PYROFLOOR²®

the next evolution in cooler technology

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KHD Humboldt Wedag is your partner in cooling technology. Since the commissioning of the first KHD clinker cooler in 1936, we have dedicated ourselves to developing products and servi-ces that exceed the needs of our customers.

For conveying and cooling hot clinker, the PYROFLOOR2® utilizes proven and reliable technologies.

The PYROFLOOR2® has been tailored to meet the growing needs of the cement industry, from the implementation of the moving floor principle, which has long been known for its efficient conveying, down to the individual design and lane arrangement of cassettes, which provide a functional meeting point for clinker transport and aeration.

PYROFLOOR2® combines established advantages from the origi-nal PFC with new features, to make it more environmentally friend-ly, cooling more efficient, maintenance easier, and operation more reliable. PYROFLOOR2® is the next evolution inproven KHD cooler technology.

innovation improvement solutions

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The PYROFLOOR2® cooler product line has been developed to cater to all production capacity scenarios. Our standard product models are suited for production capaci-ties ranging from 2,000 to 12,000 tons per day, while maintaining the optimal specific grate load.

Optimized specific grate loads ensure that the ideal ratio of clinker is spread across the width and depth of the cooler grates, resulting in consistently efficient clinker conveying and aeration.

PYROFLOOR2®

for every production need

PYROFLOOR2® - standard series

PFC2 524PFC2 530PFC2 629PFC2 635PFC2 638PFC2 643PFC2 741PFC2 844PFC2 945PFC2 952PFC2 1147PFC2 1152PFC2 1354

tpd

200025003000350040004500500060007000800090001000012000

m

33

3,63,63,63,64,24,85,45,46,66,67,8

m

15,819,819,123,125,128,427,129,029,734,331,034,335,6

PYROFLOOR2®

- Cooler Controler

(incl. TEO)

PFC2 TypeNominal

daily capacity

Grate length

Grate area

Grate load

Grate width Options

m²

47,559,468,983,290,3

102,2113,7139,4160,3185,3204,6226,5278,0

t/m²/d

42,142,143,542,144,344,044,043,043,643,243,944,143,2

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Specific grate load remains constant for any production capacity

Optimal width load reduces frequency of lane operation

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optimized chamber sizesNewly designed chamber sizes enhance the heat recuperation capa-bilities of the PYROFLOOR2®.

Temperature gradient across the length of a chamber leads to sud-den change in pressure profile within the clinker layer; this causes air to escape through the rear part of the chamber where the pressu-re is relatively low, without imparting proper cooling. With optimized chamber size clinker can be cooled more efficiently, using the same time input as the air is prevented from “escaping

„ through the rear,

resulting in higher recuperation. The recuperated heat can be reused by the plant, lowering operation costs and allowing for more environ-mentally friendly production.

• Higher recuperation and no ‘fountaining’.

• Wear-effects from aeration can be decoupled and have no in fluence on heat transfer.

The static grate with horseshoe and optimized chamber sizes deliver the required amount of air to the right areas

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new static grate with horseshoeThe new PYROSTATIC® design of the static grate com-bines the established horseshoe arrangement with a new grate plate design that offers a low pressure drop, this along with an improved inclination angle of 15°, increases cooling efficiency by leading the cooling air exactly where it is needed: to the clinker.

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Strategically integrated air blasters within the hor-seshoe allow operators to easily handle disturbed conditions, such as negotiating “snowman“ forma-tions.

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Wear parts are an important factor in clinker cooling technology. Our new low wear seal design incorporates hardened metal to metal contact, and is vertically and horizontally adjustable.

spillage prevention

• Longer operating life

• Prevents clinker dust spillage into the chambers

• Easy to install and maintain

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wear protectionThe area beyond the static grate, at the beginning of the moving la-nes, is prone to high wear as it is subject to red-hot clinker falling onto it from the static grate and because, during the retraction stroke, the lanes push the incoming clinker against the step of the static grate.

To increase the service life of this wear prone area, KHD developed PYROCAST®, a specially designed transition piece installed at the transition point from static grate to moving lanes.

PYROCAST® uniquely amalgamates the strength of metal and insula-ting properties of ceramic, offering insulation from high temperature, while its curved profile slows the impact of the falling clinker.

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The moving floor principle was invented more than 60 years ago. With newly engineered, hardened support rollers and reduced basic load, we improved upon this proven principle, making it better for transporting bulk material, ensuring smooth operation, eliminating spillage, and increasing the lifetime of all parts.

By optimizing the specific width load and maintaining consistent grate load, we can assure high transport efficiencies.

proven principles

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• Robust design

• Induction hardened up to 3mm

• Automatic grease lubrication

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The cassettes are one of the most important parts of the PYROFLOOR2®. They prevent any relative movement between clinker particles and metallic surfaces. The basic concept incor-porates the formation of a layer of passive clinker that remains on the cassettes at all times, serving two objectives:

• Provides autogenous wear protection by ensuring that no pushing surfaces that would besubject to wear are perpendicular to the clinker movement (fig. 1)

• Uses the passive clinker layer as a distributor sieve for homogenous air distribution

new cassette design

fig. 1

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aeration channels

standardized cassette

smart design

The newly standardized cassette design, with reduced height, ensures easy maintenance and handling.

The design makes local manufacturing possible and assuresno heavy replacement parts. This decreases delivery times when repairing or replacing the cassettes.

homogenous air distribution

Orientation of the aeration channels in the cassettes has been optimized, allowing for homogenous distribution of air passing through the clinker bed, resulting in efficient cooling.

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hydraulicsPYROFLOOR2® is equipped with a fully pre-wired, plug and play hydraulics concept. The system ensures simplified maintenance and reduces risks through operation.

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Robustly designed double acting hydraulic cylinders require only one per lane, controlling the back and forth movement of the cooler lanes.

PYROFLOOR2® utilizes three standard pumps, two active and one hot spare, to assure continuous and reliable operation. If one pump fails, the hot spare will compensate for its perfor-mance with 100% reliability.

To ensure that all three pumps are functionally healthy and available at all times, the active pumps occasionally rotate.

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automationFor controlling the hydraulic system, the cooler is delivered with a completely pre-programmed and tested, state-of-the-art Program-mable Logic Controller (PLC) with multi-function display panel.

Optionally, an advanced expert system called PYROFLOOR2® Cooler Controller (PFCC) can be integrated with the hydraulic PLC.

The PFCC is pre-programmed with advanced algorithms that generate optimized set points for cooler lane movement and flow set points for aeration fans, based on clinker level measurement and other process parameters measured in the cooler as well as at other point in pyro section.

The intuitively arranged display panel allows for easy monitoring and troubleshooting.

The hydraulic PLC is connected to the process control system of the plant via a communications protocol for control and monitoringfrom the central control room.

To make maintenance and handling more user friendly, we also set up a 24/7 support network. With this latest technology, we solve problems before they happen.

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PYROCRUSHER® is the robust and efficient roller type crusher from KHD, installed at the discharge end of the PYROFLOOR2® it ensures silent and optimal crushing of oversized chunks of clinker.The design is based on the principle of grinding by compression, this completely eliminates the presence of clinker chunks flying at high velocities.

As a result, walls of the housing, refractory lining and the crusher itself are subject to lowest possible wear. Dust generation is also greatly reduced due to low rotational speed of the rollers.

PYROCRUSHER®

efficient crushing

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PYROCRUSHER® has several rollers arranged in series. The trans-port rollers rotate in the direction of clinker flow, as the material pas-ses across, fines are allowed to fall through the gap between the shaft assemblies, on to the clinker conveyor below the crusher.

The larger chunks are transported to the crushing rollers where they are crushed to required size between the rollers rotating in the op-posite directions. Depending upon the crushing load, the directions of roller rotation are automatically adjusted thus assuring continuous operation of the crusher under all circumstances.

CrushingTransport

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The non-impact crushing, low rotational speed of the rollers, auto-matic load sensing mechanism and many more distinct features add up to make PYROCRUSHER® offer extremely reliable operations, su-perior wear resistance and best in class availability for uninterrupted cooler and kiln operations.

PRC 300 - 3PRC 300 - 3PRC 360 - 3PRC 360 - 3PRC 360 - 4PRC 360 - 4PRC 420 - 4PRC 480 - 4PRC 480 - 4PRC 480 - 5PRC 480 - 5PRC 480 - 6PRC 540 - 6

tpd

20002500300035004000450050006000700080009000

1000012000

m

33

3,63,63,63,64,24,84,84,84,84,85,4

#

3333444445566

• Standard drive / gear • (Bonfiglioli or Bauer Gears)• Variable speed (VFD)

• Air cooled shaft

PYROCRUSHER® - PFC2® Series

PRC TypeNominal

daily capacity

No. of rollersWidth Options

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The conventional hammer crusher can also be integrated at the di-scharge end of PYROFLOOR2® to break oversized clinker chunks.

Available in two variants, type KB 1300, and type KB 1500 suited for production capacities from 2500 tpd to 10000 tpd. Wear re-sistant impact plate lining on the inner walls of the housing, hard faced hammers, option of air cooled roller shaft, specially angled grisly bars and a heavy duty chain curtain make KHD hammer crusher one the most reliable and robust clinker crushers availa-ble.

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HAMMER CRUSHERcrushing option

CEMENTING A STRONGER FUTURE

CSC Asia Pacific

KHD Humboldt Wedag MachineryEquipment (Beijing) Co. LtdThe North Star Times Tower, Suite 1301-13038 East Beichen Road,Beijing, China 100101Tel: +86 10 6500 4101

CSC India / Sub-Sahara AfricaService Point South Africa

Humboldt Wedag GmbH31 Isando RoadIsando, JohannesburgSouth AfricaTel: +27 119 292911

For more information on KHD Spare Parts and Services, please contact your local Customer Service Center (CSC).

CSC Americas

Humboldt Wedag Inc.400 Technology ParkwayNorcross, Georgia 30092, USATel: +1 770 810 7300

CSC Asia PacificService Point Malaysia

Humboldt Wedag Malaysia Sdn, Bhd.Etiqa Twins,Suite 25, Level 25, Tower 2,No.11, Jalan Pinang, 50450,Kuala LumpurMalaysiaTel: +60 3 2726 9902

CSC Russia/CISService Point Russia

OOO KHD Humboldt EngineeringMjasnizkaja ul., 24/7, Office 108Moscow 101000, RussiaTel: +7 495 623 3480

CSC Russia/CIS

ZAB Zementanlagenbau GmbHBrauereistr. 1306847 Dessau-RosslauTel: +49 340 5029 0

CSC India / Sub-Sahara Africa

Humboldt Wedag India Pvt. LtdA – 36, Mehtab HouseMohan Co-operative Industrial EstateMathura Road New Delhi, 110044, IndiaTel: + 91 11 4210 1100

CSC AmericasService Point Brazil

Humboldt Wedag do Brasil Servicos Technicos Ltda.Av Sao Joao 2375Sala # 1102Sao Jose dos Campos - SP12242-000 - Brasil Tel: +55 (31) 3658

Service Point Saudi Arabia

Humboldt Wedag GmbHP.O. Box 380Jeddah 21411Kingdom of Saudi ArabiaTel: +966 2 671 7121

Group Support Center KHD Humboldt Wedag International AGColonia-Allee 351067 CologneGermanyTel: +49 221 6504 0info@khd.com

Service Point Turkey

Humboldt Wedag GmbH TurkeyWindowest TowerEski Büyükdere Cad. No: 26Kat. 6 Ofis No: 614, Maslak, Istanbul, TurkeyTel: +90 212 999 37 82