THE ART OF CLINKER COOLING

COOL DOWN
Experts in clinker cooling

GREETINGS
PENDULUM COOLER
Overview

Pendulum Cooler

KIDS

10

Coanda Wing

12

Mobile frame with LPS

14

Roll Crusher

16

Waste Heat Recovery

18

SOLUTIONS & SERVICES

Solutions & Services

23

COMPANY
Facts and Figures

26

IKN Worldwide

27

Klaas Windmller / Justus von Wedel

4|5

GREETINGS
Our goal is to provide you with the best possible solution for your clinker cooler and
pyro system. With more than 500 customised installations worldwide, we are proud to
be the number one choice for clinker cooling technology.
The initial development of the IKN Pendulum Cooler started more than 30 years
ago. Today, the latest design features state-of-the-art Coanda Wing technology
for optimised aeration and the LPS supporting the mobile frame. The modular
construction of the Pendulum Cooler allows for quick and easy replacement of
existing clinker coolers or the smooth integration in a greenfield project.
Even though cement is a commodity, the diverse fuels and raw materials throughout
the world as well as local regulations demand an open-minded and exible approach
to each individual challenge. With our staff of over 150 dedicated employees in our
organisation, we are prepared for those challenges and will support you before, during
and after the project phase no matter how distant your plant or how special your
request!
Our curiosity and ambition drive us to constantly work on the refinement of our products
and the development of our skills. Expect the highest standard from our organisation.

Justus von Wedel

Klaas Windmller

WASTE HEAT RECOVERY

page 18

Customised waste heat recovery solutions

continously generate electrical power from
the cooler vent air. The mid-air offtake
provides hot air at optimal temperatures.

5
KIDS

page 10

IKN KIDS distribute the clinker evenly across the grate and
condition the clinker bed for
easy passage of air, lifting the

COANDA WING

uidised fines to the surface.

The new generation Coanda Wing has a

page 12

lower pressure drop and higher air speed.

The design ensures that the grate plates are
completely surrounded by cooling air.

COOL DOWN
The IKN Pendulum Cooler
Over 500 installations of Clinker Inlet Distribution Systems (KIDS) and the Pendulum
Cooler worldwide prove that IKNs products are at the forefront of technology. They are
designed to reach the lowest clinker outlet temperatures at the highest recuperation rates.

MOBILE FRAME WITH LPS

page 14

The forward movement of the mobile frame is

ROLL CRUSHER

accomplished by an easily accessible hydraulic

page 16

drive system and supported by wear and

IKN Roll Crushers are operating

maintenance free spring steel straps.

in coolers with a capacity of up to

13.000 t/d. They offer low power

consumption and low mechanical
wear.

PENDULUM COOLER
In modern cement plants, the clinker cooler is the key to high recuperation efficiency and low
clinker outlet temperatures at the lowest possible energy consumption.

+ Compact design

+ Low power consumption

+ Efficient clinker cooling

DESIGN AND FUNCTION

COMPETITIVE ADVANTAGE

The Pendulum Cooler is designed as single grate with a

IKN was awarded the contract to supply the three largest

roll crusher at the end or as double grate with intermediate

clinker coolers ever built, which reach capacities of 13,000

crusher. Uniform clinker bed aeration is ensured by grate

t/d. After intense technical discussions, the decision

technology,

was made due to the low specific energy consumption,

which purges the fines out of the clinker bed up to the

reduced expected wear rates and related savings in terms

surface with the required air ow and improved heat

of maintenance costs and higher efficiency. Furthermore,

transfer between clinker and cooling air. The resulting

IKNs broad experience in building high-capacity clinker

clinker bed is characterised by low resistance to the

coolers contributed to the decision.

plates, equipped with IKN Coanda Wing

passage of cooling air.

The sintered clinker leaves the outlet of the kiln with an
estimated temperature of 1,400C and drops onto the

static inlet (KIDS ) where the clinker is initially cooled

and conditioned for uniform distribution to the pendulumsupported grate. The clinker is transported by the linear
strokes of the pendulum section where every third row
is movable. Further down the cooler the material passes
different air off-takes which provide hot air for drying and/or
for a waste heat recovery system. 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.

8|9

MAIN FEATURES

Low electrical power consumption

High thermal recuperation efciency
Low construction height
Modular design allows for easy assembly
Pre-assembled parts reduce installation time
Outstanding availability

3D layout

Inside view

Cooler during erection

KIDS

COANDA WING

LPS

ROLL CRUSHER

WASTE HEAT RECOVERY

KIDS
The KIDS is a revolutionary technology in clinker cooling both mechanically and process
wise. It generates a uniformly distributed clinker bed just before the clinker reaches the
mobile grate by evenly spreading the clinker and transporting the nes to the upper layer.

+ Uniform clinker bed

+ Improved recuperation

+ Low maintenance

DESIGN AND FUNCTION

The KIDS converts the ow of clinker from the kiln into

Left and right aeration by separate cooling fans controls

an even clinker bed for best possible heat exchange along

the cooling air to the coarse and fine side on the KIDS.

the entire length of the cooler. The clinker lands on the

As the fine side requires less cooling air, a more gentle

cooler centre line near the cooler front wall. The criteria

aeration of the fines prevents red river formation on the

for optimum offsets between kiln and cooler are the kiln

movable grate section. On the contrary, the coarse side

diameter, kiln speed and the angle of repose of the clinker.

requires more air for efficient cooling of the larger clinker

In addition to cooler offset, equally important performance

size.

parameters are shape of the refractory side dam, dropping

Smooth transition from the KIDS to the cooler grate area

height, inclination, length and the transit step to the

is facilitated by the CFO (Controlled Flow Optimizer). The

downstream grate.

CFO is inclined at the same angle as the KIDS rows and

As the V-shaped refractory opens up, the clinker pile at

is equipped with a special seal to allow proper transition to

the landing area spreads to the width of the grate and is

the first movable row of the grate area.

converted into a uniform clinker bed. Shape and movement

of the clinker pile can be controlled by the aeration of the
KIDS area. Typically the KIDS area is divided into three
zones: the clinker landing area and downstream the left
and right side cooling zones. Strong aeration of the landing
area prepares the clinker for optimum cooling. The fines
are transported to the surface. The voids inside the clinker
bed become more even, reducing the pressure drop and
enabling uniform aeration across the bed.

10 | 11

MAIN FEATURES

Uniform clinker distribution across the grate width

Improved transport of the nes to the bed surface
Lower clinker outlet temperature
Stabilised kiln and cooler operation
Heat savings of 20-100 kcal/kg
Easy installation into existing coolers

KIDS PERFORMANCE
Guaranteed reduction in cooler losses leading to an improvement in kiln fuel consumption. The table shows the improvements achieved after the installation of an
IKN KIDS at a customers 3,900 t/d 3-stage Fuller kiln:

BEFORE

AFTER

CHANGE

Spec. cooling air vol. (Nm/kg)

2.23

1.91

-14.3 %

Spec. vent air vol. (Nm/kg)

1.31

1.05

-19.8 %

Clinker outlet temperature (C)

163

111

-31.9 %

Heat recuperation (%)

67.3

76.4

+13.5 %

Power requirement (kWh/t)

11.9

5.85

-50.8 %

Heat consumption (kcal/kg)

902

839

-7 %

KIDS layout

KIDS module

Before and after installation of KIDS

KIDS

COANDA WING

LPS

ROLL CRUSHER

WASTE HEAT RECOVERY

Coanda Wing
The revolutionary design of the Coanda Wing ensures optimum airow into the clinker
bed. Fines are swept to the clinker bed surface and the Coanda plates are completely
surrounded by cooling air. During normal operation, temperatures between 30 C and 40 C
are measured close to the grate surface.

+ Direct air ow

+ Less pressure drop

+ Self-cleaning

DESIGN AND FUNCTION

IKN introduces its latest design of the grate surface, the

The newly designed front plate meets the critical

Coanda Wing , which is now part of all new coolers and

requirements regarding temperature resistance, low wear

can also be used to upgrade existing grates.

and easy maintenance. Grate plates with new Coanda

Wing technology are fully compatible with existing plates

The optimised shape of the Coanda Wing provides a

and can be upgraded compartment-wise within current

better airow and significantly reduces turbulences at the

surfaces. The best location to start upgrading is the first

grate surface.

compartment right after the fixed inlet.

The newly designed slots not only enhance the entire ow

of air but also provide a continuous self-cleaning effect.
This new design is highly precise and robust, making it

MAIN FEATURES

ideal for the rough atmosphere of the modern cement

factory.

GRATE PLATE
The Coanda Wing is embedded into a newly designed
and precision manufactured box. These boxes provide
optimum dimensional accuracy, allowing for seamless
installation into the whole grate area.

12 | 13

Increased air speed

Lower pressure drop

High-precision slots

No welding required

Compatible to existing IKN grate plates

Self cleaning

Shape of the new Coanda Wing

Grate plate

KIDS

COANDA WING

LPS

ROLL CRUSHER

WASTE HEAT RECOVERY

Mobile frame with LPS

The Pendulum Cooler is the only cement clinker cooler designed without any active or
lubricated components within the cooler housing. Together with the wear resistant and
maintenance free spring steel straps of the LPS, this design ensures that access to the
inside of the cooler is only required for inspection during the annual shutdown.

+ Maintenance-free spring steel straps

+ Hydraulic components located outside the cooler housing

DESIGN AND FUNCTION

The IKN grate consists of fixed and mobile rows. The

the grate is completed in a fixed time of approximately

mobile rows are mounted on top of a mobile frame. The

one second. This type of operation improves transport

frame is suspended on the patented Linear Pendulum

efficiency and balances the discharge into the clinker

Support (LPS). The fixed rows are mounted to the side

conveyor. By adjusting the number of strokes per minute,

walls of the cooler housing.

the bed height can be dynamically adjusted to varying

operational parameters. One or two hydraulic cylinders for

In contrast to all other grate coolers, every third row

each grate are located in front of the cooler underneath the

is mobile which allows for perfect alignment between

KIDS section. The operating position outside the cooler

fixed and mobile rows. During installation of the cooler,

housing protects them from clinker dust and improves

the LPS , which is installed inside the cooler housing to

accessibility for the minimal maintenance required.

give maximum exibility in grate width, is aligned once

to provide precise linear motion of the mobile frame. The
combination of the robust mobile frame and the LPS
ensures that the individual rows remain in the exact
same position during the lifetime of the cooler. The exact
positioning of the rows together with the linear motion of
the mobile portion of the grate minimizes the thrust gaps
allowing for optimum aeration through the grate plates.
The Pendulum Cooler is operated with slow and variable
forward speed movement while the retract movement of

14 | 15

MAIN FEATURES

Wear and maintenance free

Perfect linear movement
No lubrication required

LPS installed in cooler housing

KIDS

COANDA WING

LPS

ROLL CRUSHER

WASTE HEAT RECOVERY

Roll Crusher
The IKN Roll Crusher is equipped with up to six rolls for cooler capacities of up to 13,000 t/d.
Compared to a hammer crusher, there are no chain curtains, no grizzly bars and no kiln stops
caused by large lumps or coating pieces.

+ Reduced wear

+ Uniform clinker size

+ Easy maintenance

DESIGN AND FUNCTION

IKN Roll Crushers operate in coolers with capacities of up
to 13,000 t/d. They offer low power consumption and low
mechanical wear compared to other types of crushers.
The crusher can be installed at the cooler discharge or as a
mid-cooler crusher for intermediate crushing. The rolls will
automatically reverse at high torque protecting the crushing
rings against damage caused by foreign matter. Water
cooling of the crusher shafts is an option for hot operation.
Each roll is driven by an electrical gear motor with a
planetary gear unit. Typically 95% of the crushed clinker
is reduced to a particle size of less than 30 mm depending
on the size of the gap between the rolls.
For any maintenance work the IKN Roll Crusher can be
moved to a maintenance position at which all components
are easily accessible without entering the cooler.

16 | 17

MAIN FEATURES

Electrical drive with low power consumption

Rail mounted for easy maintenance
Reduced wear due to low roller speeds
Hard-faced roll teeth for long service life

3D layout

Installation on site

KIDS

COANDA WING

LPS

ROLL CRUSHER

WASTE HEAT RECOVERY

Waste Heat Recovery

Based on the experience with pyro process and cooler solutions, IKN offers Waste Heat
Recovery Systems (WHRS) for industrial applications.

+ Compact design

+ High efficiency even at partial load

+ Easy integration

WASTE HEAT RECOVERY

Energy is too valuable to be wasted. Therefore, IKN

Profound knowledge of the entire pyro process, from

offers tailor-made Waste Heat Recovery Systems for the

preheater to cooler, allows IKN to identify and to engineer

cement industry.

suitable solutions for entire kiln lines.

Due to their special design characteristics and high

efficiency, IKN Pendulum Coolers are perfectly suited
for a wide range of waste heat recovery applications.
Ventilation concepts can be adapted to the special
requirements within the plant and optimised for maximum
output or customised for auxiliary applications.

POWER GENERATION
Flexible - compact - efficient. These are the main features
of power generation plants based on ORC and similar
approaches, such as supercritical CO2 and others. Power
generation in a cement plant can be implemented at
different positions. Typical hot air tapping points are at the
preheater and/or the clinker cooler.

18 | 19

MAIN FEATURES

Independent energy generation

Improved environmental footprint
Low maintenance
High efciency even at partial load

Recovering energy from the cooling process

Industrial plants offer manifold options for WHRS

IKN SOLUTIONS & SERVICES

What can we
do for you?

20 | 21

SOLUTIONS & SERVICES

IKN offers customised solutions to increase capacity and efficiency while decreasing
operating costs. The IKN support includes mechanical and electrical maintenance and repair,
training, phone assistance and individual service packages.

SOLUTIONS

SERVICES

IKN solutions comprise three main areas: Upgrades

IKN will carry out equipment assessments to assist in

and modernisations, satellite conversions and turnkey

developing customised solutions for proposed modifi-

installations.

cations. Furthermore, regular inspections of installed IKN

IKN improves existing kiln lines, while retaining as much of

equipment contribute to improved reliability.

the original equipment as possible. Performance upgrades

Our experienced team of project managers controls

are accomplished by replacing existing grate coolers with

the project execution from the kick-off phase through

a Pendulum Cooler within the existing cooler housing.

installation and to the final handover to the customer. Firm

These upgrades are facilitated by the small dimensions

control of the schedule and a focus on avoiding problems

of the LPS .

before they occur lead to the successful completion of a

One of IKNs specialties is the replacement of satellite

project.

coolers to increase heat recuperation and plant availability

IKN employs specialists for mechanical installation as well

at lower clinker temperatures. The demolition of the existing

as cold and hot commissioning. Our supervisors monitor

satellite cooler and the installation of a preassembled

the quality of delivered equipment and coordinate the

Pendulum Cooler

are accomplished during a routine

erection works.

annual outage.

Customised training sessions qualify your operators in the

Large-scale projects are realised by the expertise of

correct use and maintenance of our equipment. The aim is

the IKN project management and service teams. Our

to promote a better understanding of our technology and

knowledge and experience ensure effective management

its application. After installation and commissioning, our

of sub-contractors to achieve precise project execution,

after sales service continues to stay in close contact with

both on time and within budget.

the operators.

IKN COMPANY

Experts in
clinker cooling.

COMPANY
IKN GmbH is a globally operating, medium-sized company located in Neustadt near Hanover,
Germany. The company specialises in the supply of plant components for the production
and cooling of cement clinker.

FACTS AND FIGURES

IKN WORLDWIDE

At the beginning, IKN revolutionised the cement industry

With more than 550 installations worldwide since 1982,

with the development of the clinker inlet distribution system,

IKN has become the market leader in the field of clinker

the KIDS . Whereas it was introduced as an upgrade to

cooling technology. References include smaller coolers

existing clinker coolers, today it forms an integral part of

with a capacity of 650 t/d as well as the three largest clinker

the IKN Pendulum Cooler .

coolers ever built each sized for a capacity of 13,000 t/d.

Further innovations, such as the highly precise and wear

A significant set of references for burning lines has been

less mobile frame support the LPS manifested the

established in Europe and the Middle East.

companys success.

Customers rely on local offices for service and sales

In 2002, IKN extended its activities further by acquiring

in China, Singapore, USA, India and Brazil, whereas

PSP in the Czech Republic. With the integration of the PSP

engineering remains concentrated at IKNs head office in

Pyro engineers, the company has widened its competence

Neustadt.

towards the entire kiln burning line under the name of IKN.

IKN BY NUMBERS

13,000

t/d

Largest cooler capacity

6.77

Bn. tons of
clinker cooled

563

Installations
worldwide

4,200

t/d

Average cooler capacity

650

t/d

Smallest cooler capacity

26 | 27

IKN GmbH

IKN China

IKN USA Inc.

IKN Engineering India

IKN Office S.E. Asia
IKN do Brasil Ltda

IKN GmbH

IKN USA Inc.

Ingenieurbro-Khlerbau-Neustadt GmbH

PHONE:

+1 904 642 4949

Mittelstrasse 4 - 5

E-MAIL:

[email protected]

31535 Neustadt am Rbenberge

Germany

IKN do Brasil Ltda

PHONE:

+49 5032 895 0

FAX:

+49 5032 895 195

E-MAIL:

[email protected]

WEB:

www.ikn.eu

PHONE:

+55 199 8401 1514

E-MAIL:

[email protected]

IKN Engineering India

PHONE:

+91 44 2363 6242

E-MAIL:

[email protected]

IKN Office S.E. Asia

PHONE:

+65 9475 5061

E-MAIL:

[email protected]

IKN China
PHONE:

+86 137 0163 7609

E-MAIL:

[email protected]

Ingenieurbro-Khlerbau-Neustadt GmbH
IKN GmbH
Mittelstrasse 4-5
31525 Neustadt
Germany

Tel +49 50 32 8 95 0
Fax +49 50 32 8 95 195
www.ikn.eu
[email protected]