was around 25 strokes per minute. Therefore a reduction of strokes is beneficial to the hydraulic system. During retraction of a grate, no clinker transport towards the discharge is realized. The shorter the retract time is, the slower a grate can run to achieve the same transport capacities. Pendulum Coolers are operated with slow and variable forward speed movements while the retract movement of the grate is fast and realized in a fixed time. For 10,000 tpd production capacities, Pendulum Coolers are operated on an average grate speed of 15 spm only. With the pre-assembly and complete testing of the electric and hydraulic system in IKN workshop and the precise hydraulic cylinder movement control by proportional valves and position transducers inside the cylinders, the parallel movement of the grate system is ensured at all times.

11. Summary Reciprocating grate coolers successfully handle production capacities of 10,000 tpd of clinker and more. In the near future also a number of scraper type coolers will become operational for this capacity range. The performance of Pendulum Coolers is based on precision of manufacture and alignment for minimal thrust gaps. Laser supported alignment is part of the investment and not subject to the diligence of the coolers annual maintenance. The wear less pendulum support of the mobile system and accurate hydraulic control provide minimal friction and energy consumption, electric and thermal, as well as minimal need of spares. By comparison with grate coolers with dead clinker layers the aggregate energy saving of the IKN coolers in operation to date is equivalent to the emission of several millions of automobiles. IKN is proud of contributing positively to the issue of CO2 emission.