Product Development

High capacity clinker coolers

Published

4 years ago

October 19, 2021

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Over the years the average size of new cement lines have continuously increased. Since the late 1990?s large clinker kilns with a capacity of 10,000 tonnes per day and more have been built by the several kiln manufacturers. IKN the leading supplier gives the latest picture.

The first of high capacity kilns were built in Thailand, Taiwan and China. Similar large kilns followed in the Middle East, mainly supplied by Chinese OEM?s. Now these high capacity kilns are being built and operated in India, too.

The main reason for these large capacities is the lower initial capital cost and lower operating cost per ton of clinker produced.

India has seen few contracts for new lines until last year. Some highlights were the 2 x 10,000 t/d plants for Ultra tech cement Ltd and the new line of Holcim at Jamul with a capacity of 9,000 t/d. UTCL plants are commissioned three years ago and presently these lines are operated upto 11,800 t/d.

This article will show how IKN contributed to the success of these lines, first by improving the existing large lines and later by supplying a large number of clinker coolers with capacities of 10,000 tpd and more.

Design of large IKN clinker coolers
The main design challenge for large clinker coolers is the ability to evenly distribute the clinker received from the kiln over a much wider cooler with a width of up to 7.2 m. First generation clinker coolers of capacity 10,000 tpd were designed with a width of 4.8 m. Based on the operation of the 9,100 tons per day IKN cooler at Sungshin Cement in Korea, IKN was confident that their fixed inlet called Klinker Inlet Distribution System (KIDS) was able to spread the clinker evenly to a width of 7.2 m and used this design as the standard for all further large coolers. This proved to be a good choice as the reliable operation of the coolers continues over many years. Fig. 1 shows an IKN KIDS in operation.

Thus, it is worth to emphasize that the development of the IKN KIDS fixed Inlet was one of the major factors that allowed the design of large and also comparably wide clinker coolers (Fig. 2). Without a fixed inlet, cooler design would have had to stay with narrow and very long coolers.

The second challenge in the design of large clinker coolers is the observation that clinker from these large kilns seems to be finer than clinker from smaller kilns. Additionally Indian plants are often operated with 100 per cent petcoke as fuel. This is more challenging for the clinker cooler than well granulated clinker. The ideal clinker bed thickness for uniform aeration of fine clinker is lower, and the cooler has to be able to operate between 450 and 550 mm of clinker bed. Compared to other cooler designs the IKN Pendulum Cooler is much more flexible and can work with almost any height of clinker bed and can therefore always operate with the most efficient parameters and the highest recuperation efficiency.

Design details of large IKN clinker coolers Linear Pendulum System
The Linear Pendulum System LPS lends itself well to the large width of these coolers: the cooler width is divided in two and each section has two LPS supports (Fig. 3). This design allows to drive the grate using only two hydraulic cylinders, which are located outside of the cooler, always within sight and continuously accessible for monitoring and maintenance.

All other components inside the cooler housing like the LPS are maintenance free, no bearings and do not require lubrication.

Coanda Wing Aeration
The slots inside the IKN grate plates are designed to use the so-called Coanda Effect to evenly distribute the air across the surface of the grate before it enters the clinker bed. This ensures best cooling of the grate itself and distributes the air evenly through the clinker bed. An in-depth study by using Computational Fluid Dynamic (CFD) showed that it was possible to further improve the velocity profiles in the slots of the grate plates. Based on this, IKN has modified the design of the blades and calls them now GC?Coanda Wings? as their profile is very similar to an airplane wing. The new grate plate shows a more direct airflow together with a uniform high slot velocity evenly distributed between all slots of the grate plate. The new design has been implemented in all new coolers and successfully operates now for more than three years.

Process results of large IKN coolers

The following table gives an overview of the main process data of the Rawan Plant of Ultratech Cement Ltd which was recorded recently.

Even after three years after the commissioning the performance of the cooler did not deteriorate

The three coolers in Tonglin and Wuhu in China operate with a mid-crusher after two thirds of the cooler. They supply additional heat from the mid-air tap to a Waste Heat Recovery System delivering additional power to the plant. In addition to this, it is also possible to recirculate the hot vent gases from stack to the selected cooling chambers to further improve the heat in mid-air.

IKN has the lowest operating cost per ton of clinker produced
Large clinker lines have a lower operating cost compared to smaller lines. The IKN clinker cooler will contribute to this by:

Very high efficiency figures
The ability to cope with fine clinker
The lowest possible electricity kWh/t cost up to 40% lower than walking floor coolers
Minimizing the maintenance cost of grate surface replacement parts by having a long wear life
A very high mechanical availability and reliability, in many cases 100%, resulting in no kiln stops caused by the IKN cooler

A comparison between several coolers clearly demonstrated that the IKN Pendulum Cooler operates with the lowest operating cost as compared to all other cooler technologies.

Conclusions
Since the founding of IKN 30 years ago, IKN has become the no. 1 clinker cooler supplier for clinker coolers of capacities with more than 10,000 tpd. In total over 600 installations including coolers from 650 to 13,000 tpd worldwide provide a solid reference base. This success for a small company like IKN with about 150 employees is simply the result of better technology.

All internal and critical components of IKN cooler are manufactured 100% in Europe. IKN engineers are dedicated to continually improve the IKN cooler. The repeat orders of our customers is the result of the success of IKN cooler projects in every aspect.

Economy & Market

Power Build’s Core Gear Series

Published

4 days ago

February 19, 2026

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A deep dive into Core Gear Series of products M, C, F and K, by Power Build, and how they represent precision in motion.

At the heart of every high-performance industrial system lies the need for robust, reliable, and efficient power transmission. Power Build answers this need with its flagship geared motor series: M, C, F and K. Each series is meticulously engineered to serve specific operational demands while maintaining the universal promise of durability, efficiency, and performance.

Series M – Helical Inline Geared Motors
Compact and powerful, the Series M delivers exceptional drive solutions for a broad range of applications. With power handling up to 160kW and torque capacity reaching 20,000 Nm, it is the trusted solution for industries requiring quiet operation, high efficiency, and space-saving design. Series M is available with multiple mounting and motor options, making it a versatile choice for manufacturers and OEMs globally.

Series C – Right Angled Heli-Worm Geared Motors
Combining the benefits of helical and worm gearing, the Series C is designed for right-angled power transmission. With gear ratios of up to 16,000:1 and torque capacities of up to 10,000 Nm, this series is optimal for applications demanding precision in compact spaces. Industries looking for a smooth, low-noise operation with maximum torque efficiency rely on Series C for dependable performance.

Series F – Parallel Shaft Mounted Geared Motors
Built for endurance in the most demanding environments, Series F is widely adopted in steel plants, hoists, cranes and heavy-duty conveyors. Offering torque up to 10,000 Nm and high gear ratios up to 20,000:1, this product features an integral torque arm and diverse output configurations to meet industry-specific challenges head-on.

Series K – Right Angle Helical Bevel Geared Motors
For industries seeking high efficiency and torque-heavy performance, Series K is the answer. This right-angled geared motor series delivers torque up to 50,000 Nm, making it a preferred choice in core infrastructure sectors such as cement, power, mining and material handling. Its flexibility in mounting and broad motor options offer engineers the freedom in design and reliability in execution.
Together, these four series reflect Power Build’s commitment to excellence in mechanical power transmission. From compact inline designs to robust right-angle drives, each geared motor is a result of decades of engineering innovation, customer-focused design and field-tested reliability. Whether the requirement is speed control, torque multiplication or space efficiency, Radicon’s Series M, C, F and K stand as trusted powerhouses for global industries.

http://www.powerbuild.in
Call: +919727719344

Economy & Market

Conveyor belts are a vital link in the supply chain

Published

8 months ago

June 16, 2025

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Kamlesh Jain, Managing Director, Elastocon, discusses how the brand delivers high-performance, customised conveyor belt solutions for demanding industries like cement, mining, and logistics, while embracing innovation, automation, and sustainability.

In today’s rapidly evolving industrial landscape, efficient material handling isn’t just a necessity—it’s a competitive advantage. As industries such as mining, cement, steel and logistics push for higher productivity, automation, and sustainability, the humble conveyor belt has taken on a mission-critical role. In this exclusive interview, Kamlesh Jain, Managing Director, Elastocon, discusses how the company is innovating for tougher terrains, smarter systems and a greener tomorrow.

Brief us about your company – in terms of its offerings, manufacturing facilities, and the key end-user industries it serves.
Elastocon, a flagship brand of the Royal Group, is a trusted name in the conveyor belt manufacturing industry. Under the brand name ELASTOCON, the company produces both open-end and endless belts, offering tailor-made solutions to some of the most demanding sectors such as cement, steel, power, mining, fertiliser, and logistics. Every belt is meticulously engineered—from fabric selection to material composition—to ensure optimal performance in tough working conditions. With advanced manufacturing facilities and strict quality protocols, Elastocon continues to deliver high-performance conveyor solutions designed for durability, safety, and efficiency.

How is the group addressing the needs for efficient material handling?
Efficient material handling is the backbone of any industrial operation. At Elastocon, our engineering philosophy revolves around creating belts that deliver consistent performance, long operational life, and minimal maintenance. We focus on key performance parameters such as tensile strength, abrasion resistance, tear strength, and low elongation at working tension. Our belts are designed to offer superior bonding between plies and covers, which directly impacts their life and reliability. We also support clients
with maintenance manuals and technical advice, helping them improve their system’s productivity and reduce downtime.

How critical are conveyor belts in ensuring seamless material handling?
Conveyor belts are a vital link in the supply chain across industries. In sectors like mining, cement, steel, and logistics, they facilitate the efficient movement of materials and help maintain uninterrupted production flows. At Elastocon, we recognise the crucial role of belts in minimising breakdowns and increasing plant uptime. Our belts are built to endure abrasive, high-temperature, or high-load environments. We also advocate proper system maintenance, including correct belt storage, jointing, roller alignment, and idler checks, to ensure smooth and centered belt movement, reducing operational interruptions.

What are the key market and demand drivers for the conveyor belt industry?
The growth of the conveyor belt industry is closely tied to infrastructure development, increased automation, and the push for higher operational efficiency. As industries strive to reduce labor dependency and improve productivity, there is a growing demand for advanced material handling systems. Customers today seek not just reliability, but also cost-effectiveness and technical superiority in the belts they choose. Enhanced product aesthetics and innovation in design are also becoming significant differentiators. These trends are pushing manufacturers to evolve continuously, and Elastocon is leading the way with customer-centric product development.

How does Elastocon address the diverse and evolving requirements of these sectors?
Our strength lies in offering a broad and technically advanced product portfolio that serves various industries. For general-purpose applications, our M24 and DINX/W grade belts offer excellent abrasion resistance, especially for RMHS and cement plants. For high-temperature operations, we provide HR and SHR T2 grade belts, as well as our flagship PYROCON and PYROKING belts, which can withstand extreme heat—up to 250°C continuous and even 400°C peak—thanks to advanced EPM polymers.
We also cater to sectors with specialised needs. For fire-prone environments like underground mining, we offer fire-resistant belts certified to IS 1891 Part V, ISO 340, and MSHA standards. Our OR-grade belts are designed for oil and chemical resistance, making them ideal for fertiliser and chemical industries. In high-moisture applications like food and agriculture, our MR-grade belts ensure optimal performance. This diverse range enables us to meet customer-specific challenges with precision and efficiency.

What core advantages does Elastocon offer that differentiate it from competitors?
Elastocon stands out due to its deep commitment to quality, innovation, and customer satisfaction. Every belt is customised to the client’s requirements, supported by a strong R&D foundation that keeps us aligned with global standards and trends. Our customer support doesn’t end at product delivery—we provide ongoing technical assistance and after-sales service that help clients maximise the value of their investments. Moreover, our focus on compliance and certifications ensures our belts meet stringent national and international safety and performance standards, giving customers added confidence.

How is Elastocon gearing up to meet its customers’ evolving needs?
We are conscious of the shift towards greener and smarter manufacturing practices. Elastocon is embracing sustainability by incorporating eco-friendly materials and energy-efficient manufacturing techniques. In parallel, we are developing belts that seamlessly integrate with automated systems and smart industrial platforms. Our vision is to make our products not just high-performing but also future-ready—aligned with global sustainability goals and compatible with emerging technologies in industrial automation and predictive maintenance.

What trends do you foresee shaping the future of the conveyor belt industry?
The conveyor belt industry is undergoing a significant transformation. As Industry 4.0 principles gain traction, we expect to see widespread adoption of smart belts equipped with sensors for real-time monitoring, diagnostics, and predictive maintenance. The demand for recyclable materials and sustainable designs will continue to grow. Furthermore, industry-specific customisation will increasingly replace standardisation, and belts will be expected to do more than just transport material—they will be integrated into intelligent production systems. Elastocon is already investing in these future-focused areas to stay ahead of the curve.

Economy & Market

Impactful Branding

Published

3 years ago

July 17, 2023

admin

Advertising or branding is never about driving sales. It’s about creating brand awareness and recall. It’s about conveying the core values of your brand to your consumers. In this context, why is branding important for cement companies? As far as the customers are concerned cement is simply cement. It is precisely for this reason that branding, marketing and advertising of cement becomes crucial. Since the customer is unable to differentiate between the shades of grey, the onus of creating this awareness is carried by the brands. That explains the heavy marketing budgets, celebrity-centric commercials, emotion-invoking taglines and campaigns enunciating the many benefits of their offerings.
Marketing strategies of cement companies have undergone gradual transformation owing to the change in consumer behaviour. While TV commercials are high on humour and emotions to establish a fast connect with the customer, social media campaigns are focussed more on capturing the consumer’s attention in an over-crowded virtual world. Branding for cement companies has become a holistic growth strategy with quantifiable results. This has made brands opt for a mix package of traditional and new-age tools, such as social media. However, the hero of every marketing communication is the message, which encapsulates the unique selling points of the product. That after all is crux of the matter here.
While cement companies are effectively using marketing tools to reach out to the consumers, they need to strengthen the four Cs of the branding process – Consumer, Cost, Communication and Convenience. Putting up the right message, at the right time and at the right place for the right kind of customer demographic is of utmost importance in the long run. It is precisely for this reason that regional players are likely to have an upper hand as they rely on local language and cultural references to drive home the point. But modern marketing and branding domain is exponentially growing and it would be an interesting exercise to tabulate and analyse its impact on branding for cement.