PYROFLOOR²®

the next evolution in cooler technology

 innovation improvement solutions
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.
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.

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.

2
3
 PYROFLOOR2®
for every production need
PYROFLOOR2® - standard series
Nominal Grate Grate Grate Grate
PFC2 Type daily width length area load Options
capacity
The PYROFLOOR2® cooler product line has tpd m m m² t/m²/d
been developed to cater to all production
PFC2 524 2000 3 15,8 47,5 42,1
capacity scenarios. Our standard product PFC2 530 2500 3 19,8 59,4 42,1
models are suited for production capaci- PFC2 629 3000 3,6 19,1 68,9 43,5
ties ranging from 2,000 to 12,000 tons per PFC2 635 3500 3,6 23,1 83,2 42,1
PYROFLOOR2®
day, while maintaining the optimal specific PFC2 638 4000 3,6 25,1 90,3 44,3
PFC2 643 4500 3,6 28,4 102,2 44,0 - Cooler Controler
grate load. PFC2 741 5000 4,2 27,1 113,7 44,0 (incl. TEO)
PFC2 844 6000 4,8 29,0 139,4 43,0
Optimized specific grate loads ensure that PFC2 945 7000 5,4 29,7 160,3 43,6
PFC2 952 8000 5,4 34,3 185,3 43,2
the ideal ratio of clinker is spread across the PFC2 1147 9000 6,6 31,0 204,6 43,9
width and depth of the cooler grates, resulting PFC2 1152 10000 6,6 34,3 226,5 44,1
in consistently efficient clinker conveying and PFC2 1354 12000 7,8 35,6 278,0 43,2
aeration.

4
Specific grate load remains constant for any production capacity

5
Optimal width load reduces frequency of lane operation
 optimized chamber sizes
Newly 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.

6
The static grate with horseshoe and optimized chamber sizes
deliver the required amount of air to the right areas
7
 new static grate with horseshoe
The 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.

8
Strategically integrated air blasters within the hor-
seshoe allow operators to easily handle disturbed
conditions, such as negotiating “snowman“ forma-
tions.

9
 spillage prevention
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.

• Longer operating life

• Prevents clinker dust spillage into the chambers
• Easy to install and maintain

10
wear protection
The 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.
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.

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.

11
 proven principles
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.

12
• Robust design
• Induction hardened up to 3mm
• Automatic grease lubrication

13
 new cassette design
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, fig. 1
serving two objectives:

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

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

14
 aeration channels
smart design
The newly standardized cassette design, with reduced
height, ensures easy maintenance and handling.

The design makes local manufacturing possible and assures

no 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.

15
standardized cassette
 hydraulics
PYROFLOOR2® is equipped with a fully pre-wired, plug and play
hydraulics concept. The system ensures simplified maintenance
and reduces risks through operation.

16
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.

17
 automation
For 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.

18
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 monitoring
from 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.

19
 PYROCRUSHER®
efficient crushing
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.

4
20
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.

Transport Crushing

215
 PYROCRUSHER® - PFC2® Series
The non-impact crushing, low rotational speed of the rollers, auto- Nominal No. of
matic load sensing mechanism and many more distinct features add PRC Type daily Width rollers Options
up to make PYROCRUSHER® offer extremely reliable operations, su- capacity
perior wear resistance and best in class availability for uninterrupted tpd m #
cooler and kiln operations.
PRC 300 - 3 2000 3 3
PRC 300 - 3 2500 3 3
PRC 360 - 3 3000 3,6 3
PRC 360 - 3 3500 3,6 3
• Standard drive / gear
PRC 360 - 4 4000 3,6 4
PRC 360 - 4 4500 3,6 4 • (Bonfiglioli or Bauer Gears)
PRC 420 - 4 5000 4,2 4 • Variable speed (VFD)
PRC 480 - 4 6000 4,8 4 • Air cooled shaft
PRC 480 - 4 7000 4,8 4
PRC 480 - 5 8000 4,8 5
PRC 480 - 5 9000 4,8 5
PRC 480 - 6 10000 4,8 6
PRC 540 - 6 12000 5,4 6

4
22
HAMMER CRUSHER
crushing option

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.

235
For more information on KHD Spare Parts and Services,
please contact your local Customer Service Center (CSC).

CSC Russia/CIS
Service Point Russia

CSC Russia/CIS OOO KHD Humboldt Engineering

Mjasnizkaja ul., 24/7, Office 108
ZAB Zementanlagenbau GmbH Moscow 101000, Russia
Brauereistr. 13 Tel: +7 495 623 3480
06847 Dessau-Rosslau CSC Asia Pacific
Tel: +49 340 5029 0
CSC Americas KHD Humboldt Wedag Machinery
CSC India / Equipment (Beijing) Co. Ltd
Humboldt Wedag Inc. Sub-Sahara Africa The North Star Times Tower, Suite 1301-1303
400 Technology Parkway
8 East Beichen Road,
Norcross, Georgia 30092, USA Humboldt Wedag India Pvt. Ltd
Beijing, China 100101
Tel: +1 770 810 7300 A – 36, Mehtab House
Tel: +86 10 6500 4101
Group Support Center Mohan Co-operative Industrial Estate
Mathura Road New Delhi, 110044, India
KHD Humboldt Wedag International AG Tel: + 91 11 4210 1100
Colonia-Allee 3
51067 Cologne
Germany CSC Americas CSC Asia Pacific
Tel: +49 221 6504 0 Service Point Brazil Service Point Malaysia
info@khd.com
Humboldt Wedag do Brasil Servicos Technicos Ltda. Humboldt Wedag Malaysia Sdn, Bhd.
Service Point Saudi Arabia Av Sao Joao 2375 Etiqa Twins,
Sala # 1102 Suite 25, Level 25, Tower 2,
Humboldt Wedag GmbH Sao Jose dos Campos - SP No.11, Jalan Pinang, 50450,
P.O. Box 380 12242-000 - Brasil Kuala Lumpur
CSC India /
Jeddah 21411 Tel: +55 (31) 3658 Malaysia
Sub-Sahara Africa
Kingdom of Saudi Arabia Service Point South Africa Tel: +60 3 2726 9902
Tel: +966 2 671 7121
Humboldt Wedag GmbH
Service Point Turkey
31 Isando Road
Humboldt Wedag GmbH Turkey Isando, Johannesburg
Windowest Tower South Africa
Eski Büyükdere Cad. No: 26 Tel: +27 119 292911
Kat. 6 Ofis No: 614, Maslak, Istanbul,
Turkey
Tel: +90 212 999 37 82

CEMENTING A STRONGER FUTURE