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Clinker Coolers
Content
Tasks of clinker cooler
Cooler types and definitions
Planetary and tube coolers
Conventional grate coolers
Definitions
As for other components of the kiln system, specific figures for
clinker coolers refer to 1 kg of clinker. This eliminates the
influence of plant size and allows direct comparison of clinker
coolers of different types and sizes.
Cooling air
is the air which passes the clinker thus being heated up while
cooling the clinker. It corresponds approximately to the
combustion air requirement, only grate coolers allow additional air
for better cooling.
Primary air
is the air which is required for proper functioning of the burner.
Ambient air insufflated by a separate small fan plus the air from a
pneumatic transport system, amounting from < 10% up to > 30% of
the air required to combust that fuel. Some precalciner burners are
equipped with primary air fans (for cooling) as well.
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/
Secondary air is the hot air entering the rotary kiln via clinker
cooler. Its flow is determined by the combustion of the burning
zone fuel.
While cooling the clinker, it reaches temperatures of 600 to over
1000C, depending on type and condition of the cooler.
Tertiary air is that part of the combustion air which is required for
combusting the precalciner fuel. It is extracted from kiln hood or
cooler roof, and then taken along a duct (=tertiary air duct) parallel
to the kiln to the precalciner.
It reaches temperatures near or equal to the level of the secondary
air.
Efficiency
expresses the quality of heat transfer from clinker to the air which
is used for combustion in the burning zone and precalciner firing.8
/
Middle air
(grate cooler only) is extracted from the cooler roof if drying of
process materials requires a temperature level which is higher
than the waste air.
If the quantity is small, up to 450C can be expected at normal
cooler operation.
Waste air
(grate cooler only) is also called cooler exit air or cooler
excess air.
The total cooling airflow from the fans is normally higher than
the flow required for combustion (=tertiary + secondary air).
The extra air, which has normally a temperature of 200 to
300C, must be vented to ambient via a dedusting system.
9
False air
is cold air entering the system via kiln outlet seal, burner opening,
casing or clinker discharge. It either dilutes secondary air thus
reducing recuperated heat or adds load to the waste air system of
grate coolers.
Specific air
Volumes are airflows per kg of clinker (m3/kg cli, Nm3/kg cli).
Independent of the kiln size, airflows of cooler systems can be
directly compared.
Specific loads
express the relation of clinker production to a characteristic
dimension of (t/d m, t/d m2, t/d m3). Exact definitions vary with
cooler type.
Radiation losses
from the cooler casing/shell are particularly important for
planetary coolers, where they actively support the cooling of the
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clinker.
/
11
12
13
h cooler =
S Q loss
Q combustion air
=
1 -
14
15
Grate:
16
Rotary:
Grate:
Vertical:
17
18
Planetary Cooler II
19
20
21
22
24
2) Uneven
clinker temp
6) Cracked kiln
shell
7) Short life of
high temperature lifters
25
3500
5000
55%
68%
730
600
0.9
1.3
1.8 - 2.0
70 - 80
< 4.5
< 25
kJ/kg
%
C
Nm3/kg
t/m2 d
t/m2 d
m/s
m/s
26
Tube Cooler
27
28
Positive pressure!
29
30
31
pexp
pexp
pcli
p c li
x
p1
p2
p3
p4
p5
32
Conventional
3500
5000
68%
64%
890
610
940
850
240
200
10 - 20
45 - 55
35 - 45
2.3
kJ/kg
%
C
C
C
C
min-1
mbar
t/d m2
Nm3/kg
33
34
Red River
Air breaking through (Geyser)
Overheated / burnt plates
Thin clinker bed
35
Influence of Clinker
36
coarse
Air distribution:
Vc
Rf + Rg
=
Vf
Rc + Rg
Vc
= 1 si Rg >> Rf, Rc
Vf
37
38
39
<= 45 t/(m2d)
>=100 mbar
Resulting in estimated
Grate speed
Clinker temperature
Efficiency at 3100 kJ/kg
10 to 15 strokes/min
~90 + t ambient
~70 %
40
fixation
Roller crusher
41
43
44
45
Fishbone aeration
47
Compact Swing
pendulum grate suspension
48
Cooling Air
50
51
53
54
55
pfan p(ducts+plate)
BLOCKAGE!
NO PROBLEM
57
Compact Swing
(CPAG) -> 2003: Standard
Pneumatic Hopper Drain PHD
(IKN)
(IKN)
58
59
60
61
62
Polytrack Cooler
64
Conveying direction
67
Start position
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
68
Benefit:
Assessment
Proven solution
Implementation during scheduled kiln stop
Relatively low cost: appr. 250000 to 400000 USD
Short payback
69
Polysius
IKN
Satarem
CemProTec
/
70
2) Short life of
grate plates
& side plates
6) Snowman,
red river
3) Excesive
fall through
8) Clinker dust
spillage from
double flap gates
71
Heat Consumption
Fluctuations
Kiln Operation
Dust Cycle
Wear
Plate Life
Kiln Availability
Maintenance
Building Volume
PERFORMANCE
Clinker Cooler
Power Consumption
Clinker Temp.
Handling
Cement Quality
Grinding System
Clinker Quality
Grindability
Filter Size
72