InterFlap

The Intercem changeover flaps or Intercem double tipping flaps are used for continuous metering, blocking and discharging of bulk materials. Furthermore, Intercem butterfly valves are manufactured for cement preheaters, which prevent counter gas flow through material pipes between two stages of the preheater. The flexible design of the flaps enables reliable guiding and separation of free-flowing bulk materials from and into pressure difference chambers (e.g. filter systems). Double flaps are operated pneumatically, electrically or mechanically. The welded construction makes the valves lighter than cast iron and less expensive. The design is adapted to the conditions and can be designed to be highly resistant to wear.

 

 

 

 

 

 

InterHop

The new InterHop

Maximum flexibility, fast truck loading and dust-free operation – all this is guaranteed by the InterHop raw material receiving hopper. 40 tonnes of material can be unloaded in 10 seconds.
Truck loading is just as possible as direct loading via a conveyor belt to the raw material silo. The InterHop impresses with its flexible design. It is a customised solution developed according to the customer’s requirements.

Low dust emissions during ship unloading with gantry crane / shovel
Low dust emissions during truck loading or handling with a conveyor belt
Fast loading process for trucks
High-speed belt conveyor loading
Robust and durable hopper construction
Flexible hopper height in case of new hopper position
The grapple feed opening has a diameter of 9.00 m and a feed opening at height.
The inlet (grate size) is 6.50 m x 6.50 m and the height of the inlet (grate size) is 15 m.
The overall dimensions (with walkways) are 10.00 x 17.80 m. The hopper has a capacity of 65 m3/ density 1.2 – 1.4 kg/dm3 and its weight is approximately 215,000 kg.

Commissioning took place in July 2021 and the InterHop has been operating successfully ever since.
So successful that the customer has already ordered a second InterHop in October 2021!

InterSeal

“InterSeal is a state-of-the-art technology, preventing the intrusion of ambient air into the process air.”

 

Own technologies | InterSeal has been especially developed by Intercem, topping by far standardized minimum requirements. It comes up to the real and daily high requirements of production flow in all areas. Thus, InterSeal cares for an increased operational safety and guarantees a long-term, trouble-free operation of the plant.

Adapted by Intercem engineers on site, existing plants are completely safe. The adaptation is executed digitally by a 3D-Scanner, which assures absolute precision work for the assembly.

As connecting element between rotary kiln and preheater, InterSeal avoids the inlet of ambient air and the escape of 800 °C hot raw meal. Furthermore, rotating as well as vertical and horizontal movements of the rotary kiln are absorbed and balanced. All this creates an enormous safety for robust production processes.

 

InterMod

“InterMod, the individually combinable module system for smaller capacities up to 30 tph can be moved and removed quickly and ultra-flexibly and thus enables a quick location change.”

 

Connect and cement | Connect and produce cement exactly where it is needed. In sufficient quantities, top quality and round the clock. InterMod, the modular system makes it possible.

The modules are pre-assembled, individually combinable, quickly removable, ultra-flexible and designed for rapid change of location. They are equipped with proven single products and electronically pre-installed.

Smaller plants are ready for operation in only a few weeks from the moment of delivery. In the same short period of time they can be disassembled and stored or rebuilt in another location. This enables the operator to react in a flexible way to economic, cultural, political or environmental modifications.

Additionally, customers who want to increase the added value of their plant find the ideal solution with InterMod. Traders can produce their own cement and react flexibly to customers’ requirements, they become independent from suppliers and can adapt to changing local circumstances. As InterMod does not need long planning- and construction times, assembly costs including accommodation are extremely reduced.

Disassembly is also quick and safe. The transport to the next operation site or to the interim storage is possible without high logistical effort. When re-assembled, the modules can be adapted to the new requirements.

Investment costs can be planned risk-free at an early stage, because for each modular system the needed capacity, the quality of results, the composition of components, the following usability, an eventual interim storage etc. can be stipulated in advance.

 

InterSep

“InterSep enables an energy-efficient separation – flexible and compact. With the new high efficiency separators of the latest generation Intercem has the appropriate product for each specific application. A low bypass-rate ensures the highest possible separation grade.”

 

Flexible and compact | Consequent further development of the separator technology results in a high efficiencyseparator of the latest generation, corre-sponding to the highest demands. Optimization of the separation chamber geometry and optimized streaming processes have been proven in different reference plants. Areas exposed to a high wear potential are equipped with highly wear-resistant materials in order to achieve a maintenance friendly product.

In direct connection with the ball mill de-dusting the separator-circulating-air-fan is omitted. This leads to a reduction of the specific labor need in the complete grinding plant.

Both separator types separate the material with the lowest bypass rate and highly efficiently. Moreover the compact construction of the high efficiency separator allows – in con-nection with further plant components – the exchange of old separator types at the same places of installation. Complicated and cost-intensive interventions into existing buildings are omitted.

The manufacturing of the high efficiency separators takes place in the manufacturing center in our site in Oelde. As an option, separator housing components can also be produced by local workshops in order to come up to high economical requirements.

 

InterGrind

“InterGrind comprises ball mills with high-performance separators in a closed grinding circuit, which optimize and modernize cement plants and increase their performance.”

 

Act internationally | Intercem is acting internationally and always offers to each customer the most economical solution, which can be planned and manufactured – as per the customer’s requirement – nationally, in Europe or globally. Specific manufacturing processes, different performance classes as well as raw materials to be used and transport facilities are included in the planning.

Thus, clients do not need to adapt to the plant, the plant is adapted to the client’s requirements. The capacity areas of the offered products and services vary from the minimum capacity up to the maximum possible. Existing cement plants are optimized, modernized and made more efficient by InterGrind. In case of completely new grinding plants customers have the choice between Intercem-owned products or alternative products. In every case, a high grinding quality, an over-average input and low wear rates are achieved.

Already existing ball mills can be equipped with completely new interior fittings leading to high performance again. For plants in operation, Intercem has spare parts on stock which can be tailor-made and adapted to the existing plant. Furthermore Intercem offers a comprehensive consulting, which can reach from material handling to the development of new cement varieties and their implementation into the regional markets.

With all InterGrind solutions Intercem achieves an individual, needs-oriented and product-specific result, which could not be realized with standard solutions.

 

InterUp

“InterUp enables the upgrading of existing cement plants to cutting-edge technologies. This leads to an effective increase of capacities and a massive reduction of operating costs.”

From old to new | No long way with Intercem. After a detailed check-up of the plant to be optimized and a planning phase aimed at cost-effectiveness, the necessary components for the plant are individually composed.

If for example up to that time only classic fuels could be used, such as oil, gas and coal, the upgrading of the preheater-technology makes the application of alternative fuels possible, as for example processed animal meal, domestic or industrial waste.

The Intercem preheater-technology comprises a 5-step-preheater with pre-calcination and integrated ter-tiary air duct connection to the clinker cooler. Upgrading the clinker cooler reduces the needed electrical energy to the minimum. The upgrade also includes the optimization of the burner technology and the filter technology, such as the kiln exhaust filter, the air cooler with exhaust filter and the gen-eral process filter. The exchange and the refurbishment of the roller station as well as an exact measurement and adjustment of existing rotary kilns perfectly complete the InterUp scope of supply.

Intercem’s refurbished spare parts increase performance capacities and minimize the energy input and consumption considerably. Moreover old technologies are replaced by efficient new components in a very economical way.

An example before-after shows how an outdated plant can be converted into a highly efficiently working cement plant, without discarding and renewing plant components which are still productive and powerful.

 

InterAdd

“InterAdd is a supplementary offer, adapting the loading and packing systems to the optimized plant.”

 

Effective and efficient | Cement plants optimized by Intercem work quicker, more effective and with more performance quality. Very often the existing loading- and packing systems have to be adapted to these new conditions. Intercem offers the ideal solution for this.

Intercem engineers analyze the new requirements with 3D-scanners and draw up a 3D-drawing of the complete plant according to the so-achieved measurements, volumes etc.

This can either mean a completely new construction or the integration into existing production areas of the build-ing. At the end of the analysis a real shot of the new packing plant visualizes the future situation.