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Water Injection System

The water injection system is used to avoid critical cooler exhaust air temperatures, which can damage peripheral equipment.

The amount of cooling water is calculated based on expected kiln upset conditions and the accepted maximum air temperature.

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Double G Damper

Most calciner installations require tertiary air taken from the kiln hood or cooler housing. IKN’s Double G Damper model is specially designed for both, air flow regulation and complete shut off in tertiary air ducts. Two in­de­pen­dent guil­lo­ti­ne type ga­tes fulfill the two main pro­cess func­ti­ons of the damper: The re­gu­la­ti­on gate is active during normal kiln ope­ra­ti­on. It is manufactured from heat re­sis­tant steel pi­pes, co­vered by precast ab­ra­si­on resistant re­frac­to­ry blocks. Located be­hind the re­gu­la­ti­on gate is the heat re­sis­tant shut off gate. Both ga­tes in con­junc­tion are used to clo­se off the ter­ti­a­ry air duct du­ring star­t-up and shut­-down cycles.

IKN Czech s.r.o. Strojárenstvo, stroje, priemysel

Waste heat recovery

Energy is too valuable to be wasted. Therefore, IKN offers taylor-made waste heat recovery systems based on the Organic Rankine Cycle (ORC) for the cement industry. Flexible - compact - efficient. Those are the main features of power generation plants based on the ORC. Power generation in a cement plant can be implemented at different positions. Due to their special design characteristics and high efficiency, IKN Pendulum Coolers ® are perfectly suited for a wide range of waste heat recovery applications. Efficient recuperation, tertiary- and mid-air extraction as well as innovative cooler ventilation concepts allow IKN to find the perfect solution for any plant optimization or new construction target. The recirculation of cooling air allows to omit an emission point and to increase available heat at constant flow or additional flow at constant temperature, respectively. No heat sensitive parts are located under the grate, thus, this unique feature of IKN coolers makes recirculation of hot air possible. But getting out as much as possible valuable energy does not stop at the cooler. Profound knowledge of the entire pyro process, from preheater to cooler, allows IKN to identify and to realize suitable solutions for entire kiln lines.

IKN Czech s.r.o. Strojárenstvo, stroje, priemysel

IKN Grate System

Horizontal air jets on the grate surface support the clinker transport, resulting in a reduction of movable rows. The size of the Coanda Wing® plates was selected to allow modular adaption of the grate width for varying kiln capacity. For further information, see all sizes available. Coanda Wing® plates, beams and mobile frames are precision machined during manufacture and laser aligned during installation. The resulting grate surface exhibits excellent mechanical operating characteristics with an optimal distribution of cooling air maximising heat transfer between cooling air and clinker.

IKN Czech s.r.o. Strojárenstvo, stroje, priemysel

Heat Shield

Heat shields are designed to stabilise secondary and tertiary air temperatures at a higher value. IKN installed heat shields in more than 60 clinker coolers. The heat shield is located at the end of the recuperation zone to reduce radiation losses. The main features of the IKN Heat Shield are: •Maintaining a constant kiln hood pressure for stable flame and kiln operation. •Separation of preheated air and vent air. •Higher heat recuperation through a reduction of radiation losses.

IKN Czech s.r.o. Strojárenstvo, stroje, priemysel

Roller Crusher

IKN Roller Crushers are operating in coolers with a capacity 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 rollers will automatically reverse at high torque levels, protecting the crushing rings against damage caused by foreign matter. Typically, 95% of the crushed clinker is reduced to a particle size of less than 35 mm. The width of the crushing slots can be adjusted to the required particle size. IKN Roller Crushers can be used for other materials than clinker. In 2004, IKN installed a 4 roll crusher for petcoke crushing at Lebec, USA. The main features of the IKN Roller Crusher are: •Large pieces of clinker cannot jam the crusher. •Reduced wear and dust generation due to low roller speeds . •Electrical drive with low power consumption. •Uniform size distribution of the crushed clinker. •The crusher is mounted on rails for easy maintenance. •Hard-faced crushing ring teeth for long service life and easy re-facing.

IKN Czech s.r.o. Strojárenstvo, stroje, priemysel

Hydraulic Drive

A reliable hydraulic drive is essential for optimum operation of the cooler and the entire kiln line. Each unit is assembled and tested in IKN’s own workshop prior to shipment. The hydraulic system is programmed with an asymmetrical travel profile, slow forward motion and fast retraction. This type of operation improves transport efficiency and balances the discharge into the clinker conveyor. Hydraulic cylinders are located outside the cooler housing, protected from contamination by clinker dust and with improved accessibility for maintenance.

IKN Czech s.r.o. Strojárenstvo, stroje, priemysel

Pre-calciner Technology

The introduction of pre-calciner technology increases clinker production and ensures that the rotary kiln keeps a manageable dimension. Pre-calcination rates in excess of 90% are achieved with approximately 60% of the total fuel directed to the pre-calciner. As combustion and pre-calcination of raw material take place outside of the rotary kiln, the heat loading of the kiln is reduced and smaller rotary kilns are possible. All IKN calciners are based on a modular system. Systems can be designed according to the fuel used or other specific requirements.

IKN Czech s.r.o. Strojárenstvo, stroje, priemysel
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