High Capacity IKN Clinker Coolers - MR Huybens Bernard, IKN

Agend a Introduction of IKN Case studies of recent und upcoming IKN Pendulum Cooler projects
U nion Ceme nt Ras Al Khaim ah U AE #4 cas e Saudi Ceme nt #5 a nd #6 cas e 3 x 13.000 t/ d IKN P endul um Co olers at Conch
References
Refer ences of high cap acity IKN Pen dulum Coole rs Lis t of clinker coole r p rojects in G er many 19 95 201 0 Refer ences in the Mid dle Eas t Regi on f rom 2 005 - 20 10
High Capacity IKN Clinker Coolers 13.-14.05.2010 Green Cementech 2010, Hyderabad
Performance ofIKN Pendulum Coolers at SCC Tung Song 6 and Qinghuangdoa Facts about IKNs standing in the cement world
Green Cementech, Hyderabad

May 2010
Agenda
1983: Karl von Wedel starts IKN 1984: First order for cooler modi f ication with IKN fixed inlet (KIDS ) 1989: First Pendul u m Cooler 1997: Sales exc eeding EUR 30 Mio. 1998: Start-up largest IKN Pendulum Cooler 9100 t/d in Korea. 2010: 28 years more than 558 installations world wide giving IKN a l eading position in the market.
IKN GmbH Neustadt, Ge rmany

Location

May 2010
IKN Timeline

May 2010
IKN Pyro / PSP Engineering Czech Republic

May 2010
IKN premises

May 2010
IKN worldwide
IKN invents the KIDS fi x ed inlet Coanda Effect horizontal aeration LPS wearless grate suspension with highest precision Hydraulic drive with single cylinder
Agend a Introduction of IKN Case studies of recent und upcoming large IKN Pendulum Cooler projects
U CC #4 cas e H ofuf #5 an d #6 cas e 3 x 13.000 t/ d IKN P endul um Co olers at Conch
References
Overall performance of existing IKN Pendulum Coolers Facts about IKNs standing in the cement world

May 2010
Techni c al highlights

May 2010
Agenda
Decisions based on hard facts 2002 to 2006 4 years IKNcooler operation atUCC line # 3: - zero maintenan ce and - 100% availability follow-up order of the 10,000 t/dIKN co oler at UCC line # 4 successful commissioning of the 10,000 t/d IK N cooler at UCC line # 4 new order of a 10,000 t/dIKN cooler at ABMC in UAE
2005 End of 2006 2007

May 2010
Story of success for high capacity IKN Pendulum Coolers started in UAE

May 2010
3D Model of the 10.000 t/d IKN Pendulum Cooler at UCC line #4
Union Cement 10.000 t/d IK N Pendulum Cooler design data Production: Grate Width: Grate Length : Grate Area: Specific Loading: Installed Electrical Power: Clinker Outlet Temperature: 10.000 t/d 6,8 m 34 m / 95 rows 229 m2 43,6 t/m2,d 5,2 kWh /t 65 C + Ambient

May 2010
Design data

May 2010
Pre-installed mobile frame of the 10.000 t/d IKN Pendulum Cooler forUCC at IKN workshop

May 2010
Installation ofmobile frame on site in UAE

May 2010
Installing the air beams on a width of 6.8 m

May 2010
Mobile frame with lower cooler housing

May 2010
Installation of the KIDS section

May 2010
Good technology joins nations

May 2010
Covering the air beams with grate plates

May 2010
229 m grate surface paved twin TA offtake

May 2010
Same twin off-take, differentview

May 2010
IKN Roll Rusher 6 Rolls of 4.8 m width (retractable for maintenance) for 10.000 t/d and more

May 2010
Two hydrauli c drives in total, located with free access in the front
Decisions based on hard facts 2006 first order for 11.000 t/d Pendulu m Cooler in Saudi Arabia - twin project ofHofuf Cement for lines #5 and #6 (both coolers equipped with intermediateIKN Roll Crusher) successful commissioning of both 11.000 t/d Pendulum Coolers at Hofuf new order of 11.000 t/dcooler in Saudi Arabia for Yanbu Cement based on the su ccess of the two IKN Pendulu m Coolers at Hofuf
03./04. 2008 2008

May 2010
Ready forcommissioning

May 2010
Story of success for high capacity IKN Pendulum Coolers proceeded in Saudi

May 2010
Layout for both identi c al 11.000 t/d lines at Hofuf

May 2010
Civil structures for both 11.000 t/d lines at Hofuf

May 2010
View along the ESP onto the 2-stages mobile structure at Hofuf #5

May 2010
Hydraulic power pack in final position simple and reliable

May 2010
View on the framefor intermediate crusher and the second stage of the grate

May 2010
Side view on the plant site

May 2010
Burner platform with twin TA-offtakes and kiln hood in background

May 2010
Rearview of the cooler

May 2010
Preparations of crusher installation

May 2010
Cooling fans in position shortly before start-up
1 x 13.000 t/d at Tongling (kiln by FLS, clinkercooler by IKN)
IKN Pendulum Cooler facts 302 m grate surface consisting of 133 rows in total
7200 m m x 11 r ows 1st s tat ic inlet 7200 m m x 80 r ows 1st Pen dulu m s ectio n 6800 m m x 4 ro ws 2n d s tatic inlet 6800 m m x 38 r ows 2n d Pendulu m s ection
16 cooling fans with operating air of 1,9 Nm/kg clinker Date of FOB delivery Septemb er 2010 Green Cementech, Hyderabad
May 2010
Facts for 13.000 t/d IKN Pendulum Coolers project at Con ch Cement, China
First KIDS
2 x 13.000 t/d at Wuhu (kilns by Polysius, both clinker coolers by IK N)
First grate

May 2010
Sectional view of 3D model of the three 13.000 t/d IKN Pendulum Coolers at Conch Cement, China
Second KIDS
New lines for AnhuiConch Cement with production capacity of 3 x 13.000 t/d
Second movable grate
Roll crusher
1. First ClinkerInlet Distribution System - KIDS

Static inlet for even dis t ribu tion o f clinker Inclination: 15 W idth 7200 mm / Lengh t 4000 mm
4. Second ClinkerInlet DistributionSystem - KIDS

Static inlet for even re dis tri buti on of clinke r Inclination: 15 W idth 6800 mm / Lengh t 1500 mm
2. First movable grate

Cool dow n the clinke r t o 200 above a mbien t Inclination : 2 W idth 7200 mm / Lengh t > 2600 0 mm Movable fra me s us pende d fr om Linea r Pend ulum Su ppo rts (LPS) Driven by 2 hyd raulic cylinde rs
5. Secondmovable grate
Cool dow n the clinke r t o 65 a bove am bient Inclination : 2 W idth 6800 mm / Lengh t > 1200 0 mm Movable fra me s us pende d fr om Linea r Pend ulum Su ppo rts (LPS) Driven by 2 hyd raulic cylinde rs
3. Intermediate Crusher
6 Roll Cr us her W idth 6800 mm W ater coole d s hafts an d air coole d hous ing

May 2010
Techni c al Concept of the three 13.000 t/d IKN Pendulum Coolers at Conch Cement, China

May 2010
Techni c al Concept of the three 13.000 t/d IKN Pendulum Coolers at Conch Cement, China
Agend a Introduction of IKN
Refe re nc es I KN Pend ul um Co ole rs > 8 .00 0 t/ d

Cou ntry C usto mer Plant Size Star t -up
Korea
S ung Shin C ement S iam Cement C BME C A S C imento
Sung S hi n #5 Thung Song #6 UC C #4 Kizil k aya
9.100 t/d 8.500 t/d 10.000 t/d 9.000 t/d 11.000 t/d 11.000 t/d 10.000 t/d 11.000 t/d 13.000 t/d 13.000 t/d 13.000 t/d
05/1998 01/1999 01/2007 03/2008 03/2008 04/2008 06/2010
Case studies of recent und upcoming large IKN Pendulum Cooler projects
Thail and UA E Turkey KSA KSA UA E KSA
S inoma for Saudi C . Hofuf #5 S inoma for Saudi C . Hofuf #6 C BME C S inoma C onch C onch C onch AB MC Yanbu Wuhu Wuhu Tongling
References
China China China
Exis ting 10.000 t/d C PA G coolers in Thail and have succes sfully been modi fied w i th IK N KID S.

May 2010
Agenda

May 2010
References ofIKN Pendulum Coolers with a capacity of more than 8.000 t/d
Lis t o f c link er co oler p ro jec , tsm o stl yen ergy eff icie ncyimprov ement s , in Germany 199 5 - 2010
Cu stomer P la nt Sup plier Tpd P roject Y ear
Refer en ces IKN Pend ulu m Co oler s in A r ab ian Pen insu la fr om 200 2 New lin es, Cap acit y > 40 milli on t on s per yea r, m ar ket s har e 50 %.
- 20 10
Teutonia Zement Dyckerhoff Zement Solnhofer Zement Heidelberger Group Spenner Zement Holcim Schw en k Lafarge Rohr dorf Zement Miebac h & Shne
H annov er kiln #7 Lengerich k iln #8 S ol nho fen B urgl engenfeld E rwitte H v er A l mendingen W oe ssingen R ohrdorf Wi ttekind
IKN IKN P oly sius IKN IKN IKN P oly sius IKN IKN IKN
2900 for new KH D k iln 3700 for new FLS k iln 1800 r etrofit o f P oly sius c ooler 2000 r etrofit o f C laudi us P e ter s cooler 2800 r epl acement of rotary cool er 3000 r epl acement of satel l ite cool er 4000 r epl acement of satel l ite cool er 2200 new li ne 4500 r epl acement of satel l ite cool er 2500 r epl acement of rotary cool er
1997 2001 2003 2003 2007 2007 2007 2007 2010 2010
Marke t sh are I K N:80 % f or cli nke rc oo lers in Ge rman y o ver th e la st 15 ye ars .

G er many has 4 cl i nker cooler s uppliers: Claudius Peters, IKN , KHD and Krupp P ol y sius .
Coun try Saudi A rabi a UA E Saudi A rabi a Saudi A rabi a Yemen Saudi A rabi a Saudi A rabi a Saudi A rabi a Saudi A rabi a Saudi A rabi a UA E Jo rd an Yemen KSA Om an Syria Syria KSA KSA UA E
C ustomer Si n oma Si n oma Si noma Si n oma C BMEC Si n oma Si n oma C NB M N anj i ng Triump h IH I C BMEC C NB M C DI Si n oma C BMEC C BMI C BMI Si n oma S PCC IH I
Plant SPC C Tahamah UC C #4 Muz amiy ah City Cement National C em ent Hofuf #5 Hofuf #6 Northern R e gion Al Jou f C em ent Qa ssim C em ent #3 ABMC /Abu Dhabi AMCP YSC C Riyadh C eme nt Rusayl #3 ABC C 1 ABC C 2 Yanbu Tahama h #2 Sharjah Cemen t
S iz e 60 00 100 00 60 00 60 00 34 50 110 00 110 00 63 00 50 00 47 00 100 00 63 00 40 00 60 00 45 00 50 00 50 00 110 00 60 00 40 00
Start-up 08/07 01/07 06/07 08/07 07/08 08/08 04/08 02/08 01/10 01/07 06/10 07/09
08/02

May 2010
Cooler projects in Germany over last 15 years

May 2010
References ofIKN Pendulum Coolers in the Middle East from 2002 - 2010
Agend a Introduction of IKN Case studies of recent und upcoming large IKN Pendulum Cooler projects
Op eratin g da ta bef ore and af te r Re trof it i nst all atio n

Bef ore
by IKN a t UCC # 3, UAE

Octo ber 2002
Clinker temperature [ C + amb] Kiln capac ity [tpd] Cooling air [N m/kg ] Tertiary air [C ] Secondary air [C ]
148 1850 2,50 760 893 60,8
85 2130 1,70 939 1004 76,2 858 259
References
Cooler efficiency [%] Heat consumption Vent air [ C] [kc al/kg]
915 255
Efficien t IKN co oler: Reduction in kiln fuel usage 57 kcal/kg

May 2010
Agenda

May 2010
Operating data ofUCC #3, UAE
G uarante ed a nd a ctua l ope rat ing v alue s f or UC C # 4 , U AE

Gu aran teed val ue Actu al value
Guaranteed and actual op erating values of the IKN P endul um Cooler 11, 000 tpd at Saudi Cement, Hofuf Saudi Arabia.
Gu aran te ed valu es
Act ua l va lue s
Clinker temp erature [above A K iln capacity [tpd] Cooling air [ Nm /kg] T ertiary air [ C] S econdar ya r i [C] Cooler effici en c y [% ] Heat con s um ption V ent air [ C] [kcal/k g]
< 65 10 .000 1 ,95 880 11 19 7 4,4 720 257
< 50 10.500 1,95 88 7 113 4 74,5 72 0 25 9
Clinke r te mpe ra ture [Abov e A ] Coo ling a ir [Nm /kg ] T ertia ry a ir [C] Seco n da ry air [C] Coo ler e fficien cy [%] Vent air [C]
65 2, 0 1067 73,7 292
57 1, 90 780 1135 75,21 172
NB: Cus tome r d ata.

May 2010
Operating data ofUCC #4, UAE

May 2010
Operating data of SCC, KSA
Gua ra nte ed a nd a ct ual op e ra ti ng v al ue s of t he IK N Pe ndulum C oole r at Thung Song Ceme nt, Tha ila nd
Gu aran teed valu es Actu al valu es
Gu arant eed a nd ac tua l op e ra tin gv alu es * o f t he IKN Pen du lu m Coo ler at Qin hu an gd ao Cemen t, Chin a
Guar anteed valu es A ctual values
Clinker temperature [above A

Cl i nke r tempe ratur e [above A Kiln cap aci t y [tpd] Cooling air [Nm /kg] Ter tiary air [ C] Se c o ndary air [C] Cooler eff i cien c y [ %] Po w er consump ti on [kWh /t ] ] 71 7 500 75,6 4,0 79 78 75
75 4000 1,65 976 81 4,0 250
40 4220 1,46 942 1053 81,5 3,52 266
Kiln capac ity [tpd] Cooling air [N m/kg ] Tertiary air [C ]
1.9
Secondary air [C ]
10 40
Cooler efficiency [%]

10 90 78,7 3, 96
Pow er consumpti on fans [kWh /t] Vent air [ C]
* actual v au l es of performance test executed by customer.
To o ur kn ow led ge no o th er typ e o f coo le r rea es chs uch perfo rma nce .

May 2010
Operating data ofThung Song, Thailand

May 2010
Operating data ofQuinhuangdao, China
Agend a
IKN per for mance at Qinhuangdao Ceme nt, China Gree ne st clink er cooler in ope ration?
Introduction of IKN Case studies of recent und upcoming large IKN Pendulum Cooler projects
Clin ker te mperature Cool er loa d Cool ing a ir Cool er effi ciency Po wer con su mption
63 deg C including A 53 tons/m2 da y 1,46 N m3/kg 81 ,5 % 3,82 kWh/t total
References
Data from co ol er perfo rmace n te st b y c ust omer.

May 2010
Operating data ofQuinhuangdao, China

May 2010
Agenda
Market Share and accep tan ce IKN has the largest market share in clinkercoolers sold in 2007-2010 worldwide (excluding P.R. China) IKN is fully approved by the largest 6cement groups. IKN has supplied andcommissioned successfully coolers in the last three years to Lafarge, Hol c im, Cemex, Heidelberg, Italcimentiand Tai y heyo and CONCH 8 of 10 cooler decisions in the last 10 years in Germany were in favour of IKN
Position amongst Chinese equipment suppliers IKN is fully approved and being selling coolers to the most important Chines e EPC suppliers as SinomaInternational, CNBM, CBMEC, TCDRI, NCDRI, CDI, CBMI and HCDR I IKN has sold more than 36 coolers to above mentioned EPC suppliers in the range from 2.000 t/d to 11.000 t/d; more than 25 of these sold coolers have a capacity between 5.000 t/d and 11.000 t/d

May 2010
IKNs standing in the cement world

May 2010
IKN has a lea ding po sit ion in the fie ld of h igh capacity clinkercoo lers IKN has successfully performed process guarantees for 10.000 t/d and 11.000 t/d clinkercoolers at Saudi Cement and Union Cement, UAE IKN has sold and successfully commissioned the largest clinkercooler in Europe (AS Cimento, Turkey with 9.000 t/dcapacity) IKN will supply 3 coolers with design capacity of 13,000 tpd IK IKN has agreement for the largestclinkercooler of 15.000 t/d capacity
cool down
Thanks for your attention!

May 2010
www.ikn.eu

High Capacity IKN Clinker Coolers - MR Huybens Bernard, IKN

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Agend a Introduction of IKN Case studies of recent und upcoming IKN Pendulum Cooler projects

Green Cementech, Hyderabad

IKN GmbH Neustadt, Ge rmany

Green Cementech, Hyderabad

Green Cementech, Hyderabad

IKN Pyro / PSP Engineering Czech Republic

Green Cementech, Hyderabad

Green Cementech, Hyderabad

Green Cementech, Hyderabad

Green Cementech, Hyderabad

2005 End of 2006 2007

Green Cementech, Hyderabad

Green Cementech, Hyderabad

3D Model of the 10.000 t/d IKN Pendulum Cooler at UCC line #4

Green Cementech, Hyderabad

Green Cementech, Hyderabad

Green Cementech, Hyderabad

Installation ofmobile frame on site in UAE

Green Cementech, Hyderabad

Installing the air beams on a width of 6.8 m

Green Cementech, Hyderabad

Mobile frame with lower cooler housing

Green Cementech, Hyderabad

Installation of the KIDS section

Green Cementech, Hyderabad

Good technology joins nations

Green Cementech, Hyderabad

Covering the air beams with grate plates

Green Cementech, Hyderabad

229 m grate surface paved twin TA offtake

Green Cementech, Hyderabad

Same twin off-take, differentview

Green Cementech, Hyderabad

Green Cementech, Hyderabad

03./04. 2008 2008

Green Cementech, Hyderabad

Green Cementech, Hyderabad

Green Cementech, Hyderabad

Layout for both identi c al 11.000 t/d lines at Hofuf

Green Cementech, Hyderabad

Civil structures for both 11.000 t/d lines at Hofuf

Green Cementech, Hyderabad

Green Cementech, Hyderabad

Hydraulic power pack in final position simple and reliable

Green Cementech, Hyderabad

Green Cementech, Hyderabad

Side view on the plant site

Green Cementech, Hyderabad

Burner platform with twin TA-offtakes and kiln hood in background

Green Cementech, Hyderabad

Rearview of the cooler

Green Cementech, Hyderabad

Preparations of crusher installation

Green Cementech, Hyderabad

Cooling fans in position shortly before start-up

1 x 13.000 t/d at Tongling (kiln by FLS, clinkercooler by IKN)

2 x 13.000 t/d at Wuhu (kilns by Polysius, both clinker coolers by IK N)

Green Cementech, Hyderabad

Second movable grate

1. First ClinkerInlet Distribution System - KIDS

4. Second ClinkerInlet DistributionSystem - KIDS

2. First movable grate

Green Cementech, Hyderabad