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Replacement and upgrading of IKN coolers

CemProTec achieved substantial improvements when modifiying IKN coolers. In addition we noticed a demand in the market looking for options. Based on both facts, CemProTec customized certain CemProTec items to permit simple replacement of IKN grate elements. Boost your cooler performance and save money on spare parts. For further deails, please rder to products.

Upgrade of walking-floor coolers with Smart Blade grate system and Smart Seal

CemProTec offers upgrades for walking-floor coolers by replacement of the static grate by our Clinker Distribution System CDS and replacement of the grate system by our Smart Blade grate system and Smart Seal.

The heat recuperation and clinker cooling will be improved. Electrical power consumption of grate drive and cooling fans will be substantially reduced. For further details, please refer to products.

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HeidelbergCement plant Hanover, Germany

CemProTec replaced the IKN static grate and the grate plates of the following chamber at HeidelbergCement plant in Hanover, previously known as Teutonia. The goal was to decrease clinker temperature and avoid clogging of grate slots. The started successfully in March 2013.

Kirchdorfer Zementwerk Hofmann GmbH

In June 2011 Kirchdorfer Zementwerk Hofmann, Austria, awarded CemProTec GmbH a contract for the engineering and supply of a complete new Clinker Cooler with Smart Blade grate system, pendulum suspended grate, hydraulic drive and roller crusher. This CemProTec cooler will replace a Claudius Peters cooler and is designed for 1500 tpd. The equipment will be supplied in November in order to start the installation of the new cooler already in December 2011. Since it will remain a backward running cooler which has to fit underneath the existing kiln piers, the space is very limited. In fact, the challenge is to optimize the gas flow under the cooler roof by utilizing almost every millimeter that is available and reduce the space underneath the grate. The client was fully aware that only a tailor-made design can achieve these goals.

Sharjah Cement, U.A.E. - Part #2

Successful operation after conversion of the IKN Pendulum Cooler with new Clinker Distribution System CDS (replacement of IKN static grate) and a new Smart Blade grate system for the pendulum grate. All process data are better than guaranteed. The clinker outlet temperature has been reduced by 70C and the vent air temperature by more than 150C. Fuel savings have been achieved accordingly. In addition, the electrical power consumption of the cooling fans reduced substantially since the pressure drop is much less. Snowman formation have not occured anymore.

This conversion confirms the value of the Smart Blade grate system and the design advantages of cooler housing and kiln hood compared to CemProTec cooler on line #1.

Zementwerk LEUBE GmbH, Austria

Zementwerk LEUBE awarded CemProTec a contract in 2008 for the supply of a complete CemProTec Pendulum Grate Cooler for kiln line #1. The cooler consists of a pendulum suspended grate with CDS, Smart Blades grate system, hydraulic drive and roller crusher. The kiln hood with tertiary air take off and cooler housing are designed for lowest dust recirculation and low dust emission to the filter. The cooler is in operation since October 2010.

CemProTec Pendulum Grate Cooler in Zliten Cement, Libya, ready for operation.

CemProTec supplied a complete cooler through CEMAG, Germany, for the new kiln line in Zliten, Libya. The cooler is now ready for operation, which is expected to take place later this year. Design capacity is 3200 tpd. The cooler consists of a pendulum suspended grate with Smart Blades grate system, hydraulic drive and roller crusher. As usual, the kiln hood and cooler housing is designed for lowest dust recirculation and hence clear flame.

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Supply of CemProTec Pendulum Grate Cooler to CEMAG, for 5000 tpd kiln line at Gharb Torbat Jam, Iran

CemProTec supplied again a complete new Clinker Cooler to CEMAG, Germany, including kiln hood, Smart Blade grate system, pendulum suspended grate, hydraulic drive and roller crusher for their project Gharb Torbat Jam, Iran. This CemProTec cooler is designed for 5000 tpd and was shipped in winter 2008/2009.

Al Bana Cement Factory, U.A.E.

After the successful project at Sharjah Cement TRANSORGA Cement AG, Switzerland, awarded CemProTec GmbH again a contract for the engineering and supply of a complete new Clinker Cooler including kiln hood, Smart Blade grate system, pendulum suspended grate and hydraulic drive at Al Bana Cement Factory in the United Arab Emirates. This CemProTec cooler is designed for 2200 tpd and was shipped in 2008. The erection is supposed to start in summer 2009.

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Successful replacement of IKN grate system

The previous IKN grate system (static grate and movable system) has been replaced by CemProTec's Clinker Distribution System "CDS" and Smart Blade grate system. Substantial improvements in clinker cooling were achieved right after start-up. The clinker moves smoothly from the static grate CDS without previous snowman formation. As usual, CDS fan pressure is much lower and aeration stronger.

Sharjah Cement, U.A.E. - Part #1

In May 2006 TRANSORGA Cement AG, Switzerland, awarded CemProTec GmbH a contract for the engineering and supply of a complete new Clinker Cooler including kiln hood, Smart Blade grate system, pendulum suspended grate, hydraulic drive and roller crusher for kiln #1 at Sharjah Cement Factories in the United Arab Emirates. This CemProTec cooler replaced a Satellite cooler and is designed for 2200 tpd. Only 5 months later, the material was shipped. In order to minimize the time for the kiln stoppage, the new cooler was installed underneath the running kiln. The installation was carried out in less than 2 months working 1 shift per day only. CemProTec passed the performance test of the cooler right away. Fortunately, there was penalty for too cold clinker temperature. Sharjah Cement is doing meanwhile more than 2400 tpd.

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