Clinker Coolers

Clinker Coolers
Learning Objectives Clinker Coolers

Know the two main tasks of the clinker cooler.
Know the definition of the cooler efficiency.
Know the cooler types and their main features.
Know symptoms and cause of the most typical
problems of grate cooler operation.

Know main design and sizing criteria of cooler types.
Know typical operating parameters of clinker coolers.
Holcim Group Support
Clinker Coolers
Content
Tasks of clinker cooler
Theory and definitions
Grate coolers
Cooler upgrade
Clinker crusher
Rotary coolers
4
Tasks of the Clinker Cooler

1) Recuperation of heat from hot clinker
2) Cooling of clinker
Approach to achieve this:
Hot clinker is exposed to a stream of cold air
for a certain period of time (=residence time)
The generated hot air is used for combustion

The clinker is conveyed at a controlled speed
The cooler is tight for clinker and air
5
Clinker Coolers
Content
Grate coolers
Cooler upgrade
Clinker crusher
Rotary coolers
Definitions
Recuperation is the recovery of heat contained in the hot clinker (1300 to 1450C) at the kiln discharge
to be used in the kiln system for the process substituting fuel.
Combustion air is the total air required for stoichiometric combustion

of the fuels in the kiln and the precalciner;
i.e. = primary + secondary + tertiary air
Waste air of (grate) clinker coolers is the cooling air that is in excess
of the combustion air and is blown to ambient (via dedusting system).
The only purpose of this air is to further cool down the clinker.
(Please see also definitions in section precalciners)
7
Cooler Recuperation Efficiency
cooler =
Q loss
Q hot air to comb.

=
Q clinker from kiln
cooler
1 -
Q clinker from kiln
Heat in hot clinker Q cli = m cli * cp cli * (t cli - t ref)

Heat in hot air
air
= v air * cp air * (t air - t ref)
Radiation loss
4
4
=
C
*
*
A{(t/100)
(t/100)
)}
rad
R
How to Improve Recuperation Efficiency

Factors influencing efficiency:
Air flow for combustion (secondary and tertiary air)

determined by system fuel requirement + excess air
Temperature of sec & tert air
determined by heat exchange in recuperation zone
Clinker temperature from kiln
determined by process; difficult to measure; ~1450C
Conclusion:
Our efforts must focus on achieving the highest

possible combustion air temperatures by optimizing
the heat exchange in the recuperation zone!
9
Heat Exchange Types in Clinker Coolers

Counter flow heat exchange
in a suspension (solids in gas)
Cross flow heat exchange
in a layer (bed)
Counter flow heat exchange
in a layer (bed)
10
Types of Clinker Coolers

Grate:
Travelling grate cooler (Recupol, Revolving Disc RDC)

Reciprocating grate cooler
Fixed grate cooler (Crossbar, Polytrack)
Moving grate cooler (- cooler)
Rotary:
Satellite (planetary) cooler

Rotary (tube) cooler
Vertical:
Gravity cooler (G-cooler)

Shaft cooler (not used in cement industry)
11
Heat Exchange Types in Coolers

Cooler Type
Grate:
Travelling grate cooler (Recupol, RDC)
Reciprocating grate cooler
Fixed grate cooler (Crossbar, Polytrack)
Moving grate cooler (- cooler)
Heat Exchange Type

Cross flow
in a layer (bed)
Rotary:
Satellite (planetary) cooler
Rotary (tube) cooler
Counter flow
in a (solids-gas) suspension
Vertical:
Shaft cooler (not used in cement industry)
Gravity cooler (G-cooler)
Counter flow
in a layer (bed)
12
Clinker Coolers
Content
Grate coolers
Cooler upgrade
Clinker crusher
Rotary coolers
13
Definition
Grate Cooler:
The clinker is discharged onto an air permeable grate
where it forms a layer. Cooling air is pressed across this
bed from below through the grate while the clinker is
moving from feed end to discharge end in 15 to 20 min,
continuously giving heat to the passing air.
Types of Grate Coolers (differ by conveying system):
Travelling Grate Coolers (until ~1985)

Reciprocating Grate Coolers (most common today)
Fixed Bottom Coolers (since 1998)
Moving Bottom Coolers (since 2002)
14
Cooling Principle in Grate Coolers

Hot combustion air to kiln
Hot waste air to filter
Hot clinker in
Slightly negative pressure!
Grate
Positive pressure!
Cooled
clinker out
15
Grate Cooler Process Terminology

Tertiary Air
Waste Air
Secondary A
ir
False Air
Fuel
Primary Air
Hot Clinker
False Air
Recuperation Zone
Aftercooling Zone
Cooling Air
Cooled
Clinker
16
Energy Flows in a Grate Cooler

Fuel Consumption
3020 kJ/kg
Total Energy
To Kiln
4160 kJ/kg
Radiation &
Convection
20 kJ/kg
Hot Clinker
1450C
1590 kJ/kg
Waste Air
285 C
350 kJ/kg
Recuperated Air
1050 C
1140 kJ/kg
Cold Clinker
120C
80 kJ/kg
Recuperation Efficiency
72%
Cooling Air
17
Significance of Fan Pressure in Grate Coolers

p, T
pexp = f(T)
p1 > p2 > p3 >..... pn
pexp
pexp
pcli
pcli
x
p1
p2
p3
p4
p5
18
Tertiary Air Extraction: Kiln Hood vs Cooler Roof
780C
1000C
280C
1300C
1000C
Recuperation Zone
20
Influence of Clinker Size and Air Resistance
21
Influence of Segregation at Kiln Discharge

Kiln Rotation
Offset
Fines
Coarse
22
HGRS Sizing Rules for Reciprocating Grate Coolers

Grate size / specific loading
<= 45 t/(m2d)
Grate width load:
1000 1500 t/(m d)
Installed cooling air:
>= 2.0 Nm3/kg cli
First fan pressure:
>=100 mbar
Resulting in estimated
Grate speed (traditional reciprocating grate)

Clinker temperature
Efficiency at 3100 kJ/kg
10 to 15 strokes/min
~90 + t ambient
>70 %
23
Range of Control Parameters of Grate Coolers
Heat Consumption
Efficiency
t sec & tert air *
t sec air
t tert air
t waste air
grate speed
first grate pressure
Specific grate load
Spec. cooling air
* TA extraction from
Modern
3000
3500
71%
76%
1070
990
1230
1170
950
850
300
300
10 - 15
80 - 100
45 - 50
1.8
kiln hood
Conventional
3500
5000
68%
64%
72
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
24
Continuously Moving Grate Cooler

Conveying Principle:
25
RECUPOL Cooler (Polysius)
26
Revolving Disc Cooler RDC Concept (CemProTec)
28
Features of RDC Concept according to CemProTec
29
Reciprocating Grate Cooler
30
Reciprocating Grate Cooler

Conveying Principle
31
1st Generation Grate Coolers from ~1950

One to three (four) grates with individual drives / speeds
Moving grate support by rollers
Inclined and/or horizontal grates
Grate plates with round conical holes
Large gaps, wearing out during operation
Air escaping through largest gaps
Few large chambers
Fans with max. 45 mbar; 2.5 to 3.5 Nm3/kg
cli
Simple side plates with large gaps
Thin bed operation; low recuperation (60 to 70%)

32
1st Generation Reciprocating Grate Coolers: Gaps
33
Typical Problems of Reciprocating Grate Coolers

Thin
bed
Geyser
(air blow-through)
Red
river
Fritting /
caking
Poor UG
seal
Snowman
Burnt
plates
High fall
through
Dust
leakage
34
Red River
A Red River is fine clinker
fluidized by cooling air on top

of and on one or both sides of
the clinker bed (like airslide).
Travelling faster than the
clinker bed, it has less

retention time, is hotter than
the clinker below and radiates
on top of black clinker.
Effect:
Damage on grate side seal

Reduced heat exchange
35
Snowman
A snowman starts when hot
clinker sticks to the cooler, often

in the in the drop area, and the
following clinker keeps piling up.
If not removed in time (by air
blaster e.g.) the snowman can

reach the kiln nose ring and must
be manually removed.
1 2 days kiln stop!
Effect:
Disturbed clinker distribution

Kiln stop (see above)
36
The Key to Excellent Reciprocating Grate Coolers
Correct allocation (= ratio) of air to clinker
Sustainably narrow gaps

between plates
rows
plates and wall
37
2nd Generation Grate Coolers from ~1985

Fixed inlet, inclined with direct aeration
Tighter grates by
wear free pendulum grate support

wear protection of critical areas
grate plates with special air slots instead of holes
Modern grate plates:
tight for clinker
high built-in p
thermally flexible
Fans:
higher pressure (up to 100 mbar)
less volume (1.6 to 1.8 Nm3/kg )
cli
Direct aeration allows smaller sections with individual aeration
(Trend: back to chamber aeration)

Side seals:
separate seals for lateral expansion and reciprocating plate movement

38
Grate Internal Pressure Drop (Resistance Grate)
Air distribution:
Vc
Rf + Rg
=
Vf
Rc + Rg
Vc
if Rg >> Rf, Rc
= 1 si
Vf
39
IKN Pendulum Cooler
41
IKN Coanda Nozzle (Grate Plate)
43
CPT Cross Motion Grate (CMG) for Large Coolers

CMG inlet section for active
clinker distribution in large units
1
9 10 11 12 13
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Direktbelftung feststehende Rostreihen
Direktbelftung Cross Motion Grate auen

Direktbelftung Cross Motion Grate auen
Ratio setter
(e.g. +10%)
Direktbelftung Cross Motionx1,1

Grate innen
II
III
Direktbelftung Cross
Motion
Grate innen
Ratio
setter
(e.g. +12%)
x1,12
Direktbelftung Zentralbreich
Correction
berbrckungsplatte
value PM
x1,14
(pressure CMGM)
Ratio setter
(e.g. +14%)
Setpoint WM
(Level CMGM)
Actual value LM
(Level CMGM)
47
Polysius Static Pregrate
Cooling Air
49
Problems with some 2nd Generation Grate Coolers

Higher Efficiency:
Reduced life of nosering-liners

and burner refractory
(up to 1250C secondary air)
Direct Aeration:
Nose wear from Sneak Air

due to inadequate seal air
Complicated and expensive
high tech equipment
51
Sneak Air (direct aeration, low seal air pressure)
pfan p(ducts+plate)
pUG (seal air)

52
3rd Generation Grate Coolers from ~2000

Fixed inlet, inclined with direct aeration
Clinker transport by separate elements, not by moving rows
Active clinker distribution by different conveying capacities
Tight grate with few gaps with relative movement
Flat bottom (no riddling conveyor)
Mild steel grate with autogenous protection by dead clinker layer
Fans:
pressure up to 100 mbar

volume 2.0 to 2.2 Nm3/kg cli
Conveying grate with chamber aeration

Mechanical flow regulators (in some cases)
Modular concept
53
Fixed Grate Coolers

Conveying Principle
Separate clinker moving devices
Entirely static grate
54
Walking Floor Principle of Conveying
Conveying direction
(Slide by courtesy of Polysius)

55
SF Crossbar Cooler (FLS Fuller)

Main Features
Crossbars for clinker conveying
Fixed grate line; no moving rows
Mechanical flow regulators; one per plate
No fall through flat bottom
Standard modules; pre-installed
Different speeds across width possible
The Crossbar Cooler was the first radically different grate cooler!
56
SF Crossbar Cooler: Conveying System
57
SF Crossbar Cooler: Crossbar Design
58
SF Crossbar Cooler:Mechanical Flow Regulator (MFR)
59
Multi Movable Crossbar Cooler (MMC)

Evolution of original Crossbar cooler
All Crossbars are movable
Conveying sequence like walking floor principle
Less wear (less relative movement clinker-Crossbars)
Better conveying efficiency
Horizontal arrangement possible
Wider modules due to mechanical restrictions
60
Multi Movable Crossbar Cooler (MMC)
61
Polytrack Cooler (Polysius)

Clinker conveying by pusher modules above the grate,
movement according to walking floor

Fixed grate line; no moving rows
Flow switches on some plates in recuperation zone
No fall through flat bottom
Standard modules
Different conveying speeds across width possible
62
Polytrack Cooler
63
Moving Grate Cooler

Conveying Principle
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
Start position
Forward stroke
lane 1-5
Backward stroke
lane
1 and 4
Backward stroke
lane 2 and 5
Backward stroke
lane 3
64
CPT Eta Cooler (-Cooler )

Clinker conveying by parallel grate lanes according to the Walking
Floor Principle
Fixed inlet (HE Modul)

Horizontal main grate (negative inclination possible)
Different speeds across width possible
No fall through -> no riddling conveyor, flat bottom
All welded steel parts (no cast!)
Modular system
Simple design, expected to become low cost cooler!
First industrial application in cement industry in the Siggenthal

plant, Switzerland. Next units for Holcim: Settat, Beli Izvor
65
CPT Eta Cooler
66
Active Clinker Distribution with 3rd Generation Grate Cooler (e.g. 2.4 m)
New Generation:
Active clinker distribution on grate
Reciprocating grate cooler:

No clinker distribution on grate
m1<=> m2<=> m3 <=> m4<=> m5 <=> m6
m = constant
E.g. ETA cooler:

6 x 0.4 m
6 individual stroke lengths
up to 6 different [t/h] per width
Reciprocating grate cooler:

1 x 2.4 m
1 fixed stroke length
Only 1 single [t/h] per width
100% even bed depth

even if inlet distribution fails!
Even bed depth depends

100% on inlet distribution
Wider grates without risk!

67
KHD Pyrofloor Cooler
68
KHD Pyrofloor Cooler

In principle a copy of the Eta cooler
No unit in operation yet; 1st 3 units sold to Russia
1st unit in Holcim: Campulung (start-up: 2007)

Main differences to Eta:
Different interpretation of
modular concept
Flow regulators
lower no of chambers and fans
69
Clinker Coolers
Content
Grate coolers
Cooler upgrade
Clinker crusher
Rotary coolers
71
Preconditions for Cooler Upgrade

Grate Coolers:
Mechanical and thermal problems in inlet section

Poor clinker distribution across width
Serious red river problems
Cooler in reasonably good mechanical condition
Desired capacity allows < 45 t/(m2 d) with cooler size
Solution: Static (fixed) inlet
Planetary coolers
Clinker temperature too high for subsequent equipment

Solution: G - cooler
72
Grate Cooler Upgrading by Static (Fixed) Inlet

Scope
Replacement of first 5 to 7 rows by static inlet

Replacement of 1 to 3 subsequent fans
Benefit:
Eliminates wear, fallthrough, burnt plates

Improves clinker distribution
Allows higher clinker bed on reciprocating grate
Assessment
Proven solution
Implementation during scheduled kiln stop
Relatively low cost: appr. 250000 to 400000 USD
Short payback
Note:
Static inlet alone is usually not sufficient!

Additional modifications are required depending on
specific situation, e.g. new fans for first compartments.
73
Grate Cooler Upgrading by Static (Fixed) Inlet
Polysius
IKN
CemProTec
74
Planetary Cooler Upgrade by G-Cooler (CPT)

Clinker from planetary cooler
G-cooler = Gravity cooler (clinker conveying by gravity)

75
Clinker Coolers
Content
Grate coolers
Cooler upgrade
Clinker crusher
Rotary coolers
78
Benefits of Roller Crusher

Equalization of material peaks
Low speed = low wear rate
Low dust generation to waste
air
Lower risk blockage by large
pieces
Mid crusher possible
Point of discussion: CAPEX
higher than hammer crusher

(electric direct drive is cheaper
than hydraulic drive)
79
Clinker Crusher: Hammer vs. Roller
BLOCKAGE!
NO PROBLEM
80
Roller Crusher as Mid Crusher (Stage Cooler)
Cooling of crushed large clinker

Lower average clinker temperature
Lower peak clinker temperature
81
Clinker Coolers
Content
Grate coolers
Cooler upgrade
Clinker crusher
Rotary coolers
82
Planetary (Satellite) Cooler
83
Planetary Cooler Process Terminology
Kiln Internal Cooling Zone
Cooling Air
Fuel
False Air
Secondary Air
Primary Air
Hot Clinker
Pre-Cooled
Clinker
Cooling Air
Radiation &
Convection
Cooled
Clinker
84
Energy Flows in a Planetary Cooler
Fuel
3400 kJ/kg
Secondary Air
900C
1070 kJ/kg
Recuperation Kiln
Internal Cooling Zone
320 kJ/kg
Hot Clinker
1450C
1590 kJ/kg
Recuperation Eff. Cooler tubes

61 %
Recuperation Eff. total
67 %
Recuperation Planets
650C
750 kJ/kg
Radiation & Convection

40 kJ/kg
Pre-Cooled Clinker
1200C
1225 kJ/kg
Radiation & Convection

340 kJ/kg
Cooling
Air
Cold Clinker
180C
135 kJ/kg
86
Planetary Cooler Internals (Estanda)
89
Planetary Cooler: Range of Control Parameters

Heat Consumption
Efficiency
t sec air
Spec. cooling air
Surface load
Cross section load
Air velocity in tube
Air velocity in elbow
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
90
Planetary Cooler: Typical Problems

1) Too high
clinker temp
2) Uneven
clinker temp
3) Clinker dust leakage
4) Too high velocity

5) Breaker bar
missing
6) Cracked kiln
shell
7) Short life of
high temperature lifters
91
Tube Cooler Equipment Terminology

Tertiary Air D
uct
Tertiary Air D
amper
Cooling Tube
Internals
Inlet
Chute
Clinker
Crusher
Cooler
Drive
93

Clinker Coolers

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Clinker Coolers

Learning Objectives Clinker Coolers

problems of grate cooler operation.

Holcim Group Support

Holcim Group Support

Tasks of the Clinker Cooler

for a certain period of time (=residence time)

The generated hot air is used for combustion

Holcim Group Support

Holcim Group Support

Combustion air is the total air required for stoichiometric combustion

Holcim Group Support

Cooler Recuperation Efficiency

Q hot air to comb.

Q clinker from kiln

Q clinker from kiln

Heat in hot clinker Q cli = m cli * cp cli * (t cli - t ref)

= v air * cp air * (t air - t ref)

Holcim Group Support

How to Improve Recuperation Efficiency

Air flow for combustion (secondary and tertiary air)

Our efforts must focus on achieving the highest

Holcim Group Support

Heat Exchange Types in Clinker Coolers

in a suspension (solids in gas)

Cross flow heat exchange

Counter flow heat exchange

Holcim Group Support

Types of Clinker Coolers

Travelling grate cooler (Recupol, Revolving Disc RDC)

Satellite (planetary) cooler

Gravity cooler (G-cooler)

Holcim Group Support

Heat Exchange Types in Coolers

Heat Exchange Type

Holcim Group Support

Holcim Group Support

Travelling Grate Coolers (until ~1985)

Holcim Group Support

Cooling Principle in Grate Coolers

Hot waste air to filter

Holcim Group Support

Grate Cooler Process Terminology

Energy Flows in a Grate Cooler

Significance of Fan Pressure in Grate Coolers

Holcim Group Support

Tertiary Air Extraction: Kiln Hood vs Cooler Roof

Holcim Group Support

Influence of Clinker Size and Air Resistance

Holcim Group Support

Influence of Segregation at Kiln Discharge

Holcim Group Support

HGRS Sizing Rules for Reciprocating Grate Coolers

Grate width load:

1000 1500 t/(m d)

Installed cooling air:

>= 2.0 Nm3/kg cli

First fan pressure:

Grate speed (traditional reciprocating grate)

Holcim Group Support

Range of Control Parameters of Grate Coolers

Holcim Group Support

Continuously Moving Grate Cooler

Holcim Group Support